Pe 100 Technical Specifications

HIGH DENSITY POLYETHYLENE (HDPE) PIPES

GENERAL TECHNICAL SPECIFICATION

Control and inspection methods and acceptance conditions of the technical specifications for the construction of HDPE pipes and special parts for use in drinking water and irrigation water networks are in this specification. HDPE pipes, TS or ISO shall be manufactured according to the equivalent standards to be accepted and the principles given to these specifications and the tests shall be carried out. The minimum requirements for HDPE pipe producers are stated below:
1.1) TS EN 12201-2 Standard Conformity Document from the Turkish Standards Institute, the pipe diameter and class to be supplied covering the current document,
1.2) Accredited by the Institution, ISO 9001 Quality Management System, 14001 Environmental Quality Management System and TS 18001 Occupational Health and Safety Management System certificates.
1.3) It has a certificate of conformity from an institution that has international validity that indicates that the raw materials and products to be used in production are suitable for drinking water.
1.4) The laboratory has sufficient capacity to carry out the tests prescribed by the standard for the determination of the initial performance of the pipes.
1.5) Basic characteristics of the piping, stacking and laying of the theoretical and practical training and applications can be given a suitable sub-structure.
1.6) When necessary, the personnel assigned to supervise the production during the production phase will have a room with all the parts and equipment that they will need to work.
1.7) The laboratory has sufficient capacity to carry out the tests prescribed by the standard for the determination of the starting performance of special parts.
1.8) The main features of the pipe element have the infrastructure to provide theoretical and practical training on the procedures of welding.

The pipes and special parts to be used in a project will be manufactured from the same raw material. Pipe and special parts manufacturers will have traceability backwards. This traceability will be a process that includes raw material batch number, raw material input quality control document, production records (work order, production, quality control stages, production machine, production date etc.) and test records.

1. HDPE PIPE AND SPECIFICATIONS OF SPECIAL PARTS

1.1 Physical characteristics

Physical properties of HDPE 100 drinking water pipes are given below:
-HDPE 100 drinking water pipes are resistant to impact (external pressure, hitting). It is more flexible and resistant to ground movements because it can grow up to 6 times the length of the neck.
-HDPE 100 drinking water pipes are resistant to ram pressure.
-It is possible to repair HDPE 100 drinking water pipes by means of suffocation when water is filled and no valves are used.
-When HDPE 100 drinking water pipes are filled with water, it can be connected to service water without cutting water with special branch separator.
- HDPE 100 breakage, cracking, etc. in drinking water pipes. No damage occurs during transportation, loading, unloading and installation.
-The internal surface of HDPE 100 drinking water pipes is smooth and the friction losses are minimum. So the project design diameter is minimized.
- HDPE 100 drinking water pipes easily flex, bend and break. So it can be rolled.
- HDPE 100 drinking water contributes to heat insulation when piped hot and cold fluid, saving energy.   

1.2 Chemical Properties

The chemical properties of HDPE 100 drinking water pipes are given below:

  • HDPE 100 drinking water pipes have high UV resistance, they keep standard properties even in outdoor storage.
  • HDPE 100 drinking water pipes have high resistance to earth alkali metals. It does not react with these species and does not rot.
  • The chemical resistance of HDPE 100 drinking water pipes is high.
  • HDPE 100 is not affected by moisture under ground of drinking water pipes.
  • HDPE 100 is resistant to corrosive and pressures of drinking water pipes.

1.3 Raw materials

  • The raw material to be used in pipe manufacturing should be PE 100 class raw material.
  • The density of PE 100 class raw materials should be 0,940 gr / cm3 min according to ISO 1183-1 standard.
  • The PE 100 grade raw material MRS value should be minimum 10 MPa and the environmental stress value should be minimum 8 N / mm2.
  • PE 100 class raw material melt flow rate (MFR) shall be in accordance with TS EN 12201-2 and tested under 190 ° C / 5 kg load according to TS EN ISO 1133-1 standard. 10 min.
  • The ratio between the produced PE 100 pipe and the raw material will not exceed ± 20%.
  • The breaking strength must comply with ISO 6259-1 Standard.
  • The breaking extension should be min. 350% according to ISO 6259-1 standard.
  • PE 100 class raw material carbon black amount When tested according to ISO 6964 standard, the amount found should be between 2% and 2.5%.
  • Carbon black distribution test on samples taken from pipelines produced from PE 100 class raw materials shall be carried out according to ISO 18553 standard. he PE 100 grade raw material oxidation time is 200 ° C min.
  • When tested according to ISO 11357-6 standard. It should be 20 minutes.
  • Pipes produced from PE 100 class raw material must have a meat thickness of 26.5 - 30 mm.
kuzeyboru-borukuzeyboru-borukuzeyboru-boru

1.3.1 Raw Material Special Conditions

  • The raw material will be in the form of carbon black added, extrusion-ready granules to increase resistance to harmful sunlight (UV).
  • The manufacturer will provide all the features of the raw material.
  • The raw material must be guaranteed by the raw material manufacturer, which is based on - 40 C temperature.
  • Pipes and fittings must be supplied by the manufacturer with chemical properties together with chemical resistance.

1.4 Mention Pressure

The nominal pressure is the maximum operating pressure level at which the HDPE 100 pipe can be used, calculated on the basis of the service life at 20 C of 50 (fifty) years by the Contractor.

The HDPE pipe and special part will be at least 8 bar in small diameter Q250 and at least 6 bar in Q250 and larger diameter than nominal pressure Q250.

HDPE pipes shall be classified at the following nominal pressures: PN (bar); 6, 8, 10, 12, 5, 16, 20, 25 The connections between the PN, S and SDR values of the MRS Class given material at 20 ° C according to EN 12201-2.

SDR
(Standard Size Ratio) 
S
(Pipe Series)
PE100
(PN, Bar)
2612,56
21108
17810
13,66,312,5
11516
9420
7,43,225

1.5 Special Parts

HDPE Pipe Special (Insertion) Parts are as follows:
Elbow : The elbows produced from PE raw materials are produced in accordance with the EF welding method. The elbows are at various angles and are used in the turns of the lines as indicated in the project..

Reducer : The joint used to narrow or expand the pipe diameter.

T-piece / Inegal T-piece : The HDPE EF Inegal Te insert, which is the raw PE100 and unequal TE, is used for the connection of HDPE pipes with different diameters and is joined by electrofusion method. This additional part is used in valves and branches in main and intermediate line outputs as HDPE Ef Equal Te.


Electrofusion saddle : The used to draw the direction of the fluid in the desired direction by ejecting the desired diameter without using Ef Semer TE joint piece with Hammaddesi PE100.

Electrofusion coupling : It is an insert used in joints made by electrofusion method. Two pipes with the same diameter are inserted into this insert.The flow to the resistances in the insert, both tubes are allowed to stick together.

Flange Adapter : The part required to connect the flanges of different types of pipes. The method of joining on the special parts and the necessary technical values shall be stated. Steel flanges to be used in flange adapters must be epoxy painted against corrosion. The steel flanges shall be delivered to the flanges of the steel valves to be used in the water lines in the appropriate pressure class and with suitable bolt holes. HDPE special parts will be produced by injection method only and will be the same as inner diameter and pressure class, pipe inner diameter and pressure class of special part.

1.6 Dimensions and Tolerance

• The manufacturer shall provide technical drawings and all measurements of pipes and fittings in all diameters and pressures manufactured by the manufacturer.
• Pipes and fittings shall be dimensioned and tolerant to DIN 16963. Manufacturers must undertake that the pipes and fittings of all diameters of the project being opened to the tender have the production technology. Here you can find the Kuzeyboru Hdpe Size Tolerance table.

2. GENERAL DELIVERY CONDITIONS OF HDPE PIPES

2.1 Marking of pipes and special parts

The name, lot number and pipe registration number information of the raw material manufacturer shall be written on all pipes, pressure class, SDR value, material type, date of manufacture, name of the work, name of the plant, standard number, manufacturer name, pipe diameter. These markings to be made shall not necessarily be erased at least once in all pipelines and shall be carried out properly during the production phase so that they can be read easily by the naked eye at least one meter away. Normal storage conditions, weather conditions, laying and handling will not affect the readability of the marks. Signs will not cause crack initiation or similar damage. When used with marking printing, the color used will be different from the main color of the substrate. The pipe special parts, the manufacturer name, SDR value, raw material class (PE100), production date and special part registration number shall be written in such a way as not to be erased. Products to be joined by electrofusion welding will also have barcode labels and source parameters on the barcode.

2.2 Inspection and Experiments

The administration, contractor and producer representative together with TS EN 12201-1, TS EN 12201-2 on the site site and TS EN 12201-3 for special parts and additionally sampling for each experiment required by DSİ: DSİ laboratories shall submit experiments to relevant laboratories in accordance with TS EN ISO / IEC 17025, which will be suitable for the relevant requirements, and shall carry out tests according to the specifications specified in the specification. This will be the record number information of the pipe / special part in the minutes to be recorded. Experiments will not be carried out at the manufacturer's premises and even at the manufacturer's laboratory where pipe / special parts are supplied, even if it is accredited.

The number of samples for the tests shall be determined from Table 2 according to the total number of pipes / specific parts, regardless of diameter and pressure class.

Table 2 Number of samples
The number of pipes or special partsSamples Number
≤ 250 3
251 - 500 4
501 – 1.250 5
1.251 – 2.500 8
2.501 – 5.000 10
5.001 - 10.000 15
>10.00030

All the tests in Schedule 3 shall be carried out on each sample determined according to Table-2.

 
Experiment Name
Experimental Management
Aranan Şartlar
1Visual inspection TS EN 12201-2 Borular, herhangi bir büyüteç kullanılmadan çıplak gözle muayene edildiğinde; iç ve dış yüzeyleri düzgün olacak, herhangi bir çukur, çatlak vb. diğer yüzey kusurları bulunmayacaktır.
2Wall thicknessTS EN ISO 3126 TS EN 12201-2 Çizelge-2'ye uygun olacaktır.
3Outside DiameterTS EN ISO 3126 TS EN 12201-2 Çizelge-1'e uygun olacaktır.
4OvalityTS EN ISO 3126 TS EN 12201-2 Çizelge-1'e uygun olacaktır.
5DensityTS EN ISO 1183 -1 ≥ 950 kg/m3 (23 °C)
6The amount of carbon blackISO 6964 %2 ≤ (kütlece %) ≤ %2,5 Kül miktarı ≤ % 0,1 (kütlece)
7Carbon black distributionTS ISO 18553 ≤ 3,0
A1, A2, A3 veya B
8Amount of volatile matterEN 12099 ≤ 350 mg/kg
9Oxidation induction time (OIT)TS EN 728,
TS EN ISO 11357-6
≥ 20 dk (200 °C, 15±2 mg)
10Mass melt flow rate (MFR).TS EN ISO 1133 0,20 g/10 dk ≤ MFR (190 °C, 5 kg yük altında) ≤ 0,35 g/10 dk
(Hammadde - boru MFR değeri arasındaki fark maksimum ± %10 )
11Break extensionEN ISO 6259-3 ≥ %500 (ekstansometre ile ölçülecektir) Tek parça halinde, liflenme veya yapraklanma olmadan kopacaktır
12Hydrostatic PressureEN ISO 1167-1, EN ISO 1167-2 80 °C, 5,4 MPa yük, 165 saat veya 20 °C, 12 MPa yük, 100 saat sonunda hasar meydana gelmeyecektir.

3. Construction of Pipeline Lines

3.1 Transport and Storage of Pipes

All necessary equipment and workmanship shall be provided by the Contractor in respect of loading, site or storage and transport and evacuation.
All the pipes in the premises shall be protected against adverse weather conditions and pollution during transportation and storage. On the pipes which are not laid in 30 days; Sunshine against sun rays, netting etc.
Will be covered. Contaminated pipes will be cleaned before installation. Pipes and special parts will be furnished within 1 (one) year from the production date, even if storage conditions are good.
Materials exceeding this period shall be immediately removed from the construction site area with the cost of the contractor. Measures shall be taken to prevent any damage during the transportation, loading and unloading of the pipes and special parts, and the pipes shall be taken against the rolling, sliding, bending and vibration. All liability in this respect shall belong to the Contractor. It will be lowered and removed as much as possible to prevent pipe damages. Only rope or rubber ropes will be used for loading or unloading. In case of visible defects and damages, pipes and special parts belonging to the contractor shall be removed immediately from the site site. Pipes shall not be moved by dragging during laying on the ground, when the welding process is applied at the edge of the trench and after it is placed in the trench, Will not be pulled out by dragging in such a way that appropriate handling and pulling means will be used. Displacement of the pipes, abrupt removal of the lifting belts, release or abandonment of the pipes quickly or to other places, etc. The pipes and special parts will be protected against impacts in the form of impact. There are some important considerations to keep in mind when storing HDPE pipes after production. -Precautions should be taken against stacking and the suggested height should be 1.5 meters. - The recommended lining for coil is silage. It is important not to disturb the balance in the kangallars which are taken individually. -Flat pipes should be arranged horizontally in order and should not be angled between bottom row and top row. The side supports should prevent the sliding of the pipes. Stacking of pipes - Pipes must be stored away from sharp objects in a horizontal plane. - The PE fittings must be stored in a closed package. - PE pipes and fittings should be protected from waste water, dirt and soil. (Figure 2). If 1.5 meters of stacking is desired, a bunk system will be created to provide support for 1.5 meters of pipelines from the ground (Figure 3). Will be created and 1.5 meters of piping will be supported from the ground (Figure 3). Pipe and special parts will not be damaged or permanently deformed. The pipe stack will be secured in such a way as to prevent the rolling of the pipes, and point contact will certainly be avoided. The pipes will not collapse randomly, the pipes will be uniform, and the paint will be from the side. The pipes will be stacked on the pipelines by placing 4 10x10 planks for 12 m pipe length which will not be laid on the soil.


Image 2. Stacking of pipes

Toprak zemin : Earth ground
Image 3. The pipeline is about 1.5 meters above the stacking height

Image 4. Stacking over the plank

  • If it is compulsory to store pipes in places where there is a danger of frost, the piping and the flooring will definitely be separated from each other and the adhesion to the floor will be avoided.
  • When a pipe is taken from a storage site, the Contractor will ensure that the remaining pipes are not slipped.
  • When the landfill is evacuated, the Contractor will clear out the area and all the way in and out and bring it back to its original state.
  • The pipes will be protected against rolling.
  • Pipes shall be shipped internally with a minimum diameter of at least two nominal diameters on the factory floor or in the construction site, but shall not be stored internally.

3.2 Combining Method

The merge shall be carried out in accordance with one of the following methods, which the tender authority shall consider appropriate.
A-butt welding
B- Joining with double sided corner weld.
C- Joining with single sided corner weld.
D-eelectrofusion combining

You can find more technical information on joining methods here.

4. Sealing Test of Pipe Line

The sealing test shall be carried out regularly during the installation, not exceeding 500 m.
There will be no pipes of different pressure class in the section to be tested. Before starting the experiment, the controls will be carried out in the following order to ensure that the part to be tested is correctly assembled:

  • it will be checked again whether the connectors are correctly installed.
  • The pipeline will be fixed in place and correctly with the anchor mass or other anchors.
  • The flange bolts will be tightened to the specified torque values.
  • The pipeline fill will be completed.
  • Pumps and valves to be used for testing shall be anchored or fitted
  • On the test line, the end point of the pipe will be supported to prevent axial movement of the pipe.

The sliding valves of the suction cups will be opened and water will be supplied. The tiled pipeline will be filled with water up to 1/10 of the line feed. When the pipeline is filled with water, all air in the line is checked to see if the suction cups are working. If the suction cup is detected, even if the suction is stopped and the suction cups are working, the water will continue to be supplied.

The two manometers will be placed at the lowest pressure point where the highest pressure value of the pipeline to be tested can be read. The sealing test in the room shall be made according to the nominal pressure of the pipe.

Once the water is filled and the valves closed, the line will be pressurized to the nominal pressure with a suitable pump within 10 minutes. Piping will continue to pump for the next 10 minutes after reaching the nominal pressure. Pumping will be stopped and the pipeline will be monitored for 30 minutes. If there is a fall in pressure, water repellent will be provided to provide the desired pressure. If the nominal pressure does not deviate by less than 5% over the next 90 minutes, the line will be considered leakproof. To be acceptable for this experiment, water will not leak in pipelines, special parts, fittings and all kinds of fittings.

If water leaks (dripping, water leaking, etc.) are detected during the test; The pipeline will gradually be emptied so that there will be no water left in the experiment. The test will be carried out again in shorter sections and after the leaks have been completely removed.


Contact with KUZEYBORU

Kuzeyboru İletişim
Mavi Piksel
Kuzeyboru Plastik Sanayi ve Ticaret Limited Şirketi
Organize Sanayi Bölgesi 1.Cadde 2.Sokak No:33/A
Aksaray-TURKEY
+90 (382) 266 23 03 (Pbx)
info[at]kuzeyboru.com.tr

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