Amiantit Polyolefin Piping Systems Co.

Product Guide HDPE Pipe Systems

1 General 2 Introduction 3 Production Process 4 Product Advantages 5 Product Characteristics

5.1 Molecular structure 5.2 Raw material classifications 5.3 Raw material colour 5.4 Pipe material classification 5.5 Material regression curve 5 5 6 6 6

2 2 3 4 5

01 02 03 04 05

6 Product Technical Data

6.1 Pipe wall thickness/weight/tolerances etc. 6.2 Steel backing rings dimensions 6.3 Allowable bending radius 6.4 Support Distance of HDPE Pipes (PE 100) 6.5 Excellent flow characteristics 6.6 Overall Service (Design) Coefficient (C) or Safety Factory 6.7 UV Resistance 6.8 Abrasion Resistance 6.9 Thermal Expansion & Contraction 6.10 Reduction Factor 6.11 Chemical Resistance Data 7 8 9 9 10 11 11 11 11 11 11

06

7 Product Range
7.1 Pipes 7.2 Fitting and accessories 7.2.1 Electrofusion Fittings and Adaptors 15 7.2.2 Injection-moulded Fittings 17 7.2.3 Segment-Welded Fittings 18 7.2.4 Compression Fittings Pe100 Sdr11 Pn16 19 14 15

13

07

8 Quality Control
8.1 QC test method with reference standards 8.2 Certificates and approvals 22 23

21

08

9 Underground Installations
9.1 Trenching & bed preparation 9.2 Trench construction & dimensions 9.3 Backfilling 24 24 24

24

09

10 Pipe Joining
10.1 Butt-fusion welding process 10.2 Electrofusion welding process 10.3 Compression coupling joint 10.4 Flange connection joint 27 27 28 28

24

10

11 Handling, Unloading and Storage

11.1 Straight lengths and bundles 11.2 Coils 29 29

29

11

12 Location Plan
1

31

12

01 02 03 04 05 06 07 08 09 10 11

1 General

Amiantit Group of Companies

The Amiantit Group is a leading global industrial organization which manufactures high-quality pipe systems and researches, develops, owns and licenses advanced pipe technologies; it also provides water management services. The Group supports global infrastructure development projects and delivers to municipal, industrial, agricultural and energy markets worldwide. Amiantit has a presence in more than 70 countries, including almost 30 wholly-owned or joint-ventured manufacturing facilities in the Middle East, Europe, Latin America, North Africa, The Far East, Central Asia, the Indian Subcontinent and Africa. Amiantit manufacturing capabilities are supported by technology companies and sales offices across the globe. Other members of the Group are predominantly limited liability companies, owned by the Amiantit Group in varying percentages, which operate under individual commercial registrations.

Amiantit Polyolefin Piping Systems Co.

APPSCo Amiantit Polyolefin Piping Systems Company (APPSCo) is a member of the Amiantit Group of companies and started full commercial production in 2002. The company manufactures high density polyethylene (HDPE) solid wall pipe for pressure applications (with diameters ranging from 16 mm to 630 mm). In addition to this, APPSCo has the in-house capabilities to produce all types of related fittings, in order to provide its customers with complete piping systems and solutions. APPSCo, constructed on a 100,000 m2 site in Al-Khumra, South Jeddah, Saudi Arabia, uses the most advanced and up-todate extrusion technology to ensure consistent high-quality products - with an annual capacity over 16,000 tons - while the plant is able to increase its capacity in accordance with market demand and requirements.

2 Introduction
The worlds infrastructure is ageing. Millions of kilometres of gas, water and sewer pipe need rehabilitation. The predicament is a worldwide problem in industrial countries, although this is not the case in many developing countries, where an ageing infrastructure is not a problem. A water infrastructure does not exist and it remains to be constructed. But these nations are facing other, difficult decisions about how to build and what materials to use in order to avoid what has happened in the more developed countries. The main problem encountered in ageing structures is corrosion. And corrosion is not a reversible process. Internally unprotected sewer pipes are rapidly deteriorating due to the presence of sulphuric acid in sanitation (sewerage) systems, which is generated through the hydrogen sulphide cycle. Externally, soil conditions and stray electrical currents deteriorate underground pipes. Metallic pipes corrode when placed in poorly-drained soils with low resistivity. The presence of sulphate-reducing bacteria accelerates this corrosion. These problems can be significantly reduced, if not eliminated, by careful selection of pipe materials, which should have corrosion-resistance protection. The remedy to this situation is very simple: Amiantit Polyolefin APPSCo pipes.

3 Production Process

01 02 03 04 05 06 07

APPSCo is equipped with a modern continuous extrusion process polyethylene pipe-manufacturing facility. APPSCo is capable of producing both High Density Polyethylene (HDPE) and Medium Density Polyethylene pipes in accordance with ISO 4427, DIN 8074 for water applications and ISO 4473, ASTM D2513 for gas applications - and any other standard required by the customers. The production process starts with the raw material, which can be either virgin HDPE and is in the form of granules. These are set to dry in the dryer in order to evaporate any water or moisture that has condensed on the raw material granules. This is then transported to the main hopper system, which doses the measured, weighed raw material into the extruder. The extruder heats the raw material to a temperature of between 180 and 200C (356-392 F) which is the idle temperature

for extrusion and shaping of HDPE. This is then ejected from the extruder in a continuous pipe shape to the screen changer. The screen changer examines the extruded product for impurities and removes them accordingly. Once the product has been extruded and cleansed of any impurities, the die and mandrel section takes place. In this section both the diameters and standard pipe dimensions are set, the die shapes the pipe diameter and the mandrels set the standard pipe dimensions (SPD). When the product has taken its final shape, it moves to the cooling & vacuum tanks. In the cooling tank the pipes are calibrated and cooled down for the final stage. The final stage consists of marking, cutting or possibly coiling the pipes.

08 09 10 11

Raw Material

Conveying System

Silo

Dryer

Main Compound Feeder

Additives Feeder

Colling Section Upto 180 mm Pipe Marking

Cooling Parts Dumping Tray Cutting Haul Off Ultrasonic Measurement

Cooling Tank Tooling (Mandrel and Die)

Extruder

Calibrator

Screen Changer

01 02 03 04 05 06 07 08 09 10 11

4 Product Advantages

Feature
High flexibility combined with high impact resistance

Benefits
Can be supplied as coils of up to 160 mm (external pipe diameter). Coils reduce the number of joints and stress to the site. Under the same conditions, PE pipe develops much lower surge pressures than rigid pipes. Unaffected by soil settlement. High tenacity and anti-impact intensity. Excellent resistance against inappropriate handling with low notch sensitivity and high tear resistance With no damage to or effect on the pipes short & long term properties

Squeeze-off ability

UV resistance

With no damage to or effect on the pipes short & long term properties

High chemical and corrosion resistance

Does not rust or corrode scaling and corrosion by electrolytic actions. Lower life cycle cost, long life expectancy. Very low maintenance. Withstands aggressive soil conditions, ground water. Suitable for use with a broad range of chemicals. Resistance to all natural gas constituents.

Non-toxic material

Approved for use in drinking water applications. Approved for food contact.

Abrasion resistance

HDPE pipes outperform conventional pipes, depending on the application, by a factor of 7

Low thermal conductivity Excellent flow characteristics

Thermal conductivity value of 0.4 W/m.C Polyolefin pipes have a hydraulically smooth bore. In the Colebrook formula K is equal to 0.001; in the Hazen-Williams formula C is equal to 155.

4.1 HDPE Pipes Applications

Polyolefin piping systems are used in many applications such as: Hot & cold water system Drinking potable water supply Irrigation Storm water drainage Land drainage Drainage of leachate systems Industrial water Chemical process piping Fire fighting system 4 Domestic gas & oil pipe systems Waste disposal Sewer network Sewer & effluent treatment plants Outfalls Waste damps Industrial waste Sand & slurry pumping Cable ducts (non-pressure pipes)

5 Product Characteristics

01 02 03 04 05 06 07

5.1 Molecular Structure

Polyethylene (PE) is a polymer consisting of long chains of the monomer ethylene C2H4, also known as ethane. The molecules, which consist of two CH2 groups, are connected by a double bond.

The properties of polyethylene are primarily determined by density, molecular weight and molecular weight distribution. The material properties vary in accordance with density. When density increases, the following properties also increase: Yield stress (tensile strength), Modulus of elasticity, Hardness, Solvent resistance, Impermeability to gases and vapours.

08 09 10 11

5.2 Raw Material Classifications

Figure 5-1 HDPE chain molecules Polyethylene is classified into several different categories, based mostly on its density and branching. The mechanical properties of PE depend significantly on variables such as the extent and type of branching, the crystal structure and the molecular weight. Below is a clarification of only the two classifications of PE that Appsco uses for producing its pipes HDPE (High density polyethylene) HDPE is characterized by a density of greater than or equal to 0.941 g/cm3.It has a low degree of branching and thus stronger intermolecular forces and tensile strength. The lack of branching is ensured by an appropriate choice of catalyst and reaction conditions. HDPE is also used in packaging products. Figure 5-2 Single HDPE molecule

Figure 5-3 Chemical chart of HDPE

The HDPE (High density poly-ethylene) pipe grade material that APPSCo uses has a low degree of branching, with short side chains (linear polyethylene). The short side chain allows higher crystallisation, thus resulting in higher density and better material properties.

01 02 03 04 05 06 07 08 09 10 11

5.3 Raw Material Colour

HDPE basic materials are classified as a non-coloured material. Pre-compounded, coloured HDPE or materials from the supplier are recommended for the manufacturing of pipes; HDPE is available in black, & blue. Other colour can be provided based on request.

Classification of HDPE PE 80 PE 100

Classification number 80 100

MRS MPa 8 10

Table 5-1 Classification of HDPE material

5.5 Material Regression Curve

The material regression curve shows the material strength in relation to the time at various temperatures (20 C, 60 C and 80 C). Following the SEM-evaluation according to ISO/TR 9080 for the HDPE material, the regression curves of both PE 100 and PE 80 material is as shown in the following figures:

Figure 5-4 Non-coloured HDPE granules

Figure 5-6 Material regression curve for PE 80

Figure 5-5 Coloured HDPE granules

Figure 5-7 Material regression curve for PE 100 Note:

Pipe colour is dictated by the applications for which they are to be used. Black and blue coloured pipes are for potable water applications and yellow are for gas applications. Other pipe colours are possible depending on the relevant water/district authority requirements.

The points below need to be considered / submitted by the pipe manufacturer in order to confirm the right material to be used: Raw material technical data sheet. Proof of the material having been listed as PE 100 or PE 80, by third parties (e.g. the Plastic pipe institute Listing in technical report TR # 4, or Ral listing for HDPE material). Third party long term test report to show MRS value and the raw material regression curve as per ISO/TR 9080.

5.4 Pipe Material Classification

High density polyethylene (HDPE) pipe grade material is classified as PE 100 and PE 80. The classification number for a thermoplastic material is 10 times the minimum required strength of the material (MRS) as shown in the following table 6

In the case of potable water, the material supplier and material code need to be approved by organizations to in order to confirm their compliance with ANSI # 61 (NSF and WRAS). UV stabilizers, colour, antioxidants and pigments are included in the pre-compounded material.

6 Product Technical Data

Standard dimension ratio (SDR)

Product technical data PE100

Nominal pressure (PN) bar PN 16 PN 12.5 PN 10 PN 8 PN 6 PN 5

7.4 9 11 13.6 17 21 26 33 41

PE 100

PN 25

PN 20

Outside diameter Ovality[1] PN 4 OD{2}

Pipe OD Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance [3] Linear weight[4] Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight[4] (mm) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) [3](mm) (kg/m) - - - - 16.3 1.2 - - - - 20.3 1.2 - - - - 25.3 1.2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32.3 1.3 - 40.4 1.4 - 50.4 1.4 - 63.4 1.5 - 75.5 1.6 - 90.6 1.8 - 110.7 2.2 - 125.8 2.5 - 140.9 2.8 - - - 161.0 3.2 - 181.1 3.6 - 201.2 4.0 - 226.4 4.5 - 251.5 5.0 - 281.7 9.8

16 0.3 2.3 0.4 0.10 2.0 0.3 0.09 - - - - - - - - - - - - - - -

20 0.3 3.0 0.4 0.16 2.3 0.4 0.13 2.3 0.3 0.12 - - - - - - - - - - - - - - - - - - - - - -

25 0.3 3.5 0.5 0.24 3.0 0.4 0.21 2.3 0.4 0.17 2.0 0.3 0.15 - - - - - - - - - - -

32 0.3 4.4 0.6 0.39 3.6 0.5 0.33 3.0 0.4 0.28 2.4 0.4 0.23 2.0 0.3 0.19 -

40 0.4 5.5 0.7 0.60 4.5 0.6 0.51 3.7 0.5 0.43 3.0 0.5 0.36 2.4 0.4 0.29 2.0 0.3 0.25

50 0.4 6.9 0.8 0.94 5.6 0.7 0.79 4.6 0.6 0.67 3.7 0.5 0.55 3.0 0.4 0.45 2.4 0.4 0.37 2.0 0.3 0.31 - -

63 0.4 8.6 1.0 1.48 7.1 0.9 1.26 5.8 0.7 1.05 4.7 0.6 0.87 3.8 0.5 0.72 3.0 0.4 0.58 2.5 0.4 0.49 - -

75 0.5 10.3 1.2 2.10 8.4 1.0 1.77 6.8 0.8 1.47 5.6 0.7 1.24 4.5 0.6 1.01 3.6 0.5 0.82 2.9 0.4 0.67 - -

90 0.6 12.3 1.4 3.02 10.1 1.2 2.56 8.2 1.0 2.13 6.7 0.8 1.77 5.4 0.7 1.46 4.3 0.6 1.18 3.5 0.5 0.97 - -

110 0.7 15.1 1.7 4.52 12.3 1.4 3.80 10.2 1.1 3.16 8.1 1.0 2.63 6.6 0.8 2.17 5.3 0.7 1.78 4.2 0.6 1.43 - - - -

125 0.8 17.1 1.9 5.81 14.0 1.6 4.91 11.4 1.3 4.16 9.2 1.1 3.38 7.4 0.9 2.77 6.0 0.7 2.27 4.8 0.6 1.84 - -

14 0 0.9 19.2 2.1 7.30 15.7 1.7 6.15 12.7 1.4 5.11 10.3 1.2 4.24 8.3 1.0 3.48 6.7 0.8 2.84 5.4 0.7 2.32 - -

160 1.0 21.9 2.3 9.51 17.9 1.9 8.01 14.6 1.6 6.70 11.8 1.3 5.53 9.5 1.1 4.54 7.7 0.9 3.73 6.2 0.8 3.05 - -

180 1.1 24.6 2.6 12.02 20.1 2.2 10.14 16.4 1.8 8.47 13.3 1.5 7.02 10.7 1.2 5.74 8.6 1.0 4.68 6.9 0.8 3.79 - -

200 1.2 27.4 2.9 14.87 22.4 2.4 12.53 18.2 2.0 10.45 14.7 1.6 8.61 11.9 1.3 7.08 9.6 1.1 5.80 7.7 0.9 4.71 - -

225 1.4 30.8 3.2 18.79 25.2 2.7 15.87 20.5 2.2 13.23 16.6 1.8 10.93 13.4 1.5 8.98 10.8 1.2 7.33 8.6 1.0 5.91 - -

250 1.5 34.2 3.6 23.20 27.9 2.9 19.5 22.7 2.4 16.27 18.4 2.0 13.47 14.8 1.6 11.01 11.9 1.3 8.97 9.6 1.1 7.33 - -

280 1.7 38.3 4.0 29.09 31.3 3.3 24.51 25.4 2.7 20.40 20.6 2.2 16.87 16.6 1.8 13.83 13.4 1.5 11.32 10.7 1.2 9.14 - -

315 1.9 43.1 4.5 36.82 35.2 3.7 31.01 28.6 3.0 25.82 23.2 2.5 21.39 18.7 2.0 17.51 15.0 1.6 14.23 12.1 1.4 11.64 9.7 1.1 9.40 7.7 0.9 7.53 316.9 11.1

355 2.2 48.5 5.0 46.69 39.7 4.1 39.38 32.2 3.4 32.77 26.1 2.8 27.12 21.1 2.3 22.29 16.9 1.8 18.07 13.6 1.5 14.72 10.9 1.2 11.89 8.7 1.0 9.58 357.2 12.5

400 2.4 54.7 5.6 59.30 44.7 4.6 49.95 36.3 3.8 41.61 29.4 3.1 34.38 23.7 2.5 28.17 19.1 2.1 23.04 15.3 1.7 18.66 12.3 1.4 15.14 9.8 1.1 12.14 402.4 14.0

450 2.7

- 50.3 5.2 63.25 40.9 4.2 52.69 33.1 3.5 43.55 26.7 2.8 35.69 21.5 2.3 29.14 17.2 1.9 23.59 13.8 1.5 19.07 11.0 1.2 15.31 452.7 15.6

500 3.0

- - 55.8 5.7 77.94 45.4 4.7 65.01 36.8 3.8 53.74 29.7 3.1 44.09 23.9 2.5 35.95 19.1 2.1 29.10 15.3 1.7 23.52 12.3 1.4 19.06 503.0 17.5

560 3.4

- -

- 50.8 5.2 81.45 41.2 4.3 67.43 33.2 3.5 55.24 26.7 2.8 44.99 21.4 2.3 36.48 17.2 1.9 29.60 13.7 1.5 23.73 563.4 19.6

630 3.8

- -

- 57.2 5.9 103.19 46.3 4.8 85.22 37.4 3.9 69.96 30.0 3.1 56.83 24.1 2.6 46.22 19.3 2.1 37.34 15.4 1.7 30.02 633.8 22.1

[1] Ovality tolerances calculated as per ISO 11922-1 Grade N [2] OD tolerances calculated as per ISO 11922-1 grade B (0.006 DN, rounded up to the next greater 0.1 mm with minimum value of 0.3 mm and max 4.0 mm. [3] Thickness tolerances calculated as per ISO 11922-1 grade V (0.1WTmin +0.1) mm rounded up to the next 0.1 mm. [4] The weight calculated with average density of 0.955 g/cm.

11

10

09

08

07

06

05

04

03

02

01

11

10

09

08

07

06

05

04

03

02

01

Product technical data PE80

Standard dimension ratio (SDR)

Nominal pressure (PN) bar PN 12.5 PN 10 PN 8 PN 6 PN 5 PN 4

7.4 9 11 13.6 17 21 26 33 41

PE 80

PN 20

PN 16

Outside diameter Ovality[1] PN 3.2 OD{2}

Pipe OD Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance [3] Linear weight[4] Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight Minimum W.T W.T tolerance Linear weight[4] (mm) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) [3](mm) (kg/m) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20.3 1.2 - 25.3 1.2 - 32.3 1.3 - 40.4 1.4 - 50.4 1.4 - 63.4 1.5 - 75.5 1.6 - 90.6 1.8 - 110.7 2.2 - 125.8 2.5 - 140.9 2.8 - - - 161.0 3.2 - 181.1 3.6 - 201.2 4.0 - 226.4 4.5 - 251.5 5.0 - 281.7 9.8

16 0.3 2.3 0.4 0.10 2.0 0.3 0.09 - - - - - - - - - - - - - - - - - - - 16.3 1.2

20 0.3 3.0 0.4 0.16 2.3 0.4 0.13 2.0 0.3 0.12 -

25 0.3 3.5 0.5 0.24 3.0 0.4 0.21 2.3 0.4 0.17 2.0 0.3 0.15 - -

32 0.3 4.4 0.6 0.39 3.6 0.5 0.33 3.0 0.4 0.28 2.4 0.4 0.23 2.0 0.3 0.19 - -

40 0.4 5.5 0.7 0.60 4.5 0.6 0.51 3.7 0.5 0.43 3.0 0.5 0.36 2.4 0.4 0.29 2.0 0.3 0.25 - -

- - - - -

50 0.4 6.9 0.8 0.94 5.6 0.7 0.79 4.6 0.6 0.67 3.7 0.5 0.55 3.0 0.4 0.45 2.4 0.4 0.37 2.0 0.3 0.31 - -

63 0.4 8.6 1.0 1.48 7.1 0.9 1.26 5.8 0.7 1.05 4.7 0.6 0.87 3.8 0.5 0.72 3.0 0.4 0.58 2.5 0.4 0.49 - -

75 0.5 10.3 1.2 2.10 8.4 1.0 1.77 6.8 0.8 1.47 5.6 0.7 1.24 4.5 0.6 1.01 3.6 0.5 0.82 2.9 0.4 0.67 - -

90 0.6 12.3 1.4 3.02 10.1 1.2 2.56 8.2 1.0 2.13 6.7 0.8 1.77 5.4 0.7 1.46 4.3 0.6 1.18 3.5 0.5 0.97 - -

110 0.7 15.1 1.7 4.52 12.3 1.4 3.80 10.0 1.1 3.16 8.1 1.0 2.63 6.6 0.8 2.17 5.3 0.7 1.78 4.2 0.6 1.43 - - - -

125 0.8 17.1 1.9 5.81 14.0 1.6 4.91 11.4 1.3 4.10 9.2 1.1 3.38 7.4 0.9 2.77 6.0 0.7 2.27 4.8 0.6 1.84 - -

140 0.9 19.2 2.1 7.30 15.7 1.7 6.15 12.7 1.4 5.11 10.3 1.2 4.24 8.3 1.0 3.48 6.7 0.8 2.84 5.4 0.7 2.32 - -

160 1.0 21.9 2.3 9.51 17.9 1.9 8.01 14.6 1.6 6.70 11.8 1.3 5.53 9.5 1.1 4.54 7.7 0.9 3.73 6.2 0.8 3.05 - -

180 1.1 24.6 2.6 12.02 20.1 2.2 10.14 16.4 1.8 8.47 13.3 1.5 7.02 10.7 1.2 5.74 8.6 1.0 4.68 6.9 0.8 3.79 - -

200 1.2 27.4 2.9 14.87 22.4 2.4 12.53 18.2 2.0 10.45 14.7 1.6 8.61 11.9 1.3 7.08 9.6 1.1 5.80 7.7 0.9 4.71

225 1.4 30.8 3.2 18.79 25.2 2.7 15.87 20.5 2.2 13.23 16.6 1.8 10.93 13.4 1.5 8.98 10.8 1.2 7.33 8.6 1.0 5.91

250 1.5 34.2 3.6 23.20 27.9 2.9 19.50 22.7 2.4 16.27 18.4 2.0 13.47 14.8 1.6 11.01 11.9 1.3 8.97 9.6 1.1 7.33

280 1.7 38.3 4.0 29.09 31.3 3.3 24.51 25.4 2.7 20.40 20.6 2.2 16.87 16.6 1.8 13.83 13.4 1.5 11.32 10.7 1.2 9.14

315 1.9 43.1 4.5 36.82 35.2 3.7 31.01 28.6 3.0 25.82 23.2 2.5 21.39 18.7 2.0 17.51 15.0 1.6 14.23 12.1 1.4 11.64 9.7 1.1 9.40 7.7 0.9 7.53 316.9 11.1

355 2.2 48.5 5.0 46.69 39.7 4.1 39.38 32.2 3.4 32.77 26.1 2.8 27.12 21.1 2.3 22.29 16.9 1.8 18.07 13.6 1.5 14.72 10.9 1.2 11.89 8.7 1.0 9.58 357.2 12.5

400 2.4 54.7 5.6 59.30 44.7 4.6 49.95 36.3 3.8 41.61 29.4 3.1 34.38 23.7 2.5 28.17 19.1 2.1 23.04 15.3 1.7 18.66 12.3 1.4 15.14 9.8 1.1 12.14 402.4 14.0

450 2.7

- 50.3 5.2 63.25 40.9 4.2 52.69 33.1 3.5 43.55 26.7 2.8 35.69 21.5 2.3 29.14 17.2 1.9 23.59 13.8 1.5 19.07 11.0 1.2 15.31 452.7 15.6

500 3.0

- - 55.8 5.7 77.94 45.4 4.7 65.01 36.8 3.8 53.74 29.7 3.1 44.09 23.9 2.5 35.95 19.1 2.1 29.10 15.3 1.7 23.52 12.3 1.4 19.06 503.0 17.5

560 3.4

- -

- 50.8 5.2 81.45 41.2 4.3 67.43 33.2 3.5 55.24 26.7 2.8 44.99 21.4 2.3 36.48 17.2 1.9 29.60 13.7 1.5 23.73 563.4 19.6

630 3.8

- -

- 57.2 5.9 103.19 46.3 4.8 85.22 37.4 3.9 69.96 30.0 3.1 56.83 24.1 2.6 46.22 19.3 2.1 37.34 15.4 1.7 30.02 633.8 22.1

[1] Ovality tolerances calculated as per ISO 11922-1 Grade N [2] OD tolerances calculated as per ISO 11922-1 grade B (0.006 DN, rounded up to the next greater 0.1 mm with minimum value of 0.3 mm and max 4.0 mm. [3] Thickness tolerances calculated as per ISO 11922-1 grade V (0.1WTmin +0.1) mm rounded up to the next 0.1 mm. [4] The weight calculated with average density of 0.955 g/cm.

Table 6-1 Pipe wall thickness/weight/tolerances

PCD ID T D
(AS PER ANSI CLASS 150 B16.5)

HDPE pipes steel backing rings for stub flanges

(AS PER DIN STANDARD) EN-1092-1 DIN-2577, PN10/16

PIPE OD Backing ring Pressure OD of backing ID PCD Bolt hole No. of Bolt size Torque Thickness External dia. ID PCD Bolt hole No. of Bolt size Torque Galvanised steel (mm) size (mm) PN (Bar) ring (mm) (mm) (mm) dia. (mm) bolts value (mm) (mm) (mm) (mm) dia. (mm) bolts (inches) value (thickness) (N.mm) (N.mm) mm 20 15 16 95 28 65 14 4 M12 15 12 90 32 60.5 16.0 4 1/2 15 11.1 25 20 16 105 34 75 14 4 M12 15 14 98 37 70.0 16.0 4 1/2 15 12.7 32 25 16 115 42 85 14 4 M16 15 16 108 44 79.5 16.0 4 1/2 15 14.3 40 32 16 140 51 100 18 4 M16 25 18 117 52 89.0 16.0 4 1/2 25 17.5 50 40 16 150 62 110 18 4 M16 35 18 127 62 98.5 16.0 4 1/2 35 17.5 63 50 16 165 78 125 18 4 M16 35 18 152 78 120.5 20.0 4 5/8 35 19.0 75 65 16 185 92 145 18 8 M16 40 18 178 92 139.5 20.0 4 5/8 40 22.3 90 80 16 200 108 160 18 8 M16 40 20 191 108 152.0 20.0 4 5/8 40 23.9 110 100 16 220 128 180 18 8 M16 40 20 229 128 190.5 20.0 8 5/8 40 23.9 125 100 16 220 135 180 18 8 M16 45 20 254 140 216.0 23.0 8 3/4 40 23.9 140 125 16 250 158 210 18 8 M16 50 24 254 158 216.0 23.0 8 3/4 50 23.9 160 150 16 285 178 240 22 8 M20 60 24 279 178 241.0 23.0 8 3/4 60 25.4 180 150 16 285 188 240 22 8 M20 60 24 279 195 241.0 23.0 8 3/4 60 25.4 200 200 16 340 235 295 22 12 M20 70 24 343 235 298.5 23.0 8 3/4 70 28.4 225 200 16 340 238 295 22 12 M20 70 24 343 240 298.5 23.0 8 3/4 70 28.4 250 250 16 405 288 355 26 12 M24 100 30 406 290 362.0 26.0 12 7/8 100 30.2 280 250 16 405 294 355 26 12 M24 100 30 406 300 362.0 26.0 12 7/8 100 30.2 315 300 16 460 338 410 26 12 M24 110 34 483 345 432.0 26.0 12 7/8 110 31.8 355 350 16 520 376 470 26 16 M24 160 42 535 376 476.0 29.0 12 1 160 35.0 400 400 16 580 430 525 30 16 M27 170 46 600 430 540.0 29.0 16 1 170 36.6 450 500 16 715 517 650 33 20 M30 190 45 635 480 578.0 32.0 16 1.1/8 190 39.6 500 500 16 715 535 650 33 20 M30 190 45 700 533 635.0 32.0 20 1.1/8 190 43.0 560 600 16 840 618 770 36 20 M33 220 50 750 590 692.0 34.9 20 1.1/4 220 46.0 630 600 16 840 645 770 36 20 M33 220 50 815 660 750.0 35.0 20 1.1/4 220 47.8

Table 6-2 Steel backing rings dimensions

11

10

09

08

07

06

05

04

03

02

01

01 02 03 04 05 06 07 08 09 10 11

6.3 Allowable Bending Radius

Appsco polyethylene products are smoother than steel, cast iron, ductile iron, or concrete etc, a smaller PE pipe can carry an equivalent volumetric flow rate at the same pressure. It has less drag and a lower tendency for turbulence at high flow. Because of Its superior chemical resistance, Appsco PE pipes are flexible in behavior, and can be readily bent in the field. In general terms, a minimum bending radius of (20-28 x DN) outside diameter of the pipe be adopted for PE 100 and PE 80 material. Minimum allowable bending radius at 24C. (in meters)
OD (mm) SDR 9 SDR 11 SDR 13.6 SDR 17 SDR 21 20 0.4 0.5 0.5 0.5 0.6 25 0.5 0.6 0.6 0.7 0.7 32 0.6 0.8 0.8 0.9 0.9 40 0.8 1.0 1.0 1.1 1.1 50 1.0 1.3 1.3 1.4 1.4 63 1.3 1.6 1.6 1.7 1.8 75 1.5 1.9 1.9 2.0 2.1 90 1.8 2.3 2.3 2.4 2.5 110 2.2 2.8 2.8 3.0 3.1 125 2.5 3.1 3.1 3.4 3.5 140 2.8 3.5 3.5 3.8 3.9 160 3.2 4.0 4.0 4.3 4.5 180 3.6 4.5 4.5 4.9 5.0 200 4.0 5.0 5.0 5.4 5.6 225 4.5 5.6 5.6 6.1 6.3 250 5.0 6.3 6.3 6.8 7.0 280 5.6 7.0 7.0 7.6 7.8 315 6.3 7.9 7.9 8.5 8.8 355 7.1 8.9 8.9 9.6 9.9 400 8.0 10.0 10.0 10.8 11.2 450 9.0 11.3 11.3 12.2 12.6 500 10.0 12.5 12.5 13.5 14.0 560 11.2 14.0 14.0 15.1 15.7 630 12.6 15.8 15.8 17.0 17.6

6.4 Support Distance of HDPE Pipes (PE100)

SIZE SDR 26 SDR 21 SDR 17 SDR 13.6 SDR 11 SDR9 20 0.5 0.5 0.6 0.6 0.6 0.7 25 0.5 0.6 0.7 0.7 0.7 0.8 32 0.6 0.7 0.8 0.8 0.9 0.9 40 0.7 0.9 0.9 1.0 1.0 1.1 50 0.9 1.0 1.0 1.1 1.2 1.2 63 1.0 1.2 1.2 1.3 1.4 1.4 75 1.1 1.3 1.4 1.5 1.5 1.6 90 1.3 1.5 1.6 1.7 1.7 1.8 110 1.5 1.7 1.8 1.9 2.0 2.1 125 1.6 1.8 2.0 2.1 2.2 2.3 140 1.7 2.0 2.1 2.2 2.4 2.5 160 1.9 2.2 2.3 2.5 2.6 2.7 200 2.2 2.5 2.7 2.9 3.0 3.2 225 2.4 2.7 2.9 3.1 3.3 3.4 250 2.6 3.0 3.1 3.3 3.5 3.7 280 2.8 3.2 3.4 3.6 3.8 4.0 315 3.0 3.4 3.7 3.9 4.1 4.3 355 3.3 3.7 4.0 4.2 4.4 4.7 400 3.5 4.0 4.3 4.5 4.8 5.0 450 3.8 4.4 4.7 4.9 5.2 5.5 500 4.1 4.7 5.0 5.3 5.6 5.9 5 60 4.4 5.1 5.4 5.7 6.0 6.0 630 4.8 5.5 5.8 6.2 6.5 6.8

Note: 1. All distance are quoted in meters. 2. These distances should not be used for gravity pipelines.

10

01 02 03 04 05 06 07

6.8 Abrasion Resistance

HDPE Pipes have high resistance to abrasion. When conveying solids or slurries that contain coarse- particlesize solids with velocities up to 3 m/s, the expected lifetime of HDPE pipe is much longer than that of other materials like steel, cement and PVC. In general terms HDPE Pipes have superior abrasion resistance to other traditional material and provide a more cost effective solution for abrasive slurry installation.

08 09 10 11

6.9 Thermal Expansion & Contraction

As a result of temperature changes, all materials experience the thermal expansion/ contraction phenomena. Coefficient of linear expansion of polyethylene is higher than most other piping materials. (1.8 x 10-4 mm/mm.C). Forces generated by thermal stresses are much lower due to lower modulus of elasticity of polyethylene and its capability to stress relaxes.

6.5 Excellent Flow Characteristics

Because polyethylene is smoother than steel, cast iron, ductile iron, or concrete, a smaller PE pipe can carry an equivalent volumetric flow rate at the same pressure. It has less drag and a lower tendency for turbulence at high flow. Its superior chemical resistance and non-stick surface combine to almost eliminate scaling and pitting and preserve the excellent hydraulic characteristics throughout the pipe service life.

6.10 Reduction Factor

Two major factors (working pressure vs. temperature) plays major role in the life span and performance of HDPE Pipes. HDPE can give optimum performance under 20 C Temperature. However, if an environment where temperature and working pressure both are high, the following reduction factor in the lifes span of HDPE Pipe will apply: Reduction Factor Vs. Temperature
Reduction Factor
1 0.8 0.6 0.4 0.2 0

6.6 Overall Service (Design) Coefficient (C) or Safety Factor

C is the overall coefficient with a value greater than 1, which takes into consideration service conditions as well as properties of the components of a piping system other than those represented in the lower confidence limit. Safety factors shall be specified in the appropriate product standards. According to ISO 12162 standard, the minimum safety factor for polyethylene pipes is 1.25 for water application and 2 for gas application as per ISO 4437.

20

30

40 C

50

60

6.11 Chemical Resistance Data

Unlike other piping materials, polyethylene is highly resistant to a wide range of chemical solutions such as acids, bases and solvents (refer to the following table for more details). Polyethylene pipe will not degrade due to chemicals in the soil. It does not support the microbiological growth as bacteria, fungi and algae. The resistance to a certain chemical depends on three factors: temperature, and chemical concentration. Two major factors (working pressure vs. temperature) plays major role in the life span and performance of HDPE Pipes. HDPE can give optimum performance under 40 Temperature. However, if an environment where temperature and working pressure both are high, the following reduction factor in the lifes span of HDPE Pipe will apply:

6.7 UV Resistance
HDPE material has generally excellent prolonged weatherability properties and can readily withstand wide variations of weather without degradation. The finely divided carbon black particles dispersed in the HDPE material (2 to 2.5% by weight) will surely ban the effect of the ultraviolet (UV) waves existing in the sunlight. Hence, unlike other plastic materials, HDPE pipes can be stored for years without any fear of degrading and require no additional protection for external storage, or prolonged use in natural conditions.

11

01 02 03 04 05 06 07 08 09 10 11

Chemical Acrylic emulsions Aluminum Chloride Aluminum Chloride con Aluminum Fluoride con Aluminum Sulfate con Ammonia 100% dry gas Ammonium Carbonate Ammonium Chloride sat Ammonium Fluoride 20% Ammonium Metaphosphate sat Ammonium Persulfate sat Ammonium Sulfate sat Ammonium Sulfide sat Ammonium Thiocyanate sat Aniline 100% Antimony Chloride Barium Carbonate sat Barium Chloride Barium Sulfate sat Barium Sulfide sat Benzene Sulfonic Acid Bismuth Carbonate sat Black Liquor Borax Cold sat Boric Acid d Boric Acid 10% Bromine Liquid 100% Butanediol 10% Butanediol 60% Butanediol 100% Butyl Acetate 100% Calcium Bisulfide Calcium Carbonate sat Calcium Chlorate sat Calcium Hypochlorite Bleach Calcium Nitrate 50% Calcium Sulfate Carbon Dioxide 100% dry Carbon Dioxide 100% wet Carbon Dioxide 100% cold sat Carbon Disulphide Carbon Monoxide Chlorine liquid Chlorosulfonic Acid Chromic Acid 50% Cider

20C S S S S S S S S S S S S S S S S S S S S S S S S S S O S S S O S S S S S S S S S NA S O U S

60C S S S S S S S S S S S S S S NA S S S S S S S S S S S U S S S U S S S S S S S S S U S U U O

Chemical Coconut of alcohols Copper Chloride sat Copper Cyanide sat Copper Fluoride Copper Nitrate sat Copper Sulfate d Copper Sulfate sat Cuprous Chloride sat Cyclohexanone Dextrin sat Dextrose sat Disodium Phosphate Diethylene Glycol Emulsions Photographic Ethyl Chloride Ferric Chloride sat Ferric Nitrate sat Ferrous Chloride sat Ferrous Sulfate Fluoboric Acid Fluorine Fluosilicic Acid 325 Fluosilicic Acid conc Formic Acid 20% Formic Acid 50% Formic Acid 100% Fructose sat Fuel oil Glycol Glycolic acid 30% Hydrobromic acid 30% Hydrocyanic acid sat Hydrochloric Acid 30% Hydrofluoric Acid 40% Hydrofluoric Acid 60% Hydrogen 100% Hydrogen Bromide 10% Hydrogen Chloride Gas dry Hydroquinone Hydrogen Sulfide Hypochlorous Acid conc Lead Acetate sat Magnesium carbonate sat Magnesium Chloride sat Magnesium Hydroxide sat Magnesium Sulfate sat

20C S S S S S S S S S S S S S O S S S S S S S S S S S S S S S S S S S S S S S S S S S S

60C S S S S S S S S S S S S S U S S S S S S S S S S S U S S S S S S S S S S S S S S S S

U U

S U

S S

S S

S S

12

Table Continues Chemical Mercuric Chloride Mercuric Cyanide sat Mercurous Nitrate sat Methyl Ethyl Ketone 100% Methyl Bromide Methylsulfuric Acid Methylene Chloride 100% Nickel Chloride sat Nickel Citrate Conc Nickel Sulfate sat Nicotinic Acid Nitric Acid <50% Nitrobenzene 100% Oleum conc Oxalic Acid d Oxalic Acid sat Petroleum Ether Phosphoric Acid 0-30% Phosphoric Acid 90% Photographic Solutions Potassium Bicarbonate sat Potassium Borate 1% Potassium Bromate 10% Potassium Bromide sat Potassium Carbonate Potassium Chlorate sat Potassium Chloride sat Potassium Chromate 40% Potassium Cyanide sat Potassium Ferri/Ferro Cyanide Potassium Fluoride Potassium Nitrate sat Potassium Perborate sat Potassium Perchlorate 10% Potassium Permangante 20 % Propargyl Alcohol Propylene Glycol Propargyl Alcohol Potassium Sulfate conc Potassium Sulfide conc Potassium Sulfite conc Potassium Persulfate sat Sea Water Shortening Silicic Acid 20C S S S U O S U S S S S S U U S S U S S S S S S S S S S S S S S S S S S S S S S S S S S S 60C S S S U U S U S S S S S U U S S U S S S S S S S S S S S S S S S S S S S S S S S S S S S Chemical Sodium Acetate sat Sodium Benzoate 35% Sodium Bisulfate sat Sodium Bisulfite sat Sodium Borate Sodium Bromide Oil sol Sodium Carbonate conc Sodium Carbonate Sodium Chlorate sat Sodium Chloride sat Sodium Cyanide Sodium Dichromate sat Sodium Ferricyanide sat Sodium Ferro cyanide Sodium Fluoride sat Sodium Nitrate Sodium Sulfate Sodium Sulfide 20% to sat Sodium Sulfite sat Stannous Chloride sat Stannic Chloride sat Starch Solution sat Sulfuric Acid <50% Sulfuric Acid 96% Sulfuric Acid 98% conc Sulfurous Acid Tannic Acid 10% Tetralin Tetrahydrofuran Tichloroacetic Acid Trisodium Phorphate sat Urea Urine Wetting Agents Xylene Zinc Chloride sat Zinc Sulfate sat Legend: S: Satisfactory O: Some Attack U: Unsatisfactory NA: No Data Available d: Diluted Conc.: Concentrated sat: Saturated sol: Solution 20C S S S S S S S S S S S S S S S S S S S S S S S O O S S 60C S S S S S S S S S S S S S S S S S S S S S S S U U S S

01 02 03 04 05 06 07 08 09 10 11

U U O O S S S S

S S S S S S S S S S U U

S S

13

01 02 03 04 05 06 07 08 09 10 11

7 Product Range

7.1 Pipes
APPSCo has four production lines and can supply an extensive range of pipes, as well as an outstanding range of fittings and accessories. The product range includes: PE solid wall pipe from gravity up to 16 bar as a standard rating and up to 32 bar on specific standard requirements. Pipes with an outside diameter between 16 mm and 630 mm. 12-meter standard pipe length Diameters of up to 160 mm can be supplied on coils.

Fittings are available as injection-moulded, electrofusion, segment-welded or compression mechanical coupling parts and include:
DIA

Tees/ reduced tees wyes (45,60) Bends/ elbows.

Reducers. Flanges connections. Saddles / tapping tees/ valves. Cross X

OD Z (mm) (mm)

Laying length (mm)

110 269 538 125 275 550 140 281 562 160 289 578 180 297 594 200 305 610 225 315 630 250 325 650 280 337 673 315 351 701 355 642 1283 400 660 1319 450 680 1359 500 700 1399 560 723 1447 630 751 1503

7.2.1 Segment Welded Fittings

22.5 , 30 elbow

14

22.5, 30

7.2 Fitting and Accessories

01 02 03 04 05 06 07
45 Elbow
45

90 Elbow
Z
M
Z
M

08 09
DIA

10 11

DI

OD Z M (mm) (mm) (mm) 110 269 72

Laying length (mm) 610

OD Z M (mm) (mm) (mm) 110 269 93

90

Laying length (mm) 362

125 275 81 631 140 281 90 652 160 180 200 225 250 280 315 355 400 450 500 560 630 289 297 305 315 325 337 351 642 660 680 700 723 751 102 114 127 142 157 175 197 221 248 279 309 346 388 680 708 737 772 807 848 898 1504 1567 1638 1708 1793 1891

125 275 105 380 140 281 117 398 160 289 133 422 180 297 149 446 200 305 165 470 225 315 185 500 250 325 205 530 280 337 228 565 315 351 256 607 355 642 288 930 400 660 324 984 450 680 364 1044 500 700 404 1104 560 723 452 1175 630 751 508 1259

60 Elbow
60

Equal Tee
Z
OD

90

OD L

DI

OD Z M (mm) (mm) (mm)

Laying length (mm)

OD Z L (mm) (mm) (mm) 110 340 680 125 350 700 140 350 700 160 360 720 180 370 740 200 380 760 225 400 800 250 400 800 280 420 840 315 440 880 355 730 1460 400 750 1500 450 780 1560 500 800 1600 560 830 1660 630 870 1740

110 269 93 631 125 275 105 655 140 281 117 679 160 289 133 711 180 297 149 743 200 305 165 775 225 315 185 815 250 325 205 855 280 337 228 901 315 351 256 957 355 642 288 1571 400 660 324 1643 450 680 364 1723 500 700 404 1803 560 723 452 1899 630 751 508 2011

15

01 02 03 04 05 06 07 08 09 10 11
OD 90 OD

Cross (X)

60 Wye

Z2

60 OD L2 Z1
L

OD Z L (mm) (mm) (mm) 110 340 680 125 350 700 140 350 700 160 360 720 180 370 740 200 380 760 225 400 800 250 400 800 280 420 840 315 440 880 355 730 1460 400 750 1500 450 780 1560 500 800 1600 560 830 1660 630 870 1740

OD Z2 Z1 Laying length 110 577 282 859 (mm) (mm) (mm) (mm) 125 588 286 874 110 458 282 739 140 599 290 889 125 467 286 753 160 613 296 909 140 476 290 766 180 627 302 929 160 487 296 783 200 642 307 949 180 499 302 801 225 660 315 974 200 511 307 818 250 678 322 1000 225 525 315 840 280 700 330 1030 250 540 322 862 315 725 340 1065 280 558 330 888 355 1252 652 1904 315 578 340 918 400 1284 665 1949 355 1016 652 1668 450 1320 679 1999 400 1043 665 1707 500 1356 693 2050 450 1072 679 1751 560 1400 711 2110 500 1101 693 1795 630 1450 731 2181 560 1137 711 1847 630 1178 731 1908

45 Wye

Z2

45 OD L Z1

OD Z2 Z1 (mm) (mm) (mm)

Laying length (mm)

110 577 282 859 125 588 286 874 140 599 290 889 160 613 296 909 180 627 302 929 200 642 307 949 225 660 315 974 250 678 322 1000 280 700 330 1030 315 725 340 1065 355 1252 652 1904 400 1284 665 1949 450 1320 679 1999 500 1356 693 2050 560 1400 711 2110 630 1450 731 2181

16

01 02 03 04 05 06 07
7.2.2 Electro Fusion Fittings and Adapters
EF Coupling EF End Cap EF Service Tee Set valued EF Service Tee Set flat with clamps

08 09 10 11

Pressure rating: SDR11 PN16 & SDR17 PN10 EF End 90 Elbow

Pressure rating: SDR11 PN16 & SDR17 PN10 EF End 45 Elbow

Pressure rating: SDR11 PN16 & SDR17 PN10

Pressure rating: SDR11 PN16 & SDR17 PN10

Pressure rating: SDR11 PN16 & SDR17 PN10 EF Concentric Reducer

Pressure rating: SDR11 PN16 & SDR17 PN10 EF Equal Tee

Pressure rating: SDR11 PN16 & SDR17 PN10 EF Service Tee Set Flat

Pressure rating: SDR11 PN16 & SDR17 PN10 EF Repair Adapter

Pressure rating: SDR11 PN16 & SDR17 PN10

Pressure rating: SDR11 PN16 & SDR17 PN10

17

01 02 03 04 05 06 07 08 09 10 11
7.2.3 Injection Moulded Fittings
90 Elbow 60 Elbow
Steel Flange (Backing Ring) Bland Steel Flange

Pressure rating: SDR11 PN16 & SDR17 PN10 45 Elbow

Pressure rating: SDR11 PN16 & SDR17 PN10 End Cap

Pressure rating: SDR11 PN16 & SDR17 PN10

Welded Steel Transition Adapter

Pressure rating: SDR11 PN16 & SDR17 PN10

Transition Adapter Female

Pressure rating: SDR11 PN16 & SDR17 PN10 Equal Tee

Pressure rating: SDR11 PN16 & SDR17 PN10 Reducer Tee Pressure rating: SDR11 PN16 & SDR17 PN10 Transition Adapter Male Pressure rating: SDR11 PN16 & SDR17 PN10

Pressure rating: SDR11 PN16 & SDR17 PN10 Reducer

Pressure rating: SDR11 PN16 & SDR17 PN10 Flange Adapter Pressure rating: SDR11 PN16 & SDR17 PN10

Pressure rating: SDR11 PN16 & SDR 17 PN10

Pressure rating: SDR 11 PN16 & SDR17 PN10

18

01 02 03 04 05 06 07
7.2.4 Compression Fittings PE100 SDR11 PN16
Coupling OD20 mm up to OD110 mm Reducing Coupling OD20 x 25 mm up to OD110 x 90 mm Flange Adaptor (Stub Flange) OD20 mm up to OD630 mm End Cap OD20 mm up to OD315 mm

08 09 10 11

Male Adaptor D20 mm x 1/2 up to OD110 mm x 4

Female Adaptor OD20 mm x 1/2 up to OD 110 mm x 4

Reducing Tee OD20 x 16 x 20 mm up to OD1 10 x 90 x 1 10 mm

Repair Slip Coupling OD40 mm up to OD110 mm

Equal Tee OD20 mm up to OD110 mm

Elbow 90 AND 45 OD20 x 25 mm up to OD110 x 90 mm

Female Tee With Peg Fitting OD32 mm x 34 x 32 mm

90 Elbow With Lateral Threaded Female Take Off OD25 mm x 25 mm x 12

Tee With Threaded Female Take Off OD20 mm x 12 up to OD110 mm x 4

Tee With Threaded Female Take Off OD20 mm x1/2x20 mm up to OD110 mm x4x110 mm

90 Tee With Increased Take Off OD20 x 25 x 20 mm up to OD40 x 50 x 40 mm

Universal Transition Coupling OD15 x 25 mm up to OD34 x 32 mm

19

01 02 03 04 05 06 07 08 09 10 11
Male Adaptor With Brass Threaded Insert OD20 mm x 12 up to OD63 mm x 2 Female Adaptor With Brass Threaded Insert OD20 mm x 12 up to OD63 mm x 2

Clamp Saddle OD25 mm x 12 up to OD125 mm x 3

Double Clamp Saddle OD25 mm x 12 up to OD125 mm x 2

Clamp Saddle with Reinforcing Ring OD25 mm x 12 up to OD125 mm x 3

Double Clamp Saddle with Reinforcing Ring OD25 mm x 12 up to OD125 mm x 2

Clamp Saddle with Reinforcing Ring PN 16 OD25 mm x 12 up to OD110 mm x 2

Double Clamp Saddle with Reinforcing Ring PN 16 OD25 mm x 12 up to OD110 mm x 2

20

8 Quality Control

01 02 03 04 05 06 07

8.1 QC Test Method With Reference Standards

Property : Melt mass flow rate (MFR) Reference test : ISO 1133

08
Property : Density Reference test : ISO 1183 Standard value : Density shall fall within PE material density range ( 0.94 ).

09 10 11

Standard value : 0.27 0.068 change in MFR value caused by processing, between the measured value for material from the pipe and the measured value for the compound, must not be greater than 25%.

Equipment:

Equipment:

Property : Tensile test Property : Longitudinal reversion (shrinkage) Reference test : ISO 2505-1 Standard value : Longitudinal reversion (shrinkage) shall be 3%. Reference test : ISO 6259 1.3 Standard value : Elongation at break must be 350%

Equipment:

Equipment:

Property : Carbon black content Property : Thermal stability oxidation induction time (OIT) Reference test : ISO / TR 10837 Standard value : O.I.T. must be 20 minutes when tested at 210 C Reference test : ISO 6964 Standard value : The content of carbon black shall be 2.25 0.25% by mass

Equipment:

Equipment:

21

01 02 03 04 05 06 07 08 09 10 11
Property : Dispersion of carbon black Reference test : ISO 11420 Standard value : Carbon black dispersion must be Grade 3 as per ISO 4427 requirements, and appearance rating must not be inferior to micrograph B1 in annex B of ISO 11420 Equipment: Property : Wall thickness and outside diameter measurement Reference test : ISO 3126 Standard value : Wall thickness must confirm to 11922 (Grade T Tolerance for minimum wall thickness up to 16 mm) and (Grade U tolerance for wall thicknesses exceeding 16 mm). OD must confirm to ISO 11922 grade B

Equipment:

Property : Environmental stress cracking resistance Property : Hydrostatic strength Reference test : ISO 1167 Standard value : More than 100 hours, @ 20C on stress level: 12.4 MPa for PE 100 9 MPa for PE 80 More than 165 hours, @ 80C on stress level: 5.5 MPa for PE 100 4.6 MPa for PE 80 Reference test : ASTM D 1693 Standard value : Condition A more than 2,000 h

Equipment:

Equipment:

22

01 02 03 04 05 06 07

8.2 Certifcates and Approvals

APPSCo pipe systems have been tested and approved for the conveyance of drinking water and meet the criteria of many of the worlds leading authorities and testing institutes, including: NSF certificate for drinking water applications, in compliance with NSF/ANSI 61 standard. NSF Certificate # 1S731-01 Health effects testing (Test report by NSF) Standard: 261 DWA Std. 61 (Drinking water system components health effects) 1st Test report # PM04475 2nd Test report # PM04475 WRAS (Water Regulations Advisory Scheme) certificate for passing full tests in respect of effect on water quality in accordance with BS 6920. Certificate # CR/JC - Test Report 253K Black-coloured polyethylene pipe and fittings are for cold water and hot water up to 50 C and are ISO 9001/2000 certified. HDPE pipes are approved by FM (Factory Mutual) as per Standard Class 1613 for firefighting system. Materials certificate # 145281 laboratory attestation certificate showing the capability to perform all the required testing in connection with the incoming raw materials, in process inspections, and HDPE finished product pipes in accordance with the relevant standards, namely: ISO 4427 ISO 1133 ISO 1183 ISO 11420 ISO/TR 10837 ISO 2505 ISO 1167 ISO 6259 An inspection certificate, issued by a well-known third party, confirming that the procedure mentioned in the test method (for all the tests available in our laboratory testing facility) is followed. Certificate #: SAR.R.4.03.299.AC01 Bodycote testing test reports for burst testing as per ASTM D 1599 To pass the requirement at the following temperatures 30 C, 40 C, 45 C, 50 C, 55 C, and 60 C, polyethylene raw materials are delivered with a vendor certification demonstrating their compliance with APPSCo quality requirements. In addition, all raw materials are sample-tested prior to use. These tests ensure that the pipe materials comply with the specifications stated. Figure 8-3 Burst testing report from Bodycote Figure 8-4 ISO 9001 certification from TV

08 09 10 11

Figure 8-1 Material Certifica- Figure 8-2 Testing methods according to SASO certification attestation tions from TV

Figure 8-5 Water quality test Figure 8-6 National Sanitaand report from WRAS tion Foundation certification

23

01 02 03 04 05 06 07 08 09 10 11

9 Underground Installations

Polyolefin pipe systems are designed to make installation quicker, easier and more cost-effective. Installation is as much a part of the costing equation as ease of maintenance and the cost of the pipe system itself. Polyolefins great advantages in terms of installation are its lightness and flexibility, coupled with its durability and totally secure jointing methods. For all modern pipelaying techniques, whether in rehabilitation work or the construction of new pipelines above or below ground level, polyolefin systems usually provide the simplest, most economical solution. And indeed, rehabilitation techniques which rely on polyethylenes unique properties have been developed. A major advantage of PE is that pipe lengths can be buttfused or electrofusion-jointed to form a continuous string of pipe and there is normally no need for thrust blocks. This, together with the materials inherent flexibility, makes polyethylene ideally suited to a full range of new and innovative installation techniques

9.2 Trench construction and dimensions

In some instances, it may be acceptable to lay PE pipe directly on the bottom of the trench - but only where the soil is uniform, relatively soft and fine-grained and free from any large flints, stones, or other hard objects that may cause point loading on the pipe. The trench bottom should be brought to an even finish, providing consistent support for pipes along their whole length. In other cases, the trench should be cut to a depth that will allow for the necessary thickness of selected bedding material below the bottom of the pipe. If soil from the excavation is unsuitable, granular material should be imported. Gravel or broken stone graded between five and ten millimetres in size provides suitable bedding, since it requires minimal compaction. Coarse sand, a sand and gravel mix, or gravel smaller than 20 mm are also all acceptable straight from the trench. Unless specified, accurate levelling of the trench bottom is unnecessary for most pressurized systems. The slope should be graded evenly in gravity flow systems. Excavators with narrow buckets are best suited to conventional trenching methods. Pipes are located by being lifted into the correct position. After installation, the ground can be backfilled and consolidated.

9.1 Trenching and bed preparation

Installation of PE/PP systems requires minimal trench width; therefore considerable savings can be made in terms of both reduced labour costs and less waste spoil to be removed from site. Additionally, it cuts reinstatement costs and requires smaller quantities of imported backfill.

Crown Invert

Figure 9-1 Pipe orientation Figure 9-2 Trenching bed layers The dimensions of a trench-line opening are normally governed by the pipe diameter, the jointing method and site conditions. The normal minimum depth of cover for mains should be 900 mm from ground level to the crown of the pipe. Trench width should be as narrow as possible, but typically not less than the outside diameter of the pipe, plus 250 mm to allow for correct compaction of side fill unless specialized narrow trenching techniques are used.

9.3 Backfilling
Unless special procedures apply, suitable excavated material may be returned to the trench and compacted in layers of an appropriate thickness, as specified in the specification, but not exceeding a layer height of 150 mm. Heavy compaction equipment should not be used until the fill over the crown of the pipe is more than 300 mm. For aboveground installations, please contact the APPSCo technical department.

24

10 Pipe Joining

01 02 03 04 05 06 07

APPSCo thermoplastic pipe can be jointed using different methods. This includes jointing by: Butt-fusion welding Electrofusion welding Compression coupling Flange connection

The ends of the two pipes to be welded are secured by the clamps of the welding machine. The end of the loose pipe or the pipe to be added to the pipeline should be placed in the movable hydraulic part of the machine.

08 09 10 11

10.1 Butt-fusion welding process

Polyethylene pipes may be produced, to be connected by means of the butt welding method, depending on the project. However there are limitations for using this jointing system, with regard to both diameter and wall thickness (figure 10-1) . Connection by this welding method can be applied to diameters of between 50 mm and 1600 mm; and in relation to the diameter, to wall thicknesses from 5 mm to 100 mm. The butt-welding process is carried out in accordance with the DVS 2207 standard. Attention should be paid to the following points when connecting PE pipes using the butt-welding method: 1 The temperature the welding environment should not be below 5 C or above 35 C. 5 Prior to the welding process, welding surfaces must be scraped (using the planer by fixing it between the two ends to be welded), any oxidation removed and the welding surfaces must come into complete contact..

Secure the longitudinal movement of the free pipe by using adjustable rollers.

2 The wall thickness of the pipes to be connected must be equal; if there is any difference, then such difference must not exceed 10%.

Pressure

Pressure level under initial heating and under joining and cooling

Head sock pressure Heating time with reduced pressure Time for removal of heating mirror

Initial heating time under pressure

Pressure build-up time Cooling time

Time

Figure 10-1 Illustration of the details during the welding 25

01 02 03 04 05 06 07 08 09 10 11
6 Once the welding surface has been scraped, it must be protected from dirt and the pipe ends need to be cleaned. If there is any re-soiling, the scraping process must be repeated. 8 After this the bead will start forming, and then the cooling period will begin. During the weld cooling period, the connection pressure values of the pipes must be kept equal.

Pipe welding calculation formula:

7

Fix the heating element, (temperature 200 C - 220 C), between the two pipe ends, keep the same hydraulic pressure for the duration of the heating up time, and then remove the heating element within a time frame equal to the release time.

( da2 - di2 ) x Apipe = ______________ ( mm2 ) 4

Welded compression force calculation
F = PSpecific APipe (N) veya dm s ( mm2 ) Symbol Apipe da di dm F Definition Pipe welding area Outer diameter Inner diameter Middle diameter Pressure surge PE = 0.15 N/mm2 PP = 0.10 N/mm2

PSpecific

Table 10-2 Symbol definition Welding pressure 0.15 N/mm2 Bead height (mm) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Heating element remove time (sec) .................5.0 5.0...........6.0 6.0...........8.0 8.0.........10.0 Pipe connection pressure operation time (minutes) ................5.0 5.0.........6.0 6.0.........8.0 8.0.......11.0

Pipe wall thickness (mm) .................4.5 4.5..........7.0 7.0........12.0 12.0........19.0 19.0........26.0 26.0........37.0 37.0........50.0 50.0........70.0

Heat time 0.02 N/mm2 (sec) .................45.0 45.0........70.0 70.0......120.0 120.0......190.0

Cooling time (minutes) .................6.0 6.0........10.0 10.0........16.0 16.0........24.0

190.0......260.0 10.0.........12.0 11.0.......14.0 24.0........32.0 260.0......370.0 12.0.........16.0 14.0.......19.0 32.0........45.0 370.0......500.0 16.0.........20.0 19.0.......25.0 45.0........60.0 500.0......700.0 20.0.........25.0 25.0.......35.0 60.0........80.0

Table 10-1 Optimum welding times of HDPE pipes at 20C environmental temperature
26

01 02 03 04 05 06 07

10.2 Electrofusion welding process

Electrofusion welded joints of polyethylene pipes are made in accordance with international standard DVS 2207. Welding pipes with two different wall thicknesses are possible using this welding method. The electrofusion welding machines used for welding are light; they also facilitate welding with various welding parameters, and filling of the welding made, if necessary. Using the electrofusion welding process, pipes made of the same raw material may be welded. The steps below must be followed before starting electrofusion welding: 1 The solution flow speed for HDPE electrofusion connection is 0.3.....1.7 gr/10 min (190 C/5kg). The solution flow speeds of pipes to be welded and the muff should be between these values. Pipes with the same solution flow speed may be welded. 2 The area in which welding is to take place must be weather-proofed. (For example, protected from snow, rain, wind, effective sunlight, etc.) The temperature of the welding environment must be between 5 C and 50 C. As all welding parameters are controlled by the site machine; the operator needs only to present the barcode (on the code card supplied with the coupling) to the machines reader and the machine setting will be done automatically.

The electrofusion welding procedure is as follows: 1 The entry limit is marked on the pipe, with the pipe edges to be welded properly cut and smooth placed inside the piece to be welded up to the pipe leaning limit (i.e. the limit to which the pipes can lean).

08 09 10 11

2 The surface to be welded must be cleaned and any surface oxidation must be scraped offor to welding.

3 4

5 The pressure test must be initialized at least one hour after the welding process is finished, once the pipes are completely cooled. The pressure test is done in accordance with DIN 4279/1.To commence this procedure 1.5 x PN. pressure is applied to the welded pipes. If this pressure value does not decrease,then the test has been passed.

The pieces to be welded must be unpacked at the welding station. All electrofusion surfaces to be welded, on both pipe and fitting, must be cleaned with industrial alcohol, and once cleaned, they must not be touched.

27

01 02 03 04 05 06 07 08 09 10 11
4 The electrofusion welding ends must be secured, once it has been checked that they are in a straight line with the pipe, with their ends facing upwards. The welding machine sockets are placed at the weld ends and prepared for welding.

10.3 Compression Coupling Joint

The pipes are connected to each other by means of coupling adaptor. Having been cut vertical to its axis, the pipe is inserted into the coupling up to the raised point. When both pipes are in position, the bolts are tightened by hand and the connection thus achieved. If the pipe diameter is 40 mm or higher, the bolts should be tightened using a special wrench rather than by hand. This joining method is not recommended for pipes with diameters exceeding 110 mm.

Once the ready has been displayed by the machine, the welding process will start when the barcode is presented to the machines reader, or when the welding parameters are entered manually. Generally, welding machines display the welding time and voltage on the monitor.

10.4 Flange Connection

A flange joint connection is used for combining PE pipes with equipment such as steel pipes, valves, pumps, and condensers. It is also used in cases where the pipeline needs to be dismantled at a later stage, or for connecting PE pipes to different pipe materials. Steel rings, the flange/backing ring, and the flange adaptor are shown in figure 10-2 . Stub ends are fixed on both ends of the PE pipes and connected with bolts and nuts. Do not torque the bolts in circular order, but in alternate rows. Do not pull on the pipelines while tightening the bolts, in order to prevent causing an overload on the structural elements that guide the pipes. Steel flange Connection with butt welding Plunge + Nut HDPE pipe

Flange adapter Figure 10-2 Flange connection 28

Gasket

Connection with muff

11 Handling and Storage

01 02 03 04 05 06 07

Polyolefin materials are flexible, lightweight and easy to handle. Nevertheless, care should be taken not to cause scuffing or gouging of the surface.

11.2 Coils
Small coils:
Small coils of pipe strapped onto pallets are easily handled by forklift. Large coils of 125 mm to 180 mm pipe will require lifting individually by forklift and can be lifted as shown in the following figures:

08 09 10 11

11.1 Straight Lengths and Bundles

A flatbed vehicle, free from sharp objects and projections, should be used for the transportation of pipe systems. When lifting pipe bundles by crane, wideband slings should be used; do not use chains or hooks. For lengths of over 6 metres, load distributing beams should be inserted, spaced at equal distances. Allow for a certain amount of deflection or slight bending of pipe bundles when loading or unloading. 6 metre bundles may be handled using a forklift, but longer lengths should be moved using a side loader of four supporting forks or by a crane with a load-distributing beam. Individual lengths should be handled in a similar way. Skid timbers and rope slings can be used to ease unloading on site.

Figure 11-1 Pallet off-loading

Figure 11-2 Sample of large diameter coil truck loading

Figure 11-3 Lifting the coiled pipes with a crane and straps

29

01 02 03 04 05 06 07 08 09 10 11
Releasing coils: Pipes held in coils are under high tension and must be strapped accordingly. These can be hazardous if released incorrectly, particularly if the end of the pipe is not kept restrained at all times. It is most important to read and understand the following guidelines before attempting to release coils. When uncoiling coiled pipes with an OD of more than 63 mm, care must be taken to prevent the straps being released suddenly, and the use of an uncoiling stand is recommended. Always: Examine the pipes carefully before installation and any damaged pipes.

Store pipes on flat, firm ground which is able to withstand the weight of the pipes and the lifting apparatus. Stack the heaviest pipe at the bottom. Anchor the load securely to prevent slippage. (As PE pipes have very smooth inner and outer surfaces. Be sure the unloading equipment is rated to handle the weight of the pipe).

For outer bands with additional strapping of individual layers: Do not remove any of these bands until the pipe is required for installation. Remove them carefully, from the outmost layer first, so that only the length of pipe needed immediately is released.

Avoid excessive stacking heights and stack pipes in straight rows. Pipes can become distorted if they are not stored properly. Unload one pallet, bundle, or strip load layer at a time. Truck straps securing a bundle or strip load layer should be released when that bundle or layer is to be unloaded. Keep pipe/fittings well away from sharp objects. Use wide, non-metallic slings.

Successive layers can be released by removing banding as the pipe is drawn away from the coil.

Exercise special care when handling pipes in wet conditions, since they may become slippery. Keep protective packaging intact until the pipes/ fittings are required for use. Keep pipes/fittings away from intense heat, except when jointing. Allow for some bending deflection when pipes are loaded and unloaded. Lifting points should be evenly spaced.

Never: Drag or roll individual pipes or bundles.

Throw or drop the pipe or fitting from the delivery vehicle. Use metal slings, hooks, or chains when handling. Expose pipes or fittings to prolonged sunlight. Stack more than three metres or three bundles high.

Place pipes or fittings in contact with lubricant or hydraulic oils, gasoline, solvents or other aggressive materials.

30

18.50 km N 3.00 km TRAFIC CIRCLE TRAFIC CIRCLE 2.50 km

TO MAKKAH

12 Location Plan

WAREHOUSES AREA

TRAFIC CIRCLE
TO AL-KHUMRA

KING FAISAL NAVAL BASE CHECK POINT AL-MAJADOUE

ARAMCO

AL-KHAIR BRIDGE

TO SOUTH CORNICE

AL-RAAJ STEEL COMPANY

31

211700.71N 391110.22E

AMIANTIT GROUP OF COMPANY GRP AND PE PLANT - JEDDAH

Note :

32

Note :

33

Utmost care has been taken to ensure that all the contents of this brochure are accurate. However, AMIANTIT and its subsidiaries do not accept responsibility for any problems which may arise as a result of errors in this publication. Therefore customers should make inquiries into the potential product supplier and convince themselves of the suitability of any products supplied or manufactured by AMIANTIT and/or its subsidiaries before using them.

Distributed by:

AMIANTIT Polyolefin Piping Systems Co. (APPSCo) P.O. Box 32262 Jeddah 21451 Phone : +966 2 692 94 31 +966 2 651 56 76 Fax : +966 920004070 ext. 2444 +966 2 651 91 49

APPSCo PG V2, 10-12