PE PIPE PRODUCTION PROCESS, QA/QC REQUIREMENTS &
STANDARDS
MWANZA SEMINAR
22nd July 2015
PRODUCTION PROCESS
Plastic conversion process
The manufacturing processes related to Polyethylene involve the melting of the raw material and then its conversion to form a finished product
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Common process Manufacture of
EXTRUSION Pipes, Films etc.
INJECTION MOULDING Pipe fittings and other complicated shapes
BLOW MOULDING Bottles etc.
ROTO MOULDING Tanks, Large containers
A Modern HDPE Extrusion Line
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Constant speed
Simplified Diagram of an Extruder
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The Pipe Extrusion Process
Extruder BarrelDie
Sizing / Calibration
Cooling /Haul Off
Finished Pipe
Electric Heaters
Screw
Material Hopper
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The Pipe Extrusion Process
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HDPE RAW MATERIAL MOLTEN MATERIAL
FROM DIE HEAD
FINISHED PIPE
The Pipe Manufacturing Process
The extrusion process is used in manufacturing of solid wall
pipes for pressure systems
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State-of-the-art Machines
PLASCOs latest European made large diameter PE pipe production line, can produce HDPE pipes of up to 630mm OD The largest size covered by the international standards
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State-of-the-art Machines
Vacuum tank and Ovality Control Unit
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State-of-the-art Machines
Ultrasonic Pipe Scanner for continuous wall thickness measurement
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HDPE Pipes for water and other applications
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HDPE pipes can be produced in straight lengths for pipes up to 630mm OD and coils for pipes of up to 125mm OD.
Plasco Gas Pipe Production
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Plasgas 355mm PE100 SDR11 Gas Pipe
Marking of Pipes.Traceability
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Marking of Pipes.Traceability
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ALL pipes from PLASCO are clearly marked with the
following information :
Manufacturer name
Diameter
Pressure rating
ISO Standard
Manufacturing details
Marking of Pipes.Traceability
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OF PIPES WITH NO MARKINGS.!!!
THEY MAY BE CHEAPER BUT.. DO THEY MEET THE REQUIRED STANDARDS ???IT WILL COST YOU MORE IN THE LONG RUN !
International PE Pipe Standard ISO 4427
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HDPE Pipes from Plasco are produced to the latest revision of the international standard
International uPVC Pipe Standard ISO 1452
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uPVC Pipes from Plasco are produced to the latest revision of the international standard
QA/QC REQUIREMENTS& STANDARDS
QUALITY ASSURANCE
Tests for Raw Materials
Melt Flow Index Test
Bulk Density Test
Oxidation Induction Time Test
Moisture Content Test
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Why use raw material from reputed producers?
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Did you know that
All PE100 materials are not the same
High performance grades designed for gas pipe extrusion
Not all the raw materials meet the demanding requirements of the
PE100+ association
Using PE100+ endorsed raw material guarantees consistent
quality that ensures a long pipe life
QUALITY ASSURANCE
Tests for Finished Products (Pipes and Fittings) Dimensions Test Thermal Reversion Test Impact Test Long Term and Short Term Hydrostatic Pressure
Tests @ 20C or 80C Rapid Crack Propagation (RCP) test for Gas Pipes Tensile Strength and Compression Test
We can supply Quality and Test Certificates
with all our products
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Potential problems & consequences
Low quality of raw material
Addition of Fillers
Sub-standard machinery
Incorrect tolerances
Poor quality control
Lack of testing facilities
Non-compliance with specified standards
No after sales service
Problems with installation
Pipe failure
Safety issues
Downtime
Production losses
Increased cost ie doing the job twice
Must consider long term costs
PROBLEMS CONSEQUENCES
Are you getting value for your money ?
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How do we do it..
Fully equipped Laboratory for testing Raw Materials & Pressure pipes
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Quality Control & Assurance at Plasco
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Plasco deploys state-of-the-art automated, European equipment to
ensure high quality product output
and minimize manual errors
Quality Control & Assurance at Plasco
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Service Agreement with SCITEQ,
Denmark
Maintenance of our quality control equipment is of high priority -
annual service agreement with
SCITEQ is in place.
Calibration, maintenance and necessary repairs are carried out
at regular intervals.
A long, reliable lifetime of the equipment is ensured resulting in
reliable and accurate test results.
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From Raw materials to Finished goods, our quality control regime ensures top class products being
delivered to our customers
Quality Control & Assurance at Plasco
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Pressure tests are carried out round-the-clock with 10 test stations
that are monitored by PC-software
and temperature control tanks.
Quality Control & Assurance at Plasco
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Rapid Crack Propagation (RCP) testing:
For determining arrest or propagation of a crack initiated
in a thermoplastic pipe intended for the supply of gases
or liquids at a specific temperature and internal pressure.
Small-scale steady-state test (S4 test).
Quality Control & Assurance at Plasco
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Tensile strength and elongation testing:
For determining tensile strength properties of raw materials
Quality Control & Assurance at Plasco
RAPID CRACK PROPAGATION TEST
RAPID CRACK PROPAGATION TEST
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Classic example of a RCP failure on site
RCP failure
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Figure represents a creep rupture curve where the ductile-brittle transition signals the onset of a SCG.
RCP failure
THANK YOU
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PLASCO LTD.
Your one-stop-shop for
piping solutions
www.plasco.co.tz
Sales Hotlines : +255 717 752 726 / +255 686 350 543 / +255 769 756 495