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Chevron Munaigas Inc. Atyrau Polyethylene Pipe Plant Product catalog Polyethylene pipes, fittings, welding equipment, valves Atyrau 2010
Chevron Munaigas Inc.
Atyrau Polyethylene Pipe Plant
Product catalog
Polyethylene pipes, fittings, welding equipment, valves
Atyrau 2010
About the company
Chevron Energy Corporation has nearly 20 years of experience working in the oil and gas fields of Kazakhstan. During this time, the company has established several joint ventures (TCO, KPO, CTC). Many years ago, Chevron was one of the first companies to begin working to diversify the Kazakh economy.
Its first such project involved creating a network of modern service stations in
Kazakhstan's central cities, which served as the impetus behind the spread of high-quality service stations throughout the country. In 2003, Chevron invested $24 in the construction of a polyethylene pipe plant in Atyrau. All of the projects have been successful and profitable. By 2008, the sales of the Polyethylene Pipe Plant had fully recouped the initial investment.
However, our company never rests on its laurels and continues to work to develop
Kazakhstan's economy. In 2010, work is underway on enhancing the capacity of the Atyrau Plant, which has resulted in a the production of metal-plastic pipes for internal water supply and heating. The Atyrau Plant is also producing high-performance valves for utilities. The project team is developing the conceptual design. Launch is scheduled for the end of 2012.
Company Chevron primarily pays great attention to the quality of their products and
to safe working practices. The Chevron Munaigas Atyrau Polyethylene Pipe Plant is one of Kazakhstan's largest
producers of polyethylene pipes for use in industry and communal services. In its operations, the plant applies the company's 20-year experience of
manufacturing polyethylene pipes in the USA and Mexico. The Atyrau Polyethylene Pipe Plant means the most advanced technology and high-quality raw materials, innovative solutions, highly qualified technical and production staff, and active development of production.
The plant's products meet all requirements in the fields of plumbing, sewerage and
gas systems. We produce gas and water pipes from polyethylene - HDPE high-density
polyethylene, with diameters from 100 to 1200 mm, various wall thicknesses and an operating pressure of up to 25 PSI. Pipes are produced in lengths of 11.85 meters and coils of in lengths of 100 and 200 meters.
We also offer our clients ready-made solutions, such as welding equipment, couplings and valves.
List of standards for manufactured and sold products
Our company takes great pains to ensure the quality of our products. APPP boasts the only accredited laboratory in Kazakhstan . At all stages of manufacturing, we exercise strict control of the production process and the finished products. The laboratory also handles ...
The products manufactured by the Atyrau Polyethylene Pipe Plant meet all standards established for plumbing, sewage and gas pipeline systems.
1 ST RK ISO 4427-2004 (GOST 18599-2001)
Polyethylene pipes for water supply. Specifications
2 ST RK ISO 4437-2004 (GOST Р 50838-95)
Polyethylene pipes for underground feed of gaseous fuels. Metric series. Specifications
3 ST RK ISO 8770-2004 High-density polyethylene pipes and fittings for internal drainage of waste and effluents (low and high temperature). Technical conditions
4 ST RK ISO 8772-2004 (GOST 226-89.0-89)
Polyethylene pipes and fittings for underground drainage and sewage systems. Specifications
5 TU RK-2310 387941781000-002-2005
Polyethylene pipes for water supply. Specifications
6 ST FC 387941781000-003-2006
Low-pressure polyethylene welding parts. Specifications
9 GOST R 52134-2003 in Rev. No. 1
Thermoplastic pressure pipes and fittings for water supply and heating systems. General specifications
Advantages of polyethylene pipes
Polyethylene pipes are an effective energy-efficient for a broad range of transportation tasks in industry, utilities, merchant fleet, mining andagriculture. Polyethylene pipes have proven their capacity for use suspended over land, on the surface, unsupported, floating and underground. Among the transportable itemsare water, effluents, slurry, compressed gases, chemicals and corrosive waste.
High chemical tolerance
There is no material more suitable to withstanding the effects of corrosive acids, alkalis and salts. In addition, polyethylene is not susceptibleto bacteria, fungi and even the majority of "aggressive" soils. Do not require cathodic protection, and therefore do not require service.
Resistant to contamination
The purity of the liquids transported is guaranteed to be free of harmful leached substances. Pipes made of polyethylene are a reliable shield against microorganisms and bacteria, and their inner coating will not allow any harmful impurities to leach into water.
Superior hydraulic characteristics
Polyethylene pipes are a "perfectly smooth pipeline" and provide verylittle resistance to the flow of fluids. Their excellent tolerance to chemical resistance and non-abrasive surface almost negates such problems as the formation of deposits and surface defects, while maintaining their superior hydraulic characteristics over the service life.
Flexibility and strength
Polyethylene pipes allow for cold weather loading and unloading, includingbending. This simplifies installation and reduces costs. The pipes' flexibility pipe allows them to follow the terrain,reducing the need for fittings. Due to the high plasticity of polyethylene, the likelihood of ruptures in a pipeline due to freezing of the liquid transported is minimal, since the pipe does not rupture, but expands, acquiring its former dimensions as the fluid thaws.
Light weight
Made from materials with a densityequal to only 1/8 the density of steel, polyethylene pipes are lightweight and do not require the use of heavy lifting equipment during installation and transportation. Their low weight makes them easier to mount, especially in cramped conditions.
Resistance to abrasion wear
Our considerable experience in using polyethylene pipes in mining, dredging or similar operationshas demonstrated that, when transporting the abrasive slurry, polyethylene pipes wear less than pipes made of more expensive materials.
Hermetically sealed joints
Polyethylene pipes with control of outer diameter along the length of the pipes can be joined into continuous lengths of piping, using the heat soldering method, creating homogeneous connections which are as strong and chemical resistant asthe pipes themselves.
Low thermal conductivity
Thanks to this property, polyethylene pipes lose little heat, with no condensate forming on their surfaces.
Durability
Polyethylene pipes are guaranteed for a service life of 50 years. Polyethylene pipes retain their physical and chemical properties throughout their service lives.
Application of polyethylene pipes
Today, polyethylene pipes are replacing steel pipes, primarily due to their cost-saving benefits. Therefore, the range of applications for polyethylene pipes today considerable:
1. Water supply systems; 2. Gas pipelines; 3. Pressure sewage systems; 4. Transportation of pulp and other abrasive-bearing substances; 5. Aeration systems; 6. Agriculture, irrigation and drip irrigation system; 7. Mining, leaching; 8. Cabling and fiber-optic lines; 9. Factory process pipelines; 10. Transportation of hazardous wastes, acid and alkaline media; 11. Drainage systems; 12. Temporary or bypass pipelines; 13. Underground fire-prevention systems
Raw Materials
Chevron Munaigas Inc. pipes and welded fittings are made of bimodal high-density HDPE100 polyethylene, with an added stabilizer in the form of carbon for UV ray protection. Only top-quality primary raw materials produced by the companies LyondellBasell (Netherlands) and Borealis (Austria) are used in manufacturing our pipes.
Working from the requirements of ISO and GOST standards, as well as Chevron's own high standards for quality, we do NOT USE low-quality secondary raw materials in the production of out pressure pipes!
Below is a table with the characteristics of the raw materials used. Physical and mechanical characteristics of materials
Properties Unit Test method Borealis BorSafeR
HE3490-LS-H
LyondellBasellHostalen CRP100
Color - ISO
1183/ISO1872-2
Black Black RAL 9004
Classification - ISO 9080 10.0 10.0
Density at t 230С kg/м3 ISO
1183/ISO1872-2
959 959
Melt fluidity at a load of 5.0 kg / 1900C
g/10 min ISO 1133 0.25 0.22
Fluidity point at t 230С and flow speed 50 mm/min MPa ISO 527-2 25 23
Elongation at break, at t 230C and flow speed 50 mm/min
% ISO 527-2 >600 >350
Modulus of flexure t 230С and flow speed 1 mm/min MPa ISO 527-2 1100 900
Vicat softening point 5 kg
0С ISO 306 - 74
Brittleness temperature 0С ASTM D 746 <-70 <-70
Thermal stability min EN 728 >20 >20
(2000C) (2100C)
Carbon dispersion ISO/11420 ISO 18553 <3 <2
Black carbon content % ISO 6964 >2.0 2.25
Moisture content mg/kg ISO 4437 <50
Classification of plastic materials
Since the discovery in in 1941 of low-density polyethylene to the first production of high-density polyethylene in 1957 using a low-pressure process, polyethylene has evolved into a diverse family of materials used in packaging, wire and cable insulation, pipes, etc. The requirements for polyethylene used in pipeline systems ensure a long service life and resistance to damage from extended loading.
As new types of polyethylene are developed for this sector, its density and resistance to mechanical stress has been increased. Accordingly, wall thickness and weight has decreased as stronger raw materials have been in their the manufacture. As of today, pipes are made of materials including PE63, PE80 and PE100. They differ from one another in one of the key quality indicators of polyethylene - Minimum Required Strength. The classification of polyethylene raw materials in accordance with the MRS is listed in the table. It is, therefore, clear that PE100 polyethylene PE100 is the most durable and cost-effective material for production of pipeline systems. MRS classification of PE materials.
Class materials MRS value (MPa)
PE32 3.2
PE40 4
PE63 6.3
PE80 8
PE100 10
For a visual comparison, see section tubes with outside diameter of 110 mm and
working pressure of 10 bar from raw material PE 32, d 63, PE 80 and PE 100:
PE 32 PE 63 PE 80 PE 100
S: 18-63 mm S: 10 mm S: 8.1 mm S: 6.6 m
m 5.9 kg/m m: 3.14 kg/m m: 2.62 kg/m m: 2.17 kg/m S: Wall thickness mm Weight per meter.
Basic parameters of polyethylene pipes
• OD- polyethylene pipes are measured by the external diameter; • SDR - ratio of external diameter to wall thickness; • Snom – nominal wall thickness;
OD
Snom
OD Snom=
SDR
OD
Snom SDR=
Standard SDR: 7,4; 9; 11; 13.6; 17; 17.6; 21; 26; 33; 41
Chemical resistance of polyethylene pipes
Substance Formula
Concentration T, PE-
HD
Substance Formula
Concentration T, PE-
HD
Substance Formula
Concentration T, PE-
HD % OS % OS % OS
Nitric acid HNO3 25 20 1
Formic acid НСООН 50 20 1
Sodium sulfate Na2SO4 20 1
60 1 60 1 60 1
Nitric acid HNO3 50 20 2
Calcium nitrate Ca (NO3) 2 20 1
Ammonium sulfide (NH4)2S >10 20 1
60 3 60 1 60 1
Nitric acid HNO3 75 20 3
Sodium nitrate NaNO3 20 1
Carbon tetrafluoride CCI4 100 20 2
60 3 60 1 60 3
Nitric acid HNO3 100 20 3
Sodium nitrite NaNO2 20 1
Triethanolamine N (CH2CH2OH)
3 >10 20 1
60 3 60 1 60 2
Ammonia (aqueous solution) NH3 <10
20 1 Carbon monoxide СО 100
20 1 Acetic acid СНЗСООН 10
20 1 60 1 60 1 60 1
Ammonia (gas) NH3 100 20 1
Trisodium phosphate Na3PO4 20 1
Formaldehyde НСНО 40 20 1
60 1 60 1 60 1
Ammonia (liquid) NH3 100 20 1
Orthophosphoric acid Н3РO4 50 20 1 Hydrofluoric/hydrofluori
c acid HF 4 20 1
30 1 60 1 60 1
Acetone СНЗ-СО-СНЗ 100
20 2 Orthophosphoric acid Н3РO4 95
20 1 Hydrofluoric/hydrofluoric acid HF 60
20 1 60 2 60 2 60 2
Gasoline 20 1 Potassium
permanganate KMnO4 20 20 1 Chlorine (aqueous
solution) Cl2 20 2
60 2 60 1 60 3
Benzene С6Н6 100 20 2
Sulfuric acid H2SO4 10 20 1
Calcium chlorate Са(СlOЗ)2 20 1
60 3 60 1 60 1
Bromovodorodnaâ acid НВr 10
20 1 Sulfuric acid H2SO4 50
20 1 Barium chloride ВаСl2
20 1 60 1 60 1 60 1
Hydrogen H2 100 20 1
Sulfuric acid H2SO4 98 20 1
Ferric chloride FeCl3 20 1
60 1 60 3 60 1
Heptane С7Н16 100 20 1
Hydrogen Sulfide H2S 100 20 1
Magnesium chloride MgCl2 20 1
60 3 60 1 60 1
Potassium hydroxide КОН 10
20 1 Hydrochloric acid HCI 10
20 1 Potassium chloride KCI
20 1 60 2 60 1 60 1
Potassium hydroxide КОН >10
20 1 Hydrochloric acid HCI
saturation
20 1 Calcium chloride СаCl2
20 1 60 1 60 1 60 1
Calcium hydroxide Са(OН)2 20 1
Ammonium sulfate (NH4) 2SO4 saturatio
n 20 1
Sodium chloride NaCI 20 1
60 1 60 1 60 1
Calcium carbonate СаСОЗ 20 1
Barium sulfate BaSO4 20 1
Zinc chloride ZnCI2 20 1
60 1 60 1 60 1
Caustic soda NaOH >10 20 1
Ferrous sulfate Fe2 (S04) 3 20 1
Cyclohexanol С6Н110Н 100 20 1
60 1 60 1 60 2
Methanol CH3OH 100 20 1
Calcium sulfate CaSO4 20 1
Ethanol С2Н50Н 40 20 1
60 1 60 1 60 2
Mineral oil 20 1
Sodium sulfite Na2SO3 20 1
Ethylene Glycol OНСН2СН2OН 100 20 1
60 2 60 1 60 1
PE-HD - high density polyethylene 1- resistant 2- limited resistance 3 - unstable
Table of primary pipe characteristics
HDPE 100 polyethylene water pipes
The pressure for the transported product temperature 20ºc.
Outer diameter
mm
Pressure 16 bar SDR 11
Pressure 10 bar SDR 17
Pressure 8 bar SDR 21
Pressure 6.3 bar. SDR 26
Pressure 5 bar SDR 33
Inner diameter, mm
minimum wall
thickness mm
Weight kg per 1 meter
Inner diameter,
mm
minimum wall
thickness mm
Weight kg per 1 meter
Inner diameter,
mm
minimum wall
thickness mm
Weight kg per 1 meter
Inner diameter,
mm
minimum wall
thickness mm
Weight kg per 1 meter
Inner diameter,
mm
minimum wall
thickness mm
Weight kg per 1 meter
25 20.1 2.3 0.166 21.8 1.5 0.112
32 25.6 3 0.277 27.1 2.3 0.218
40 32.2 3.7 0.427 34.9 2.4 0.288 35.1 2.3 0.276
50 40.2 4.6 0.664 43.6 3 0.45 44.9 2.4 0.364 45 2.3 0.356
63 50.7 5.8 1.055 54.9 3.8 0.717 56.6 3 0.574 57.6 2.5 0.492
75 60.6 6.8 1.475 65.5 4.5 1.011 67.4 3.6 0.82 68.7 2.9 0.68 70 2.3 0.544
90 72.6 8.2 2.134 78.6 5.4 1.456 80.9 4.3 1.176 82.4 3.5 0.984 84 2.8 0.794
110 88.8 10 3.181 96 6.6 2.176 98.8 5.3 1.77 101.1 4.2 1.419 102.8 3.4 1.158
125 100.8 11.4 4.119 109.3 7.4 2.774 112.3 6 2.278 114.8 4.8 1.842 116.7 3.9 1.509
140 113.1 12.7 5.143 122.4 8.3 3.485 125.8 6.7 2.85 128.6 5.4 2.32 130.9 4.3 1.864
160 129 14.6 6.753 139.9 9.5 4.558 143.7 7.7 3.742 146.9 6.2 3.044 149.6 4.9 2.428
180 145.2 16.4 8.535 157.3 10.7 5.775 161.8 8.6 4.703 165.4 6.9 3.813 168.3 5.5 3.066
200 161.4 18.2 10.525 174.8 11.9 7.136 179.6 9.6 5.832 183.7 7.7 4.727 186.9 6.2 3.838
225 181.5 20.5 13.335 196.6 13.4 9.04 202.1 10.8 7.381 206.8 8.6 5.942 210.4 6.9 4.807
250 201.9 22.7 16.413 218.6 14.8 11.098 224.8 11.9 9.04 229.6 9.6 7.368 233.6 7.7 5.982
280 226.2 25.4 20.571 244.8 16.6 13.94 251.6 13.4 11.398 257.3 10.7 9.199 261.8 8.6 7.455
315 254.4 28.6 26.056 275.4 18.7 17.665 283.2 15 14.358 289.3 12.1 11.701 294.4 9.7 9.459
355 286.7 32.2 33.064 310.3 21.1 22.461 319.2 16.9 18.231 326.2 13.6 14.823 331.9 10.9 11.98
400 323 36.3 41.997 349.8 23.7 28.433 359.5 19.1 23.212 367.6 15.3 18.791 373.9 12.3 15.232
450 363.3 40.9 53.225 393.4 26.7 36.032 404.4 21.5 29.394 413.5 17.2 23.766 420.7 13.8 19.227
500 403.8 45.4 65.653 437 29.7 44.531 449.3 23.9 36.305 459.5 19.1 29.325 467.6 15.3 23.688
560 452.3 50.8 82.286 489.6 33.2 55.759 503.4 26.7 45.431 514.6 21.4 36.798 523.5 17.2 29.821
630 508.7 57.2 104.224 550.7 37.4 70.659 566.4 30 57.431 578.9 24.1 46.619 589.1 19.3 37.648
710 614.9 42.1 95.142 633.4 33.9 77.682 648.5 27.2 63.032 660.7 21.8 50.972
800 692.9 47.4 120.705 713.9 38.1 98.388 730.8 30.6 79.905 744.6 24.5 64.552
900 779.5 53.3 152.7 803 42.9 124.625 822.3 34.4 101.06 837.6 27.6 81.806
1000 866 59.3 188.749 892.2 47.7 153.96 913.7 38.2 124.696 930.8 30.6 100.784
1200 1070.7 57.2 221.556 1096.3 45.9 179.786 1117.1 36.7 145.052
The table indicates the basic SDR. Pipes are made in segments of 11.85 m Pipe diameter of up to 110 mm are also manufactured in coils of 100 and 200 meters
Gas pipes from polyethylene HDPE 100
External diameter
mm
SDR 9 SDR 11 SDR 13.6 SDR 17 SDR 17.6
Internal diameter
mm
Minimum wall
thickness mm
Weight kg per 1 meter
Internal diameter
mm
Minimum wall
thicknessmm
Weightkg per 1 meter
Internal diameter
mm
Minimum wall
thickness mm
Weightkg per 1 meter
Internal diameter
mm
Minimum wall
thicknessmm
Weightkg per 1 meter
Internal diameter
mm
Minimum wall
thickness mm
Weight kg per 1 meter
32 23.9 3.6 0.340 25.6 3.0 0.277 26.9 2.4 0.226 27.1 2.3 0.218 27.1 2.3 0.218
40 30.0 4.5 0.530 32.2 3.7 0.427 33.6 3.0 0.353 34.9 2.4 0.288 35.1 2.3 0.276
50 37.5 5.6 0.828 40.2 4.6 0.664 42.2 3.7 0.546 43.6 3.0 0.450 43.9 2.9 0.436
63 47.1 7.1 1.322 50.7 5.8 1.055 53.0 4.7 0.873 54.9 3.8 0.717 55.4 3.6 0.682
75 56.2 8.4 1.863 60.6 6.8 1.475 63.1 5.6 1.238 65.5 4.5 1.011 65.9 4.3 0.969
90 67.4 10.1 2.687 72.6 8.2 2.134 75.8 6.7 1.777 78.6 5.4 1.456 79.0 5.2 1.406
110 82.5 12.3 3.991 88.8 10.0 3.181 92.8 8.1 2.629 96.0 6.6 2.176 96.6 6.3 2.083
125 93.6 14.0 5.175 100.8 11.4 4.119 105.5 9.2 3.393 109.3 7.4 2.774 109.9 7.1 2.669
140 104.8 15.7 6.499 113.1 12.7 5.143 118.2 10.3 4.255 122.4 8.3 3.485 123.0 8.0 3.367
160 119.9 17.9 8.471 129.0 14.6 6.753 135.0 11.8 5.570 139.9 9.5 4.558 140.7 9.1 4.379
180 135.0 20.1 10.704 145.2 16.4 8.535 151.8 13.3 7.061 157.3 10.7 5.775 158.2 10.3 5.573
200 149.8 22.4 13.248 161.4 18.2 10.525 168.8 14.7 8.676 174.8 11.9 7.136 175.8 11.4 6.856
225 168.6 25.2 16.767 181.5 20.5 13.335 189.8 16.6 11.018 196.6 13.4 9.040 197.9 12.8 8.661
250 187.5 27.9 20.637 201.9 22.7 16.413 211.0 18.4 13.573 218.6 14.8 11.098 219.9 14.2 10.677
280 209.9 31.3 25.924 226.2 25.4 20.571 236.3 20.6 17.019 244.8 16.6 13.940 246.3 15.9 13.390
315 236.2 35.2 32.800 254.4 28.6 26.056 265.8 23.2 21.561 275.4 18.7 17.665 277.1 17.9 16.958
355 266.1 39.7 41.686 286.5 32.3 33.156 299.7 26.1 27.341 310.3 21.1 22.461 312.2 20.2 21.565
400 299.9 44.7 52.892 322.8 36.4 42.101 337.7 29.4 34.702 349.8 23.7 28.433 351.7 22.8 27.423
450 337.3 50.3 66.955 363.3 40.9 53.225 379.8 33.1 43.951 393.4 26.7 36.032 395.7 25.6 34.643
500 375.0 55.8 82.548 403.5 45.5 65.782 422.0 36.8 54.290 437.0 29.7 44.531 439.8 28.4 42.707
560 452.1 50.9 82.430 472.7 41.2 68.077 489.6 33.2 55.759 492.4 31.9 53.717
630 508.5 57.3 104.387 531.8 46.3 86.075 550.7 37.4 70.659 554.1 35.8 67.830
Pipes are made in segments of 11.85 m Pipe diameter of up to 110 mm are also manufactured in coils of 100 and 200 meters
Labelling of polyethylene pipes
Pipes produced by Chevron's Atyrau Polyethylene Pipe Plant are marked along their length with colored stripes according to their purpose (blue for water pipes, yellow for gas) and a stamp repeated every meter. The stamp shall contain the following information:
1. Name of manufacturer (Chevron APPP) 2. Purpose of pipe (gas or water) 3. Dimensions: External diameter and wall thickness 4. SDR-standard ratio of pipe diameter and wall thickness 5. Operating pressure (water pipes) 6. Type of polyethylene 7. Date of manufacture 8. ISO standard number 9. Company contact telephone number
Chevron APPP gas 110x10.0 SDR11 PE100 271009 ST RК ISO 4437 8(7122)294000
Water
Gas:
Chevron APPP (water) 315x18.7 SDR17 PE100 PN10 070309 ST РК ISO 4427 8(7122)294000
Storage, loading, unloading TRANSPORTATION AND STORAGE OF PIPES AND FITTINGS To be edited
Pipes can be transported by any form of transport with a closed or open bay (closed or open wagons) with a support to prevent the pipes from hanging free, as well as by water transport using load-bearing packaging.
When transporting and storing pipes and fittings, they should be stacked on a flat surface with no sharp edges or rough edges, in order to prevent blows, mechanical loads and scratches. Extreme caution must be observed when handling pipes and fittings at low temperatures.
When loading or unloading, do not drag pipes. When lifting packages of fittings, hooks must not be used. Lift truck grippers should
be closed, for example, using sections of polyethylene pipe, but it is better to use wooden pallets.
Pipes must be stored in a horizontal position, on racks in warehouses, preventing exposure to direct and indirect sunlight. The height of storage stacks when storing for more than 2 months must not exceed 2 m. Pipe storage conditions must prevent their mechanical damage.
Fittings must be stored in closed warehouses under conditions preventing their deformation, contamination with oils and lubricants (placed in plastic bags), at least 1 m from heating devices, preferably on racks. Fittings with MN are stored in individual sealed plastic bags until they are used.
Fittings with butt welded elbows can be stored in the open air, provided they are protection from damage and direct sunlight.
The guaranteed period of storage, for both water and gas pipes is two years from the date of manufacture.
The period of storage for fittings is two years from the date of manufacture. Foreign manufacturers allow for storage of parts for up to four years.
Loading and unloading of packaged sections
• For transportation of PE pipes, flat platform trailers without sharp edges should be
used;
• When loading a package of pipe with a crane, you must use wide slings (metal chains, hooks and ropes must not be used);
• If the length of the pipes exceeds 6 m, spacers must be used to balance the load,
inserted through equal intervals.
Loading and unloading of coils
Small coils fixed on pallets can be moved easily with a forklift. Warning: pipe in coils is under tension.
Warning! Malformed pallets, reels or packs may slip or collapse, injuring personnel and causing damage and destruction.
Storage of pipes Separate pipes, not tied in packages, should be laid in the form of a pyramid to a
height not to exceed 1 m, and the bottom layer of the pipe must be secured with wedges. In certain areas, the lower pipes should be supported by wooden joists at intervals of 1 m. On site, the pipes may be laid out in a line, end to end. Where necessary, safety barriers with warning signs and lighting should be erected.
Pipes in packages should be stored in a clean, level surface, and supported by pillars on the outside. For security reasons, the height of stacked packages shall not exceed 2 m.
Up to 1 m
support joists
1 meter Stands
Pipes in coils should be stored in a horizontal format, especially in warmer weather, and on a firm, flat surface, it is necessary that the lower coil was stable, in places where space is limited, the coil can be laid one on another so they are resilient, and to be able to secure the top coil. The height of stacked coils shall in no case exceed 2 m.
Large diameter reels must be stored in an upright position between special supports. The warehouse must have equipment for safe lifting, moving and loading available.
Up to 2 m
Outdoor storage
Black polyethylene material contains contains technical carbon, which provides good protection against decay under the effects of ultraviolet radiation.
Rules for use and storage
Never: • drag or roll single pipes or packages; • throw / drop pipe/fittings from vehicles; • use metal straps, hooks or chains; • place more than 3 packages one on top of the other, or to a height in excess of 2
meters; • allow pipes and fittings to come into contact with oils and hydraulic fluids, gasoline,
other lubricants, solvents and other hazardous substances Always:
• keep your pipes on a flat, hard surface, capable of supporting the weight of the pipes/fittings and lifting equipment;
• keep the pipe/fittings away from sharp objects; • use broad non-metallic slings (nylon or polypropylene); • take precautions when handling with pipes in wet or freezing weather, as they may
become slippery; • take into account some degree of deviation of pipes in their loading and unloading;
The basic ways of connection of polyethylene pipes
Reliable operation of polyethylene pipelines is ensured not only with high quality characteristics of pipes, but also applied at installation connecting elements. Connection methods of polymeric pipelines are traditional – welding or mechanical dock structural elements are often used and when installing metal piping. However, the methods of connections have their differences.
The most common connection methods are: polyethylene pipes
Butt welding for pipes with diameters from 32 up to 1200 mm; Connection couplings with embedded heating elements from 32 up to 800 mm; Flange connections, from 32 up to 1200 mm; Mechanical connection is reusable quick-fit compression fittings, from 32 to 110 mm.
The first three methods have been successfully applied in installation of trunk pipelines with a diameter of more than 110 mm. To perform welding jobs require special welding equipment, and trained personnel for its services. For the installation of pipelines with a diameter of less than 110 mm widely accepted use of mechanical connections using compression fittings.
Butt welding for pipes with diameters from 32 up to 1200 mm
Butt welding is the simultaneous fusion of the surface of pipe ends and their subsequent coupling using heating tools. In this way, pipes and fittings can be joined, given a wall thickness at the butt of more than 5 mm and an ambient temperature from -15 оС to +40 оС. Butt-welding of couplings is not only the most economical method, but is also equal in strength to the rest of the pipe, which greatly simplifies installation.
Main parameters of butt welding
• temperature of heated tools; • duration of heating; • pressure when heated; • duration of technological pause; • pressure during welding; • cooling time of welded joint under pressure;
Requirements for the quality control of welded joints
Welded joints that do not pass visual inspection and inspection for dimensions cannot be corrected and must be removed from the pipeline. Mandatory methods of quality control for all types of welded couplings include:
• External examination; • Hydraulic or pneumatic testing; • Test of axial stretching; • Ultrasonic testing (for gas).
Connection using fittings with built-in heating elements
Electric sleeve weldingis welding performed with an electrical welding sleeve (sleeve with a built-in heating element) and is intended for operating pressures up to 16 bar.
Electric sleeve welding is more expensive than butt welding, but it can be used in confined spaces, where there is not enough room for a large butt-welding apparatus.
Joining using fittings with built-in heating elements is often used in Kazakhstan for joining polyethylene pipes when laying underground gas pipelines.
Electric sleeve welding is most often used to join two pipes in their straight sections. However, it may also be used for electrofusion of tees, saddle points, etc.
Procedure for welding with an electric sleeve with built-in heating element
Prior to welding, you must remove dirt and remove the surface later at joining sections from the pipes. The electric sleeve and pipes should be laid out on precisely the same axis.
Connect the current generator. The sleeve's heating element will begin to heat up and melt the surrounding material
The area of molten polyethylene in the electric sleeve will expand and the heat will be transferred to the surface of the pipe, which will also begin to melt.
The heated pipe will increase in diameter and the molten polyethylene, its expansion by the diameter of the electric welding sleeve, will reach welding pressure.
Feeding equipment may be disabled. The electric sleeve weld, when it becomes homogeneous, will be ready once it ha cooled. However, the feeding apparatus of the highest class may independently conduct the welding cycle and enter data in a special email protocol, which can then be printed.
Flange connections
Flange connections are the most common type of detachable joint. Connection sleeve for the manufacture flanges welded to the ends of polyethylene pipes and cast metal flanges.
This type of connection is most often used for connecting polyethylene pipes with
metal components (pumps, valves, etc.)
Connection with quick-fit, reusable fittings
For small-diameter pipes (110 mm and smaller), i.e. where there are flange connections and butt welding are not cost-effective or are impossible in practice, compression fittings are used
Compression fittings are designed for pressures up to 16 bar. In these fittings, resistance to mechanical stress is ensured by incision into the pipe of teeth of a cut plastic bushing, with a tight seal ensured by a rubber O-ring.
Compression fittings are widely used to connect polyethylene pipes together and when connecting a polyethylene pipe with a pipe made from another material. For example, when replacing a worn-out piece of steel pipe with a polyethylene pipe, compression fittings are useful in joining the plastic pipe with the metal.
Range of fittings Consonant fittings All fittings are made of PE100 grade polyethylene. SDR-Class Diameter, D 90° bend (GDE)
injection molding
SDR17 63-315 mm SDR11
20-315 mm
45° elbow (HDE) injection molding
SDR17 75-315 mm SDR11
20-315 mm
Welded 90° elbow (SWBE 90) segment-welded
SDR21 63 – 800 mm SDR17
SDR11
63 – 800 mm 63 - 630 mm
Welded 60° elbow (SWBE 60) segment-welded
SDR21 63 – 800 mm SDR17
SDR11
63 – 800 mm 63 - 630 mm
Welded 45° elbow (SWBE 45) segment-welded
SDR21 63 - 630 mm SDR17
SDR11
63 - 630 mm 63 - 630 mm
Welded bend at 30° (SWBE 30) segment-welded
SDR21 63 – 800 mm SDR17
SDR11
63 – 800 mm 63 - 630 mm
Welded 90° tee flush joint (TWBE 90) segment-welded
SDR17 110-630 mm SDR11
110-630 mm
T-form flush joint at 90° (TDE) injection molding
SDR17 75-400 mm SDR11 20-500 mm
T-form 90° saddle junction (TRDE) injection molding
SDR17 63/50-315/250 mm SDR11 63/32-315/250 mm
Adapter (RDE) injection molding
SDR17 75/63-400/355 mm SDR11
25/20-400/355 mm
End cap(CDE) injection molding
SDR17 50-400 mm SDR11
20-400 mm
Extended flange SDR17 63 – 1000 mm
bushing (QDE) injection molding
SDR11
20-630 mm
Shaped flange ring (PPDA) grey cast iron/pp for bushing
PN16 20-400 mm PN10
PN6
450-630 mm 710 – 900 mm
Shaped saddle ring (EPDM) rubber bushings
SDR17 25-630 mm SDR11
25-630 mm
Fittings with built-in electric heating element Fittings are manufactured from PE100 grade polyethylene. They have an open heating coil for optimum heat transfer, greater depth of insertion and a particularly wide lateral and central area, preventing outflow of the melted mass. SDR-Class Diameter (D) Coupling without
stop (UB)
SDR11 20-630 mm SDR17 560-800 mm
Coupling plug (MV)
SDR11 20-225 mm
Reducing coupling (MR)
SDR11 32/20-160/110 mm
30° elbow (W30)
SDR11 90-225 mm
45° elbow (W45)
SDR11 32-225 mm
90° elbow (W90)
SDR11 25-225 mm
T-form flush joint (T)
SDR11 25-225 mm
Adapter PE-VP/steel (USTR)
SDR11 25/20-225/200 mm
Spigot paddle (SA)
SDR11 63/32 – 225/160 mm
Top-Loading type spigot paddle (SA-TL) clamp required
SDR11 250-560/32-250-560/90 mm
Pressure tapping tee (DAA)
SDR11 40/20 – 225/63 mm
Pressure tapping valve (DAV)
SDR11 50/32 at 225-63 mm
Compression fittings Fittings are made of polypropylene (PP) SDR-Class Diameter (D) Clamping saddle tap
(UFM/505) with internal thread
PN10 20x½” – 315x4”
90о Branch
(AGN/513)
PN16 16-63 mm PN10 75 – 110 mm
Tee (ATN/514)
PN16 16 – 63 PN10 75 - 110
Coupling sleeve (ABN/510)
PN16 16 – 63 PN10 75 - 110
Adapter (ABRN/512)
PN16 16-20/63/50 mm PN10 50 – 75/110/90 mm
Adapter with female thread (AFN/601)
PN16 16 x 3/8 "-63x2" PN10 75x2 "-110x4"
Adapter with male thread (AMN/511)
PN16 16 x 3/8 "-63x2Ž" PN10 75x2 "-110x4"
Plug (ACN/521)
PN16 16-63 mm PN10 75 – 110 mm
Ball valve with compression sleeve and inner thread (VSYV/305)
PN16 16 x 3/8 "-63x2" mm
Welding equipment
Hydraulic machines for pipe butt-welding are equipped with the patented McElroy Centerline Guidance System system and are designed for high-quality welding of both pipes and tees, elbows and other fittings, without the use of special holders. Beveled inserts are used for welding bends. The positioning fork can be easily dismounted from its wheeled chassis for use in a trench. Built-in hydraulic lifts for pipes make inserting the pipes in the positioner easier. The machine has quick-release connector for connection to the DataLogger ™ recording machine.
Range of machines: No. 14 (for pipes with diameters from 32 to 110 mm), No. 28 (from 63 to 521 mm), No. 412 (from 11 to 340 mm) A universal welding machine for welding of fittings with built-in heating elements, offering a logging and reverse tracking function (Traceability), a durable plastic housing, extended welding and power cord, ease of management, barcode reading device and conveniently located keyboard.
shielding class II Welding of pipes of all sizes from 20 to d 710 mm (d)
Assortment of slide valves and valves
Delivery of products according to AVK product catalog (Denmark). SDR-Class Diameter (D) Flange wedge
shutter (06/30)
PN10/16 50-630 mm
Wedge shutter with PE100 ends (36/80 and 36/8Х)
SDR11 75-315 mm SDR17 32-63 mm
Flange gas shutter (06/70)
63-315 mm
Gas valve with PE100 ends (36/90)
SDR11 32-315 mm
Reverse ball valve (53/35)
PN10/16 63-450 mm
Underground fire hydrant DN 125 (35/72)
PN16 L1250-L3500 mm
Rotary disk shutter (75/30)
PN10/16 63-315 mm
Extension rod (04/04 and 04/07)
04/07 32-63 mm 04/04 63-450 mm
Universal street hatch (04/12)
25-225 mm
Base plate for hatches and extension rod (04/12)
