05. Standard Specification Of Mdpe Ball Valve 204q

TECHNICAL VOLUME

INDRAPRASTHA GAS LIMITED (IGL)

TECHNICAL TENDER FOR SUPPLY OF MDPE FITTINGS & BALL VALVE TENDER DOCUMENT NO: xxxxxxxxxxx VCS REFERENCE NO: xxxxxxxxxxxx

(VOLUME II)

A Rev

Rev. A

17.03.2017 Date

ISSUED FOR REVIEW & COMMENT Description

Author

Checked

SUPPLY OF MDPE FITTINGS & BALL VALVE

Approved

Page 1 of 30


TABLE OF CONTENTS SI. NO.

DESCRIPTION

DOCUMENT NO.

REVISION

1

MATERIAL REQUISITION

A

2

TECHNICAL SPECIFICATION FOR FITTINGS

A

3

TECHNICAL SPECIFICATION FOR BALL VALVES

A

Rev. A


Page 2 of 30


MATERIAL REQUISITION FOR FITTINGS AND BALL VALVE

Rev. A


Page 3 of 30


MDPE FITTINGS & BALL VALVE INTRODUCTION: Indraprastha Gas Limited (IGL) is a t venture company of M/s Gas Authority of India Limited (GAIL), M/s Bharat Petroleum Corporation Limited (BPCL) and Govt. of National Capital Territory of Delhi (NCT). IGL supplies Natural Gas to domestic & commercial consumers in NCT of Delhi and NCR. IGL wants to augment their PNG network. VCS Quality Services PVT LTD. is an inspection service provider across various industry sector. VCS is now inviting tender for procurement of MDPE Fittings & Ball Valve in NCT of Delhi and NCR. This document covers the technical specification for the enquiry. SCOPE OF SUPPLY:

Rev. A

S. No.

Material Description

A 1 2 3 4 B 1 2 3 4 5 6 C 1 2 3 4 5 D 1 2 3 4

MDPE Ball Valve MDPE BALL VALVE 63 EF END (WITHOUT STEM) MDPE BALL VALVE 125 EF END (WITHOUT STEM MDPE BALL VALVE 180 EF END (WITHOUT STEM MDPE BALL VALVE 32 EF END (WITHOUT STEM) MDPE Bends MDPE BENDS 63 MM OD 90 DEG PE80/100 BEND MDPE 125 X 90 DEG PE80/ PE 100 BEND MDPE 180MM 90 DEG. PE80/ PE100 MDPE BENDS OF SIZE 63 MM OD OF 45 DEGREE BEND MDPE 125 X 45 DEG PE80/ PE100 BEND MDPE 180MM 45 DEG PE80/ PE100 MDPE Coupler COUPLER MDPE 20MM OD PE80/ PE100 COUPLER MDPE 32MM OD PE80/ PE100 COUPLER MDPE 63MM OD PE80/ PE100 COUPLER MDPE 125MM OD PE80/ PE100 COUPLER MDPE 180MM PE80/ PE100 MDPE Saddle SADDLE TAPP. MDPE 63X20MM PE80/PE100 SADDLE TAPP. MDPE 63X32MM PE80/PE100 SADDLE TAPP. MDPE 32X20MM PE80/PE100 SAD TAP. MDPE 125X63MM PE80/PE100 W LR

UOM

Total Quantity

NO NO NO NO

3962 339 250 0

NO NO NO NO NO NO

1520 942 832 0 0 0

NO NO NO NO NO

0 2147 2117 3563 16584

NO NO NO NO

0 1466 0 0


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TECHNICAL SPECIFICATION FOR MDPE FITTINGS

5 6 7 8 E 1 2 3 4 F 1 2 3 4 5 G 1 2 3 4 5 H 1 2 3 4 5 6

Rev. A

SADDLE TAPP. MDPE 180X32MM PE80/PE100 SADDLE TAPP. MDPE 125X32MM PE80/PE100 SAD TAP. MDPE 180X63MM PE80/PE100 W LR REDUCER MDPE 180X125 PE80/PE100 WTH LR MDPE Reducer REDUCER MDPE 63X32 PE80/PE100 WTH LR REDUCER MDPE 180X63 PE80/PE100 WTH LR REDUCER MDPE 125X63 PE80/PE100 WTH LR REDUCER MDPE 32X20 PE80/PE100 WTH LR MDPE Equal Tee EQUAL TEE MDPE 20MM PE80/PE100 WITH LR EQUAL TEE MDPE 32MM PE80/PE100 WTH LR EQUAL TEE MDPE 63MM PE80/PE100 WTH LR EQUAL TEE MDPE 125MM PE80/PE100 WTH LR EQUAL TEE MDPE 180MM PE80/PE100 WTH LR MDPE End Cap END CAP MDPE 20MM EF END PE80/ PE100 END CAP MDPE 32MM EF END PE80/ PE100 END CAP MDPE 63MM EF END PE80/ PE100 END CAP MDPE 125MM EF END PE80/ PE100 END CAP MDPE 180MM EF END PE80/ PE100 MDPE Transition Fittings TR. FITTING PE TO CS 32MM X 1" PE80/100 TRANSITION FITTING PE TO GI 32MM TO 3/4" TR. FITTING PE TO CS 180MM X 4" PE80/100 TR. FITTING PE TO CS 125MM X 3 PE80/100 TR. FITTING PE TO CS 63MM X 2" PE80/100 TR. FITTING PE TO SS 20MM X1/2" PE80/100

NO NO NO NO

0 0 0 0

NO NO NO NO

0 0 0 0

NO NO NO NO NO

0 0 0 0 0

NO NO NO NO NO

0 1558 583 0 0

NO NO NO NO NO NO

0 1039 0 20 0 20155


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TECHNICAL SPECIFICATION FOR MEDIUM DENSITY POLYETHLENE FITTINGS

Rev. A


Page 6 of 30


CONTENTS

Rev. A

1.

SCOPE AND FIELD OF APPLICATION

2.

REFERENCES

3.

SYMBOLS & DEFINITIONS

4.

DESIGNTION

5.

DESIGN

6.

ELECTRICAL CHARACTERISTICS

7.

DIMENSIONAL

8.

PERFORMANCE REQUIREMENTS

9.

MARKING

10.

PACKAGING


Page 7 of 30


1.0

SCOPE AND FIELD OF APPLICATION This specification along with applicable codes and standards describes the minimum requirements for design, selection, manufacture, inspection/ testing and supply of "MDPE FITTINGS". This specification elaborates the requirements for Electrofusion fittings in the nominal size range 16 to 180 mm made from PE compound used with PE pipes for supply of natural gas and to be used at operating pressure 4.0 Bar(g) & operating temperature 25°C. The material grades to be used are PE80 / PE100. The bidder shall highlight any conflict before finalizing the offer and purchaser’s decision shall be final in this regard. Compliance with this specification shall not relieve the vendor of the responsibility of furnishing equipment and auxiliaries of proper design, material and workmanship to meet specified operating conditions.

ELECTRO FUSION FITTING TING

Rev. A

1.1

For Electro Fusion fitting ting an electrical resistance element is incorporated in the socket of fitting which when connected to an appropriate power supply, melts and fuses the materials of the pipe and fitting together.

1.2

The effectiveness of this technique depends on attention to the preparation of the ting surfaces, in particular the removal of the oxidized surface of the pipe over the socket depth and ensuring the ting surface are clean. If ovality causes gap between concentrically located pipe and the fitting to exceed 1% of the pipe OD after re-rounding to ensure correct welding. If the gap still exceeds 1% of the pipe OD after re-rounding, then a check should be made of the pipe OD dimensions to determine if it meets specification.

1.3

The maximum gap between eccentrically located pipe and fitting i.e. pipe touching fitting at one point must not exceed 2% of the pipe OD.

1.4

Sometimes coiled pipes may be too oval to fit into couplers or the end of the pipe may make the alignment of the ends impossible. In such circumstances, the use of a mechanical pipe straightener or rounding tool is necessary.


Page 8 of 30


2.0

REFERENCES: prEN 1555-1: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 1: General prEN 1555-3: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 3: Fittings prEN 1555-7: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 7: Guidance for assessment of conformity ISO CD 12176-4: Plastics pipes and fittings - Equipment for fusion ting polyethylene system - part 4: Traceability coding ISO TR 13950: Plastics pipes and fittings - Automatic recognition systems for Electro fusions.

3.0

SYMBOLS & DEFINITIONS

3.1

SYMBOLS FOR ELECTRO FUSION FITTINGS

3.1.1 SYMBOLS FOR ELECTRO FUSION SOCKET FITTINGS The dimensions and main symbols used in this part of ISO 8085 are shown in figure 1, where, D1 is the mean inside diameter in the fusion zone comprising the mean inside diameter measured in a plane parallel to the plane of the mouth at a distance of L3 + 0.5 L2 from the plane at the mouth. D2 is the minimum bore comprising the minimum diameter of the flow channel through the body of the fitting. L1 is the depth of penetration of the pipe or of the male end of spigot fittings. L2 is the nominal length of the fusion zone corresponding to the heated length. L3 is the nominal unheated entrance length of the fitting comprising the distance between the mouth of the fittings and the near end of the fusion zone.

Rev. A


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3.1.2 SYMBOLS FOR ELECTRO FUSION TAPPING TEES The main symbols used for tapping tees are shown in Figure 2, where, h is the height of the service pipe and comprising the distance between the axis of the main pipe and the axis of the service pipe. L is the width of the tapping tee and comprising the distance between the axis of the main pipe and the plane of the mouth of the service pipe. H is the height of the saddle which, comprises the distance from the top of the main to the top of the tapping tee or saddle.

Rev. A


Page 10 of 30


3.2

DEFINITIONS

3.2.1 Geometrical Definitions a)

Nominal diameter (dn / do): The nominal diameter is taken as the nominal outside diameter of the corresponding pipe series.

b)

Nominal wall thickness (en): The nominal wall thickness is taken as the nominal wall thickness of the corresponding pipe series.

c)

Mean inside diameter: The arithmetic mean of at least two inside diameter measured at right angles to each other in transverse planes.

d)

Out of roundness of the Socket: The maximum inside diameter minus the minimum inside diameter of the socket, measured in the same plane, parallel to the plane of the mouth.

e)

Maximum out of roundness of the socket: The greatest value of the out of roundness between the plane of the mouth and a plane separated from it by a distance L1.

f)

SDR value for a fitting: The SDR value for a fitting is taken as being the same as that for the corresponding pipe series. Where, SDR = dn/en

g)

Wall thickness (E) of a fitting: The wall thickness of a fitting at any point of the body of the fitting which could be submitted to a stress inducted by the pressure of the gas in the piping system.

3.2.2 Material Definition a)

Rev. A

Virgin Material: Materials in form such as granules or powder that has not been subjected to use or processing other than that required for its manufacturer and to which no reprocessable or recyclable materials have been added.


Page 11 of 30


b)

Own Reprocessable Material: Material prepared from rejected unused pipes, fittings or valves, including trimmings from the production of pipes, fittings or valve, that will be reprocessed in a manufacturer’s plant after having been previously processed by the same manufacturer by a process such as injection moulding or extrusion.

c)

Compound: A homogenous mix of base polymer (PE) and additives, i.e. antioxidants, pigments, UVstabilizers etc, at a dosage level necessary for the processing and of components of this standard. The additives shall not have a negative influence on the performance with respect to feasibility. All additives shall be uniformly dispersed.

3.2.3 Definition related to Material Characteristics a)

Lower Confidence Limit (LCL): A quantity with the unit in mega Pascal’s (MPs), which can be considered as a property of the material representing the 97.5% lower confidence limit of the predicted long-term hydrostatic strength at a temperature 20° C for 50 years in water.

b)

Overall Service (Design) Coefficient (C): An overall coefficient with a value larger than 1.0, which takes into consideration service conditions as well properties of the components of a piping system other than those represented in LCL. For gas applications, C can have any value equal to or greater than 2.0.

c)

Minimum Required Strength(MRS): The value of the LCL rounded down to the next lower value of the R 10 series when the LCL is less than 10 Mpa or to the next lower value of the R 20 series when the LCL is greater than or equal to 10 Mpa. Note: R10 and R 20 series are the Renard number series according the ISO 3 and ISO 497

d)

Melt Mass Flow Rate (MFR): A value related to the viscosity of the molten material at a specified temperature and rate of shear.

3.2.4 Definitions Related to Service Conditions

Rev. A

a)

Gaseous Fuel: Any fuel, which is in the gaseous state at a temp. of + 15° C and a pressure of 1 bar.

b)

Maximum Operating Pressure (MOP)


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The maximum effective pressure of the gas in the piping system, expressed in bar, which is allowed in continuous use. It takes into the physical and the mechanic characteristics of the components of a piping system. MOP = (20 x MRS) / (C x (SDR-1)). 3.2.5 Definition on Design of Electrofusion Fittings: a)

Electro fusion Socket Fitting: A polyethylene (PE) fittings which contains one or more integral heating elements, that are capable of transforming electrical energy into head to realize a fusion t with a spigot – end or a pipe.

b)

Electrofusion Saddle Fitting: A polyethylene (PE) fitting (top loading or wrap around) which contains one or more integral heating elements, that are capable of transforming electrical energy into head to realize a fusion t onto a pipe.

c)

Tapping Tee: An Electro fusion saddle fitting, which contains an integral cutter, to cut through the pipe wall. The cutter remains in the body of the saddle after installation.

d)

Branch Saddle: An Electro fusion saddle fitting, which requires an ancillary cutting tool for drilling a hole in the ading main pipe.

e)

U Regulation: Control of the energy supplied during the fusion process of an Electrofusion fitting, by means of the voltage parameter.

f)

Rev. A

I Regulation: Control of the energy supplied, during the fusion process of an Electrofusion fitting by means of the current parameter.


Page 13 of 30


4.0

DESIGNATION

4.1

Fittings shall be designed according to the grade of material, nominal diameter and Standard Dimension Ratio (SDR).

4.2

GRADE OF MATERIAL:

4.2.1 Fittings shall be classified according to grade of material, as given in following table: TABLE 1 M.R.S. LCL (200C, 50Yrs 97.5%) Maximum Allowable Material Mpa Mpa Operating Pressure PE 80 8.0 8.00< LCL < 9.09 5.5 bar PE 100 10.0 10.00< LCL < 11.19 7.0 bar 4.3

NOMINAL DIAMETER: The Nominal Diameter for fittings covered in this standard are 16, 20, 25, 32, 40, 63, 75, 90, 110,125, 140, 160 ,180 mm.

4.4

MATERIAL

4.4.1 Polyethylene Compound: The Polyethylene compound used in the manufacture of fitting shall be a cium free compound. It shall be free from visible water, shall comply with the requirements as specified in Table-2. TABLE-2: CHARACTERISTICS OF PE COMPOUND Characteristics

Rev. A

Units

Requirements

Test parameters

Test Methods

Conventional Density Melt mass Flow rate

Kg/m3

>930 (base polymer)

230C

ISO 1183-ISO 1872/1

g/10min

1900C condition 18

ISO 1133

Thermal Stability

Minutes

+ 20% of value nominated by compound producer > 20

2000C (2)

ISO TR 10837

Volatile Content at extrusion Water Content (3)

mg/kg

<350

ISO 4437 Annex. A

mg/kg

<300

ASTM D 4019

Carbon black Content Carbon Black Dispersion (4)

% (m/m)

2.0< ………..<2.5

ISO 6964

Grade

<3

ISO DIS 11420


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Characteristics Pigment Dispersion (5) Resistance to Gas Constituents Resistance to rapid crack propagation (R) (6)

Units

Test parameters

Test Methods

Grade

<3

h

>20

800C 2 Mpa

ISO 4437 Annex. B

Mpa

The critical pressure in the FS test shall be greater than or equal to the value of the MOP of the system multiplied by 1:5

00C

ISO DIS 13478

S4 Test : in principle according to all diameters(7)

Mpa

00C

ISO DIS 13477

Resistance to slow crack growth en > 5mm

h

The critical pressure in the S4 test shall be equal to or greater than the value of MOP of the system divided by 2.4 (8) 165

800C, 8.0bar (f) (9) 800C, 9.2bar (f) (10)

ISO DIS 13479

Full Scale (FS) test: d ≥ 250mm Or

1) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Rev. A

Requirements

ISO DIS 13949

. Non black compound shall conform to the weathering requirements to ISO 4437. Test may be carried out at 210°C providing that there is a clear correlation to the results at 200°C, in case of dispute the reference temperature shall be 200°C. Only applicable if the compound does not conform to the requirement for volatile content. In case of dispute the requirements for water content shall apply. Carbon black dispersion for black compounds only. Pigment dispersion method for non-black compounds only. Only applicable for fittings which incorporate extruded pipe elements. Shall be performed on pipe with a wall thickness of >15 mm. This factor 2.4 is still under study and may be subject to change. If the requirement is not met, then retesting by using the Full Scale (FS) test shall be performed. Test parameter for PE 80. Test parameter for PE 100.


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5.0

DESIGN 

Fittings shall be designed for system operation at the pressures given in Table – 1.



Fittings shall be free from cracks, voids, blisters, distortion, dent or other defects.

 Fittings shall be capable of being fusion ted to pipes using control boxes. The fittings shall exhibit the strengths and fusion compatibility with, pipes of respective sizes. 

Each fitting shall be bar coated and shall have a permanent fusion indicator.

 Heating coil design shall be such that it should not be damaged during assembly leading to short circuit of heating coil. 5.1

ELECTROFUSION SOCKET FITTINGS Electrofusion Socket Fittings shall incorporate a method of controlling pipe penetration within each socket. The inner cold zone of each socket shall not be less than (0.1 d + 5) mm for sizes upto 125 mm & 0.1 d for sizes greater than 125 mm.

5.2

TAPPING TEES Tapping tees shall be capable of installation by a force between 1 kN and 1.5 kN applied from above and on the centre line of the tapping tees stack. The tapping tees shall provide a means of cutting through the pressurised main pipe and allowing the gas flow into the outlet pipe.

5.3

TRANSITION PIECES To make connection between steel pipe and MDPE pipe specially fabricated transition pieces consisting of steel and MDPE pipes should conform to the requirements mentioned herein.

5.3.1 MDPE Pipe: The MDPE pipe with one end plain should conform to the specification (IS:14885/ SDR 11). 5.3.2 Steel pipe Black ERW steel pipe should conform to the specifications as laid in API STD 5L (latest revision). 5.3.3 Pipe End One end of the pipe should be beveled for welding angle of bevel should be 30° + 5°. 5.3.4 ting between Steel and MDPE Pipes:

Rev. A


Page 16 of 30


Steel and MDPE pipes should be so ted in the factory so as to have a monolithic t which is leak free and should be mechanically as strong or stronger than the PE Pipe. 5.4

TRANSITION FITTINGS (MDPE PIPES TO THREADED G.I. FITTING) Transition fitting for ting of MDPE Pipes confirming to specification IS:14855/ SDR 11 to threaded G.I. tubing confirming to specification. The MDPE end of the transition fitting shall be ted with MDPE Pipe with the electrofusion method. The transition fittings shall be bar coded electrofusion type for PE connection, NPT Female threading confirming to ANSI B 20.1 for G.I connection & butt welded for carbon steel end. The carbon steel material of transition fittings shall be confirming to APL 5L.

6.0

ELECTRICAL CHARACTERISTICS For each size and type of fitting, the manufacturer shall declare the nominal resistance of the heating element and specify the production tolerances. The manufacturer shall demonstrate that satisfactory t can be made using the extremes of these tolerances. All fittings shall have mechanically shrouded. The fittings terminals connections shall be suitable for use with voltage less than or equal to 48 volts. Considerations should be given to the design of the shroud with respect to impact damage. When hollow terminal pins are used, the hole at the top of the pin shall be less than 1 mm diameter. The terminal pin material shall be corrosion resistant and the surface finish shall be N7. Fittings incorporation two electrofusion sockets shall have both sockets fused in a single operation. The heating elements shall be suitable designed to prevent short circuiting or local overheating/ under heating during the fusion operation. Protective coating applied to the heating element shall not have a detrimental effect on the t. The heating element wire shall not be disturbed during assembly.

7.0

DIMENSION

7.1

MEASURING TEMPERATURE Fittings shall not be measured within 24 hrs. of manufacturer to allow for normalization. The fittings shall be measured at an ambient temperature of 23 + 2°C, after a conditioning period

Rev. A


Page 17 of 30


of 5 Hrs. Methods of measurements shall provide the appropriate degree of accuracy, and the reference conditions specified in this clause apply in case of disputes in dimensional measurement. 7.2

DIMENSIONAL STABILITY

7.2.1 Couplers (Including all forms of socket fittings) All coupler dimensions shall conform to their specified value when the fitting has been stored for a period of 12 months at a temperature of 30 + 2°C. 7.2.2 Tapping Tees and Branch Saddles: All tapping tee and branch saddle dimensions shall conform to their specified agreed values when the fitting has been stored for a period of 12 months at a temperature of 30 + 2°C. TABLE-3: SOCKET DIMENSIONS Pipe Size d (mm)

16 20 25 32 40 50 55 63 75 90 110 125 140 160 180

Limits for average diameter d on each fitting measured over apparent fusion length L (mm) Maximum Minimum 16.6 16.4 20.6 20.4 25.6 25.4 32.9 32.5 41.0 40.6 51.1 50.7 56.1 64.1 76.3 91.5 111.3 126.7 141.7 162.1 182.1

55.7 63.7 75.9 91.1 111.1 126.2 141.2 161.4 181.5

Apparent fusion length L (mm)

Penetration depth L (mm)

Minimum 15 16 18 18 18 20

Maximum 41 41 41 41 49 55

21 23 25 28 32 35 38 42 46

63 63 70 79 82 87 92 98 105

Notes: 1. The apparent fusion length, L, is the length of the integral heating elements, from the first regular section of the element to the end of the regular section, on one side of the fitting. This dimension to be measured from outside edge to outside edge of wire. 2. Any protrusions into the bore of the fitting (e.g. centralization ribs) shall not

Rev. A


Page 18 of 30


prevent easy assembly in the field. 3. The overall length of a straight coupler is equal to twice the quoted maximum penetration depth L. TABLE-4: OVERALL LENGTH OF REDUCERS Major Diameter (mm) 25 32 63 90 125 180

Maximum Length (mm) 90 90 120 180 215 280

TABLE-5: BRANCH SADDLE ASSEMBLY OUTLET LENGTH Off-take size mm

63 63 90 90 125 125 180 180 * ** *** +

Shut-Off method

Dimension from flange face to crown of main Class B Class B fitting mm fitting mm 260* 400 180** 360 180*** 360 180+

Valve Squeeze Valve Squeeze Valve Squeeze Valve Squeeze Flange size DN 50 Flange size DN 100 Flange size DN 150 Flange size DN 250

8.0

PERFORMANCE REQUIREMENTS

8.1

MECHANICAL CHARACTERISTICS

Dimension from pipe end to crown of main Class B Class B fitting mm fitting mm 400 550 750 -

Fittings shall be tested using pipes, which conform to ISO 4437. Test samples shall be assembled in accordance with ISO DIS 11413. Following the technical instruction of the manufacturer and using fusion equipment conforming ISO DIS 12176.2.

Rev. A


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TECHNICAL SPECIFICATION FOR MDPE FITTINGS When tested in accordance with the test methods as specified in Table – 6 using the indicated parameters, the fittings have mechanical characteristics confirming to the requirements given in Table 6. TABLE -6: MECHANICAL PROPERTIES Characteristics Hydrostatic strength at 20°C

Units H

Requirements Failure time >100

Hydrostatic strength at 80°C

H

Failure time >165

Hydrostatic strength at 80°C

H

Failure time >1000

Cohesive resistance

mm

Length of initiation of brittle fracture L/3

Impact strength (B)

Pressure (B)

Rev. A

drop

No failure No leakage

M3/h

0.5 mbar : dn < 63 0.1 mbar : dn2 > 63

Test End caps orientation conditioning time. Type of test circumferential (hoop) stress pipe PE 80, PE 100, Test temperature. End caps orientation conditioning time. Type of test circumferential (hoop) stress pipe PE 80, PE 100, Test temperature. End caps orientation conditioning time. Type of test circumferential (hoop) stress pipe PE 80, PE 100, Test temperature. Test temperature choice of method

Parameter Type a) free 1 h 9 Mpa, 12.4 Mpa, 20°C

Test method ISO DIS 9356

Type a) free 12 h water-in-water 4.6 Mpa 5.5 Mpa 80°C

ISO DIS 9356

Type a) free 12 h water-in-water 4 Mpa, 5 Mpa, 80°C

ISO DIS 9356

23°C

ISO 13954 (A) ISO 13955 (A) ISO 13956 (B)

Test temperature Falling height Mass of the striker Air flow rate Test medium Test pressure

20°C 23°C 5m 5kg

ISO DIS 13957

Indicated by the manufacturer Air source 25 mbar

PrEN 12117


Page 20 of 30


(A)

Electro Fusion Socket Testing

(B)

Tapping Tees For hydrostatic strength test at 80°C only brittle failure shall be taken into . If ductile failure occurs before the required time, a lower stress shall be selected and the minimum test time will be obtained from the line through the stress/ time points given in Table – 7. TABLE-7 HYDROSTATIC STRENGTH (800C)-STRESS/ MINIMUM FAILURE TIME CORRELATION

Stress Mpa 4.6 4.5 4.4 4.3 4.2 4.1 4.0 8.2

PE-80 Minimum Failure Time (h) 165 219 293 394 533 727 100

PE-100 Stress Mpa 5.5 5.4 5.3 5.2 5.1 5.0 -

Minimum Failure Time (h) 165 233 332 476 688 1000 -

PHYSICAL CHARACTERISTICS When tested in accordance with the test methods as specified in Table 8 using the indicated parameters, the fittings shall have physical characteristics conforming to the requirements given in Table 8. TABLE-8: PHYSICAL CHARACTERISTICS OF FITTINGS Property

Units

Requirements

Thermal Stability Melt Mass-flow Rate (MFR)

Minutes

> 20

g/10 min

0.2 < MFR < 1.4 and after processing maximum deviation of + 20% of the value measured on the batch compound

Test Parameters 200 °C (1)

Test Methods

Condition 18

ISO 4440.1

ISO TR 10837

Test may be carried out at 210 °C providing that there is a clear correlation to the results at 200 °C, in case of dispute the reference temperature shall be 200 °C.

Rev. A


Page 21 of 30


8.3

TECHNICAL FILE The manufacturer of the fittings shall make availability of a technical file (generally confidential) with all relevant data to prove the conformity of the fittings to this specification. It shall include all results of the type testing and shall conform to the specification relevant technical brochure (e.g. ISO 12093 for electro fusion fittings). The technical description of the manufacturer shall include the following information: Field of appliance (pipe and fitting temperature limits SDR’s and out of roundness). Assembly instructions. Fusion instruction (fusion parameters with limits). For saddles and tapping tee  The means of attachment (tools and/ or under clamp).  The need to maintain the under clamp in position in order to ensure the performances of the assembly. For electrofusion fitting, the format of the technical brochure shall conform to ISO DIS 12093. In the event of modification of the fusion parameters, the manufacturer shall ensure that the t conforms to this standard. 1. 2. 3. 4.

9.0

MARKING Following information shall be embossed upto height of 0.15 mm onto the fitting and also in the form of bar code: a) The manufacturer’s identity b) The size of the fitting in mm c) Material and Designation d) The date of manufacturer (code may be used) e) Fusion time in seconds f) Cooling time in minutes g) Fusion parameters in BAR code h) Lot Number The information may be printed on a label associated with the fitting.

10.0

PACKING The fittings shall be packaged in bulk or individually protected where necessary in order to prevent deterioration. Whenever possible, they shall be placed in airtight plastic bags in card board boxes or cartons. The cartons and/or individual bags shall bear at least one label with the manufacturer’s name, date of manufacturer, type and dimensions of the part, number of units in the box, and any special storage conditions and storage time limits.

Rev. A


Page 22 of 30

TECHNICAL SPECIFICATION FOR MDPE BALL VALVE

TECHNICAL SPECIFICATION FOR MEDIUM DENSITY POLYETHLENE BALL VALVES

Rev. A


Page 23 of 30


CONTENTS

Rev. A

1.

SCOPE AND FIELD OF APPLICETION

2.

REFERENCES

3.

DEFINITIONS

4.

GENERAL SPECIFICATION

5.

MATERIAL PARTICULARITIES

6.

VALVES GENERAL PARTICULARITIES

7.

MECHANICAL CHARACTERISTICS FOR ASSEMBLED VALVES

8.

MARKING

9.

PACKAGING

10.

DATASHEET OF BALL VALVE


Page 24 of 30


1.0

SCOPE AND FIELD OF APPLICATION: This General Technical Specification specifies the requirements for Ball Valves and its component made from extruded or injected moulded polyethylene (PE) and which are intended to be used for the Natural gas distribution systems where the operating pressure (MOP) is 4 barg and operating temperature is 250C. In addition, it specifies some general properties of the materials from which these valves are made. It applies to bi-directional valves with Electro fusion sockets intended to be fused with polyethylene pipes. This specification is limited to valves with a nominal diameter (do) up to and including 180 mm.

2.0

REFERENCES: prEN 1555-1: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 1: General prEN 1555-3: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 3: Fittings prEN 1555-4: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 4: Valves prEN 1555-7: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) part 7: Guidance for assessment of conformity ISO CD 12176-4: Plastics pipes and fittings - Equipment for fusion ting polyethylene system - part 4: Traceability coding ISO TR 13950: Plastics pipes and fittings - Automatic recognition systems for Electro fusions.

Rev. A

3.0

DEFINITIONS:

3.1

VALVES An obtruding device designed to stop or restore the gas flow by operating and closing mechanisms.


Page 25 of 30


3.2

EXTERNAL LEAK TIGHTNESS The tightness of the body enveloping the space containing the gas, with respect to the atmosphere.

3.3

INTERNAL LEAK-TIGHTNESS The tightness between the inlet and the outlet of the valve, obtained by closing the operating mechanism.

3.4

LEAK-TIGHTNESS TEST Test to determine  The internal leak-tightness of the valve’s closing seat when closed and pressurized from either side.  The external leak-tightness of the valve when half open.

3.5

INITIATING TORQUE Torque required to initiate movement of the obturator.

3.6

RUNNING TORQUE Torque required to achieve full opening or closing of the valve at maximum allowable operating pressure.

3.7

LEAKAGE Emission of gas through the body, sealing membrane or any other component of the valve.

4.0

GENERAL SPECIFICATION: The present specification is based on the European Standards EN 1555 series prepared by technical committee CEN/TC 155 plastic technical and ducting system. The requirements of this General technical specification are chosen in order to guarantee a high quality gas system which will respond to the European Standards for gas supply systems.  The valves described in this General technical specification comply with the standard PrENl555-4 and the complementary particular requirements or options of the present GTS.  The valves are intended to be use in gas distribution networks made of PE pipes and accessories.  The valves are laid and welded.

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5.0

MATERIAL PARTICULARITIES:

5.1

GENERAL All parts of the valve in with the gas stream shall be resistant to the gas, its condensates and other occurring substances such as dust. All metallic parts of the PE valve shall resist to both internal and external corrosion.

5.2

PE COMPOUND FOR POLYETHYLENE VALVES BODIES  The PE compound from which the valve body, with electro fusion socket is made out, shall conform to prENl555-1.  The PE valves bodies are PE 80 / PE 100 class made from below listed material are forbidden: a) Use of recycled materials b) Mixture of different materials c) Addition of complementary materials

5.3

SEALS The seals shall be so mounted as to be resistant to normally occurring mechanical loads. Creep and cold flow effects shall be taken into . Any mechanism that puts a loading on the seals shall be permanently locked. Line pressure shall not be used as the sole means of seal activation.  The seals shall be homogeneous, without any inner crack, inclusion or impurities and cannot contain any component that can alter the properties of the materials they are in with and prevent the nonconformity of those materials with the present specification.  Additives shall be distributed evenly.  The rubber seal rings shall comply with standard EN 682.  Other seals shall comply with the relevant standard and be suitable for gas service.

5.4

LUBRICANTS Lubricants cannot have any adverse effects on the long term performance of the valve parts.

6.0

VALVES GENERAL PARTICULARITIES:

6.1

TECHNICAL FILE The manufactures of the valves-shall deliver for each type of valve a technical file which includes:

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 Raw material used.  Drawings, dimensions and tolerances, including for the accessories.  Application range (temperature and pressure limits).  Running torque and initiating torque.  Pressure drop and flow diagram.  Test results and Data proving the conformity of the valve in accordance with prENl5554 and PrENl555-7.  The pipe elements used during valves testing.  The assembly pipes/valves realized during testing shall be in conformity with the manufactures instructions and the extreme installation conditions.  For the test assembly due consideration should be taken regarding the fabrication tolerances and the variation of the outside ambient temperature. 6.2

DESIGN  Design pressure of valve shall be in accordance with IS-14885.  The wall thickness of the PE valve body shall be equal or greater than the minimum wall thickness of the corresponding SDR 11 series pipes.  Valves body and valves ends form an indivisible whole.  The operating mechanism and the stop wedges will be protected against water intrusion.  The valve body is completely sealed.

6.3

APPEARANCE The internal and external surfaces of valve shall be smooth clean and shall have no scoring, cavities or other defects to an extra that would prevent non-conformity to the present GTS or to the standard PrEN1555-4.

6.4

DIMENSIONS The dimensions will be in conformity with the standard PrENl555-3 and PrENl555-4.

7.0

MECHANICAL CHARACTERISTICS FOR ASSEMBLED VALVES:

7.1

GENERAL The valve shall have mechanical characteristics and be tested as specified in the standard prEN1555-4.

7.2

RUNNING TORQUE The running torque and the concept of the valve shall prevent the valve from being easily operated (by hand) without an operating key. Running torque shall be as per standard PrEN 1555-4.

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7.3

INDIVIDUAL TEST (BATCH RELEASE TEST) Before delivery, each valves will be individually tested for mechanical strength and leak tightness as per standard prEN 1555-4. A combined mechanic resistance and leak-tightness test shall be performed in conformity with the prEN 1555-4. By batch of valves a supplementary leak-tightness test (25 mbar) shall be performed in conformity with the prEN 1555-4 on 3 valves taken at random.

7.4

PRESSURE DROP AT LOW PRESSURE For natural gas, allowable pressure drop shall be as per the standard EN 12117.

8.0

MARKING: At least the information given below shall be printed or formed directly on the valve: a) Manufacturer’s name and/or trademark b) Material and designation c) Design application series d) Nominal diameter e) Internal fluid gas f) Traceability code (valve and component) as per standard ISO/FDIS 12176-4 g) Number of the system standard. This information can be printed/formed directly on the valve or on a label associated with the valve or on an individual bag h) Production period, year and month The marking shall stay legible during normal manipulation, storage and installation. The marking shall not adversely influence the performance of the valve and prevent the nonconformity of the valve.

9.0

PACKAGING: The valve and its accessories shall be packaged individually in plastic bags in order to prevent them from deterioration. The valves ends shall be protected with external caps. The cartons and/or individual bags shall bear at least one label with the manufacturer’s name, type and dimensions of the part number, number of units in the box and, any special storage conditions and storage time limits.

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10

10. DATA SHEET FOR MDPE BALL VALVES (WITHOUT STEM)

1

Service

Natural Gas

2

Size ( Diameter)

63mm, 125mm, 180mm

3

Model

Vendor to specify

4

Standard

ASME B 16.40 / EN 1554-4

5

Process Class

SDR 11

6

Design Pressure (Bar g)

As per IS-14885

7

Operating pressure (Bar g)

4.0

8

Design Temperature (Deg. C)

60

9

Operating Temperature (Deg.C)

25

10

Location

Underground / Aboveground

11

Pattern

Full Bore

12

End Connection

PE 80 / PE 100 grade material (Electrofusion type)

13

Stem

Without Stem

14

Valve Design

1 piece construction

15

Ball position indicator

Open / close indicator required

16

Mechanical stops

For open / close limits required

17

Tests

As per ASME B 16.40 / EN 1554-4

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