PPT on Mdpe inspection.pptx

The presentation covers all technical values about MDPE pipe which is use to expand the cgd network.

1. Inspection of MDPE Pipe

2. SCOPE IS 14885 covers the requirements for polyethylene pipe from dia. 16 mm to 630 mm with SDR 9,11,14 and 17.6 and in material grade PE-80 & PE- 100. Raw Material Inspection Raw material inspection In Process Inspection Final Inspection

3. RAW MATERIAL CRP 100 Orange - CRP 100 orange is a high density polyethylene, The product is used for PE 100 and provides excellent stress crack resistance properties (ESCR) with very good long term hydrostatic strength. PE 100 XSC50 - It is a high performance hexene based orange compound, with a MRS 10 MPa. Eltex TUB 125 N2025- Eltex TUB 125 N2025 is a high-density polyethylene copolymer designed for the extrusion of pipes for gas applications. HE3492 LSH- It is used to ensure excellent long-term thermal stability and UV-resistance.

4. INSPECTION RAW MATERIAL INSPECTION IN PROCESS INSPECTION FINAL INSPECTION

5. RAW MATERIAL INSPECTION Density Test Melt Flow Rate Thermal Stability (OIT) Pigment Dispersion Volatile Matter Content

6. DENSITY IS 14885, CL.-8.3, IS 7328, ANNEX-A The density is determine by the buoyancy method by finding the mass in air and mass in butyl acetate. Apparatus- Analytical balance, butyl acetate, hydrometer, beaker Test sample- Weight- 50gm Calculation – Density of PE (KG/M³) = a 1 * ρ *100/(a 1 -a 2 ) a 1 - Mass of specimen in air (gm) a 2 - Mass of specimen in butyl acetate (gm) ρ - Density of butyl acetate (0.877 KG/M³) Density of butyl acetate determined by hydrometer. Density of pe should be 928.4 KG/M³ @23 & KG/M³ @27  

7. MELT FLOW RATE (MFR) (IS 14885, CL.- 8.4, IS 2530) Melt Flow Rate measures the rate of extrusion of thermoplastics through MFT at given temperature and load. It provides measuring flow of a melted material which can be used to differentiate grades of pipes. Sample size – 5 gm. @190 , min. 3 nos. sample required Weight (Load) – 5kg. Calculation- MFR=m*600/t for gm/10 min. m - avg. mass of minimum 3 nos. sample. t - cut off time (240 sec.) MFR of the compound material shall be 20 .  

8. MELT FLOW TESTER

9. Thermal Stability (OIT) (IS 14885, CL.-8.5, ANNEX-D) OIT (oxidation induction time) is a type of test/method to measures the level of thermal stabilization or oxidation induction time of the pe material. The time between melting and the decomposition is measured. The atmosphere is nitrogen up to melting and then oxygen. For long term strength Stability of material For electrofusion jointing w.r.t. temperature. Sample size- 15 mg Test temperature - 200 Gas flow of N2 & O2 – 50CM³/min. Thermal analyser equipment used for this test OIT  

10. PIGMENT DISPERSION (IS 14885, CL.- 5.4, ANNEX-E) The test is perform to check the proper dispersion in PE material. Apparatus- Microscope of at X 100 linear magnification. Microtome Hot plate Test specimen- Six test pieces shall be taken from different parts of the cross-section. Thickness & Area of specimen- 10 to 20 & 7 mm Weight – 5 mg Principle- A microtomed section of material is examined by transmitted light at a magnification of X 100 and compared against standard photomicrographs. Acceptance- T he grading should be 3.  

12. Volatile matter content (IS 14885, CL.- 8.6, ANNEX-H) Volatile matter is an unstable material. Volatile matter tends to not remain in one state and will rapidly transition to another state, or vaporize, when the right conditions are met. The volatile content is determined as the loss of mass of a sample, which has been put in a drying oven . Calculation – V=(P1-P2)10^6/(P1-P0) V- volatile matter content (mg/kg) P0- weight of empty weighing cup (dia. 35mm) in gm. P1- weight of weighing cup & sample P2- weight of weighing cup and sample after 1 hr @105 Sample size- 25 gm. Volatile matter content should be  

13. In Process Inspection Colour Finish Of Pipe Outside Diameter Wall Thickness Ovality Marking Length

14. Colour The colour of the pipes shall be yellow when manufactured from PE-80 grade and orange from PE-1OOgrade. Colour coding confirm with BS 5252 PE 100 – CODE 08 E 55 PE 80 – CODE 08 E 53

15. Finish of Pipe Smooth Clean Free from grooves The ends shall be cleanly cut and shall be square with axis. Considerable “ Out of Square Tolerance of End”- 2mm for 16 to 90mm dia. 3mm for 90 to 140mm dia. 4mm for 140 to 200mm dia.

16. Outside dia.

17. Wall thickness Negative tolerance should not allowed during inspection of pipe. Ball ended micrometer used to check the thickness. Acceptable plus tolerance- Table 4 & 5 of IS 14885

18. Ovality

19. Marking All pipes shall be permanently marked along their length with a legend, which shall be impressed to a depth of not more than 0.2 mm. Marking details shall be formed on the pipe in such away that the marking does not initiate cracks or other type of failure. The embossing for yellow/ orange pipe shall have black Colour . The height of the character shall be uniform and at least 3 mm for 5 mm for 90mm. The legend shall be repeated at intervals of 1 m . Manufacturer’s name, Designation and Batch or lot number. Each pipe may also be marked with the Standard Mark.  

20. Length PE 100 DN 20MM SDR 11 – 200 MTRS. PE 100 DN 32MM SDR 11 – 200 MTRS. PE 100 DN 63 MM SDR 11 – 100 MTRS. PE 100 DN 125 MM SDR 17.6- 50 MTRS.

21. Final Inspection Hydraulic Pressure Resistance Test Reversion Tensile test (Tensile Strength at Yield & Elongation at Break) Resistance to weathering (Exposure to sunlight) Supply, Packaging, Handling & Transportation

22. Hydraulic Pressure Resistance Test (IS 14885, CL. 8.1, ANNEX-A&B, TABLE -7) When specimen subjected to internal pressure as per given procedure, sample shall show no sign of swelling, leakage, burst or any type of physical damage. TEST SPECIMAN – Sample taken after 24 hrs. of manufacturing. Size- 10*OD (250mm to 750mm). For @80 for 165 hrs. 5.5 Mpa (induced stress) For @80 for 165 hrs. 4.6 Mpa (induced stress) Calculation – Test Pressure (in MPA)=2 s – minimum wall thickness d – outside dia. Conclusion - sample shall show no sign of swelling, leakage, burst Or any Damage during test perform @ above given condition https://www.youtube.com/watch?v=0qD05rWK39g  

23. Hot water bath Test Sample

24. REVERSION (Shrinkage Or Expansion) (IS 14885, CL. 8.2) The test is performed to check the shrinkage or expansion of pipe. Apparatus- Hot air circulating oven (@110 Vernier caliper Glass plate Talcum powder Test specimen- Size- 200mm for & Axial arc of 200mm for No. of sample – Calculation - Reversion (%)= (Li- Lf )*100/Li Conclusion - Value should be in b/w of +3 and -3 in percentage.  

25. Hot air circulating oven

26. Tensile test- (IS 14885, CL. 8.7, 8.1, CL.-06 OF IS 2530) Tensile yield strength & Elongation at break test of mdpe . Test speciman - Use a sufficiently long piece of pipe, and divide its circumference into a certain number of sectors with an arc length of 150 mm. For thickness of specimen- @ 23°C & 100 mm/min @ 23°C & 25 mm/min Apparatus – Universal tensile tester Procedure - The test pieces shall be conditioned for two hours in air or one hour in water so that it is at a temperature of 27°C immediately before test. Acceptance- Tensile yield strength 15 Mpa Elongation at break 350 percent, Min  

28. Resistance to weathering (Exposure to sunlight) (IS 14885, CL.-8.8, ANNEX-F) Test specimen – Length – 1 mtr . 0.2 mm upper layer of specimen shall be remove before testing. Time period – Sample shall be exposed for a period of six months . The size of the apparatus and the distance between the specimens shall be such that no shadows fall across the specimens for the period of at least 8 h during which the sun is normally the strongest. Acceptance- Elongation as per 8.7.1 Hydraulic characteristics as per 8.1 Thermal stability to oxidation as per 8.5

29. Supply, Packaging, Handling & Transportation (IS 14885, CL. 11, ANNEX-K) SUPPLY - The polyethylene pipes shall be supplied as straight length either independent or bundled together. Pipe ends shall be cleanly cut, square with the axis of pipe and with appropriate end caps Coils - Polyethylene pipes may be coiled or packed on drums. Large diameter coils with d> 90 mm should be stored flat or vertically. Coil Dimension and Winding Temperature- Size Minimum internal dia Max. external coil dia 20/25 mm 0.6 m 3.2 m 32 mm 0.7 m 3.2 m 63 mm 1.3 m 3.2 m 125 mm 2.5 m 3.2 m Maximum external surface temperature at time of coiling- 35 All the coils shall be wrapped with PP woven sack & PE film.  

30. THANK YOU Himanshu shukla