Acu-Tech Piping Systems PRODUCT APPRAISAL REPORT 14/02

Transcription

1 WSAA Product Appraisal 14/02 1 Acu-Tech Piping Systems PRODUCT APPRAISAL REPORT 14/02 Maxiplast Polyethylene (PE) Pressure Pipe AS/NZS 4130:2009 Polyethylene pipes for pressure applications Publication Date 18 June 2014

2 WSAA Product Appraisal 11/08 Issue 2 2 Document History The following information indicates the changes made to this document. Date Version File Location 13 May 2014 Peer Review draft 19 June 2014 Publication version U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1402 Acu-Tech Piping Systems - Maxiplast Polyethylene\Maxiplast PE Appraisal Draft docx U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1402 Acu-Tech Piping Systems - Maxiplast Polyethylene\Final\PA 1402 Maxiplast PE Appraisal final.docx Peer Reviewers Name/Title Organisation Date Peter Pittard, Contractor WSAA 7/5/2014 Carl Radford, Product Appraisal Manager WSAA 12/5/2014 Adam Glasson, Technical Officer Goulburn Valley Water 14/5/2014 Mohamed Yoosuf, Senior Engineer, Standards City West Water 27/5/2014 David Moore, Manager, Design City West Water 27/5/2014 Colin Paxman - Manager Products and Standards South East Water 2/6/2014 Approvals Name/Title Signature Date Carl Radford, Product Appraisal Manager Carl Radford 19/6/2014

3 WSAA Product Appraisal 14/02 3 Overview of WSAA The Water Services Association of Australia (WSAA) is the peak body of the Australian urban water industry. Its members and associate members provide water and wastewater services to approximately 16 million Australians and to many of our largest industrial and commercial enterprises. Urban water service providers have a critical role in ensuring that Australians have access to adequate and high quality water services. As Australia s population continues to grow, with most of this growth occurring in cities, that role becomes increasingly important. WSAA s vision is for Australian urban water utilities to be valued as leaders in the innovative, sustainable and cost effective delivery of water services. WSAA strives to achieve this vision by promoting knowledge sharing, networking and cooperation amongst members. WSAA identifies emerging issues and develops industry-wide responses. WSAA is the national voice of the urban water industry, speaking to government, the broader water sector and the Australian community. Copyright This document is copyrighted. Apart from any use as permitted under the Copyright Act 1968, no part of this document may be reproduced or transmitted in any form or by any means, electronically or mechanical, for any purpose, without the express written permission of the Water Services Association of Australia Limited. Copyright 2014 by WATER SERVICES ASSOCIATION of Australia Limited All rights reserved.

4 WSAA Product Appraisal 14/02 4 CONTENTS 1 EXECUTIVE SUMMARY Recommendations THE APPLICANT THE PRODUCT SCOPE OF THE APPRAISAL APPRAISAL CRITERIA General Quality Assurance Requirements Performance Requirements COMPLIANCE WITH APPRAISAL CRITERIA Compliance with Quality Assurance Requirements Compliance with Performance Requirements Polyethylene (PE) compounds Testing of pipes Suitability for contact with drinking water Colour coding FITTING INSTRUCTIONS, TRAINING AND INSTALLATION PRODUCT MARKING PACKAGING AND TRANSPORTATION PRODUCT WARRANTY WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT LIFE EXPECTANCY DISCLAIMER Issue of Report Limits on Reliance on Information and Recommendations Disclaimer of liability Need for independent assessment No Updating No Warranty APPENDIX A - QUALITY CERTIFICATIONS APPENDIX B - WSAA PRODUCT SPECIFICATION APPENDIX C - SUPPLIER CONTACTS... 21

5 WSAA Product Appraisal 14/ EXECUTIVE SUMMARY The Acu-Tech Group is a manufacturer and supplier of high performance, thermoplastic pipeline systems for fluid and gas transfer and cable protection. Products are manufactured primarily from polyethylene and polypropylene materials and are utilized for a wide range of applications in plumbing, mining, civil and mechanical services markets. Established in 2000, the Acu-Tech Group is a privately owned and operated company based in Maddington, Perth WA and Tullamarine, Melbourne Victoria. The group consists of Maxiplast, the manufacturer of polyethylene pipe and fittings and Acu-Tech Piping Systems, the sales and distribution division for the Maxiplast range of products. This Appraisal covers Series 1 PE100 plain walled pipes manufactured by Maxiplast in compliance with AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications. The range includes Series 1 PE100 plain walled pipes in sizes from DN 20 up to DN 800 and a wide range of pressure classifications up to and including PN 25. Acu-Tech Group Series 1 PE Pipe has the following applications for Water Agencies: reticulation (pressure drinking 1 sewerage) property services (water supply and sewerage) water supply and gravity, pressure and vacuum Pipes are offered in lengths of 6m, 12m and 20m for all sizes, in coiled lengths of 50m, 100m, 150m and 200m for sizes DN20 to DN125 and in coiled lengths of 100m for sizes >DN125 and DN160. The pipe brands submitted for appraisal are as detailed below although other colour options can be provided on request. Brand Colour Coding Application Acu-Water Black with Blue stripes Drinking Water Acu-Sewer Black with Cream Stripes or with Cream Internal Jacket Pressure Sewer (also suitable for non-pressure sewer) Recycle Black with Purple Stripes or with Recycled Water Tech Purple Outer Jacket Acu-Black Plain Black Multi-purpose Acu-Tech and Maxiplast both have Quality Management certification to ISO 9001:2008. Maxiplast has Type 5 Product Certification (ApprovalMark) and WaterMark certification for its range of PE100 pipes. Plastic pipeline systems are commonly designed on the basis of 50 year extrapolated material test data. For correctly manufactured and installed systems, the actual life cannot be predicted, but can reasonably be expected to be well in excess of 100 years before major rehabilitation is required. Pipe life expectancy can vary with the quality of installation workmanship, system operating conditions and other site-specific factors. This appraisal concludes that Maxiplast PE100 pipe is fit for purpose and is suitable for use in water supply reticulation networks, recycled water applications and pressure sewerage applications including vacuum sewerage. 1.1 Recommendations It is recommended that WSAA members and associates accept/authorise Maxiplast pipes as listed in Section 4 Scope of the Appraisal and in conjunction with the ApprovalMark Schedule. The recommendation is subject to the pipes being designed, installed, tested,

6 WSAA Product Appraisal 14/02 6 commissioned and tapped in accordance with Maxiplast recommendations, appropriate WSAA Codes, Technical Notes and nominated Standards. 2 THE APPLICANT The Acu-Tech Group is a manufacturer and supplier of high performance, thermoplastic pipeline systems for fluid and gas transfer and cable protection. Products are manufactured primarily from polyethylene and polypropylene materials and are utilized for a wide range of applications in plumbing, mining, civil and mechanical services markets. Established in 2000, Acu-Tech is a privately owned and operated company based in Maddington, Western Australia. The group consists of Maxiplast, the manufacturer of polyethylene pipe and fittings and Acu-Tech Piping Systems, the sales and distribution division for the Maxiplast range of products. Acu-Tech provides the complete pipeline system package including valves, fusion welding equipment, training, QA and technical support. Polyweldtech, a wholly owned subsidiary company, provides fusion weld training and quality assurance services and also operates a fully equipped NATA accredited laboratory, providing material and destructive weld testing services. Acu-Tech also has a sales and distribution centre in Melbourne VIC at Tullamarine. 3 THE PRODUCT Maxiplast PE100 plain ended pipe is product certified for compliance with AS/NZS 4130:2009 by Approval Mark International (ApprovalMark Certificate No. AMI and WaterMark Certificate No. WMKA22040). The product is based on black, fully compounded PE100 resin compliant to AS/NZS 4131:2010, and all jacket/stripe coloured resin is also based on fully compounded PE100 resin. The final compound is in compliance with AS/NZS 4130:2009 section 7.3 Striping and jacket compounds. Maxiplast PE pipe is available as solid black, black with coloured stripes, or black with coloured jacket. 4 SCOPE OF THE APPRAIS AL This product appraisal applies to Maxiplast PE pressure pipe manufactured to AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications for use in water supply, recycled water supply and sewerage systems as described below: (a) Series 1 (b) (c) Material Classification: PE100 (HDS 8 MPa) Pressure Classes: PN 6.3, PN 8, PN 10, PN 12.5, PN 16, PN 20 and PN 25 as defined in AS/NZS 4130 Clause 6. (d) Sizes: DN 20 to DN 800 as defined in AS/NZS 4130 Table 2 (e) (f) Pipe Length: 6 m, 12 m or 20 m Coil Length: DN 20 to DN m, 100 m, 150 m and 200 m; >DN 125 to DN m and100 m. The pipe brands submitted for appraisal are as detailed in Table 1 below:

7 WSAA Product Appraisal 14/02 7 TABLE 1 MAXIPLAST PE PIPE BRANDS Brand Colour Coding Application Acu-Water Black with Blue stripes Drinking Water Acu-Sewer Black with Cream Stripes or with Cream Internal Jacket Pressure Sewer (also suitable for non-pressure sewer) Recycle Black with Purple Stripes or with Recycled Water Tech Purple Outer Jacket Acu-Black Plain Black Multi-purpose Pipe included in the Scope is listed on the ApprovalMark Schedule shown in Appendix A. 5 APPRAISAL CRITERIA 5.1 General Appraisal criteria is determined by the WSAA Infrastructure Products and Materials Network and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members. 5.2 Quality Assurance Requirements The WSAA product appraisal network accepts polyethylene pipe manufactured in compliance with AS/NZS 4130 and duly verified by means of an ISO Type 5 product certification scheme undertaken by a JAS-ANZ accredited Conformity Assessment Body (CAB) or by means of an equivalent international accreditation system recognised by JAS- ANZ. The manufacturer is generally expected to have a production management and control system that has been duly accredited in accordance with AS/NZS ISO 9001, as a prerequisite to undergoing a product certification audit. 5.3 Performance Requirements Maxiplast PE100 pressure pipe has been appraised for compliance with AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications. Readers are also referred to the following WSAA National Codes List : WSA Polyethylene Pipeline Code The WSAA Product Specifications that are most relevant to this application are as follows: (a) WSA PS-207 Polyethylene (PE) Pipes for Pressure Applications Water Supply and Sewerage (b) WSA PS-215 Polyethylene (PE) Property Service Pipes for Pressure Applications Water Supply. To view or download a copy WSA PS-207 and WSA PS-215 visit the WSAA website. A copy of WSA PS-207 and WSA PS-215 has also been attached as Appendix B. 6 COMPLIANCE WITH APPRAISAL CRITERIA 6.1 Compliance with Quality Assurance Requirements Maxiplast holds a Quality Management System certification complying with ISO 9001:2008 as demonstrated by Certificate No. QMS 75367, issued by Approval Mark International, for the manufacture and supply of quality polyethylene pipes and conduits for pressure and non-pressure applications. Acu-Tech Piping Systems is also licensed to ISO 9001:2008 by SAI-Global, Certificate No. QEC29280, for the supply of piping systems and components.

8 WSAA Product Appraisal 14/ Compliance with Performance Requirements Polyethylene (PE) compounds Maxiplast manufactures PE pipe using polyethylene compound PE100 complying with AS/NZS 4131:2010. The PIPA Polyolefin Technical Committee has evaluated available compounds used for PE pipe including for coloured pipe jacket and stripe production and has listed compliant materials in its Industry Guideline POP004. Maxiplast has provided documentation to demonstrate that the materials utilised in their pipe production are contained within POP Testing of pipes The material compounds utilised, process verification and batch release test results confirm that the pipe meets the requirements of AS/NZS 4130:2009. Batch release testing is done in-house on appropriate specialised testing equipment. Maxiplast has provided copies of Type Test reports conducted by Vipac Plumbing Products Laboratory and Chisolm Institute to demonstrate compliance with the requirements of AS/NZS AMS Laboratories completed testing for compliance to AS/NZS4020. All laboratories are NATA accredited. Table 2 summarises the Type Testing results. TABLE 2 TYPE TESTING RESULTS Requirement Clause Requirement Result Pipe Size Dimensional Measurements 9.1, 9.4 Geometrical characteristics for diameter, wall thickness and out-of-roundness Effect on water 9.6 Comply with AS/NZS4020 Resistance to internal pressure at 80⁰C. Resistance to internal pressure at 80⁰C Withstand 5.4MPa hydrostatic pressure at 80 C for 165h Withstand 5.0MPa hydrostatic pressure at 80 C for 1000h Reversion % when tested at 110⁰C Thermal stability 10.3 Slow crack growth resistance PE100 SDR Oxidation induction time 20 min at 200⁰C. 500 Hours when tested at 920kPa Pressure Vipac Reports Complies AMS Report Complies Vipac Reports Complies Vipac Reports Complies Vipac Reports Complies Chisolm Report 207/11 Complies Vipac Report Complies DN25 DN63 DN160 DN20 DN25 DN63 DN160 DN25 DN63 DN160 DN25 DN63 DN160 DN25 DN63 DN160 DN 110

9 WSAA Product Appraisal 14/ Suitability for contact with drinking water Maxiplast PE100 pressure pipe complies with the requirements of AS/NZS 4020:2005 Test report No , from AMS Laboratories, was submitted for DN 20 PE100 Series 1 SDR11 PN16 Pressure Pipe to demonstrate compliance with AS/NZS 4020:2005 Product for use in contact with drinking water Colour coding Maxiplast PE100 pressure pipe complies with the colour coding scheme specified in AS/NZS 4130:2009, i.e.: (a) (b) (c) Solid black pipe with blue stripes no darker than RAL 5012 for drinking water supply reticulation networks. Solid black pipe with purple stripes or jackets no lighter than RAL nor darker than RAL for recycled water applications. Solid black pipe with cream stripes or jackets no lighter than RAL nor darker than RAL for sewerage applications. 7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION PE pressure pipe has been a commonly used product in the urban water industry for many years. Maxiplast PE pipe is compatible with fittings manufactured in accordance with AS/NZS 4129:2008 Fittings for polyethylene pipes for pressure applications. For specific design and installation information relating to PE pressure pipelines and PE gravity pipelines refer to the WSAA Polyethylene Pipeline Code - WSA 01 available at the WSAA web site or AS/NZS 2033:2008 Installation of polyethylene pipe systems. Electrofusion welding, butt fusion and mechanical compression fittings may be used for joining pipe-to-pipe or fitting-to-pipe. All welding shall be performed by welders who have successfully completed training by a Registered Training Organisation, endorsed by the Plastics Industry Pipe Association for the relevant welding method(s). The Plastics Industry Pipe Association provides technical guidelines for jointing in the following documents. (a) (b) POP001 Electrofusion Jointing of Pipe and fittings for Pressure Applications. POP003 Butt Fusion Jointing of PE Pipes and Fittings Recommended Parameters. POP001 contains recommendations for equipment required, for jointing, maintenance, servicing and calibration procedures, records to be kept and the training program to be respected to produce good fusion joints in polyethylene pipes. POP003 is a guide to the butt fusion of polyethylene pipe using AS/NZS 4130 material as a basis, recommending the butt fusion procedures and parameters as specified in ISO Copies of these documents can be downloaded from the PIPA website 8 PRODUCT MARKING Maxiplast pipes are marked in accordance with the requirements of AS/NZS 4130:2009 as follows: Manufacturers Name: ACU-TECH Trademark: ACU-WATER, ACU-SEWER, RECYCLE-TECH, ACU-BLACK Product Code: e.g. PBS Pipe Series Number: S1

10 WSAA Product Appraisal 14/02 10 Nominal outside diameter, classification and SDR: e.g. DN180 PN16 SDR11 PE material classification: PE100 Date of manufacture using the ISO system: e.g (i.e. 1st April 2014) Time of manufacture: e.g Identification of manufacturing site: MADE IN WA BY ACU-TECH Extrusion Line No: e.g. L3 The standard number: AS/NZS 4130 ApprovalMark Licence: - AMI WaterMark Licence: WMKA Special Application information: e.g. RECYCLED WATER - DO NOT DRINK or SEWAGE Example PE Pressure Pipe ACU-WATER PBS S1 DN180 PN16 SDR11 PE100 AS/NZS 4130 WMKA AMI MADE IN WA BY ACU-TECH (08) L3 9 PACKAGING AND TRANSPORTATION Acu-Tech advises that transport, handling and storage as set out in AS/NZS 2033 is recommended. Acu-Tech has documented packaging and delivery procedures for transporting pipes of various sizes from their plant. Pipe is packaged using timber bases and scalloped slats between each row, as well as strapping to minimise movement during transport. Agencies should ensure pipe is inspected when delivered to site to see that there has been no transport damage caused by movement and abrasion or serious distortion caused by excessive tightening of holding straps. Pipes are delivered by road transport and delivered directly to site, unless advised otherwise by customers. The Plastics Industry Pipe Association also provides technical guidelines for Packaging, Handling and storage of Polyethylene pipe and fittings in POP005 Packaging, Handling, and Storage of Polyethylene Pipes and Fittings. Copies of these documents can be downloaded from the PIPA website 10 PRODUCT WARRANTY The products are covered by the normal commercial and legal requirements of the Competition and Consumer Act 2010 (Cth), which covers manufacture to the relevant standard. Details of Acu-Tech Piping Systems warranty is included in their terms and conditions of sale. 11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT At the time of writing there is no field report available on the installation of Maxiplast PE pipes. However, PE pipe is becoming a common use pipe material and it is expected that little would be learned from a field test report. Maxiplast PE100 pipe has been used successfully in a number of projects over the past 5 years. Examples of some recent installations include the following: (a) 10,000 m of DN 200 Acu-Water PN12.5 SDR 13.6 in 20m lengths for a Western Australian Water Corporation project at Dwellingup installed by DM Civil.

11 WSAA Product Appraisal 14/02 11 (b) (c) 2,000m of DN560 Acu-Black PN16 SDR11 for the Western Australian Water Corporation Esperence Port Access Corridor project installed by John Holland. Both installation contractors reported a high level of quality and service. Water Corporation (Western Australia) has recently issued an approval certificate for the range of Acu-Tech PE100 pipe for PN1 2.5, PN 16 and PN 20 in sizes from DN 25 to DN LIFE EXPECTANCY Based on the documented conformance to the nominated standards and the industry material operational experience, PE pipe has been rated A Life expectancy in excess of 100 years before major rehabilitation. This rating is only a general guide to life expectancy and may increase or decrease as a result of the quality of installation, system operating conditions, operating environment and other geographical and site specific factors. Using modern rehabilitation techniques, pipeline systems can be successfully maintained and operated indefinitely provided the pipe and other structures do not collapse. 13 DISCLAIMER This Product Appraisal Report (Report) is issued by the Water Services Association of Australia Limited on the understanding that: This Report applies to the product(s) as submitted. Any changes to the product(s) either minor or major shall void this Report. To maintain the recommendations of this Report any such changes shall be detailed and notified to the Product Appraisal Manager for consideration and review of the Report and appropriate action. Appraisals and their recommendations will be the subject of continuous review dependent upon the satisfactory performance of products. WSAA reserves the right to undertake random audits of product manufacture and installation. Where products fail to maintain appraised performance requirements the appraisal and its recommendations may be modified and reissued. Appraisal reports will be reviewed and reissued at regular intervals not exceeding five (5) years. The following information explains a number of very important limits on your ability to rely on the information in this Report. Please read it carefully and take it into account when considering the contents of this Report. Any enquiries regarding this report should be directed to the Program Manager, Carl Radford, Phone: carl.radford@wsaa.asn.au Issue of Report This Report has been published and/or prepared by the Water Services Association of Australia Limited and nominated Project Manager and peer group of technical specialists (the Publishers). The Report has been prepared for use within Australia only by technical specialists that have expertise in the function of products such as those appraised in the Report (the Recipients). By accepting this Report, the Recipient acknowledges and represents to the Publisher(s) and each person involved in the preparation of the Report that the Recipient has understood and accepted the terms of this Disclaimer Limits on Reliance on Information and Recommendations Disclaimer of liability Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s) any liability for any loss or damage suffered by any person however caused (including

12 WSAA Product Appraisal 14/02 12 negligence or the omission by any person to do anything) relating in any way to the Report or the product appraisal criteria underlying it. This includes (without limitation) any liability for any recommendation or information in the Report or any errors or omissions Need for independent assessment The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith. However, you should treat the information as indicative only. You should not rely on that information or any such recommendation except to the extent that you reach an agreement to the contrary with the Publisher(s). This Report does not contain all information that a person might require for the purposes of assessing any product discussed or appraised within it (Product). The product appraisal criteria used in preparing this Report may not address all relevant aspects of the Product. Recipients should seek independent evidence of any matter which is material to their decisions in connection with an assessment of the Product and consult their own advisers for any technical information required. Any decision to use the Product should take into account the reliability of that independent evidence obtained by the Recipient regarding the Product. Recipients should also independently verify and assess the appropriateness of any recommendation in the Report, especially given that any recommendation will not take into account a Recipient s particular needs or circumstances. WSAA has not evaluated the extent of the product liability and professional indemnify insurance that the provider of the product maintains. Recipients should ensure that they evaluate the allocation of liability for product defects and any professional advice obtained in relation to the product or its specification including the requirements for product liability and professional indemnity insurance No Updating Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have] any obligation to notify you of any change in the information contained in this Report or of any new information concerning the Publisher(s) or the Product or any other matter No Warranty The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit the accuracy or completeness of the information in this Report, or the accuracy, completeness or reasonableness of any recommendation in this Report.

13 WSAA Product Appraisal 14/02 13 APPENDIX A - QUALITY CERTIFICATIONS TABLE A1 BT FAMILY TRUST T/A MAXIPLAST MANAGEMENT SYSTEM Quality Systems Standard ISO 9001:2008 Certification licence no. QMS Certifying agency Approval Mark International First date of certification 16 November 2013 Current date of certification 16 November 2013 Expiry date of certification 16 November 2015 TABLE A2 BT FAMILY TRUST T/A MAXIPLAST PRODUCT CERTIFICATION Product Standard/Spec AS/NZS 4130:2009 Certificate No. AMI Certifying agency Approval Mark International First date of certification 5 December 2013 Current date of certification 5 December 2013 Expiry date of certification 5 December 2018 TABLE A3 MORREN FAMILY TRUST T/A ACU-TECH PIPING SYSTEMS MANAGEMENT SYSTEM Quality Systems Standard ISO 9001:2008 Certification licence no. QEC Certifying agency SAI-Global First date of certification 17 February 2012 Current date of certification 25 March 2013 Expiry date of certification 16 February 2015

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19 WSAA Product Appraisal 14/02 19 APPENDIX B - WSAA PRODUCT SPECIFICATION

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21 WSAA Product Appraisal 14/02 21 APPENDIX C - SUPPLIER CONTACTS Acu-Tech Piping Systems Manufacturing, Sales and Distribution Address 119 Kelvin Road Maddington WA 6109 PO Box 103 Maddington WA 6989 Contact Person Caleb Morren Phone Fax caleb@acu-tech.com.au Acu-Tech Piping Systems Melbourne Depot Address Suite 3 47 Allied Drive Tullamarine Vic 3043 Contact Ralph Morren Phone Fax ralph@acu-tech.com.au

22 WSAA Product Appraisal 14/02 22 Melbourne Office Level 8, 401 Docklands Drive Docklands VIC 3008 Phone: (03) Fax: (03) Sydney Office Level 11, 39 Martin Place Sydney NSW 2000 GPO Box 915 Sydney NSW 2001 Phone: (02) Fax: (