DEKS Industries Pty Ltd PRODUCT APPRAISAL REPORT No 1501 Issue 2

Transcription

1 WSAA Product Appraisal PA1501 Issue 2 1 DEKS Industries Pty Ltd PRODUCT APPRAISAL REPORT No 1501 Issue 2 DEKS Stainless Steel Repair Clamps AS 4181: 2013 Repair and off-take clamps for water industry purposes Publication Date: 11 February 2016

2 WSAA Product Appraisal Report No 1501 Issue 2 2 Document History The following information indicates the changes made to this document. Date Version File Location 15/ 7/2015 Peer Review Draft 11/8/2015 Final 11/02/2016 Issue 2 Final U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2015\PA 1501 Deks - Stainless Steel Repair Clamp\PA 0000 Report\PA1501 DEKS Stainless Steel Repair Clamps Draft Report for Peer Review Prep docx U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2015\PA 1501 Deks - Stainless Steel Repair Clamp\PA 1501Deks SS Repair Clamp Report\PA1501 DEKS Stainless Steel Repair Clamps final.docx U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2015\PA 1501 Deks - Stainless Steel Repair Clamp\PA 1501Deks SS Repair Clamp Report\PA1501 DEKS Stainless Steel Repair Clamps final.docx Peer Reviewers Name/Title Organisation Date Peter Pittard, WSAA Consultant WSAA 14/7/2015 Adam Glasson, Technical Officer Goulburn Valley Water 5/8/2015 David Moore, Design Manager City West Water 11/08/2015 Carl Radford, Product Appraisal Manager WSAA 15/7/2015 Carl Radford, Product Appraisal Manager WSAA 11/02/2016 Approvals Name/Title Signature Date Carl Radford, Product Appraisal Manager WSAA 11/8/2015 Carl Radford, Product Appraisal Manager WSAA 11/02/2016

3 WSAA Product Appraisal PA1501 Issue 2 3 Overview of WSAA The Water Services Association of Australia (WSAA) is the peak industry body that supports the Australian Urban Water Industry. Its members and associate members provide water and sewerage services to approximately 20 million Australians and many of Australia s largest industrial and commercial enterprises. The Association facilitates collaboration, knowledge sharing, networking and cooperation within the urban water industry. It is proud of the collegiate attitude of its members which has led to industry-wide approaches to national water issues. WSAA can demonstrate success in the standardisation of industry performance monitoring and benchmarking, as well as many research outcomes of national significance. The WSAA Executive retains strong links with policy makers and legislative bodies and their influences, to monitor emerging issues of importance to the urban water industry. WSAA is regularly consulted and its advice sought by decision makers when developing strategic directions for the water industry. WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information relating to the provision of urban water services between industry, government and the community, and to promote sustainable water resource management. The Association s main activities focus on four areas: 1. Influencing national and state policies on the provision of urban water services and sustainable water resource management; 2. Promoting debate on environmentally sustainable development and management of water resources and the community health requirements of public water supplies; 3. Improving industry performance and establishing benchmarks and industry leading practices for water service processes; and 4. Fostering the exchange of information on education, training, research, water and wastewater management and treatment and other matters of common interest. 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 Water Services Association of Australia Limited. Copyright 2016 by WATER SERVICES ASSOCIATION of Australia Limited All rights reserved.

4 WSAA Product Appraisal PA1501 Issue 2 4 CONTENTS 1 EXECUTIVE SUMMARY Recommendation THE APPLICANT THE MANUFACTURER 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 Material Requirements Clamp body Fasteners Seals Contamination of Drinking Water Design DEKS Stainless Steel Repair Clamps are of basic standard design Performance Tests FITTING INSTRUCTIONS, TRAINING AND INSTALLATION PRODUCT MARKING PACKAGING AND TRANSPORTATION WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT PRODUCT WARRANTY FUTURE WORKS REPORT RECOMMENDATION DISCLAIMER Issue of Report Limits on Reliance on Information and Recommendations Disclaimer of liability Need for independent assessment No Updating No Warranty APPENDIX A - TECHNICAL MANUAL/BROCHURES APPENDIX B - QUALITY ASSURANCE APPENDIX C WSAA PRODUCT SPECIFICATION PRODUCT SPECIFICATION APPENDIX D - SUPPLIER CONTACTS... 25

5 WSAA Product Appraisal PA1501 Issue EXECUTIVE SUMMARY This appraisal is for a range of Deks Industries Pty Ltd PN16 Stainless Steel Repair Clamps in sizes DN80 to DN300, manufactured to AS Repair and off-take clamps for water industry purposes. This Issue 2 deletes future works items that have now been completed and includes an additional product (DRC100L) to the range. The DEKS Stainless Steel Repair Clamps are designed to act as a permanent repair option for cracks, holes, splits and pinholes in water or sewer pipes. Each clamp has a 10mm pipe diameter size range to enable compatibility with various pipe outside diameters, except where the clamp is designated Type F and would encompass both Series 1 and Series 2 pipe outside diameters. In those cases the pipe diameter size range is limited to 5mm. DEKS Stainless Steel Repair Clamps have been product certified by IAPMO R&T OCEANA to AS and type test reports by NATA accredited test laboratories have been submitted. Deks Industries Pty Ltd is certified by British Standards Institute (BSI) as a Quality Endorsed Company complying with AS/NZS ISO 9001:2008. The range of sizes covered by this Appraisal is DN80 to DN300 and specific products are detailed in Section 3. The pipe diameter size range and compatibility with rigid pipes or flexible pipes is denoted for each clamp. A critical design feature of a repair clamp for Type F application is the inclusion of a full circle design, including a positive stop to prevent diametral deflection greater than 2.5%. There appeared to be a lack of understanding by Deks, the CAB and the testing laboratories in regard to the purpose of the Assembly type tests to demonstrate compliance to this feature. Assembly tests for DN100 and DN250 clamps were conducted on both Series 1 and Series 2 PVC pipes and declared acceptable, however it is not possible to have a full circle design feature on a single clamp for both Series 1 and Series 2 pipe outside diameters. When this anomaly was pointed out to Deks they re-nominated those two clamps as Type R only and have amended the clamp markings and associated literature accordingly. In addition, the nominated size range for DRC200S1 and DRC225S1 was reduced to and respectively, to exclude compatibility for Series 2 flexible pipes. DEKS stainless steel repair clamps are supplied with Grade 316 stainless steel body and fasteners with Nitrile (NBR) elastomeric seals. DEKS Stainless Steel Repair Clamps are considered as fit for purpose. 1.1 Recommendation It is recommended that WSAA members and associates, subject to any specific requirements of the member or associate, accept or authorise the DEKS Stainless Steel Repair Clamps, as detailed in this report, for waterworks purposes. DEKS Stainless Steel Repair Clamps are intended for repair of pipes, other than PE, in water and sewerage applications. 2 THE APPLICANT (as provided by Deks) Deks was established in Australia by Mr. George Cupit in 1947 and remained a family business until it became part of the Skellerup Group in Deks continues to service its clients in over 28 countries, providing the construction and industrial markets with high quality products. In 1910, George Skellerup opened the first rubber goods store in New Zealand and developed his Para Rubber Co into 52 stores. Skellerup Industries was listed as a public company in 1947 and has since expanded to cover a wide variety of global operations. Both companies have a long and successful history as manufacturers of rubber products.

6 WSAA Product Appraisal PA1501 Issue 2 6 In August 2005, Deks acquired Jenco Products Pty Ltd. Jenco was a well-established Australian manufacturer producing above and belowground plumbing products, including a comprehensive range of pipe connectors and cast iron drainage systems. The Jenco range provided complimentary products to those already offered by Deks. The acquisition is part of a long-term plan to broaden the range of market leading products for the plumbing and building sector. A national distribution network, located in each state, provides a distribution facility for a range of couplings and cast iron surface fittings to water utilities and installation contractors Australia wide. 2.1 THE MANUFACTURER Dalian Zhuhong Mechanical Co., Ltd is a design and manufacturing company located in the city of Dalian, China. Its main products are pipe couplings, repair clamps and other pipe fittings. Established in 2000, as a cast iron foundry for pipe couplings and fittings, the company has been transferred into a modern manufacturing base with its own tooling and stamping workshop, welding workshop, powder coating workshop and assembly workshop. The annual production capacity is over 3000 tons. The company s quality management system is licensed to ISO Its products have been exported to North America, Britain, France, Germany, Spain, Singapore, Australia and other parts of the world. 3 THE PRODUCT DEKS Stainless Steel Repair Clamps are designed to suit a wide range of pipe OD s and are suitable for repairing cracks, holes, splits and pinholes in pipe manufactured from grey or ductile cast iron, steel, PVC-U, PVC-M, PVC-O and asbestos cement. The clamps are not suitable for use with polyethylene (PE) pipes. They have limited ability to accommodate axial deflection and are therefore not intended for joining two pipes together. The clamps are suitable for use in contact with drinking water and neutral fluids (sewage) to a maximum temperature of 40ºC. The available range is DN80, DN 100, DN 150, DN 200, DN225, DN 250 and DN 300 as detailed in Table 1. The range of outside diameters of pipe for which the clamps are designed is given in Table 1 together with the designated Type. Type F clamps are designed for application to flexible pipes including PVC-U, PVC-M, PVC- O, GRP and other plastics pipes except PE. Type R clamps are designed for use on rigid pipes including DI, CI, Steel, Copper, Reinforced Concrete and Asbestos Cement.

7 WSAA Product Appraisal PA1501 Issue 2 7 TABLE 1 DEKS STAINLESS STEEL REPAIR CLAMP RANGE Part No Nominal Pipe Size Type Size Range (mm) Width Bolts DN F R Min Max mm DRC x M16 DRC X x M16 DRC100L 100 X x M16 DRC150S x M16 DRC150S1L x M16 DRC150S x M16 DRC150S2L x M16 DRC200S x M16 DRC200S x M16 DRC225S x M16 DRC225S x M16 DRC X x M20 DRC300S x M20 DRC300S x M20 The Clamps considered within this Appraisal are single segment Grade 316 Stainless Steel bodies with Grade 316 Stainless Steel studs, nuts and washers and Nitrile elastomeric mat seal. Plastic caps are fitted to the end of the studs to protect the protruding thread beyond the nut. The threads of the bolts and nuts are treated with a galling prevention compound. The clamps are rated as PN16 with an Allowable Operating Pressure of 1.6 MPa 4 SCOPE OF THE APPRAISAL The scope of this appraisal covers DEKS Stainless Steel Repair Clamps as specified in Section 3 and Appendix A. 5 APPRAISAL CRITERIA 5.1 General Appraisal criteria is determined by the WSAA Infrastructure and Materials (IPAM) Network and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members. 5.2 Quality Assurance Requirements The WSAA IPAM Network accepts repair and off-take clamps manufactured under cover of a third party certified management system complying with AS/NZS ISO 9001 and having ISO Type 5 product certification in accordance with AS Repair and off-take clamps for water industry purposes, by a JAS-ANZ accredited Conformity Assessment Body (CAB) or by a CAB accredited by international accreditation system recognised by JAS-ANZ. 5.3 Performance Requirements The DEKS Stainless Steel Repair Clamps have been appraised for compliance with AS Repair and off-take clamps for water industry purposes. The following Product Specification is also relevant to this application: WSA PS 313 Repair and off-take clamps for pressure applications water supply A copy of the above Product Specification can be found in Appendix C or downloaded from the WSAA website.

8 WSAA Product Appraisal PA1501 Issue COMPLIANCE WITH APPRAISAL CRITERIA 6.1 Compliance with Quality Assurance Requirements Deks Industries Pty Ltd has submitted a copy of their British Standards Institute (BSI) Certificate of Registration No. FS to certify that their quality management system is in accordance with ISO 9001:2008. The Scope is stated as Importing storage and distribution of products for the civil and construction industry. A copy of an OCEANAMARK Certificate No OMK30043 for AS 4181:2013 Repair and offtake clamps for water industry purposes, issued by IAPMO R & T Oceana, has also been provided. Type Test results have been submitted to satisfactorily demonstrate compliance to AS 4181 for the products listed in Table 1. Deks has also submitted a copy of the ISO 9001:2008 Quality Management System licence, issued by Beijing East Allreach Certification Center (EACC), for Dalian Zhuhong Mechanical Co. Ltd. EACC is a member of the International Accreditation Forum, which attracts recognition by JAS-ANZ. 6.2 Compliance with Performance Requirements Material Requirements Table 2.1 of AS 1831:2013 details allowable material requirements for the clamp body Clamp body The DEKS clamp bodies are manufactured from Grade 316/316L in accordance with ASTM A240/A240M. Typical material test certificates issued by Universal Scientific Laboratories confirm compliance to the specification. Welding is required to be carried out in accordance with AS/NZS with welding quality 2B. A copy of Deks welding procedure manual has been provided together with copies of test reports to demonstrate compliance to the requirements Fasteners DEKS stainless steel repair couplings are fitted with Grade 316/316L stainless steel studs, washers and nuts in accordance with ASTM A240/A240M. The threads are roll formed and coated with a galling protection compound Seals DEKS stainless steel repair couplings are provided with NBR (Nitrile) mat seals complying with AS Typical test certificates provided by Deks confirm compliance to the specification Contamination of Drinking Water Deks has provided a letter from their CAB which nominates suitability of the Stainless Steel Repair Clamps based on a successful AS4020 Type Test carried out on Deks mechanical couplings. The rubber compound used in both products is the same and it is submitted and accepted that the exposure of water to the rubber mat is less than that in the coupling and is therefore accepted for this application Design DEKS Stainless Steel Repair Clamps are of basic standard design. The clamps utilise 2 x M16 studs for sizes up to DN150, 3 x M16 studs for DN200, 4 x M16 studs for DN225 and 4 x M20 studs for sizes up to DN300. Repair clamps may be designed to suit either flexible pipes (Type F) or rigid pipes (Type R) or may be designed to suit both flexible and rigid.

9 WSAA Product Appraisal PA1501 Issue 2 9 A critical design feature of a repair clamp for Type F application is the inclusion of a full circle design, including a positive stop to prevent diametral deflection greater than 2.5%. In cases where the pipe diameter range of a clamp includes both Series 1 and Series 2 pipe outside diameters, the clamp cannot be nominated as Type F, as it is not possible to incorporate a positive stop, full circle design for both pipe outside diameters. The pipe diameter range for the DEKS Stainless Steel Repair Clamps is typically 10mm, except for those clamps designed for DN200 and DN225 Series 1 pipes, where the diameter range is limited to 5mm to avoid their use with Series 2 flexible pipes. For DN100 and DN250 clamps where the 10mm pipe diameter range covers both Series 1 and Series 2 pipe outside diameters, Deks has designated these clamps as Type R only Performance Tests Deks submitted copies of Type Test reports to demonstrate conformance to the requirements of Section 4 of AS 4181:2013. CSIRO Infrastructure Technologies (NATA Accreditation No 165) and Prove Standards and Engineering Pty Ltd (NATA Accreditation No 4580) completed the type tests specified in AS All required tests were completed successfully except for the Assembly tests where there appeared to be a lack of understanding by Deks, the CAB and testing laboratories in regard to the purpose of those tests. As described in Clause above, a critical design feature of a repair clamp for Type F application is the inclusion of a full circle design, including a positive stop to prevent diametral deflection greater than 2.5%. The Assembly Test as specified in AS 4181 is to demonstrate the effectiveness of the positive stop and full circle design. Assembly tests for DN100 and DN250 clamps were conducted on both Series 1 and Series 2 PVC pipes and declared acceptable, however it is not possible to have a full circle design feature on a single clamp for both Series 1 and Series 2 pipe outside diameters. When this anomaly was pointed out to Deks they re-nominated those two clamp sizes as Type R only and have amended the clamp markings and associated literature accordingly. In addition the nominated size range for DRC200S1 and DRC225S1 was reduced to and respectively, to exclude compatibility for Series 2 flexible pipes. Based on the re-designation of the clamps as described above, the testing is considered to comply with AS FITTING INSTRUCTIONS, TRAINING AND INSTALLATION Deks has provided an Installation Guide for their stainless steel repair clamps. See Appendix A. Stainless Steel Repair Clamps are common fittings in the water industry and installation training is not regarded as an industry requirement. 8 PRODUCT MARKING The products have the following markings stenciled onto the body of the clamp. Name of Manufacturer (DEKS) Nominal diameter (DN100) Pressure Classification (PN16) Pipe outside diameter range ( ) Type of clamp (Type R or Type F or Type R and Type F) The number of this standard (AS 4181)

10 WSAA Product Appraisal PA1501 Issue 2 10 FIGURE 1 MARKING 9 PACKAGING AND TRANSPORTATION The packaging of clamps for transportation range from a single clamp boxed into a carton or a selection of clamps packed onto a wooden pallet/crate and securely wrapped with shrinkwrap. FIG 2 PACKAGING 10 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT Stainless Steel Repair Clamps are considered standard products and installation trials were not required as part of this Appraisal. 11 PRODUCT WARRANTY Deks Industries Pty Ltd warrants that its manufactured products are fit for purpose and supplied free of manufacturing defects. A copy of Deks Industries Pty Ltd full warranty is available from Deks or WSAA. 12 FUTURE WORKS No future works are required.

11 WSAA Product Appraisal PA1501 Issue REPORT RECOMMENDATION It is recommended that WSAA members and associates, subject to any specific requirements of the member or associate, accept/authorise DEKS Stainless Steel Repair Clamps, as listed in Section 3 of this Report, that are relevant to their pressure pipelines in water supply and sewer networks. The DEKS Stainless Steel Repair Clamps are intended for repair of pipes, other than PE, in water and sewerage applications, either above or belowground. The clamps have limited ability to accommodate axial deflection and are therefore should not be used as couplings to join two pipes together. 14 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 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

12 WSAA Product Appraisal PA1501 Issue 2 12 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 PA1501 Issue 2 13 APPENDIX A - TECHNICAL MANUAL/BROCHURES

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17 WSAA Product Appraisal PA1501 Issue 2 17 APPENDIX B - QUALITY ASSURANCE CERTIFICATES AND SCHEDULES Copies of the following Quality Certification Certificates are also available for downloading from the WSAA Members Only IPAM Portal Website. TABLE B1 DEKS INDUSTRIES PTY LTD MANAGEMENT SYSTEMS Quality Systems Standard ISO 9001:2008 Certificate Registration No. FS Certifying agency BSI Issued 22 April 2014 Originally Certified 12 June 1998 Expiry date of certification 30 April 2017 TABLE B2 DEKS INDUSTRIES PTY LTD PRODUCT CERTIFICATION Production Certification AS 4181:2013 Certificate Registration No. Certifying agency OMK30043 IAPMO R&T Oceana Issued: 19 November 2015 Originally Certified 1 October 2014 Expires 30 September 2019 TABLE B3 DALIAN ZHUHONG MECHANICAL CO LTD MANAGEMENT SYSTEMS Quality Systems Standard ISO 9001:2008 Certificate Registration No Certifying agency Beijing East Allreach Certification Centre (EACC) Issued 14 August 2013 Expiry date of certification 13 August 2016

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24 WSAA Product Appraisal PA1501 Issue 2 24 APPENDIX C WSAA PRODUCT SPECIFICATION PRODUCT SPECIFICATION

25 WSAA Product Appraisal PA1501 Issue 2 25 APPENDIX D - SUPPLIER CONTACTS HEAD OFFICE: Deks Industries Pty Ltd 5/841 Mountain Hwy Bayswater, VIC, 3153 Australia PO Box 569 Bayswater, VIC, 3153 Australia Phone: Fax: info@deks.com.au Website:

26 WSAA Product Appraisal PA1501 Issue 2 26 Melbourne Office Suite 8.02, Level 8, 401 Docklands Drive Docklands VIC 3008 Phone: (03) Fax: (03) Sydney Office Level 1, 39 Martin Place Sydney NSW