Interconnecting Utilities and Offsite of MOKRAN

Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 1 of 6

Fabrication Procedure for HDPE Material

Approved: Vendor shall issue “AFC/ AFD/AFP/AFT/AFI” status.

Code1
Approved as noted: Vendor to amend and submit the “Issued for
Code 2
Approval” status.
Commented: Vendor to amend and submit the “Issued for Approval”
Code 3
status.
Rejected: (vendor to resubmit with same revision
Code 4
The above checking result by Purchaser shall in no way relieve Vendor of any liability,
obligation and responsibility out of the purchase order and the mutual agreement in writing

Date: Dept.: Signature:

Only for internal review

CV PI EL IN ME MA
ST MC PR SF HV TC

A 09-Jan-2023 ISSUE FOR COMMENT A.Amini A.Amini A.Amini

Rev. DATE PURPOSE OF ISSUE PREPARED CHECKED APPROVED
 Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 2 of 6

Revision Index
Revisions Revisions
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 Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 3 of 6

TABLE OF CONTENT

1. Goal .....................................................................................................................................................................4
2. Standard .............................................................................................................................................................4
3. Manufacturing Pipes .........................................................................................................................................4
4. Instruction of Fabricating Joints through butt welding process ..................................................................5
4.1. Reducing tee ..............................................................................................................................................5
4.2. Equal Tee ....................................................................................................................................................5
4.3. Elbow ...........................................................................................................................................................5
5. Injection molding ...............................................................................................................................................6
 Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 4 of 6

1. GOAL

Brief Description of HDPE Pipes and Fittings Production at P.E.S Company

2. STANDARD

INSO 14427-2
DIN 8074
DIN 16963

3. MANUFACTURING PIPES

Procedure Steps:
• Issuing request form and collect the raw material from the warehouse
• Control of raw materials in appearance
• Discharge of the raw materials into the silo allotted to each machine
• Control of the suction machinery in terms of the amount of raw materials extracted
• Continues control of the pipe production starting from the beginning till the end of project

The manufacturing process start by transfer the raw material into the hopper, in the next stage material enters
in to the cylindrical parts of extruder. it is melted by thermal elements and controlled by thermocouple. Due
to the rotation of screw the material is homogenized and transferred in to the die, which is also heated by the
external and internal heaters. The molten material then exits the die head and enters in to the vacuum tank.
At the beginning of the vacuum tank, there is a bronze-alloy part called calibrator which determines the size of
the pipe.
The calibrator has the function to shape the pipe by forming the advancing vacuum in the vacuum tank. after
leaving the vacuum tank the pipe enters the cooling tanks. the number of cooling tanks varies depending on
the size of the pipe. After leaving the last cooling tank the pipes are marked by using special cliches, the next
station is the Haul off (cutter pillar), and the last station is the saw section, in which it is automatically cut at
the specified intervals, depending on the required length of the pipe. The roller transfers straight pipe to the
end of the production hall and from there the forklift take the pipes to the end product warehouse.
 Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 5 of 6

4. INSTRUCTION OF FABRICATING JOINTS THROUGH BUTT WELDING PROCESS

Objective: Precise planning to produce joints by butt welding

4.1. Reducing tee

First, cut the main part of the reducing tee to the size ordered (by the customer or with the agreement of the
parties) and smooth the two ends of the parts completely. The form template for one end of the umbilical
segment cord is lined and cut by an arc machine on an angled saw. After preparing main part and umbilical
segment, turn on the heater unit and adjust it to 220̊ C, after the heater is heated and is ready for operation
put the main part in the welding machine, close it and place the umbilical segment in the horizontal clamp
section. Now place the heater in the center of the main part and move the umbilical segment gently toward to
the heater by using the jack, so that the umbilical segment and the main part are heated together. As soon as
the welding bid is reached separate the heater from the operation zone. Then, gently insert the umbilical
segment back to the part of the body close to it and apply the necessary pressure to perform the welding
procedure. After cooling, the edge of the weld is separated from the horizontal clamp and the body is opened
from the welding machine. After operation We smooth the welding inside the connection of the navel to the
body with a saw and a special stone saw.

4.2. Equal Tee

This type of tee is made with a special tee welding machine. First, we cut the first three segments according to
the dimensions mentioned in DIN 16963 standard (part two) and cut the pipes with a special saw machine for
angling. Then, two segments of pipe. Close the machine 90 degrees and after smoothing and preparing the
edge of the pipe for welding, perform the welding operation. Then, weld the third segment to the center of
the previous two pieces.

4.3. Elbow

We cut the pipes according to the angles mentioned in DIN 16963 standard Part 1 with a special elbow welding
machine, in the next step we put the parts in elbow welding machine and perform the smoothing operation of
the ends and later on weld them together, and in the same way, the next segments are welded together, and
the elbow is fabricated according to the angle, number of pieces by exact following the standard.
 Interconnecting Utilities and Offsite of MOKRAN
Petrochemical Complex - Stage 1

Fabrication Procedure for HDPE Material

Purch. Vendor. PO No. Dis. Tag No. Doc. Seq. Rev.

Document No.:
TSC PES 0003 PI BM VPCR 015 00
TSC PES 0003 PI BM VPCR 015 A Page 6 of 6

5. INJECTION MOLDING

Fittings and shapes for piping systems, including bends, elbows, tees, stub ends, flanges, reducers, etc.,
are produced also by injection molding process.
The HDPE raw material is fed in via a hopper mounted on the top of the machine. Due to the heating of the
cylinder and the rotation of the screw, the material is heated to melting point, homogenized and also conveyed
onward. Back pressure returns the screw to its starting position during the plasticization process.
The gate system's function is that of filling the mold uniformly, with no voids, and without excessive internal
stresses. This is important, in particular, in the processing of high-molecular-weight, PE100 molding compound.
The quality of a fitting depends not only on the gate system, however, injection speed, holding pressure and
uniform cooling of the component in the mold are also important.
Quality management is an extremely important factor in achieving high standards.