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Ir C K CheungHong Kong Institution of Certified Auditors

香港專業審核師學會

WSD Contract RequirementsFor Factory Inspection of

Waterworks Products

WSD Contract RequirementsFor Factory Inspection of

Waterworks Products

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Definition of InspectionDefinition of Inspection

• Inspection

• Examination of a product design, product, service, process or plant, and determination of their conformity with specific requirements or, on the basis of professional judgement, general requirements.

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Type of Inspection BodyType of Inspection Body

• Type A – 3rd party inspection

• Type B – inspection to its parent organization

• Type C – inspection to its own organization

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Type of InspectionType of Inspection• 1. Pre-production Inspection• Inspection of pre-production against specifications of raw

materials• 2. During production Inspection• Inspection of a general manufacturing process-witnessing

of the production line & QC • Inspection of the manufacturing process in particular for

the purchased batch of products against the client’s specifications or standards

• 3. Pre-shipment Inspection• Inspection of the purchased products, with simple tests to

check compliance prior to shipment• 4. In-service Inspection• Inspection of cars and crane

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WSD Products for Inspection

WSD Products for Inspection

• Water pipes – Steel, DI, Polyethylene, UPVC, lined GI & fittings

• Valves – CI, air relief, butterfly, non-return, copper alloy stop/gate valve

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Factory Inspection ofSteel Pipes

BS EN 10224:2002BS EN 10311:2005

Factory Inspection ofSteel Pipes

BS EN 10224:2002BS EN 10311:2005

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BS 534BS 534

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WSD Spec for steel pipeWSD Spec for steel pipe

• BS EN 10221 and BS EN 10220• By Electric Resistance Welding (ERW)

or Submerged Arc Welding (SAW)• Mini tensile strength 430 MPa• Full length 8 m• Joint : flanged, slip-on coupling, collar

weld, spigot & socket welded joints

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Steel pipe materialsSteel pipe materials

• Pipe to BS EN 10221 and BS EN 10220

• Pipe specials such as tee and collar to BS EN 10220

• Non-metallic products in contact with water to BS 6920: Part 1

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Methods of making pipe bodyMethods of making pipe body

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Butt welded steel pipeButt welded steel pipe

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Electric resistance welded steel pipe

Electric resistance welded steel pipe

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Seamless steel pipeSeamless steel pipe

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Submerged arc welded steel pipeSubmerged arc welded steel pipe

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Submerged-arc weldingSubmerged-arc welding

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Different types of jointsDifferent types of joints

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Coating for steel pipeCoating for steel pipe

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Epoxy CoatingEpoxy Coating

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Pipe protectionPipe protection

• External : Fusion bonded epoxy system to ANSI/AWWA C213 or chemically-cured liquid epoxy system to ANSI/AWWA C210, mini dry film thickness 400 microns

• Plus pipe exposed outdoor under direct sunlight, a topcoat of aliphatic polyurethane at 50 microns

• Internal : 400 micron to C213 but 750 micron to C210

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Coating materialsCoating materials

• Coating material for internal lining tested to BS 6920, A certification by Water Research Centre of UK approval for contact with potable water suitable for human consumption or equivalent

• Ext & int : mini adhesion strength to ASTM D4541 19 MPa mini impact test to ASTM D2794 0.136 kgm, mini abrasion to ASTM D4060 200mg/1000rotation, loaded at 1000g

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Lining for steel pipeLining for steel pipe

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Concrete liningConcrete lining

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Cement mortar lining

Cement mortar lining

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BS 3601:1987BS 3601:1987

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BS 3601 Chemical composition and Mechanical Propreties

BS 3601 Chemical composition and Mechanical Propreties

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BS 3601 Mechanical propertyBS 3601 Mechanical property

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BS 3601 Quality Control Testing by ManufacturerBS 3601 Quality Control Testing by Manufacturer

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BS 3601 Mechanical TestsBS 3601 Mechanical Tests

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Flattening TestFlattening Test

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Hydraulic testHydraulic test

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Eddy current test

Eddy current test

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Test certificateTest certificate

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Pipe MarkingPipe Marking

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BS 3601 to be replaced by

BS EN 10224

BS 3601 to be replaced by

BS EN 10224

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Chemical compositionChemical composition

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Mechanical propertiesMechanical properties

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NDT of weldsNDT of welds

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Testing & Inspectionby Manufacturer

Testing & Inspectionby Manufacturer

• Test certificate to BS EN 10224:2002• 100% radiographic inspection may be

used in lieu of hydraulic test• All epoxy & plastic based coating to BS

6920 • All pipes & fittings shall be capable of

withstanding the max field hydrostatic test pressure specified.

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BS 6920-1:2000BS 6920-1:2000

• Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of the water

• Specification

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BS 6920-1:2000BS 6920-1:2000

• Odour and flavour of water• Appearance • Growth of aquatic microorganisms• Extraction of substances

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WSD Spec for ductile iron pipeWSD Spec for ductile iron pipe

• Pipe to BSEN 545, gasket to BSEN 681-1 and pipe length 5.5m

• Unless specified, all pipe & fitting shall be hydraulic pressure rated 1.6MPa

• All maxi field test pressure 2.5 MPa• Liquid : potable, sea & treated effluent• Joint: spigot & socket, flanged

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Testing & Inspection by Manufacturer

Testing & Inspection by Manufacturer

• Tensile test to BS 4772, Cl. 2.5.1 & 2• Straightness test to BS 4772• Work proof test• Hardness test• Gasket to BS 2494• Type test on welded-on flanges to BS

4772

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Sampling procedure to BS6001Sampling procedure to BS6001Steel/Polyethylene/DI/UPVC/Lined GI Pipes, CI Gate Valves, Air Relief Valves and Copper Alloy Stop/Gate Valves (A) Water/Hydrostatic Pressure Test

(1) For lot size less than 20 No., the sample size shall be equal to the lot size. For lot size equal to or more than 20 No., the sample size shall be 20 No.

(2) Duration of tests for polyethylene pipes shall be in accordance with the relevant

specification. Duration of tests shall be 2 minutes for other pipes and shall be in accordance with BS 6755 : Part 1:1986 for valves.

(3) Tests shall be witnessed before any finishing treatment.

(4) Acceptance criteria shall be no failure of witnessed water/hydrostatic pressure tests.

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(B) Other Tests (1) Sample size shall be determined in accordance with

BS 6001 : Part 1:1991 at inspection level II for single sampling plan. Materials from sub-contractors /different sources shall be sampled as isolated lots.

(2) Normal inspection shall be used at the start of inspection.

Inspection may be switched to tightened or reduced inspection and switched back to normal inspection in accordance with the procedures stipulated in Cl. 9.3 of BS 6001 : Part 1:1991.

(3) Acceptable quality level (AQL) shall be 4.0.

Sampling procedure to BS6001

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Factory Inspection of Water Valves

BS 5150

Factory Inspection of Water Valves

BS 5150

Coating for CI valveCoating for CI valve

Coating All cast iron parts for all valves including those of nominal sizes above DN600 shall be coated with an epoxy or plastic based materials. The proposed coating shall be suitable for use in potable water and shall comply with the requirement of BS6920. The epoxy or plastic based coating shall comply with the performance requirement of WIS4-52-01. The following minimum thickness for epoxy coating shall apply:-

Electrostatically Fusion Powder Coated Epoxy

(µm)

Airless Sprayed Application

(µm) Flat and Pressurised Parts 250 400 Convex Outer Edges 150 300

Details of such coating and certificate from an independent laboratory/inspection authority shall also be submitted to the Engineer for consideration

Materials for CI valveMaterials for CI valve

Materials 10.1 The valve components shall be manufactured from the materials given, as

appropriate, in Table 1 of this Specification. 10.2 The alternative materials contained in Table 6 of BS 5163:1986 shall not,

except where expressly permitted above, be used without the prior approval of the Engineer.

10.3 The Contractor shall provide test certificates on chemical and mechanical properties of the materials from an approved laboratory to provide the necessary evidence of suitability.

Table 1 – Materials for valves

Component Category ‘RES’ (Resilient seated) Category ‘CF’ (copper alloy faced)

Material Ref. Grade of designation

Material Ref. Grade or designation

Body, bonnet, stufing box, stem seal hsg. Bridge

Spheroidal graphite cast iron

BS EN 1563 : 1997 EN-GJS-400-18, EN-GJS-450-10, EN-GJS-500-7

Spheroidal graphite cast iron

BS EN 1563 : 1997 EN-GJS-400-18, EN-GJS-450-10, EN-GJS-500-7

Handwheel, stem cap

Grey (flake graphite) cast iron

BS EN 1561 : 1997 EN-GJL-250, EN-GJL-300, EN-GJL-350

Grey (flake graphite) cast iron

BS EN 1561 : 1997 EN-GJL-250, EN-GJL-300, EN-GJL-350

Obturator with integral faces

Grey (flake graphite) cast iron

BS EN 1561 : 1997 EN-GJL-250, EN-GJL-300, EN-GJL-350

Copper alloy BS EN 1982 : 1999 CC491K CC492K CC331G

Obturator with separate facings

Grey (flake graphite) cast iron

BS EN 1561 : 1997 EN-GJL-250, EN-GJL-300, EN-GJL-350

Grey (flake graphite) cast iron

BS EN 1561 : 1997 EN-GJL-250, EN-GJL-300, EN-GJL-350

Obturator facing or lining

Resilient material BS EN 681-1 : 1996 Grades shall comply with the specific requirements for Type WA

Copper alloy BS EN 1982 : 1999 CC491K CC492K CC331G

Testing for CI valveTesting for CI valveTesting

11.1 Test requirements shall be as specified in BS 5163:1986 for valves of nominal

sizes up to DN600 and in BS 5150:1990 and BS 6755:Part 1:1986 for valves of nominal sizes above DN600 unless otherwise specified. Seat testing for all valves shall be carried out on both sides of an obturator under an open end condition.

11.2 Test Certificates are required for all valves. 11.3 All certificates for non-metallic materials showing compliance with BS 6920

issued by an independent laboratory/inspection authority must be submitted to the Engineer for consideration.

WSD Spec for air relief valveWSD Spec for air relief valve

• To BS 21, BS 1452, BS 4504, BS 5163• Small orifice air valve• Double orifice air valve• Material: Grey CI to BS 1452• Test to BS 5163

WSD Spec 150mm pedestal fire hydrant

WSD Spec 150mm pedestal fire hydrant

• Ferrous casting to BS 1452 grade 220 density > 7200kg/m3

• Non-ferrous casting: bronze to BS1400 with zinc content < 1%

• All hydrant test to pressure 25bar• Painting: coated internally to BS 4147 & BS

3416 Type1, Grade C• External coated to epoxy resin to 280um• Painting on any casting must not be carried

out until the casting is declared satisfactory by IIB

Factory Inspectionof Water Valves

Siam Cast Iron Plant

Factory Inspectionof Water Valves

Siam Cast Iron Plant

Factory Inspection of Polyethene PE Pipe

ISO 4427

Factory Inspection of Polyethene PE Pipe

ISO 4427

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End of SeminarEnd of Seminar