Manufacturing

Processes

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December 01,

MANUFACTURING PROCESS
Currently a number of manufacturing techniques are used by Hydro Dynamic Pipe Engineering. These
include extrusion, rotation moulding, fabrication and machining. The process used will vary based on the
type of products and customer requirements.

Our pipes are manufactured using a process known as extrusion which can be summarized as
follows;
The raw material is melted and homogenized in an extrusion machine. The melted material is pushed
through a die at a continuous and constant rate. The pipe is then slightly cooled and passed through a
vacuum calibrator tank to obtain the final dimensions required. The pipe is pulled throughout the entire
process at a rate directly equivalent to that of the extruder.

The freshly created pipe then travels through sealed water tanks to continue to cool down and reach
final hardness.

The cooled pipe is then passed through a printing machine for batch number

and other pertinent information to be labeled on the pipe. Finally the pipe passes through the cutter
which cuts the pipe to the lengths requested by the customer.

Quality is at the forefront of HOPE's production methodology. Since inception HOPE has gained ISO
9001, 14001 and OHSAS 18001 accreditation as well as a number of other approvals from third
parties. This mentality is ingrained into our production cycle right from the selection of only premium raw
materials up until testing of our finished product is carried out in our in-house lab. As a result of this
emphasis Hydro Dynamic Pipe Engineering has supplied significant amounts of HOPE pipe and
products which are manufactured in accordance with DIN8077, IS04427, IS04437 and to individual
client's specified requirements.

Our staff are also trained in the custom fabrication of HOPE items designed to suit specific applications.
In addition we maintain a full fleet of butt fusion welding machines and can carry out on site jointing to
meet your needs.

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December 01,
2011

MANUFACTURE OF HOPE PIPES

Start Heater 6 hours

before production
schedule

Assemble the Die Set-up

while Pre-heat is going on

Fill in Raw HOPE into the

Raw Material Box

l
Transfer the Raw HOPE into
the Heater bvVacuum Valve

Start Heating Process at

220C

Heated Raw Material

will pass through Water
& Air Vacuum Tank at
15-22C

l
And then through the
Sealed Water Vacuum Tank
at 15- 20C

And then through the three

(3) Water Vacuum Tank at
20C

Cooled Pipe will then pass

through the Printing Machine
for Serial No

I
And then through the
Rotating Cutting
Machine

Scrap Materials will then

be vacuumed off by the AR
Compressor

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December 01,

PRE-PRODUCTION

1.

Start Heater 6 hours before production schedule. The 500kva diesel generator should be filled with diesel
ensuring that the amount transferred from the diesel storage tank is marked as issued to production on
the Daily Production Report.

2.

While pre-heating. assemble the Die Set-up according to specified size.

3.

Using the forklift, fill in the Raw HOPE into the Hopper. The raw material should be allowed to dry for the
specified period. Pipe Grade PE100 raw materials should be used.

4.

Complete the raw materials section of the Daily Production Report ensuring materials issued to
production section is completed.

PRODUCTION

5.

Transfer the Raw HOPE into the Heater by Vacuum Valve.

6.

Start the Heating Process at 220 2C.

7.

Raw HOPE Material will melts and passes through the die creating the pipe diameter required.

8.

During the extrusion process the new pipe will begin extruding. The wall thickness should be
measured at this point to ensure compliance with the pressure requirements. This newly extruded pipe
should then be attached to an existing pipe of the same diameter to allow the new pipe to pull through the
next station.

9.

The freshly created pipe will then travel through the Water & Air Vacuum Tank to cool down.

10.

Further downstream the Pipe will then pass through the Sealed Water Vacuum Tank for cooling

11.

And then through three (3) Water Vacuum Tanks for further cooling.

12.

Cooled down pipe will then pass through the Printing Machine for the Batch Number and other
pertinent information to be labeled on the pipe.

13.

Color of the printing should be WHITE, which differs from the color of the pipe which is BLACK.

14.

The marking shall be such that it is legible without magnification.

15.

Minimum required marking shall be in accordance to ISO 4427-2:2007 Table 6, with the frequency of
marking being less than once per meter.

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December 01,
2011

ASPECT

16.

MARKING

Standard Number

IS04427

Manufacturer's Identification

Hydro Dynamic Pipe Engineering FZ LLC, RAK, UAE

Dimensions

Eg: (IJ 200

SDR Series

Eg: SDRll

Material Designation

PE 100

Pressure Rating

Eg: PN16

Production Period (date or code)

Eg: SHIFT 'B = 070209

Finished product will then pass through the Rotating Cutting Machine and lengths of pipe will be cut
according to customer requirements.

POST PRODUCTION
17.

Scrap Materials shall then be vacuumed off by the AR Compressor for storage and finally reprocessing.