Introduction.1 PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems introduction contents Vinidex the Company 3 Quality Policy 3 Product Background 4 Worldwide Use 4 Australian Use 4 Pipe Extrusion 5 Fittings 6 End Treatments 6 Product Standards 7 Relevant Australian Standards 7
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Introduction.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
introduction
contents
Vinidex the Company 3
Quality Policy 3
Product Background 4
Worldwide Use 4
Australian Use 4
Pipe Extrusion 5
Fittings 6
End Treatments 6
Product Standards 7
Relevant Australian Standards 7
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsIntroduction.2
introduction
Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
Introduction.3PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
introduction
Vinidexthe CompanyVinidex Pty Limited is Australia’s leadingmanufacturer of thermoplastic pipe andfittings systems.
Vinidex manufactures and distributesplastic piping systems used in thetransportation of fluids, energy and datafor infrastructure development,agriculture, mining and building.
From its modest beginnings in Sydney in1960, the company has experienceddynamic growth. The company now hasfactories and distribution centres locatedin Sydney, Melbourne, Brisbane,Townsville, Launceston, Perth, Adelaide,Darwin and Mildura and a significantpresence in the Asia-Pacific Rim, withoperations in China and Hong Kong.
The first 15 years saw Vinidex establishtechnical and market leadership in themanufacture and supply of PVC pipingsystems. Regular evaluations of markettrends, customer requirements andoverseas developments provided theinsight into the potential for polyethylenepipe, particularly in the rural and miningindustries. Strategic companyacquisitions from 1988 to 1990 broughttechnical expertise and the capacity tomanufacture polyethylene pipes to1 metre diameter.
Quality Policy“Vinidex manufactures anddistributes plastic piping systemsused in the transportation of fluids,energy and data for infrastructuredevelopment, agriculture, mining andbuilding.
Vinidex is committed to ensuring itsproducts and services always meetits customer’s expectations andneeds, and when relevant alwaysconform to Australian andInternational Standards.
Vinidex will maintain strong tradingpartnerships with its customers andsuppliers and help them meet futureneeds in order to develop commonbusiness.
Vinidex is committed to ISO 9000Quality Management Systems andcontinuous improvement throughoutthe company.”
The 1990s saw a consolidation ofVinidex’s position as a leading supplierof pipeline systems. This was largely dueto the performance and acceptance ofPVC and polyethylene pipes for a widevariety of uses enabling the company tosuccessfully challenge other pipingmaterials such as metals, earthenware,concrete and fibre cement.
Vinidex pipe and fitting systems are usedin a broad cross-section of markets infields which include:
• Mining and industrial
• Water, wastewater and drainage
• Irrigation
• Plumbing
• Gas
• Communications
• Electrical
• Power
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsIntroduction.4
introduction
ProductBackground
Worldwide Use
Polyethylene (PE) materials wereinitially introduced in the UK in 1933and have progressively been used inthe pipeline industry since the late1930s.
The physical properties of the PEmaterials have been continuallyupgraded with improvements incrack propagation resistance,increased hydrostatic pressureresistance, ductility and elevatedtemperature resistance resultingfrom developments in the methodsof polymerisation. Thesedevelopments have resulted inincreased applications of PE in thepipeline industry in such areas asgas reticulation, water supply,mining slurries, irrigation, sewerand general industrial applications.
The engineering application basisfor the use of PE pipes in Europe wasprovided by the German Standard DIN8074 developed in 1960, and in the UKby the British Standards Institution BS3284 for cold water service applicationsdeveloped in 1967. Progressivedevelopments have followed Europeanstandards throughout Europe, NorthAmerica and Asia, with the developmentof International Standards Organisationand National Specifications.
The well recognised attributes of highimpact resistance, ease of installation,flexibility, smooth hydraulic flowcharacteristics, high abrasion resistance,
potable water and natural gasreticulation by gas and water utilitiesthroughout Australia.
Subsequent developments at StandardsAustralia resulted in the progressivedevelopment of Standard Specificationsfor PE compounds, PE gas pipes, PEfittings, irrigation systems, drainage,sewer and PE pipeline systeminstallation guidelines.
Recently, significant PE polymerdevelopments have led to review ofthese specifications, culminating in thepublication of the 1997 PE StandardsAS/NZS 4130 PE Pipes and AS/NZS4131 PE Compounds.
These Standards have introduced thelatest International developments andterminologies, and also provideduniform specifications throughoutAustralasia.
Polymer developments have resulted inPE80B materials, which have improvedductility and thermal stability, plusPE100 materials for use in largediameter and high pressure applicationsfor gas and water distribution.
Large diameter PE pipelines have nowbecome the preferred solution in manyapplications where the unique propertiesof PE provides the most cost effectivesolution.
Vinidex provide Australia widemanufacturing and supply services forPE pipeline systems in a wide range ofend use applications for pipes up to1000 mm diameter.
and excellent chemical reagentresistance have resulted in PE pipelinesystems being routinely specified andused in a wide range of applications inpipe sizes up to 1600 mm diameter.
Australian Use
PE pipe extrusion commenced inAustralia in the mid 1950s where smalldiameter pipes were used in irrigation,rural and industrial applications.
The Australian Standards for PE pressurepipes were initially developed as ASK119in 1962, and progressively improved andmetricated as AS1159 PE Pipes forPressure Applications in 1972 to include1000mm diameter. These specificationsprovided the engineering basis for theapproval and use of PE as approvedpipeline materials in such applications as
Introduction.5PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
introduction
Pipe ExtrusionVinidex PE pipes are extruded usingsophisticated, highly controlledmanufacturing processes andtechnologies.
The PE raw materials used in extrusionare compounded into pelletised formcontaining precise amounts of polymer,lubricants, stabilisers, antioxidants andpigments for the specific end productapplication.
The PE compound (1) is preheated toremove moisture and volatiles and isconveyed into the extruder by acontrolled rate feeder (2).
The extruder (3), consists of a singlescrew configuration which melts andconveys the PE material along the lengthof the extruder barrel. The design of theextruder barrel/screw is complex andtakes into account the properties of thevarious types of PE material grades usedin pipe applications. Various zones existalong the length of the screw and act tomelt, mix, de-gas and compress the PEcompound. External electrical heaterbands along the barrel, together with thefrictional heat generated as the PEmaterial passes through the gapsbetween barrel and screw provide theenergy needed to fully melt the PEcompound materials. The total heat inputis carefully controlled to ensure fullmelting of the PE without thermaldegradation.
After passing through a mixing zone atthe tip of the extruder, the PE melt thenfeeds into a head and die combination(4), where the melt is formed into thesize of pipe required. The correct designof the head and die is essential to permitthe production of pipe to AustralianStandards requirements and to ensure
retention of the physical properties of thePE materials.
Once the molten PE pipe form leaves thedie, it enters the sizing system (5), whereit is initially cooled to the requireddimensions. This is performed using anexternal vacuum pressure system wherethe pipe surfaces are cooled withrefrigerated water sprays whilst incontact with precision machined sizingsleeves. The initially cooled pipe is thenprogressively passed through a series ofwater spray cooling tanks (6) to reducethe PE material to ambient temperature,and to finalise the pipe dimensions.
As the pipe passes along the extrusionline, it is pulled along at a constant speedusing a caterpillar track haul off (7). Thishaul off speed is closely co-ordinated
with the speed of the extruder outputusing closed loop process controllers, tominimise built in stress in the pipe.
The pipe information of size, material,class, and batch data required byAustralian Standards, or by specificclient specification, is then marked onthe pipe by an in-line printer (8) toprovide continuous branding at specifiedintervals.
The completed pipe is then cut tostandard or required length by an in-linesaw (9), and then packed into stillages,or for large diameter pipes stored (10).Small diameter pipes are either cut tostandard length, or coiled (11), and thefinished coils are strapped in standardcoil sizes.
Raw Material Batching Extruder
Head & Die Sizing Haul Off
Print Station Saw Storage/Coiling Dispatch
1 2 3
4 5 6
8 9 10 11 12
Cooling
7
Figure 1.1 Typical Pipe Extrusion Line
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsIntroduction.6
introduction
FittingsFittings used with Vinidex PE pipesystems depend on the diameter and theend use application of the pipes. Smalldiameter pipes may use compressionjointing systems made from metal orplastics materials, socket fusion orelectrofusion systems made from PEmaterials.
Large diameter fittings are injectionmoulded or fabricated from PE pipe andjoined to the pipe by butt welding andelectrofusion.
Details of the specific Vinidex fittingsystems are contained in the ProductData section.
End TreatmentsVinidex PE pipes are supplied in anumber of alternative end treatmentconfigurations.
Small diameter pipes are supplied withplain ends to allow jointing by buttwelding, socket fusion, electrofusion, orcompression fittings.
Large diameter pipes are supplied withplain ends to allow jointing byelectrofusion, butt welding, ormechanical couplings. Alternatively,flanges can be welded on to the ends ofthe pipes under factory conditions.
Introduction.7PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
introduction
Product StandardsThe raw materials used in Vinidex PEpipeline systems are required to meetstringent specifications and supplies aremade against the latest Australian andInternational Standards.
The production of PE pipe within Vinidexfactories is subject to detailed processcontrol procedures, continuouslymonitored by trained staff.
Finished goods are inspected and testedto ensure compliance with the relevantAustralian or International Standard forthe particular field application. Themonitoring and recording system usedallows for full tracing of production.
Relevant AustralianStandards
AS 1460-1989
Fittings for use with polyethylene pipesPart 1: Mechanical Jointing FittingsPart 2: Electrofusion Fittings
AS 2033-1980
Installation of Polyethylene Pipe Systems
AS/NZS 2566.1-1998
Buried Flexible Pipelines
AS/NZS 2698-1984
Plastics Pipes and Fittings for Irrigationand Rural Applications
Part 1: Polyethylene Micro-IrrigationPipePart 2: Polyethylene Rural PipePart 3: Mechanical joint fittings foruse with micro-irrigation pipes
AS 3723-1989
Installation and maintenance of plasticspipe systems for gas
AS/NZS 4129(Int)-1997
Fittings for polyethylene (PE) pipes forpressure applications
AS/NZS 4130-1997
Polyethylene pipes for pressureapplications
AS/NZS 4131-1997
Polyethylene compounds for pipes andfittings applications
The quality assurance schemes adoptedby Vinidex have been accepted byappropriate government purchasingauthorities and have led to Vinidex beingregarded as a preferred supplier.
This commitment to total qualitymanagement is further evidenced byaccreditation under the SupplierAssessment Scheme as a QualityEndorsed Company to AS 3902/ISO 9002.
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Materials.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
m a t e r i a l s
contents
Polyethylene as a Material 3
Low Density PE 3
Linear Low Density PE 3
Medium Density PE 3
High Density PE 3
Properties of PE 4
Stress Regression Curves 5
Material Classification and Stress Regression 5Hydrostatic Design Stress 5
Chemical Resistance Classification 6
Introduction 6
Important Information 6
Classes of Chemical Resistance 6
Abbreviations 6
Chemical Attack on Thermoplastics & Elastomers 7
Factors Affecting Chemical Resistance 7
Chemical Resistance of Polyethylene 7
General Effect of Chemicals on Polyethylene Pipe 7
Chemical Resistance of Joints 8
General Guide for Chemical Resistance of Various Elastomers (Rubber Rings) 8
Chemical Resistance Tables 9-25
Material Performance Aspects 26
Abrasion Resistance 26
Weathering 27
Permeation 27
Food Contact Applications 27
Biological Resistance 27
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsMaterials.2
m a t e r i a l s
Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
Materials.3PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
m a t e r i a l s
Polyethylene asa MaterialPolyethylene materials are manufacturedfrom natural gas derived feedstocks bytwo basic polymerisation processes.
The low pressure polymerisation processresults in linear polymer chains withshort side branches. Densitymodifications to the resultant polymerare made by varying the amount ofcomonomer used with the ethyleneduring the polymerisation process.
The high pressure polymerisationprocess results in polymer chains withmore highly developed side branches.Density modifications to the resultantpolymer are made by varying thetemperatures and pressures used duringthe polymerisation process.
The physical properties of PE materialsare specific to each grade or type, andcan be modified by both variations indensity, and in the molecular weightdistribution. General physical propertiesare listed in Table 2.1.
A large number of grades of PE materialsare used in pipe and fittings systems andthe specific properties are tailored for theparticular application. Advice can beobtained from Vinidex as to the mosteffective choice for each installation.
The most general types of PE materialsare as follows:
Low Density PE (LDPE)
LDPE has a highly branched chainstructure with a combination of smalland large side chains.
The density of LDPE ranges between910-940 kg/m3 and LDPE exhibits highflexibility and retention of properties atlow temperatures.
The main use for LDPE in piping is in themicro irrigation or dripper tubeapplications with sizes up to 32 mmdiameter.
LDPE materials may be modified withelastomers (rubber modified) to improveEnvironmental Stress Crack Resistance(ESCR) values in micro irrigationapplications where pipes operate inexposed environments whilst carryingagricultural chemicals.
Linear Low Density PE(LLDPE)
LLDPE has a chain structure with littleside branching and the resultantnarrower molecular weight distributionresults in improved ESCR and tensileproperties when compared to LDPEmaterials.
LLDPE materials may be used either as asingle polymer or as a blend with LDPE,in micro irrigation applications to takeadvantage of the material flexibility.
Medium Density PE(MDPE)
MDPE base resin is manufactured usinga low pressure polymerisation process,and the limited side branch chainstructure results in a material densityrange of 930-940 kg/m3.
MDPE materials qualify as PE63 andPE80B in accordance with AS/NZS 4131.
MDPE materials provide improved pipeproperties when compared to the earlierhigh density materials used in pipes.These properties include life, flexibility,ductility, slow crack growth resistanceand crack propagation resistance.
These properties of the MDPE materialsare utilised in gas reticulation, smalldiameter pipe coils, travelling irrigatorcoils and water reticulation applications.
High Density PE (HDPE)
HDPE base resins are manufactured by alow pressure process, resulting in achain structure with small side branchesand a material density range of930-960 kg/m3.
HDPE materials qualify as PE80C andPE100 in accordance with AS/NZS 4131.
HDPE materials are widely used in bothpressure and non pressure applicationssuch as water supply, liners, drains,outfalls, and sewers in pipe sizes up to1000 mm diameter. The increasedstiffness of HDPE is used to advantage insuch applications as electrical andcommunications conduits, sub-soildrainage, sewer and stormwater.
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Table 2.1 Properties of Polyethylene
Typical values of the most commonly used properties
Property Test Method PE80B PE80C PE100
Density kg/m3 ISO1183D, ISO1872-2B 950 960 960
Tensile Yield Strength MPa ISO527 20 21 23
Elongation at Yield % ISO527 10 8 8
Tensile Break Strength MPa ISO527 27 33 37
Elongation at Break % ISO527 > 800 > 600 > 600
Tensile Modulus MPa Short term ref. AS/NZS 2566 700 750 950
Long term ref. AS/NZS 2566 200 210 260
Hardness Shore D DIN 53505 59 60 64
Notched Impact Strength kJ/m2 (23°C) ISO179/1 e A 35 24 26
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Stress RegressionCurvesTo design a pipe with the requiredthickness for a given pressure anddiameter, for example, the followingformula applies:
σ = MRS/C
σ = p(D-e)/2e
where
σ = wall tension, dimension stress
MRS= Minimum Required Strength
C = safety factor, typically 1.25 forwater
p = internal pipe pressure
D = external pipe diameter
e = pipe thickness
Figure 2.1 Typical Stress Regression Curves
MaterialClassification andStress Regression
Hydrostatic Design Stress
The allowable hydrostatic design stressis based on the Minimum RequiredStrength (MRS) which is in turn obtainedfrom stress regression curves.
Stress regression curves are developedfrom short and long term pressuretesting of pipe specimens.
As there is a linear relationship betweenthe logarithm of the applied stress andthe logarithm of time to failure, the testpoints are plotted and extrapolated to anarbitrarily chosen 50 year point.
0.10 1.0 10 102 103
1 month 1 year 10 years 50 years
104 105 106 hours
20°C
80°C
1
2
3
4
5
10
15
20MPa
Time to Failure
Hoop
Stre
ss
PE 100PE 80BPE 80C
In some cases, especially at highertemperatures, there is a sudden changein slope of the regression curve, knownas the ‘knee’. The knee, as illustrated inFigure 2.1 represents the transition fromductile failure mode to brittle failuremode.
The relationship between the curves fordifferent test temperatures enablesprediction of the position of the knee at20°C, based on a known position atelevated temperature – see Figure 2.1.This in turn enables prediction of ductilelife at 20°C.
The value of the predicted hoop stress(97.5% lower confidence limit) at the 50year point, is used to determine the MRSof the material, i.e. 6.3, 8.0 or 10.0 MPa.
The hydrostatic design stress is obtainedby application of a factor, not less than1.25, to the MRS value.
It is emphasised that stress regressioncurves form a design basis only, and donot predict system life.
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ChemicalResistanceClassification
Introduction
The following section tabulates theclasses of chemical resistance ofthermoplastic and elastomeric materialsmost commonly used in pipe and fittingssystems for the conveyance of liquidsand gases.
It is generally known that pipes andfittings in thermoplastic material arewidely used in industries whereconveyance of highly corrosive liquidsand gases requires high-qualityconstruction materials, featuringexcellent corrosion resistance.
Stainless steel, coated steel, glass andceramic materials can often beadvantageously replaced bythermoplastic materials, ensuring safety,reliability and economic benefits undersimilar operating conditions.
Important Information
The listed data are based on results ofimmersion tests on specimens, in theabsence of any applied stress. In certaincircumstances, where the preliminaryclassification indicates high or limitedresistance, it may be necessary toconduct further tests to assess thebehaviour of pipes and fittings underinternal pressure or other stresses.
Variations in the analysis of the chemicalcompounds as well as in the operatingconditions (pressure and temperature)can significantly modify the actualchemical resistance of the materials incomparison with this chart’s indicatedvalue.
It should be stressed that these ratingsare intended only as a guide to be usedfor initial information on the material tobe selected. They may not cover theparticular application underconsideration and the effects of alteredtemperatures or concentrations mayneed to be evaluated by testing underspecific conditions. No guarantee can begiven in respect of the listed data.Vinidex reserves the right to make anymodification whatsoever, based uponfurther research and experiences.
Three Different Classes ofChemical Resistance areConventionally Used inthis Guide.
Class 1: High Resistance
(Corrosion proof)
All materials belonging to this class arecompletely or almost completelycorrosion proof against the conveyedfluid according to the specified operatingconditions.
Class 2: Limited Resistance
The materials belonging to this class arepartially attacked by the conveyedchemical compound. The average life ofthe material is therefore shorter, and it isadvisable to use a higher safety factorthan the one adopted for Class 1materials.
Class 3: No Resistance
All materials belonging to this class aresubject to corrosion by the conveyedfluid and they should therefore not beused.
The absence of any class indicationmeans that no data is availableconcerning the chemical resistance ofthe material in respect of the conveyedfluid.
Abbreviations
Code Denomination
uPVC unplasticized polyvinyl chloride
PE polyethylene PE63 PE80 PE100
PP polypropylene
PVDF polyvinylidene fluoride
PVC-C chlorinated polyvinyl chloride
NBR butadiene-acrylnitrile rubber
EPM ethylene-propylene copolymer
FPM vinylidene fluoride copolymer
Notes
nd undefined concentration
deb weak concentration
comm commercial solution
dil diluted solution
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Chemical Attack onThermoplastics &ElastomersChemicals that attack polymers do so atdiffering rates and in differing ways.There are two general types of chemicalattack on polymer:
1. Swelling of the polymer occurs butthe polymer returns to its originalcondition if the chemical is removed.However, if the polymer has acompounding ingredient that issoluble in the chemical, theproperties of the polymer may bechanged because of the removal ofthis ingredient and the chemical itselfwill be contaminated.
2 The base resin or polymer moleculesare changed by crosslinking,oxidation, substitution reactions orchain scission. In these situations thepolymer cannot be restored by theremoval of the chemical. Examples ofthis type of attack on PVC are aquaregia at 20O°C and wet chlorine gas.
Factors AffectingChemical Resistance
A number of factors can affect the rateand type of chemical attack that mayoccur. These are:
Concentration:
In general, the rate of attack increaseswith concentration, but in many casesthere are threshold levels below whichno significant chemical effect will benoted.
Temperature:
As with all processes, rate of attackincreases as temperature rises. Again,threshold temperatures may exist.
Period of Contact:
In many cases rates of attack are slowand of significance only with sustainedcontact.
Stress:
Some polymers under stress canundergo higher rates of attack. In generalPVC is considered relatively insensitiveto “stress corrosion”.
ChemicalResistance OfPolyethyleneThe outstanding resistance of Vinidexpolyethylene systems to a variety ofchemical reagents, allows their use in awide range of chemical processes.
Chemical resistance of polyethylene isdue to the non polar or paraffinic natureof the material and is a function ofreagent concentration and temperature.Some attack may occur under specificconditions however, use of Vinidexpolyethylene systems provides a costeffective solution when the behaviour ofpolyethylene is compared to that ofalternative materials.
Where rubber modified LDPE blends areused for improved ESCR properties inirrigation applications, the effect ofspeciality chemicals may requireevaluation eg. micro-irrigation tube/dripper tube.
Lower alcohols, esters, ketones, ethers,aromatic hydrocarbons, mineral oil.
In most cases non-resistant:
Light naphtha, fuel mixture.
Completely non-resistant:
Unsaturated chlorinated hydrocarbons,turpentine.
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ChemicalResistance of Joints
Fusion Joints (PE)
Fusion joints include those made by buttfusion, electrofusion and socket fusionand these types will have the samechemical resistance as listed for PE.
Rubber Ring Joints (Elastomers)
Chemical resistance of Rubber RingJoints may be assessed by reference tothe accompanying Table 2.2 GeneralGuide for Chemical Resistance ofVarious Elastomers as well as the pipematerial guide.
Other Fittings
PE pipe systems often employ fittingsand accessories manufactured frommaterials dissimilar to the pipe material,such as brass, aluminium, iron andpolypropylene. In such cases, thedesigner should refer to the appropriatemanufacturer for advice on the chemicalresistance of these materials.
Material & Generally GenerallyDesignation resistant to not resistant to
Natural Most Moderate Ozone, StrongRubber Chemicals Wet or Dry, Acids, Fats, Oils,
NR Organic Acids, Alcohols, Greases, MostKetones, Aldehydes Hydrocarbons
Styrene As for As forButadiene Natural Rubber Natural Rubber
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m a t e r i a l s
MaterialPerformanceAspects
Abrasion Resistance
The transmission of solids in eitherliquid or gaseous carriers in PE pipelinesresults in abrasion of the internal pipewalls, especially at points of highturbulence such as bends or junctions.
The high resistance to abrasion,flexibility, light weight, and robustness ofVinidex PE pipes, have led to theirwidespread use in applications such astransportation of slurries and minetailings.
Abrasion occurs as a result of frictionbetween the pipe wall and thetransported particles.
The actual amount and rate of abrasionof the pipe wall is determined by acombination of:
• the specific gravity of the solids
• the solids content in the slurry
• solid particle shape, hardness andsize
• fluid velocity
• PE pipe material grade
The interaction of these parametersmeans that any prediction of the rate ofabrasion wear can only proceed wheretesting of wear rates has been performedon the specific slurry under the proposedoperational conditions.
Under varying test conditions the relativeranking of different pipe materials maychange, and where possible testingshould be performed.
A comprehensive collection of casehistory data has been assembled byVinidex design engineers for particularapplications, and this information isavailable on request.
In general terms, PE pipes have superiorabrasion resistance to steel, ductile iron,FRP, asbestos and fibre reinforcedcement pipes, providing a more costeffective solution for abrasive slurryinstallations.
Laboratory test programs have beenperformed in the UK, Germany and USAto obtain relative wear comparisons forvarious materials using sliding androtating pipe surfaces.
The results of test programs using theDarmstadt (Germany) method ofKirschmer and reported by Meldt(Hoechst AG) for a slurry of quartz sand/gravel water with a solids content 46%by volume and a flow velocity of 0.36m/sare shown in Figure 2.2.
These were performed across a range ofmaterials and show the excellentabrasion resistance of PE pipe materials.
Similarly, Boothroyde and Jacobs (BHRAPR 1448) performed closed loop testsusing iron ore slurry in a concentrationrange of 5 to 10% and ranked PE aheadof mild steel and asbestos cement inabrasion resistance.
For most grades, the difference inabrasion resistance between MDPE(PE80B) and HDPE (PE80C and PE100)is not significant. However, Vinidexoffers grades which are specificallyselected to maximise abrasionresistance, whilst also maximisingpressure rating and crack growthresistance.
The design of fittings involving change offlow direction is critical in slurry lines.The lower the rate of change of direction,the lower the abrasion rate. For bends, alarge centreline radius must be used.Where possible, a radius of at least 20times the pipe diameter should be used,along with a long straight lead-in lengthcontaining no joints.
In practice, the effective lifetime of thePE pipeline can be increased by usingdemountable joints to periodically rotatethe PE pipe sections to distribute theabrasion wear evenly around thecircumference of the pipe.
Figure 2.2Comparative AbrasionRates of Pipe Materials
AsbestosCement
200 400 600
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
Abra
sion
(mm
)
Number of Load Cycles (000)
Fibreglass
Concrete
PVCVit Clay
HDPE
00
Materials.27PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
WeatheringWeathering of plastics occurs by aprocess of surface degradation, oroxidation, due to a combined effect ofultra violet radiation, increasedtemperature, and moisture when pipesare stored in exposed locations.
All Vinidex PE pipe systems containantioxidants, stabilisers and pigments toprovide protection under Australianconstruction conditions.
Black PE pipes contain carbon blackwhich act as both a pigment and an ultraviolet stabiliser, and these pipes requireno additional protection for externalstorage and use.
Other colours such as white, blue, yellowor lilac do not possess the same stabilityas the black pigmented systems and theperiod of exposure should be limited toone year for optimum retention ofproperties. With these colour systemsthe external surface oxidation layersdevelop at a faster rate than those incarbon black stabilised PE pipes.
For exposure periods longer than oneyear, additional protection such ascovering should be adopted.
PermeationPermeation of PE pipe systems fromexternal sources may occur when thesurrounding soils are contaminated.
Organic compounds of the non polar,low molecular type are those whichpermeate most rapidly through the PEpipe walls. Accordingly, where materialssuch as aliphatic hydrocarbons,chlorinated hydrocarbons and alkylatedbenzenes are encountered, considerationto impermeable ducting should be given.
Where contamination is suspected, soilsampling should be performed and in thecase of potable water transmission lines,protection to the PE pipes should beprovided where contamination is found.
Food Contact ApplicationsWhere the pipeline system is used forfood processing or transport purposes,Vinidex PE pipes can be supplied usingPE materials complying with AS 2070 -Plastics for Use in Food ContactApplications. In these applications theadvice of Vinidex engineers should beobtained as to the effect of the systemon food quality, and the most appropriatejointing systems to prevent detention ofthe food materials through the pipesystem.
Biological Resistance PE pipes may be subject to damagefrom biological sources such as ants orrodents. The resistance to attack isdetermined by the hardness of the PEused, the geometry of the PE surfaces,and the conditions of the installation.
Small diameter irrigation applicationsusing LDPE materials may be attackedby ants or termites due to the relativelythin wall sections and the hardness ofthe LDPE. In these instances the sourceof the ants should be treated by normalinsecticide techniques.
Both MDPE and HDPE material typeshave a higher hardness value than LDPE,and together with the thicker pipe wallsections used in PE63, PE80, and PE100applications provide a generally resistantsolution. In small diameter pipes, thethin wall sections may be damaged bytermites in extreme cases.
However damage often ascribed totermite attack in PE has subsequentlybeen found to be due to other sources ofmechanical damage.
PE pipe systems are generally unaffectedby biological organisms in both land, andmarine applications, and the paraffinicnature of the PE pipe surfaces retardsthe build up of marine growths inservice.
m a t e r i a l s
Applications.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
applications
contents
Summary 3
Typical Applications 4
Water Supply 4
Mine Tailings and Slurry Lines 4
Above Ground Pipelines 4
Gas Distribution 5
Submarine Pipelines 5
Relining & Rehabilitation 5
Industrial and Chemical Pipelines 6
Compressed Air 6
DWV Drainage and Trade Waste 6
Stormwater Drainage 7
Communications 7
Protective Conduits for Cables 7
Rural and Irrigation 8
Driplines 8
Aquaculture – Fish Cages 8
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsApplications.2
applications
Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
Applications.3PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
applications
SummaryThe success and the continued high levelof growth in the application ofpolyethylene for piping systems has notcome about by chance. Polyethyenesystems offer significant advantagesover ‘traditional’ iron, steel and cementsystems.
Primarily, the material is free fromcorrosion in all ground conditions and itsflexibility allows it to withstand groundmovement. Corrosion and joint leakageare prevalent in iron and cementsystems, usually within desired lifetimes.Polyethylene offers the solution toavoiding the premature failure ofpipelines in such materials.
Polyethylene is basically chemically inertand therefore, unlike iron or cement, willbe unaffected by acidic soil conditions orother corrosion inducing conditions. Noprotective layers or finishing processesare required, thus avoiding additionalexpense and further potential risk offailure.
The flexibility of polyethylene is a keyproperty which has greatly enhanced thevalue of the material to the pipelineengineer. Apart from the value inallowing substantial cost savings duringinstallation, a polyethylene system hasan inherent resistance to the effects ofground movement from temperaturefluctuation or instability. Polyethylenegas and water systems have been theonly systems to survive majorearthquakes such as those whichoccurred in Kobe, Japan in 1995.Polyethylene systems can be fusionwelded, so unlike rubber ring type jointsor other mechanical systems, there is norisk of leakage as a result of jointdistortion. Systems are fully end loadbearing and costly anchorage is notrequired at junctions and bends. Rootpenetration is not a problem.
The flexibility of PE pipe allows it to becoiled and supplied in long lengths,avoiding frequent joints and fittings. Thisflexibility and low weight has alsoresulted in the development of costsaving installation techniques reducingdisturbance to the public and theenvironment. Long lengths can be pulledthrough holes below the ground boredby mechanical moles, avoiding the needfor open cut trenches. The material lendsitself readily to renovation by insertion asa lining into old, leaking pipelines,offering further cost saving solutions tothe water and gas engineer.
The low friction bores are not subject toscale buildup. The material is biologicallyinert. Polyethylene can be colour codedto suit the end application. Typically bluefor water and yellow for gas, or by colourstripes on black pipe.
The polyethylene pipeline system hasbeen developed as an integrated pipeand fitting system. It has a track recordof high reliability over a period nowapproaching 50 years. There is no costpenalty in obtaining these advantages,indeed the PE system is cost effectivewith a long maintenance free lifetime andlow wholelife costs, and the installedsystem costs are often less than fortraditional materials.
To summarise, the principal advantagesof polyethylene piping systems are:
• Flexibility
• Chemical resistance
• Fusion welded jointing
• Resistance to ground movementand end load
• Cost effective installation techniques
• High impact strength
• Abrasion resistance
• High flow capacity
• Weathering resistance
• Low whole life costs
• Long lengths
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsApplications.4
applications
Above GroundPipelines
• Ultra-violet (UV) resistance
• High impact strength
PE pipe is widely used in above groundapplications, particularly in demandingconditions typical of mining and ruralregions.
Water Supply
• Long life, corrosion resistant
• High water quality
10kms of 450mm PE100 pipe deliverswater to Stratford Power Station, NewZealand.
Mine Tailings &Slurry Lines
• Abrasion and UV resistance
• High impact strength
PE pipes are an ideal solution for slurrysystems, pit dewatering and chemicaltreatment applications in miningoperations.
Applications.5PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
applications
Gas Distribution
• Long life
• Corrosion resistance
A new 250mm gas main installed inMelbourne’s CBD did not greatlyinterfere with traffic or pedestrians, asinstallation time was reduced by 40%.
Relining & Rehabilitation
• Long lengths and minimal disruption
• Corrosion resistance
Sliplining and pipe bursting with longlengths of PE pipes provide minimaldisruption to existing water and sewersystems and the local community.
Submarine Pipelines
• Lightweight , corrosion resistance
• Superior flow characteristics
A 1000mm seamless effluent PE pipelinewas floated and then sunk into place onthis Gold Coast river bed.
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsApplications.6
applications
Compressed Air
• Easy, clean, quick & safe installation
• Corrosion resistance
Vinidexair high strength PE pipingsystem is a proven performer inindustries requiring compressed airlines.
Industrial &Chemical Pipelines
• A range of fittings solutions
• Excellent chemical resistance
PE pipe systems are installed in difficultto access industrial situations.
DWV Drainage& Trade Waste
• Smooth bore
• Excellent chemical and abrasionresistance
PE pipe is increasingly used fortransporting industrial, laboratory andtrade waste.
Applications.7PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
applications
Protective Conduitsfor Cables
• Flexibility
• Durability
Nearly 14kms of PE pipe was specifiedas Cable Sheathing in the landmarkAnzac Bridge, Sydney.
Stormwater Drainage
• Resistance to ground movement
• Ease of on-site jointing of largediameter pipe
1000mm PE pipes were joined aboveground and hands-free lowered into an 8metre trench in unstable ground withheavy gases present.
Communications
• Flexibility
• Long coil lengths
Cablecon conduit is a value-addedducting solution supplied pre-lubricatedand with a pre-installed draw rope.
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsApplications.8
Rural and Irrigation
• High resistance to impact andweathering
• Flexibility and ease of jointing
PE pipes are widely used for stockwatering, watermains, irrigation systemsand reticulation of elevated temperatureartesian bore water.
Aquaculture – Fish Cages
• Flexibility and ease of fabrication
• Corrosion resistance
Salmon farming cages in Tasmaniautilise the flotation properties of PE pipe.
Dripline
• Water efficient
• Cost effective long term irrigation
Ecodrip regular and pressurecompensated (PC) dripline: available in avariety of wall thicknesses for cropsincluding grapes, olives, vegetables,orchards, flowers, sugar cane, cotton etc.
applications
Design.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
d e s i g n
contents
Pipe Selection 3
Pipe Dimensions 4
Allowable Operating Pressure 5
Temperature Influences 7
Service Lifetimes 7
Pipe Design for Variable Operating Conditions 8
E Modulus 10
Selection of Wall Thickness for Special Applications 10
Hydraulic Design 11
Flow Chart Worked Examples 13
Part Full Flow 15
Resistance Coefficients 16
Flow Charts 17-26
Surge and Fatigue 27
Celerity 28
Slurry Flow 29
Pipe Wear 30
Maintenance and Operation 31
Fittings 31
Pneumatic Flow 32
System Design Guidelines for the Selection of Vinidexair Compressed Air Pipelines 33
Expansion And Contraction 35
External Pressure Resistance 36
Trench Design 37
Allowable Bending Radius 38
Deflection Questionnaire – FAX BACK 39
Deflection Questionnaire – Vinidex locations 40
Thrust Block Supports 41
Electrical Conductivity 43
Vibration 43
Heat Sources 43
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsDesign.2
d e s i g n
Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
Design.3PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
d e s i g n
Pipe SelectionVinidex PE pipes are available in acomprehensive range of sizes up to1000mm diameter, and pressure classesin accordance with the requirements ofAS/NZS 4130 - Polyethylene (PE) pipesfor pressure applications.
Additional sizes and pressure classes toAS/NZS 4130 requirements are addedfrom time to time and subject tominimum quantity requirements, pipesmade to specific sizes, lengths orpressure classes are available.
The Standard AS/NZS 4130 includes arange of PE material designations basedon the Minimum Required Stress (MRS),and classified as PE63, PE80, andPE100. When pipes are made to thesame dimensions, but from differentrated PE materials, then the pipes willhave different pressure ratings.
The relationship between the dimensionsof the pipes, the PE materialclassification and the working pressurerating are as shown in Table 4.1.
For simplicity, the dimensions of the pipehave been referred in terms of theStandard Dimension Ratio (SDR) where:
Outside DiameterSDR =
Wall Thickness
Table 4.1 Comparison of SDR & Pressure Ratings (PN)
SDR 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 - PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 - PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
Notes:
PE Long term rupture stress at 20°C (MPa x 10) to which a minimum design factoris applied to obtain the 20°C hydrostatic design hoop stress.
PN Pipe pressure rating at 20°C (MPa x10).
SDR Nominal ratio of outside diameter to wall thickness.
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsDesign.4
d e s i g n
Pipe DimensionsTable 4.2 PE Pipe Dimensions AS/NZS 4130
Nom
inal
Size DN
SDR
41SD
R 33
SDR
26SD
R 21
SDR
17SD
R 13
.6SD
R 11
SDR
9SD
R 7.
4M
in. W
allTh
ickne
ss(m
m)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
Min
. Wall
Thick
ness
(mm
)
Mea
nI.D
.(m
m)
161.
613
1.6
131.
613
1.6
131.
613
1.6
131.
613
1.8
122.
211
201.
617
1.6
171.
617
1.6
171.
617
1.6
171.
916
2.3
152.
814
251.
622
1.6
221.
622
1.6
221.
622
1.9
212.
320
2.8
193.
518
321.
629
1.6
291.
629
1.6
291.
928
2.4
272.
926
3.6
244.
423
401.
637
1.6
371.
637
1.9
362.
435
3.0
343.
732
4.5
315.
528
501.
647
1.6
472.
046
2.4
453.
044
3.7
424.
640
5.6
386.
935
631.
660
2.0
592.
458
3.0
573.
855
4.7
535.
851
7.1
488.
645
751.
971
2.3
702.
969
3.6
674.
566
5.5
636.
861
8.4
5810
.353
902.
286
2.8
843.
583
4.3
815.
478
6.6
768.
273
10.1
6912
.365
110
2.7
105
3.4
103
4.3
101
5.3
996.
696
8.1
9310
.089
12.3
8415
.178
125
3.1
119
3.9
117
4.8
115
6.0
113
7.4
110
9.2
106
11.4
101
14.0
9617
.189
140
3.5
133
4.3
131
5.4
129
6.7
126
8.3
123
10.3
118
12.7
114
15.7
108
19.2
99
160
4.0
152
4.9
150
6.2
148
7.7
144
9.5
140
11.8
136
14.6
130
17.9
123
21.9
114
180
4.4
171
5.5
169
6.9
166
8.6
163
10.7
158
13.3
153
16.4
145
20.1
138
24.6
128
200
4.9
190
6.2
188
7.7
184
9.6
180
11.9
175
14.7
170
18.2
162
22.4
154
27.3
143
225
5.5
215
6.9
211
8.6
207
10.8
203
13.4
198
16.6
191
20.5
183
25.1
173
30.8
161
250
6.2
238
7.7
235
9.6
230
11.9
225
14.8
219
18.4
212
22.7
203
27.9
192
34.2
179
280
6.9
267
8.6
263
10.7
258
13.4
253
16.6
246
20.6
238
25.4
228
31.3
215
38.3
200
315
7.7
300
9.7
296
12.1
290
15.0
285
18.7
278
23.2
268
28.6
256
35.2
242
43.0
226
355
8.7
338
10.9
333
13.6
328
16.9
320
21.1
311
26.1
301
32.2
289
39.6
273
48.5
255
400
9.8
380
12.3
376
15.3
370
19.1
362
23.7
351
29.4
340
36.3
326
44.7
307
54.6
287
450
11.0
429
13.8
422
17.2
415
21.5
406
26.7
395
33.1
382
40.9
366
50.2
347
61.5
322
500
12.3
476
15.3
470
19.1
462
23.9
452
29.6
440
36.8
424
45.4
407
55.8
384
--
560
13.7
534
17.2
526
21.4
518
26.7
506
33.2
494
41.2
475
50.8
455
--
--
630
15.4
600
19.3
592
24.1
582
30.0
570
37.3
554
46.3
535
57.2
512
--
--
710
17.4
676
21.8
667
27.2
656
33.9
641
42.1
624
52.2
603
--
--
--
800
19.6
762
24.5
752
30.6
739
38.1
723
47.4
704
58.8
679
--
--
--
900
22.0
858
27.6
846
34.4
831
42.9
814
53.5
791
--
--
--
--
1000
24.5
953
30.6
940
38.2
924
47.7
904
59.3
880
--
--
--
--
Po
lyeth
yle
ne P
ipe D
imen
sio
ns
(base
d o
n A
S/N
ZS 4
130-1
997,
Po
lyeth
yle
ne p
ipes
for
pre
ssu
re a
pp
lica
tio
ns.
)
SD
R –
No
min
al
rati
o o
f o
uts
ide d
iam
ete
r to
wall
th
ickn
ess
.
ID
– i
nte
rnal
dia
mete
r
Design.5PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
d e s i g n
AllowableOperating Pressure
Hydrostatic Design Basis
Vinidex pipes manufactured to AS/NZS4130, Series 1 have wall thickness andpressure ratings determined by theBarlow formula as follows:
T = minimum wall thickness (mm)P = normal working pressure
of pipe (MPa)D = minimum mean OD (mm)S = hydrostatic design stress
at 20°C (MPa)See Table 4.2.
Hydrostatic Design Stress
The design of AS/NZS 4130 pipes hasbeen based on the static workingpressure operating continuously at themaximum value for the entire lifetime ofthe pipeline.
The value of maximum hoop stress usedin the selection of the pipe wall thicknessis known as the Hydrostatic DesignStress (S). This value is dependent uponthe type of PE material being used andthe pipe material service temperature. InAS/NZS 4131, materials are classified forlong term strength by the designationMinimum Required Strength (MRS).
The MRS is the value resulting fromextrapolation of short and long termtests to a 50 year point at 20°C.
Note: See Figure 2.1 for typical stressregression curves.
Material Designation Minimum Required Strength Hydrostatic Design Stress(MRS) MPa (S) MPa
PE63 5.0 6.3
PE80 6.3 8.0
PE100 8.0 10.0
These standard values are polymerdependent and long term properties foreach pipe grade material are establishedby long term testing to the requirementsof ISO/DIS 9080 by the polymerproducers. Individual PE grades mayexhibit different characteristics and PEmaterials can be provided with enhancedspecific properties. In these cases theadvice of Vinidex engineers should beobtained.
Maximum AllowableOperating Pressure
where
MAOP is the maximum allowableoperating pressure in MPa.
PN is the pipe classification inaccordance with AS/NZS 4130.
F is the Design Factor.
For example, if the minimum value of F ischosen (F = 1.25), a PN10 pipe will havea MAOP of 1.0 MPa at 20°C.
T =PD
2S + P
S =MRS
F
MAOP =PN x 0.125
F
The Hydrostatic Design Stress (S) isobtained by application of a Design orSafety Factor (F) to the MRS.
See Table 4.3.
The specific value selected for theDesign Factor depends on a number ofvariables, including the nature of thetransmitted fluid, the location of thepipeline, and the risk of third partydamage.
The wall thickness values for Series 1pipes to AS/NZS 4130 were derivedusing a value of 1.25 for F, this being theminimum value applicable.
AS/NZS 4131 specifics MRS values of6.3 MPa, 8.0 MPa and 10.0 MPa for thegrades designated as PE63, PE80 andPE100 respectively.
The relationship between the S and MRSstandard values in AS/NZS 4131 is asshown in Table 4.3.
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsDesign.6
d e s i g n
Table 4.6 Design Factors – Gas Pipes
Installation Conditions Design Factor Value
Fluid type Natural Gas f0 2.0
LPG 2.2
Pipe Form Straight length f1 1.0
Coils 1.2
Soil Temperature (Av. °C) -10 < t < 0 f2 1.2
0 < t < 20 1.0
20 < t < 30 1.1
30 < t < 35 1.3
Designation Distribution f3 1.0
Transport 0.9
Rapid Crack Resistance f4 1.0
Population density & area loading
Open field f5 0.9
Less trafficed roads in inbuilt areas 1.05
Heavy trafficed roads in inbuilt areas 1.15
Roads in populated area 1.20
Roads in industrial area 1.25
Private area habitation 1.05
Private area industry 1.20
Note: Where factor values are not listed, consult with Vinidex engineers forrecommendations.
Where installation applications are usedto carry fluids other than water, thenanother value of the Design Factor mayneed to be selected. The value selectedwill depend on both the nature of thefluid being carried and the location of thepipeline installation. For specificinstallations, the advice of Vinidexengineers should be obtained.
In the case of gas pipes in AS/NZS 4130,both Series 2 and Series 3, a DesignFactor ranging between F = 2.0 andF = 4.0 applies depending on the specificinstallation conditions; see Table 4.6.
Table 4.4Typical Design Factors
Pipeline Application Design Factor
20°C F
Water Supply 1.25
Natural Gas 2.0
Compressed Air 2.0
LPG 2.2
Where the Design Factor is varied, thenthe MAOP for the particular Series 1 pipePN rating can be calculated as follows:
In the particular case of gas distribution,then the type of gas, and the pipelineinstallation conditions need to beconsidered. In this case the DesignFactor is a combination of a number ofsub factors (fx) which must be factoredtogether to give the final value for F suchthat:
Design.7PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
d e s i g n
TemperatureInfluencesThe physical properties of Vinidex PEpipes are related to a standard referencetemperature of 20°C. Where physicalproperty values are quoted to ISO andDIN Standard test methods, these are forthe 20°C condition, unless otherwisequoted. Wherever PE pipelines operate atelevated temperatures, the pressureratings (PN) must be revised.
The temperature to be considered for there rating is the pipe material servicetemperature, and the actual operatingconditions for each specific installationmust be evaluated.
For long length installations atemperature gradient will exist along thelength of the pipe line. This gradient willbe dependent upon site conditions, andthe fluid being carried will approach theambient temperature of the surrounds.
The rate of temperature loss will bedetermined by inlet temperature, fluidflow rate, soil conductivity, ambienttemperature and depth of burial. Asthese factors are specific to eachinstallation, the temperature gradientcalculations are complex and in order toassist the designer, Vinidex havedeveloped computer software to predictthe temperature gradient along thepipeline.
This is available on request to Vinidexdesign engineers.
Service LifetimesThe design basis used in AS/NZS 4130for PN rating of PE pipes to determinethe minimum wall thickness for eachdiameter and PN rating provides for thesteady and continuous application of themaximum allowable working pressureover an arbitrary period of 50 years.
The selection of the long termhydrostatic design stress value (HDS) isdependent on the specific grade of PEand the pipe material servicetemperature. For the grades of PEmaterials contained in AS/NZS 4131the specific values are contained inTable 4.3.
As these values are polymer dependent,individual grades may exhibit differentcharacteristics and materials can beprovided with enhanced properties forcrack resistance or elevated temperatureperformance. In these cases the adviceof Vinidex design engineers should beobtained.
Vinidex PE pipes are continually tested incombinations of elevated temperature(80°C water conditions) and pressure toensure compliance with specificationrequirements.
The adoption of a 50 year design life inAS/NZS 4130 to establish a value of theHDS is arbitrary, and does not relate tothe actual service lifetime of the pipeline.
Where pipelines are used for applicationssuch as water supply, where economicevaluations such as present valuecalculations are performed, the lifetimesof PE lines designed and operated withinthe AS guidelines may be regarded as70–100 years for the purpose of thecalculations. Any lifetime values beyondthese figures are meaningless, as theassumptions made in other parts of theeconomic evaluations outweigh theeffect of pipe lifetime.
The grades of PE specified in AS/NZS4131 are produced by differentpolymerisation methods, and as suchhave different responses to temperaturevariations.
Pipe Classification (PN) is based oncontinuous operation at 20°C and thepressure rating will be reduced forhigher temperatures. In addition, as PEis an oxidising material, the lifetime ofsome grades will be limited by elevatedtemperature operation. Table 4.7 givestemperature rerating data for Vinidexpipes made to AS/NZS 4130.
In these tables, allowable workingpressures are derived from ISO 13761*and assume continuous operation at thetemperatures listed.
Extrapolation limit is maximum allowableextrapolation time in years, based ondata analysis in accordance with ISO/DIS9080**, and at least two years of test at80°C for PE80B and PE100. Actualproduct life may well be in excess ofthese values.
The performance of compounds used inthe manufacture of Vinidex pipes toAS/NZS 4130 has been verified byappropriate data analysis.
In addition, Vinidex offers pipes madefrom specialised compounds forparticular applications, such as elevatedtemperature use.
Contact Vinidex engineers for specialrequirements.
Note:
* Plastics pipes and fittings – pressurereduction factors for polyethylenepipeline systems for use attemperatures above 20°C.
** Plastics piping and ducting systems –determination of long-termhydrostatic strength ofthermoplastics materials in pipe formby extrapolation.
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Pipe Design forVariableOperationalConditionsThe following examples assist in thedesign and selection of polyethylenepipes for variable operating conditions
Given Operating Conditions
Pressure/Temperature/Time Relationship
Determine
Material
Class of pipe
Life
Steps
1. Assume a material
2. Determine Class from
Temperature Rating Table 4.7
Note: For brief periods at elevatedtemperature it may be appropriate todecrease the safety factor to a value of x,i.e. multiply the working pressure by:
3. By the following process,
assess whether life is ‘used up’
For each combination of time andtemperature, estimate the proportion oflife ‘used up’ by using the time/temperature relationships in the table.
If the proportion is less than unity, thematerial is satisfactory.
1 25.x
The data in the tables are obtained fromthe use of ISO 13761 and ISO/DIS 9080,and are appropriate for compoundstypically used by Vinidex.
Example
Pumped system normally working at amaximum head, including surge of 60m.At startup, the mean pipe walltemperature is 55°C, dropping to 35°Cafter 1 hour. Pump operation is for 10hours per day, with a system life of 15years.
1. Assume PE 80B
2. Determine Pipe Class
The worst situation is operation at 55°C.
From Table 4.7, PN10 pipe at 55°C hasan allowable working head of 60m.
PN10 pipe is therefore satisfactory.
3. Determine Life
Total time at 55°C
= 1 x 365 x 15 = 5475h = 0.625y.
From Table 4.7, Lmin for 55°C is 24 years,therefore proportion of time used is:
Total time at 35°C
= 9 x 365 x 15 = 49275h = 5.625y.
From the table, Lmin for 35°C is 100 years,therefore proportion of time used is:
Total proportion is 8.2% of life used in15 years (6.25 years actual operation).
0.62524
= 0.026 = 2.6%
5.625100
= 0.056 = 5.6%
Design.9PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Selection of WallThickness forSpecialApplicationsFor a required nominal diameter (DN)and working pressure, the necessarywall thickness for special applicationsmay be calculated using the Barlowformula:
where
t = minimum wall thickness (mm)
P = maximum working pressure (MPa)
DN = nominal outside diameter (mm)
S = design hoop stress (MPa)
where
F = design factor,typically 1.25 for water
Example
P = 900kPa = 0.9MPa
DN = 630
MRS = 10 (PE100)
F = 1.25
tP DNS P
=+
..2
SMRS
F= S MPa= =10
1 258 0
..
tx
mm=+
=0 9 63016 0 9
33 6.
..
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Hydraulic Design
Design Basis
Vinidex Polyethylene (PE) pipes offeradvantages to the designer due to thesmooth internal bores which aremaintained over the working lifetime ofthe pipelines. The surface energycharacteristics of PE inhibit the build upof deposits on the internal pipe surfacesthereby retaining the maximum boredimensions and flow capacities.
The flow charts presented in this sectionrelate the combinations of pipediameters, flow velocities and head losswith discharge of water in PE pipelines.These charts have been developed forthe flow of water through the pipes.Where fluids other than water are beingconsidered, the charts may not beapplicable due to the flow properties ofthese different fluids. In these cases theadvice of Vinidex engineers should beobtained.
There are a number of flow formulae incommon use which have either atheoretical or empirical background.However, only the Hazen-Williams andColebrook-White formulae areconsidered in this section.
Hazen - Williams
The original Hazen-Williams formula waspublished in 1920 in the form:
v = C1 r0.63 s0.54 0.001-0.04
where
C1 = Hazen-Williams roughnesscoefficient
r = hydraulic radius (ft)
s = hydraulic gradient
Colebrook - White
The development from first principles ofthe Darcy-Weisbach formula results inthe expression
where
and
f = Darcy friction factor
H = head loss due to friction (m)
D = pipe internal diameter (m)
L = pipe length (metres)
v = flow velocity (m/s)
g = gravitational acceleration(9.81 m/s2)
R = Reynolds Number
This is valid for the laminar flow region(R 2000), however, as most pipeapplications are likely to operate in thetransition zone between smooth and fullturbulence, the transition functiondeveloped by Colebrook-White isnecessary to establish the relationshipbetween f and R.
where
k = Colebrook-White roughnesscoefficient (m)
The appropriate value for PE pipes is:
k = 0.007 x 10 -3 m
= 0.007 mm
This value provides for the range ofpipe diameters, and water flowvelocities encountered in normalpipeline installations.
HfLvD g
=2
2
fR
= 64
12
3 72 51
1 2 10 1 2f
kD Rf/ /
log.
.= − +
The variations inherent with diameterchanges are accounted for by theintroduction of the coefficient C2 so that
C2 = C1 r0.02
Adoption of a Hazen-Williams roughnesscoefficient of 155 results in the followingrelationship for discharge in Vinidex PEpipes
Q = 4.03 x 10-5 D2.65 H0.54
where
Q = discharge (litres/second)
D = internal diameter (mm)
H = head loss (metres/100 metreslength of pipe)
Flow charts for pipe systems using theHazen - Williams formula have been inoperation in Australia for over 30 years.The charts calculate the volumes ofwater transmitted through pipelines ofvarious materials, and have been provenin practical installations.
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Head Loss in Fittings
Wherever a change to pipe cross section,or a change in the direction of flowoccurs in a pipeline, energy is lost andthis must be accounted for in thehydraulic design.
Under normal circumstances involvinglong pipelines these head losses aresmall in relation to the head losses dueto pipe wall friction.
However, geometry and inlet/exitcondition head losses may be significantin short pipe runs or in complexinstallations where a large number offittings are included in the design.
The general relationship for head lossesin fittings may be expressed as:
where
H = head loss (m)
V = velocity of flow (m/s)
K = head loss coefficient
g = gravitational acceleration(9.81 m/s2)
The value of the head loss coefficient Kis dependent on the particular geometryof each fitting, and values for specificcases are listed in Table 4.9.
The total head loss in the pipelinenetwork is then obtained by addingtogether the calculations performed foreach fitting in the system, the head lossin the pipes, and any other design headlosses.
Worked Example
What is the head loss occurring in a250mm equal tee with the flow in themain pipeline at a flow velocity of 2 m/s?
where
K = 0.35 (Table 4.9)
V = 2 m/s
g = 9.81 m/s
If the total system contains 15 teesunder the same conditions, then the totalhead loss in the fittings is 15 x 0.07 =1.05 metres.
Flow Variations
The flow charts presented for PE pipesare based on a number of assumptions,and variations to these standardconditions may require evaluation as tothe effect on discharge.
Water Temperature
The charts are based on a watertemperature of 20°C. A watertemperature increase above this value,results in a decrease in viscosity of thewater, with a corresponding increase indischarge ( or reduced head loss )through the pipeline.
An allowance of approximately 1%increase in the water discharge must bemade for each 3°C increase intemperature above 20°C. Similarly, adecrease of approximately 1% indischarge occurs for each 3°C stepbelow 20°C water temperature.
Pipe Dimensions
The flow charts presented in this sectionare based on mean pipe dimensions ofSeries 1 pipes made to AS/NZS 4130 PEpipes for Pressure applications.
Surface Roughness
The roughness coefficients adopted forVinidex PE pipes result fromexperimental programs performed inEurope and the USA, and follow therecommendations laid down inAustralian Standard AS2200 - DesignCharts for Water Supply and Sewerage.
H KVg
=
2
2
H KVg
=
2
2
H = ××
0 35 22 9 81
2..
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Flow ChartWorked Examples
Example 1 - Gravity Main(refer Figure 4.1)
A flow of water of 32 litres/second isrequired to flow from a storage tanklocated on a hill 50 metres above anoutlet. The tank is located 4.5 km awayfrom the outlet.
Hence the information available is :
Q = 32 l/s
Head available = 50 metres
Length of pipeline = 4500 metres
Minimum PN rating of pipe available towithstand the 50 m static head is PN6.3.
Head loss per 100 m length of pipe is :
Use Table 4.1 to select the SDR rating ofPN6.3 class pipes in both PE80, andPE100 materials.
504500
100 1 11 100x m m= . /
Figure 4.1 Gravity Flow Example
Maximum differencein water level
50m
Discharge4,500m of
Vinidex PE Pipe
Storagetank
PE80 Material Option
PE80 PN6.3 pipe is SDR 21.
Use the SDR 21 flow chart, readintersection of discharge line at 32 l/sand head loss line at 1.11m/100m ofpipe. Select the next largest pipe size.
This results in a DN200 mm pipediameter.
PE100 Material Option
PE100 PN6.3 pipe is SDR 26.
Use the SDR26 flow chart, read theintersection of discharge line at 32 l/sand head loss line at 1.11m/100m ofpipe. Select the next largest pipe size.
This results in a DN180 mm pipediameter.
Hence for this application, there are twooptions available, either :
1. DN 200 PE80 PN6.3 or2. DN 180 PE100 PN6.3
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3. Fittings head losses
From Figure 4.2, identify the type andnumber of different fittings used in thepipeline. Select the appropriate formfactor value K for each fitting type fromTable 4.9. Then:
Fitting Form Head Loss mFactor K
Foot valve 15.0 15 x 0.05 = 0.75
Gate valve 0.2 2 x 0.2 x 0.05 = 0.02
Reflux valve 2.5 2.5 x 0.05 = 0.125
90° elbow 1.1 4 x 1.1 x 0.05 = 0.220
45° elbow 0.35 2 x 0.35 x 0.05 = 0.035
Square outlet 1.0 1.0 x 0.05 = 0.050
Total fittings head loss = 1.2
Velocity Headvg
=2
2
= =1 02 9 81
0 052..
.x
0 5100
5000 25.
x m=
Example 2 - Pumped Main(refer Figure 4.2)
A line is required to provide 20 litres/second of water from a dam to a highlevel storage tank located 5000 metresaway. The tank has a maximum waterelevation of 100 m and the minimumwater elevation in the dam is 70 m.
The maximum flow velocity is required tobe limited to 1.0 metres/second tominimise water hammer effects.
The maximum head required at the pump= static head + pipe friction head+ fittings form loss
1. Static head
= 100 - 70 = 30 m
2. Pipe friction head
Considering the data available, start witha PN6.3 class pipe.
PE80 Option
From Table 4.1, PE80 PN6.3 pipe isSDR21.
Use the SDR 21 flow chart, find theintersection of the discharge line at 20 l/sand the velocity line at 1 m/s. Select thecorresponding or next largest size ofpipe. Where the discharge line intersectsthe selected pipe size, trace across to findthe head loss per 100m length of pipe.
This gives a value of 0.5m/100m.
Calculate the total friction head loss in thepipe:
Figure 4.2 Pumped Flow Example
Maximum differencein water level - 30m
90°Elbow
GateValve
Pump GateValve 2x90°
Elbows
Hinged Disc Foot Valve
with Strainer
RL 100m
RL 70m
Min Level of Dam
Reflux Valve45° Elbow
5,000mof Vinidex PE Pipe
45° Elbow
SquareOutlet
90° Elbow
Storage TankMax Level of Tank
Then from the flow chart, estimate thevelocity of flow
This gives 1 m/s.
4. Total pumping head
= 30 + 25 + 1.2 = 56.2 m
allow 57 m.
Note: The example does not make anyprovision for surge allowance inpressure class selection.
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Part Full FlowNon pressure pipes are designed to runfull under anticipated peak flowconditions. However, for a considerableperiod the pipes run at less than full flowconditions and in these circumstancesthey act as open channels with a freefluid to air surface.
In these instances consideration must begiven to maintaining a minimumtransport velocity to prevent depositionof solids and blockage of the pipeline.
For pipes flowing part full, the mostusual self cleansing velocity adopted forsewers is 0.6 metres/second.
Example 3. Determineflow velocity anddischarge under part fullflow conditions
Given gravity conditions:
Pipe DN 200 PE80 PN6.3
Mean Pipe ID 180 mm ( Refer Table XXPE pipe dimensions, or AS/NZS 4130 )
Gradient 1 in 100
Depth of flow 80 mm
Problem:
Find flow and velocity
Solution:
Proportional DepthDepth of flow
Pipe ID=
= =80180
0 44.
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
Discharge
Velocity
Proportional Discharge & Velocity
Prop
ortio
nal D
epth
Figure 4.3 Part Full Flow
From Figure 4.3 Part Full Flow, for aproportional depth of 0.44, theproportional discharge is 0.4 and theproportional velocity if 0.95.
Refer to the Vinidex PE pipe flow chartfor the SDR 21 pipe.
For a gradient of 1 in 100 full flow is39 l/s and the velocity is 1.6 m/s.
Then, for part full flow
Discharge = 0.4 x 39
= 15.6 l/s
Velocity = 0.95 x 1.6
= 1.52 m/s
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsDesign.16
Head Loss - Metres Head of Water per 100 metres of Pipe
NOMINAL SIZE
NOMINAL SIZE
VE
LOC
ITY
m/s
90
110
125
140
160
180
200
225
250
280
315
355
400
450
4.0
3.0
2.0
1.5
1.0
0.5
0.25
Flo
w C
hart
fo
r Po
lyeth
yle
ne P
ipe –
SD
R 9
(PE80: PN
16
& P
E1
00
: PN
20
)
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Flow Chart for Polyethylene Pipe – SDR 7.4(PE100: PN25)
Dis
char
ge
- L
itre
s p
er S
eco
nd
(L
/s)
Head Loss - Metres Head of Water per 100 metres of Pipe
NOMINAL S
IZE
NOMINAL SIZE
VE
LOC
ITY
m/s
90
110
125
140
160
180
200
225
250
280
315
355
400
450
4.0
3.0
2.0
1.5
1.0
0.5
0.25
Flo
w C
hart
fo
r Po
lyeth
yle
ne P
ipe –
SD
R 7
.4 (
PE1
00
: PN
25
)
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d e s i g n
Surge & FatigueSurge, or ‘water hammer’, is a temporarychange in pressure caused by a changein velocity of flow in the pipeline,whereas fatigue is the effect induced inthe pipe or fitting by repeated surgeevents.
For Vinidex PE pipes to AS/NZS 4130,operating under the following limitations,it is not necessary to make specificallowance for fatigue effects:
(a) The maximum pressure in the pipefrom all sources must be less than thepressure equivalent to the Classificationof the pipe (PN).
and
(b) The amplitude between minimum andmaximum pressure from all sourcesmust not exceed the pressure equivalentto the Classification of the pipe (PN).
Care must be taken to ensure that theminimum pressure does not reach alevel that may result in vacuum collapse(see External Pressure Resistance, pageDesign.36).
Surge may take the form of positive and/or negative pressure pulses resultingfrom change of flow velocity, such asarising from valve or pump operation.Such changes of flow velocity lead toinduced pressure waves in the pipeline.
Ptt
Pc
2 1=
tL
C= 2
C = W1K
+SDR
E
−03
.5
mx 10 / sec
P C V1 = .
This represents the case of a singlepipeline with the flow being completelyclosed off. The pressure rises generatedby flow changes in PE pipelines are thelowest generated in major pipelinematerials due to the relatively lowmodulus values.
Further, as medium density materialshave lower modulus values than highdensity materials, the pressure rise inPE80B materials will be lower than thatin PE80C and PE100 materials.
Water hammer (surge) analysis ofpipeline networks is complex and beyondthe scope of this Manual. Whererequired, detailed analysis should beundertaken by experts.
The velocity of the pressure wave,referred to as celerity (C), depends onthe pipe material, pipe dimensions, andthe liquid properties in accordance withthe following relationship:
where
W = liquid density (1000 kg/m3
for water)
SDR = Standard Dimension Ratioof the pipe
K = liquid bulk modulus (2150 MPa)
E = pipe material short termmodulus (MPa) refer Table 4.8
The time taken for the pressure wave totravel the length of the pipeline andreturn is
where:
t = time in seconds
L = length of pipeline
If the valve closure time tc is less than t,the pressure rise due to the valve closureis given by:
where:
P1 = pressure rise in kPa
v = liquid velocity in m/sec
If the valve closure time tc is greater thant, then the pressure rise is approximatedby:
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CelerityThe surge celerity in a polyethylenepipeline filled with liquid can bedetermined by:
where
W = liquid density (1000 kg/m3
for water)
SDR = Standard Dimension Ratioof the pipe
K = liquid bulk modulus (2150MPa)
E = pipe material ‘instantaneous’modulus (taken as 1000MPa forPE80B, 1200MPa for PE80C,1500MPa for PE100)
Table 4.10 Surge Celerity
Celerity m/sSDR MDPE (PE 80B) HDPE (PE 80C) HDPE (PE 100)
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Slurry Flow
General DesignConsiderations
The abrasion resistance characteristicsand flexibility of Vinidex PE pipes makeslurry flow lines, such as mine tailings,ideal applications for the material andsuch installations are in widespread usethroughout Australia.
The transportation of Non Newtonianfluids such as liquids or liquid/liquid,liquid/solid mixtures or slurries is ahighly complex process and requires adetailed knowledge of the specific fluidbefore flow rate calculations can beperformed.
As distinct from water, many fluidsregarded as slurries have propertieswhich are either time or shear ratedependent or a combination of bothcharacteristics. Hence it is essential forthe properties of the specific fluid to beestablished under the operatingconditions being considered for eachdesign installation.
In addition to water flow, slurry flowdesign needs to take into account thepotential for abrasion of the pipe walls,especially at changes of direction orzones of turbulence.
The most usual applications of VinidexPE pipes involve liquid/solid mixturesand these must first be categorisedaccording to flow type:
• Homogeneous Suspensions
• Heterogeneous Suspensions
Homogeneous Suspensions
Homogeneous suspensions are thoseshowing no appreciable density gradientacross the cross section of the pipe.These slurries consist of materialparticles uniformly suspended in thetransport fluid.
Generally, the particle size can be used todetermine the flow type and suspensionswith particle sizes up to 20 microns canbe regarded as homogeneous across therange of flow velocities experienced.
Heterogeneous Suspensions
Heterogeneous suspensions are thoseshowing appreciable density gradientsacross the cross section of the pipe, andare those containing large particleswithin the fluid.
Suspensions containing particle sizes of40 microns and above may be regardedas heterogeneous.
In addition to the fluid characterisationsfor both types, the tendency for solids tosettle out of the flow means that aminimum flow velocity must bemaintained.
This velocity, the Minimum TransportVelocity, is defined as the velocity atwhich particles are just starting toappear on the bottom of the pipe.
The flow in short length pipelines differsin that these lines may be flushed outwith water before shut down ofoperations. Long length pipelines cannotbe flushed out in the same way and theselection of operating velocities and pipediameter needs to address this aspect.
The design of slurry pipelines is aniterative process requiring designassumptions to be made initially, andthen repeatedly being checked and testedfor suitability. The specific fluid underconsideration requires full scale flowtesting to be conducted to establish theaccurate flow properties for the liquid/particle combinations to be used in theinstalled pipeline.
Without this specific data, theassumptions made as to the fluid flowbehaviour may result in the operationalpipeline being at a variance to theassumed behaviour. The principles ofslurry pipeline design as outlined in themethods of Durand, Wasp, and Govierand Aziz are recommended in theselection of Vinidex PE pipes for theseapplications.
Note:
The published Vinidex PE pipe flowcharts relate ONLY to water or otherliquids which behave as Newtonianfluids.
They are not suitable for calculating theflow discharges of other fluids, includingslurries.
For further information on slurry pipelinedesign, the designer is referred to suchpublications as Govier G.W. and Aziz K,The Flow of Complex Mixtures in Pipes.Rheinhold, 1972. and Wasp E.J. SolidLiquid Flow - Slurry PipelineTransportation. Trans Tech Publications.1977.
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Pipe WearPolyethylene pipe has been a provenperformer over many decades inresisting internal abrasion due to slurry.It is particularly resistant to abrasionfrom particles less than 500 microns insize depending on particle shape.
The abrasive wear of any slurry handlingsystem is heavily dependent on thephysical characteristics of the solidsbeing transported. These characteristicsinclude angularity, degree of particleattrition, angle of attack, velocity, and theconcentration of solids in thetransporting fluid.
With metal pipes, corrosive wearinteracts synergistically with abrasivewear, producing rates of wear that can bemany times greater than a simplecombination of the two modes of wear.Corrosive attack on a piping material canlead to increasing roughness of thesurface, loss of pressure and localisededdying, and hence increase the abrasiveattack.
Factors Affecting Ratesof Wear
The wall of polyethylene pipes are wornby contact with the solids particles. Theprincipal causes of wear are as follows:
• Particle Size
• Particle Specific Gravity
• Velocity
• Angle of Attack
Particle Size
The size of the particle combined withthe requisite velocity is one of theprincipal factors which contribute towear. The rate of wear increases withparticle size with very little wearoccurring on polyethylene systemsbelow 300 microns. Above this size therate of wear will increase proportionallywith particle size with the maximumpractical D50 size around 1mm. Manyresearchers have attempted to developrelationships between particle size andrates of wear, however, these have notproven to be accurate due to the widevariation of slurry characteristics. Thewear mechanism involved is notthoroughly understood, however, it isbelieved the higher impact energyresulting from a combination of particlemass and the high velocity required totransport this larger particle are theprincipal contributing factors.
Particle Specific Gravity
Similarly, the specific gravity willincrease the mass of the particleresulting in increased wear. This is aresult of the increased impact energyfrom the mass of the particle combinedwith the faster carrier velocity.
Velocity
A minimum velocity is required toprovide the necessary uplift forces tokeep a solid particle in suspension. Thisvelocity also increases the impact energyof the particle against the wall of thepipe.
Angle of Attack
There are essentially two modes of wear,impingement and cutting. Cutting wearis considered to be caused by the lowangle impingement of particles. Inpractice, cutting wear comprises acutting action, and the accommodationof some of the energy of impact withinthe matrix of the material being worn.Hence, cutting wear also incorporates acomponent of deformation wear. Therequirement for wear is that some of thesolid particles must have sufficientenergy to penetrate and shear a material,perhaps gouging fragments loose. As aresult, a low modulus material such aspolyethylene has very good resistance tocutting wear due to the resultingdeformation upon impact. In the case ofangular particles the cutting action isincreased resulting in increased pipewear.
The simple theory of abrasive wearsuggests that specific wear (wear perunit mass transported) is proportional tonormal force at the pipe wall. Thereforethe wear rate will increase as the angle ofattack to the pipe wall increases. Theincrease in angle will also increase theamount of energy with which the particlestrikes the pipe wall. It is for this reasonthat accelerated wear is caused by:
i) Fittings which effect a change in theangle of flow such as tees and bends
ii) Butt weld joints. Butt weld internalbeads will cause eddying which willresult in increases in angle of attackof the particle to the pipe wall. As aresult accelerated wear generallyoccurs immediately downstream ofthe bead. This is usually prominent inD50 particle sizes over 300 microns.For coarse particle slurries theinternal bead should be removed.
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Maintenance andOperationTo reduce the cost of wear on a pipelineasset it is general practice to rotate thepipes at the appropriate intervals, this isparticularly important when transportingsand slurries. In this respect mechanicaljoints are useful, although re-welding ofpipes over 500mm has been preferred insome cases to reduce capital costs.These mechanical joints are usuallyinstalled at every 20m pipe length toassist the pipe rotation process and alsopermit clearance of blockages.
Slurry pipelines are usually operated asclose to the critical settling velocity aspractical to reduce operating costs.Unfortunately, if an increase in particlesize occurs, then saltation willcommence increasing friction losseventually resulting in a blockage. Otherfactors that cause blockages areincreases in solids concentration, loss ofpump pressure due to power failure, orpump impellor wear. Polyethylenepipelines may be cleared of blockages byclear water pumping provided they havebeen installed on flat even ground.Sudden vertical ‘V’ bends with anglesover 10° may cause an accumulation ofsolids in the bore, preventing clearing byclear water pumping. If vertical bendsare unavoidable then they should beinstalled with mechanical joints to permittheir easy removal for clearing.
FittingsA range of mechanical joints areavailable for polyethylene slurrypipelines. They include stub flanges andbacking rings, Hugger couplings,shouldered end/Victaulic couplings,compression couplings and rubber ringjoint fittings.
References
The Transportation of Flyash and BottomAsh in Slurry Form, C G Verkerk
Relative Wear Rate Determinations forSlurry Pipelines, C A Shook, D B Haas,W H W Husband and M Small
Warman Slurry Pumping Handbook,Warman International Ltd.
iii) Fittings joints. At connections ofmechanical fittings somemisalignment of the mating facesmay occur resulting in increasedangles of attack of the particles.
iv) Change in velocity. Somecompression fittings cause areduction in the internal diameter ofthe pipe under the fitting resulting inturbulence. A mismatching valvebore will also cause turbulence. It isfor this reason that the use of clearbore valves such as knife gate valvesis preferred for slurry pipelines.
v) Increased velocity. High velocitiesare required to create sufficientturbulence for the suspension ofheavy particles. This turbulenceincreases the angle of attack to thepipe wall, resulting in increased wearfor large particles.
vi) Insufficient velocity. When a systemis operated near its settling velocity,the heavier particles migrate towardsthe lower half of the pipe crosssection. This will cause a generalincrease in pipe wear in this area. Ifsaltation/moving bed occurs, thenthe heavy particles will impactagainst the pipe bottom, causing anaccelerated wave profile wear. Shoulddeposition occur on the floor of thepipe, then the particles above thisdeposition will cause the maximumamount of wear as they interact withthe flow. This is characterised by theformation of wave marks on the 5and 7 o’clock position of the pipe.
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Pneumatic FlowVinidex PE pipe systems are ideal for thetransmission of gases both in the highand low pressure range.
The use of compressible liquids in PEpipes requires a number of specificdesign considerations as distinct fromthe techniques adopted in the calculationof discharge rates for fluids such aswater.
In particular:
• Compressed air may be at a highertemperature than the surroundingambient air temperature, especiallyclose to compressor line inlets, andthe pressure rating of the PE pipesrequire temperature re ratingaccordingly.
For air cooled compressors, thedelivered compressed airtemperature averages 15°C above thesurrounding air temperature. Forwater cooled compressors, thedelivered compressed airtemperature averages 10°C above thecooling water temperature.
• For underground applications wherethe PE pipes are exposed to ambientconditions, the surrounding airtemperature may reach 30°C, and thepipe physical properties requireadjustment accordingly.
• High pressure lines must bemechanically protected from damageespecially in exposed installations.
• Valve closing speed must be reducedto prevent a build up of pressurewaves in the compressible gas flow.
• Where gaseous fuels such aspropane, natural gas, or mixtures arecarried, the gas must be dry and freefrom liquid contamination which maycause stress cracking of the PE pipewalls.
• Vinidex PE pipes should not beconnected directly to compressoroutlets or air receivers. A 21 metrelength of metal pipe should beinserted between the air receiver andthe start of the PE pipe to allow forcooling of the compressed air.
• Dry gases, and gas/solids mixturesmay generate static electrical chargesand these may need to be dissipatedto prevent the possibility ofexplosion. PE pipes will not conductelectrical charges, and conductinginserts or plugs must be inserted intothe pipe to complete an earthingcircuit.
• Compressed air must be dry, andfilters installed in the pipeline toprevent condensation of lubricantswhich can lead to stress cracking inthe PE pipe material.
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System DesignGuidelines for theSelection ofVinidexairCompressed AirPipelinesIt is customary to find the InsideDiameter of the pipe by using formulassuch as shown below. The formulas usedare generally for approximation purposesonly, surmising that the temperature ofthe compressed air corresponds roughlyto the induction temperature. Anacceptable approximation is obtainedthrough the following equation:
4 Using point (3) draw a diagonalline to the separation line.
5 Go to top of nomogram and usethe point indicating the Length ofPipe and draw a line down tomeet horizontal line from point(4).
6 Move to the Pressure Decrease inthe Pipe (∆p) at the bottom ofnomogram and draw a verticalline up to meet the diagonaldrawn from point (5).
7 The Nominal Diameter of Pipe cannow be found by reading frompoint (6) across to the left handside of the nomogram. From thisexample DN63 pipe should beselected. If the completednomogram falls between twosizes of pipe, always use thelarger size.
Correction factors forfittings
Table 4.11 indicates the approximatepressure loss for fittings in terms of anequivalent length of straight pipe inmetres. For each pipeline fitting, add theequivalent length of pipe to the originallength of pipeline. This length is used forthe calculation of the equation above orfor the nomogram, Figure 4.4.
The advantage of using the nomogram isthat no further conversion factors arerequired for pipe sizing. Also, when fourof the parameters are known the fifth canbe determined by reading directly fromthe nomogram.
Example for the use ofthe air-line nomogram(Figure 4.4) to determinethe required pipe size
Working Pressure 7 bar
Volumetric Flowrate 30 L/s
Nominal length 200 m
Pressure Decrease 0.05 bar
1 Utilising the above operatingfigures, proceed to mark thosepositions around the perimeter ofthe nomogram.
2 Locate the separation linebetween (∆p) & (p). (See base ofnomogram.)
3 Commencing at the lower righthand side of the nomogram drawa line up from the WorkingPressure (p) to the line indicatingthe Volumetric Flowrate (Q).
where
d = Pipe Internal Diameter in mm
LE = Pipe Length in m
Q = Volumetric Flowrate in L/s
Dp = Pressure Decrease in bar
p = Working Pressure in bar
Table 4.11 Pressure Loss for Fittings
Fitting equivalent pipe length in m
DN 20 DN 25 DN 32 DN 40 DN 50 DN 63 DN 90
socket welding joint 0.2 0.2 0.3 0.4 0.5 0.6 1.1
45° bend 0.2 0.3 0.4 0.6 0.9 1.2 2.3
90° bend 0.4 0.7 1.0 1.3 1.8 2.3 4.5
tees 0.8 1.4 1.9 2.4 2.8 3.8 7.5
reducer 0.3 0.4 0.5 0.6 0.7 0.9 2.1
The use of a nomogram is a quicker andeasier method to source information (seeFigure 4.4). In this nomogram thePressure Decrease (∆p) is indicated inbar, the Working Pressure (p) in bar, theVolumetric Flowrate (Q) in L/s, the PipeLength (LE) in m, and the Pipe NominalDiameter DN.
dL Qp pE= 450 185
5. .
.
.
∆
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Figure 4.4Compressed AirFlow Nomogram
0.002 0.01 0.05 0.1 0.2 0.5 1 2 4 6 10 15500
400
300
63
90
50
40
32
25
20
200
100
50
30
20
15
10
5
3
2
1.5
1
1 2 5 10 20 50 100 200 500 1000 2000
3
37
4
6
5
2
no
min
al d
iam
ete
r D
N vo
lum
etric
flow
rate
(Q) in
L/s
pressure decrease in the pipe (∆p) in bar
length of the pipe (L) in m
working pressure (p) in bar
Sources:
Feldmann, K.H.:Druckluftverteilung in der Praxis(Munchen 1985)
Atlas Copco :information sheets
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Expansion andContractionExpansion and contraction of PE pipesoccurs with changes in the pipe materialservice temperature.
This is in common with all pipe materialsand in order to determine the actualamount of expansion or contraction, theactual temperature change, and thedegree of restraint of the installedpipeline need to be known.
For design purposes, an average value of2.0 x 10-4/°C for Vinidex PE pipes may beused.
The relationship between temperaturechange and length change for differentPE grades is as shown in Figure 4.5.
Worked Example
A 100 metre long PE80C pipelineoperates during the day at a steadytemperature of 48°C and when closeddown at night cools to an ambienttemperature of 18°C. What allowance forexpansion/contraction must be made?
1. The temperature change experienced= 48 - 18 = 30°C.
2. The thermal movement rate(Figure 4.5) in mm/m for 30°C= 6.0 mm/m.
3. The total thermal movement is then6.0 x 100 = 600 mm.
Where pipes are buried, the changes intemperature are small and slow acting,and the amount of expansion/contractionof the PE pipe is relatively small. Inaddition, the frictional support of thebackfill against the outside of the piperestrains the movement and any thermaleffects are translated into stress in thewall of the pipe.
Accordingly, in buried pipelines the mainconsideration of thermal movement isduring installation in high ambienttemperatures.
Under these conditions the PE pipe willbe at it’s maximum surface temperaturewhen placed into a shaded trench, andwhen backfilled will undergo themaximum temperature change, andhence thermal movement.
In these cases the effects of temperaturechange can be minimised by snaking thepipe in the trench for small sizes (up toDN110) and allowing the temperature tostabilise prior to backfilling.
For large sizes, the final connectionshould be left until the pipe temperaturehas stabilised.
Above ground pipes require noexpansion/contraction considerations forfree ended pipe or where lateralmovement is of no concern on site.Alternatively, pipes may be anchored atintervals to allow lateral movement to bespread evenly along the length of thepipeline.
Where above ground pipes are installedin confined conditions such as industrialor chemical process plants theexpansion/contraction movement can betaken up with sliding expansion joints.Where these cannot be used due to thefluid type being carried ( such as slurriescontaining solid particles ) the advice ofVinidex design engineers should besought for each particular installation.
Figure 4.5 Thermal Expansion and Contraction for PE
0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
Expa
nsio
n an
d Co
ntra
ctio
n (m
m/m
)
Pipe Material Temperature Change (°C)0 10 20 30 40 50 60 70 80
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External PressureResistanceThe possibility of external pressure(buckling) being the controlling designcondition must be evaluated in thedesign of PE pipelines.
All flexible pipe materials can be subjectto buckling due to external pressure andPE pipes behave in a similar fashion toPVC and steel pipes.
For pipe of uniform cross-section, thecritical buckling pressure (Pc) can becalculated as follows:
where
Pc = critical buckling pressure, kPa
E = modulus, MPa from Table 4.8
SDR = pipe SDR from Table 4.1
As the modulus is temperature and timedependent, the advice of Vinidexengineers should be sought forappropriate values.
Where ovality exists in the PE pipes, theeffective value of the critical bucklingpressure will be reduced.
The reduction in Pc for various levels ofinitial ovality are as follows:
Ovality % 0 1 2 5 10
Reduction 1.0 0.99 0.97 0.93 0.86
Where pipes are buried and supportedby backfill soil, the additional support(Pb) may be calculated from:
Pb = 1.15 (Pc E´) 0.5
Where E´ = soil modulus fromAS/NZS2566 - Buried Flexible Pipelines.
Pc =2380 • E
SDR − 1( )3
Tabulations of the value of E´ for variouscombinations of soil types and compac-tions are contained in AS/NZS2566.
The value of Pc calculated requires afactor of safety to be applied and a factorof 1.5 may be applied for thoseconditions where the negative pressureconditions can be accurately assessed.
Where soil support is taken into accountthen a factor of 3 is more appropriatedue to the uneven nature of soil support.
In general terms, PN10 PE pipe shouldbe used as a minimum for pump suctionline installations.
Where installation conditions potentiallylead to negative pressures, considerationmay need to be given to modification ofconstruction technique. For example,ducting pipes may need to be sealed andfilled with water during concreteencasement.
In operation, fluid may be removed fromthe pipeline faster than it is suppliedfrom the source. This can arise fromvalve operation, draining of the line orrupture of the line in service. Air valvesmust be provided at high points in theline and downstream from control valvesto allow the entry of air into the line andprevent the creation of vacuumconditions. On long rising grades or flatruns where there are no significant highpoints or grade changes, air valvesshould be placed at least every 500-1000metres at the engineer’s discretion.
Soil Description E´ MPa
Gravel – graded 20
Gravel – single size 14
Sand and coarse-grained soilwith less than 12% fines 14
Coarse-grained soilwith more than 12% fines 10
Fine-grained soil (LL<50%)with medium to no plasticity andcontaining more than 25%coarse-grained particles 10
Fine-grained soil (LL<50%)with medium to no plasticity andcontaining less than 25%coarse-grained particles 10
Fine-grained soil (LL<50%)with medium to high plasticity NR
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Trench Design
Minimum Cover
The recommended minimum coverdepths for Vinidex PE pipes are listed inTable 4.12.
These cover depths are indicative only,and specific installations should beevaluated in accordance with AS/NZS2566 - Buried Flexible Pipelines.
The minimum cover depths listed maybe reduced where load reductiontechniques are used, such as loadbearing beams, concrete slabs, conduitsleeves, or increased backfillcompaction.
Trench WidthsIn general practice, the trench widthshould be kept to the minimum thatenables construction to readily proceed.Refer to Figures 4.6 and 4.7.
The trench width used with PE pipe maybe reduced from those used with otherpipe types by buttwelding, orelectrofusion jointing above ground, andthen feeding the jointed pipe into thetrench. Similarly, small diameter pipe incoil form can be welded or mechanicallyjointed above ground and then fed intothe trench.
The minimum trench width should allowfor adequate tamping of side supportmaterial and should be not less than200mm greater than the diameter of thepipe. In very small diameter pipes thismay be reduced to a trench width oftwice the pipe diameter.
Installation Condition Cover over Pipe Crown (mm)
Open country 300
Traffic Loading No pavement 450
Sealed pavement 600
Unsealed pavement 750
Construction equipment 750
Embankment 750
Table 4.12 Minimum Cover
Side SupportMaterial used for side support shouldcomply with the requirements of thebedding materials.
The side support material should beevenly tamped in layers of 75 mm forpipes up to 250mm diameter, and 150mm for pipes of diameters 315mm andabove.
Compaction should be brought evenly tothe design value required by AS/NZS2566 for the specific installation.
BackfillOnce the sidefill has been placed andcompacted as required over the top ofthe pipe, backfill material may be placedusing excavated material.
Trench backfills should not be used as adump for large rocks, builders debris, orother unwanted site materials.
The maximum trench width should berestricted as much as possible,depending on the soil conditions. This isnecessary to reduce the cost ofexcavation, and to develop adequate sidesupport.
Where wide trenches or embankmentsare encountered, then the pipe should beinstalled on a 75 mm layer of tamped orcompacted bedding material as shownon the cross section diagrams. Wherepossible a sub trench should beconstructed at the base of the maintrench to reduce the soil loadsdeveloped. AS/NZS 2566 provides fulldetails for evaluating the loads developedunder wide trench conditions.
BeddingPE Pipes should be bedded on acontinuous layer, 75 mm thick, ofmaterials complying with the followingrequirements:
• Sand, free from rocks or other hardor sharp objects retained on a13.2mm sieve.
• Gravel or crushed rock of suitablegrading up to a max. size of 15mm.
•. The excavated material, free fromrocks and broken up such that itcontains no clay lumps greater than75mm which would prevent adequatecompaction.
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Figure 4.7Narrow Trench Condition
Figure 4.6Wide Trench Condition
Allowable BendingRadiusVinidex PE pipes are flexible inbehaviour, and can be readily bent in thefield.
In general terms, a minimum bendingradius of 33 x outside diameter of thepipe (33D) can be adopted for PE80C,and PE100 material pipes, whilst a radiusof 20 x outside diameter of the pipe(20D) can be adopted for PE63, andPE80B material pipes during installation.
This flexibility enables PE pipes toaccommodate uneven site conditions,and, by reducing the number of bendsrequired, cuts down total job costs.
For certain situations, the designer maywish to evaluate the resistance to kinkingor the minimum bending radius arisingfrom strain limitation. The long termstrain from all sources should not exceed0.04 (4%).
Rk = SDR (SDR-1)1.12
100mm min
100mm minD
Bedding75mm min
100mmmin
100mmmin
Bedding75mm min
When bending pipes there are twocontrol conditions:
1. Kinking in pipes with high SDRratios.
2. High outer fibre strain in highpressure class pipes with low SDRratios.
For condition 1
The minimum radius to prevent kinking(Rk) may be calculated by:
For condition 2
The minimum radius to prevent excessstrain (Re) may be calculated by:
where
ε = outer fibre strain(maximum allowable = 0.04)
D = mean Di (mm)
RD
e =2
ε
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DeflectionQuestionnaire
AS/NZS 2566 DeflectionCalculation for BuriedFlexible Pipes
The following questionnaire is to assistdesigners in the calculation of deflectionfor buried flexible pipe.
Company _______________________________________________________________________________
Name __________________________________________________________________________________
Embedment Material ______________________________________________________________________
Degree of Compaction _____________________________________________________________________
Please photocopy before completing this form.Retain this master for future use.Complete all information and forward to yournearest Vinidex office – refer over leaf.
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d e s i g n
Thrust BlockSupportsPE pipes and fittings joined by buttwelding, electrofusion, or other end loadbearing joint system do not normallyrequire anchorage to withstand loadsarising from internal pressure and flow.
For joint types which do not resist endloads, plus fabricated fittings whichincorporate welded PE pipe segments,anchorage support must be provided inorder to prevent joint or fitting failure. Inaddition, appurtenances such as valves,should be independently supported inorder to prevent excessive shear loadsbeing transferred to the PE pipe.
Static Pressure Thrust
where
R = resultant thrust (kN)
P = pressure (MPa)
A = area of pipe cross section (mm2)
φ = angle of fitting (degrees)
For blank ends, tees and valves
R = PA 10-3
For reducers
R = P(A1 - A2) 10-3
R = 2PA . sin φ .10-3
2
R = 2 w a V2. sin φ.10-9
2
Soil Type Safe Bearing Capacity
(N/m2)
Rock and sandstone (hard thick layers) 100 x 105
Rock- solid shale and hard medium layers 90 x 104
Rock- poor shale, limestone 24 x 104
Gravel and coarse sand 20 x 104
Sand- compacted, firm, dry 15 x 104
Clay- hard, dry 15 x 104
Clay- readily indented 12 x 104
Clay/Sandy loam 9 x 104
Peat, wet alluvial soils, silt Nil
Velocity (Kinetic) Thrust
The velocity or kinetic thrust applies onlyat changes of direction.
where
w = fluid density (kg/m3)
a = inside pipe cross section area(mm2)
V = flow velocity (m/s)
The velocity thrust is generally small incomparison to the pressure thrust.
The pressure used in the calculationsshould be the maximum working, or testpressure, applied to the line.
Bearing Loads of Soils
The thrust developed must be resistedby the surrounding soil. The indicativebearing capacities of various soil typesare tabulated below:
The figures in the table below are forhorizontal thrusts, and may be doubledfor downward acting vertical thrusts. Forupward acting vertical thrusts, theweight of the thrust block mustcounteract the developed loads.
In shallow (<600mm) cover installationsor in unstable conditions of fill, the soil
support may be considerably reducedfrom the values tabulated, and acomplete soil analysis may be needed.
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Thrust BlockSize Calculations
1. Establish the maximum pressure tobe applied to the line
2. Calculate the thrust developed at thefitting being considered
3. Divide (2) by the safe bearingcapacity of the soil type againstwhich the thrust block must bear.
Worked Example
What bearing area of thrust block isrequired for a 160 mm PN12.5 90° bendin hard, dry clay?
1. Maximum working pressure ofPN12.5 pipe is 1.25 MPa.
Test pressure is 1.25 x WP
= 1.56 MPa.
2.
3. Bearing capacity of hard, dry clay is15x104 N/m2
Thrust blocks may be concrete or timber.Where cast insitu concrete is used, anadequate curing period must be providedto allow strength development in theconcrete before pressure is introduced tothe pipeline. Where timber blocks areused, test pressures may be introducedimmediately, but care needs to be takento ensure that the blocks will not rot andwill not be attacked by termites or ants.
=4
Bearing area of thrust block 3.8 x 104
2
15 x 10
= 0.25m
Figure 4.8 Thrust Blocks
Closed end and hydrant anchorage
Valve anchorage
Bend in vertical plane anchorage
Bend in horizontal plane anchorage
Tee anchorage
R = 2 PA .sin φ.102
= 3.8 x 10-4
-3
N
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ElectricalConductivityVinidex PE pipes are non conductive andcannot be used for electrical earthingpurposes or dissipating static electricitycharges.
Where PE pipes are used to replaceexisting metal water pipes, the designermust consider any existing systems usedfor earthing or corrosion controlpurposes. In these cases the appropriateelectrical supply authority must beconsulted to determine theirrequirements.
In dry, dusty, or explosive atmospheres,potential generation of electricity mustbe evaluated and static dissipationmeasures adopted to prevent anypossibility of explosion.
Heat SourcesPE pipes and fittings should be protectedfrom external heat sources which wouldbring the continuous pipe materialservice temperature above 80°C.
Where the PE pipes are installed aboveground, the protection system usedmust be resistant to ultra violet radiationand the effects of weathering, PE pipesrunning across roofing should besupported above the roof sheeting inorder to prevent temperature build up.
See Table 4.7 Temperature Rating Table.
VibrationDirect connection to sources of highfrequency such as pump outlet flangesshould be avoided. All fabricated fittingsmanufactured by cutting and weldingtechniques must be isolated fromvibration.
Where high frequency vibration sourcesexist in the pipeline, the PE sectionsshould be connected using a flexiblejoint such as a repair coupling,expansion joint, or wire reinforcedrubber bellows joint. When used aboveground such joints may need to berestrained to prevent pipe end pullout.
d e s i g n
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installation
contents
Handling & Storage 3
Site Preparation 5
Thrust Blocks & Pipe Restraint 7
Pipeline Curvature 7
Relining & Sliplining 8
Pipeline Detection 10
Above Ground Installation 11
Accommodation of Thermal Movement by Deflection Legs 13
Service Connections 14
Concrete Encasement 14
Fire Rating 14
Testing & Commissioning 15
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Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
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Handling & StorageVinidex PE pipes are available in a rangeof sizes ranging from 16mm to 1000mmin configurations complying withAS/NZS4130. Pipes may be supplied tocustomer requirements in either smalldiameter pipe in coil lengths up to9500m, or in straight lengths up to 25m.
Vinidex PE pipes are robust, flexible, andoffer the installer many cost savingadvantages. Whilst they are resistant tosite damage, normal care and goodhousekeeping practices are necessary toensure trouble free operations.
Handling
Handling of Vinidex PE pipes is madeeasier due to the light weights of bothcoiled and straight length pipe. Caremust be exercised however, to avoiddamage to the pipe walls, pre-assembledend fittings, or sub assemblies.
Safety aspects need to be addressed, asthe nature of PE pipes is such that incold and wet weather the pipes becomeslippery and difficult to handle. In thesecircumstances, additional care should beexercised when handling coils or bundlesof pipe. In hot weather, especially withblack pipes, the pipe surface may reach70°C, when the ambient temperaturesreach 40°C. Handling PE pipes at thesetemperatures requires gloves, or otherprotection, to prevent the possibility ofskin burns.
Fabric slings are recommended for liftingand handling PE pipe in order to preventdamage.
Where wire ropes or chains are used,then all of the contact points between theslings and the pipe must be protected bysuitable padding. Where pipes are incoils, the slings must be placed evenlyaround the entire coil. Similarly, wherecoils or straight lengths are lifted by forklift the contact points must be protected.When lifting coils, the lifting must beperformed on the entire coil, and the forklift tynes not inserted into the coilwinding. When lifting packs of pipes, thetynes must be placed under the entirepack, and the tynes not pushed into thepack. Pipes must not be lifted by placingmetal hooks into the ends of straightlengths.
In conditions approaching freezing, theimpact resistance of PE reduces, andcare must be exercised to preventdamage during handling.
Pipe lengths greater than 6 metresshould be lifted using a spreader bar, andwide band slings. PE pipes will flexduring lifting, and care needs to beexercised to prevent damage to pipes orend fittings arising from contact with theground. Care needs to be taken to centrethe pipe in the slings.
A reduction in the pipe wall thickness ofup to 10% may be tolerated. However,sections with sharp notches should berejected, or the damaged area buffed outto remove the sharp edges.
Transport
PE pipes stacked for transport must beevenly supported in order to preventdistortion. All bearing surfaces must befree from contact with sharp objects. Anyprojecting sections such as stub flangesmust be supported to prevent damage.
For straight lengths of pipe, suitablesupport beneath the pipes is provided bybeams of minimum width 75 mm,spaced horizontally at 1.5 m centres. Forrectangular stacks, additional verticalsupports at 3 metre spacing should beused. For pyramid stacks, the bottompipe layers also need to be chocked toprevent stack collapse.
For large diameter pipes (DN 630 andabove) it may be necessary to tom, orinternally support the ends of the pipe inorder to prevent distortion.
Where end treatments such as flangesare applied in the factory, thesetreatments must be protected fromdamage.
Where coils are stacked vertically thestacks may need to be restrained inorder to prevent the bottom section ofthe coil being flattened or distorted.
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installation
Table 5.1 Storage Height
Straight Lengths
PE Material Height (m) Height (m)
up to SDR 21 above SDR 21
MDPE (PE63, PE80B) 2.0 2.25
HDPE (PE80C, PE100) 2.0 2.50
Coils
Pipe diameter mm Coil stacks (number)
up to 32 5
50, 63 4
90, 110 2
Note: Coils must be stacked flat, and even.
Storage
Straight length pipes must be supportedby timber spacers of minimum width75mm placed at 1.5 metre centres. Therecommended maximum height of longterm stacks is as listed in Table 5.1.Where pipes are crated, the crates maybe stacked on timber to timber, in stacksup to 3 metres high.
PE pipes are capable of supportingcombustion, and need to be isolatedfrom ignition sources. PE pipes must bekept away from high temperaturesources, and not be in contact withobjects of temperature higher than 70°C.Storage of PE pipes in field locationsmay be subject to fire regulations, andthe requirements of the local authoritiesmust be observed.
Black pipes do not need protection fromthe effects of UV exposure, but colouredpipes, if potentially exposed for longerthan 6 months, may need protection.
In selecting the method of protectionconsideration may need to be given totemperature effects, as elevatedtemperatures may lead to pipe distortion.
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installation
Site Preparation
Trench Preparation
All other services must be located (suchas telephone conduits, gas, water mains,sewers, electrical conduits, and cable TVconduits) in the area of the PE pipelinebefore any work commences. This mayrequire some localised excavation, andall safety requirements must beobserved.
When pipes are installed on the naturalsurface, the pipeline route must be clearof obstructions and where required,sufficient space must be allowed forexpansion/contraction movement.
PE pipes may be joined outside thetrench, allowing narrower trenches andconsequent reduced excavation cost.
PE pipes have a density less than that ofwater, and may float if water is present inthe trench, and the pipes are notrestrained. Trench excavations need tobe kept free of water, and if necessary,dewatering equipment installed.
Trench Widths
Table 5.2 lists recommended trenchwidths. These values are consistent withthe principles that trench width shouldbe as narrow as possible in order tominimise external loads and installationcosts, whilst also affording sufficientspace to provide the specifiedcompaction.
The actual trench width adopted will beinfluenced by the soil conditions, thejointing systems, and whether joints aremade in the trench.
Table 5.2 Recommended Trench Widths
Pipe Diameter ( mm ) Minimum Trench Width (mm)
16 to 63 15075 to 110 250125 to 315 500355 to 500 700630 to 710 910800 to 1000 1200
Table 5.3 Minimum Cover
Installation Condition Cover over pipe crown (mm)Open Country 300Traffic Loading No pavement 450
Poor soil conditions may necessitate awider trench to accommodate supportstructures or dewatering equipment, andthe ready removal of this equipment afterthe pipes have been laid. Where suchsupports are used, they must beremoved with care, in order to preventdisturbance of pipe, bedding or trenchwalls.
Pressure pipes, especially in rural areas,may be installed in narrow trenches withsufficient space to allow the backfill ofthe trench. No additional compactionmay be necessary, and the natural soilconsolidation allowed to occur with time.
Where PE pipes are installed with otherservices in common trench situations,the trench width may be specified byLocal Authority regulations in order topermit later maintenance activities.
Trench Depths
Where the PE pipe grade line is notspecified, the cover over the top of thePE pipes needs to be set so thatadequate protection from external loads,third party damage, and constructiontraffic is provided.
Where possible, pipes should beinstalled under minimum depthconditions and, as a guide, the valueslisted in Table 5.3 above should beadopted.
Trench walls in poor soil conditions mayneed to be excavated in steps, or bebattered, to prevent collapse of thetrench wall materials.
For embankment installations, a subtrench may be excavated once theembankment has been partly built up, inorder to help protect the PE pipes fromconstruction vehicles, and also lessenthe external loads acting on the pipe.
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installation
Side Support & Overlay
PE pipes act as flexible pipes to resistexternal loading, and the side supportmaterials must be evenly added to thesame compaction standards as thebedding materials so that the installedPE pipe is not disturbed.
Sidefill materials should be built upequally on both sides of the pipes inlayers of 150mm, and compacted evenlyto the AS/NZS 2566 design level. Thesidefill materials must be carefully placedaround the haunches of the pipes toensure that the PE pipes are evenlysupported.
Vibrating plate compactors must not beused until there is a 300mm layer ofoverlay soil over the crown of the PEpipe.
Detector tapes, or marker strips, shouldbe laid on top of the overlay once a layerof 150mm soil has been compacted.
The overlay materials should be built upin compacted layers until the overlaymaterial is to a level of a minimum of150 mm above the top of the PE pipes.(See Figure 5.1). Large diameter (450mm and above) PE pipes require theoverlay materials to be carried to a coverof 300mm above the top of the PE pipes.
Backfill
The remainder of the trench, orembankment fill may be made with thepreviously excavated native materials.These must be free from large rocks,vegetable matter, and contaminatedmaterials, and all materials must have amaximum particle size less than 75 mm.
Where PE pipelines are installed in areaswith high external loads, then the backfillmaterials must be of the same standardas the bedding and overlay materials.
Figure 5.1Trench Installations
Figure 5.2Embankment Installations
Bedding Material
The excavated trench floors must betrimmed even, and be free from all rocks,and hard objects.
In poor soil conditions, an additionallayer of imported bedding material mayneed to be introduced, and a geofabricrestraint of bedding/backfill material maybe required.
The bedding materials used in bothtrenchs and embankments shall followthe guidelines of AS2033, and should beone of the following:
1. Sand or soil, free from rocks greaterthan 15 mm, and any hard claylumps greater than 75 mm in size.
2. Crushed rock, gravel, or gradedmaterials of even grading with amaximum size of 15 mm.
3. Excavated material free from rocks orvegetable matter.
4. Clay lumps which can be reduced toless than 75 mm in size.
Excavated materials in accordance with3. and 4. above are often used forpressure pipelines and in rural areas.
However, in areas of high loading, suchas under roads, imported materials mayneed to be used.
In the majority of PE pipe applications, aminimum of 75 mm of bedding materialis used in both trenches andembankments in soil excavations. Forexcavations in rock, 150 mm beddingdepth may be required.
Where fittings or mechanical joints areused, the bedding material may need tobe excavated to prevent point loading. Allpegs and markers used in aligning andlevelling the pipes must be removedfrom the trench floor prior to beddingmaterials being placed.
Compaction Standards
It is essential that the AS/NZS 2566compaction levels are attained, as PEpipes behave as flexible structures.Large diameter PE pipe installations mayrequire the compaction at each stage ofthe installation to be confirmed by test.
Where high external loads areencountered, or where it is not possibleto attain the required level of compactionin the sidefill materials, a mixture ofsand/cement in the ratio of 14:1 may beused in the sidefill zones.
The selection of compaction standardused in the sidefill materials needs to betaken from AS/NZS 2566 for the sidefillmaterials available on the particular site.
D
80mm min.
300mmmin
Compactedbedding material
Fill material
BackfillMaterial
150mmminimum
Compact.side support
75mmminimumbedding
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installation
Thrust Blocks &Pipe RestraintThrust blocks are required for Vinidex PEpipes in pressure applications where thejoints do not resist longitudinal loads.The thrust blocks must be provided at allchanges in direction. The standardmethods of calculating the size of thrustblocks for all pipeline materials are thoseused with PE pipes and are contained inthe Design section of this manual.
Where concrete blocks are used, thecontact points between the PE pipe, orfitting and the thrust block must beprotected to prevent abrasion of the PE.Rubber or malthoid sheeting may beused for this purpose.
All fittings and heavy items such as castiron valves must be supported in orderto prevent point loading on the PEmaterials. In addition, where valves areused, the torque loads arising from theopening/closing operations must beresisted with block supports.
Pipeline CurvatureAll PE pipes installed on a curvedalignment must be drawn evenly over theentire curve length, and not over a shortsection. This can lead to kinking in smalldiameter, and/or thin wall pipes.
Large diameter PE pipes (450mm andabove) must be joined together, and thendrawn evenly to the desired radius.
Care must be exercised duringconstruction to prevent over stressing ofjoints and fittings. Where mechanicaljoints are used, any joint deflectionlimitations must be observed. Duringinstallation, minimum radii of 20 x DNfor MDPE (PE63 and PE80B) and 33 xDN for HDPE (PE80C and PE100) may beused.
In addition, evaluation of bucklingresistance of thin wall pipes may benecessary. This should be done asshown in the Design Section of thisManual.
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installation
Relining &SlipliningVinidex PE pipes have the chemicalresistance properties and longitudinalflexibility to provide an ideal solution forrelining existing corroded or damagedpipelines in water supply, sewers, anddrain applications.
Existing pipelines used to transportaggressive and dangerous fluids may berestored by relining techniques, and costeffective solutions are provided byeliminating the need for open cuttrenches in urban and heavily built upareas. Installations can be plannedaround off peak traffic periods tominimise disruption and reduceinstallation times.
Existing pipelines can be renovated byinserting Vinidex PE pipes into the oldpipes. Insertion pipes can be pulled intoposition by mechanical winches.
Although insertion of the PE pipes willreduce the internal diameter of thepipeline, the effective flow capacity of therenovated line may in fact be greaterthan the existing installation due to theimproved pipe wall friction factors of PEas compared to the existing pipe withheavily corroded or damaged internalsurfaces. Inspection of the existing lineshould be performed by CCTV to providedata as to the actual likely flow frictionfactors.
Relining with PE pipes provides astructural element that is capable ofwithstanding either internal pressure orexternal loading without relying on theresidual strength of the original degradedpipe elements.
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The PE pipes require short length inletand exit trenches to accommodate thePE pipe radius to lead into the existingpipeline, and the winch assembly used topull the PE liner along the pipeline. Theminimum bending radius of the PE linercan be calculated as described underPipeline Curvature in this section of themanual.
LG H R H1 4= −( )
LG H R H2 2= −( )
The dimensions (Refer to Figure 5.3) ofexcavations required for slip lining are:
1. Where the PE insert pipe is on thenatural surface level
2. Where the PE insert pipe is at aheight H above the natural surfacelevel
where
H = depth to invert of existing pipeline
R = radius of liner pipe
Grouting
Grouting of the gap between the outsidediameter of the PE liner, and the inside ofthe existing pipe is necessary only whenthe original pipe has been damaged tothe extent that there is no residualexternal load capacity, or where manholeconnections cannot be sealed off toprevent groundwater infiltration.
Where grouting is applied, the pressureshould not exceed 50 kPa, anddepending on the PN rating of the PEliner pipe, external collapse calculationsshould be carried out. Where cementbased grouts are used, the temperaturerise in the PE liner due to the heat ofhydration must be taken into account.
The PE liner pipes may be filled withwater prior to grouting to increase theexternal pressure resistance, and toprovide additional line weight to preventthe PE liner pipe floating during grouting,and losing the final grade line.
Figure 5.3 PE Sliplining Trench Opening
2
2H
H
1
R
LGLG
2LG 2
1
2
NS
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Pipeline DetectionVinidex PE pipes are electrically nonconductive and cannot be detected bymetallic detection devices inunderground installations.
Several techniques are available to detectburied PE pipelines.
Metal Detector TapesFoil based tapes may be located in thetrench on top of the PE pipe overlaymaterial ( 150 - 300 mm above the PEpipe crown ), and these tapes can bedetected at depths up to 600 mm bymetal detection equipment operating inthe 4 - 20 MHz frequency range.
The tape backs may also be colour codedand printed in order to provide earlywarning of the presence of the PEpipeline during later excavation.
Tracer WiresPE pipes installed deeper than 600 mmmay be detected by the use of tracerwires placed on, or taped to, the top ofthe PE pipes.
Application of a suppressed currentallows the detection of pipes up to adepth of 3 metres. However, both endsof the tracer wire must be accessible,and a complete electrical circuit presentover the entire length of the pipeline.
Audio DetectionAcoustic, or ultra sonic, noise detectiondevices are available which use either thenoise from water flowing in the pipes, oran introduced noise signal, to detect thepresence of buried PE pipelines.
Excavation
Sliplining existing pipes using Vinidex PEpipes allows for a reduction ofexcavation in built up areas.
Only the excavation necessary to feedthe PE liner pipe into the existing line isrequired and depending on the totallength of the line and the location ofexisting manholes, a liner length ofapproximately 100 metres may be drawnalong the line in each section. For smalldiameter pipes, the PE can be supplied inVinidex pipe reels. This allows for asingle run of PE to be inserted intoexisting pipe without the need forintermediate jointing.
Where the existing service cannot betaken out of service, or temporarilyblocked off during the relining process,extra excavation may be required toallow for the installation of a temporarydiversion line.
Jointing the Liner
Depending on the diameter of the pipe, asingle length of PE pipe can be installedto provide a single length of seamlessliner.
For larger (160mm and above) PE pipescan be butt welded above ground on siteto provide a continuous length pipewhich can be inspected for joint integritybefore installation.
The butt weld process provides a jointwhich resists longitudinal load and hasthe same chemical resistance propertiesas the pipe. The external diameter weldbead sections may be mechanicallyremoved prior to insertion to prevent anypossibility of snagging on damagedsections, or protrusions, in the bore ofthe existing pipe to be relined. Whereweld beads are removed, care must betaken not to notch the PE pipe wall. Buttwelded joints must be allowed to cool toambient temperature prior to drawinginto the final position so as to preventany damage to the joint section.
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Supports
Pipe hangers, or supports, should belocated evenly along the length of the PEpipeline, and additionally at localisedpoints with heavy items such as valves,and fittings.
The supports should provide a bearingsurface of 120° under the base of thepipes. The PE pipes may need to beprotected from damage at the supports.This protection may be provided by amembrane of PE, PVC or rubber.
Location and type of support must takeinto account provision for thermalmovement, if required. If the supportsare to resist thermal movement, anassessment of the stress induced inpipes, fittings and supports may need tobe made.
Support Spans
Support spans depend on the pipematerial and dimensions, nature of flowmedium, operating temperature, andarrangement of the pipes.
In calculating support spans, amaximum deflection of spans/500between supports has been adopted asthe basis.
The spans in Table 5.4 are based on theuse of PE80B (MDPE), full of water,support over multiple spans, andoperating at 20°C for 50 years.
For other service temperatures, thespans should be reduced as follows:
30°C 5%40°C 9%50°C 13%
For fluids with density between 1000kg/m3 and 1250 kg/m3, decrease spansby 4%.
For Vinidexair systems, the spans maybe increased by up to 30%.
Above GroundInstallationVinidex PE pipes may be installed aboveground for pressure and non pressureapplications in both direct exposure andprotected conditions.
Black PE pipes made to AS/NZS 4130requirements may be used in directsunlight exposure conditions without anyadditional protection. Where PE pipes ofcolours other than black are used inexposed conditions, then the pipes mayneed to be protected from sunlight.
Where PE pipes are installed in directexposure conditions, then the increasedPE material temperature due to exposuremust be taken into account inestablishing the operational pressurerating of the PE pipes. Localisedtemperature build up conditions such asproximity to steam lines, radiators, orexhaust stacks must be avoided unlessthe PE pipes are suitably protected.Where lagging materials are used, thesemust be suitable for external exposureapplications.
For Vinidex Geberit waste systems, thepipes are manufactured specifically forthe application and reference should bemade to Vinidex engineers forcomprehensive installation details.
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For above ground pipelines, expansionand contraction movements should betaken up by the pipeline where possiblewithout expansion joints.
This may be achieved in lines laiddirectly on the natural surface by snakingthe pipe during installation and allowingthe pipe to move freely in service. Wherethe final joint connections are made inhigh ambient temperature, sufficient pipelength must be allowed to permit thepipe to cool, and hence contract, withoutpulling out of non end load bearingjoints.
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installation
Accommodation ofThermal Movementby Deflection LegsChanges in length are caused bychanges in operating temperatures. Oninstallation of piping systems aboveground, attention must be paid tocompensate for axial movements.
In most cases, changes in direction inthe run of piping may be used to absorblength change, given that appropriatedeflection legs are provided. Otherwise,compensation loops or special fittingsmay need to be installed.
Table 5.5 lists minimum deflection leglengths for given run length changes.See Figures 5.4 and 5.5.
For non-pressure applications, thesevalues may be reduced by 30%, or forVinidex Geberit systems, up to 60%. Forspecific data, reference should be madeto Vinidex engineers.
The deflection leg is expressed by:
where
Ls = deflection leg (mm)
∆L = change in length (mm)
DN = pipe outside diameter (mm)
k = material specific proportionalityfactor (average value for PE of 26)
Figure 5.4Absorption of change in lengthby deflection leg
Figure 5.5Absorption of change in lengthby a compensation elbow
F = Fixed PointLs = Deflection Leg
F = Fixed PointLP = Loose Point (eg. pipe clips)Ls = Deflection Leg
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installation
ConcreteEncasementAt entry and exit points of concrete slabsor walls, a flexible joint must be providedin the PE pipeline to cater for movementsdue to soil settlement, or seasonalexpansion/contraction of the soil.
Where expansion joints are provided inthe concrete slab, expansion jointsshould be provided at the same point inthe pipeline. At these points a flexiblemembrane should be provided to preventshear stresses developing across thejoint.
PE pipes behave as flexible structureswhen externally loaded, and care needsto be exercised by the designer whenusing concrete encasement so that theeffective strength of the pipeline is notreduced.
Fire RatingPE pipe systems will supportcombustion and as such are not suitablefor use in fire rated zones in buildingswithout suitable protection. Theindividual fire rating indices for PEmaterials may be established by testingto the requirements of AS1530.
In multiple storey buildings PE systemspenetrating floor cavities must beenclosed in fire rated service ductsappropriate to the Class of the buildingconcerned.
Service Connections
Tapping SaddlesService connections may be provided inPE pipe systems using tapping saddleswhich are either electrofusion ormechanically connected.
Tapping saddles should not be installedcloser than 100mm to prevent reductionin pressure capacity in the pipeline.
A range of tapping saddles suitable foruse with Vinidex PE pipes are listed inthe Product Data section of this manual.
Tapping saddles may be used fortappings up to 30% of the size of themain pipe or a maximum diameter of50mm. Where larger offtake sizes arerequired, then a reducing tee sectionshould be used.
Tapping saddles of the mechanical straptype should not be used on curved pipes.Tapping saddles of the saddle fusion, orelectrofusion type should only be usedon the top of curved lines, and not becloser to the end of the pipe than500mm.
Connection may then be made withoutloss of the operating service.
Alternatively, tapping may be performedon new main lines prior topressurisation, and entry into serviceusing the same techniques.
Direct TappingThe tapping of services directly into thepipe wall by drilling and tapping a threadin the wall material is not recommendedin PE pipes.
This practice may lead to prematurefailure of the system.
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Testing &Commissioning
Pressure Installations
Pre Test PrecautionsPrior to testing, the entire PE pipelineshould be checked to ensure all debrisand construction materials are removedfrom contact with the pipes and fittings.
Where concrete anchor or thrust blocksare used no pressure testing should takeplace within 7 days of casting the blocks.
All mechanical ring seal joints must berestrained either by sand bags, or bypartial backfilling of the line leaving thejoints open for visual inspection. Allvalves must be placed in the openposition, and a valve provided at the endof the line to allow air to be vented fromthe line during filling.
Where thermal fusion jointing has beenused, no testing should take place untilthe joints have completely cooled toambient temperature.
Local authority regulations may differbetween each other in the pressuretesting routines, and individualrequirements must be followed at alltimes.
Pressure TestingTest water should be slowly introducedinto the PE pipeline until all air is purgedfrom the line and water flows freely atthe end of the line. The water shouldpreferable be introduced into the pipelineat the lowest point to assist the removalof air.
It is essential that all air is removedfrom the line prior to commencing thetest procedure. Entrapped air can resultin erroneous pressure/time recordings.
Test sections may be either the completeline, or, in large installations, in sectionssuch that the test section can be filledwith water within 5 hours to allowpressure observations.
Pressure should be built up evenly in theline without pressure shock.
A test pressure of 1.25 times themaximum working pressure should beapplied for pipelines up to 110 mm indiameter and 100 metres in length andalso for testing valve anchorages. Thetest pressure in these instances shouldbe held for a minimum period of 15minutes, and the pressure gaugesinspected for pressure drop readings.
In addition, all joints must be visuallyinspected for evidence of weeping orleakage.
For large diameter pipes, and for pipelinelengths up to 800 metres, the elasticproperties of PE are such that theintroduction of test pressures will causeexpansion in the line and require makeup pressure to restore gauge readings.This volume make up will generally be inthe order of 1%, and may be applied atthe time of initial pressurisation. The testpressure of 1.25 times the maximumworking pressure should be maintainedfor a maximum period of 24 hours, or forthe time necessary to visually inspect alljoints in the line.
A smaller drop in pressure may beobserved due to thermal expansion.However, this does not indicate leakagein the pipeline.
Where the installation consists of smalladditions to existing pipelines the testpressure period may be 15 minutes.
The maximum test pressure to beapplied must not exceed 1.25WP. Testpressure in excess of this value maystrain the pipe material and damagecontrol appliance s connected to thepipeline.
High pressure testing using air must notbe carried out.
Note:
Where the time of pressure testingexceeds 15 minutes, increases in pipetemperature above 20°C may occur. Inthese cases the test pressure must bederated.
Refer to Table 4.7 in the Design sectionof this manual.
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Non Pressure Installations
1. Above Ground
All sections of the installation should besealed off and water introduced througha stand pipe to provide a static head of 3metres above the top point in the PEpipeline. All openings in the PE pipelinemust be sealed, or plugged, beforestarting testing. Either water or airtesting may be performed on nonpressure PE pipelines, depending on theavailability of test water, or the ability todrain the test water away from thepipeline alignment after the testing iscompleted.
2. Below Ground
(a) Water Testing
For PE drain lines, a riser pipe should befitted at the top point in the pipeline toallow a minimum water head of 1 metreto be applied. For waste waterapplications, a water test pressure of amaximum of 1.25 WP ( maximum headat the lowest point ) should be appliedby either a stand pipe connection, orusing a test pump.
The test water should be introducedevenly into the pipeline, and brought upto pressure after allowing all entrappedair to be purged out of the line.
All joints and connections should beinspected for leakage, and the testpressure maintained for a minimumperiod of 15 minutes after the final jointhas been inspected, or for a period of 30minutes.
No leakage or loss of pressure shouldtake place in this period.
Large diameter installations may requirea period of up to 8 hours to allow forcomplete inspection of all joints in thepipeline network.
(b) Air Testing
Where water is unavailable, orundesirable, for testing then air testingmay be performed.
All openings must be sealed prior totesting, and air pumped slowly into thePE pipeline until a test pressure of 50KPais reached.
This test pressure should be maintainedfor a minimum time of 3 minutes, and ifno leaks are detected, or pressure lossobserved on the gauge, the air supplycontrol valve should be turned off andthe test pressure held for a minimumtime of 1 minute.
If the test gauge pressure reading hasnot fallen below 35KPa after this time,then the test should be discontinued.
Should the test pressure drop below35KPa after 1 minute, then the pressureshould be returned to 50KPa andmaintained until a full inspection of thePE pipeline has been completed. Alljoints and connections need to beindividually inspected for leakage using asolution of water and detergent pouredover any suspect joint. If a leak ispresent, it will cause the detergentsolution to bubble, and foam.
Deflection TestingPE drainage pipelines are designed tosupport external loading within theacceptable limits of diameter deflectionfor structural reasons.
Where this is a critical feature of theinstallation, then a plug, or proving tool,can be pulled along the PE pipelinebetween manholes, or other entry points.
For joints without any protrusions intothe pipe bore, the proving plug can besized to the minimum internal dimensionallowed in the design. For butt weldedpipes, unless the internal beads areremoved, the plug needs to be reducedin size to allow for the weld bead.
In both cases, the plug must be able tobe pulled completely through the PEpipeline.
Flushing and DisinfectionWhere Vinidex PE pipes are used forpotable water applications, standardflushing and disinfection proceduresmust be followed.
Some pipe materials require additionalflushing or disinfection in order to purgecontamination rising from the pipematerial itself. Vinidex PE pipes,however, are made from PE grades thatcomply with water quality requirementswithout additional treatment.
For potable water applications, thefollowing procedure may be used:
1. Flush out all construction debris fromthe pipes by running water throughthe line for 15 minutes.
2. Carry out the hydrostatic pressuretesting.
3. Introduce a chlorine, or chloramine,solution into the line at aconcentration of 50 mg/l, and allowto stand for 24 hours.
4. Flush out the pipeline for 15 minutesto remove all disinfectant andbiological residues from the water.
installation
Jointing.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
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contents
Jointing Methods 3
Thermal Fusion Process 3
Butt Fusion 3
Electrofusion 5
Socket Fusion 6
Mechanical Joint Fittings 7
Flanged Ends 8
Hugger Bolted Couplings 8
Threads 8
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Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
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Jointing MethodsVinidex PE pipes are produced in a rangeof sizes between 16 mm to 1000 mmdiameter, and these pipes can be joinedby a variety of methods.
Methods include mechanical joints and arange of thermal fusion procedures. Thenature of the PE materials precludes theuse of adhesive based systems.
Thermal Fusion ProcessesThermal fusion proceeds by melting thePE material at the joint surfaces,bringing the molten surfaces togetherunder closely controlled pressures, andholding the surfaces together until thejoint has cooled.
In all thermal fusion processes, the fieldpipe jointing should only be performedby trained fusion operators usingproperly maintained and calibratedfusion machines.
The fusion compatibility of PE materialsmust be established before welding, andif doubts exist then the advice of Vinidexengineers should be sought.
Butt FusionButt fusion is generally applied to PEpipes within the size range 90 mm to1000 mm for joints on pipes, fittings,and end treatments. Butt fusion providesa homogeneous joint with the sameproperties as the pipe and fittingsmaterials, and ability to resistlongitudinal loads.
Butt fusion machines need to besufficiently robust to align andpressurise the pipe ends within closetolerances, and to provide heating andpressurisation of the jointing surfaceswithin required parameter tolerances.
All butt fusion should be performedunder cover, and the ends of the PEpipes blocked off to assist withtemperature control and preventcontamination of the joints.
The butt fusion process consists of thefollowing steps which are shown inprinciple in Figure 6.2.
1. The pipes must be installed in thewelding machine, and the endscleaned with non depositing alcoholto remove all dirt, dust, moisture,and greasy films from a zoneapproximately 75 mm from the endof each pipe, on both inside andoutside diameter faces.
2. The ends of the pipes are trimmedusing a rotating cutter to remove allrough ends and oxidation layers. Thetrimmed end faces must be squareand parallel.
3. The ends of the PE pipes are heatedby contact under pressure against aheater plate. The heater plates mustbe clean and free fromcontamination, and maintained withina surface temperature range of 190°Cto 225°C (depending on the size ofthe pipe). Contact is maintained untileven heating is established aroundthe pipe ends, and the contactpressure then reduced to a lowervalue called the heat soak pressure.Contact is then maintained until theappropriate heat soak time elapses.
4. The heated pipe ends are thenretracted and the heater plateremoved. The heated PE pipe endsare then brought together andpressurised evenly to the weldingpressure value. This pressure is thenmaintained for a period to allow thewelding process to take place, andthe fused joint to cool down toambient temperature and hencedevelop full joint strength. Thepressure adopted in this phaseshould be in the range 0.15MPa to0.18MPa on the ends of the pipes.During this cooling period the jointsmust remain undisturbed and undercompression. Under nocircumstances should the joints besprayed with cold water.
The combinations of times,temperatures, and pressures to beadopted depends on the PE materialgrade, the diameter and wall thickness ofthe pipes, and the brand and model offusion machine being used. Vinidexengineers can provide guidance in theseparameters.
The final weld beads should be fullyrolled over, free from pitting and voids,correctly sized, and free fromdiscolouration.
When correctly performed, the minimumlong term strength of the butt fusionjoint should be 90% of the strength ofthe parent PE pipe.
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Note: The pressure needed to bring the pipe ends together (Drag Pressure) for eachjoint must be added to the calculated pressure at each stage.
Zone 1 Initial Bead Pressure P1 kPa
Time T1 Seconds (min)
Zone 2 Heat Soak Pressure P2 kPa
Time T2 Seconds
Zone 3 Change Over Time T3 Seconds (max)
Zone 4 Weld Pressure Build Up Seconds (min)
Welding Pressure P3 kPa
Welding/Cooling Time T5 Minutes
Figure 6.1Butt Welding Parameters
Figure 6.2Schematic Sketch of the Butt Welding Process
T1
P1
Zone 1 Zone 2
Zone 3
P2
T2 T3 T4 T5
Zone 4
P3
Time
DRAG
Pressure Pd
In field applications full QA records oftimes, temperatures and pressuresachieved for all joints should berecorded, and the locations of weldsidentified on as-constructed site plans.
The most reliable methods of weldevaluation are the destructive type.
Destructive test methods require tensiletesting of welds and pipe in order toestablish the strength of the weld as apercentage of pipe strength.
Flexural testing may also be required inorder to evaluate the effect of any jointmisalignment.
Hydrostatic pressure testing will notdetermine the strength of butt welds, dueto the stress across the plane of the buttweld being only 50% of the hoop stressin the pipe section.
Weld beads are normally left in place onthe pipe section, unless required to beremoved from the outside diameter toallow slip lining, or from the insidediameter to prevent potential materialblockage in sewer rising mains.
Jointing.5PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
j o i n t i n g
ElectrofusionVinidex PE electrofusion system consistsof moulded couplings, tapping saddles,and fittings with electric elementscontained in the fitting. (Figure 6.3).
When a controlled electrical current ispassed through the resistance wire,there is a temperature increase, theresulting heat being transferred to thejointing surfaces until melting occurs.The joint surfaces are held underpressure until cooled.
Vinidex electrofusion fittings require a39.5 (40) Volt power source provided bya control box from a 240 Volt 50Hz,single phase supply. Where a generatoris used, this requires a minimum powerof 3 kVA. If multiple control boxes areused on a project, then a 5 kVAgenerator may be required.
Vinidex electrofusion fittings use a singleconnection pin of 4.7 mm diameter.
Electrofusion control boxes must not beused in explosive atmospheres. In deeptrenches, tunnels, or mine workings, thepower source may require approval bythe local electricity utility.
All electrofusion joints must be carriedout under cover to preventcontamination by dust, moisture anddirt, and be clamped to preventmovement in the joint until the coolingperiod has been completed.
1. Cut the pipes square, and mark thepipes at a length equal to the socketdepth.
2. Scrape the marked section of thepipe spigot to remove all oxidised PElayers to a depth of approximately0.3mm. Use a hand scraper, or arotating peel scraper to remove thePE layers. Do not use sand paper.Leave the electrofusion fittings in thesealed plastic bag until needed forassembly. Do not scrape the inside ofthe fitting, clean with an approvedcleaner to remove all dust, dirt, andmoisture.
3. Insert the pipe into the coupling up tothe witness marks. Ensure pipes arerounded, and when using coiled PEpipes, re rounding clamps may beneeded to remove ovality. Clamp thejoint assembly.
4. Connect the electrical circuit, andfollow the instructions for theparticular power control box. Do notchange the standard fusionconditions for the particular size andtype of fitting.
5. Leave the joint in the clamp assemblyuntil the full cooling time has beencompleted.
Figure 6.3 Electrofusion
Heating element
PE Pipe
Power connection terminals
Coupling PE Pipe
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsJointing.6
j o i n t i n g
Socket FusionSocket fusion of Vinidex PE systems isavailable in the diameter range 20mm to110mm.
Socket fusion consists of jointingcouplings, and fittings with a closetolerance moulded socket section intowhich the pipe or fitting spigot isinserted.
The fusion process is achieved byheating the spigot, and socket jointingsurfaces above the crystalline melt pointtemperature of PE by insertion into aheated element tool. The heated jointsections are then assembled, and helduntil cooling to ambient temperaturetakes place. See Figure 6.4.
The heater elements are PTFE coated,and at all times must be kept clean andfree from contamination. The heatertools need to be set and calibrated tomaintain a surface temperature range of260°C +/- 5°C. All jointing must beperformed under cover to preventcontamination of the joints by dust, dirt,or moisture.
1. Cut the pipes square, clean the spigotsection with a clean cloth and a nondepositing alcohol to the full depth ofthe socket. Mark the length of thesocket. Clean the inside of the socketsection.
2. Scrape the outside of the pipe spigotto remove the oxidised layer from thepipe. Do not scrape the inside of thesockets.
3. Confirm the temperature of theheating elements, and ensure that theheating surfaces are clean.
4. Push the spigot, and socket sectionson to the heating elements to the fulllength of engagement, and allow toheat for the appropriate period.See Table 6.1.
5. Pull the spigot and socket sectionsfrom the heating elements, and pushtogether evenly to the full length ofengagement without distortion of thejoints. Clamp the joints and hold untilfully cooled. The weld flow beadshould then appear evenly around thefull circumference of the socket end.
The completed joints must be allowed tocool fully to ambient temperature beforeperforming pressure tests.
Table 6.1 Socket Fusion Times
Pipe Diameter DN Tool Heating Time Assembly Time Cooling Timemm seconds seconds minutes
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsJointing.8
j o i n t i n g
Flanged EndsVinidex PE pipes are provided withflange connections by using PE stubends jointed to the ends of the pipes byeither electrofusion or butt welding.
These are used in conjunction with metalbacking plates, and rubber sealinggaskets in order to provide ademountable joint. Sealing gaskets aremade from natural rubber orpolychloroprene depending on the fluidbeing carried.
Where hot fluids or chemical reagentsare carried, the suitability of the sealinggasket material must be determined, andthe advice of Vinidex engineers obtained.The sealing gaskets must be clean andfree from creases when fitted to theflange assembly.
Flanges are available across the full sizerange of Vinidex PE pipes (up to1000mm diameter), and to the samepressure PN rating as the pipes.
Metal backing plates are available in hotdip galvanised form, and thickness to AS2129, and AS 4087 as required. Thethickness of the metal backing platemust be assessed for the operatingpressures in each particular pipelineusing the requirements of AS 2129 andAS 4087.
The fixing bolts must be tightened evenlyaround the flange. Bolts must not beover tightened, and a torque wrenchshould be used to prevent buckling ofthe metal backing plate.
Hugger Bolted CouplingsBolted couplings are fitted directly to theends of the PE pipes, and the serratedinside section of the coupling grips theoutside diameter of the PE pipe,providing longitudinal restraint.
The central rubber sealing ring providesa pressure seal.
The ends of the PE pipes must be cutsquare, and be free from all dirt andgrease when pushed together, without agap between the pipe ends.
The seal ring must be clean, and fittedevenly over the ends of the pipe. Thecoupling housing must be fitted evenlyover the rubber ring, and the boltstightened fully.
ThreadsThe cutting of threads is notrecommended.
Where threaded fittings are used then :
1. Only PTFE tape should be used as asealant. Hemp, paste, and petroleumcompounds must not be used.
2. The joint should be made firm byhand, or by strap wrench to preventover straining of the joint. Serratedjaw wrenches must not be used.
3. Where possible, the pipeline systemshould be designed so as to ensurethat PE/metal thread joints are suchthat the male thread is PE, and thefemale thread form is metal.
Figure 6.6Hugger Bolted Couplings
Figure 6.5Stub Flanges &Backing Plates
Size 90mm-315mm
Z
Gasket
Steel pipe
Back-up plate
Polyethelenepipe Stub flange
Steel to polyethylene
MS flange
Polyethylene to polyethyleneBack-up plates
PolyethylenepipeGasket
Stub flange
Polyethylenepipe Stub flange
product.data
Product Data.1PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
contents
Pressure Pipe 3
Polyethylene Pipe Reels 11
Gas Pipe 12
Rural Pipe 13
Low Density Irrigation Pipe 13
Syphon Tube 14
Flood Pipe 14
Fittings for Butt Welding 15
Mechanical Couplings 35
Metal Backing Rings 36
Electrofusion Fittings 39
Metric Compression Fittings 61
Tapping Saddles 85
Polypropylene Valves 89
Rural Compression Fittings 92
Threaded Fittings 100
Compressed Air Pipe & Fittings for Socket Fusion 105
Welding Equipment 111
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.2
Limitation of LiabilityThis manual has been compiled by Vinidex PtyLimited (“the Company”) to promote betterunderstanding of the technical aspects of theCompany’s products to assist users in obtainingfrom them the best possible performance.
The manual is supplied subject toacknowledgement of the following conditions:
• The manual is protected by Copyright and maynot be copied or reproduced in any form or byany means in whole or in part without priorconsent in writing by the Company.
• Product specifications, usage data and advisoryinformation may change from time to time withadvances in research and field experience. TheCompany reserves the right to make suchchanges at any time without notice.
• Correct usage of the Company’s productsinvolves engineering judgements which cannotbe properly made without full knowledge of allthe conditions pertaining to each specificinstallation. The Company expressly disclaimsall and any liability to any person whethersupplied with this publication or not in respectof anything and of the consequences of anythingdone or omitted to be done by any such personin reliance whether whole or partial upon thewhole or any part of the contents of thispublication.
• No offer to trade, nor any conditions of trading,are expressed or implied by the issue of contentof this manual. Nothing herein shall override theCompany’s Conditions of Sale, which may beobtained from the Registered Office or any SalesOffice of the Company.
• This manual is and shall remain the property ofthe Company, and shall be surrendered ondemand to the Company.
• Information supplied in this manual does notoverride a job specification, where such conflictarises, consult the authority supervising the job.
SIZES 20mm to 1000mm T = Average wall thickness (mm)
Pipes in sizes 20mm to 63mm, SDR 21 & SDR 17 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
Pipes in sizes 20mm to 63mm, SDR 13.6, SDR 11 and SDR 9 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
SIZES 20mm TO 1000 mm T = Average wall thickness (mm).
Pipes in sizes 20mm to 63mm, SDR 21 and SDR 17 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
Pipes in sizes 20mm to 63mm, SDR 13.6, SDR 11 and SDR 9 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
O.D.
T
SIZES 20mm TO 630mm T = Average wall thickness (mm).
Sizes 20mm TO 1000mm T = Average wall thickness (mm)
Pipes in sizes 20mm to 63mm, SDR 26 and SDR 21 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
AS/NZS 4130 - PE 100 BLACK - 12 Metre Pipe Lengths
Sizes 20mm TO 1000mm T = Average wall thickness (mm)
Pipes in sizes 20mm to 63mm, SDR 17, SDR 13.6 and SDR 11 are available subject to minimum order quantities.For identification purposes PE pipe can be supplied in other colours, or striped, subject to order quantities.
O.D.
T
PE Pressure Pipe
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Product Data.11PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Polyethylene Pipe Reels
PE Pressure Pipe
Vinidex polyethylene pipe is now availablecoiled on large reels. The reels are capableof carrying pipe sizes from 20mm to125mm diameter in lengths from 250metres up to 9.5 kilometres.The availability of extended pipe lengthsallows continuous runs of pipe withminimal jointing, reducing labour andmaterial costs. Further advantages are easeof handling and speed of pipe installation.The increased rate at which pipe can be laidalso minimises disruption caused by pipeinstallation. Site restoration work can startalmost immediately and well-plannedmedium size projects can be completedwithin a day.
ApplicationsThe polyethylene pipe reels have beenproven in the field on a range of projects,including:• Mains relining• Mains replacement by pipe bursting/
cracking techniques• Gas distribution pipelines• Agricultural and horticultural irrigation• Golf course watering systems• Direct lay and directional boring• Plough-in
Customer benefits• Longer pipe lengths• Ease of handling• Improved rate of laying• Lower installation costs• Shorter installation time• Minimal joints• Ability to control wastage• Protection against damage• Minimal site storage
For identification purposes PE gas pipe is supplied yellow or black with yellow stripe.Pipes can be supplied in coils or straight lengths, subject to order quantities. Coils 16mm-125mm, straight lengths 40mm-630mm
O.D.
T
SIZES 16mm TO 630mm T = Average wall thickness (mm).
PE Gas Pipe
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Product Data.13PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
These reducers can be cut.Products above are available in polypropylene, subject to minimum order quantities, special lead times and pricing arrangements.
RINGS MANUFACTURED ACCORDING TO AS 2129Galvanised steel* Note: 225mm backing rings to suit polyethylene stub flanges have a PCD of 292mm which differs from AS2129 of 324mm
IDOD
T1
PCD
Metal Backing Rings for Polyethylene Stub Flanges
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.36
RINGS MANUFACTURED ACCORDING TO AS 2129Galvanised steel* Note: 225mm backing rings to suit polyethylene stub flanges have a PCD of 292mm which differs from AS2129 of 324mm
IDOD
T1
PCD
Metal Backing Rings for Polyethylene Stub Flanges
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Product Data.37PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.38
Plasson Specifications
RAW MATERIALS • MDPE - Medium Density Polyethylene black UV stabilised• Density greater than 0.93g/cm 3 (DIN 53479, procedure A)• Melt Index (MFI 190/5) : 0.7 - 1.3g/10min ( DIN 53735)• PE 80 or PE 100 in accordance with AS/NZS 4131
MELT COMPATIBILITY • The PE used for the Plasson EF program is compatible with most of the raw materials HDPE and MDPEand can be fused with pipes of the fusion index groups 005 and 010 (MFI 190/5 0.4 - 1.3g/10min)accordingto DIN 16776 Part 1 (April 1978)
• Suits PE pipe made from PE 63, PE 80, and PE 100 - AS/NZS 4130
AUTOMATIC WELDING • The Plasson - Fusamatic fittings incorporate a resistor in one of the fittings terminals (a red pin) which isspecific to that fitting. The Plasson - Fusamatic Automatic control box reads the fitting resistor andautomatically sets and welds for the correct weld time and avoids operator error. Fittings are also labelledfor barcode reading, manual set times and have rising melt indicators. Terminal pin diameter is 4.9mm.
QUALITY • Plasson has incorporated a quality assurance system in accordance with ISO 9002.• Standardsmark licence No. 2018 - AS 4129 (INT).
MANUAL WELDING • Plasson - Fusamatic fittings are labelled with weld and cool times and can be welded with othermanufacturers’ 40 V (non - automatic) control boxes.
SPECIFICATIONS • Threads on transition fittings conform to DIN 2999,BSZI : 1973, AS 1722 Part 1 - 1975.
• For oval pipe use rerounding clamps. If ovalitycauses a gap between concentrically located pipeand fitting to exceed 1% of pipe OD then the pipemust be rerounded to ensure correct welding.After rerounding, if the gap still exceeds 1% ofpipe OD, then check the pipe OD dimension as itmay be an under specified OD. Note: Themaximum gap between eccentrically located pipeand fitting (i.e. pipe touching fitting at one point)must not exceed 2% of pipe OD. See diagram.
• Cutter sizes: From 20mm to 32mm depending on pipeand outlet size.
PERFORMANCE REQUIREMENTS Resistance to internal pressure– APPROVAL TESTS Plasson electrofusion socket fittings are tested to PN rating using the test method defined by ISO1167. The samples are
prepared to conform to ISO/TC 138/SC 5 requirements with minimum temperature -10°C and maximum temperature+45°C. The test pressures are calculated as specified by:• PREN 1555-3 (water systems)• PREN 122201-3 and ISO/DIS 8085-3 (gaseous fuel systems)Joint StrengthThe joint strength of Plasson electrofusion socket fittings is assessed according to GBE/PL2: Part 4, appendices J and K(crush test and peel test).Determination of Fitting Cooling TimeFitting cooling time is determined according to GBE/PL2: Part 4, appendix H with the following exceptions:• Pipe and coupler are conditioned to 45°C before fusion as opposed to 23°C.• Maximum power conditions are simulated using V = 41.0 volts as opposed to 40 V.Assessment of Fitting Resistance Tolerance BandThe resistance tolerance band is determined according to GBE/PL2: Part 4, appendix G with the following exceptions:• Pipe and coupler are conditioned to 45°C before fusion as opposed to 23°C.• Maximum power conditions are simulated using V = 41.0 volts as opposed to 40 V.Assessment of Safety Factor for WeldThe factor of safety is assessed according to the procedure laid out in AFNOR NF T 54-066, appendix H. Fittings alsocomply with maximum pressure ratings in AS1460 – 2 1989 Part 2, and are rated PN16 for water (PN7 for gas) whenextrapolated from Class 15 to PN16 test requirements.Warning: Do not weld saddles to 40, 50, & 63 SDR 11 live gas pipe where internal pressure exceeds 4 BAR, as pipedamage will occur due to pipe softening.
PE Electrofusion Fittings
ConcentricallyLocated
Max. gap1% of pipe OD
EccentricallyLocated
Max. gap2% of pipe OD
Pressure Conditions/Pipe Dimensions
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Product Data.39PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Safe pipe Standard Cutter Long CutterSDR (1) Minimum Pipe SDR Minimum Pipe SDR (3)
Notes:(1) Minimum wall thickness of any pipe must be 2.3mm.(2) When fused to pipes of SDR less than or equal to 17.6 Plasson Electrofusion couplers meet the safety factor requirements of the International Standards to
which they comply.If pipes of SDR 21 are used, the factor of safety for the fusion cycle may be less if welded in high temperature ambient conditions.
(3) With sizes 280-355 the long cutter is supplied as standard.(4) Long cutters are available as spares – Code Number: 30034280 for pipes with lower SDR's.
PE Electrofusion FittingsPipe Thickness/SDR Specifications
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.40
REDUCING JOINERS 9110
HEATING COOLING PN 16SIZE L A Z TIME (secs) TIME (min) CODE kg
20 x 16 6402725 x 20 66 38 2 30 3 69085 0.04632 x 20 80 36-42 2 30 3 69089 0.05632 x 25 66 41 2 45 3 69091 0.06540 x 32 90 42-47 2 60 5 69093 0.09463 x 32 97 62 9 50 5 69105 0.12063 x 40 97 62 5 70 5 69107 0.11063 x 50 97 62 5 120 10 69109 0.15090 x 63 153 77 8 100 10 69111 0.500
110 x 90 181 95 3 120 10 69121 1.100125 x 90 181 95 3 220 10 69123 1.000
180 x 125 222 128 3 360 20 69131 2.000225 x 180 64026250 x 225 222 183 5 600 30 69135 6.800
TRANSITION COUPLING - POLYETHYLENE TO STEEL (BSP) 9477
PN16SIZE CODE kg
32 x 25 7148740 x 32 41488
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.50
TAPPING SADDLES - WITH UNDERPART 9630
HEATING COOLING PN 16SIZE OUTLET H B C A TIME (secs) TIME (min) CODE kg40 20 105 66 7 94 50 3 62284 0.350 ●
40 32 120 66 12 94 50 3 62285 0.370 ●
50 20 110 76 7 98 60 3 62286 0.390 ●
50 32 120 76 12 98 60 3 62287 0.410 ●
63 20 116 92 7 98 120 3 62288 0.436 ●
63 32 125 92 12 98 120 10 62123 0.455 ●
63 40 148 103 65 177 120 10 62134 1.070 ✤
63 50 141 103 65 177 120 10 62145 1.085 ✤
63 63 178 103 65 177 120 10 62156 1.100 ✤
75 32 127 117 65 177 120 10 62124 1.120 ✤
75 40 148 117 65 177 120 10 62135 1.130 ✤
75 50 141 117 65 177 120 10 62146 1.140 ✤
75 63 178 117 65 177 120 10 62157 1.150 ✤
90 32 125 124 18 116 120 10 62125 1.120 ▲
90 40 133 124 21 116 120 10 62136 1.130 ▲
90 50 141 124 65 177 120 10 62147 1.210 ✤
90 63 178 124 65 177 120 10 62158 1.270 ✤
110 32 127 145 18 116 140 10 62126 1.170 ▲
110 40 137 145 21 116 140 10 62137 1.190 ▲
110 50 141 145 65 177 140 10 62148 1.210 ✤
110 63 178 145 65 177 140 10 62159 1.220 ✤
125 32 130 162 18 116 140 10 62127 1.230 ▲
125 40 140 162 21 115 140 10 62138 1.280 ▲
125 50 141 162 65 177 140 10 62149 1.290 ✤
125 63 178 162 65 177 140 10 62160 1.310 ✤
140 32 127 178 65 177 140 10 62128 1.350 ✤
140 40 148 178 65 177 140 10 62139 1.360 ✤
140 50 141 178 65 177 140 10 62150 1.370 ✤
140 63 178 178 65 177 140 10 62161 1.410 ✤
Continued over page
PE Electrofusion FittingsPlasson
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Product Data.51PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
TAPPING SADDLES - WITH UNDERPART 9630 (Continued)
HEATING COOLING PN 16SIZE OUTLET H B C A TIME (secs) TIME (min) CODE kg
160 32 143 199 18 137 140 10 62129 1.345 ✤
160 40 156 199 21 137 140 10 62140 1.360 ✤
160 50 169 199 25 137 140 10 62151 1.375 ✤
160 63 195 199 20 137 140 10 62162 1.390 ✤
180 32 143 219 18 137 140 10 62130 1.565 ✤
180 40 156 219 21 137 140 10 62141 1.580 ✤
180 50 169 219 25 137 140 10 62152 1.595 ✤
180 63 195 219 20 137 140 10 62163 1.605 ✤
*200 32 127 184 65 177 120 10 62131 1.750 ✤
*200 40 148 184 65 177 120 10 62142 1.760 ✤
*200 50 141 184 65 177 120 10 62153 1.770 ✤
*200 63 178 184 65 177 120 10 62164 1.780 ✤
*225 32 127 214 65 177 120 10 62132 1.810 ✤
*225 40 148 214 65 177 120 10 62143 1.820 ✤
*225 50 141 214 65 177 120 10 62154 1.830 ✤
*225 63 178 214 65 177 120 10 62165 1.840 ✤
*250 32 127 233 65 177 120 10 62155 1.830 ✤
*250 40 148 233 65 177 120 10 62155 1.830 ✤
*250 50 141 233 65 177 120 10 62155 1.830 ✤
*250 63 178 233 65 177 120 10 62166 1.840 ✤
* includes metal clamping strapsCut hole after welding and cooling time completed.Spigot length on sizes 63 to 180 with 32mm diameter cutters permit use of Plasson compression fittings.
PE Electrofusion FittingsPlasson
Saddle Cutter mm Cutter Welded CapSize Material Length mm Size
Cut hole after welding and cooling completed.*For sizes 200, 225, 250 use Saddle Clamp Kit no. 3 (see below) # For sizes 280, 315, use Topload G clamp – 29263315 (see below).^ For sizes 110, 125, 180 use Saddle Clamp code 29200004 (see below ) • For sizes 355 use Topload G Clamp code G Clamps L (see below).180 x 125 68807TOPLOAD G CLAMP Part no. 29263315 62113TOPLOAD G CLAMP Part no. G Clamp SLSADDLE CLAMP Part no. 29200004 Comprises batwing , spreader bar, 32 & 63 test caps universal miniclamp,
20, 25 and 32mm miniscraper (cutter key, Harris scraper, box) 62116LONG CUTTER (For Tapping saddles) Part no. 30034280. 62274
See pipe thickness/SDR specs. for electrofusion welding on page 39 in Product Data section.
BRANCH SADDLES - WITH UNDERPART 9580
HEATING COOLING PN 16SIZE BRANCH B H H1 TIME (secs) TIME (min) CODE kg63 32 103 61 51 120 10 62096 0.38075 32 117 61 51 120 10 62097 0.42090 32 124 61 51 120 10 62098 0.490
Cut hole after welding and cooling completed.F.B.S.P. threaded outlets are stainless steel reinforced.
PE Electrofusion FittingsPlasson
TAPPING SADDLES – PE TO NYLON 9619
HEATING COOLINGSIZE d1 H B H1 H2 TIME (secs) TIME (min) CODE kg
40 x 18 71499 .40 x 50 64064 .50 x 18 64065 .50 x 50 64066 .63 x 18 64067 .63 x 50 64068 .90 x 18 64069 .90 x 50 64070 .110 x 18 64071 .110 x 50 64072 .160 x 18 64073 .160 x 50 64074 .
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Product Data.55PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
TRANSITION SADDLES - WITH UNDERPART 9380 (DZR Brass female thread)
HEATING COOLING PN 16SIZE H B L TIME (secs) TIME (min) CODE GRAMS
63 x 11/4" 135 62 117 120 10 62175 0.77090 x 2" 156 56 166 160 10 62178 1.280110 x 11/4" 176 56 166 120 10 62179 2.140110 x 11/2" 176 56 166 120 10 62180 1.990110 x 2" 176 56 166 120 10 62181 1.640125 x 2" 191 56 166 120 10 62184 1.540160 x 2" 224 56 216 120 10 62187 2.000180 x 2" 246 56 216 120 10 62190 1.800
REPAIR SADDLES - WITH UNDERPART 9520
HEATING COOLING PN 16SIZE B H TIME (secs) TIME (min) CODE kg63 103 29 120 10 62167 0.36875 117 29 120 10 62168 0.41090 124 29 120 10 62169 0.485
Repairs with water in the line. The EF repair shield is made of PE sponge. It will stop water leakage ( zero pressure ) from flowing into the couplingwhilst a repair is made. The coupler is slid onto one pipe and the shield is fitted between the two pipes. The coupler is positioned for welding asusual.
Tapper® SaddlesBODY/COMPRESSION FITTING PolypropyleneBOLT AND NUT Stainless steel to DIN 17 440, 1.4301.CUTTER Brass to BS 2874-CZ122.O-RING NBRSADDLE SEAL EPDMSPLIT RING Polyacetal
ValvesBODY Polypropylene, high grade copolymer.O-RING NBR, EPDM or FRM O – depending on valve.SPRING (items 3067, 3039) Stainless steel
Threaded Fittings Polypropylene. SS reinforced outlets areavailable
OPERATING PRESSURECompression fittings comply with requirements of AS/NZS 4129 (Int).Operating pressures at 20°C (water)PN16 Up to 63mm diameterPN12.5 75mm-125mm diameterPN10 160mm diameterAll female threads from 1 1/4" to 4" have stainless steel reinforcing rings and arerated as above except that 4" is suitable for PN 6.3 only.Plasson Tapping Saddles and Plasson Compression Saddles comply withspecification 025 – 'Tapping Bands' of Australian Standard SAA MP52-1991 .Tapper®. WIS 4-22-02/WRC Standards – PN 16.Plasson polypropylene BSP threaded fittings: 1.0 MPa for male fittings, 0.6 MPa forfemale fittings (1.0 MPa for SS reinforced female fittings).Plasson polypropylene valves: PN10 or PN12.5.
PIPE SUITABILITYPlasson Compression Fittings : for pipes 16mm to 160mm outside diameter.Metric OD System for use with polyethylene pipe manufactured to:• AS1159 - 1988 – Polyethylene Pipes for Pressure Applications• AS4130 (Int) – PE Pipes for Pressure Applications• PE Pipes with outside dimensions to ISO OD series system.
Plasson Rural Fittings: for Type 50 Class Rural Polyethylene Pipe manufactured to:
• AS 2698.2 (ID Series) – Class 6.
Specifications for Plasson Compression Fittings, Saddles & Valves
OPERATING TEMPERATUREThe compression saddles, fittings and valves are not for use with hot water althoughthey withstand the same temperature as most polyethylene pipes. The fittings andvalves will withstand sub-zero temperatures.
FLANGESFlange dimensions in accordance with AS/NZS 4331-1995.Metal backing rings to be used with all flanges
THREADSInternal parallel thread up to 2 1/2"; internal taper thread 3"and up.External taper thread all sizes. All threads conform to ISO7; BS21 - 1973; DIN2999;NEN3258; AS1722 Part 1 - 1975.
CHEMICAL RESISTANCEPlasson polypropylene fittings are supplied, as standard, with Nitrile (NBR) ringsand acetal split rings which are suitable for water supply and many chemicalhandling applications.For many chemicals however, NBR and acetal are unsuitable and Plasson sparerings of either EPDM or VITON (FPM) should be used to replace the nitrile rings.CPVC split rings are also available to replace acetal. Generally nitrile is good in oilyapplications whilst EPDM or VITON are more suitable in acidic applications. A briefindication of chemical resistance at 20°C follows:
O Rings Plasson Nut Split RingsNBR (1) EPDM (2) FPM (2) + Body PP (1) Acetal (1) CPVC (2)
FPM although the most resistant is expensive – EPDM is usually the economicalsolution. Generally, if EPDM or FPM O Rings are required, then CPVC split ringsshould be used in place of standard acetal split rings. This is intended as a guideonly. Tapping Saddles used in chemical applications or permanently buriedsituations may require stainless steel bolts and nuts. In many sizes the NBR ring canbe replaced with EPDM or FPM.(1) Supplied as standard component in Plasson fittings(2) Available as Plasson spare partsNBR O Rings Cat 7002 FPM O Rings Cat 7920EPDM O Rings Cat 7910 CPVC Split Rings Cat 7008
APPROVALSPlasson fittings have been tested and approved by major standard institutions suchas WRC (GB), Staatliche Materialprufungsanstalt Darmstadt (analogous to DIN8078Part 1) (D); KIWA (NL); Standards Institution of Israel (IL); Australian Authorities(AUS); Statens Provningsanstalt Stockholm (S); Statens Planmerk (S); SGWA (CH);Byggestyrelsen (DK); SKZ GmbH (analogous to DIN8076 Part 3 - 12/87) (D). QASStandards Australia – StandardsMark Licence.
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Product Data.61PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
d x d1 E I CODE kg PACK QTY25 x 20 54 53 68191 132 x 20 64 61 68192 132 x 25 64 56 68193 140 x 32 82 72 68194 150 x 25 6820150 x 32 96 87 68195 150 x 40 96 83 68196 163 x 25 113 89 68197 163 x 32 6820363 x 40 113 103 68198 163 x 50 113 102 68199 1
Metric Compression FittingsPlasson
product.data
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.68
90° ELBOWS - WITH THREADED FEMALE OFFTAKE 7150
PN16 PN12.5 PACKd x G E I I2 A A1 CODE kg CODE kg QTY
NOTE: The 7894 NUT is used (and pictured above) with the 7890THREADED ADAPTOR. When ordering, please enter two codeson your order, one for the chosen THREADED ADAPTOR and onefor the relevant NUT.
Metric Compression FittingsPlasson
product.data
Product Data.79PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Metric Compression FittingsPlasson
POLY TO COPPER CONNECTOR 7119
25 x 15 7142525 x 20 7142632 x 20 64002
POLY TO COPPER TEE 7349
25 x 15 7142725 x 20 71428
POLY TO COPPER ELBOW 7519
25 x 15 7142925 x 20 71430
POLY TO COPPER KIT* 7439
20 x 15 71423 Kit25 x 20 71424 Kit*15 NB Copper Kit fits any 20mm Plasson end. 20 NB Copper Kit fits any 25mm Plasson end.Kit contains copper coloured nut, rubber liner, SS ring and copper coloured cone.
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.80
For closing and tightening the PP nuts of Plasson fittings.It is important when closing the nut on Plasson fittings that thenut is NOT OVER - TIGHTENED as the nut can be deformed - thismay result in a pipe blowing or pulling out of a fitting.
For overall pipe diameters from 16 to 63 mm.The tool operates like a pencil sharpener and it isimportant to chamfer pipes from 40 to 63 mm to easejointing pressures.
CHAMFER TOOL - FOR PE PIPES 7960
SIZE CODE kg PACK QTY16 - 63 mm 69499 0.345 1
Metric Compression FittingsPlasson
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Product Data.81PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
O-RINGS 7002, 7920, 7910
7002 7920 7910O - RING (Nitrile) NBR O - RING VITON (FPM) * O - RING (EPDM) **
The nuts and bolts are made of galvanized steel. The O-rings of NBR rubber. Stainless steel nuts and bolts can be supplied as can FPM and EPDM O-rings but aresubject to special pricing and delivery arrangements.
Tapping SaddlesPlasson
2
BOLTS
4
BOLTS
6
BOLTS
product.data
Product Data.85PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Tapping SaddlesPlasson
TAPPING SADDLES WITH S/STEEL REINFORCING RING NUTS & BOLTS 16077PN 16 PN 12.5 PN 10
d G B L H A Bolt Dim. CODE kg CODE kg CODE kg20 15 10.0 70 45 32.7 6 X 30 - 64052 65 -25 15 14.5 75 50 35.5 6 X 30 - 68501 72 -25 20 14.5 75 50 36.5 6 X 30 - 68505 75 -32 15 16.0 92 60 40.0 8 X 45 - 68507 132 -32 20 19.0 92 60 41.0 8 X 45 - 68509 134 -32 25 19.0 92 60 42.0 8 X 45 - 68511 140 -40 15 16.0 92 60 44.5 8 X 45 - 68513 140 -40 20 19.0 92 60 45.5 8 X 45 - 68515 142 -40 25 25.0 92 60 49.0 8 X 45 - 68517 150 -50 15 16.0 106 73 50.8 8 X 45 - 68519 179 -50 20 21.0 106 73 51.8 8 X 45 - 68521 180 -50 25 25.0 106 73 54.3 8 X 45 - 68523 188 -50 32 25.0 106 73 58.3 8 X 45 - 68525 210 -63 15 16.0 116 84 57.8 8 X 45 - 68527 278 -63 20 20.0 116 84 58.8 8 X 45 68529 280 -63 25 25.0 116 84 61.3 8 X 45 - 68531 288 -63 32 32.0 116 84 66.0 8 X 45 - 68533 308 -63 40 39.0 116 84 66.5 8 X 45 - 68535 322 -75 15 16.0 122 98 63.8 8 X 60 - 68537 370 -75 20 20.0 122 98 64.8 8 X 60 - 68539 372 -75 25 25.0 122 98 67.3 8 X 60 - - 68541 37675 32 32.0 122 98 72.0 8 X 60 - - 68543 39975 40 40.0 122 98 72.5 8 X 60 - - 68545 40975 50 40.0 122 98 77.5 8 X 60 - - 68547 43390 15 16.0 141 105 71.5 8 X 60 - 68549 454 -90 20 20.0 141 105 72.5 8 X 60 - 68551 453 -90 25 25.0 141 105 75.0 8 X 60 - - 68553 46190 32 32.0 141 105 80.0 8 X 60 - - 68555 48190 40 40.0 141 105 81.0 8 X 60 - - 68557 49490 50 50.0 141 105 86.0 8 X 60 - - 68559 511
The nuts and bolts are made of 306 stainless steel. The O-rings of NBR rubber. Stainless steel nuts and bolts can be supplied as can FPM and EPDM O-rings but aresubject to special pricing and delivery arrangements.
2
BOLTS
4
BOLTS
6
BOLT
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.86
Tapping SaddlesPlasson
THREADED ADAPTOR 6933
d x d CODE50 x 32 6401450 x 40 64015
Female BSP adaptor, fits 50mm compression end
COMPRESSION SADDLE 6810
d x d CODE90 x 50 64010
110 x 50 64011140 x 50 64012160 x 50 64013
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Product Data.87PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
TAPPER SWIVEL TEE TO SUIT PVC PIPE Grey Ring 6540
d x d H B H1 H2 CODE125 x 25 106 201 59 132 68687125 x 32 111 201 59 132 68692150 x 25 106 223 59 132 68707150 x 32 111 223 59 132 68712AS/NZS1477 Series 1
TAPPER SWIVEL TEE FOR POLYETHYLENE PIPE Blue Ring 6530
d x d H B H1 H2 CODE63 x 25 106 116 57 130 6864563 x 32 111 116 57 130 6865075 x 25 106 122 57 130 6865575 x 32 111 122 57 130 6866090 x 25 106 141 58 131 6866590 x 32 111 141 58 131 68670110 x 25 106 165 59 132 68675110 x 32 111 165 59 132 68680125 x 25 106 184 58 132 68685125 x 32 111 184 58 132 68690140 x 25 106 201 59 132 68695140 x 32 111 201 59 132 68700160 x 25 106 223 59 132 68705160 x 32 111 223 59 132 68710180 x 25 106 245 60 133 68715180 x 32 111 245 60 133 68720
TAPPER SWIVEL TEE – PVC VINYL IRON Grey Ring 6542
d x d H B H1 H2 CODE100 x 25 106 184 58 131 68677100 x 32 111 184 58 131 68682150 x 25 106 245 60 133 68706150 x 32 111 245 60 133 68711AS/NZS1477 Series 2 & AS/NZS4441 (Int.) Series 2
Tapping SaddlesPlasson
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.88
PN10G x d E H I I2 A CODE kg PACK QTY15 x 20 48 172 58 16 113 86201 0.17620 x 25 54 187 60 8 121 86203 0.23825 x 32 64 212 70 20 140 86205 0.36032 x 40 82 258 86 22 180 86207 0.61840 x 50 96 296 98 22 207 86218 0.93950 x 63 113 338 112 26 246 86215 1.518
CHECK VALVE (EPDM Threaded Inlet/Outlet) 3067
PN10G x d H I2 A CODE kg PACK QTY20 x 20 151 18 92 86230 0.15225 x 25 170 20 106 86232 0.22932 x 32 200 22 134 86234 0.38940 x 40 225 22 155 86236 0.58650 x 50 254 26 182 86238 0.975
ANGLE SEAT VALVE (FPM Threaded Inlet/Outlet) 3049
PN10G x d H I2 A CODE kg PACK QTY15 x 15 134 16 113 89219 0.13620 x 20 151 18 121 86220 0.19125 x 25 170 20 140 86226 0.28032 x 32 200 22 180 86224 0.73340 x 40 225 22 207 86226 0.47450 x 50 254 26 246 86228 1.186
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.90
QUICK COUPLING VALVE (Spring of stainless steel VA2) 3039
PN 10 PACKG H I2 CODE kg QTY20 146 17 69490 0.144 525 148 18 69492 0.148 5
KEY - FOR QUICK COUPLING VALVE 3139
PN 10 PACKG H I2 CODE kg QTY20 173 18 69494 0.066 5
TWO WAY VALVE INLET AND OUTLET FEMALE THREADED 3405
PN 10 PACKG x G H I2 A CODE kg QTY
20 x 20 78 18 92 69487 0.115 525 x 25 82 20 92 69488 0.129 5
Polypropylene ValvesPlasson
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Product Data.91PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Rural Compression Fittings
REDUCING COUPLINGS 7112
SIZE CODE kg PACK QTY20 x 15 68002 0.074 1025 x 15 68005 0.096 1025 x 20 68006 0.105 1032 x 20 68009 0.149 532 x 25 68010 0.172 540 x 25 68013 0.261 540 x 32 68014 0.299 550 x 25 68019 0.342 550 x 32 68017 0.384 550 x 40 68018 0.468 5
Product Data.93PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Rural Compression Fittings
90° REDUCING TEES 7342
SIZE CODE kg PACK QTY20 x 20 x 15 68068 1025 x 25 x 20 68073 0.185 1032 x 32 x 25 68076 0.284 540 x 40 x 32 68079 0.517 250 x 50 x 25 6808550 x 50 x 32 6807750 x 50 x 40 68081 0.751 2
90° TEES - WITH THREADED FEMALE OFFTAKE 7142
SIZE CODE kg PACK QTY15 x 15 x 15 69202 0.070 1015 x 15 x 20 69204 0.070 1020 x 20 x 20 68088 0.114 1020 x 15 x 20 68087 0.114 1020 x 20 x 15 68086 0.114 1025 x 20 x 20 68091 0.130 1025 x 25 x 15 68090 0.164 1025 x 25 x 20 68092 0.130 10
*25 x 25 x 25 68094 0.174 1025 x 25 x 32 68093 0.205 1032 x 25 x 25 68095 0.196 532 x 32 x 20 68097 0.243 532 x 32 x 25 68096 0.244 5
*32 x 32 x 32 68098 0.273 5*32 x 32 x 40 68099 0.295 540 x 40 x 25 68101 0.416 2
*40 x 40 x 32 68100 0.426 2*40 x 40 x 40 68102 0.444 2*40 x 40 x 50 68103 0.493 2*50 x 50 x 40 68104 0.669 2*50 x 50 x 50 68106 0.681 2
* Fitting with stainless steel reinforcing ring.
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.94
90° TEES - WITH THREADED MALE OFFTAKE 7842
SIZE CODE kg PACK QTY20 x 20 x 15 68180 0.108 1020 x 20 x 20 68182 0.117 1025 x 1' x 15 68108 0.139 1025 x 25 x 20 68110 0.142 1032 x 32 x 25 68184 0.236 540 x 40 x 32 68186 0.369 240 x 40 x 40 68188 0.369 250 x 50 x 32 6818950 x 50 x 40 68190 0.600 2
Rural Compression Fittings
90° ELBOWS - WITH THREADED FEMALE OFFTAKE 7152
SIZE CODE kg PACK QTY15 x 15 69342 0.050 1020 x 15 68126 0.064 1020 x 20 68128 0.072 1025 x 20 68132 0.088 1025 x 25 68134 0.096 1032 x 20 68135 0.158 532 x 25 68136 0.148 5
*32 x 32 68138 0.171 540 x 25 68139
*40 x 32 68140 0.297 5*40 x 40 68142 0.307 5*40 x 50 68143 0.317 550 x 25 68145
*50 x 32 68147 0.361 250 x 40 68144
*50 x 50 68146 0.403 2
* Fitting with stainless steel reinforcing ring.
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Product Data.95PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
SIZE CODE kg PACK QTY20 x 15 68160 0.072 1020 x 20 68162 0.067 1025 x 15 6816325 x 20 68164 0.085 1025 x 25 6816532 x 25 68166 0.143 532 x 32 6816740 x 25 6816940 x 32 68168 0.278 540 x 40 68170 0.270 550 x 25 6817150 x 32 68172 550 x 40 68174 5
45° ELBOW - WITH THREADED MALE OFFTAKE 7452
SIZE CODE kg PACK QTY15 68113 1020 68112 10
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.96
Rural Compression Fittings
MALE THREADED ADAPTORS 7022
SIZE CODE kg PACK QTY15 x 15 68902 1015 x 20 68904 1020 x 15 68024 0.064 1020 x 20 68026 0.065 1020 x 25 68025 0.063 1025 x 15 68027 0.078 1025 x 20 68028 0.076 1025 x 25 68030 0.075 1032 x 20 68031 0.116 532 x 25 68032 0.136 532 x 32 68034 0.158 532 x 40 68033 0.142 540 x 25 68035 0.219 540 x 32 68036 0.225 540 x 40 68038 0.238 540 x 50 68037 0.241 550 x 25 62841 0.312 550 x 32 68039 0.312 550 x 40 68040 0.313 550 x 50 68042 0.325 5
FEMALE THREADED ADAPTORS 7032
SIZE CODE kg PACK QTY15 x 15 68970 1015 x 20 68972 1020 x 15 68048 62 1020 x 20 68050 16 1020 x 25 68051 73 1025 x 20 68052 80 1025 x 25 68054 80 1032 x 20 68055 116 532 x 25 68056 117 5
*32 x 32 68058 168 540 x 25 68059 210 5
*40 x 32 68060 225 5*40 x 40 68062 249 550 x 32 68063 268 5
*50 x 40 68064 306 5*50 x 50 68066 320 5
*Fitting with stainless steel reinforcing ring.
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Product Data.97PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
ADAPTOR - WITH THREADED MALE OFFTAKE & NUT 7250
SIZE CODE PACK QTY32 x 15 69390 232 x 20 69392 232 x 25 69394 240 x 25 69396 240 x 32 69398 240 x 40 69400 250 x 25 69402 250 x 32 69404 250 x 40 69406 250 x 50 69408 2
CONVERSION KIT – RURAL TO METRIC 7980
SIZE CODE PACK QTY20 x 20 7141125 x 25 7141232 x 32 7141340 x 40 7141450 x 50 71415
Use to seal any metricor rural compression fitting
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.110
Plasson
Welding Equipment
PIPE SCRAPERS
PLASSON PART NO. CODEMINISCRAPER - 20 mm 29110020 63557MINISCRAPER - 25 mm 29110025 63558MINISCRAPER - 32 mm 29110032 63559MAXISCRAPER - 40 mm 29110040 63560MAXISCRAPER - 50 mm 29110050 63561MAXISCRAPER - 63 mm 29110063 63562HARRIS HAND SCRAPER - SMALL 29110001 63563HARRIS HAND SCRAPER - LARGE 29110002 63564CALDER SCRAPER 90-250mm 2912000 99274
PIPE WIPES (For PE pipe cleaning) VFPW 99275
ELECTROFUSION WELDING EQUIPMENT
PLASSON PART NO. CODEELECTROFUSION CONTROL BOXESPF MONOMATIC – 5m lead PFMONO5DL 63617PF MONOMATIC – 10m lead PFMONO10DL 71103PF MONOMATIC (DATA) – 5m lead PFMONODATA5DLPF MONOMATIC (DATA) – 10m lead PFMONODATA10DLPF DIGIMATIC TIME – 5m lead PFDIGITIME5FL 71108PF DIGIMATIC (DATA) – 5m lead PFDIGIDATA5DL 71107PF DIGIMATIC (DATA) – 10m lead PFDIGIDATA10DL 71106PF POLYMATIC PLUS (DATA) – 5m lead PFPOLYPLUS5DLPF POLYMATIC PLUS (DATA) – 10m lead PFPOLYPLUS10DLSpare Parts for Series 35 and Series A60 ModelsDATA RETRIEVAL PRINTER (for use with Electrofusion Control Box 29000000) 29000005 63551OUTPUT LEADS (for Electrofusion Control Box) - 5m 29000050 63552OUTPUT LEADS (for Electrofusion Control Box) - 10m 29000100 63553OUTPUT LEADS (for Electrofusion Control Box) - 15m 29000150 63554
ELECTROFUSION CONTROL BOX
CALDER SCRAPER 90-250mm
PIPE WIPES
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Product Data.111PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
SADDLE CLAMP COMPONENTS
PLASSON PART NO. CODESADDLE CLAMP KIT NO. 3 (Contains rings for 200, 225, 250 mm) 29200005 62115TOPLOAD G CLAMP (63 - 315 mm) 29263315 62113TOPLOAD G CLAMP (63 - 400 mm) GCLAMPSL 62117Note: 50, 80 and 100 Series 3 Gas Pipe Clamps available on request
Plasson
Welding Equipment
SADDLE CLAMP KIT NOS. 1 & 3
TOPLOAD G CLAMP
SADDLE CLAMP KIT NOS. 1 & 3
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.112
Plasson
Welding Equipment
MAIN CLAMP PARTS
PLASSON PART NO. CODE
PLAIN BASE - 460 mm 29300460 63586SLOTTED BASE - 460 mm 29300461 63587RING - 180 mm ( Universal with Dovetail Blocks ) 29300181 63589DOVETAIL SLIDE BLOCK 29300006 63590LINER RING - 250 x 225 mm (2 x 180° Segments) for 29300250 293250225 63591LINER RING - 225 x 200 mm (2 x 180° Segments) for 29300250 293225200 63592LINER RING - 180 x 160 mm (2 x 180° Segments) 293180160 63593LINER RING - 180 x 140 mm (2 x 180° Segments) 293180140 63594LINER RING - 180 x 125 mm (2 x 180° Segments) 293180125 63595LINER RING - 160 x 110 mm (2 x 180° Segments) 293160110 63595LINER RING - 160 x 75 mm (2 x 180° Segments) 293160075 63597LINER RING - 125 x 90 mm (2 x 180° Segments) 293125090 63599LINER RING - 125 x 63 mm (2 x 180° Segments) 293125063 63600T BAR (with screws) 29300010 63601SPANNER 29300012 63602ALLEN KEY 29300014 63603ALLEN KEYS FOR LINERS - SET OF 4 29300016 63604METAL TRANSPORTATION BOX 29300018 63605SWIVEL JOINT 29300020 63606SAW SAWSAW GUIDE S. GUIDE
MULTICLAMP KIT - 250mm (Comprising 2 - 250mm Rings mounted on base) 29300250 63584MULTICLAMP KIT - 315mm (Comprising 2 - 315mm Rings mounted on base) 29300315 63585MULTICLAMP KIT - 355mm (Comprising 2 - 355mm Rings mounted on base) 29300355 63548Reductions. Reductions to sizes 200, 225 and 280mm can be made using Liners from Butt FusionMachines (only 4 x 180° segments required).
SERVICE CLAMPS
ALIGNMENT CLAMPS
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Product Data.113PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Plasson
Welding Equipment
DRILLS
PLASSON PART NO. CODE
UNDER PRESSURE DRILL - 63mm (use with Multiclamps) BF63DRILL 63624UNDER PRESSURE DRILL - 90/125mm (use with Multiclamps) UPLDDRILL 63625UNDER PRESSURE DRILL - 90/125mm - Squeeze off extension kit(use with Multiclamps) UPLDDRSQKIT 63626NON PRESSURE DRILL - For outlets 63, 90, 125mm(For use on unpressured lines ) NPLDDRILL 63627
COILED PIPE CLAMPS
Has base similar to a Multiclamp Kit and used to manually align pipes unwound from coils lyinghorizontally on the ground.
PLASSON PART NO. CODE
COILED PIPE CLAMP - 63 mm 297000063 63619COILED PIPE CLAMP - 75 mm 297000075 63620COILED PIPE CLAMP - 90 mm 297000090 63621COILED PIPE CLAMP - 110 mm 297000110AUS 63622COILED PIPE CLAMP - 125 mm 297000125AUS 63623110mm made with a 125 x 110mm aluminium liner (Code No. BF1L125110) inside a 125mm coiled pipeclamp - suits both 110 and 125 diameter polyethylene pipe
HYDRAULIC COILED PIPE JOINERS
Normally used for joining pipe unwound from vertical reels into the trench. Suitable for PE80 pipes up toSDR11 wall thickness. ( not for use with PE100 pipe - a special coiled pipe joiner is available )
PLASSON PART NO. CODE
HYDRAULIC COIL JOINER - Pipes 90 - 125 mm ( with hand pump )* 297019125 63607HYDRAULIC COIL JOINER - Pipes 125 - 180 mm ( with hand pump )* 297125180 63608* Liner sets required for intermediate sizes
COILED PIPE CLAMP
NON PRESSURE DRILL
COILED PIPE JOINER
UNDER PRESSURE DRILL
product.data
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.114
DEBEADING
PLASSON PART NO. CODE
EXTERNAL DEBEADER. Debead 90-400 mm 29110400 63565PIPE CUTTING HEAD ASSEMBLYFits into External Debeader tool to cut pipe sizes 90-315mmfor all SDR Ratings 11, 17 & 26. 21858INTERNAL BEAD REMOVAL KIT. Up to 12m insertionFor pipe sizes 110 - 400mm O.D. For S.D.R. 44 to 7.3(Available as Kit or as single units for specific sizes) 29110412 63566
SQUEEZE TOOLS
PLASSON PART NO. CODE
SQUEEZE TOOL 16 - 32 mm For ≤ SDR 11 Pipe SQT32 63628SQUEEZE TOOL 16 - 63 mm For 3/4", 1", 2" SQT63 63629SQUEEZE TOOL 63 - 180 mm For SDR 17.6 & SDR 11 SQT180 63630SQUEEZE TOOL 180 - 250 mm All SDR Ratings SQT250 99172SQUEEZE TOOL 250 - 400 mm All SDR Ratings SQT355 99173
Plasson
Welding Equipment
product.data
Product Data.115PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Plasson
Welding Equipment
SQUEEZE OFF
PLASSON PART NO. CODE
POST SQUEEZE OFF REROUNDING CLAMPS - 63 mm 29600063 63631POST SQUEEZE OFF REROUNDING CLAMPS - 75 mm 29600075 63632POST SQUEEZE OFF REROUNDING CLAMPS - 90 mm 29600090 63633POST SQUEEZE OFF REROUNDING CLAMPS - 110 mm 29600110 63634POST SQUEEZE OFF REROUNDING CLAMPS - 125 mm 29600125 63635POST SQUEEZE OFF REROUNDING CLAMPS - 140 mm 29600140POST SQUEEZE OFF REROUNDING CLAMPS - 160 mm 29600160 63636POST SQUEEZE OFF REROUNDING CLAMPS - 180 mm 29600180 63637POST SQUEEZE OFF REROUNDING CLAMPS - 200 mm 29600200 63638POST SQUEEZE OFF REROUNDING CLAMPS - 225 mm 29600225 63639
REROUNDING TOOLS
To reround oval pipes for Electrofusion PLASSON PART NO. CODE
TYPE 1 16 mm 29500016 63640TYPE 1 20 mm 29500020 63641TYPE 1 25 mm 29500025 63642TYPE 1 32 mm 29500032 63643TYPE 2 40 mm 29500040 63644TYPE 2 50 mm 29500050 63645TYPE 2 63 mm 29500063 63646TYPE 2 75 mm 29500075 63647TYPE 2 90 mm 29500090 63648TYPE 2 110 mm 29500110-2TYPE 2 125 mm 29500125 63649TYPE 3 110 mm 29500110 63650TYPE 3 160 mm 29500160 63651TYPE 3 180 mm 29500180 63652TYPE 3 200 mm 29500200 63653TYPE 3 225 mm 29500225 63654TYPE 3 250 mm 29500250 63655Note: Rerounding tools also available for imperial pipe 1/2"-4"110mm made with a 125 x 110mm aluminium liner (Code No. 22211) inside a 125mm tool - suits both 110and 125 diameter polyethylene pipe
SQUEEZE OFF
REROUNDING TOOLS
REROUNDING TOOL – TYPE 3
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.116
PIPE CUTTERS
PLASSON PART NO. CODE
SECATEUR PIPE CUTTERS Up to 32mm PCS2032 99104SECATEUR PIPE CUTTERS Up to 63mm PCS2063 99174GUILLOTINE CUTTERS Up to 225mm PCG200 99105GUILLOTINE CUTTERS Up to 315mm PCG315 99106
Plasson
Welding Equipment
GUILLOTINE CUTTERS
SECATEUR PIPE CUTTERS
product.data
Product Data.117PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
Butt Fusion Equipment
Welding Equipment
BF1 BUTT FUSION MACHINE 50 - 125mm
PART NO. CODESEMI AUTOMATIC BF1MSComprising: 180mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer Stand, Heater Stand, DSA 23 Hydraulic Power Pack, 2 Ratchet spannersLINERS (8 HALF SEGMENTS)125 x 110mm Liner Set BFL125110 99110125 x 90mm Liner Set BFL12590 99111125 x 75mm Liner Set BFL 12565 99112125 x 63mm Liner Set BFL 12563 99113125 x 50mm Liner Set BFL 12550 99114TRIMMER BLADE BF1.03128Minimum Generator size 2.0 kVANote: Automatic Machines can be converted to semi-automatic function by addition of a DSA 23 or60 Hydraulic Power Pack and a manual over-ride unit.The machine will then weld in semi-automatic mode to preset welding parameters – however, data recording ofthe welds will not be available.
BF 180 BUTT FUSION MACHINE 63 - 180mm
PART NO. CODEAUTOMATIC BF180AFV 99115Comprising: Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, Micro Processor Contoller, 2 Ratchet, Printer
SEMI AUTOMATIC BF180SFV 99116Comprising: 180mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, DSA 23 Hydraulic Power Pack, 2 Ratchet Spanners
LINERS (8 HALF SEGMENTS)180 x 160mm Liner Set BFL180160 99119180 x 140mm Liner Set BFL180140 99120180 x 125mm Liner Set BFL180125 99121180 x 110mm Liner Set BFL180110 99122180 x 90mm Liner Set BFL18090 99123180 x 75mm Liner Set BFL18075 99124180 x 63mm Liner Set BFL18063 99125TRIMMER BLADE 31638
DSA23 HYDRAULIC POWER PACK DSA23 99126
MANUAL OVERIDE UNIT MOBB 99127Minimum Generator size 2.8 kVA
SEMI AUTOMATIC BUTT FUSION MACHINE
AUTOMATIC BUTT FUSION MACHINE
SEMI AUTOMATIC BUTT FUSION MACHINE
product.data
PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.118
Butt Fusion Equipment
Welding Equipment
BF 250 BUTT FUSION MACHINE 63 - 250mm
PART NO. CODE
AUTOMATIC BF250AFV 99128Comprising: 250mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, Micro Processor Contoller, 2 Ratchet Spanners, Printer
SEMI AUTOMATIC BF250SFV 99129Comprising: 250mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, DSA 23 Hydraulic Power Pack, 2 Ratchet Spanners
LINERS (8 HALF SEGMENTS)250 x 225mm Liner Set BFL250225 99131250 x 200mm Liner Set BFL250200 99132250 x 180mm Liner Set BFL250180 99133180 x 160mm Liner Set BFL180160 99134180 x 140mm Liner Set BFL180140 99135180 x 125mm Liner Set BFL180125 99136180 x 110mm Liner Set BFL180110 99137180 x 90mm Liner Set BFL18090 99138180 x 75mm Liner Set BFL18075 99139180 x 63mm Liner Set BFL18063 99140TRIMMER BLADE 31639
DSA23 HYDRAULIC POWER PACK DSA23 99141
MANUAL OVERIDE UNIT MOBB 99142Minimum Generator size 4.2 kVA
BF 315 BUTT FUSION MACHINE 90 - 315mm
PART NO. CODE
AUTOMATIC BF315AFV 99143Comprising: 315mm Chassis, Frame and Hoses, Trimmer, Auto Lift Heater,Trimmer and Heater Stand, Micro Processor Controller, 2 Ratchet Spanners, Printer
SEMI AUTOMATIC BF315SFV 99144Comprising: 315mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, DSA 60 Hydraulic Power Pack, 2 Ratchet Spanners
LINERS (8 HALF SEGMENTS)315 x 280mm Liner Set BFL315280 99147315 x 250mm Liner Set BFL315250 99148250 x 225mm Liner Set BFL250225 99149250 x 200mm Liner Set BFL250200 99150250 x 180mm Liner Set BFL250180 99151180 x 160mm Liner Set BFL180160 99152180 x 140mm Liner Set BFL180140 99153180 x 125mm Liner Set BFL180125 99154180 x 110mm Liner Set BFL180110 99155180 x 90mm Liner Set BFL18090 99156TRIMMER BLADE 31638
DSA60 HYDRAULIC POWER PACK DSA60 99157
MANUAL OVERIDE UNIT MOBB 99158Minimum Generator size 4.2 kVA
AUTOMATIC BUTT FUSION MACHINE
SEMI AUTOMATIC BUTT FUSION MACHINE
AUTOMATIC BUTT FUSION MACHINE
SEMI AUTOMATIC BUTT FUSION MACHINE
product.data
Product Data.119PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems
MANUAL - "Torque Wrench" Lever (non hydraulic) BF110000L 99051Comprising: 110mm Machine Complete. Portable Facer with Electric Drill, Portable Electric Heater,Heater/Facer Stand and a Steel Carry Case (holds all items)
PIPE LINERS (2 Rings)110-90mm Liner Set BF110990 99082110-75mm Liner Set BF110975 99084110-63mm Liner Set BF110963 99086
NARROW FITTINGS CLAMP - Sliding110-90mm Liner Set BF110790 99083110-75mm Liner Set BF110775 99085110-63mm Liner Set BF110763 99087
AUTOMATIC BF400AV 99159Comprising: 400mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, Micro Processor Contoller, 2 Ratchet Spanners, Printer
SEMI AUTOMATIC BF400SV 99160Comprising: 400mm Chassis, Frame and Hoses, Trimmer, Auto Lift HeaterTrimmer and Heater Stand, DSA 60 Hydraulic Power Pack, 2 Ratchet Spanners
LINERS (8 HALF SEGMENTS)400 x 355mm Liner Set BFL400355 99162400 x 315mm Liner Set BFL400315 99163315 x 280mm Liner Set BFL315280 99164315 x 250mm Liner Set BFL315250 99165TRIMMER BLADE 31640
DSA60 HYDRAULIC POWER PACK DSA60 99166
MANUAL OVERIDE UNIT MOBB 99167Minimum Generator size 6 kVA
AUTOMATIC BUTT FUSION MACHINE
SEMI AUTOMATIC BUTT FUSION MACHINE
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PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe SystemsProduct Data.120
MANUAL - Hydraulic Pump BF225000H 99326Comprising: 225mm Machine Complete. Portable Facer with Electric Drill, Portable Electric Heater,Heater/Facer Stand, Fittings Chuck and a Steel Carry Case (holds accessories only). 2 Wheels
LINERS (2 Rings)225-200mm Liner Set BF225920 99211225-160mm Liner Set BF225916 99215225-110mm Liner Set BF225911 99221
SEMI-AUTOMATIC - Electric Hydraulic Pump BF225000E 99327Comprising: 225mm Machine Complete. Portable Facer with Electric Drill, Portable Electric Heater,Heater/Facer Stand, Fittings Chuck and a Steel Carry Case (holds accessories only). 2 Wheels
LINERS (4 Rings)225-200mm Liner Set BF225920 99211225-160mm Liner Set BF225916 99215225-110mm Liner Set BF225911 99221
Product Data.121PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems PE Pipe Systems