Technical Guide Wavin PVC Pressure Pipe Systems
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PVC pipes' technical information...
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Waste water drainage TECHNICAL MANUAL
Wavin PVC Pressure Pipe systems
PVC Pressure Pipe systems Product and Technical Guide
1
Contents
2
page 4
1.
Materials for water distribution
1.1
Classification of plastics for piping systems
page 4
1.2
Standard Dimension Ratio SDR
page 5
2.
General material properties
page 6
2.1
Polyvinylchloride PVC-U
page 6
2.2
Chemical resistance
page
2.3
Technical data
page 7
2.4
Features & Benefits
page
3.
Apollo bi-axial PVC-O
page 9
4.
Standards & Regulations
page 11
5.
Product range
page 13
6.
Installation
page
6.1
Rubber ring jointing
page 15
6.2
Solvent cement jointing
page 17
6.3
Connections
page 21
6.4
Flange type connection
page 22
6.5
Threaded or adapter joints
page 23
6.6
Fixing
6.7
Installation of Apollo
PVC Pressure Pipe systems Product and Technical Guide
6 8
15
page 27 page 28
Phone. +31(0)38 42 94 951
7.
Design of water supply pipelines
page 31
7.1
Piping design, pipe arrangement, linear expansion calculation
page 33
7.2
Longitudal expansion and contracting of plastic pipes
page 35
7.3
Hydraulic flow: Frictional losses
page 36
7.4
Water flow diagram
page 37
7.5
Pressure variations
page 38
8.
Laying instructions
page 39
8.1
Pressure testing
page 40
9.
Anchorage
page 42
10.
Handling & Storage
page
11.
Notes
page 47
PVC Pressure Pipe systems Product and Technical Guide
45
3
1. Materials for water distribution 1.1 Classification of plastics for piping systems
example, common PE pipe materials.
Procedure At
different
internal
temperatures,
pressures
(=
different
They have a MRS of 10 MPa. They are
circumferen
therefore called PE 100 in accordance
The development of plastics used in gas
tial stress in the pipe wall) are applied
and water distribution is continuous. In
to the specimens. The (load) duration
recent years outstanding progress has
until break is determined. The respec-
Unlike the existing classification methods
been achieved.
tive breaking stress is applied over the
based upon the dimensional stress and
appropriate load time. This results in the
the “safety coefficients” (sometimes dif-
load duration graph.
ferent in each nation), the new system
The creation of new material types with increased strength, higher property con-
with the new system.
refers to a uniformly determined mate-
sistency and at the same time good
The circumferential stress values for
rial parameter. This eliminates earlier
or better processability are paramount.
20˚C are extrapolated to 50 years accor-
misunderstandings due to the different
Moreover, European standardisation
ding to ISO/DIS 9080 and lead to
starting points.
already shows the first conceivable effects in as far as classification systems come into use today, with subsequent lasting influences on pipe construction with plastics (prEN 1555, prEN 12201,
LTHS anticipated value, 50 years the (Long Term Hydrostatic Strength), the 97.5 % LCL (Lower Confidence Limit).
EN1452).
From classification to application The MRS value represents the long-term circumferential stress in the pipe where
This LCL value is categorised in accor-
the break may occur after 50 years at
The starting point for the new classifica-
dance with the Renard series of numbers
the earliest. The calculation stress ss is
tion system according to ISO 12162 and
(R10 or R20 in accordance with ISO 3
applied for dimensioning of the piping
EN 32162 is the long-term behaviour of
and ISO 497). The calculated LCL value
network. This is calculated from:
the respective material under internal
is reduced to the next lower Renard
pressure. For this purpose, values are
number. This results in the required MRS
obtained with a pipe-type specimen fil-
(Minimum Required Strength).
σs = ----------
and evaluated by means of the Standard
This MRS value in MPa is the basis
with C= total operating coefficient.
Extrapolation Method in accordance
for the classification. The MRS value
with ISO/DIS 9080.
multiplied
led with water at different temperatures
MRS C
the
The total operating coefficient replaces
“classification” of the material. As
by
10
results
in
the classical “safety coefficient” and considers the facts of application, the installation conditions etc.
4
PVC Pressure Pipe systems Product and Technical Guide
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Within the course of harmonisation of
1.2 Standard Dimension Ratio SDR
standards in Europe, uniform guideli-
The relation between the SDR geometrical
code
and
the
maximum
nes were also created by defining the
In the relevant regulations for plastic
permitted internal pressure in the pipes
“minimum
operating
pipes for distribution, specific pipe
important for the user is produced from
coefficient’. For PE materials primarily
applied
total
dimensions have been fixed based on
the equations:
used in the distribution industry, the
the pipe outer diameter and the pipe
minimum values for C are as follows:
wall thickness in accordance with the
σu= p x (da – e) / (20 x e)
respective pipe series. At the same time,
and
each pipe series is geometrically defined
C
by the SDR code = Standard Dimension
σv = σu ≤ σzul.
PVC-U PVC 250
Material
2.0
Ratio, whereby:
The following equation:
PVC 315
1.6
PVC 355
1.6
SDR = d / e
PVC 400
1.6
SDR = 20 x (σzul./p) + 1 If one defines, based on the PE tensile
PVC 410
1.4
or
properties for the life span of 50 years
PVC 500
1.4
PVC-O
for example, SDR = 2[s] + 1
The responsibility of selecting the C
σzul.= MRS/C
factor to be applied lies with the plan-
to calculate [s]:
ning engineer, who can/must also apply
higher values after taking into conside-
ration all relevant operating and ambient
[s] =
conditions.
The following relation is produced:
outside diameter - wall thickness 2 x wall thickness
The essential pipe series used for gas
SDR = (( 20/p) x (MRS/C)) + 1
and water distribution are described by the pipe outer diameter d and the pipe
As alternate you can use
wall thickness e.
outside diameter
SDR =
wall thickness
or
OD
SDR =
e
PVC Pressure Pipe systems Product and Technical Guide
5
2. General material properties 2.1 Polyvinylchloride PVC-U
From 2006 onwards Wavin replaced the
nated hydrocarbons, nitro compounds,
tin stabilizers by a biological stabilizer
some petrol/benzine mixtures, and simi-
Polyvinylchloride is more commonly
to further improve the efforts in enviro-
lar solvents which lead to a marked
known by its abbreviated name PVC. It
mental care.
swelling and softening of the material.
is the oldest and most common plastic, being used in many branches of the
Consideration should also be given to 2.2 Chemical resistance
industry as well as in daily life. Contrary
the effect of the fluid on the rubber ring. Unless otherwise specified, rings
to popular belief, this plastic that comes
PVC-U is resistant against most acids
of natural rubber will be supplied. Rings
from the thermoplastic group is easily
and alkalis. As a result, it is also used
compounded in neoprene and styrene
cementable, fusible, repeatedly reshape-
for storage and transport of aggressive
butadiene are also available.
able under heat, and highly recyclable.
media. That is why, PVC-U is preferred
Scrap PVC may be recycled.
in pipe constructions like:
Natural rubber gaskets are generally resistant to most inorganic chemicals,
PVC is made by polymerising vinylchloride, a gas-like monomer. Wavin pipes, fittings and valves for buried pipelines and for installations of drinking water systems are manufactured from PVC-U (PVC unplasticized) without
Drinking water main lines Drinking water supply lines Discharge lines Irrigation lines Plant construction Piping systems for the industry
including acids, alkalis including salts, together with organic acids, alcohols, ketones and aldehydes. They can be attacked by ozone, strong acids, oils, greases and many hydrocarbons however.
softener and without fillers. For indu-
Plastic pipe systems are ideal for trans-
strial applications, besides PVC-U, even
porting a wide variety of chemicals and
Where soil conditions are unknown or
PVC-C (PVC rechlorinated) is used.
are widely used in industries where con-
known to be harmful, a soils analysis
PVC-C is distinguished by a higher
veyance of highly corrosive liquids and
should be carried out to determine any
temperature resistance and is exclusi-
gases require products with excellent
likely contaminents or talk directly to
vely solvent cemented.
corrosion resistance.
Wavin.
To enable working on extruding, calan
PVC pipe systems have outstanding
Wavin provides extensive technical sup-
dering and injection moulding machines,
resistance to a wide range of chemical
port and will be pleased to assist when
additives should be added to the PVC-
reagents at temperatures up to 50 °C.
doubt exists over a product’s suitability.
U. They are lubricants and stabilizers; moreover, if the product should be dyed,
In general PVC is suitable to convey
then pigments should be added. The
most strong acids, alkalies and aque-
total of all additives is below 5 %.
ous solutions (except those which are strongly oxidising), aliphatic hydrocar-
PVC-U fittings and valves are dark grey
bons, fluorides, photographic and pla-
in color, in accordance with RAL 7011.
ting solutions, brine, mireral oils, fats and alcohols. The suitability of a PVC pipeline for conveying a given chemical
Additives
will depend on such factors as: the conMetal stabilizers are used for protection
centration of the chemical in the fluid to
against thermal decomposition during
be conveyed, flow rates, the presence of
treatment and against the effects of UV
pockets or “dead spots” in the pipeline
radiation. Wavin uses tin stabilized PVC
and other factors.
for manufacturing fittings and valves.
6
This ensures that the products can be
PVC should not normally be used with
used worldwide in the food industry,
aldehydes and ketones, ethers, cyclic
for example, drinking water applications.
ethers, esters and aromatic and chlori-
PVC Pressure Pipe systems Product and Technical Guide
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2.3 Technical data Wavin PVC-U pressure pipes are in
Identification
PVC dimensions
Wavin pressure pipes bear the following
In the pipe industry there are two dif-
signs:
ferent ways to indicate the dimension.
accordance with EN 1452. The pipes
One is the DN size (nominal diame-
are manufactured from unplasticized
Wavin, material, nominal size, nomi-
ter), which is used for iron pipes. The
PVC and are subject to the technical
nal pressure, date of manufacture (day,
second one is used for the plastics
delivery conditions for PVC-U pipes of
week, year), quality mark, standard num-
industry which is OD (outside diameter).
the Gütegemeinschaft Kunststoffrohre
ber, machine number.
The next table indicates the OD sizes
e.V., Bonn.
against the DN size for PVC pipes. Example:
Colour: Dark grey in accordance with RAL 7011.
Wavin, PVC, DN100, PN 10, 1.14.06,
DN
OD
EN 1542, 57
40
50
50
63
In accordance with the DVGW (=DIN)
65
75
agrément certificate Wavin pipes bear
70
-
the following register numbers:
80
90
100
110
K 026 – up to DN 40 K 027 – from DN 50 up to DN 150 K 028 – from DN 200 up to DN 400 Technical data for PVC pipes: Designation: PVC Density 1410
125
125
PN 10 and PN 16
125
140
PN 10 and PN 16
150
160
PN 10 and PN 16 (up to DN 300)
150
180
200
200
Typical Values
200
225
Unit
250
250
250
280
kg/m
ISO 1183
3000
MPa
3
Test Method:
300
315
ISO 527
350
355
ISO 1133 cond. 18
400
400
400
450
Modulus of elasticity (1 mm/min.)
Melt index
g/10 min
Linear coefficient of thermal expansion
0.7x10
°K
VDE 0304
500
500
Specific heat
1.0
J/g ° K
Calorimetric at 23 °C
500
560
DIN 52 612 at 23 °C
600
630
-4
-1
Thermal conductivity
0.15
W/m ° K
Min. radius of curvature
300 x dy *
at 20°C
Environmental technical properties Wavin’s pressure pipes and fittings are tested and approved according to The Environmental Agency’s demands and found suitable for conducting potable water in water supply systems. Chemical resistance Refer to DS/ISO DATA 7 “Unplasticized polyvinyl chloride pipes and fittings. Chemical resistance with respect to fluids.” *dy = outside diameter of plastic pipe
PVC Pressure Pipe systems Product and Technical Guide
7
2.4 Features & Benefits
Features and benefits
Meeting all requirements Wavin PVC-U pipes and fittings meet all the major European standards like
manufactured from unplasticised poly-
High reliability and proven service performance
vinyl chloride polymer which is a ther-
PVC-U pipes and fittings are the
Product and material certificates offer
moplastic material commonly used for
preferred piping material world-wide
the customer the highest level of qua-
potable water distribution, irrigation
for potable water supply and
lity and reliability. (See 5. Standards
systems and sewer mains.
distribution pipes.
& Regulations.)
The high strength to weight ratio, toge-
Complete plastic system Extensive range of pipes and fit-
Special projects
ther with exceptional resistance to cor-
tings.
A specialised team within Wavin is dedi-
rosion makes these pipes ideal for major
Smooth bore, free from incrustations
cated to supplying all required pro-
PVC-U pressure pipes and fittings are
infrastructure applications.
DIN8061/62, ISO4422, EN1452, etc.
ducts for large-scale pipe projects;
Maintaining a smooth internal
Wavin’s own products can be com-
Range
surface, preventing the build-up of
bined with those of other manufacturers
The lightweight pipes and fittings are
deposits. Minimum maintenance
to supply a complete package to the
available in diameters from 16 mm -
required.
customer. This team is experienced
630 mm and in pressure classes ran-
Corrosion resistant Durable and complete plastic
in arranging very large quantities of
ging from PN 6 to PN 16. Also unique tensile resistant couplers are available
system with smooth internal bore.
construction projects. Upon request
(up to 630 mm). The PVC-U pressure
technical advice and training can be
pipes are available in socketed and plain
Light weight Which makes it easy to handle and
ended lengths. They can be jointed in
install, resulting in reduced laying
these projects.
various ways. (See installation).
costs.
product “right on time” to complex
offered by Wavin experts to assist in
Reliable and durable Both, the easy rubber ring push-fit system and solvent cement ensure a tight and durable connection. Safe for potable water supply PVC-U is proven to be one of the most reliable and safe piping materials for potable water. Effective rubber ring seal joint Reduced jointing effort and improved reliability. Fields of application
High chemical resistance Wavin PVC-U pressure pipes and
The PVC-U pressure pipes and fittings
fittings are resistant to a great
from Wavin are suitable for the following
number of chemical agents.
applications: potable water distribution systems industrial process pipelines pressure sewer effluent pipelines slurry pipelines irrigation and watering systems
8
PVC Pressure Pipe systems Product and Technical Guide
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3. Apollo bi-axial PVC-O Features and benefits High burst strength Increased material strength allows
Meeting all requirements Published standards on Bi-axially oriented PVC-U are:
reduced wall thickness and therefore a reduced pipe weight per metre.
- British specification WIS 4-31-08
High impact strength Provides better protection against
- Dutch water industry specification
damage during storage, handling
(1991) BRL-K 565/01 (1998)
The Apollo pressure pipe is the result
and installation than conventional
- ISO Standard ISO 16422
of several years of research by Wavin
PVC-U pipes.
- ASTM F1483
to develop a fully Bi-axial oriented PVC
- Draft AZ/NZS 4441
pipe based on the proven properties of
esistance to low temperatures R The increased toughness allows
PVC-U. Apollo not only offers a pipe-
pipe installation at temperatures
Absolutely superior!
line material with increased strength
down
The Apollo pipe from Wavin is produced
and increased toughness over standard
to -20 ˚C.
by an unique patented in-line process.
PVC-U and polyethylene, but also a
Apollo is the first pipe to be successfully
much-improved ductility and therefore
Resistance to point loading The layered wall structure of Apollo
pipe performance. This new material
reduces the chance of premature
axial direction manufactured by a conti-
provides a water distribution pipe that
failure under point loading conditi-
nuous process.
is substantially tougher and lighter in
ons.
weight. Apollo has been developed spe-
The orientation process is based on the
cifically for potable water pressure distri-
Light weight As less material is used, Apollo
bution systems.
pipes are not only lighter than the
duce a true laminated wall structure, sig-
equivalent PVC-U pipes but are
nificantly increasing mechanical strength
Range
seven times lighter than ductile iron.
and material toughness. (See figure 1).
Apollo is available in 10 bar, 12.5 bar and
Thus an absolute winner in ease of
16 bar from 110 mm to 400 mm in diame-
handling and installation.
ter. The pipes are coloured blue or cream and Apollo is also available in black for
Improved flow performance The reduced wall thickness of
buried non-potable applications. Apollo
Apollo pipes results in a larger bore
pipes are produced plain ended or
compared to an equivalent PVC-U
with integral sockets. The Apollo pipes
pipe.
have an effective length of 6 metres.
The flow capacity is improved by
Other lengths are available on request.
approximately 5%.
A full range of standard PVC-U and
Joint integrity The Apollo on-line consistent
The increased strenght of Apollo is a
ductile iron fittings is available to com-
socketing process with ”factory fit-
direct result of the fact that oriented
plement the Apollo pipes.
ted” ring seal, eliminates the risk of
molecules can take more load.
oriented in line, in both the hoop and the
concept of stretching molecules to pro-
Figure 1. Mono-axial and Bi-axial Orientation
ring Fields of application
displacement during jointing.
Apollo is applicable for potable water pressure distribution systems. Apollo
Excellent hydraulic characteristics The non-corrosive smooth bore
can also be used for buried non-potable
maintains the excellent flow
applications such as grey water, irriga-
properties.
tion and sewer pumping mains.
Improved properties against surge and fatigue
Figure 2. Increased Strenght of Apollo
PVC Pressure Pipe systems Product and Technical Guide
9
Product details Apollo has been designed as a 10 bar pressure pipe system operating with a safety factor of 1.6 and a 16 bar pressure pipe system operating with a safety factor of 1.4. As a thin walled pipe system, pipe stiff ness is an important design consideration. Plastic pressure pipes must have a minimum stiffness of 4kPa. Stiffness is calculated using the following information: S=
Et3 12D3
E – modulus t – wall thickness Apollo socket
Apollo ring
Apollo sockets are manufactured on-
The Apollo ring seal, shown below, has
Therefore to achieve 4kPa, a minimum
line by a process which supports the
been specifically designed for use with
wall thickness equivalent to SDR41 is
socket internally, preserving hoop as
molecular oriented PVC-O, providing
required.
well as axial orientation in the socket.
a combined lip and compression seal
This method ensures the consistency of
which is firmly locked inside the pipe
socket size and eliminates the risk of ring
socket (see below).
D – mean diameter
PRODUCT SPECIFICATION Diameter
Wall Thickness
SDR
displacement during pipe jointing.
(mm)
(mm)
110
2,7
37
The Apollo process allows optimum
the rubber sealing element is designed
160
3.9
41
balance
axial
to deform, creating a sealing pressure
200
4.9
41
stretching to maintain wall thickness
acting on both the socket and spigot.
250
6.1
41
throughout the socket.
315
7.7
41
400
9,8
41
When two pipes are pushed together, between
hoop
and
Figure 3: Product specifications.
Sealing Element
Reinforcement Element
The flexible EPDM section acts
The polypropylene rein-
on both spigot and socket for
forcement bonded to the
maximum joint security.
EPDM section holds the seal firmly in place.
Figure 4: The Apollo ring seal. Figure 5: The Apollo sealing and reinforcement elements.
10
PVC Pressure Pipe systems Product and Technical Guide
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4. Standards & Regulations Wavin products meet the requirements
AII European product standards have a
The Wavin range of products is designed
of the relevant international and national
uniform structure. They consist of 7 parts
in such a way that they comply with these
standards and regulations with regard to
with the following structure:
standards. Our commitment to quality
dimensions, identification, materials and mechanical and physical properties.
and the knowledge that standards only Part 1: General
include the minimum requirements, have
Part 2: Pipes
resulted in internal quality standards at
The relevant standards can primarily be
Part 3: Fittings
Wavin, which are more or less above the
divided into three main groups, as shown
Part 4: Valves
“Norm level”.
below,
Part 5: Fitness for purpose Part 6: Recommended practice for
Norms Committees ISO International Organisation for
installation Part 7: Assessment of conformity
Standardisation. Organisation Internationale de Normalisation EN Europäisches Komitee für
ISO certification Wavin Overseas operates under a Quality Management System, which is accredited to EN ISO 9001:2000 by the Dutch
Plastic products that are used for under-
Council for Accreditation. We constantly
ground piping for gas and water distributi-
strive to enhance this QA-system in order
on, are subject to the following standards:
to improve customer satisfaction.
Normung. Comité Européen de Normalisation. European
prEN 1452: PVC in water distribution
Committee for Standardisation
prEN 12201: PE in water distribution prEN 1555: PE in gas distribution
SN,DS, National Committees for Norms UNI, DIN, BS, NF, O Norm, DVGW etc.
European product standards The harmonisation of European standards is one of the key achievements of the common European market. Technical regulations and national standards are no longer allowed to restrict the free exchange of goods and services. In the CEN (Comité Européen de Nor malisation) committees, users national associations/ organisations and manufacturers have come together to create uniform European standards. These CEN Standards will become imperative for all members of the European Community as well as for the EFTA States who voted in its favour. They may then not be overruled by a national standard.
PVC Pressure Pipe systems Product and Technical Guide
11
List of relevant standards PVC-U pressure pipe systems ISO 2045
Minimum insertion depth for push-fit sockets
ISO 2536
Flange dimensions
ISO 3460
PVC adapter for backing flange
ISO 3603
Leak test under internal pressure
ISO/DIN 4422
PVC pipes and fittings for water supply
EN 1452
Plastic pipelines for water supply (PVC-U)
EN 1456
Buried pressure drainage and sewage pressure lines (PVC-U)
EN 1295-1
Structural design of burried pipelines undervarious conditions of loading
DIN 2501 Part 1
Flange, connection dimensions
DIN 3441 Part 1
PVC valves; requirements and testing
DIN 3543
PVC tapping valves, dimensions
DIN 4279 Part 7
Internal pressure test of PVC pressure pipelines for water
DIN 8061 Part I
PVC pipes; general quality requirements
DIN 8062
PVC pipes; dimensions
DIN 8063 Part 4 Pipe joints and piping components for PVC pressure pipelines; adapters, flanges, seals, dimensions DIN 8063 Part 5 Pipe joints and piping components for PVC pressure pipes; general quality requirements, tests DIN 16450
Fittings for PVC pressure pipes; designations, symbols
DIN 16929
Chemical resistance of PVC
DIN 19532
PVC pipelines for drinking water supply
KRV A 1.1.2
Push-fit joints on PVC pressure pipes and fittings, dimensions, requirements, test
KIWA BRL K 603
Plastic gate valves of nominal sizes from 25 mm through 150 mm
KIWA Quality Specification No. 53
Couplings and fittings of unplasticized polyvinylchlorid for water pipes
KIWA Criteria Nr. 23
Injection moulded PVC-fittings with flange connections
KIWA BRLK 2013
Rubber rings and flange gaskets for potable and foul water pipe connections
EN 681
Seals (water)
WIS 4-31-07 Specification for emplasticized PVC pressure fittings and assemblies for cold potable water (underground use)
12
PVC Pressure Pipe systems Product and Technical Guide
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5. Product range PVC-U pipes PN 10 - PN 16 (EN 1452) Nominal (minimum wall thickness) Pipe series S
S 12,5
S 10
S 8
S 6,3
(SDR 26)
(SDR 21)
(SDR 17)
(SDR 13,6)
PVC-U solvent cement
Nominal pressure PN based on service (design) coefficient C=2,5 DN
PN 10
PN 12,5
PN 16
12
x
x
x
x
16
x
x
x
x
20
x
x
x
1,5
25
x
x
1,5
1,9
32
x
1,6
1,9
2,4
40
x
1,9
2,4
3
50
x
2,4
3
3,7
63
x
3
3,8
4,7
75
x
3,6
4,5
5,6
90
x
4,3
5,4
6,7
PVC-U rubber-ring joint
Nominal pressure PN based on service (design) coefficient C=2,0 DN
PN 10
PN 12,5
PN 16
PN 20
110
4,2
5,3
6,6
8,1
125
4,8
6
7,4
9,2
140
5,4
6,7
8,3
10,3
160
6,2
7,7
9,5
11,8
180
6,9
8,6
10,7
13,3
200
7,7
9,6
11,9
14,7
225
8,6
10,8
13,4
16,6
250
9,6
11,9
14,8
18,4
280
10,7
13,4
16,6
20,6
315
12,1
15
18,7
23,2
355
13,6
16,9
21,1
26,1
400
15,3
19,1
23,7
29,4
450
17,2
21,5
26,7
33,1
500
19,1
23,9
29,7
36,8
560
21,4
26,7
x
x
630
24,1
30
x
x
Note 1: The nominal wall thicknesses conform to ISO 4065:1996 / EN 1452-2 Note 2: To apply an overall service (design) coefficient of 2,5 (instead of 2,0) for pipes with nominal diameters above 90 mm, the next higher pressure rating, PN, shall be chosen. Note 3: The dimensions are in millimetres Note 4: DN = Nominal Diameter Note 5: Other pipe sizes are available on request. PVC Pressure Pipe systems Product and Technical Guide
13
APOLLO Pipe Range Nominal
Bore
Pressure
Weight per
Pipes per Bundles
Size (mm)
(mm)
Rating (Bar)
Metre (Kg)
Bundle
per Load
90
84.0
10
1.28
116
12
110
104.0
10
1.57
77
12
160
152.0
10
3.05
30
12
200
190.2
10
4.7
20
12
250
237.6
10
7.5
12
12
315
299.6
10
11.84
9
12
Note: All Apollo pipe has an effective length of 6 metres.
Wavin is able to provide you with a full range of PVC-U and/or ductile iron fittings like tees, bends and all other assecories which can be requested in PN 10 and PN 16.
14
PVC Pressure Pipe systems Product and Technical Guide
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6. Installation The jointing possibilities of Wavin PVC-U
long service life with unchanging pro-
Insert the spigot end into the socket pipe
pressure pipes and fittings are various.
perties. The push-fit connection is not
end. Chamfering is not necessary with
The possible assembly solutions are:
longitudinal force-connected. It enables
the sealing system. Jointing is easy as
connecting PVC pipes and fittings.
the rubber ring is of the low-compression
Rubber ring / push-fit jointing Solvent cement jointing
Installation is above ground and only
type.
Mechanical jointing Flanged connections
sure pipelines should be installed with
possible without pressure. Buried presabutment (for instance, according to DVGW GW 310) or with appropriate protection
against
longitudinal
movement. PVC push-fit connections are used in the following applications: Water distribution Service water systems
Figure 6.
Irrigation Pressure and vacuum
Remove the protective sealing cap both
Drainage
from the socket end of the pipe already laid and from the spigot end of the next
All sizes of Wavin PVC pressure pipes
pipe.
and fittings are supplied with a rubberring sealing system in order to make jointing as easy and secure as possible. The system is based on factory fitted, fixed rubber rings. The rubber rings on the pipes are preIubricated at the factory with a special long lasting silicone lubricant, which offers the following advantages: For underground applications the solvent cement joint is NOT recommended! The rubber ring seal joint is by far the prefer-
Correct consistency, both at high and low temperatures Waterproof No noxious substances
Figure 7.
applications.
The factory fitted rubber ring is pre-lubri-
Selection of the appropriate installation
Approved for usage in drinking water lines
red jointing technique for underground
method must be based on local circumstances.
cated with long lasting silicone lubricant. NB: When jointing to fittings do not forget
To ensure that the pipes remain internally
to apply lubricant to the rubber ring.
clean - even in the pipe trench - both pipe 6.1 Rubber ring jointing
ends are sealed by special tightly fitting plastic caps. The sealing system makes
The rubber ring push-fit connection for
jointing of both pipes and fittings easier.
PVC piping systems is distinguished by its simple and quick installation and a
PVC Pressure Pipe systems Product and Technical Guide
15
In case of pipes laid in pits the expansion and the support regulations must be taken into account. Bends, elbows, end pieces, valves, hydrants, branches etc. installed in non-positive axial pipelines must be adequately supported and anchored. The figures below indicate the necessary support. See chapter 10 Anchorage. Figure 8.
Figure 11.
Centre pipe and socket end. Ensure
…or a jack, with the bucket of the
that the spigot end is inserted in the
excavator as back bracing.
socket at the correct angle. Chamfering is unnecessary. If pipes need to be cut,
NB:
the pipe ends must be chamfered and
Never use the bucket of the excavator to
be de-burred using a rasp or scraper.
push the pipes together. The integral rubber ring joint is a nonpositive axial joint. Pipe component parts incorporating integral rubber ring joints may be laid into any soil - with the exception of not bearing soil to ground category 2.22 of DIN 18300. If the pipeline is to carry liquids of a temperature exceeding 15°C, ensure
Figure 9.
there is free thermal movement of the
Push the spigot into the socket until it
pipe within the socket.
reaches the depth of entry mark, do not over insert. This must be done manually. Use a steel crowbar if necessary. Protect the pipe end with a block of wood. Figure 10.
D1)
R
A in meters for pipe
A in meters for pipe
DN
mm
M
lengths of 6 m
lengths of 12 m
50
63
18,9
0,94
3,69
65
75
22,5
0,80
3,13
80
90
27,0
0,66
2,63
100
110
33,0
0,54
2,16
125
140
42,0
0,43
1,70
150
160
48,0
0,38
1,49
200
225
67,5
0,27
1,07
250
280
84,0
0,22
0,86
300
315
94,5
0,19
0,76
400
450
135,0
0,13
0,54
1) Outside pipe diameter If a crowbar does not give sufficient leverage, special jointing tackle (straps and hoist) can be used…
16
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
6.2 Solvent cement jointing
Tools and accessories
Solvent cement jointing calls for ade-
The following materials and tools are required for connecting pipes and fittings:
quate technical knowledge that can be acquired from appropriate training cour-
THF adhesive
Basis tetrahydrofurane
ses. We will gladly provide information
Cleaner
Basis methylene chloride
about our training sessions. Adhesive and cleaner consumption for 100 joints: The dimensions of Wavin fittings and
DN
Adhesive kg
Cleaner Litres
pipes generally correspond to the most
25
ca. 0,7
ca. 0,35
diverse national standards as well as
32
ca. 1,0
ca. 0,50
to the ISO 727. These fittings can be
40
ca. 1,3
ca. 0,65
connected with all PVC-U pipes whose
50
ca. 1,5
ca. 0,75
outer diameter tolerances conform to
65
ca. 2,0
ca. 1,00
ISO 11922-1.
80
4,0 – 5,0
2,0 – 2,50
100
6,0 – 8,0
3,00 – 4,00
The solvent cement joint is a positive
125
12,0 – 13,0
6,0 – 6,50
axial joint.
150
16,0 – 19,0
8,0 – 9,50
It is particularly recommended for:
200
23,0 – 26,0
11,5 – 13,0
250
34,0 – 37,0
17,0 – 18,50
Not bearing soils (ground category 2.22 to DIN 18300).
Lubricant consumption
Paint brush (unlacquered, natural bristles)
DN
Lubricant
DN
mm brush
50
50 joints 1 kg
Up to 25
8 mm round brush
65 + 80
30 joints 1 kg
From 32
25/3 mm flat brush
The adhesive employed is on the basis
100
25 joints 1 kg
From 65
50/10 mm flat brush
of te-trahydrofurane (THF) to DIN 16970
125
20 joints 1 kg
From 200
65/20 mm flat brush
and rule R 1.1.7 of the Gütegemeinschaft
150
15 joints 1 kg
Kunststoffrohre e.V.
200 – 250
10 joints 1 kg
In case of drinking water pipelines, the
Lubricant in tubes of 150 g, 250 g, 500 g, 1000 g.
Pipes laid in ducts and pits. Underwater and bridge pipelines.
adhesive must also be in accordance with DIN 19532. The adhesive supplied
Absorbent, non-fibering, uncoloured paper
by Wavin meets these requirements.
Brush socket Plastic pipe cutter or saw Chamfering device or file cut 2, medium Shaver Soft pencil Jointing tackle
from DN 150 recommendable
from DN 200 required
Note: for larger pipe dimensions, please contact Wavin for the consumption of adhesive, lubricant and cleaner.
PVC Pressure Pipe systems Product and Technical Guide
17
Preparations
a perfect seal, should never exceed 0,6
Pipe must be cut off at right angles.
mm with a dense-type adhesive and 0,3
Cut by means of a fine toothed saw or a
mm with a fluid-type adhesive. In order
suitable plastic pipe cutter. Utilise ade-
to obtain a perfect joint, it is recommen-
quate devices to make certain that the
ded that the adhesive manufacturer’s
pipe end is square to the pipe axis.
instructions be strictly followed.
Remove any burr or unevenness from
Wipe the pipe end and the socket with
the sawn-ends by means of a shaver
a clean cloth. Clean the outside of the
or an arm file. Carefully chamfer the cut pipe ends prior to jointing, as illustrated
pipe end and the inside of the socCutting the pipe to length.
in the sketch below.
ket thoroughly with PVC-U cleaner and absorbent paper. Use a fresh piece of paper each time. Cleaned areas must be dry before the cement is applied. Remove any condensation, which may have formed on the parts. The cleaner should dissolve the pipe surface. Check if the PVC-U is actually dissolved. If not, then roughen the surface using abrasive cloth k 80 and clean again.
Chamfering the pipe. Storage Pipe outer diameter mm B
Adhesive and cleaner must be stored in
6-16 mm
1-2 mm
a cool and dry place. Pay attention to the
20-50 mm
2-4 mm
maximum storage time of the adhesive
63 mm 20 m Wat.Col. OK
Necessary pressure at consumer: 2 bars (20 m Wat.Col.)
[Qm] x 24-hour ft
Using the pipe dimensions below the
Maximum consumption per hour = 2,5 x Qmax
where Qmax = avarage daily consumption
Pressure at station A is measured at 3.5 bars (35 m Wat.Col.)
persons per household 4
= hour factor
Where normal types of housing are hours/pe and fd at 2. This gives a Q
max
Main line
involved, Qmax can be set at 200 I/24 of
200 x 2 = 400 l / 24 hours/pe. For normal types of housing ft
max
is set at 2.5.
10 houses
A
C
8 houses D
15 houses
B
500 m
50 m
650 m
200 m
Figure 20: Diagram of pipeline in example.
Section
Pressure loss
Pressure loss of
Quantity of water (l/s)
Length (m)
Pipe-dimension (mm)
M Wat.Col./km)
section (m Wat.Col.)
A-B
1,52
500
Ø 63
15
7,5
B-C
1,06
650
Ø 63
7
4,6
C-D
0,37
250
Ø 63
3,7
0,9
Sum
13
Table: Example of dimensioning diagram for calculation of pressure loss.
PVC Pressure Pipe systems Product and Technical Guide
31
32
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
Determination of the required spring
Because of the pipe elasticity the linear
arrangement, linear
leg length in case of a linear
expansion ∆I can be cushioned by sprin-
expansion calculation
expansion of ∆I.
ging of pipe section a.
When laying PVC-U pipes, the following
Base your determination of the spring
The values given in the table for the
have to be taken into account:
leg length (a) on the higher figure, in this
springing resulting from the linear expan-
instance 4 mm. The required spring leg
sion ∆I must not be exceeded.
7.1 Piping design, pipe
- linear expansion
length (a) de-pends on the outside pipe
- pipe clip or bracket arrangement
diameter (d) and on the linear expansion
- wall and ceiling transition
∆I.
- installed pipe protection - connection of water heaters
If in our example the outside pipe diameter (d) is 50 mm, the required spring
Linear expansion
leg length (a) is 500 mm in case of the
When calculating linear expansion consi-
maximum linear expansion of ∆I = 4 mm
der the following conditions:
as can be seen from the table below.
1. The ambient temperature 2. The lowest and highest pipe wall temperature to be expected Linear expansion is 0.08 mm per m and per K (Kelvin) change in temperature and can be calculated as follows:
Springing pipeline
Linear expansion
DN
Linear expansion (mm) = pipe length (m)
I (mm)
x temperature difference (K) x coefficient
10
16
14
31
55
86
of linear expansion (0.08).
15
20
11
25
44
69
∆I = L x ∆T x 0.08
20
25
9
20
35
55
25
32
7
15
28
43
62
32
40
5
12
22
34
50
Example of calculation:
40
50
4
10
18
27
40
70
Pipe length: 5m
50
63
8
14
22
32
55
Lowest pipe wall temperature
65
75
6
12
18
27
47
to be expected: +5°C
80
90
5
10
15
22
40
100
110
4
8
12
18
32
Ambient temperature
125
140
6
9
14
25
whilst
150
160
5
8
12
22
installing: + 10°C
200
225
4
6
9
15
Temperature difference = 5 K
Spring leg length
a (mm)
1000
1250
1500
2000
500
750
Highest wall temperature to be expected: + 20°C Temperature difference = 10 K Maximum shortening to be expected: ∆I1 = 5 m x 5 K x 0.08 mm/mK = 2 mm Maximum elongation to be expected: ∆I2= 5 m x 10 K x 0.08 mm/mK = 4 mm
PVC Pressure Pipe systems Product and Technical Guide
33
Intermediate data can be seen from the
Between two fixed points linear expan-
the following table in order to prevent
following diagram.
sion can be absorbed by changes of
the pipeline comprising bellow expan-
direction, expansion bends or bellow
sion joints from buckling.
expansion joints. It may be necessary to provide contiClip or bracket arrangement in case of
nuos pipe support if the ambient tempe-
changes of direction.
ratures or the temperatures of the liquids
Pipe installation between two fixed
are high.
points. Steel or aluminium angles or U-profiles as well as sheet metal semi-shells are suitable. Clip and bracket
Splitting up the linear expansion By providing fixed points in case of
arrangement Fix the pipeline in such a way that linear
Use only bellow expansion joints the
longer pipe sections linear expansion
expansion is not interfered with. Arrange
inherent resistance of which is low.
can be split up and thus - related to the
the pipe clips, brackets and fittings in
single sections - better absorbed.
such a way that it is possible for the pipe to spring. Clip or bracket arrangement in case of branches. Arrangement of fittings in case of
To give an example: rubber bellow
branches.
expansion joints are suitable. The bellow expansion joint position is dependent on the linear expansion worked out. Observe the clip and bracket centres of
Clip and bracket centres in cm for horizontal and vertical installations at temperatures of 20 to 60 °C.
34
Horizontal
DN
d
20 °C
30 °C
40 °C
10
16
75
60
40
Continuous
80
15
20
85
70
50
support
90
20
25
90
75
55
45
30
100
25
32
100
85
65
50
35
120
32
40
110
100
80
60
40
140
40
50
125
115
95
70
45
160
50
63
140
130
110
85
55
180
65
75
150
140
120
95
60
200
80
90
165
155
135
105
70
220
100
110
185
175
155
120
80
240
125
140
215
205
185
160
110
250
150
160
225
215
200
170
130
250
200
225
250
240
225
200
160
250
PVC Pressure Pipe systems Product and Technical Guide
50 °C
60 °C
vertical
Phone. +31(0)38 42 94 951
Wall and ceiling ducts
Not upholstered pipes
Pay attention to DIN 1988.
Immediate bedding of the pipe is allo-
7.2 Longitudinal expansion and contraction of plastic pipes
wed if the change of temperature during Well laying
service does not exceed 10 K.
In case of rising mains passing through
Plastics have a comparatively high coefficient of linear heat expansion, which
wells take care to allow for the branch
Take care that the pipe is well bedded
should be taken into account when lay-
pipe of floor branches to spring suffi-
and that hollow spaces are avoided. The
ing plastic pipes.
ciently. This can be ensured by suitably
mortar must not be too lean (cement
placing the rising mains in the well (1),
mortar mixture 1:3 to 1:4) so that forces
Pipe with socket joints do not normally
by providing a sufficiently di-mensioned
occurring due to temperature changes
require special measures to be taken
branch liner (2) or by installing a spring
can be led off into the wall without
regarding expansion caused by tempe-
leg (3).
causing plaster gaps. The people in
rature changes, as each socket acts as
charge of the bedding should be instruc-
an expansion piece.
ted accordingly. Examine whether this method of installation is feasible within
However, in the case of a long section of
housing spaces for reasons of noise
adhesive-jointed PVC pipes, the whole
control (DIN 4109).
section will behave as a single long pipe. Expansion or contraction will thus be
Installed pipe protection
concentrated and the whole section will
Protect exposed pipes from impact and
expand or contract.
shocks. When installing potable water pipes ensure that the pipe wall tempe-
Formula 2
rature does not exceed 30 ˚C. This is particularly important if there are parallel or crossing warm water or heating pipes.
∆L
= ∆t x L x α
where ∆L = longitudinal expansion/con-
Industrial pipes are to be protected from
traction [m]
out-side heat. If welding, burning or soldering works are being carried out near
∆t
= T1 - T2 [°C]
the pipe system, protect it by means of asbestos sheet, for example.
T1
= stable soil temperature
T2
= temperature of pipe when laid
Connection to water heaters
L
= length of section [m]
A thermal resistant pipe of a minimum
α
= coefficient
length of 0.5 m must be fitted to the
of
linear
heat
expansion
water heater safety group. Installation of buried floor pipes Upholstered pipes Wrap a felt or similar strip around the entire pipe length. Put elastic materials (glass wool, rock wool, cellular or similar materials) around fittings and spring legs at tees, angles and other changes of direction in order to allow free linear expansion.
PVC Pressure Pipe systems Product and Technical Guide
35
Use of plastic pipes at temperatures exceeding 20°C
Q = water discharge [m3/s ]
7.3 Hydraulic Flow:
Di = internal pipe diameter [m]
Frictional Losses
I = frictional loss [m/m] [number] Where circumstances require that the
Formula
normal maximum operating temperature
Water
of a pipe be exceeded, the reduction in
ted according to the Colebrook-White
k = 0.00001 m
pressure necessary to obtain the same
formula:
for diameter > 200 mm
flow
k = frictional resistance [m] diagrams
are
calcula-
service life as at a 20°C operating tem-
k = 0.00005 m
perature can be calculated from the
Formula 4
diagram below.
The curves are designated by trade 0.74 k
Formula 3 PNt
= PN x Ct
for diameter ≤ 200 mm
name (external diameter) but calculated
Q = -6.95 x log ( + ) x Di 2 x √ Di x I
according to the internal pipe diameter
making it possible to read the capa-
Di x √ Di x I x 106
3.71 x Di
city of the pipes direct without having to interpolate between the curves. From the diagrams the frictional loss of the plastic pipe itself appears. Individual resistances such as bends, valves, reducers, tees, inlet and outlet taps etc. are not taken into account. For most water supply projects the different individual resistances will normally not be calculated. In such a case 2 - 5% is added to the frictional loss of the pipeline. High Water Velocity For projects with much higher water velocity or projects for which a detailed calculation of different individual resistances is desirable the following formula can be used: Formula 5
v2
∆H = ζ x –––
2g
where ∆H = pressure head loss(m)
ζ = resistance (number)
v = velocity (m/s)
g = gravity = (9.81 m/s2)
If the ζ -values of our products are Diagram – Permissible operating pressure at temperatures exceeding 20°C
36
PVC Pressure Pipe systems Product and Technical Guide
required please contact Wavin.
Phone. +31(0)38 42 94 951
7.4 Water Flow Diagram for Wavin PVC Pressure Pipes PN10 The curves are calculated according to the inside diameter of the PVC pipes.
PVC Pressure Pipe systems Product and Technical Guide
37
7.5 Pressure Variations
Rapid filling of a pressure pipe line and
Where pressure rises occur infrequently,
variations between trapped air masses
e.g. pressure testing, power failure etc.,
Water Hammer
may also cause sharp rises in pressure.
the permissible maximum pressure may
Each time the rate of flow in a pipe
Pipe lines should therefore be designed
exceed the nominal pressure by 50%.
system changes, a pressure wave is
to allow bleeding wherever required and
created. This can result in such large
filling speeds should be kept low.
variations in pressure as to cause a
For PVC pipes it furthermore applies that where pressure rises occur frequently
water hammer, which may exceed the
The speed of the pressure wave depends
(maximum 106 instances in a 50-year
permissible load on the pipes (force
on the pipe material, wall thickness and
period) the permissible maximum pres-
acting upon it).
the substance carried by the pipe.
sure may exceed the nominal pressure
In pump systems changes in the rate of
Pressure class
PVC
not result in a pressure amplitude higher
flow can occur in the case of e.g. power
PN
a [m/s]
than 30%.
cut, sudden blockages, rapid closing of
16
444
valves etc. If this takes place at one end
10
362
of a long pipe line, the pressure waves
8
327
will rebound from the other end and
6.3
-
may cause damage when they return to
6
288
their point of origin - particularly if this
5
263
end is completely shut off and the incre-
4
237
by 25%, but such pressure rises must
In case of doubt please contact Wavin.
ased pressure cannot escape. The risk of water hammer may necessitate the
The following pressure wave speed
installation of devices to minimize
values a [m/s] apply for water carrying
the effect of the pressure waves and
(incl. waste water) Wavin pipes:
will often require special operating nstructions.
All known materials show to a varying degree a tendency to suffer fatigue when
There is ample technical literature
subjected to dynamic forces. Incidences
available on the subject. Comprehen
of water hammer will therefore reduce
sive guidance is given on calculation
the service life of the pipes - the extent
methods but these are both complica-
of such reduction depending upon the
ted and time-consuming. However, data
composition of the dynamic forces i.e.:
Figure 21: Example of variation in pressure.
programs have been produced which plicated problems. In compiling these
The duration of the pressure rise The maximum value of the above
programs, information concerning the
compared with the level of the static
special characteristics of the pump,
mean stress
pressure head and torque, the valve clo-
The time interval between rises in pressure (frequency) etc.
are able to solve even the most com-
sure, the air valves and various designs of the longitudinal profile etc. has been included. As a result there is a risk of
The following permissible pressure rises
pressure variations, rates of flow, vibra-
apply for pressure pipes used in water
tion frequencies, volumes of air valve
supply systems:
and pressure changes along the pipe line as a function of time.
38
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
8. L aying instructions European standard EN 1452-6 “Plastic
The back fill must conform with the
In case of descending gradients the
piping systems for water supply” gui-
requirements placed upon it by the type
stonefree layer must be prevented from
dance for installation applies for the lay-
of construction (road, pavement or the
being washed away by concrete or clay
ing of pressure pipes.
like) above the pipeline.
stoppers. Drainage might also be advisable.
The standard lays down that a pipeline
The standard states that the soil cove-
should be located at such a distance
ring (hd) must not be less than 0.6 m
from other pipelines and installations that
where the pipeline will be exposed to
it causes no damage to these and allows
traffic load, unless special measures
the repair of other installations. Reference
are taken. In view of the requirement
should be made to the standard for the
that pipelines are laid in frost-free soil,
distances in question. Requirements are
pipelines carrying, e.g. potable water,
also attached to the design of the pipe
are normally laid with a 1.1 m soil cover.
Concrete stoppers
trench. The levelling layer must be laid or loosened and subsequently levelled so
Pipe trench
that the pipes are evenly supported.
The depth of pipe trench should be such
In case of changing layers and conse-
that all pipe component parts can be
quently changing soil bearing capacity of
The side fill layer must provide ade-
perfectly laid below the frost line (mini-
the trench bottom, provide an adequate
quate side support for the pipes and it is
mum depth of cover 1.0-1.8 m accor-
fine gravel or sand filling (approximately
therefore important that this layer is
ding to climate and soil conditions). It
10xd) at the points of transition. Should
compacted, e.g. by stamping with the
the ground is rocky or stony the trench
there be parallel or crossing other pipe
foot.
bottom should be lowered by at least
conveying warm liquids, then care must
0.15 m and the excavated earth replaced
be taken that the PVC-U pipe’s surface
by a stonefree layer (sand, fine gravel).
temperature does not rise above 20˚C.
The pipe trench is to be in accordance
Back-filling
with DIN 18300, DIN 18303, DIN 4124
Filling of the trench is to be done in lay-
The particle size must not exceed 16 mm
sheet 1 and DIN 19630.
ers up to a depth of approximately 0.30
In case of stony or rocky ground: provide
m above the top of the pipe, utilising
he content of particles of between T 8 and 16 mm must not exceed 10%
a stonefree layer of 0.15m.
stonefree soil and stamping carefully by
The materials employed for the levelling layer and the side tilt must meet the following criteria:
hand. If necessary, suitable soil must be
The material must not be frozen Sharp flints or other crushed
procured.
material must not be employed
Figure 22. Diagram of trench design
D1)
R
a in m for pipe lengths of
DN
(mm) M
6 m
12 m
50
63
18,9
0,94
3,69
65
75
22,5
0,80
3,13
80
90
27,0
0,66
2,63
100
110
33,0
0,54
2,16
125
140
42,0
0,43
1,70
150
160
48,0
0,38
1,49
200
225
67,5
0,27
1,07
250
280
84,0
0,22
0,86
300
315
94,5
0,19
0,76
400
450
135,0
0,13
0,54
1) Outside pipe diameter.
PVC Pressure Pipe systems Product and Technical Guide
39
If the pipe temperature is considerably
4) It should be possible to connect a
Procedure for Pressure Testing of
higher than the trench temperature due
filter socket in the lowest point and
Pipe Systems
to solar radiation, then put first a thin
ventilation (air escape) in the summit
Below is the procedure for pressure tes-
layer of stonefree soil on to the pipe prior
to the starting and end points of the
ting of pipe systems. The procedure is
to final back-filling in order to achieve
line respectively.
in accordance with the standard of the
stressfree laying. Pay attention to pipe
5) Bends, tees, reducers, valves, end
Danish Engineers Union: ‘Tightness of
movement resulting from temperature
caps etc. should be anchored for the
underground sewer systems” DS 455,
differences.
increased testing pressure.
1st edition, January 1985.
6) The demands placed by the owner on Final back-filling is then to be effected.
possible pressure testing should
Before pressure testing the following
Mechanical rammers can be used after
appear from the project description
must be observed:
the prescribed dumping height has been
enabling the contractor to take the
1) End caps are mounted on all ends of
reached.
necessary measures for pressure
the system. The end cap can be an
testing.
end socket or a blank flange. A 90˚C
Special measures
7) Choice of pipe and fitting material
bend, a ball valve and a 32 mm
If district heating pipelines are crossed,
should be made under reference to
tensile resistant coupler are mounted
the PVC-U pipes must be protected from
EN1555/12201/1452
on the end cap, for mounting of a
heat. DIN 19630 refers.
32 mm PE pipe. When the above conditions have been
2) AII end caps must be anchored.
fulfilled the next step is the practical
3) The system must be filled with water
accomplishment of the job, and here
at least 24 hours prior to the start
Pressure Testing of PVC-U
the following points may contribute to
of the pressure test. Ensure that the
Pressure Lines
problem-free pressure testing:
8.1 Pressure Testing
It is possible to pressure test a PVC-U
system is entirely ventilated. 4) During the first 6 hours the pressure in the system must be 1.3 x the
(taken over by the client).
Correct transport, storage and handling of pipes and fittings
important in order that the result of
Pressure testing is carried out accor-
Correct excavation, laying, filling and compaction Correctly used jointing components and methods
the test must be documentable to the
pressure line, before it is put into service
ding to DS 455. It pressure testing is requested, it should form part of the project, and here the following conditions should be observed:
the test is not misleading. This part of inspection authorities. 5) There must be access to water on
It is highly important that above mentioned rules are observed as they will
1) The longitudinal profile should be
nominal pressure class. This is very
influence the final result of the project.
the testing site. 6) Pressure testing against a valve is at your own risk.
projected with a slight upward incline for ventilation purposes. 2) A form of ventilation (manual - automatic) should be installed in all summits - correct installation of ventilation: In the direction of flow a little below exact summit. 3) Barring procedures should be established enabling pressure testing of the line by stages.
During pressure testing the following is to be observed: 1) The actual pressure is measured and water is added to the system if required. 2) The system is exposed to a pressure corresponding to 1.3 x the nominal pressure class (testing pressure). 3) This pressure is maintained for 2 hours. Supplementary filling of water is allowed.
40
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
4) During the following 60 minutes water must not be added.
The following table takes into account the test pressure of 1.5x nominal pressure. Axial forces P and resultant forces R for 10 bar working pressure pipelines.
5) After 60 minutes the pressure is
D1)
the pressure is again 1.3 x the
DN
(mm)
(N)
nominal pressure class
50
63
(testing pressure).
65
75
80
of water added must not exceed the following limits:
measured and water is added until
P
R(N)
11º
22º
30º
45º
90º
4579
882
1765
2353
3530
6472
6492
1225
2500
3383
4952
9218
90
9365
1765
3579
4854
7207
13238
100
110
13974
2696
5393
7256
10787
19809
125
140
22653
4364
8678
11767
17455
31969
150
160
29518
5687
11277
15396
22653
41776
200
225
58447
11179
22359
30302
44718
82375
250
280
90515
17357
34617
46973
69627
128467
a) pressure drop in percentage of initial
300
315
114541
21966
43737
59428
87769
162790
pressure = 2%
400
450
233888
45895
91201
121602
179461
331464
b) water quantity in litres/metres =
1) Outside pipe diameter
6) The fall in pressure and the amount
Formula 6
0.02di - 0.001 + ∆V Axial forces P and resultant forces R for 16 bar working pressure pipelines. ∆V = 0.05 x d2 for PVC pipes
D1)
di = inside diameter
DN
(mm)
50 After pressure testing the end caps are
65
demounted.
∆V = 0.08 X d2 for PE pipes
P
R(N)
(N)
11º
22º
30º
45º
90º
63
7325
1412
2824
3765
5648
10355
75
10385
1961
4001
5413
7923
14749
80
90
14984
2824
5727
7766
11532
21182
100
110
22359
4314
8629
11611
17259
31695
125
140
36245
6982
13886
18828
27929
51151
150
160
47228
9100
18044
24634
36245
66842
200
225
93516
17887
35774
48484
71549
131801
250
280
144824
27772
55387
75158
111403
205547
300
315
183266
35147
69980
95085
140431
260464
400
450
374221
73432
145922
194563
287138
530343
1) Outside pipe diameter
Figure 23. Diagram of pressure testing of pipeline.
PVC Pressure Pipe systems Product and Technical Guide
41
9. Anchorage The size of the axial force depends on
Formula 8
Anchorage of bends
the dimension and working pressure (testing pressure) of the pipe line and is
The resulting force for bends can be N = p x N1
calculated as follows:
where N1 = axial force at 1 bar [kN]
Formula 9 α R = 2 x N1 x p x sin —
calculated as follows: Formula 7
π x dy2 x p
p = max. pressure occurring
N = ———————
in pipeline [bar] possibly
testing pressure
104 x 4
2
where N1 = axial force at 1 bar [kN] (table 7)
where N = axial force [kN]
dy = external pipe diameter [mm]
p = max. pressure occurring in
p = max. pressure occurring in pipeline [bar] possibly
pipeline [bar] possibly testing
testing pressure
pressure
Anchorage of tees, end caps and
PE
valves
α = angle of bend [degrees]
R = resulting force [kN]
Fittings exposed to shearing forces caused by internal water pressure, e.g. bands, tees, end caps, reducers and
Figure 24: Diagram showing
valves must be anchored. The shearing
anchorage of tee.
Angle α 11˚ 22˚ 30˚ 45˚ 60˚ 90˚ k 0.19 0.38 0.52 0.77 1.00 1.41
force which the anchorage is intended Table of angle constants.
to withstand can be easily calculated by using the figures in the below table in the following simplified formula:
The resulting shearing force which the anchorage is intended to withstand can
Outside
42
Axial force at 1
be easily calculated by using the figures
diameter [mm]
bar N1 [kN]
40
0.13
50
0.20
63
0.32
75
0.45
90
0.64
110
0.95
125
1.23
140
1.54
160
2.00
200
3.15
225
4.00
250
4.90
pipeline [bar] possibly
280
6.16
testing pressure
315
7.80
400
12.60
500
19.60
630
31.20
in the tables in the following simplified formula: Formula 10 Figure 25: Diagram showing anchorage of tee.
PVC Pressure Pipe systems Product and Technical Guide
R = k x p x N1 Where k = constant for resulting force (see table of angle constants)
p = max. pressure occurring in
N1 = axial force at 1 bar [kN]
Phone. +31(0)38 42 94 951
Anchorage block
Formula 11
Now the size of the concrete block can
be calculated by using formula 11:
R
b= h/
σ earth
where b = width of anchorage [m]
b=
R
hx
σ earth
h = height of anchorage [m]
σ earth is estimated at [kN/m ] 2
The height is estimated at:
R = resulting force [kN]
h = 0.2 (height of pipe)
σ earth = permissible earth
The minimum width must then be:
pressure [200 kN/m2]
Figure 26: Diagram of anchorage of bend.
It is a condition for the strength of the
21.83
b =
= 0.55 m
anchorage that the concrete is cast 0.2 x 200
against a solid wall of the pipe trench. It may, however, sometimes be necessary to cast against carefully compacted fill.
Anchorage of reducer
In such case account should be taken in the calculations of the lower strength
The axial force for reducer is found by
of the fill. The fitting in question must
means of formula 12:
be protected from the damage by the Figure 27: Diagram of anchorage of
concrete by an intermediate layer of e.g.
Formula 12
plastic film before casting takes place.
bend.
π x (dy21 x dy22) x p
N= Example of anchorage of bend
104 x 4
Conditions:
where dy21 = the outside diameter [mm]
paid to the permissible earth pressure,
- Ø 200 x 45º PVC pressure pipe bend
which in each individual case has to be
- Testing pressure (maximum pressure)
When calculating the area necessary for the determination of the size of the anchorage, due consideration has to be
of the largest pipe
determined by geotechnical surveys. In
dy22 = the outside diameter [mm] of the smallest pipe
9 bar
most cases it is sufficient to use the following formula:
Formula 10 is applied as follows:
σ earth
R = k x p x N1
= 200 (kN/m2)
The person in charge of the project should always make an appraisal of the
where k = 0.77 according to table of
relevance of this value.
angle constants
This width of an anchorage can then be
calculated by means of the following
formula:
p = 9 bar N1 = 3.15 according to table of the previous page
Figure 28: Diagram of anchorage of reducer.
The resulting force will then be:
R = 0.77 x 9 x 3.15 = 21.83 kN
PVC Pressure Pipe systems Product and Technical Guide
43
Example of anchorage of reducer Conditions: - Ø 200/110 PVC reducer - Testing pressure (maximum pressure) 9 bar which is inserted in formula 12:
π x (2002 - 1102) x 9
N=
104 x 4
N = 19.72 kN The anchorage (concrete block) is calculated as follows:
h = (is estimated at) 0.2m
σ earth
= (is estimated at) 200kN/m2
N
b= hx
σ earth
19.72 b= 0.2 x 200 b = 0.49 m
Figure 29. Diagram of anchorage of reducer.
44
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
10. Handling and Storage Handling plastic piping systems
Figure 31 Bearers must be placed on the truck body.
Wavin pressure pipes are supplied in
Support the full length of the load.
pre-packed bundles to ensure adequate
Always load and unload properly.
protection during transport and storage.
Do not tip or throw the pipes from
The pipes are supplied with end caps
the carrier.
protecting the pipes effectively from dirt entering the pipes.
Handling on site Figure 32 Small-diameter pipes can easily be carried without the use of auxiliary equipment.
Figure 33 Figure 30: Pipes should be handled and stored in bundles as delive-
Do not drag the pipes across the ground and avoid sharp edges.
red from Wavin for as long as possible.
Transport Vehicles for transporting pipes should
Figure 34
be selected in such a way that the
Small-diameter pipes can be
pipes lie completely on the floor of
manually placed in the trench.
the vehicle, without jutting out of the vehicle. Sagging is to be prevented. Impacts are to be avoided under all circumstances, particularly at temperatures near the freezing point. To protect the pipes and fittings from damage,
Figure 35
they should not grind against the load
Pipes in larger diameter may
area of the vehicle or against the floor
necessitate slings. Always use at
of the vehicle during transportation.
least 2 slings.
Pipes and fittings should be loaded and unloaded with extreme caution and care. If hoists are used, then pipe components may not be thrown from the vehicle into the storage area. Figure 36 Larger diameters may necessitate a special lifting bar.
PVC Pressure Pipe systems Product and Technical Guide
45
Storage
pletely protected from the effects of oil,
Storage areas for pipes should be
solvents and other chemical substances
without gravel and plain. Storage and
during the storage period. The area
stock heights should be selected in
where the pipes are to be placed should
such a way, as to avoid damages or
be covered with sheeting or cardboard
permanent deformations. Pipes with
(including the side supports) in order
large diameters and small wall thickness
to avoid damage caused by protruding
should be equipped with circular stif-
rivets and nails.
feners. Point and line supports for the pipes should be avoided.
The influence of weather on stored pipe components should be kept to a mini-
The recommendation for the permitted
mum, i.e. the pipe components should
stacking height for PE pipes not stored
be kept in a warehouse. If the pipes
on pallets is 1 m. Pipes should be
are stored in the open (construction
stacked in layers with sockets placed
sites), then they should be covered with
at alternate ends of the stack to ensure
coloured or black sheeting to protect
their support along the entire length.
them from the influence of weather (for example, UV rays). Wavin PE fittings and valves are packed in PE plastic bags to protect them from ultraviolet radiation and dust. We recommend removing the pipes from the packing only shortly before installation. Moreover, one-sided heat exposure caused
Figure 37. Loose pipes with sockets
by
sunshine
can
lead
to
deformations in the pipes.
must be stored socket end/ spigot end alternately to
Maximum permitted storage periods
prevent pipes from resting on
should be adhered to (for example,
the sockets.
DVGW). The pipe components should be used in the order of their manufacture
If the pipes are stacked on pallets
and delivery to ensure appropriate stock
and are secured against lateral move-
turnover.
ments, the stacking height can be increased to 1.5 m. When spacing the pipes the bearing width of the supports and timbers respectively must be at least 7.5 cm. The distance between the supports and timbers respective-
Note 1: PE pipes should read PVC pipes.
ly should be 1-2 m. The outer sup-
Note 2: Rubber rings will be supplied in plastic bags
ports and timbers respectively are to be
The area where pipe components are stored should provide as much protec-
1,50 m
arranged 0.5-1.0 m from the stack end.
tion as possible. Pipes should be com-
46
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
11. Notes This document gives units of the interna-
Dimensions and units
tional system (SI), e.g. the unit for force Newton (N) instead of pond (p) and the
Dimensions are indicated in mm and/or
unit of power Watt (W) instead of kcal/h.
inches and are specified as nominal or standard sizes.
Conversion: 1 kp
1 Mp
d, d1, d2, d3, d4 Diameter
= 9.80665 N or 1 kp ≈ 10 N
= 9806.65 N
or 1 Mp ≈ 10 kN
and 1 Mp/m = 10 kN/m
DN Nominal diameter SC Size of hexagonal bolts AL
Number of screw holes
s Width across flats of hexagonal bolts
1 kp/cm2 = 9.80665 N/cm2 =
g
Weight in grams
0.0980665 N/mm2 =
SP Quantity per standard pack
0.0980665 Mpa or
GP Quantity per large pack
1 kp/cm2 ≈ 0.1 N/mm2
e
Pipe wall thickness
1 m of water column
PN Nominal pressure
Rp Parallel internal pipe thread to
= 0.0980665 bar or 1 m of
water column ≈ 0.1 bar
1 kcal/m h degree
ISO 7-1 R Conical external pipe thread to
= 1.16 W/mK (Thermal
ISO 7-1
conductivity) or 1 kcal/m h
ppm Parts per million
degree ≈ 1.2 W/mK
1 bar = 0.1 N/mm2
= 0.1 Mpa (Megapascal)
The thermal conductivity is given in W/
= 14.504 psi
mK. One gets here identical figures for
C
Design factor
K and °C respectively as it is a matter of
S
Pipe series
temperature differences. In this sense,
SDR Standard Dimension Ratio
1 W/m °C is identical to 1 W/mK.
MFR Melt Flow Rate According to ISO 4440
K (Kelvin) is the SI unit for the temperature. The Celsius temperature (t) differs from
SDR
the Kelvin temperature (T) by 273.15 K. SDR Standard Dimension Ratio: t (°C) = T – To = T – 273.15 K.
OD / SDR = WT OD / WT = SDR
In this document, g is supposed to be 10 m/s, the fault of approximately 2%
OD = Outside Diameter
being neglected. DN means nominal
WT = Wall Thickness
diameter, PN is nominal pressure.
PVC Pressure Pipe systems Product and Technical Guide
47
Pressure system dimensions
Explanations of abbreviations
DN = Nominal Diameter OD = Outside Diameter DIN DN
48
DIN/ISO/EN
versus OD versus
Polybutylene
PE
Polyethylene
PE-X
Cross-linked polyethylene
4
6
PP
Polypropylene
5
8
PVC
Polyvinylchloride
6
10
PVC-C Rechlorinated polyvinylchlori-
8
12
1/4’’
de (increased chloride content)
10
16
3/8”
PVC-U Unplasticised polyvinylchloride
15
20
1/2”
PVC-O Oriented polyvinylchloride
20
25
3/4”
25
32
1”
32
40
1 1/4”
40
50
1 1/2”
50
63
2”
65
75
2 1/2”
80
90
3”
100
110
4”
125
125
5”
125
140
5”
150
160
6”
150
180
6”
GAS
200
200
8”
200
225
8”
250
250
10”
250
280
10”
300
315
12”
350
355
14”
400
400
16”
400
450
500
500
20”
500
560
22”
600
630
DIN
DIN DIN
DIN DIN
Inch
PB
18”
24”
PSI
BAR (PN)
Mpa
Kpa
87,08
6
0,6
600
91,44
6,3
0,63
630
108,85
7,5
0,75
750
116,11
8
0,8
800
145,14
10
1
1000
181,42
12,5
1,25
1250
232,22
16
1,6
1600
290,28
20
2
2000
PVC Pressure Pipe systems Product and Technical Guide
Phone. +31(0)38 42 94 951
PVC Pressure Pipe systems Product and Technical Guide
49
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Wavin operates a programme of continuous product development, and therefore reserves the right to modify or amend the specification of their products without notice. All information in this publication is given in good faith, and believed to be correct at the time of going to press. However, no responsibility can be accepted for any errors, omissions or incorrect assumptions. Users should satisfy themselves that products are suitable for the purpose and application intended.
1507 15-305 - July 2015
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