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The company GEMA PLAST KM Andon DOOEL was founded in 1990 and since then has operated in the

e Industrial Area in municipally of Gevgelija, Republic of Macedonia. GEMA PLAST KM is a modern industry which produces plastic hoses made of polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC) in accordance with European standards. GEMA PLAST KM is one of more famous producers of plastic hoses in Republic of Macedonia and in the Balkan area. With its big team for planning, production and installation, GEMA PLAST KM takes its participation in different fields like in technical sector, agriculture, industrial sector etc. GEMA PLAST KM reached very important positions at the Macedonian market. As the market sector in the Macedonian industry increases, the success of the company is also bigger and is based on setting a goal for high quality of its products and services, quick and service on time for all clients, respecting and protection of the environment as well as researching of new and better products. The growth of GEMA PLAST KM in one of the most dynamic firms in the industrial field of plastic in Macedonia and Balkan was based on: Modernization of production recourses of the company and employment of Stable effort for improvement of the products and services in frame of Quality Excellent service to the client during the whole course of the sale. Development of full sale net at the domestic and the markets in the area. The company was verified with certificate issued by the Ministry of Trade of specialized technical and learned potential. Management System according the standard ISO 9001:2000. -

Republic of Macedonia for using the mark of the campaign For our sake Made in Macedonia Buy Macedonian products. INVESTMENT PROGRAM The main office of the company GEMA PLAST KM is located in the industrial part of Gevgelija, on its own property of 6000m2 of which 3000m2 are buildings which include offices, production capacities and warehouses. At the beginning of the year 2000, the company successfully projected one very ambitious investment program which is expected to be finished financially and also with the investment till 2005.The following activities are included in this program: increasing of the production and modernization of the production capacities and production of new products, concrete introducing of production line System drop by drop.
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INTRODUCTION

The results which are expected are the following: The investment project for production of hose for irrigation by system drop by drop which is first of this type in our country is in its final phase. This project is financially supported by the Ministry of Economy of USA through PRIZMA Partners for local economic development in Macedonia. With finalization of this project, the problem of all individual farmers with the irrigation will be solved. The machines for production of PE hoses are equipped with on-line control system, which records and notes the critical parameters for the quality of the products. The control sector is based on new high technological equipment for testing, confirming the orientation of the company for researching and development of new products. The success of the firm is also based on its working potential. The educational level and experience of the labor of the company are very important factors to insure the high quality as well as to fulfill the expectations of all clients.

SERVICES TO THE CLIENTS GEMA PLAST KM guaranties best service with its most expeditious and efficient service experience for the clients. The company offers: Full assortment of qualified products on the field of plastic mass. Certified and high-quality management system for all products and services. Efficient technical support. Competitive and market conditions for sale.

The company makes big efforts to satisfy its clients and it is based on its experience as honorable service politics. The way the company appears in front of its client, the great honor and gratitude for their confidence is one of the most important factors for the companys success. Main clients of the company are: Technical companies in Macedonia, Performers of public matters and big warehouses for sale of plastics as well as many individual farmers and other individual persons. In the last few years it was made big effort for development of the export activity in: Albania, Bulgaria and Serbia and Montenegro with successful results.

INTRODUCTION

CONTENTS
GEMA PLAST KM........................................................ 2 Products.................................................. 7 Technique .............................................. 8 Attests and certificates ................................................ 9 What is polyethylene ..................................................... 14 Specific features .................................................... 19 Production methods ................................................... 21 Polyethylene pipes ........................................................ 23 Nomogram of course ........................................................ 29 Installation instructions for pipe systems ................................................... 30 Modification of the length under influence of chemicals ........................................... 35 Chemical features .............................................. 37 Methods of connection .. ............................................... 42 Electrfusion welding of PEHD pipes and fittings ............................................... 47 Polypropylene pipes ............................................... 50 Way of creation of pipeline ............................................... 54 Compensation extensions .................................................... 57 Technical characteristics ...................................................... 61 PE 100 pipes ....................................................... 62 PE 63 pipes ..................................................... 64 PE P pipes ....................................................... 65 Adapter flansh ........................................................ 66 Cap ................................................... 67 Reducer ................................................... 68 90 TEE .................................................. 72 Elbow ....................................................... 73 Reducer gradual ............................................................ 76 Electro fused socket ......................................................... 77 Electro fused 90 TEE ...................................................... 78 Electro fused 90 TEE reducer .................................................... 79 Electro fused elbow 45 ..................................................... 80
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CONTENTS

PE 80 pipes ......................................................... 63

GEMA PLAST KM is a famous Macedonian producer of qualified products and is located in the south of Macedonia, in Gevgelija. In the 25-year existing and experience the company reached great results on the field of production of melted plastics and melted products. In the latest 10 years the company attained huge results on the field of extruding of polyethylene and polypropylene hoses and pipes.

Especially GEMA PLAST KM became famous with installation of full systems projecting, production, transport, installation of pipeline. The systems of GEMA PLAST KM satisfy the highest standards of pipe systems for water and sewerage systems and protection of the environment.

INTRODUCTION

ORGANIZATION SCHEME

GENERAL MANAGER

FINANCIAL SECTOR
RESPONSIBLE

COORDINATOR FOR THE QUALITY

CADRE SECTOR
RESPONSIBLE

PRODUCTION
MANAGER

COMMERCE
COMMERCIAL OFFICER

RESPONSIBLE FOR INSTALLATION

WAREHOUSE FOR RAW MATERIALS


WAREHOUSE CLERK

MAINTENANCE OF THE EQUIPMENT MAINTENANCE

WAREHOUSE FOR FINAL PRODUCTS WAREHOUSE CLERK

INTRODUCTION

PRODUCTS
GEMA PLAST KM offers complete assortment of products in accordance with the latest technical standards, which is based on the continuous development of PE pipelines. PE 100 PE 100 pipes are made of hard polyethylene with big density (HDPE) of the third generation MPC10 and they are used for underground nets for carrying over drinking water. PE 80 PE 80 pipes are made of hard polyethylene with big density (HDPE) of the second generation MPC10 and they are used for underground and undersea nets for carrying over water, waste water and for protection of cables, as well as for underground nets for carrying over drinking water. PE 63 PE 63 pipes are made of polyethylene with low density (LDPE) and they are used for irrigating with atomizers. PE-GEMA GAS Gema-gas pipes are made of hard polyethylene (HDPE) of the second generation and they are used for underground nets for transport and distribution of gas. PE GEMAKAN AND GEMADREN Gemakan and Gemadren pipes may be in two or three layers and they are used for sewerage systems. GEMA-TERM Polypropylene pipe systems for sanitary use indoor installation for hot / cold water, floor heating, connection of radiator systems.

INTRODUCTION

TECHNIQUES
As a result of the development of materials, there are several techniques for connect and installation of the pipes: Connecting with mechanical elements With dimensions F16 to F110mm. Training for usage is on the place of the sale of the elements. Connection with frontal welding With dimensions bigger then F110mm. It is recommended for water supply systems under pressure. They are being installed only by expert team with special equipment. Connection with covering welding - PP pipes and fittings with special tools and expertness. Electrofusion is a technique which is specially used in the gas installations. Experts and special equipment are needed.

TECHNICAL CHARACTERISTICS

As a huge recognition from the long-standing experience of GEMA PLAST KM, of course is the standard ISO 9001 : 2000 by the renowned Britain Institution for Standards BSI. Therefore GEMA PLAST KM assigned to lead the Policy for Quality and its basic principals are: Creation of working system for quality oriented to the clients in order to increase their confidence. Orientation and accommodation to the market, in order to take bigger High-quality products, in order to improve the renown of the firm. Identification and elimination of every defect which may cause loss of clients, Fulfill the needs of the employees.

participation there.

work, profit.

GEMA PLAST KM is obliged to maintain and improve the System for Quality and with that it fulfills the requests by the standard ISO 9001:2000, and also satisfies the requests of the clients.

FM 61542 ISO 9001:2000

TECHNICAL CHARACTERISTICS

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TECHNICAL CHARACTERISTICS

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TECHNICAL CHARACTERISTICS

POLYETHYLENE
In many countries the polyethylene (PE) as a material for pipes is used for transport of This material has the following advantages for the clients:

Small specific weight Flexibility Good chemical resistance Excellent welding Excellent resistance of heat Resistance to movement of the ground Smooth interior of the pipes with resistance of accumulate layer Sanitary they are correct in case of having contact with food products

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TECHNICAL CHARACTERISTICS

gas, water supply systems, sewerage systems, irrigating systems etc.

WHAT IS POLYETHYLENE
The polyethylene is thermoplastic matter which was produced with polymerization of the ethylene (C2H4), unsaturated hydro carbonate, in normal circumstances it is a gas. Structure of the ethylene molecule Structure of the ethylene molecule Ethylene gas

C - Carbon H - hydrogen

Polymerization is establishing connections between ethylene molecules in long range and it forms hard compound called polymer. Polymerization Molecule of polyethylene l l

Molecules are forming polymers and can be less or more expanded, shorter or longer, closed together or separated. These characteristics are giving the main features of the polyethylene: Density (depends of the distance between the molecules) Molecular weight (depends of the length) Molecular weight distribution (depends of the distance between the molecules and the length)

DEVELOPMENT OF THE POLYETHYLENE


For the first time the polyethylene was produced in England in 1939, when was build the first factory for production of polyethylene. Its first usage was as a material for isolation and protection of high-frequent cables during the Second World War. After the war its usage is increasing and many other features have been discovered. Since 1954 the method of Zigler has been used for production of polyethylene. Simultaneously has been developed the method of Philips.
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TECHNICAL CHARACTERISTICS

After that the polyethylene started to be used in packaging industry, and later in agriculture industry (for irrigation pipes, system drop by drop), in water supply systems (regional and community), in systems for transportation of gas, for protection of optical cables, in chemical industry and in the sewerage systems. For the first time PE material used for pipes was PE with low density (LDPE) with MPC from 3.2 MPA (PE 32). In the latest 50-ies it was presented polyethylene with high density (HDPE) with MPC 6.3 MRS (minimum required strength). This was turn over in the usage of the polyethylene for higher pressures for reduction of the thickness of the wall. As a result of the further development of the PE material in the last few years the features of PE pipes and fittings are being improved. These days the polyethylene (PE) is not classified according its density (LDPE, MDPE, HDPE), but there are several classes now (PE 63, PE 80, PE 100).

New polyethylene class PE 100


The newest development of polyethylene is the third generation of HDPE, which is qualified as PE 100. These materials are also described as MPC 10 materials. This is a new development of the polyethylene which with modified polymerization process. However PE 100 has the highest density and according to this also has improved mechanical features as increased squeeze and hardness. Consequently to this, this material is appropriate for production of hoses and pipes under pressure with big diameters and in comparison with PE 80has smaller thickness of the wall. The development of polyethylene on scheme looks like this:

PE 63

LOW DENSITY

Linear low and middle density

Middle and high density

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TECHNICAL CHARACTERISTICS

The connection between the classes of materials with the working pressures is given below:
CLASS OF MATERIALS PN IN BARS

The meaning of the formula:

- project effort SDR - standard dimension proportion = D/e (e - thickness of the wall of pipes) D diameter of the pipes MRS minimum required strength, (MPa) minimal required strength S - standard series of pipes is a number of marking the pipes according ISO 4065.

C - Safety coefficient: for water = 1.25, for gas = 2 PN - Nominal pressure NON TOXIC MATERIAL Polyethylene material is in according with the regulations and standards for materials that have contact with food.

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TECHNICAL CHARACTERISTICS

So, PE pipes and fittings are verified and registered according international standards for object that have contact with food and Macedonian health institute.

BEHAVE ON ABRASIVE FLUIDS Basically, thermoplastic pipes are better for transportation of liquid with hard particles than cement or steel pipes. We have positive experience of this use. By development method of Darmstadt, 1 m is taken as abrasive unit. Advantages of thermoplastic pipes for transportation of mixtures with hard particles into open canal can be seen by the test: Also other test shows that when the media is pumped through pipe, possibility to check behave on abrasive of that kind of system is to determine time to appearance on the hole. As it can be seen by the diagram, thermoplastic pipes (in this case PE pipes in combination with PP pipes - gives same or better results) are given with all advantages according with steel pipes. For transporting of dry abrasive fluids, only electro conductive materials can be used cause of electrostatic possibility (PE, PP-R-S, PP-R). long pipe is curled with frequency of 018 Hz. Local decrease of the wall after the loading

ABRASIVE BEHAVE ACCORDING DARMSTADT METHOD Media: Soil, sand - gravel, water - mixture 46 vol % soil, sand - gravel, dimension of particle to 30 mm.
middle abrasion

Abrasion time of HDPE and steel elbows for different radius depends on portion of the hard phase.
straight pipe

metal pipe

HDPE pipe

cement pipe

covered with MC-DUR cement pipe ceramics pipe PVC - pipe PP or HDPE pipe

Radius of the structure

GFK - pipe

Fluids, middle range water with 14% of sand Density 1.07, 1,15 kg/l

numbers of alternative load

Time of abrasion in hours till hole appears

UV RESISTANCE Polyethylene pipes are UV protected as a result of content of UV stabilizer - active smoke with quantity max. 2,5%.
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TECHNICAL CHARACTERISTICS

MAIN FEATURES - TECHNICAL CHARACTERISTIC OF POLYETHYLENE Main physics characteristic of polyethylene

Characteristics Density on 23C

Standard

Unit

earlier PEHD middle density

earlier PEHD

Deterioration pressure on straining Deterioration and straining Deterioration pressure on breaking Deterioration on breaking
Mechanical characteristics

Curling pressure on 3,5% deformation Elastic module Cutting module Hardness on ball mark

Value of hit by Sharpie on 23C with cut Fusion temperature on crystal structure
Softness temperature by Vacate

Bending temperature on load

Method A Method B Thermo conductivity (on 20C) Thermo expansion coefficient Inflammability

Electric characteristics

Specific resistance Dielectric intensity Surface resistance

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TECHNICAL CHARACTERISTICS

Flowing index

Thermal characteristics

The pipes made of PE may be rolled up in contour with big pulleys, they can be easily curved because of their flexibility, and as a result of that the time needed for installation of fittings and the time needed for installation is decreasing. Thanks to the small weight, the pipes are easy for handling and they reduce the lasting usage. In our country the usage of PE pipes started before 10 years. At the first time they were used in the agriculture, and then in the latest years their usage is being more intensive especially on the field of water supply systems. The industrial complexes use them because of their resistance on chemicals. GEMA PLAST KM from Gevgelija is the only firm with its presence on the market with pipes from the latest generation of polyethylene PE 100 which enable thinner wall of the pipes and also increasing the strait for 33% and working pressures to 32 bars. They are corrosion-resistant which enables long lasting. In the last 5 years they are used in Macedonian Telecommunications, through the pipe for protection of optical cable. Gas pipes are satisfying every regulations and standards. This technology enables reconstructions of old pipes without addition digging, simply through the old systems without any decrease of the passage of the pipe.

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TECHNICAL CHARACTERISTICS

transport costs. PE pipes ensure the most economic salvation for certain work and long-

PRODUCTION METHODS PE pipes are produced by the method of extrusion. Through the hole, material is putted into the extruder. Main parts of the extruder (1) are: Input hole (2), cylinder of the extruder that is heated by the heaters (3). With the motor (4) rolling of the snail (5) and material is possible. The snail is separated on a few zones where the material is extruder (6) and with appropriate tool (7), the material is modeling, in this case in pipe. Than the pipe pass into vacuum (8) and water (9) tube where the final modeling is made. After that with pull-device (10) the final line is pull out. The final operation is cutting or rolling of the pipe (11). heating, melting and compressing. After that, the material comes to the head of the

CERTIFICATES
All products of GEMA PLAST KM from Gevgelija are attested according the current standards for that kind of product. GEMA PLAST KM is a recipient of ISO 9001:2000 certificate which is certified by OQC, London for production and delivery of plastic pipes and connection elements. This is result of our promises that the quality is strategy in every sector of our industry. Types of pipes produced by GEMA PLAST KM: Polyethylene pipes Polyethylene pipes Polypropylene pipes Made of PE 80 and connected with mechanical link Polyethylene pipes made of PE 100 and connected with mechanical fittings and frontal welding Polypropylene pipes made of PPR and connected with thermal welding Construction Infrastructural work Construction Infrastructural work Construction Infrastructural work

20-315 mm

63-315 mm

20-315 mm

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TECHNICAL CHARACTERISTICS

FIELD OF USE OF THE PIPES INFRASTRUCTURAL WORK Water supply systems, irrigation, sewerage systems, protection of cables, providing and distribution of natural gas, underground collection of atmospheric water etc.

INDUSTRY System for sucking in and pumping out the water, drinks, food, fuel, chemicals, gases etc.

AGRICULTURE Surface or underground system for supplying and distribution of water for irrigation, system drop by drop.

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TECHNICAL CHARACTERISTICS

POLYETHYLENE PIPES
1. WATERSUPPLY PIPES F 20 F 630 mm 6-10-16-20-25-32 PE 80 (6.3 MRS 8) PrEN12201 -2, ISO 4427; MKS G C6, 602

External diameter: Working pressures: Classification: Standard: Technical features

Possible length of pipes: From F 16 mm to F 32 pulley to 700m From F 40 mm to F 50 pulley to 350m From F 63 mm to F 75 pulley to 250m From F 90mm to F 110 pulley to 100m From F 125 mm to F 630 straight pipes by order to 16m Color: Light blue or black with co-extruded lines Working temperature: Use: They can be used in underground water supply installations, for transport of drinking water, for regional and main plumbing and in other purposes as pipes under pressure. Maximum to +60C The material is stable till -30C

PE 80 Service lines

PE 100

Main water supply

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TECHNICAL CHARACTERISTICS

2.

WATER SUPPLY PIPES F 20 F 630 mm 6-10-16-20-25-32 PE 100 (8.0 MRS 10) PrEN12201 -2, ISO 4427; MKS G C6, 602

External diameter: Working pressures: Classification: Standard: Technical features

Color: Dark blue Working temperature: Use: They can be used in underground water supply installations, for transport of drinking water, for regional and main plumbing and in other purposes as pipes under pressure. Maximum to +80C The material is stable till -30C

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TECHNICAL CHARACTERISTICS

Possible length of pipes: From F 16 mm to F 32 pulley to 700m From F 40 mm to F 50 pulley to 350m From F 63 mm to F 75 pulley to 250m From F 90mm to F 110 pulley to 100m From F 125 mm to F 630 straight pipes by order to 16m

Straining on curling can be calculated with this formula:

Defining of section on pipe Next processes are calculated by the formulas: For fluids with constant volume passage: V - Volume passage (m3/x) A - Free section on pipe (mm) - Speed of flowing (m/s) For materials in condition on gas and condensation, the material passage is constant and the formula is: A - Material passage - Consistence on medium depend p - Pressure and temperature (kg/x) If the constant values in these formulas will be added together, all formulas that are in real use for calculation of needed section of the pipe are: di - Internal diameter of pipe (mm) Q - Escorted quantity amount (m3/x) Q - Escorted quantity amount (1/s) v - Speed on flowing (m/s) Referent values for calculation of flowing speed can be for fluids: v ~ 0,5 - 1,0 m/s (for sucking); v ~ 0,5 - 1,0 m/s (for pressure)

Referent values for calculation of flowing speed of gas: v ~ 10 - 20 m/s


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TECHNICAL CHARACTERISTICS

Pk - Critic pressure on curling (bar) Ec - Module on coming down (H/mm2) - Poisons coefficient (for thermopile in basic 0,4) S - Thickness of the wall (mm) rm - Middle radius on pipe (mm) k - Straining on curl Pk - Critic pressure on curl rm - Middle radius on pipe (mm) S - Thickness on wall

BASIC CALCULATIONS Calculation of hydraulic shocks In case the flowing speed thought the pipe unexpectedly to be changed, as a result of closing the valve or stopping of pump, also internal pressure of the pipe is changed. In that case the Bernoullis formula cant be changed. These unexpected changes are known as hydraulic shocks. For pipes that are closer to the tank (having permanent level), where the passage is controlled by valve located on distance L of the tank, whole pressure generated of unexpected stop on valve, influence on relation of working time of the valve t, and time u. This is time that wave of pressure to come to the position of valve after the jump from the tank. This time is calculated by the formula: U - Phase of shock a - transmission of the wave to whole pipe, and it is given by the formula: Where: d - Internal diameter of pipe (mm) s - Thickness of the wall of pipe (mm) g - Gravitation acceleration Ew - Module of water flexibility = 2,1 GPa Epe - Module of PE flexibility = 0,8 GPa - Specific weight of water = 1000 kg/m3 f - = 1,23 for free pipe and f =1 for connected pipe

- Posens coefficient. In this case PE=0,4


CALCULATION OF HYDRAULIC LOSE In pipes, next reasons can cause lose and consequent energy loses through the transport system. Length of the pipe line Diagonal section on straight pipeline Roughness of the pipe Quality of the fittings, installation and quality of connections Viscosity and density of the flowing media Type of flowing (laminate or turbulence) Calculating of loses on pressure is result of sum of all pressures in the pipe:

CALCULATION OF OTHER LOSES OF PRESSURE Loses of pressure in straight pipes. Next formulas are valid for fluids. Also, they can be used for some gases, with approximate value.
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TECHNICAL CHARACTERISTICS

- Fricative index of the pipe (usually 0,02 is


excepted) L - Length of pipe lines ai - Internal diameter of the pipe (m) - Density of the media (kg/m3) - Speed of flowing (m/s) Loses of pressure into the fittings:

In the table below are shown resistant coefficients of the fittings for small diameter pipes. Coefficient is increasing as the pipes diameter. Precisions calculating can be found in the literature. F - Loses of pressure by the installation - Resistant coefficient - Density of the media (kg/m3) - Speed of flowing Depending of construction and nominal value of installation, resistant coefficient is between 0,5 and 5,0. If usually used Kv-value of installation is known, loses of pressure can be calculated with: Q - Volume passage (m3/x) - Density of the media (kg/m3) Kv - Specific installation value (m3/x)
Type of fitting Curve =90 Curve =45 Elbow Perim. Resistance coeff. Dir. of move

TEE 90

TEE 90 Concentric reducers Concentric reducers

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TECHNICAL CHARACTERISTICS

- Resistant coefficient - Density of the media (kg/m3) - Speed of flowing (m/s)

LOSES OF PRESSURE ON CONNECTIONG It is impossible to have the right information, because the type and the quality of the connections are variable. With calculation of the total loses of pressure, it is from 3% to 5%.

Nom. height Resistance coefficient

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TECHNICAL CHARACTERISTICS

NOMOGRAM OF FLOWING For rude calculating of the speed of flowing, loses of pressure and quantity, the parameters are given in the following nomogram of flowing. By the average speed of flowing to 20 m length, for every TEE socket, reducer and elbow 90, add about 10 m of pipe length. For every curve r=d and about 5 m of pipe for every radius r=1,5 x d, add about 10 m of pipe.

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TECHNICAL CHARACTERISTICS

Internal diameter Quantity of volume passage of the pipe d (m) Q (l/s)

Speed of flowing v (m/s)

Loses of pressure to meter of pipe p/L (mbar/m)

INSTALLATION INSTRUCTIONS FOR PIPELINES Distance between the holders Lkn for fixed systems If the pipe lines are installed on this way, than axial displace is impossible, critical length of bending is basic of system of calculation. Calculated distance of holders for every pipe must to provide factor of safety of minimum 2.0. If Lkn is smaller, than the distance between the holders L must be changed. Lkn is calculated with the following formula for minimal safety factor 2.0: Lkn - Distance between the holders for bending (mm) JR - moment of inertia (mm4) AR - Ring surface of pipes wall (mm2) - Preventive heating expansion Notes: If the fixed system is working on higher temperature, the distance between the holders must be reduced on 20%. High temperature is: For PEHD > 45C For PP > 60C CALCULATION POSSIBILITIES Following parameters are necessary for calculation of the holder distance: Pipes material Dimensions (da x s) Installation temperature Maximum operating temperature Maximum operating pressure Density of the flowing media DISTANCE OF HOLDERS FOR PIPES MADE OF PPR AND PE Distance of holders depends of characteristics of the pipe material, dimension of the pipe, weight of the flowing media, operation temperature and position of the pipes. Distance of the holders is given in the table below. The values are given on the base of flowing media with density of 1 gr/cm3 and horizontal pipes. Based on calculation of distance of holders, maximal bend of L/500 between two holders on the pipe can be taken as basis.

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TECHNICAL CHARACTERISTICS

DISTANCE OF HOLDERS FOR PIPES MADE OF PE 80 (PE 100) PN 1

Distance of holders L (cm) for

CHANGING FACTOR FOR PIPES MADE OF PEHD AND PPH Distance of the holders, given in the table, can be used for other pressures: PN 3,2 -2,5% PN 6 9% PN 16 +7% Distance between the holders must be reduced for 4% for fluids with density of 1,0 g/cm3 to 1,25 g/cm3. Distance between the holders must be increased as below in transportation of gas with density < 0,01 g/cm3: PN 6 PN 10 PN 16 Distance for pipes made of ppr Calculation of the distance for holders of pipes made of PPR, for holders made of PPH, must be reduced for 25%. +47% +30% +21%

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TECHNICAL CHARACTERISTICS

INSTALLATION INSTUCTIONS FOR PIPE LINES Resistance on temperature Because the polyethylene is thermo plastic material, it means that increasing of the linear dimension is expected. So, till planning of the project, project team must take into consideration the factor of changing of length of pipeline. It is useful for new construction of pipeline, the final connections to be done after adapting of the pipes on the air temperature. Calculation of the operating pressure according the temperature and expected time is given below:

temperature

Series Life time PH 2.5 PH 3.2 PH 4 PH 6 PH 10 PH 16 Permitted operational pressure

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TECHNICAL CHARACTERISTICS

Base for calculation

Curve of pressure for pipes made of PE 80

Time of slacking in years

Time of slacking

Curve of pressure for pipes made of PE 100

Time of slacking in years

Time of slacking

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TECHNICAL CHARACTERISTICS

Straining

Straining

Calculation of the changes of length Changes of the length by temperature difference For calculation of the length changes of the pipe, use following formula: LT - Changes of length till the temperature change (mm) - Linear coefficient of expansion (mm/m*K) L - Pipe length (m) T - Temperature difference (K) For determination of the T, the highest difference of the installation temperature to the highest operation temperature is used. Average value of : PP0,15; PEHD0,20

Temperature

Temperature

Linear expansion coefficient for PP Calculation of length changes

Linear expansion coefficient for PEHD

Linear changes causes of internal pressure influence With internal pressure, expansion of the length of closed and fricative pipe system is: L - Length of the pipe system (mm) p - Operational pressure (bar) - Transferal contractive coefficient Ec - Crawl module da - Outer diameter of the pipe di - Internal diameter of the pipe

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TECHNICAL CHARACTERISTICS

Expansion coefficient

Expansion coefficient

Changes of the length causes of chemical influence Changes of the length into the pipe system can be higher, as much as the diameter of the pipe increases under chemical influence. Simultaneously, mechanical features are reduced. Expected change of the length under influence of the chemical mixture can be calculated with main factor of the distortion. Till testing of the drain pipe made of PEHD and PP that are transporting chemical mixture, factor of distortion is useful. Fch=0,025...0,040 (depending of planned pipe line) Change of length in this test approximately is:

Lch=Fch*L

L - Length of the pipe system (mm) Fch - Distortion factor

Note: For correct calculation, factor of distortion can be determinate with individual test for different material. Console calculation Changes of the console can be caused of change of the operational or air temperature. Big attention must be taken of the installation of the pipe line on the ground because of the axial motion are quite compensated. In most cases, change of the direction of the pipeline can cause contracting of pipeline length. Also, change of the direction can be used for compensation of length expand. Depend of the construction, compensators can be axial, lateral or angled. Distance to the fixed point (length of the banded end of the pipe - console) easily can be calculated as: Ls - Length of the console (mm) L - Change of length (mm) da - Outer diameter of the pipe (mm) k - Specific constant of the material Specific constant of the material:

On temperature change

On unit temperature change

Note: Installation temperature of 20 is based on calculation of k-value. Shock strength has to be taken into calculations when low temperature. K - Value can be reduced to 30% for pipes without pressure (ventilation).

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TECHNICAL CHARACTERISTICS

Compensation of the changes with compensation console (left) Compensation of the changes of the length with elastic arch (right) F - Fixed point LP - slide point

Console length in cm for pipes made of PP and PE depended of the change of the length L
Changes of height L (cm)

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TECHNICAL CHARACTERISTICS

CHEMICAL CHARACTERISTICS PE pipes have great resistance on many chemicals and different temperature. Legend: _____________ Full resistance ----Limited resistance --No information B.P. Water mixture 3.V.P. Saturated mixture H.K. Low concentration
Chemical substance Gases that contain Acetic acid Acetic acid Anhydrid of Acetic acid Acetone Alum Amonia gas Amonia liquid Animal and vegetable oil Beer Benzol Sodium preborath (borax) Boric acid Butanone Calcium hipochloride Carbon dioxide Carbon monoxide Carbon tetrachloride Carbon bisulfate Chloride of different metals Chloroacetic acid Chloroform Chromium acid Lemon acid Oil Detergent Dextrin Dichlore ethane Dichlore ethylene Diesel oil Diethyl ether Dry chlorine Ethyl oil Ethyl alcohol Ethyl acetate Fatty oil Phenol Concentration Temperature (C)

Traces

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TECHNICAL CHARACTERISTICS

Chemical substance Formaldehyde Formic acid Fruit juices Dairy acid Glucose

Concentration

Temperature (C)

Chloral carbonic acid Chloral carbonic acid (gas, hard or liquid) Fluorite carbonic acid Traces Carbon Bromine carbon Carbon peroxide Carbon peroxide Carbon sulfide Ferro chloride Ketenes Vinegar Mercury Methanol Methyl chloride Molasses Oil Naphthalene Nitrite of different metals Nitric acid Nitric acid Nitro benzene Nitric steam Nitric steam Mineral oil Ozone Paraffin oil Per chloride acid Gasoline Petroleum Phosphoric acid Phosphoric acid Phosphoric acid Photograph regencies Cilium borate Cilium bromide Cilium dichromate Cilium hydroxide

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TECHNICAL CHARACTERISTICS

Glycerin Chloral carbonic acid

Chemical substance Sodium carbonate Sodium chloride Sodium hydroxide Sodium hypochlorite Sodium silicate Starch Staerate acid Sulfate of different metals Sulfate dioxide Sulfate dioxide Sulfate acid Sulfate acid Sulfate acid Sulfate acid Sulfuric acid Tan acid Vine acid Tetrachloride Toluene Oil for el. transformers Turpentine oil Urine

Concentration

Temperature (C)

Clean

ADVANTEGES OF POLYETHYLENE PIPES Big flexibility - small weight


Radius of curling R according the diameter

Polyethylene pipes have great flexibility that causes easy and fast installation and makes reducing of use of special fittings (packs of the pipes with long length in contours). Next table gives possibilities of curling of the pipes dependent on nominal diameter, SDR and temperature. Resistance on moving on the ground

Causes of the elastics, PE pipes are used in areas with bad seismologic characteristics and overloaded roads. Great resistance on mechanical hits

Polyethylene pipe shows very big resistance on mechanical hits. However, testing on mechanical hits is not present in the international standards of this kind. Smaller friction coefficient than any other material of same use High nonporous pipes High quality of the lines
37

TECHNICAL CHARACTERISTICS

Ecological material - protection of quality of the water without changes of taste and color of the water. High resistance on chemical corrosion - no need of additional cover on the pipes Fast installation Long length without connectors. Welding out of the ditch. Smaller installation depth. Tinny ditches. Continuing on and with any kind of pipeline without problems.

Black colored HDPE - pipes are specially resistant on UV radiation and freezing. Colored pipes have some UV stabilizer that makes them more resistant.

PACKAGING

Packaging of pipes to 90 mm is in contours and look like this:

Packaging of pipes 110 mm looks like this:

to

TRANSPORTATION AND STORAGE Transportation and storage of PE pipes have to be handled with care, so none of the known damages to become as: Incorrect handle on high temperature

Storage on high temperature, combined with length loading, ca causes deformation (oval pipes).
38

TECHNICAL CHARACTERISTICS

Possibilities for installation of outer pipelines

Scrape with sharp object

Pipes can be pulled and dropped or set on rude surface... If the pipes are overloaded, or unloaded with metal wires, handled care is needed. Deformation caused of outer load

These kinds of damages usually are because of incorrect load or unload and hits by the transportation. For best protection by the transportation

Straight pipes must lie on the bottom, on clean surface on the whole length of the pipe as it is on the picture below. Transportation of different kind of pipes (types and diameters), the hardest pipes must be on the bottom Avoid to put one on another pipe, except when transportation. Contours must be storage as they come from the manufacturer. If need of moving - protect the pipes of mechanical hits. Ends of the pipes that are rounded and ready for connection have to be protected.

TRANSPORTATION

WRONG

CORRECT

WRONG

CORRECT

39

TECHNICAL CHARACTERISTICS

INSTALATION It is recommended for installation of pipes to be putted into the ditch with minimal depth of 45 - 60 cm depends of freezing zone. Installation of the pipes is allowed on air temperature from -5C to +60C. METHODS OF CONNECTION The polyethylene can be connected on many ways. Frequently used: Frontal welding Electrofusion welding Mechanical connecting INSTRUCTIONS FOR WELDING Basic information about MFI group (Melt Flof Index) These instructions are used for welding of pipes and fittings made of thermoplastic:
Material substance Polyethylene PE 80, PE 100 Polypropylene PPH, PPR Especial types PE 80 - el PPR - el PPR - s - el Welting compatibility MFI group 005 with 010 MFI group 003 with 006 PPH with PPR PE 80 - el with PE 80 PPR - el with PPH and PPR PPR - s - el with PPH and PPR MFI value PE (190/5) 0,3 - 0,7 g/10 min 0,4 - 0,8 g/10 min 0,7 - 1,3 g/10 min

MFI group 003 005 006 010

MFI value PP (230/2,16) 0,2 - 0,4 g/10 min

Who can welt? Only special trained and qualified persons. Welding can be done only with the machines according the DVS 2208/part 1 standards. Used parameters for every welt must be noticed in the welding report. Basic instructions Surrounding of welding place must be protected of air conditions (wind, humidity, intensive UV radiation, temperature <5C). Parts that are welding must be not damaged and clean. Also the surrounding must be clean. Use is limited of different types of connection If it is possible - all connections to be isolated so any kind of strain to be avoided. Strain that can be caused of difference of temperatures between the ditch and operational conditions must be as much as possible on lower level. In the table are given permitted types of connection for appropriate class of pipes.

40

TECHNICAL CHARACTERISTICS

Type of connection

Mechanical connection Frontal welding

With covered welding Electro fusion welding Flange welding

Legend:

PPH, PPR, PE, Special types (PE 80 el, PPR-el, PPR-s-el)

INSTRUCTIONS FOR FRONTAL WELDING (By DVS 2207, part 1 and 2 for PEHD and part 11 from PP) Welding method Element for frontal welding is integral part of welding equipment. Two ends of (pipe and fitting) bring with pressure on the heating plate. So the parts are heating up to the temperature of fusion with reduced pressure (pre warming) and than take off the heating plate and connect the ends with pressure. Specific heating pressure In most cases, heating pressure (bar) or the power of heating (Kp) has to be set from the table for welding machine. For check of use or if you dont have table for pressure, wanted pressure of heating can be calculated with the formula: Calculation of power of heating: Parameters of welding Specific heating pressure (Pspec) PPH, PPR (el) 0,10 N/min2 PE 80 (el) 0,15 N/min2 Welding temperature (T) PPH, PPR (el) 195/205C PE 80 (el) 200/210C When use of hydraulic equipment, calculated welding power (Kp) has to be converted on permitted adjustable hydraulic pressure.

41

TECHNICAL CHARACTERISTICS

Welding parameters
Temperature Pressure

Setting by the connection pressure

Pre heating pressure

Setting time

Time of pre heating

Time of taking Connection off the pressure heating plate

Cooling time

Total connection time

Welding time

T1 - time needed to set the pipes T2 - time needed for continued heating T3 - Time for taking off the heating plate T4 - Time needed to reach the pressure T5 - Cooling time Common table of welding parameters:
Type of material Thickness of wall (mm) Height of the welt (mm) Time of pre heating (sec) Time of change (sec) Pressure of connection Cooling time

Units with determination of the power: Units with determination of the pressure:

Fconn. = Fw + Ftable Pconn. = Pw + Ptable

Instructions for successful welding Prepare the operational place (tools, machine) and if needed set a tent.

42

TECHNICAL CHARACTERISTICS

Setting of the machine for welding Setting of the appropriate pipe and fitting holders, so ends to be parallel. Insure free move of the end that will be welded. Clean internal and outer surface of the welding part with acetone or alcohol. Smoothing of the two ends and removing of any kind of edges or trash. Once again check the parallelism of the two ends. Check the heating temperature before the start of the process (start the process at least 5 min after the reaching of given welding temperature). Keep the heating plate on special holders, before and after the welding. Clean the heating plate before start of welding with appropriate towel or paper. Set the needed parameters. Measure the pressure needed for moving the part into the welding zone and add it to the pressure needed for pipe welding.

Performance of the process of frontal welding Put the heating plate. Set the needed pressure. Keep the pressure till the welding surfaces are set for the heating plate. With this setting, latter formed edge must be equal for whole section of the pipe. Reduce the pressure on P=0,01 H/mm2 and keep it for pre warming time (by the table). Remove the heating plate and connect the welding surfaces in short time. Easily increase the pressure to the asked value. Keep this pressure for the cooling time. Take off the holders after the cooling time.

Visual control of finished weld and possible defect After the connection the weld must be formed identically to whole circumference of a pipe. For every case, welt must be visually controlled, so put attention on: Equal height of the edge Slide surface of the edge

43

TECHNICAL CHARACTERISTICS

Possible failures and reasons for their appearance Failure INSUFFICIENT FUSION Appearance Possible reasons Low temperature of heating plate, great amount of high pressure resulting in material pressing out Pipe overheating or overloading prior the required cooling time Insufficient joining pressure or too short pressure action Welding edges improperly cleaned Dust, sand or metal shavings

Crack inside the welding area Hole within the fusion area Porosity Unclean welding edges

TESTING UNDER PRESSURE All welded joints should be completely cold before testing under pressure (in principle 1 hr after the last weld). Testing under pressure should be undertaken in compliance to the valid standard regulations (VS 2210 part 1, DVGW work list w 210). Thus, the maximal pressure applied here is 1.5 h PH, where no leakage should occur during testing (at least 10 minutes). The pipe system should be protected from environmental temperatures changes (UV radiation).

44

TECHNICAL CHARACTERISTICS

ELECTROFUSION WELDING OF PEHD PIPES AND FITTINGS Preparation of the welding spot: Adjustment of the equipment: (Preparation of tools and machine), welding control unit. Preparation of welding edges (refers to any item prior welding process begins). Cut the right angle pipe by means of an appropriate cutting tool. Clean the pipe alongside L + 50 mm minimum with dry cloth (L= length entering the electric fitting). The shiny surface inside and outside the pipe edge is carefully removed using peeling tool or scraping knife inserted on a suitable device around the pipe diameter. Having cleaned the welding area (both pipe and fitting) with acetone (or alike) and with soft tissue making sure no traces remain (piles etc.) Pre-welding preparations Fitting to be welded is removed from its case making sure not to touch its inside and prepared pipe - it is then inserted into the prepared pipe end until front end of the fitting connects to the pipe edge. Welding areas should be dried before pipe is inserted into the fitting. This means removing any moisture or cleaning residues with absorbing paper. Having fixed the device supports around the pipe thus indirectly fixing the el. fitting edges. Prepare the second part to be welded in the same way. Insert the other part of the pipe or the fitting into the socket and fasten both ends with special support, thus avoiding pressure increase in the welding area. Electrofusion welding process Having completed preparations as mentioned above, check once again to make sure there is no axial displacement of the socket and connector is then connected to the welding cord. Proper connection of the welding equipment is shown on the device. WELDING INSTRUCTIONS Electrofusion welding of PE This method is used for welding pipes and fittings by means of a resistant wire. The resistant wire is built within the fitting wall. Electric current is used to do the welding. During heating period the inside of both the fitting and the pipe are melted.

45

TECHNICAL CHARACTERISTICS

WELDING PROCESS

The fitting shrinking is precisely measured during heating which guarantees that the joining pressure, previously unnecessary shall be modified. The completed welding process results in a homogenous joint that guarantees a 100% tightness. The complete electrofusion welding process shown in the picture. FUNDAMENTAL APPLICATION OF THIS WELDING TECHNIQUE Only parts of same material can be welded. The electrofusion fittings flow index is in the range of 0,7 1,3g/10 min. Only universal tools subject to bar-code can be used on the butt welding machine. Pipe oval shape should not exceed 1.5%. ELECTROFUSION WELDING DEVICE Appropriate machines are being used for electrofusion welding manufactured by numerous producers. These machines monitor all the welding process functions and record these. Each fitting should have its code card showing all welding data. By inserting this card (or manually entering the data) the machine receives all the welding parameters required and welding process begins on basis of this information. Having loaded the data, it is erased from the card thus making sure it can be used only once. Welding parameters are entered with pen or scanner. A sound beep shall register the completion of data entering process. Having entered the welding parameters, the size and outside temperature are displayed. These values must be known. Welding process begins with pressing the green start button. At the same time the welding time required and current time as well as welding voltage are displayed. Joint supports should remain in position during complete welding process (including the cooling time). There is a sound beep at the end of the welding process.

WELDING PREPARATION

STICKING AND PRE HEATING

CONNECTING AND COOLING

46

TECHNICAL CHARACTERISTICS

Supports can be removed after the cooling. Cooling time should be observed. In case of interruptions in welding process for any reasons (power failure) it is not recommended to use the same fitting again. Visual inspection and documentation The welding indicator makes a visual weld inspection on the fitting itself. All welding parameters can be printed thus providing the welding report.

47

TECHNICAL CHARACTERISTICS

POLYPROPYLENE PIPES
POTENTIAL OF APPLICATION SANITARY INSTALLATION The PPR system has been developed for application in sanitary installations in construction, in compliance to DIN 8078 prescribing operating pressure of PN 25 for pipes and fittings. FLOOR HEATING Thanks to the PP - Pa specific flexibility and the option of applying concrete, the system is suitable for floor heating also. RADIATOR HEATING Considering the parameters, the thermal radiation in particular, the material is suitable for designing radiator heating systems. INDUSTRY Thermal and chemical resistance of the material allows its application in the transport of compressed air, gas, liquid food products etc. SPECIAL APPLICATIONS Small weight, persistency to salt water and vibration adjustments open opportunities for usage in ships and camping vehicles. ENERGY SAVING Low thermal dispersion within the fitting with low thermal inertia enables quick hot water delivery even if the piping has not yet reached the average operating temperature. Energy savings amount from 10 to 20%. HARMLESS TO HEALTH The PPR system meets in full international requirements in view of application of plastic materials in potable water delivery. METAL THREADED INSERTS All threaded inserts built in fittings are manufactured of treated Ms - 58, plated protected (Ni) and guarantee watertight layers within all other metal components of the system. WELDING This is one of the fundamental properties of the system. All system parts can be joined by means of semi-fusion or electric socket welding technique. VERSATILITY Low specific weight enables transport and handling. The system can be easily composed at the construction site or placed in front of the wall.

48

TECHNICAL CHARACTERISTICS

FROST RESISTANCE The elasticity of PP-Pa enables increase of pipe cross-section in case of increasing the liquid delivered volume occurring in freezing conditions. SURFACE ELECTRICITY Thanks to the low electric conductivity this system is protected from so called astray currents. RESISTANCE TO FRICTION AND CORROSION This property enables high flow velocities of the transport medium (up to 7 m/sec) with no risk of erosion even in the presence of alkali and acidic substances to pH 1-14. LOW THERMAL CONDUCTIVITY Since PP-R is a very poor heat conductor, condensation and thermal leakages are minimized. RESISTANCE TO ABRASION The pipes allow high water velocity without any corroding problems. TREMOR ZONES APPLICATIONS Thanks to its flexibility and resistance to hits the PP-Ra pipelines can be laid in tremor zones also. LOWER PRESSURE LOSSES Thanks to its smooth surface inside the pipe, no deposits occur which in turn result in lower pressure losses in relation to other materials used for the same purpose. NOISE FREE As all plastic substances the PP-R represents a sound insulator, elastic and absorbing all water changes causing vibrations and building noises. LONG DURATION Up to 50 years depending on operating temperature and pressure.

49

TECHNICAL CHARACTERISTICS

SEMIFUSION WELDING Welding is carried out by means of a welding device with simultaneous heating of both joining elements of the system. When welding temperature has been reached the elements imprint one into another thus creating an absolute closed connection. PREPARATION External pipe surfaces and fitting part must be alike and smooth. Pipe ends must be cut at right angle. Prior welding begins the device operation and reached welding temperature should be checked. PERFORMANCE Pipes and fitting parts should be imprinted straight and with no axial movement into the heating accessories (casing and prickle) up to the spacer. When the heating time has elapsed, the heated pipe and fitting part to be removed from the device and immediately with no movements to be inserted one into the other. It is very important to observe the prescribed insertion depth in order not to exceed the fitting part spacer.

50

TECHNICAL CHARACTERISTICS

ELECTRIC SOCKET WELDING The electric socket is mainly used in repairing and welding the existing installations. The procedure is simple and safe provided some simple rules are observed. Connection parts must be headed axially. After the parts have been inserted into the E-socket they are connected to the welding device. Subsequent procedure follows automatically only permitted. To avoid disruption of PP-R pipes quality it is recommended to follow these instructions: Do not use open flame to create a curve, since temperature can not be controlled and it can lead to molecular temperature damage. It is possible to make a 90 deg elbow only care should be taken the bending radius not to be less than 8 X diameter. Pipes with no protection from external conditions can lead to outside damages caused by UV rays in combination with oxygen. It is not recommended to use metal elements causing abrasion. In case metal elements are of satisfying quality the connection is done with Teflon band. Avoid hits, sharp bending especially at pipe ends and edges Not to use broken and damaged pipes Any movements of pipes and fittings can be done only during or immediately after installation up to 30 deg maximum NO NO NO NO the connection must not be overloaded until completely cooled. Cooling agents are not

51

TECHNICAL CHARACTERISTICS

METHOD OF PIPELINE CONSTRUCTION TECHNICAL FIXATION PP-R pipelines holders should be inserted according to PP-R pipe diameter. Care should be taken fixing material not to cause any technical damage to the external surface of PP-R pipes. Tapping saddles with rubber inserts represent ideal pipe fixation elements whereby rubber inserts composition is specially adapted to the PPR pipes. Two types of supports are used in pipeline construction: rigid (fixed support) sliding (guide support) RIGID (FIXED) SUPPORT Even placement of the rigid support (fixed spots) divide the pipeline into separately controlled distances. This construction type allows avoiding uncontrolled movements inside the pipeline and secures pipe guidance. Fixed support size and design should allow any extension and possible additional loading forces of pipes to be received and compensated. When threaded rods are being used as holder support, one should bear in mind the short distances to the roof and wall these are fixed to. Swinging tapping saddles are not suitable for construction of fixed supports. In principle vertical distributions can be rigidly fitted. Compensation arcs of perpendiculars elongation are not required. Tapping saddle and support must be stable and fixed in a satisfactory manner to be able to accept forces occurring following pipe elongation. PP-R pipe tapping saddles meet above mentioned conditions and when fitting instructions are observed, these are ideal for construction of fixed and sliding supports. When metal tapping saddle with specific rubber insert is used mechanical damage to pipes is excluded. When positioning the sliding support care should be taken not to prevent axial movements to the pipe parts placed too close, such as fitting parts, armatures etc. ELONGATION Pipeline elongation depends on its heating. Cold fluid pipelines are not prone to elongation and therefore not of interest in this respect. In hot fluids and heating pipelines installation however, the pipeline length changes due to temperature differences affecting the material behavior should be taken into account. Each material should be considered separately in accordance with the method of pipeline construction. Pipelines within walls, floor etc (mortar, concrete) Pipelines and canals Pipelines in open space

52

TECHNICAL CHARACTERISTICS

PIPELINES WITHIN WALLS, FLOOR LINES When laying pipelines within walls, floor etc. PPR pipes elongation is not taken into into account. By insertion of pipeline into the concrete, mortar and alike elongation caused by temperature conditions is prevented. Thus generated forces are being equalized with with the elasticity of the material and therefore not critical. PIPELINE CANALS When placing PP-R pipelines in various canals, modifications in view of length should be taken into account, i.e. branching arms to have sufficient space to follow the elongation. This can be achieved in various ways: 1. By proper placement of perpendiculars in the canal. 2. By proper sizing of the hole for finding the branching pipeline through the canal wall, i.e. by pipe covering size for finding the wall. 3. By making knots enabling torsion compensation

53

TECHNICAL CHARACTERISTICS

PIPELINES IN OPEN SPACE In line structures including cold and hot distributions (such as cellars, boiler rooms etc.) great attention is paid to the external appearance and stable form of the pipeline. PP-R pipe elongation coefficient is:

0,15mm x m x *C
ELONGATION (mm)

Below examples show elongation calculation in practice. The difference between operating temperature and temperature at the moment of placement of pipe is very important in calculating the elongation value. CALCULATION OF ELONGATION VALUES KNOWN AND REQUIRED VALUES
Designation Significance Elongation Linear elongation of PP-R pipes 7 Pipe length Operating temperature Temperature at fitting Temperature difference between tR and tM t=tR-tM Value ? 0.15 10 50 25 25 Unit mm mm / mC m C C C

L
L tr tm

Calculation is made on basis of following formulas: PP-R pipe material

54

TECHNICAL CHARACTERISTICS

COMPENSATION ELONGATIONS Supports are easily fitted and fixed to PP-R as well as metal pipes. In open space installation elongation has to be taken into consideration even during pipeline designs. Pipeline construction must be designed in a way to allow elongation and unobstructed movement of pipe within the elongation calculation values. Only two simple options can be considered regarding compensation modification of length. CHANGE OF DIRECTION ELASTIC ARC

ELASTIC ARC MODIFICATION COMPENSATORS Not all compensator types for metal pipelines are recommended for PP-R pipelines. CHANGE OF DIRECTION In most cases the change of direction can be used to compensate the elongation. The distance to the fixed support, i.e. to the pipe bending end (bracket) can be easily calculated using the following formula. Calculation example: Bracket length Known and required values
Designation Significance Bracket length Spec. const, mat. PP-R pipe Outside diameter of the pipe Elongation Value ? 20 32 20 Unit mm / mm mm

LK L
D

Bracket length is calculated using the following formulas:

On basis f the example as calculated above the bracket length LK is 506 mm. KT - slide point FT - fixed point
55

TECHNICAL CHARACTERISTICS

ELASTIC ARC (LIRA) IRA) In case elongation compensation is not possible it is necessary to insert an elastic arc (lira). Certain quantity of pipes and additional four 900 elbows are required to make this. Calculation example: ELASTIC ARC (LIRA) Known and required values
Designation Significance MIn. width of the elastic arc Elongation Safe distance Value ? 20 100 Unit mm mm mm

Amin L
SA

Calculation of the electric arc width is performed using the following formulas: Amin = L + SA Amin = 2 x 2mm + 100mm Amin = 140mm

Elastic arc width in this case is 140 mm minimum. KT - slide point FT - fixed point

VOLTAGE ELASTIC ARC This type of construction can provide less bracket length on the arc itself which is convenient in limited space during construction. Proper design of this method leads to improved pipeline optical appearance also since movements due to elongations are practically invisible. Bracket length of voltage elastic arc is determined as follows: Calculation example: Bracket length of voltage elastic arc Known and required values.
Designation Significance Bracket length of voltage elastic arc Spec. const, mat. PP-R pipe Outside diameter of the pipe Elongation Value ? 20 32 20 Unit mm / mm mm

LKp K
D

Bracket length is determined using the following formulas:

On basis of the above values, the bracket length of voltage elastic arc is 358.0 mm.

56

TECHNICAL CHARACTERISTICS

DISTANCE BETWEEN PP-R PIPE SUPPORTS CE The method and frequency of PP-R pipeline fixation depends also on the amount of elongation caused by temperature differences. Fixed support enables pipeline to be divided into several individual sections providing an elongation possibility. Placing of pipes inside individual sections is made possible by inserting sliding supports. Distance between supports depends also on conditions the pipeline is used in, pipe material, pipeline weight including the filling medium weight. The distances in the table below have shown the best performances in practice.
Pipe diameter Temp. Difference Support distance in cm.

SYSTEM CLEANING (WASHING) Having completed the pipeline, irrespective of the used system materials and especially in potable water installations it is necessary the system to be thoroughly washed. In order the system to receive its application clearance without restrictions the following prerequisites must be fulfilled: Making sure on the potable water quality; Removing corroding effects; Removing functional defects of armatures and devices; Cleaning the pipe inside surface.

These prerequisites can be fulfilled in the following two ways: Washing with water Washing with water/air mixture The The experience of fitters, requests of the investor as well as manufacturer's recommendations of the system material must be taken into account when making the decision on which method of cleaning to use. Condition under 1 above - washing with water, is absolutely satisfactory in drinking water installations completely constructed of PP-R system. No additional substances (glue, tinol) are used in pipelines constructed against the PPr system. Connection is made exclusively by fusion. The system remains clean of additional substances after connection. For these reasons it is rather satisfactory to wash the system with clean water.
57

TECHNICAL CHARACTERISTICS

POTENTIAL LEVELLING (EARTHING) No electricity breaks can occur in PP-R pipelines armature connections such as bath taps, faucets etc. thus it is not required to provide for grounding. The same goes for acrylic tubs and showers of plastic materials. In case of metal tubs grounding should be provided for. TRANSPORTATION AND STORAGE PP-R pipes can be stored at any external temperatures. Storage area should be flat so that pipes lie across all their length on basement. Bending of pipes during transport and storage should be avoided. In case of temperatures below 00C there is a possibility pipes to be damaged when strongly hit; careful handling is therefore recommended in very low temperature ranges. In spite of the fact that PP-R pipes are very resistant, careful handling is nevertheless recommended. UV radiation affects all high polymeric plastic substances. PP-R pipes and fittings contain UV stabilizer enabling storage in open space up to 6 months

FINDAMENTAL CALCULATIONS Numerous parameters are required in determination of drinking water pipe diameter in buildings. The simplified method includes all pipes resistances and other individual resistances. This method offers the best possible accuracy and coming very near the real exploitation conditions. Following parameters are required for pipe diameter determination: The lowest supply overpressure or outlet pressure of the pressure control valve (pressure increase or decrease); Geodetic level difference; Pressure losses in devices such as: water meters, filters, softeners etc.; Minimal flow pressures used for floor armatures; Pressure drop value bearing in mind the friction within pipe material; Losses coefficient of used fittings parts.
Fittings part Socket Reduction Elbow 90 Elbow 45 TEE part Socket with UN Socket with SN Elbow with UN Elbow with SN TEE part UN TEE part SN Flat permeable valve Outlet valve Value 0.25 0.40 - 0.80 1.20 0.50 0.25 - 3.00 0.50 0.70 1.40 1.60 1.60 1.80 9.50 - 7.60 0.25 58

TECHNICAL CHARACTERISTICS

TECHNICAL CHARACTERISTICS

59

TECHNICAL CHARACTERISTICS

TECHNICAL SPECIFICATIONS OF POLYTHENE AND POLYPROPYLENE PIPES AND FITTINGS

PE 100 - PIPES ISO 4427


*admissible operating pressure. see technical information

60

TECHNICAL CHARACTERISTICS

PE 80 - PIPES ISO 4427


*admissible operating pressure. see technical information

61

TECHNICAL CHARACTERISTICS

PE 63 - PIPES ISO 8077


*admissible operating pressure. see technical information

62

TECHNICAL CHARACTERISTICS

PP - R PIPES ISO 8077


*admissible operating pressure. see technical

Weight (kg/m)

Weight (kg/m)

in standard length at 4m. in rolls available for PN10 (10 bar) for F16mm and F20 mm.

63

TECHNICAL CHARACTERISTICS

information

STUB FLANGE
* molded out of PE100 * black *admissible operating pressure see technical information

Weight (kg)

Weight (kg)

1) from dimension 250: SDR 17/ ISO S-8


64

TECHNICAL CHARACTERISTICS

END KAP

* admissible operating pressure see technical information

Weight (kg)

Weight (kg)

1) from dimension 250: SDR 17/ISO S-8

65

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE100

REDUCER
* elongated * molded out of PE 100 * black * admissible operating pressure see technical

Weight (kg)

66

TECHNICAL CHARACTERISTICS

information

REDUCER
* elongated * molded out of PE 100 * black * admissible operating pressure see technical information

Weight (kg)

1) from dimension 250: SDR 17.6/ISO S-8.3 2) reducer diameter SDR 11/ISO S-5

67

TECHNICAL CHARACTERISTICS

REDUCER
* elongated * molded out of PE 100 * black * admissible operating pressure see technical

Weight (kg)

68

TECHNICAL CHARACTERISTICS

information

REDUCER
* elongated * molded out of PE 100 * black * admissible operating pressure see technical

Weight (kg)

1) branch SDR 11/ISO S-5

69

TECHNICAL CHARACTERISTICS

information

TEE
* elongated * molded out of PE 100 * black * admissible operating pressure see technical

Weight (kg)

Weight (kg)

1) from dimension 250: SDR 17.6/ ISO S-8.3


70

TECHNICAL CHARACTERISTICS

information

ELBOW 90
* elongated * molded out of PE 100 * black * admissible operating pressure see technical information

Weight (kg)

Weight (kg)

1) from dimension 250: SDR 17.6 / ISO S -8.31

71

TECHNICAL CHARACTERISTICS

ELBOW 45
* elongated g * molded out of PE 100 * black

Weight (kg)

Weight (kg)

1) from dimension 250: SDR 17.6 /ISO S-8.3 17.6

72

TECHNICAL CHARACTERISTICS

* admissible operating pressure see technical information

ELBOW 90
* elongated * molded out of PE 100 * black

Weight (kg)

73

TECHNICAL CHARACTERISTICS

* admissible operating pressure see technical information

REDUCER CONCENTRIC

* admissible operating pressure see technical information

Weight (kg)

Weight (kg)

74

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 * black

ELECTROFUSION SOCKET
* elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at 20*C)

75

TECHNICAL CHARACTERISTICS

ELECTROFUSION TEE
* elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at 20*C)

76

TECHNICAL CHARACTERISTICS

ELECTROFUSION TEE REDUCED

* admissible operating pressure for water (at 20*C)

77

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 (PE 80 on request) * black

ELECTROFUSION ELBOW 45
* elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at 20*C)

78

TECHNICAL CHARACTERISTICS

ELECTROFUSION ELBOW 90

* admissible operating pressure for water (at 20*C)

79

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 (PE 80 on request) * black

ELECTROFUSION REDUCER

* admissible operating pressure for water (at 20*C)

80

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 (PE 80 on request) * black

ELECTROFUSION END CAP

* admissible operating pressure for water (at 20*C)

81

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 (PE 80 on request) * black

ELECTROFUSION ADAPTER SOCKED


INTEGRATED WELDING MODULE MALE THREAD OUT OF BRASS
* elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at 20*C)

82

TECHNICAL CHARACTERISTICS

ELECTROFUSION ADAPTER ELBOW 45


INTEGRATED WELDING MODULE MALE THREAD OUT OF BRASS
* elongated * molded out of PE 100 (PE 80 on request) * black

20*C)

1) Thread according to DIN 2999


83

TECHNICAL CHARACTERISTICS

* admissible operating pressure for water (at

ELECTROFUSION ADAPTER ELBOW 90


INTEGRATED WELDING MODULE MALE THREAD OUT OF BRASS
* elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at 20*C)

84

TECHNICAL CHARACTERISTICS

TAPPING SADDLE
INTEGRATED WELDING MODULE WITH ELECTROFUSION SELAING CAP
* elongated * molded out of PE 80 * black

20*C)

85

TECHNICAL CHARACTERISTICS

* admissible operating pressure for water (at

UNIVERSAL TAPPING VALVE


INTEGRATED WELDING MODULE WITH TREAD INSER OUT OF BRASS

* admissible operating pressure for water (at 20*C)

86

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 80 * black

PLASTIC TAPPING VALVE


INTEGRATED WELDING MODULE WITH INTEGRATED CUTTER

* admissible gas operating pressure 4 bar, for water 10 bar

87

TECHNICAL CHARACTERISTICS

* elongated * molded out of PE 100 * black

BACKING RING
* molded out of PP * black * admissible gas operating pressure according

* On request

88

TECHNICAL CHARACTERISTICS

DIN (16962/5)

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