GF
GF
GF
Table of Contents
Overview General Properties - PROGEF Standard, PROGEF Natural and PPro-Seal Polypropylene Specications Pressure/Temperature
Figures Long-term Stress (Fig. 1) Regression Curve (Fig. 2) Temperature/Pressure Curve (Fig. 3)
5 13
14 24
24 25 27
28
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Figures Hazen and Williams Formula (Fig. 4) Tables Flow-rate vs. Friction Loss - PROGEF Standard (Table 2) Flow-rate vs. Friction Loss - PROGEF Natural (Table 3) Flow-rate vs. Friction Loss - PPro-Seal Natural (Table 4) Friction Loss through Fittings (Table 5)
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30 31 36 38 40
41
42
43
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Expansion/Contraction
Figures Modulus of Elasticity of Plastics (Fig. 6) Tables Length Change of Straight Pipe (Table 7) Length of Flexible Sections (Table 8)
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47 51 52
Installation
Figures Padding of Pipe Work (Fig. 7) Tables Pipe Bracket Intervals (Table 9)
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55 57
Mechanical Connections
Figures Gasket Dimension (Fig. 8) Pinch Test (Fig. 9) Gap Test (Fig. 10) Alignment Test (Fig. 11) Flange Installation Tag (Fig. 12) Union Installation Tag (Fig. 13) Tables Gasket Dimensions - Outside/Inside (Table 10) Fastener Specications (Table 11) Multiple Pass Bolt Torque (Table 12) Tightening Guide for Union and Ball Valve Nuts (Table 13) Threaded Connection Guide (Table 14)
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60 63 64 64 67 71 60 62 66 70 72
73 76 83
Overview
General Information
Polypropylene is a thermoplastic belonging to the polyolen group. It is a semi-crystalline material. Its density is lower than that of other well-known thermoplastics. Its mechanical characteristics, its chemical resistance, and especially its relatively high heat deection temperature have made polypropylene one of the most important materials used in piping installations today. PP is formed by the polymerisation of propylene (C 3H6) using Ziegler-Natta catalysts. There are three different types which are conventionally supplied for piping installations: Isotactic PP Homopolymeride (PP-H) PP block co-polymeride (PP-B) PP random co-polymeride (PP-R). Because of its high internal pressure resistance, PP-H is preferred for industrial applications. On the other hand, PP-R is used predominantly in sanitary applications because of its low e-modulus (exible piping) and its high internal pressure resistance at high temperatures. PP-B is mainly used for sewage piping systems because of its high impact strength especially at low temperatures and its low thermal endurance.
The PP-H resin used by GF for PROGEF Standard PP industrial piping systems is characterized by Advantages good chemical resistance high internal pressure resistance high impact strength high thermal ageing and thermal forming resistance high stress fracture resistance outstanding weldability homogeneous, ne structure
Mechanical Properties
PP-H has the highest crystallinity and therefore the highest hardness, tensile strength and stiffness, so the pipes hardly sag anda greater distance between supportsis possible. PP-R has a very good long-term creep strength at higher temperatures, such as, for example, 80C at continuous stress. Unlike PE, PP is not as impact-resistant below 0C. Because of this, GF recommends ABS or PE for low temperature applications. The long-term behavior for internal pressure resistance is provided by the hydrostatic strength curve based on the EN ISO 15494 standard (see the Calculation and Long-Term Behavior section for PE). The application limits for pipes and ttings, as shown in the pressure-temperature diagram, can be derived from these curves.
If polypropylene is exposed to direct sunlight over a long period of time, it will, like most natural and plastic materials, be damaged by the short-wave UV portion of sunlight together with oxygen in the air, causing photo-oxidation. PP ttings and valves are highly heat stabilized. As perapprovals, polypropylene has no special additive against the effects of UV radiation. The same applies to PP piping. Piping which is exposed to UV light should therefore be protected. This is achieved by covering the pipes, e.g.with insulation or also by painting the piping system with a UV absorbing paint.
Thermal Properties
In general polypropylene can be used at temperatures from 0C to +80C, Beta-PP-H in the range from 10C up to 95C. Below 10C, the outstanding impact strength of the material is reduced. On the other hand, the stiffness is even higher at low temperatures. Please consult the pressure-temperature diagram for your maximum working temperature. For temperatures below 0C it must be ensured, as for every other material, that the medium does not freeze, consequently damaging the piping system. As with all thermoplastics, PP shows a higher thermal expansion (0.16 to 0.18 mm/mK) than metal. As long as this is taken into account during the planning of the installation, there should be no problems in this regard. The thermal conductivity is 0.23 W/mK. Because of the resulting insulation properties, a PP piping system is notably more economical in comparison to a system made of a metal like copper.
Combustion Behavior
Polypropylene is a ammable plastic. The oxygen index amounts to 19%. (Materials that burn with less than 21% of oxygen in the air are considered to be ammable). PP drips and continues to burn without soot after removing the ame. Basically, toxic substances are released by all burning processes. Carbon monoxide is generally the combustion product most dangerous to humans. When PP burns, primarily carbon dioxide, carbon monoxide and water are by-products of combustion. The following classications in accordance with differing combustion standards are used: According to UL94, PP is classied as HB (Horizontal Burning) and according to DIN 53438-1 as K2. According to DIN 4102-1 and EN 13501-1, PP is listed as B2 (normally ammable).
According to ASTM D 1929, the self-ignition temperature is 360C. Suitable re-ghting agents are water, foam or carbon dioxide.
Electrical Properties
Since PP is a non-polar hydrocarbon polymer, it is an outstanding insulator. These properties, however, can be worsened considerably as a result of pollution, effects of oxidizing media or weathering. The dielectric characteristics are essentially independent of temperature and frequency. The specic volume resistance is > 1016 cm; the dielectric strength is 75 kV/mm. Because of the possible development of electrostatic charges, caution is recommended when using PP in applications where the danger of res or explosion is given.
This system includes all commonly required pressure pipe ttings, including threaded adaptors and anges for ease of mating to equipment or other piping materials. Ball valves are available in sizes up to 2 (PP), diaphragm valves up to 4 (PP) and buttery valves in sizes up to 36 (metal external bodies with elastomer seals). Other valves, including check valves and metering valves are also available for this system.
See product guide for details on full line of available products.
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11
Electrofusion Joining
Electrofusion joining is an excellent joining solution that provides numerous advantages. The process of joining pipe to a tting socket uses wires to transfer the heat energy to the plastic material. The heat energy is sufcient to melt the plastic surrounding the wires. This generates a zone called the melt zone. This melt zone encapsulates the wires, which are at its origin along the center line. These features makes this one of the safest and easiest fusion technologies on the market. Advantages Fast fusion times Fuse multiple joints in one heat cycle Easiest fusion method Corrosion resistant
Socket Fitting
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Density Tensile Strength @ 73F (Yield) Tensile Strength @ 73F (Break) Modules of Elasticity Tensile @ 73F Compressive Strength @ 73F Flexural Modulus @ 73F Izod Impact @ 73F Relative Hardness @ 73F
ASTM D792 ASTM D638 ASTM D638 ASTM D638 ASTM D695 ASTM D790 ASTM D256 ASTM D2240
Thermodynamics
Properties Melt Index Melting Point Coefcient of Thermal Linear Expansion per F Thermal Conductivity Maximum Operating Temperature Unit gm/10min F in/in/F
BTU-in/ft2/ hr/F
ASTM Test ASTM D1238 ASTM D789 ASTM D696 ASTM D177
0.30-0.40 0.40-0.80
ASTM D648
Other
Properties Water Absorption Poissons Ratio @ 73F Industry Standard Color Food and Drug Association (FDA) United States Pharmacopeia (USP) Unit % PROGEF Standard <0.1% 0.38 7032 YES YES PROGEF Natural <0.1% 0.38 Neutral YES YES PPro-Seal Natural <0.03% 0.38 Neutral YES YES RAL 9005 CFR 21.177.1520 USP 25 Class VI ASTM Test ASTM D570
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2.02 VALVES
A. Ball Valves: Ball valves shall be full port, true union end constructed of polypropylene with EPDM or FPM seals available, manufactured for installation in PROGEF Standard piping system, Type 546 as manufactured by GF Piping Systems. B. Diaphragm Valves: Diaphragm valves shall be constructed of polypropylene with EPDM or PTFE Seal congurations, manufactured for installation in PROGEF Standard piping system, Type 514, 515, 517 or 519 as manufactured by GF Piping Systems. C. Three-Way Ball Valves: Ball valves shall be L-Port/T-Port type constructed of polypropylene with EPDM or FPM seats available, manufactured for installation in PROGEF Standard Piping system, Type 543 as manufactured by GF Piping Systems.
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D.
Buttery Valves: Buttery valves shall be constructed of polypropylene with EPDM or FPM seats available, manufactured for installation in PROGEF Standard Piping system, Type 567 (lug style) or Type 568 (wafer style) as manufactured by GF Piping Systems.
3.2
INSTALLATION
A. System components shall be installed using the [Socket, IR (Infrared) Butt Fusion or Standard Butt Fusion] joining method according to current installation instructions as delivered in print or documented online at www.gfpiping.com. An on-site installation seminar shall be conducted by GF personnel who are certied to conduct said seminar. Seminar topics shall include all aspects of product installation (storage, set up, support spacing, fusion process, machine care, testing procedure, etc.). At the conclusion of the seminar, all installers will be given a written certication test and will be required to prepare and complete one fusion joint of the type being implemented on the project. Upon successful completion of said test, the installer will be issued a certication card verifying that they have met the requirements of the manufacturer with regards to knowledge of proper product installation and testing methods. B. Only the following GF Piping Systems fusion units may be used to install the PROGEF Standard piping system: For Socket Fusion Installation SG 110 Socket Fusion Machine or MSE hand tool Butt Fusion Installation SG 160, GF 160-315, GF 160-500, Butt Fusion Machine For IR Fusion Installation IR63 Plus, IR225 Plus, IR-315 Plus, Infrared Butt Fusion Machines Under this specication, the contractor shall be responsible for the purchase or rental of the proper machine required to meet the intent of the specication and be
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used for installation of the product on site. NOTE: When using socket fusion joining, the installer shall use the proper socket fusion (bench) machine (SG-110, SG-160) per manufacturers recommendations, for as many of the required ttings as possible, with minimal use of the MSA hand tool. C. Installer shall ensure that all pipe and ttings used for Pure Water Piping are components of the same system. No mixing of various manufacturers pipe and/or ttings shall be allowed.
3.3
TESTING
A. The system shall be tested in accordance with the manufacturers recommendations Following is a general test procedure for Georg Fischer plastic piping. It applies to most applications. Certain applications may require additional consideration. For further questions regarding your application, please contact your local GF representative 1 All piping systems should be pressure tested prior to being placed into operational service. 2 All pressure tests should be conducted in accordance with the appropriate building, plumbing, mechanical and safety codes for the area where the piping is being installed. 3 When testing plastic piping systems, all tests should be conducted hydrostatically and should not exceed the pressure rating of the lowest rated component in the piping system (often a valve). Test the system at 150% of the designed operational pressure, i.e.: If the system is designed to operate at 80PSI, then the test will be conducted at 120PSI. 4 When hydrostatic pressure is introduced to the system, it should be done gradually through a low point in the piping system with care taken to eliminate any entrapped air by bleeding at high points within the system. This should be done in four stages, waiting ten minutes at each stage (adding the total desired pressure at each stage). 5 Allow one hour for system to stabilize after reaching desired pressure. After the hour, in case of pressure drop, increase pressure back to desired amount and hold for 30 minutes. If pressure drops by more than 6%, check system for leaks.
Note: If ambient temperature changes by more than 10F during the test, a retest may be necessary.
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2.02 VALVES
A. Ball Valves: Ball valves shall be full port, true union end constructed of polypropylene with EPDM or FPM seals available, manufactured for installation in PROGEF Natural Piping system, Type 546 as manufactured by GF Piping Systems.
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B. Diaphragm Valves: Diaphragm valves shall be constructed of polypropylene with EPDM or PTFE Seal congurations, manufactured for installation in PROGEF Natural piping system, Type 515, 517 and 519 (Zero Static) as manufactured by GF Piping Systems. Diaphragm valves shall be rated for 150 psi when measured at 68F (20C). Pneumatic valve actuators, if required, shall be supplied by GF Piping Systems to ensure proper system operation. C. Three-Way Ball Valves: Ball valves shall be L-Port/T-Port type constructed of polypropylene with EPDM or FPM seats available, manufactured for installation in PROGEF Natural piping system, Type 543 as manufactured by GF Piping Systems. D. Buttery Valves: Buttery valves shall be constructed of polypropylene with EPDM or FPM seats available, manufactured for installation in PROGEF Natural Piping system, Type 567 (lug style) or Type 568 (wafer style) as manufactured by GF Piping Systems.
3.2
INSTALLATION
A. System components shall be installed using the BCF (Bead and Crevice Free) joining methods according to current installation instructions as delivered in print or documented online at www.gfpiping.com. An on-site installation seminar shall be conducted by GF personnel who are certied to conduct said seminar. Seminar topics shall include all aspects of product installation (storage, set up, support spacing, fusion process, machine care, testing procedure, etc.). At the conclusion of the seminar, all installers will be given a written certication test and will be required to prepare and complete one fusion joint of the type being implemented on the project. Upon successful completion of said test, the installer will be issued a certication card verifying that they have met the requirements of the manufacturer with regards to knowledge of proper product installation and testing methods.
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B.
Only the following GF Piping Systems fusion units may be used to install the PROGEF Natural piping system: For IR Fusion Installation IR63 Plus, IR225 Plus, IR-315 Plus, Infrared Butt Fusion Machines For BCF Fusion Installations BCF Plus Under this specication, the contractor shall be responsible for the purchase or rental of the proper machine required to meet the intent of the specication and be used for installation of the product on site.
C.
Installer shall ensure that all pipe and ttings used for Pure Water Piping are components of the same system. No mixing of various manufacturers pipe and or ttings shall be allowed.
3.3
TESTING
A. The system shall be tested in accordance with the manufacturers recommendations Following is a general test procedure for Georg Fischer plastic piping. It applies to most applications. Certain applications may require additional consideration. For further questions regarding your application, please contact your local GF representative 1 All piping systems should be pressure tested prior to being placed into operational service. 2 All pressure tests should be conducted in accordance with the appropriate building, plumbing, mechanical and safety codes for the area where the piping is being installed. 3 When testing plastic piping systems, all tests should be conducted hydrostatically and should not exceed the pressure rating of the lowest rated component in the piping system (often a valve). Test the system at 150% of the designed operational pressure, i.e.: If the system is designed to operate at 80PSI, then the test will be conducted at 120PSI.
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2.02 VALVES
A. Ball Valves: Ball valves shall be oating ball design with full-port true union end constructed of natural virgin copolymer polypropylene with no added plasticizers, pigments or re-grind. All O rings shall be FPM and the valve seats shall be PTFE, manufactured for installation in PPro-Seal Natural PP Piping System, Type 375 as manufactured by GF Piping Systems. Valve shall have a pressure rating of 150 psi at 68F. B. Diaphragm Valves: Diaphragm valves upper body shall be glass lled polypropylene material connected to lower body with exposed stainless steel bolts. Lower bodies shall be natural virgin polypropylene with no plasticizers, pigments or re-grind. Diaphragms shall be fabricated of EPDM material with EPDM elastomer backing, manufactured for installation in PPro-Seal Natural PP Piping system, Type 315, as manufactured by GF Piping Systems. Valve shall have a pressure rating of 150 psi at 68F.
3.2
INSTALLATION
A. Pipe and ttings shall be installed according to current PPro-Seal installation instructions as delivered in print or found online at www.gfpiping.com. An on-site installation seminar shall be conducted by GF Piping Systems personnel who are certied to conduct said installation seminar. Seminar topics shall include all aspects of product installation (storage, set-up, support spacing, fusion procedure, threaded joint installation procedure, product testing procedures, etc.). At the conclusion of the installation seminar, all installers will be given a certication test and, upon successful completion of the test, will be issued a certication card verifying they have met the requirements of the factory with regards to proper product installation methods thereby meeting the intent of the specications.
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B.
Only the following GF Piping Systems fusion units MSA-250SE or Electro Plus may be used to install the PPro-Seal Natural PP piping system. GF Piping systems personnel shall also conduct an on site installation seminar with certication test for all installers using these fusion units. Under this section, the contractor shall purchase either an MSA-250SE or an Electro Plus fusion unit to be used in the installation of the pipe and tting system. At the completion of the installation and testing of the system, the contractor shall turn over the fusion unit to the facility personnel for their use in future system upgrades.
C. Installer shall ensure that all pipe and ttings used for Pure Water Piping are components of the same system. No mixing of various manufacturers pipe and or ttings shall be allowed.
3.3
TESTING
A. The system shall be tested in accordance with the manufacturers recommendations Following is a general test procedure for Georg Fischer plastic piping. It applies to most applications. Certain applications may require additional consideration. For further questions regarding your application, please contact your local GF representative 1 All piping systems should be pressure tested prior to being placed into operational service. 2 All pressure tests should be conducted in accordance with the appropriate building, plumbing, mechanical and safety codes for the area where the piping is being installed. 3 When testing plastic piping systems, all tests should be conducted hydrostatically and should not exceed the pressure rating of the lowest rated component in the piping system (often a valve). Test the system at 150% of the designed operational pressure, i.e.: If the system is designed to operate at 80PSI, then the test will be conducted at 120PSI. This should be done in four stages, waiting ten minutes at each stage (adding 1/4 the total desired pressure at each stage).
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Pressure/Temperature
Long-Term Stress
To determine the long-term strength of thermoplastic pipe, lengths of pipe are capped at both ends (Figure 1) and subjected to various internal pressures, to produce circumferential stresses that will predict failure in from 10 hours to 50 years. The test is run according to ASTM D1598, Standard Test for Time to Failure of Plastic Pipe Under Long-Term Hydrostatic Pressure. The resulting failure points are used in a statistical analysis (outlined in ASTM D2837) to determine the characteristic regression curve that represents the stress/time-to-failure relationship of the particular thermoplastic pipe compound. The curve is represented by the equation log T = a+b log S
Where a and b are constants describing the slope and intercept of the curve, and T and S are time-to-failure and stress, respectively. Figure 1
Length = 7 x min. dia. 12 min. for any size
O.D. = Do
The regression curve may be plotted on log-log paper as shown in Figure 2 and extrapolated from 5 years to 25 years. The stress at 25 years is known as the hydrostatic design basis (HDB) for that particular thermoplastic compound. From this HDB the hydrostatic design stress (HDS) is determined by applying the service factor multiplier.
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1450 1305 1160 1015 870 725 580 508 435 363 290
10hrs
100hrs
5yrs
1hr
10yrs
25yrs 1000hrs
4351
Time to Failure
1450 1305 1160 1015 870 725 580 508 435 363 290
10hrs
100hrs
5yrs
1hr
10yrs
25yrs 1000hrs
4351
25yrs
Time to Failure
24
25yrs
50yrs
0.1hr
1yr
50yrs
0.1hr
1yr
Figure 2c.
Hoop Stress (lbs/in2)
1450 1305 1160 1015 870 725 580 508 435 363 290
10hrs
100hrs
5yrs
1hr
10yrs
25yrs 1000hrs
4351
Time to Failure
25yrs
50yrs
0.1hr
1yr
25
Working Temperature and Pressures for PROGEF Standard (PP-H), PROGEF Natural (PP-R) and PPro-Seal (PP-R)
Based on 25-year service life. Service Factor C=2.0 Figure 3
260 240 220 200 PP-H SDR11
Based on 25yrs
180 PP-R SDR11 160 140 120 100 80 60 40 20 0 30 50 70 90 110 130 150 170 190 PPro-Seal
Temperature (F)
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C Factors
Tests made both with new pipe and pipe that had been in service revealed that (C) factor values for plastic pipe ranged between 160 and 165. Thus the factor of 150 recommended for water in the equation (located in Figure 4) is on the conservative side. On the other hand, the (C) factor for metallic pipe varies from 65 to 125, depending upon the time in service and the interior roughening. The obvious benet is that with Polyethylene piping systems, it is often possible to use a smaller diameter pipe and still obtain the same or even lower friction losses.
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Independent variable for these tests are gallons per minute and nominal pipe size (OD). Dependent variables for these tests are gallons per minute and nominal pipe size OD. Dependent 4Q(0.1337) V= 2 Di with variables are the velocity friction head and pressure drop per 100ft. 60 of pipe, the interior 12 smooth.
( )
1.852
Figure 4
Step 1: Solve for V: P = H/2.31 4Q(0.1337) V= Di 2 4Q(0.1337) 60 V= 12 Di 2 60 4Q(0.1337) V= Step 2: Solve for H: 12 Di 2 1.852 V 60 H = (L + Le) 12 D 0.63 1.318 V C ( 4 ) 1.852 H = (L + Le) D 1.318 C ( 4 )0.63 1.852 P = H/2.31 V H = (L + Le) D 1.318 C ( 4 )0.63 Step 3: Solve for P: P = H/2.31
V - Fluid Velocity (ft/sec) P - Head Loss (lb/in2 /100 ft of pipe H - Head Loss (ft of water /100 ft of pipe) L - Length of Pipe Run (ft) Le - Equivalent Length of Pipe for minor losses (ft) Di - Pipe Inside Diameter (in) Q - Fluid Flow (gal/min) C - Constant for Plastic Pipes (conservative - 150)
( (
( ) ( ) (( )
) )
P = H/2.31
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Note: Caution should be taken when velocities fall within the shaded levels.
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Note: Caution should be taken when velocities fall within the shaded levels.
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Note: Caution should be taken when velocities fall within the shaded levels.
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Note: Caution should be taken when velocities fall within the shaded levels.
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Note: Caution should be taken when velocities fall within the shaded levels.
34
Note: Caution should be taken when velocities fall within the shaded levels.
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Note: Caution should be taken when velocities fall within the shaded levels.
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37
Note: Caution should be taken when velocities fall within the shaded levels.
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Fitting or Valve Type Nominal Pipe Size, mm 20 25 32 40 50 63 75 90 110 160 200 225 250 315 355 400 450 500 Nominal Pipe Size, in. 1 1 2 3 1.5 2.0 2.5 4.0 5.7 7.9
Male/Female Adapter
1.486 R2/3 S1/2 n 1.486 Q =A R2/3 S1/2 n FORMULA Q =A 1.486 S1/2 R2/3 n 12 1/2 1.486 S V = R2/3 n 12 V =
1.486 (0.1073)2/3 (0.020 0.009 1.486 Q = .0723 (0.1073)2/3 (0.020 0.009 Q = .0723 1.486 0.144 (0.1073)2/3 0.009 12 1.486 0.144 V = (0.1073)2/3 0.009 12 V =
FORMULA
Example Problem
System Information Material: Outer Diameter: Inside Diameter: Q - Flow Rate (gpm) A - Section Area Pipe 0.1446 full = 0.0723 full (ft2) n - Manning Friction Factor 0.009 R - Hydraulic Radius of pipe 0.1073 (ft) S - Hydraulic Gradient - Slope 1/8 (in/ft) = 0.0104
FORMULA
Slope 1.486 1/2 (in/ft) = 0.0416 1.486 Q =A R2/3 S1/2 Q = .0723 (0.1073)2/3 (0.0208)1/2 Q = 11.94 0.226 0.144 n 0.009 1.486 1.486 =A R2/3 S1/2 Q = .0723FORMULA (0.1073)2/3 (0.0208)1/2 Q = 11.94 0.226 0.144 Q = 0.102 (ft3/sec) Q = 123.4 (gpm 1.486 n 2/3 1/2 1.4860.009 R S Q = .0723 (0.1073)2/3 (0.0208)1/2 Q = 11.94 0.226 0.144 Q = 0.102 (ft3/sec) Q = 123.4 (gpm) 1.486 1.486 S1/2 0.144 n 0.009 1.486 2/3 2/3 R 0.144 Q =V0.102 = (ft3/sec) (0.1073) V = 165.1 0.226 0.012 .0723 (0.1073)2/3 (0.0208)1/2 V = Q = 11.94 0.226 Q = 123.4 (gpm) ULA n 0.009 12 12 0.009 3 3)2/3 1.486 (0.0208)1/2 Q = 11.94 0.226 0.144 Q = 0.102 (ft /sec) Q = 123.4 (gpm) 1.486 S1/2 0.144 = R2/31/2 V = (0.1073)2/3 V = 165.1 0.226 0.012 V = 0.32 (ft/sec) .486 n 2/3 1.4860.009 S 0.144 12 2/3 R 0.144 Q = 0.102 V = (ft3/sec) (0.1073) (gpm)12 V = 165.1 0.226 0.012 V = 0.32 (ft/sec) .94 0.226 Q = 123.4 n 12 1.486 12 0.1440.009 V = (0.1073)2/3 V = 165.1 0.226 0.012 V = 0.32 (ft/sec) 0.144 0.009 12 2/3 )= V = 165.1 0.226 0.012 V = 0.32 (ft/sec) 3 0.102 12(ft /sec) Q = 123.4 (gpm)
V = 0.32 (ft/sec)
ULA
Table 6
0.5 0.9 1.7 3.0 5.5 10.2 16.4 26.6 45.5 123.4 224.1 306.6 406.9 753.5 1037.1 1425.3 1949.4 2583.3
0.08 0.09 0.11 0.13 0.15 0.17 0.19 0.22 0.25 0.32 0.37 0.40 0.43 0.50 0.54 0.58 0.63 0.68
0.7 1.2 2.4 4.3 7.8 14.5 23.2 37.7 64.4 174.5 316.9 433.6 575.4 1065.7 1466.6 2015.6 2756.9 3653.4
0.11 0.13 0.15 0.18 0.21 0.24 0.27 0.31 0.35 0.45 0.52 0.56 0.60 0.70 0.76 0.83 0.89 0.96
PPro-Seal Natural Polypropylene 1/8 (in/ft) Slope Nominal Pipe Diameter (inch) 1 1 2 3 Flowrate (gpm) Velocity (fps) 1/4 (in/ft) Slope Flowrate (gpm) Velocity (fps) 1/2 (in/ft) Slope Flowrate (gpm) 0.10 0.12 0.15 0.20 0.23 0.31
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Pressure Change
Figure 5 The maximum positive or negative addition of pressure due to surging is a function of uid velocity, uid density, bulk uid density and pipe dimensions of the piping system. It can be calculated using the following steps.
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Step 1
Determine the velocity of the pressure wave in pipes. V w - Velocity of Pressure Wave (ft./sec) K - Bulk Density of Water 3.19 x 105 (lb/in2)
STEP 1: STEP 1:
Vw =
STEP 2:
STEP 1:
w STEP 1:
V =
Vw = Vw = Step 2 1 3.19 x 105 STEP 2: n K 1.937 i valve closure. Critical Vw =time for Vw = 144 Vw = 4870 (ft/sec) 1 1.937 ni 144 t - Time for Valve Closure (sec) c STEP 2: 2L 2 500 STEP 3: tc = 0.2 tc = tc = (sec) Wave of Pressure (ft/sec) V w - Velocity 4870 Vw STEP 2: 2L 2 500 L - Upstream Pipe Length (ft) tc = 0.2 (sec) tc = tc = Pi = V Vw ni 4870 V 500 2L 2 w tc = 0.2 (sec) tc = tc = Step 3 3: V STEP 4870
Maximum pressure increase; assume valve closure time STEP 3: time is less than the critical closure 1.937 4
w
K n K i
Vw =
3.19 x 105
1 144
K ni
Vw =
3.19
1 144
tc =
2 500 4870
Pi =
1.93
3 4870 - Fluid Density (slugs/ft 2 ) Pi =STEP 262 4: (lb/in ) V - Fluid Velocity (ft/sec) STEP 3: 144 Wave 1.937 4 4870 Vw - Velocity of Pressure 2 Pi = V Vw ni Pi = Pi = 262 (lb/in Pmax = P)i1/144 + Ps (ft2 /in2)Pmax = 262 + Conversion Factor n 144 1.937 4 4870 i Pi = V Vw ni Pi = Pi = 262 (lb/in2) 144 STEP 4: Special Consideration 2 STEP P 4: = Maximum Pi + Ps Instantaneous Pmax = 262 + 50 Pmax = 312 STEP (lb/in Calculate the System max Cautionary Note5: )
Pi =
Pressure. STEP 4:
Pmax = Pi + Ps Pmax = Pi + Ps
STEP 5:
max 2 Pmax = 312 (lb/in )maximum L V nsystem 2the greater than i 21 Pg = =(lb/in2) g pressure Pmax design =P 312 multiplied by a safety tv
Caution is recommended if P
is
factor of 2x.
e.g. - Pipe 1 is rated at 150 psi. If max = P + P PP max g s 4 144300psi (150psi x 2 safety 2 1.937 500exceeds Pg P = - Maximum Pressure Increase Pg (lb/in = 2) Pg = 26.9 (lb/in2) i STEP 5: tv 2 factor), then precaution must be 1 2 LV nSystem 2s - Standard Operating Pressure (lb/in ) P i 144 2 1.937 500 4implemented case of maximum Pg = Pg = = 26.9 (lb/in2) Pin 1 g 2 tL V ni pressure wave (i.e. water hammer) to 2 500 4 144 2 1.937 2 v 2 Pmax =P P +P Pmax = 26.9 + 50 = 76.9 ) Pg = = =(lb/in 26.9 (lb/in ) Pg pipe s gg prevent possible failure. tv 2 Pmax2 - Maximum Operating Pressure (lb/in2) L V System n
STEP 5: i
Pmax = Pg + Ps Pmax = Pg + Ps
Pmax = Pi + Ps Step 4
Determine the Maximum System Pressure Increase with Gradual Valve Closure Pg - Gradual Pressure Increase with Valve Closure (lb/in2) L - Upstream Pipe Length (ft.) V - Fluid Velocity (ft./sec) ni - Conversion Factor 1/144 (ft2 /in2) tc - Time of Valve Closure (sec)
STEP 5:
Pmax = 26
Pg =
2 L V ni tv
Pg = Pmax = Pg + Ps
Example Problem
A water pipeline from a storage tank is connected to a master valve, which is hydraulically actuated with an electrical remote control. The piping system ow rate is 300 (gal/min) with a velocity of 4 (ft./sec); thus requiring a 160mm nominal pipeline. The operating pressure of the system will be 50 (lb/in2), the valve will be 500 (ft.) from the storage tank and the valve closing time is 2.0 (sec). Determine the critical time of closure for the valve, and the internal system pressure should the valve be instantaneously or suddenly closed vs. gradually closing the valve (10 times slower).
Pipe Details
System Information Material: Flow Rate: Pipeline Length: Operating Pressure: 160mm PROGEF Standard (PP-H) 300 (gal/min) 500 (ft) 50 (lb/in2)
STEP 1:
Other Information Bulk Water Density (K) Fluid Density () Valve Closing Time Water Velocity 3.19 x 105 (lb/in2) 1.937 (slugs/ft3) 2.0 (sec) 4.0 (ft/sec)
Vw =
STEP 2:
K - Bulk Density of Water 3.19 x 105 (lb/in2) ni - Conversion Factor 1/144 (ft2 /in2) - Fluid Density 1.937 (slugs/ft3)
Vw =
STEP 2:
ni
Vw =
K ni
Vw =
3.19 x 105
1 144
1.937
Vw = 487
1 144
tc = 0.2 (sec)
tc =
44
STEP 3:
2L Vw
tc =
2 500 4870
Pi = V Vw ni
Pi =
Pi =
STEP 1:
STEP 1:
Vw =
K 3.19 x 105 STEP 2: 5= STEP 1: V V = Vw = K Closure Time3.19 x 10 w w 1 Step 2 Critical Valve V= Vw = V = 4870 (ft/sec) 1.937 n w w 1 144 i Determine the Critical Time K ni Closure 144 1.937 STEP 1: 3.19 x 105 STEP 1: 500 2L 2 Vw = Vw = tc = 1 tc = Vw = 4870 (ft/sec) tc = 0.2 (sec STEP 2: t - Critical Closure Time (sec) 4870 V 1.937 n 144 5 w i STEP 2: STEP 1: 3.19 x 105 K 3.19 x 10 K V - Velocity of Wave 4870 (ft/sec) V = V = Vw = VPressure = V = 4870 (ft/sec) w w 1 w w 1 ni L - Upstream Pipe Length 500 (ft) n 1.937 2L 2 5500 STEP 2: 144 1.937 144 i STEP 1: 3.19 x 10 K t tc = V = tc = = 0.2 (sec) STEP 1: 2L 2 500 4870 (ft/sec tc = t c = Vw = tc 3: = 0.2 w (sec) 1 4870 Vw = c V STEP w 105 STEP 2: 144 1.937 ni x 4870 3.19 Vw K STEP 2: 2L 2 500 3.19 K Vw = Vw 1:= tc Vw t = 4870 tc = STEP = = 0.2 (ft/sec) (sec) Vw = c Vw = 1 1 Step 3 - Maximum Pressure Increase 4870 VSTEP n 1.937 4 4870144 w 2: n 1 144 1.937 i 500 2L 2 P = P = V V n 2L 2 i500 w i x 105 t i = STEPi 3: t t = = 0 3.19 K t tSTEP = t = = 0.2 (sec) 1: 144 Determine3: the Maximum Pressure Increase; Assume: Valve Closure < Critical Closure Time t and c c c c Vw c = Vw c= Time V = 4870 (ft/sec) 4870 Vw 4870 Vw STEP w 1 STEP STEP 2: 2: Fluid Velocity goes to 0. 2L 2 500 5 144 1.937t = 0.2 (sec) t = ni tc = 3.19 x 10 K c c STEP 3: 1.937 4 4870 (lb/in ) Vw = P - Maximum Pressure Vw = Increase = 4870 4870 VV P (ft/sec) Pi = 2 P VV ni 1.937 4 =4870 ww 1 i w 500 2L 2= Pt == V Vw n144 Pi = 262 (lb/in 2L ) 144 2 500 1.937 nFluid 1.937 (slugs/ft ) = P2: STEP i Density i t i i t = 0.2 (sec) tc = tc = STEPc 4: STEP 3: 144 c c STEP 3: 4870 V 1.937 4 4870 V - Fluid Velocity 4 (ft/sec) 4870 V 2 w w Pi = V Vw ni Pi = Pi = 262 (lb/in ) STEP 2: V - Velocity of Pressure Wave 4870 (ft/sec) 2L 144 500 2 STEP 3: Pt Ptmax 262 + 50 =3 t = = Pi + Ps == 0.2 (sec) 1.937 P 4 487 max max 1.937 c4 4870 n - Conversion Factor 1/144 (ft /in ) = c c Pi(lb/in = 2V Pi = 4870 Vw STEP Pi = V Vw ni Pi = Pi 4: = 262 ) Vw ni 144 2L STEP 2 500 144 4: 3: STEP STEP 3: 4 4870 tc = 0.2 (sec) tc = tc = 1.937 Pi = V Vw ni P = Pi = 262 (lb/ 4870 Vw Pmax Pressure = Pi + i Ps Pmax = 262 + 50 Pmax = 3 144 STEP 4: Consideration: Maximum Instantaneous System Pmax = Pi + Ps Pmax = 262 + 50 4 4870 Pmax = 312 (lb/in2) 1.937 1.937 STEP 3: 2 Pi = Maximum V Vw n Pi = PP = 262 (lb/in Determining the Instantaneous System Pressure: if PV is greater P = STEP 5: Caution is recommended n) i i i = V w i i 144 STEP 4: 2 STEP 4: Pmax = Pi +Pressure Ps Pmax =by 262 50 Factor. Pmax = 312 (lb/in ) than the Maximum System Operating multiplied a 2x + Service STEP 3: LP V= ni1.937 4 4870 2 1.937 2 500(lb/in 4 1 PSTEP = 4: V = Vw n = 262 Pressure (lb/in ) P - Maximum Instantaneous Operating i i 2) = P + P i P 262 + 50 P = max = P Pg P Pmax = Pi + Ps Pmax = 262 + 50i PP = 312 (lb/in 144 max i s g max STEP 5: P - Valve Pressure (instantaneous) (lb/in ) tv 2 1.937 4 4870 STEP 5: 2 STEP Pi = P V VStandard n 4: System Pi = (lb/in )+ STEP 4: 50 Operating Pressure (lb/in ) P Pi = 262 Pmax = Pi + Pmax = 262 Pmax = 312 (lb/in2) 1 w i s 144 L V n 2 STEP 5: Standard Polypropylene pipe In this case, 160mm PROGEF i 1 2 1.937 500 4 14 2LVn Pg = Pg2 i 1.937 500 4 = 2= P = P + P Pmax 144 2 = 26.9 + 5 max g s P = P + P P = 262 + 50 P 312 (lb/in ) is rated at 150psi. Therefore, the system design is outside Pg = P 26.9 ) = 262 + Pmax P =g P= + Ps (lb/in Pmax tv max 2 STEP 4:g max i s max i 1 tv 2 STEP 5: STEP 5: 2 L V ni safety limits (300psi max). 2 1.937 500 4 144 Pg = Pg = Pg = 26.9 (lb/in STEP 4: 2 tv PSTEP 2 = P + P P = 262 + 50 P = 312 (lb/in )+5 1 max 5: i s max LP max Vn 2 = Pg + Psmax P = 26.9 2 L V ni i 1.937 50 2 max 2 1.937 500 4 2 144 2 P = P + P P = 26.9 + 50 = 76.9 (lb/in ) Step 4 - Maximum with Gradual Closure P = PValve Pg = = = max in Pressure = 26.9 (lb/in ) Pg Change g s max g g g 2 2 1 Pmax P = 312 (lb/in )tv STEP 5: tv = Pi + Ps STEP 5: Pmax = 262 + 50 2 L max Vn 2 Determine the Maximum Change in2 System Pressure with Valve Closure (2 Second Close Time). i + Gradual 26.9 1.937 500 4 144 2 P = P P P = + 50 = 76.9 (lb/in ) max g s Pg = Pg max = Pg = 2 - Maximum Gradual Pressure Change t (lb/in ) P 2 1 v 2 L V ni V = niP + P 2 2 L 4 144 2 1.937 500(lb/in PP 2 1 2 Pmax 5: = 26.9 PmaxClosing = Pg Time + Ps2 (sec) STEP Pmax max = 26.9 g (lb/in s Ptg = - Valve Pg = + 50 = 76.9 ) = 2= Pg = ) P g g tvPipe Length 500 (ft) 2 L - Upstream tv 1 50 = 76.9 (lb/ P = Pg + Ps P = 26.9 + STEP 5: L V n 2 V - Fluid Velocity 4 (ft/sec) max i 500 4 144 2 1.937max Pg = (ft /in ) Pg = Pg = 26 n - Conversion Factor 1/144 2 t 2 1 P = P + P P = 26.9 + 50 = 76.9 (lb/in ) Pmax = Pg + Ps 2 L V g v s max n - Fluid Density 1.937 (slugs/ft ) i 1.937 500 4 144 2max Pg = Pg = 26.9 (lb/in2) Pg = tv 2 Pmax = Pg + Ps Pmax = 26.9 + 50 = 76.9 (lb/in
K ni
Vw =
3.19 x 105
1 144
1.937
Vw =
max
max i
Pmax = Pg + Ps
45
Expansion/Contraction
Allowing for Length Changes in PP Pipelines
Variations in temperature cause greater length changes in thermoplastic materials than in metals. In the case of above ground, wall or duct mounted pipe work, particularly where subjected to varying working temperatures, it is necessary to make suitable provision for length changes in order to prevent additional stresses.
400
200
100
87
There are two primary methods of controlling or compensating for thermal expansion of plastic piping systems: taking advantage of offsets and changes of direction in the piping and expansion loops.
Figure 6
46
150
420
423
a
Guide Fixed Guide Guide Fixed
Most piping systems have occasional changes in directions which will allow the thermally included length changes to be taken up in offsets of the pipe beyond the bends. Where this method is employed, the pipe must be able to oat except at anchor points. 15
Fixed
Fixed Guide Fixed Guide Fixed
25
a
Guide Guide Fixed Guide
Guide
Fixed
Guide
Changes in Direction
6min.
Offsets 6min.
Type 2 - Expansion Loops For expansion loops the exible section is broken into two offsets close together. By utilizing the exible members between the legs and 4 elbows the a length is slightly shorter than the a in the standalone offset.
Fixed
Expansion Loop
Guide
Guide
47
L = L T
(inch) = (inch) (F) (inch/inchF)
L = Length change in inches L = Length in inches of the pipe or pipe section where the length change is to be determined T = Difference between installation temperature and maximum or minimum working temperature in F = Coefcient of linear expansion - 0.000083 in/inF
Important: If the operating temperature is higher than the installation temperature, then the pipe becomes longer. If, on the other hand, the operating temperature is lower than the installation temperature, then the pipe contracts its length. The installation temperature must therefore be incorporated into the calculation, as well as the maximum and minimum operating temperatures.
+l
Installation
L = 315in +l2 Fixed Point
Expansion
48
L = 315in -l1
Problem
The procedure is explained using a coolant pipe as an example: Length of the pipe from the xed point to the branch where the length change is to be taken up: L = 315 inch Installation temperature: Tv = 73F Temperature of the coolant: T1= 40F Temperature when defrosting and cleaning: T2= 95F Material: 250mm PROGEF Standard (PPH) Difference in Contraction Temperature T1 = Tv - T1 = 73F - 40F = 33F Difference in Expansion Temperature T2 = T2 - Tv = 95F - 73F = 22F Contraction during service with coolant
L L1 = L T1 = 315in 33 (0.000083) = 0.86in
Contraction
-l
Installation
L = 315in +l2 Fixed Point
Expansion
L = 315in -l1 Fixed Point
Contraction
49
50
Le
0.9 Determining the Length of the Flexible Section (a) 0.8 (Example 2)0.7
The values required to determine the length of the exible (a) section are: The maximum length change L in comparison with the zero position during installation, 0.1 (which can be either an expansion30.0 or a contraction), pipe diameter (d). 15.0 45.0 and the 60.0 75.0
90.0 105.0
Flexible Section Length (a) in inches If values L and (d) are known, Table 8 shows the length of exible section (a) required.
0.6 0.5
a k d
a = k L d
L = Change in Length
Flexib Sectio
0.1 0.2 0.3 0.4 0.5 0.6 0.7 Length Change - L (in) 0.8 0.9 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
8 12 15 17 19 21 22 24 25 27 38 46 53 60 65 70 75 80 84
9 13 16 19 21 23 25 27 28 30 42 52 60 67 73 79 84 89 94
11 15 18 21 24 26 28 30 32 34 48 58 67 75 82 89 95 101 106
33 47 58 67 75 82 88 94 100 106 149 183 211 236 259 280 299 317 334
35 50 61 71 79 87 94 100 106 112 159 194 224 251 275 297 317 336 355
38 53 65 75 84 92 100 106 113 119 168 206 238 266 292 315 337 357 376
51
Change of Direction
L
Fixed Guide
1in
2in
3in
Fixed
Guide
1 1/2in
1/2in
3/4in
9 12 15 17 19 21 23 25 26 27 39 48 55 61 67 73 78 82 87
10 14 17 19 22 24 26
Fixed
11 15 19 22 24 27 29 31
Guide
15
18
a
Guide
Guide 25 Fixed 21
25 29 33 36 39 41 44 46
Guide
31 35 40 43 47 50 53 56
Fixed
6min.
Expansion
15
L
Guide
a
Guide
Fixed Fixed2 5
27
a
Guide
Guide
29 31 43 53 61 69 75 81 87 92 97
33 34 49 60 69 77 84 91 97 103 109
Guide Guide
6min.
Offeset
a
Guide Fixed Fixed
L
Guide
Guide
6.0 7.0
a
Guide Fixed Guide Guide
Guide
Guide
Installation Hints
The length changes in pipe sections should be clearly controlled by the arrangement of xed Fixed Guide Fixed Guide brackets. It is possible to distribute the length changes in pipe sections using proper positioning of xed brackets (see adjoining examples).
Guide Fixed Guide
If it is not possible to include a exible section at a change of direction or branch, or if extensive length changes must be taken up in straight sections of pipe work, expansion loops may also be installed. In this case, the length change is distributed over two exible sections. Note To eliminate bilateral expansion thrust blocks are recommended at intersections. For an expansion loop, (taking Example 1), the length change of 1.28in would require a exible section length of a = 42.6in. A single exible section on the other hand, would need to be 106.5in. in length.
52
Pre-Stressing
In particularly difcult cases, where the length changes are large and acting in one direction only, it is also possible to pre-stress the exible section during installation, in order to reduce the length of a. This procedure is illustrated in the following example:
a
Installation conditions L = 315in.
Fixed Guide Fixed
L
Guide
d = 250mm. (nominal) Installation temperature: 73F Max. working temperature: 35F Material: PP-H 1 . Length change +L = L T = 315 38 (0.000083) = 0.99in.
Guide
a
Fixed Guide
2. Flexible section required to take up length change of L = 0.99in according to Table 7: a = approx. 94in.
3. If, on the other hand, the exible section is pre-stressed to L/2, the required length of
Fixed is reduced Guide to approx. 1500mm (59in.). The length Fixed change, starting Guide exible section from the zero
position, then amounts to L/2 = 0.99in/2 = 0.50in. a = approx. 67in. (per Table 7)
Guide Fixed Guide
In special cases, particularly at high working temperatures, pre-stressing of a exible section improves the appearance of the pipeline in service, as the exible section is less strongly deected.
Installation
The Incorporation of Valves
Valves should be mounted as directly as possible; they should be formed as xed points. The actuating force is thus transmitted directly, and not through the pipeline. The length changes, starting from the valve, are to be controlled as described previously. For safe mounting of plastic valves, Georg Fischer valves are equipped with metal threaded inserts for direct mounted installation.
53
Vibration Dampeners
There are two principal ways to control stress caused by vibration. You can usually observe the stability of the system during initial operation and add restraints or supports as required to reduce effects of equipment vibration. Where necessary restraint ttings may be used to effectively hold pipe from lifting or moving laterally. In special cases where the source of vibration is excessive (such as that resulting from pumps running unbalanced), an elastomeric expansion joint or other vibration absorber may be considered. This may be the case at pumps where restricting the source of vibration is not recommended.
Figure 7
54
Pipe Bracket Spacing in the Case of Fluids with Specic Gravity 1.0 (62.4 Lb/Ft3) Where uids with a specic gravity exceeding 1g/cm3 are to be conveyed, pipe spacing can be adjusted by dividing the support spacing by the specic gravity (See example next page). Installation of Closely Spaced Pipe Brackets A continuous support may be more advantageous and economical than pipe brackets for small diameter horizontal pipe work, especially in a higher temperature range. Installation in a V-or U-shaped support made of metal or heat-resistant plastic material has proven satisfactory. Pipe Bracket Requirements When mounted, the inside diameter of the bracket must be greater than the outside diameter of the pipe, in order to allow length changes of the pipe at the specied points. The inside edges of the pipe bracket must be formed in such a way that no damage to the pipe surface is possible. George Fischer pipe brackets meet these requirements. They are made of plastic and may be used under rugged working conditions and also in areas where the pipe work is subjected to the external inuence of aggressive atmospheres or media. Georg Fischer pipe brackets are suitable for PVC, CPVC, PE, PP and PVDF pipes. Arrangement of Fixed Brackets If the pipe bracket is positioned directly beside a tting, the length change of the pipeline is limited to one direction only (one-sided xed point). If it is, as in most cases, necessary to control the length change of the pipeline in both directions, the pipe bracket must be positioned between two ttings. The pipe bracket must be robust and rmly mounted in order to take up the force arising from the length change in the pipeline. Hanger type brackets are not suitable as xed points.
55
General Pipe Supports and Brackets for Liquids with a Specic Gravity 1.0 (62.4 lb/ft3)
Table 9
Pipe Bracket Intervals L (ft.) for PROGEF Standard 65F 65F 105F 125F 140F Pipe Size (mm) 20 25 32 40 50 63 75 90 160 200 225 250 315 355 400 450 500 176F Pipe Size (mm) 20 25 32 40 50 63 90 Pipe Size (inch) 1 1 2 3 3.8 4.0 4.5 5.0 5.5 6.5 Pipe Bracket Intervals L (ft.) for PROGEF Natural 105F 125F 140F 1.5 1.7 2.1 2.4 2.4 3.3 3.6 3.0 3.5 3.8 4.3 4.5 5.5 176F 1.4 1.6 1.9 2.1 2.5 3.1 3.3 2.8 3.0 3.3 3.8 4.0 5.0 85F 1.6 1.9 2.3 2.6 3.0 3.5 3.9
2.3 2.6 3.1 3.6 4.1 4.8 5.1 5.4 7.4 8.2 8.7 9.2 10.3 11.0 11.6 12.3 13.0
85F 2.2 2.5 3.0 3.5 4.0 4.7 4.9 5.2 7.2 7.9 8.4 8.9 10.0 10.7 11.3 12.0 12.6
2.1 2.5 3.0 3.4 3.9 4.6 4.8 5.1 6.9 7.5 8.0 8.5 9.7 10.3 11.0 11.6 12.3
2.1 2.4 2.9 3.3 3.8 4.4 4.6 4.9 6.6 7.2 7.7 8.2 9.4 10.0 10.7 11.3 12.0
2.0 2.3 2.8 3.1 3.6 4.3 4.4 4.8 6.2 6.9 7.4 7.9 8.9 9.5 10.2 10.8 11.5
1.8 2.1 2.5 2.9 3.3 3.9 4.1 4.4 5.6 6.2 6.6 7.1 8.0 8.7 9.4 10.0 10.7
Pipe Bracket Intervals L (ft.) for PPro-Seal 3.8 4.0 4.5 5.0 5.5 6.5 3.7 3.9 4.3 4.8 5.3 6.3 3.5 3.8 4.0 4.8 5.0 6.0
Note: General rule of thumb: pipe spacing can be adjusted by dividing the support spacing by the specic gravity. Example: 63mm pipe carrying media with a specic gravity of 1.6 4.8ft divided by 1.6 = approx. 3ft centers.
56
Mechanical Connections
Mechanical Joining of Piping Systems
Flange Connections Flange adapters for butt fusion Coated Metal Flanges Backing Rings Plastics-oriented connections between same plastics Transitions to other plastics Seal: O-ring Plastic ttings with reinforcement ring and tapered Female NPT threads. (Note: PPro-Seal does not utilize a reinforcement ring)
Unions
Threaded Fittings
Threaded Connections
The following different types of threads are used
Designation of the thread G (Buttress Threads) According to standard ISO 228 Typical use Unions Description Parallel internal or external pipe thread, where pressure-tight joints are not made on the threads Taper internal or external pipe thread for plastic pipes and ttings, where pressure-tight joints are made on the threads
ASTM F1498
Flanged Connections
Creating Flange Joints When making a ange connection, the following points have to be taken into consideration: There is a general difference between the connection of plastic pipes and so-called adapter joints, which represent the transition from a plastic pipe to a metal pipe or a metal valve. Seals and anges should be selected accordingly. Flanges with sufcient thermal and mechanical stability should be used. GF ange types fulll these requirements. A robust and effective seal can only be achieved if sufcient compressive forces are transmitted to the polyethylene stub end via the ductile iron backup ring. These compressive forces must be of sufcient magnitude to overcome uctuating hydrostatic and temperature generated forces encountered during the lifetime of the joint. It is possible to achieve a good seal between polyethylene stub ends without the use of a gasket, but in some circumstances a gasket may be used. In assembling the stub ends, gasket and backup rings it is extremely important to ensure
57
cleanliness and true alignment of all mating surfaces. The correct bolt tightening procedure must also be followed and allowance made for the stress relaxation characteristics of the polyethylene stub ends. Alignment 1. Full parallel contact of the sealing faces is essential. 2. The backup ring must contact the stub end evenly around the circumference. 3. Misalignment can lead to excessive and damaging stresses in either the stub
Materials
Plastic Flanges Visually inspect anges for cracks, deformities or other obstructions on the sealing surfaces. Gasket A rubber gasket must be used between the ange faces in order to ensure a good seal. GF recommends a 0.125 thick, full-face gasket with Shore A scale hardness of 705, and the bolt torque values (Table 12) are based on this specication. For other hardness requirements, contact GF Technical Services. Select the gasket material based on the chemical resistance requirements of your system. A full-face gasket should cover the entire ange-to-ange interface without extending into the ow path.
58
Table 10
Size O.D. (in) 3.50 3.86 4.25 4.61 5.00 5.98 7.01 7.48 9.02 10.98 13.50 13.50 16.00 19.00 21.00 23.50 PROGEF I.D. (in) 1.10 1.34 1.65 2.01 2.44 3.07 3.62 4.33 5.24 7.05 9.30 9.42 11.35 13.31 14.80 16.93 PPro-Seal I.D. (in) 0.88 1.10 1.38 1.93 2.44 3.59
63mm (2) 75mm (2) 90mm (3) 110mm (4) 160mm (6)
Figure 8
200mm (8) 225mm (8) 250mm (10) 315mm (12) 355mm (14) 400mm (16)
59
Fasteners It is critical to avoid excessive compression stress on a ange. Therefore, only low-friction fastener materials should be used. Low-friction materials allow torque to be applied easily and gradually, ensuring that the ange is not subjected to sudden, uneven stress during installation, which can lead to cracking. Either the bolt or the nut, and preferably both, should be zinc-plated to ensure minimal friction. If using stainless steel bolt and nut, lubricant must be used to prevent high friction and seizing. In summary, the following fastener combinations are acceptable: zinc-on-zinc, with or without lube zinc-on-stainless-steel, with or without lube stainless-on-stainless, with lube only Cadmium-plated fasteners, while becoming more difcult to obtain due to environmental concerns, are also acceptable with or without lubrication. Galvanized and carbon-steel fasteners are not recommended. Use a copper-graphite anti seize lubricant to ensure smooth engagement and the ability to disassemble and reassemble the system easily. Bolts must be long enough that two complete threads are exposed when the nut is tightened by hand. Using a longer bolt does not compromise the integrity of the ange connection, although it wastes material and may make tightening more difcult due to interference with nearby system components.
60
Suggested bolt length for ange-to-ange connection with 0.125 thick gasket. Adjust bolt length as required for other types of connections. Minimum spec. Use of a stronger or thicker washer is always acceptable as long as published torque limits are observed. Also known as Type A Plain Washers, Narrow Series. ASTM F436 required for larger sizes to prevent warping at high torque.
A washer must be used under each bolt head and nut. The purpose of the washer is to distribute pressure over a wider area, reducing the compression stress under the bolt head and nut. Failure to use washers voids the GF warranty.
61
Torque Wrench Compared to metals, plastics are relatively exible and deform slightly under stress. Therefore, not only must bolt torque be controlled in order to avoid cracking the ange, but continuing to tighten the bolts beyond the recommended torque levels may actually make the seal worse, not better. Because bolt torque is critical to the proper function of a ange, a current, calibrated torque wrench accurate to within 1 ft-lb must be used when installing anges. Experienced installers may be tempted to forgo the use of a torque wrench, relying instead on feel. GF does not endorse this practice. Job-site studies have shown that experienced installers are only slightly better than new trainees at estimating bolt torque by feel. A torque wrench is always recommended. Checking System Alignment Before assembling the ange, be sure that the two parts of the system being joined are properly aligned. GF has developed a pinch test that allows the installer to assess system alignment quickly and easily with minimal tools. First check the gap between the ange faces by pinching the two mating components toward each other with one hand as shown below. If the faces can be made to touch, then the gap between them is acceptable. Figure 9
62
Next check the angle between the ange faces. If the faces are completely ush when pinched together, as shown above, then the alignment is perfect, and you may continue installation. Otherwise, pinch the faces together so that one side is touching, then measure the gap between the faces on the opposite side. The gap should be no more than 1/8. Figure 10
To assess high-low misalignment, pull the ange faces ush together. If the faces are concentric within 1/8, then the high-low misalignment is acceptable Figure 11
If the gap between the mating components can not be closed by pinching them with one hand, or if the angle or high-low misalignment between them is too large, then using the bolts to force the components together will result in excessive stress and possible failure during or after installation. In this case, inspect the system to nd the greatest source of misalignment and ret the system with proper alignment before bolting.
63
Tightening the Bolts Tightening one bolt to the maximum recommended torque while other bolts are only hand-tight, or tightening bolts in the wrong order, produces uneven stresses that may result in poor sealing. To ensure even distribution of stresses in the fully-installed ange, tighten the bolts in a star pattern as described in ANSI B16.5. The torque required on each bolt in order to achieve the best seal with minimal mechanical stress has been carefully studied in laboratory and eld installations, and is given in Table 12 . To ensure even distribution of stresses and a uniform seal, tighten the bolts to the rst torque value in the sequence, using a star pattern, then repeat the star pattern while tightening to the next torque value, and so on up to the maximum torque value. All thermoplastics deform slightly under stress. A nal tightening after 24 hours is recommended, when practical, to ensure that any bolts that have loosened due to relaxation of the polymer are fully engaged. If a ange leaks when pressure-tested, retighten the bolts to the full recommended torque and retest. Do not exceed the recommended torque before consulting an engineer or GF representative.
64
Size (mm) 20 25 32 40 50 63 75 90 110 160 200 225 250 315 355 400 450 500
Size (in) 1 1 1 2 2 3 4 6 8 9 10 12 14 16 18 20
* Assumes the use of SS, zinc- or cadmium-plated bolt and/or nut along with copper-graphite anti seize lubricant brushed directly onto the bolt threads.
** Assumes the use of zinc- or cadmium-plated bolt, nut, or both. Never use unlubricated, uncoated bolts and nuts with vinyl anges, as high friction and seizing lead to unpredictable torque and a high incidence of cracking and poor sealing.
Note that the torques listed in Table 12 are for ange-to-ange connections in which the full faces of the anges are in contact. For other types of connections, such as between a ange and a buttery valve, where the full face of the ange is not in contact with the mating component, less torque will be required. Do not apply the maximum listed torque to the bolts in such connections, which may cause deformation or cracking, since the ange is not fully supported by the mating component. Instead, start with approximately two-thirds of the listed maximum torque and increase as necessary to make the system leak-free after pressure testing.
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Documentation Keep Instructions Available Provide a copy of these instructions to every installer on the job site prior to beginning installation. Installers who have worked primarily with metal anges often make critical mistakes when installing vinyl anges. Even experienced vinyl installers will benet from a quick review of good installation practices before starting a new job. Installation Tags (Figure 12) Best practices include tagging each ange with Installers initials Installation date Final torque value (e.g., 29.2-31.5) Conrmation of 24-hour torque check (y or n)
Figure 12
Installed By
This information can be recorded on pre-printed stickers, as shown below, and placed on each ange immediately after installation.
Date
Experience has shown that installation tags speed up the process of resolving system leaks and product failures, improve communication between the contractor and distributor or manufacturer, highlight training opportunities, and promote worker diligence.
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Union Connection There should be no gap between the mating components, so that the threaded nut serves only to compress the o-ring, thus creating the seal. However, a small gap (less than 1/8) between the mating components is acceptable. Never use the union nuts to draw together any gaps between the mating faces of the components or to correct any system misalignment. Hand-Tightening (all sizes) (see Table 13) The next step is to hand-tighten the union nut. With the o-ring in place, engage the nut with its mating threads and turn clockwise with one hand. Continue turning with moderate force until the nut no longer turns. Be careful to use reasonable force when tightening the nut. Your grip should be rm but not aggressive. The nut should turn easily until it bottoms out and brings the mating faces into direct contact. It is recommended that you place an indexing mark with a permanent marker on the union nut and body to identify the hand tight position. Do not use any form of lubricant on the threads of the union nut. Union and ball valve sizes 3/8 through 1 should be sufciently sealed after hand-tightening, for the hydrostatic pressure test of the system.
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Optional: Further Tightening (2) (see Table 13) Based on experience, or system requirements, the installer may choose to turn the nut an additional 1/8 turn (approximately 45) in order to ensure a better seal before hydrostatically pressure testing the system. To do this, use a strap wrench to turn the nut 1/8 turn past the index mark applied after assembly. Do not exceed 1/8 turn past the index mark. Do not use any metallic tools. (Tool marks on the union nut will void manufacturers warranty.) At this point, the system should be hydrostatically pressure tested before turning the union nut any farther. Table 13 Tightening Guide for Union and Ball Valve Nuts
Nominal Size (inch) 1 1 2 Initial Hand-Tight Hand-Tight Hand-Tight Hand-Tight Hand-Tight Additional Pre-Test None None None None 1/8 Turn (max) Additional Post-Test 1/8 Turn (max) 1/8 Turn (max) 1/8 Turn (max) 1/8 Turn (max) 1/8 Turn (max)
Post-Test Tightening (Sizes 1/2 to 1 only) (see Table 1) It is highly unlikely that any union nut connection; when tightened as instructed above, will leak under normal operating conditions. In the unlikely event that a leak occurs, the union nut at the leaking joint may be tightened an additional 1/8 turn, as described above. The system should then be re-tested. If the joint still leaks after post-test tightening, do not continue to tighten the nut at the leaking joint. Disassemble the leaking joint, re-check system alignment, and check for obstructions in the sealing area. If the cause of a leak can not be determined, or if you suspect that the union or valve is defective, contact your GF representative at (800) 854-4090 for further instructions. Quality Check After Assembly To check if the union connections are installed in a stress-free manner, GF recommends that a random check of alignment be done by removing the nut on selected union connection one at a time. A properly installed system will not have any movement of the piping as the nut is loosened. If any springing action is noticed, steps should be taken to remove the stress prior to re-installing the union nut.
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Documentation
Keep Instructions Available installation. Installation Tags Best practices include tagging each union with: Installers initials Installation date Provide a copy of these instructions to every installer on the job site prior to beginning
Installed By Date
This information can be recorded on pre-printed stickers, as shown below, and placed on each union nut immediately after installation.
Installed By Date
Figure 13
Experience has shown that installation tags speed up the process of resolving system leaks and product failures, improve communication between the contractor and distributor or manufacturer, highlight training opportunities, and promote worker diligence. See the GF vinyl technical manual for information on guides, support spacing, and allowance for thermal expansion.
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Design Considerations Due to the difference in stiffness between plastic and metal, a metal male-to-plastic female joint must be installed with care and should be avoided if possible. Only Schedule 80 pipe may be threaded. Threading reduces the rated pressure of the pipe by one-half.
Preparation
Thread Sealant A thread sealant (or pipe dope) approved for use with plastic or PTFE (Teon) tape must be used to seal threads.
Installation
Thread Sealant Use a thin, even coat of sealant. PTFE tape must be installed in a clockwise direction, starting at the bottom of the thread and overlapping each pass. Making the Connection Start the threaded connection carefully by hand to avoid cross threading or damaging threads. Turn until hand tight. Mark the location with a marker. With a strap wrench on the plastic part, turn an additional half turn. If leakage occurs during pressure testing, consult the chart for next steps. Table 14 Threaded Connection Guide
Connection Type Plastic to Plastic Plastic Male to Metal Female Metal Male to Plastic Female Next Step Tighten up to 1/2 turn Tighten up to 1/2 turn Consult Factory
Alignment Threaded connections are susceptible to fracture or leaking due to misalignment. Pipe should be installed without bending. See the GF vinyl technical manual for information on guides, support spacing, and allowance for thermal expansion.
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The resulting fusion joints are homogeneous and display the following characteristics: Non-contact heating of the joining components eliminates the risk of contamination Smaller joining beads due to adjustment of joining pressure path prior to the fusion elimination of the equalization process Adjustment of the joining pressure path also ensures excellent reproducibility of the Low-stress fusion joints due to very uniform heating by means of IR radiator fusion joints General Requirements The basic rule is that only similar materials can be fusion joined. For the best results only components which have a melt ow index in the range from MFR 190/5 0.3 to 1.7 g/10 min should be fusion joined. The components to be joined must have the same wall thicknesses in the fusion area. Maximum permissible wall displacement: 10%. Only same wall thicknesses in the fusion area and inhomogeneities; process itself, i.e.
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A incorrect B correct
IR fusion joining must only be performed by personnel trained in the use of this method. Training is provided world-wide by qualied GF IR Plus welding instructors. Tools Required Infrared fusion joining requires a special joining machine in addition to the tools normally used for plastic pipe work construction (pipe cutters, etc.).
General Conditions Protect the area of the fusion joint from adverse weather conditions, such as rain, snow or wind. The permitted temperature range for IR Plus fusion joining between +5C and +40C. Outside this range, suitable action must be taken to ensure that these conditions are maintained. It must also be ensured that the components being joined are in this temperature range.
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Preparing the Fusion Joint and Operating the IR Fusion Joining Machine In principle, IR fusion joining machines do not require any special preparation, but it should be ensured that the components being joined are clean. Operation of the IR machines is dened exactly in the operating instructions, but we strongly recommend attending a 1-day training course to become a qualied IR welder.
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General Requirements The basic rule is that only similar materials can be fusion joined, i.e.: PE with PE. For best results, only components which have a melt ow index in the range from MFR 190/5 0.3 to 1.7 g/10 min should be fusion joined. This requirement is met by PE butt fusion ttings from GF. The components to be joined must have the same wall thicknesses in the fusion area. Join only components with similar wall thicknesses
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(A) incorrect
(B) correct
Heated tool butt fusion joining may only be performed by adequately trained personnel. Tools Required Butt fusion joining requires a special joining machine in addition to the tools normally used for plastic piping construction (pipe cutters, saw with cutting guide). The fusion joining machine must meet the following minimum requirements: The clamping equipment must hold the various parts securely without damaging the surfaces. Possible ovality can be largely compensated by centered clamping of the components to be joined. It must also be possible to hold all parts rmly in alignment. The machine must also be capable of face planing the fusion surfaces of pipes and ttings. The fusion joining machine must be sufciently solid to be able to absorb the pressures arising during the fusion procedure without detrimentally deforming the joint. The heating surfaces of the heating element must be at and parallel. The temperature variation over the working area must not exceed 10C. The machine should be set up and operated according to the manufacturers instructions. The fusion procedure detailed below including the preparation is based on DVS 2207-1 Welding of thermoplastics - Heated tool welding of pipes, pipeline, components and sheets made from PE. General Conditions Protect the area of the fusion joint from adverse weather conditions, such as rain, snow and wind. At temperatures below +5C or above +45C, measures must be taken to ensure that the temperature in the working area is in the range required for satisfactory joining and does not hinder the necessary manual tasks.
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Protect the Fusion Area Screening the fusion area can ensure a more even temperature distribution on the entire circumference of a pipe subject to direct sunlight. The pipe ends at the opposite end of the fusion areas should be sealed whenever possible to reduce to a minimum the cooling of the fusion surfaces which can becaused by wind.
Preparation of the Fusion Joint The quality of the fusion process is governed by the care with which the preparatory work is carried out. This part of the procedure therefore deserves special attention. Heating Tool X Wall thickness in mm Y Heating tool temperature C The fusion temperature should be between 204C 232C. In principle, the upper temperature should be aimed at for less thick walls and the lower temperature for thicker walls.
Check the Temperature To test the thermostat, check temperature before commencing the fusion joining. This is best carried out with the help of a digital thermometer. But only thermometers with a sensor for measuring surface temperature are suitable. To ensure it is being maintained at the correct level the fusion temperature should be checked from time to time during the joining work. The temperature of the heating element is particularly sensitive to wind.
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Clean the Heating Element Clean the heating element with dry, clean paper before each fusion joint! Protect the working surface of the heating element from becoming soiled. Clean both faces of the heating element with dry, lint-free paper before each fusion joint. Protect the heating element from wind, damage and soiling during the intervals between making fusion joints.
Planing and Subsequent Checking Before machining the joining surfaces, make sure that the tools and the work pieces are clean and grease-free beyond the actual fusion zone; if necessary, clean with a cleaning uid. All the components clamped into the fusion joining machine are planed simultaneously with the planer provided. The shavings should not be thicker than d 0.2mm. This step is completed when there is no un-machined area left on either of the parts to be joined. This is normally the case when no more shavings come off the machined surface. Remove any shavings which may have fallen into the pipe or tting with a brush. The fusion surfaces should not be touched by hand under any circumstances. Otherwise they must be cleaned with cleaning uid. Once they have been machined, the parts are moved together until they touch. The gap between the two parts must not exceed 0.5 mm at any point.
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Check the Wall Alignment and Gap The alignment of the two parts should be checked at the same time. A possible misalignment on the outside must not exceed 10% of the thickness of the wall. If this limit is exceeded, a better clamping position is to be sought, e.g.: by rotating the pipe. In such a case, however, the surface must be re-planed. Important: The fusion surfaces must be planed immediately prior to the joining. Setting the Fusion Pressure Fusion joining requires different pressures to be applied during equalization and joining on the one hand and during the heat soak period on the other. Please see the following diagram.
The specic joining pressure required for equalization and fusion can be found in the following table with the heating and cooling periods. The table lists the times for various wall thicknesses. Interpolate for intermediate values. The force needed for equalization and joining (FA) is given by the product of the fusion area and the specic joining pressure (FA = A p). The force (FB) required to move the pipe must be added to this. (Ftot = FA + FB). This latter force includes the intrinsic resistance of the machine and the resistance of the axially mobile pipe or tting clamped in it. The resistance of longer pipes should be reduced as far as possible by placing rollers beneath them. The kinetic force (FB) should not exceed the joining force (FA).
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up to 6.9 7.0 ... 11.4 11.5 ... 18.2 18.3 ... or greater
1) in accordance with DVS 2207-1 2) The times are affected by the pipe wall thickness, the outside temperature and wind strength.
Determine the values to be set for equalization and joining on the basis of the information above, bearing in mind the instructions from the manufacturer of the fusion joining machine before commencing the fusion process.
Fusion Joining Procedure Once it has attained the fusion temperature, position the heating element in the fusion joining machine. Press the parts to be joined against the heating element with the force required for equalisation until the entire circumference of each of the joining faces rests completely against it and a bead (see the table) has formed. Reduce the equalisation pressure almost to 0 (p ~ 0.01 N/mm). The heating time listed in the table is measured from this moment.
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Join and Cool Leave parts in the fusion joining machine at fusion pressure until the end of the cooling period!
Once the heating period has elapsed, remove the parts from the heating element which should then be removed without touching the joining surfaces and push the parts together immediately. The changeover time must not exceed the value listed in the table. Pay particular attention during joining that the parts be moved together swiftly until the surfaces are about to touch. Then they should be moved together so that they are in contact along the entire circumference. Next the pressure should be increased rapidly to the present joining pressure within the period of time specied in the table. This pressure must be maintained during the entire cooling period. Adjustment may be necessary, especially shortly after the joining pressure has been attained. The joined parts must stay in the fusion joining machine under joining pressure until the end of the cooling period specied in the table.
Fusion Check A bead should form around the entire circumference of the pipe. K in the diagram to the left should always be positive. Carrying Out the Pressure Test All fusion joints must be allowed to cool completely before pressure testing, i.e.: as a rule wait about 1 hour after the last joint has been completed.
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Electrofusion
Electrofusion Joining Method
The fusion area of the pipes and socket ttings are heated to fusion temperature and joined by means of an interference t, without using additional materials. A homogeneous joint between socket and spigot is accomplished. Electrofusion must only be carried out with fusion joining machines by Georg Fischer that tightly control the fusion parameters. Details of the requirements for machines and equipment used for electrofusion joining of PPro-Seal Natural Polypropylene is included in the GF training manual and can be made available upon request. The Principle of Electrofusion Joining The electrofusion process of joining a pipe to a socket uses wires to transfer the heat energy to the plastic material. The heat energy will be sufcient to melt the plastic surrounding the wires. The will generate a zone called the melt zone. The melt zone, by denition encapsulates the wires, which are at its origin along the center line. The Computer Simulation on the bottom shows the heat distribution and the melt zone regional.
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The Computer Simulation on the bottom shows the heat distribution and the melt zone regional.
General Requirements The basic rule is that only similar materials can be fusion joined, i.e. PP with PP. The components must be joined with the tting inserted to the full socket depth for the joint to be considered acceptable. Should this not be the case, failure to meet the depth requirement could result in joint failure, overheating and intrusion of the heating coil.
Use a ne tooth hand saw and miter box, a power cutoff saw with blade for plastic or a wheel type pipe cutter for plastic. **Ratchet Type pipe cutters are not recommended
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Remove all burrs from pipe end. Chamfer the pipe end to ease insertion of the pipe and to prevent the fusion coil from being displaced. Note: The deburring tool shown is from Wheeler Rex. www.wheelerrex.com, Part no. 30100, for 1 pipes. It can be purchased from professional vendors.
Clean pipe surface and inside of tting socket with Isopropyl Alcohol Solution. *(i.e. IPA) The alcohol concentration has to be 70% or higher! Do not handle the freshly cleaned surfaces before assembling. If the ttings have become excessively dirty due to the atmosphere, coils should be carefully removed and ttings hub and coils cleaned of debris and dirt. Care should be used when removing coils. * For proper use and safety regulations of IPA, please see suppliers Material Safety Data Sheets
Socket Depth
11
16
25
32 32
31
Insert the pipe end into the tting socket, while holding the coil wires to one side. The pipe must be fully inserted past the coil to the pipe stop. Check socket depth mark to be sure the pipe is fully inserted.
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Check the continuity of every fusion coil with the continuity tester before fusing. A green light will indicate a good fusion collar.
MSA250
Electro-Plus
Connect the factory- supplied fusion cables to the plugs of the fusion coils. Check how many joints are possible per cycle.
Attach the cable connectors with Velcro self-gripping straps to the pipe, to prevent the fusion wires from pulling out during the fusion process. Velcro self-gripping straps can be purchased at Home Depot or any other professional vendors.
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The technical data is not binding. They neither constitute expressly warranted characteristics nor guaranteed properties nor a guaranteed durability. They are subject to modication. Our General Terms of Sale apply.
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