STANDARD SPECIFICATIONS

Specifications of ABS Pressure Piping System for Supply and Installation

1.0 ABS PIPE AND FITTINGS GENERAL SPECIFICATIONS

1.0 ABS (Acrylonitrile Butadiene Styrene) material from which the pipe and fittings is made shall be in virgin material and approved by SIRIM.1.0 The ABS pipe and fittings shall be approved by SPAN and Local Water Authorities and manufactured from reliable manufacturer AZEETA or equivalent.

1.0 All ABS pipes must be certified by SIRIM Product Certification License and be suitable for use with potable water which must passed the test of BS 6920: Part 1 2000/ MS 1583: Part 1 - 2003 (Suitability of Non Metallic Product for Use in Contact with Water Intended for Human Consumption with Regard to Their Effect on The Quality of The Water).

1.0 Installation shall be in accordance with MS 1419 Part 4:1998 Guides for Installation of ABS Pipe Systems and the manufacturers recommendations.

1.0 All ABS joints shall be of cold solvent cement welded. The Contractor shall provide sufficient ABS solvent cement and ABS Primer for all pipe joints under this contract.

1.0 All ABS pipe and fittings shall be manufactured in dark blue/ grey colour and accordance with Malaysian Standard MS 1419: Part 1:2007 from size range DN 15 (1/2) up to OD 630 (24) and must be branded accordingly. 1.0 All ABS Pipes, Fittings, Solvent Cement and Primer used for jointing must be manufactured and supplied by same manufacturer to ensure compatibility in dimensions and qualities otherwise will be rejected.

1.0 Goods supplied which do not comply with the provision of the standard specifications or which has defects will be rejected and return to the supplier or manufacturer.

1.0 The diameter and classes of ABS pipe and fittings indicated in the drawing should not be varied without written permission from relevant authorities and Consultant or authorized site representative.

1.0 The contractor shall ensure all personnel involved with the installation are familiar with the installation procedures for the ABS piping systems.

1.0 Pipe shall be inserted to full depth of fitting socket. Installed fittings which do not have pipe inserted to full depth shall be considered below standard and shall be rejected or rectified at the installers expense.

1.0 ABS pipes manufactured in accordance to MS 1419: Part 1: 2007 adopt a 50 year design basis and shall conform to the dimensions given in Table 1.0 Nominal Size (DN/OD)Mean OD

(mm)Minimum Wall Thickness (mm)

2.0 Class 9Class 10Class12Class 15

DN 15 ()21.4---2.0

DN 20 ()26.8---2.4

DN 25 (1)33.62.0-2.53.0

DN 32 (1 )42.32.4-3.13.8

DN 40 (1 )48.32.7-3.64.4

DN 50 (2)60.43.4-4.55.5

DN 65 (2 )75.44.3-5.66.8

DN 80 (3)88.95.0-6.68.1

DN 100 (4)114.36.5-8.410.4

DN 150 (6)168.39.5-12.415.3

DN 200 (8)219.112.4-16.219.9

OD 225 (9)225.3-10.712.715.7

OD 250 (10)250.4-11.914.217.4

OD 280 (11)280.4-13.315.819.5

OD 315 (12)315.5-15.017.822.0

OD 355 (14)355.5-16.920.124.8

OD 400 (16)400.5-19.122.627.9

OD 450 (18)450.5-21.425.531.4

OD 500 (20)500.5-23.828.334.9

OD 560 (22)560.5-26.731.739.1

OD 630 (24)630.6-30.035.744.0

Table 1.0 Dimensions of ABS Pressure Pipe3.0 HANDLING AND STORAGE3.0 ABS pipes and fittings shall not be subjected to rough handling particularly during loading and unloading operations. Where ropes or chains are employed, pipes shall be suitably protected against scoring.

3.0 Pipes stacked for transportation shall be continuously and evenly supported to minimize distortion. Alternatively, horizontal supports of at least 75mm bearing width spaced not further apart than 1.5m centre to centre shall be placed beneath the pipes.

3.0 If the stacks are rectangular, vertical supports at twice that spacing should be provided at sides. In such load bearing stacks, maximum free height shall not exceed 3m.

3.0 For long terms storage (more than three months) maximum free height should not exceed 1.5m. If different classes of pipe are kept in the same stacks, the highest class shall always be at the bottom.

3.0 Bearing with sharp sections shall be avoided as these can cause indentations in or scoring of the pipe wall.

3.0 Pipes and fittings shall be protected from elevated temperatures. Uneven heating around the circumference of pipes may cause differential expansion along their length, which may result in twisting and bowing3.0 All pipes and fittings must be sheltered from sunlight. Elevated temperature may soften the pipes and where pipes are stored in stacks, the bottom layers may become distorted.3.0 Pipes with end treatment such as socket or pre-assembled fittings shall be stacked or supported so that the ends are free from loading; if necessary they shall be protected from damage.

4.0 JOINING METHODS AND PROCEDURE4.0 The layout of all pipe work shall be checked on site prior to installation and care shall be taken to ensure a neat and workmanlike appearance of the installation.

4.0 Measure and cut the pipe clean and square. Remove internal and external burr and clean out swart and file a 2 to 10mm 30( chamfer on the outer edge of the pipe.

4.0 Mark the pipe at a distance back from the end which is equal to the depth of the socket. This is to allow the installer to identify whether the pipe is pushed fully home into the fittings.

4.0 Lightly abrade the end the pipe outer surface over the length equal to the socket depth and the inner surface of the fitting using emery paper.

4.0 Clean the abraded surface with a clean brush or rag moistened with ABS Primer.

4.0 ABS Solvent Cement shall be stirred well before use. Do not thin solvent cement with ABS Primer or any other solvents.

4.0 Apply the solvent cement as quickly as possible to the abraded surface of the pipe and fitting, ensure that both surfaces are evenly coated. For sizes DN 100 (4) and above, two coats will be required on the pipe.

4.0 Immediately after application of the solvent cement push pipe fully home into the fitting by using the mark on the pipe as a guide. Do not twist fitting or vice versa. If using a monkey wrench, do not exert additional force once the pipe is pushed fully home.

4.0 For size DN150 and above, position the monkey wrench to pull the joint together after solvent cement is applied. The use of hammers etc, to push fitting into pipe is NOT PERMITTED at ANY time.

4.0 Wipe off excessive solvent cement from the joint. Care should be taken to avoid excessive deposits of solvent cement inside small diameter pipe and fittings as this can weaken the wall of the pipe or fitting.

4.0 All ABS fitting are of tapered interference fit. Hence, it is essential that the fitting is held in position for times varying from 10 seconds to one minute to prevent any movement. When using monkey wrench on larger fittings leave it in position until you reach for the next joint.4.0 Replace lids after use. Clean brushes in ABS Primer.

4.0 PVC solvent cement and primer are strictly not allowed for use with ABS pipe and fittings. Only specially prepared ABS solvent cement and ABS Primer from the same manufacturer is approved for jointing. Performance guarantee is null and void if other solvent cements or cleaner are used.4.0 Flanges or other suitable methods in accordance with the manufacturers instruction shall be used to join ABS pipes and fittings to other material. 4.0 ABS pipes cannot be successfully solvent cemented under wet conditions. Pipe must be clean and dry for effective jointing.

4.0 In preparation for jointing, pipe should be stored in a shaded area as the working life of solvent cement is reduced when applied to hot pipe and fitting.

4.0 A canopy over the jointing area is desirable when working under direct sunlight.

5.0 SAFETY PRECAUTIONS.

5.0 Work in a shaded, well ventilated, and clear of hazards area.

5.0 Treat ABS Solvent Cement and ABS Primer with care, as they are volatile and flammable liquids. Replace lids after use.

5.0 Solvent cement may be removed from your hands with soap and water or industrial hand cleaning soap. Do not use ABS Primer for removing ABS Solvent Cement from your skin.

5.0 The following requirements are in addition to any government safety legislation or established company work practices

i) Read safety precautions on ABS Solvent Cement and ABS Primer tins.

ii) As solvent cement and primer are flammable liquids ensure working area is clear of falling sparks or other sources of ignition e.g. smoking.

iii) Wear a safety glass and protective glove at all times when using ABS Solvent Cement and ABS Primer.

iv) No smoking is allowed when jointing ABS pipes and fittings using solvent cement and or primer.6.0 PIPE SUPPORT6.0 The maximum distance between pipe support and width of pipe supports shall be in accordance with the manufacturers recommendations.

6.0 Pipe supports shall not exert undue pressure on the pipe wall or deform the pipe wall against the clamp or support. All clamps on horizontal pipe shall allow axial movement of the pipe.

6.0 Recommended maximum spacing of horizontal pipe support for ABS pipe at various temperatures are given in Table 2.0. Maximum spacing of vertical pipe supports is the same with that of horizontal pipe support at 20C.Nominal Pipe Size

(DN/OD)Recommended Maximum Spacing of Support, (m)

Horizontal or Graded PipesVertical

Pipes

Temperature ((C)

7.0 20(C50(C70(C

DN 15 ()0.90.70.40.9

DN 20 ()1.00.70.61.0

DN 25 (1)1.00.850.71.0

DN 32 (1 )1.20.90.71.2

DN 40 (1 )1.21.00.71.2

DN 50 (2)1.31.00.71.3

DN 80 (3)1.61.30.91.6

DN 100 (4)1.91.51.01.9

DN 150 (6)2.11.81.02.1

DN 200 (8)2.41.91.22.4

OD 225 (9)2.41.91.62.4

OD 250 (10)2.72.21.82.7

OD 315 (12)3.02.41.83.0

OD 355 (14)3.02.42.03.0

OD 400 (16)3.32.72.43.3

OD 450 (18)3.32.72.43.3

OD 500 (20)3.63.02.63.6

OD 560 (22)3.63.02.73.6

OD 630 (24)3.93.33.03.9

Table 2.0 Recommended maximum spacing of supports for all classes of pipe

Figure 1 Typical vertical pipe support (Anchoring point)7.0 Firm supports or anchoring points as depicted in Figure 1 at a distance not more than 20m apart shall be installed on vertical pipe to prevent undue loading and stress being transmitted to the riser or dropper pipe.

7.0 Large valve, filter or other heavy items shall always be independently supported or anchored to prevent undue loading and stress being transmitted to the pipe. Valve support plates can be used in place of flange backing ring to provide necessary support.8.0 USAGE OF SOLVENT CEMENT

8.0 An estimation of the number of joints likely to be made with ABS Solvent Cement when following the recommended procedure is as follows Table 3.0:

Pipe Diameter*Solvent Welds per Litre

Up to DN 50 (2)135

DN 80 (3)45

DN 100 (4)35

DN 150 (6)20

DN 200 (8)10

OD 225 (9)10

OD 250 (10)4

OD 315 (12)4

OD 355 (14)3

OD 400 (16)2

OD 450 (18)1

OD 500 (20)1

OD 630 (24)0.5

Table 3.0*Note: Actual usage may vary from quantity stated in Table 4. A socket counts as 2 joints, a tee as 3 joints etc. The usage of ABS Primer is approximately 2/3 times that of ABS Solvent Cement9.0 SOLVENT CEMENT WELDING DRYING TIMES

9.0 The drying time for joints varies depending on:

i) The amount of ABS Solvent Cement and ABS Primer applied.

ii) The diameter of the pipe or fitting.

iii) Ambient temperature.

iv) The fit between the pipe and fitting.

v) Class of the pipe.

9.0 Whilst full rated working pressure shall not be applied for 24 hours, joints in smaller diameters can often be put back into service within relatively short period after jointing. An approximate guide is to allow 1 (one) hour per 100kPa working pressure for size up to DN 80 (3). For size DN 100 (4) and above this time should be increased to 1.5 hours per 100kPa. (Actual curing time may differ depending on site environmental condition.)

10.0 JOINTING SYSTEMS

10.0 Pipe and plain ended fitting may be joined by the following methods;

i) Sockets

ii) Flanges

iii) Shoulder style two bolt coupling

iv) Threaded adapters

v) Unions

10.0 In each of the above methods the selected fitting must be cold solvent welded to the end of the ABS pipe or fitting.

10.0 O ring repair sockets and Shoulder couplings are also available and may be used for jointing pipe, however their use is normally confined to jointing of replacement pipe sections. 10.0 ABS pipe may be connected directly to other pipe or equipment using flange or threaded connection. Flanges are the recommended method for all sizes, however threaded connections may be used for sizes DN 65 (2 ) and below.

10.0 Stub and Full Face flange, available in size DN 80 (3) to OD 630 (24).

10.0 Backing rings must be used in conjunction with stub flanges and are available in all standard drilling configurations. Gaskets must be used in conjunction with flanges.

10.0 ABS stub flange assembly may be bolted directly to other pipe systems and appendages of the same flange-drilling standard.

10.0 Flange bolt torque values for ABS pipe (as shown in Table 4.0) need not be as high as those commonly used on steel pipe systems. Higher torque values may result in distortion of the flange face.

Recommended Bolt Torques and Bolt Sizes

Pipe Sizes (DN/OD)Bolt SizesRecommended Torque (NM)Hole per Flange

DN 15 ()M 12 x 5074

DN 20 ()M 12 x 50104

DN 25 (1)M 12 x 50144

DN 32 (1 )M 12 x 50134

DN 40 (1 )M 16 x 60204

DN 50 (2)M 16 x 65224

DN 80 (3)M 16 x 70334

DN 100 (4)M 16 x 80258

DN 150 (6)M 20 x 90428

DN 200 (8)M 20 x 100428

OD 225 (9)M 20 x 1308012

OD 250 (10)M 20 x 15010812

OD 315 (12)M 20 x 15010812

OD 355 (14)M 24 x 16013312

OD 400 (16)M 24 x 18015716

OD 450 (18)M 24 x 19018516

OD 500 (20)M 27 x 23019116

OD 630 (24)M 27 x 28020020

Table 4.0 Recommended bolt torques and bolt sizes

10.0 Standard butterfly valves may be placed between ABS stub flange assembly without modification. Valve should be checked for full and free movement prior to final tightening of flange bolts.

10.0 All threaded fitting are rated 1200Kpa at 20(C.

10.0 For high-pressure installations it is preferable to use adaptors or fitting with male ABS threads in preference to female threaded fittings particularly in systems subject to thermal cycling.10.0 Tightening should only be done by hand with a maximum of an extra quarter turn with a pipe wrench. There is often a tendency to over tighten threads and causes distortions and leakages.

10.0 If a threaded connection is leaking, disassemble the join. If there is no apparent damage, remake the connection by taking care not to over tighten.

10.0 PTFE tape can be used as thread sealant.

10.0 Do not use liquid thread sealant, e.g. Loctite or PTFE paste, as they contain chemicals, which may attack plastic materials.

11.0 BURIED PIPES11.0 All installation of ABS pipe work shall complied with statutory regulation, where these applicable.11.0 Pipe Trench

i) Trenches shall be constructed in accordance with AS 2566 1982.

ii) In general, trenches shall be as narrow as possible with regard to the practicality of handing the pipe in the trench and the stability of the ground conditions.

iii) A minimum bottom of trench width equal to the outside diameter of the pipe plus 200 to 300mm shall be sufficient. Depth of the trench, as per the Table 5.0, shall allow for the required top cover plus the diameter of the pipe and the depth of the bedding. iv) Where very heavy vehicle loads are anticipated, trench depths shall be calculated in accordance with AS 2566 1982.

v) Requirements of regulatory authorities may specify different depths for local conditions.

MINIMUM COVER OVER PIPE (H)

Not subject to vehicular loading300 mm

Subject to vehicular loading

i) not in roadways

ii) in sealed roadways

iii) under unsealed roadways450 mm

600 mm

750 mm

Pipes in embankment condition or subject to construction equipment loading750 mm

Table 5.0

. . . . . .

Backfill

..

...

. . . .

. . . . . . .

. . . . . .

H minCompacted Pipe . . min . . . . . min . .

Overlay

. 100 mm . . D . .100 mm .

150 mm

. . . . . . .

min

. . . . . . . .

Contacted Pipe . . . . . . .

Side Support

. . . . . .

D

. . . . . .

. . . . . . . .

Compacted Pipe

. . . . . . .

75 mm min

Underlay

B min*Figure 2 Typical installations in a trench* Minimum width of trench B min = D + 200 mm for DN 100 (4) and above, or 2D for DN smaller than 100mm.11.0 Trench Componenti) Bedding Material Suitable sand (free of rocks) or crushed rock/ gravel (max size = 14mm)

ii) Pipe side support Clayey sand or fine sand

iii) Pipe overlay Sand or gravel

iv) Backfill Excavated material from site (mixed soil)

11.0 Thrust Blocksi) Thrust blocks are not required for cold solvent cement welded buried pipelines at changes of direction, terminations, and changes in pipe diameter or tees. Thrust blocks may be required where valve or other equipment is positioned in the pipeline and are not independently supported.

11.0 Backfilling and Tampingi) Backfill must be effectively tamped under both sides of the pipe to provide proper supports. Joints shall be left uncover until pressure testing has been completed. Excavated material may be used for final backfilling.

ii) For pipelines operating at above or below ambient temperatures contact the manufacturer for installation instruction.12.0 INSTALLATION OF PIPEWORK ABOVE GROUND12.0 ABS pipe exposed to direct sunlight shall be painted with water based paint. Coating pipes with acrylic or water base paint is effective in minimizing any effects of ultraviolet radiation.12.0 ABS piping system shall be installed to allow thermal movement, where high temperature variations are likely to occur, such as in cavity walls or roof spaces. The coefficient of thermal linear expansion of ABS is 10.1 x 10-5 m/m C.

12.0 The maximum pipe thermal movement can be calculated by using the following equation.

(L = L x C x (T

where:(L = pipe expansion/contraction, m

L= original pipe length, m

C= coefficient of thermal linear expansion, m/m(C

(T= pipe wall temperature variation, (C

12.0 The pipe wall temperature variation can be calculated by using the formula below:

(T = 0.65 (TL + 0.10 (TAWhere:(T= pipe wall temperature variation, (C

(TL= maximum temperature variation in pipe content, (C

(TA= maximum temperature variation of external air, (C

12.0 Expansion joints which may be incorporated in a fitting or as separate fittings shell be installed in accordance with manufacturers instructions in the position shown in the design for the particular installation.

12.0 Where expansion loops are to be used, they shall be installed in accordance with manufacturers instructions in the position shown in the design for the particular installation.

12.0 Sliding supports shall be provided to allow a guide without restraint for the direction of movement of pipes subject to thermal expansion.

12.0 All pipe clips should permit free axial pipe movement at all temperatures and shall give good bearing support to the pipe.

12.0 Any ABS Pipe or fittings built into, or passing through any floor of wall shall be surrounded by a conduit or flexible membrane or a suitable permanent annular space to permit movement without scoring the ABS material, unless otherwise specified.

13.0 TEMPERATURE CONSIDERATION

13.0 Where ABS Pipe or fittings are under pressure and in continuous service at any temperature in 20C to 70C, the safe working pressure should be reduced in accordance with the values in Table 6.13.0 Due allowance shall be made for expansion that will occur as pipe change temperature. The coefficient of thermal linear expansion of ABS is 10.1 x 10-5/K

TEMP

CDESIGN

LIFE

YEARSPIPE CLASS

4.5691215

WORKING PRESSURE, BAR

201

5

10

25

505.1

4.8

4.7

4.6

4.56.8

6.4

6.3

6.2

6.010.2

9.6

9.5

9.3

9.013.6

12.8

12.6

12.4

12.017.0

16.0

15.8

15.5

15.0

301

5

10

25

504.4

4.1

4.1

4.0

3.95.8

5.5

5.4

5.3

5.28.7

8.3

8.1

8.0

7.711.6

11.0

10.8

10.7

10.314.6

13.8

13.5

13.4

12.9

401

5

10

25

503.7

3.5

3.5

3.4

3.34.9

4.7

4.6

4.5

4.47.4

7.0

6.9

6.8

6.69.8

9.4

9.2

9.0

8.812.3

11.7

11.6

11.3

11.0

501

5

10

25

503.1

2.9

2.8

2.8

2.74.1

3.8

3.8

3.7

3.66.1

5.8

5.7

5.6

5.48.2

7.7

7.6

7.4

7.210.2

9.6

9.5

9.3

9.0

601

5

10

25

502.3

2.2

2.1

2.1

-3.1

2.9

2.8

2.8

-4.6

4.3

4.2

4.1

-6.1

5.8

5.6

5.5

-7.7

7.2

7.1

6.9

-

TABLE 6 Recommended Maximum Static Working Pressure of Pipe Systems According To Pipe Material Temperature14.0 WATER TANK CONNECTION

14.0 The appropriate installation of ABS inlet pipe to HDPE Tank in order to avoid any unnecessary premature failure of the ABS pipe is as depicted in figure 3.

HDPE Tank

Bracket to prevent flexing. But allow axial movement only

Float Valve

H

Bracket allow axialWater movement only

ABS Pipe

Figure 3 Recommendation

(L

H = 32.7 x ( D x (L

H

Where:

D = Outside Diameter

Figure 4 Calculation of Distant, H

HDPE Tank

Flexing

Float Valve

Crack

Flexing

Water

ABS Pipe

Figure 5 Flexing of ABS Inlet Pipe Induced by Flexing of HDPE Tank

14.0 Distant H are show as following Table 7L (mm)1.02.03.04.05.06.07.08.09.010.0

Pipe SizeDistant H (mm)

DN 15151.3213.9262.0302.5338.3370.5400.2427.9453.8478.4

DN 20169.3239.4293.2338.6378.5414.7447.9478.8507.9535.3

DN 25189.5268.1328.3379.1423.8464.3501.5536.1568.6599.4

DN 32212.7300.8368.4425.4475.6520.9562.7601.5638.0672.5

DN 40227.3321.4393.6454.5508.2556.7601.3642.8681.8718.7

DN 50254.1359.4440.2508.3568.3622.5672.4718.8762.4803.6

TABLE 715.0 VALVE AND FLUSH VALVE CONNECTION15.0 All flush valves must be set to slow closing mode to reduce water hammering effects and fatigue loading in the piping system.

15.0 Pressure Reducing Valve (PRV) shell be installed at every 30m (3 bar) height.15.0 Recommended to use pilot-acting PRV in order to cater for small demand and the flow velocity shall be limited to 1-1.5 m/s maximum at termination point.

15.0 Recommended to install appropriately designed surge tank for both gravity and plumbing systems.

16.0 PUMP SELECTION14.1Recommended to use variable speed control for booster pump system. Motor speed shall be calibrated to limit flow velocity to 1 -1.5m/s for small demand. Hydro-pneumatic type is NOT suitable for plumbing usage.

17.0 HYDROSTATIC PRESSURE TESTING17.0 The following are requirements for pressure testing of all ABS pressure piping applications as set out in MS1419: Part 4:1998 Section 5: Pressure Testing.i) Preparation for test

Air shall be removed by flushing or venting at highest point. Pipelines shall not be tested to working pressure until 24 hours after the last joint have been made. Testing at pressure above working pressure shall not be performed until at least 48 hours after the last joint has been made. ii) Test pressure, duration and temperature

A test pressure of 1.5 times the design pressure shall be applied to the section under test. The test section shall then be allowed to stand under pressure without make-up for at least 15 minutes, or the time necessary to inspect all the joints in the completed section (12 hours maximum) at a temperature of 20C.iii) Temperature considerations (MS1419: Part 4: 1998 clause 2.4.2)

Where ABS pipe and fittings are under pressure and in continuous service at any temperature in the range 20C to 70C, the safe working pressure shall be reduced in accordance with the values in Table 6.0iv) Acceptance criteria

A new pipeline shall be deemed to have passed the pressure test if there is no marked loss of test pressure and there is no evidence of leaks of the test fluid either after at least 15 minutes under pressure or after the time necessary to inspect all joints in the completed section (12 hours maximum). CAUTION: Under no circumstances shall pressure tests be carried out using pressurize gases. Such a test can be extremely dangerous shall a failure occur.

ABS Pipe

Concrete Wall

Wall Plugs

ABS Pipe

ABS Stub Flange

ABS Stub Flange

Bolt

Backing Ring

Rubber Gasket

Valve Support Plate

Nuts

815 1998 Copyright Reserve

ABS PIPING SYSTEM