Eng. Katalog Gema Plast - Km

The company GEMA PLAST – KM Andon DOOEL was founded in 1990 and since

then has operated in the Industrial Area in municipally of Gevgelija, Republic of

Macedonia. GEMA PLAST – KM is a modern industry which produces plastic hoses

made of polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC) in

accordance with European standards.

GEMA PLAST – KM is one of more famous producers of plastic hoses in Republic of

Macedonia and in the Balkan area.

With its big team for planning, production and installation, GEMA PLAST – KM takes its participation in different fields like in technical sector, agriculture,

industrial sector etc.

GEMA PLAST – KM reached very important positions at the Macedonian market. As

the market sector in the Macedonian industry increases, the success of the company is

also bigger and is based on setting a goal for high quality of its products and services,

quick and service on time for all clients, respecting and protection of the environment as

well as researching of new and better products.

The growth of GEMA PLAST – KM in one of the most dynamic firms in the industrial

field of plastic in Macedonia and Balkan was based on:

- Modernization of production recourses of the company and employment of

specialized technical and learned potential.

- Stable effort for improvement of the products and services in frame of Quality

Management System according the standard ISO 9001:2000.

- Excellent service to the client during the whole course of the sale.

- Development of full sale net at the domestic and the markets in the area.

- The company was verified with certificate issued by the Ministry of Trade of

Republic of Macedonia for using the mark of the campaign – For our sake – Made in

Macedonia – Buy Macedonian products.

INVESTMENT PROGRAM The main office of the company GEMA PLAST – KM is located in the

industrial part of Gevgelija, on its own property of 6000m2 of which 3000m2 are

buildings which include offices, production capacities and warehouses.

At the beginning of the year 2000, the company successfully projected one very

ambitious investment program which is expected to be finished financially and also with

the investment till 2005.The following activities are included in this program: increasing

of the production and modernization of the production capacities and production of new

products, concrete introducing of production line “System drop by drop”.

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The results which are expected are the following:

The investment project for production of hose for irrigation by system “drop by drop”

which is first of this type in our country is in its final phase. This project is financially

supported by the Ministry of Economy of USA through PRIZMA – Partners for local

economic development in Macedonia. With finalization of this project, the problem of all

individual farmers with the irrigation will be solved.

The machines for production of PE hoses are equipped with on-line control system,

which records and notes the critical parameters for the quality of the products.

The control sector is based on new high technological equipment for testing,

confirming the orientation of the company for researching and development of new

products.

The success of the firm is also based on its working potential. The educational level

and experience of the labor of the company are very important factors to insure the high

quality as well as to fulfill the expectations of all clients.

SERVICES TO THE CLIENTS

GEMA PLAST – KM guaranties best service with its most expeditious and efficient

service experience for the clients. The company offers:

- Full assortment of qualified products on the field of plastic mass.

- Certified and high-quality management system for all products and services.

- Efficient technical support.

- Competitive and market conditions for sale.

The company makes big efforts to satisfy its clients and it is based on its experience

as honorable service politics. The way the company appears in front of its client, the

great honor and gratitude for their confidence is one of the most important factors for the

company’s success.

Main clients of the company are: Technical companies in Macedonia, Performers of

public matters and big warehouses for sale of plastics as well as many individual farmers

and other individual persons. In the last few years it was made big effort for development

of the export activity in: Albania, Bulgaria and Serbia and Montenegro with successful

results.

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C O N T E N T S

GEMA PLAST – KM……………………..........................................………….............. 2

Products……………………………………………….…................................................. 7

Technique ………………………………………………...................................…........... 8

Attests and certificates ………………………………....................................…............ 9

What is polyethylene ………………………………..................................................... 14

Specific features …………………………………….................................................... 19

Production methods …………………………………................................................... 21

Polyethylene pipes ………………………………........................................................ 23

Nomogram of course …………………………........................................................… 29

Installation instructions for pipe systems ………..........................…......................... 30

Modification of the length under influence of chemicals ........................................... 35

Chemical features ……………………………………….............................................. 37

Methods of connection ……………………………….. ............................................... 42

Electrfusion welding of PEHD pipes and fittings ……............................................... 47

Polypropylene pipes ……………………………………............................................... 50

Way of creation of pipeline ……………………………............................................... 54

Compensation extensions ………………………….................................................... 57

Technical characteristics …………………………...................................................... 61

PE – 100 pipes ……………………………………....................................................... 62

PE – 80 pipes ……………………………………......................................................... 63

PE – 63 pipes ………………………………………..................................................... 64

PE – P pipes ……………………………….………...................................................... 65

Adapter flansh ……………………………………........................................................ 66

Cap ……………………………………………………................................................... 67

Reducer ………………………………………………................................................... 68

90° TEE ……………………………………………….................................................. 72

Elbow ………………………………………………....................................................... 73

Reducer gradual ………………………………............................................................ 76

Electro fused socket ……………………………......................................................... 77

Electro fused 90° TEE ……………..……………….................................................... 78

Electro fused 90° TEE reducer …………………….................................................... 79

Electro fused elbow 45 ……………………………..................................................... 80

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GEMA PLAST – KM is a famous Macedonian producer of qualified products and is

located in the south of Macedonia, in Gevgelija. In the 25-year existing and experience

the company reached great results on the field of production of melted plastics and

melted products.

In the latest 10 years the company attained huge results on the field of extruding of

polyethylene and polypropylene hoses and pipes.

Especially GEMA PLAST – KM became famous with installation of full systems –

projecting, production, transport, installation of pipeline.

The systems of GEMA PLAST – KM satisfy the highest standards of pipe systems

for water and sewerage systems and protection of the environment.

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ORGANIZATION SCHEME

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GENERAL MANAGER

FINANCIAL SECTOR

RESPONSIBLE

COORDINATOR FOR THE QUALITY

PRODUCTION CADRE SECTOR RESPONSIBLE MANAGER

RESPONSIBLE FOR

INSTALLATION

MAINTENANCE OF THE EQUIPMENT

COMMERCE COMMERCIAL

OFFICER

WAREHOUSE FOR RAW MATERIALS

WAREHOUSE CLERK

WAREHOUSE FOR FINAL PRODUCTS

WAREHOUSE CLERK MAINTENANCE

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GEMA PLAST – KM offers complete assortment of products in accordance with the latest technical standards, which is based on the continuous development of PE pipelines.

PE 100

PE 100 pipes are made of hard polyethylene with big density (HDPE) of the third generation MPC10 and they are used for underground nets for carrying over drinking water.

PE 80

PE 80 pipes are made of hard polyethylene with big density (HDPE) of the second generation MPC10 and they are used for underground and undersea nets for carrying over water, waste water and for protection of cables, as well as for underground nets for carrying over drinking water.

PE 63

PE 63 pipes are made of polyethylene with low density (LDPE) and they are used for irrigating with atomizers.

PE-GEMA GAS

Gema-gas pipes are made of hard polyethylene (HDPE) of the second generation and they are used for underground nets for transport and distribution of gas.

PE – GEMAKAN AND GEMADREN

Gemakan and Gemadren pipes may be in two or three layers and they are used for sewerage systems.

GEMA-TERM

Polypropylene pipe systems for sanitary use – indoor installation for hot / cold water, floor heating, connection of radiator systems.

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As a result of the development of materials, there are several techniques for connect and installation of the pipes:

Connecting with mechanical elements With dimensions F16 to F110mm. Training for usage is on the place of the sale of the

elements. Connection with frontal welding With dimensions bigger then F110mm. It is recommended for water supply systems

under pressure. They are being installed only by expert team with special equipment. Connection with covering welding - PP pipes and fittings with special tools and expertness. Electrofusion is a technique which is specially used in the gas installations. Experts

and special equipment are needed. T

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T E C H N I Q U E S

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As a huge recognition from the long-standing experience of GEMA PLAST – KM, of

course is the standard ISO 9001 : 2000 by the renowned Britain Institution for Standards

BSI.

Therefore GEMA PLAST – KM assigned to lead the Policy for Quality and its basic

principals are:

Creation of working system for quality oriented to the clients in order to increase their

confidence.

• Orientation and accommodation to the market, in order to take bigger

participation there.

• High-quality products, in order to improve the renown of the firm.

• Identification and elimination of every defect which may cause loss of clients,

work, profit.

• Fulfill the needs of the employees.

GEMA PLAST – KM is obliged to maintain and improve the System for Quality and

with that it fulfills the requests by the standard ISO 9001:2000, and also satisfies the

requests of the clients.

FM 61542 ISO 9001:2000

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P O L Y E T H Y L E N E

In many countries the polyethylene (PE) as a material for pipes is used for transport of

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

This material has the following advantages for the clients:

• Small specific weight

• Flexibility

• Good chemical resistance

• Excellent welding

• Excellent resistance of heat

• Resistance to movement of the ground

• Smooth interior of the pipes with resistance of accumulate layer

• Sanitary they are correct in case of having contact with food products

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WHAT IS POLYETHYLENE The polyethylene is thermoplastic matter which was produced with polymerization of

the ethylene (C2H4), unsaturated hydro carbonate, in normal circumstances it is a gas. Structure of the ethylene molecule

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

Molecules are forming polymers and can be less or more expanded, shorter or longer, closed together or separated. These characteristics are giving the main features of the polyethylene:

• Density (depends of the distance between the molecules) • Molecular weight (depends of the length) • Molecular weight distribution (depends of the distance between the molecules

and the length)

DEVELOPMENT OF THE POLYETHYLENE

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

Since 1954 the method of Zigler has been used for production of polyethylene. Simultaneously has been developed the method of Philips. T

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Ethylene gas Structure of the ethylene molecule

C - Carbon H - hydrogen

Molecule of polyethylene l l

Polymerization

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After that the polyethylene started to be used in packaging industry, and later in agriculture industry (for irrigation pipes, system drop by drop), in water supply systems (regional and community), in systems for transportation of gas, for protection of optical cables, in chemical industry and in the sewerage systems.

For the first time PE material used for pipes was PE with low density (LDPE) with

MPC from 3.2 MPA (PE 32). In the latest 50-ies it was presented polyethylene with high density (HDPE) with MPC

6.3 MRS (minimum required strength). This was turn over in the usage of the polyethylene for higher pressures for reduction

of the thickness of the wall. As a result of the further development of the PE material in the last few years the features of PE pipes and fittings are being improved.

These days the polyethylene (PE) is not classified according its density (LDPE,

MDPE, HDPE), but there are several classes now (PE 63, PE 80, PE 100). New polyethylene class PE 100 The newest development of polyethylene is the third generation of HDPE, which is

qualified as PE 100. These materials are also described as MPC 10 materials. This is a new development of the polyethylene which with modified polymerization

process. However PE 100 has the highest density and according to this also has improved

mechanical features as increased squeeze and hardness. Consequently to this, this material is appropriate for production of hoses and pipes under pressure with big diameters and in comparison with PE 80has smaller thickness of the wall.

The development of polyethylene on scheme looks like this:

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Middle and high density

Linear low and middle density

LOW DENSITY

PE 63

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The connection between the classes of materials with the working pressures is given below:

The meaning of the formula:

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

C - Safety coefficient: for water = 1.25, for gas = 2 PN - Nominal pressure

NON TOXIC MATERIAL Polyethylene material is in according with the regulations and standards for materials

that have contact with food.

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CLASS OF MATERIALS

PN IN BARS

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So, PE pipes and fittings are verified and registered according international

standards for object that have contact with food and Macedonian health institute.

BEHAVE ON ABRASIVE FLUIDS Basically, thermoplastic pipes are better for transportation of liquid with hard particles

than cement or steel pipes.

We have positive experience of this use. By development method of Darmstadt, 1 m

long pipe is curled with frequency of 018 Hz. Local decrease of the wall after the loading

is taken as abrasive unit. Advantages of thermoplastic pipes for transportation of

mixtures with hard particles into open canal can be seen by the test:

Also other test shows that when the media is pumped through pipe, possibility to

check behave on abrasive of that kind of system is to determine time to appearance on

the hole. As it can be seen by the diagram, thermoplastic pipes (in this case PE pipes in

combination with PP pipes - gives same or better results) are given with all advantages

according with steel pipes.

For transporting of dry abrasive fluids, only electro conductive materials can be used

cause of electrostatic possibility (PE, PP-R-S, PP-R).

ABRASIVE BEHAVE ACCORDING DARMSTADT METHOD

UV RESISTANCE Polyethylene pipes are UV protected as a result of content of UV stabilizer - active

smoke with quantity max. 2,5%.

Media: Soil, sand - gravel, water - mixture 46 vol % soil, sand - gravel, dimension of particle to 30 mm.

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

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Time of abrasion in hours till hole appears

HDPE pipe

Fluids, middle range water with 14% of

sand Density 1.07, 1,15 kg/l Rad

ius

of th

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metal pipe

straight pipe

PP or HDPE pipe

numbers of alternative load

ceramics pipe

PVC - pipe

cement pipe

cement pipe covered with MC-DUR

GFK - pipe

middle abrasion

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MAIN FEATURES - TECHNICAL CHARACTERISTIC OF POLYETHYLENE

Main physics characteristic of polyethylene

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Bending temperature on load Method A Method B

Thermo conductivity (on 20°C)

Thermo expansion coefficient

Inflammability

Specific resistance

Dielectric intensity

Surface resistance

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Value of hit by Sharpie on 23°C with cut

Fusion temperature on crystal structure

Flowing index

Deterioration pressure on straining

Deterioration and straining

Deterioration pressure on breaking

Curling pressure on 3,5% deformation

Elastic module

Cutting module

Hardness on ball mark

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Deterioration on breaking

Characteristics

Standard

Unit earlier PEHD middle

density earlier PEHD

Density on 23°C

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The pipes made of PE may be rolled up in contour with big pulleys, they can be

easily curved because of their flexibility, and as a result of that the time needed for

installation of fittings and the time needed for installation is decreasing.

Thanks to the small weight, the pipes are easy for handling and they reduce the

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

lasting usage.

In our country the usage of PE pipes started before 10 years. At the first time they

were used in the agriculture, and then in the latest years their usage is being more

intensive especially on the field of water supply systems. The industrial complexes use

them because of their resistance on chemicals.

GEMA PLAST – KM from Gevgelija is the only firm with its presence on the market

with pipes from the latest generation of polyethylene PE 100 which enable thinner wall of

the pipes and also increasing the strait for 33% and working pressures to 32 bars.

They are corrosion-resistant which enables long lasting.

In the last 5 years they are used in Macedonian Telecommunications, through the

pipe for protection of optical cable.

Gas pipes are satisfying every regulations and standards. This technology enables

reconstructions of old pipes without addition digging, simply through the old systems

without any decrease of the passage of the pipe.

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PRODUCTION METHODS

PE pipes are produced by the method of extrusion. Through the hole, material is

putted into the extruder. Main parts of the extruder (1) are: Input hole (2), cylinder of the

extruder that is heated by the heaters (3). With the motor (4) rolling of the “snail” (5) and

material is possible. The “snail” is separated on a few zones where the material is

heating, melting and compressing. After that, the material comes to the “head” of the

extruder (6) and with appropriate tool (7), the material is modeling, in this case in pipe.

Than the pipe pass into vacuum (8) and water (9) tube where the final modeling is made.

After that with pull-device (10) the final line is pull out. The final operation is cutting or

rolling of the pipe (11).

CERTIFICATES

All products of GEMA PLAST – KM from Gevgelija are attested according the current standards for that kind of product.

GEMA PLAST – KM is a recipient of ISO 9001:2000 certificate which is certified by OQC, London for production and delivery of plastic pipes and connection elements. This is result of our promises that the quality is strategy in every sector of our industry.

Types of pipes produced by GEMA PLAST – KM:

Polyethylene pipes

Made of PE 80 and connected with mechanical link

20-315 mm Construction Infrastructural work

Polyethylene pipes

Polyethylene pipes made of PE 100 and connected with mechanical fittings and frontal welding


Polypropylene pipes

Polypropylene pipes made of PPR and connected with thermal welding


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FIELD OF USE OF THE PIPES INFRASTRUCTURAL WORK

Water supply systems, irrigation, sewerage systems, protection of cables, providing

and distribution of natural gas, underground collection of atmospheric water etc.

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

etc.

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

system drop by drop.

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POLYETHYLENE PIPES

1. WATERSUPPLY PIPES External diameter: F 20 – F 630 mm Working pressures: 6-10-16-20-25-32 Classification: PE 80 (6.3 – MRS 8) Standard: PrEN12201 -2, ISO 4427; MKS G C6, 602 Technical features Possible length of pipes:

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

Color:

• Light blue or black with co-extruded lines Working temperature: • Maximum to +60○C • The material is stable till -30○C

Use: They can be used in underground water supply installations, for transport of drinking

water, for regional and main plumbing and in other purposes as pipes under pressure.

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S PE 80 Service lines

PE 100 Main water supply

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2. WATER SUPPLY PIPES External diameter: F 20 – F 630 mm Working pressures: 6-10-16-20-25-32 Classification: PE 100 (8.0 – MRS 10) Standard: PrEN12201 -2, ISO 4427; MKS G C6, 602 Technical features Possible length of pipes:

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

Color:

• Dark blue Working temperature:

• Maximum to +80○C • The material is stable till -30○C

Use: They can be used in underground water supply installations, for transport of drinking

water, for regional and main plumbing and in other purposes as pipes under pressure.

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Straining on curling can be calculated with this formula:

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

Defining of section on pipe Next processes are calculated by the formulas: For fluids with constant volume passage:

V - Volume passage (m3/x) A - Free section on pipe (mm) ν - Speed of flowing (m/s)

For materials in condition on gas and condensation, the material passage is

constant and the formula is:

A - Material passage ν - Consistence on medium depend p - Pressure and temperature (kg/x)

If the constant values in these formulas will be added together, all formulas that are in real use for calculation of needed section of the pipe are:

di - Internal diameter of pipe (mm) Q’ - Escorted quantity amount (m3/x) Q’’ - Escorted quantity amount (1/s) v - Speed on flowing (m/s)

Referent values for calculation of flowing speed can be for fluids:

v ~ 0,5 - 1,0 m/s (for sucking); v ~ 0,5 - 1,0 m/s (for pressure)

Referent values for calculation of flowing speed of gas:

v ~ 10 - 20 m/s TEC

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BASIC CALCULATIONS Calculation of hydraulic shocks In case the flowing speed thought the pipe unexpectedly to be changed, as a result

of closing the valve or stopping of pump, also internal pressure of the pipe is changed. In that case the Bernoulli’s formula can’t be changed. These unexpected changes are known as hydraulic shocks. For pipes that are closer to the tank (having permanent level), where the passage is controlled by valve located on distance L of the tank, whole pressure generated of unexpected stop on valve, influence on relation of working time of the valve t, and time u. This is time that wave of pressure to come to the position of valve after the jump from the tank. This time is calculated by the formula:

U - Phase of shock a - transmission of the wave to whole pipe, and it is given by the formula:

Where: d - Internal diameter of pipe (mm) s - Thickness of the wall of pipe (mm) g - Gravitation acceleration Ew - Module of water flexibility = 2,1 GPa Epe - Module of PE flexibility = 0,8 GPa ε - Specific weight of water = 1000 kg/m3 f - = 1,23 for free pipe and f =1 for connected pipe µ - Posen’s coefficient. In this case PE=0,4

CALCULATION OF HYDRAULIC LOSE In pipes, next reasons can cause lose and consequent energy loses through the

transport system. • Length of the pipe line • Diagonal section on straight pipeline • Roughness of the pipe • Quality of the fittings, installation and quality of connections • Viscosity and density of the flowing media • Type of flowing (laminate or turbulence) Calculating of loses on pressure is result of sum of all pressures in the pipe:

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

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λ - Fricative index of the pipe (usually 0,02 is excepted) L - Length of pipe lines ai - Internal diameter of the pipe (m) ρ - Density of the media (kg/m3)

ν - Speed of flowing (m/s)

Loses of pressure into the fittings:

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

In the table below are shown resistant coefficients of the fittings for small diameter

pipes. Coefficient is increasing as the pipe’s diameter. Precisions calculating can be found in the literature.

∆ρF - Loses of pressure by the installation λ - Resistant coefficient ρ - Density of the media (kg/m3) ν - Speed of flowing

Depending of construction and nominal value of installation, resistant coefficient is between 0,5 and 5,0. If usually used Kv-value of installation is known, loses of pressure can be calculated with:

Q - Volume passage (m3/x) ρ - Density of the media (kg/m3) Kv - Specific installation value (m3/x)

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S Type of fitting Perim. Resistance coeff. Dir. of move

Curve =90° α

Curve α=45°

Elbow

TEE 90°

TEE 90°

Concentric reducers

Concentric reducers

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OSES OF PRESSURE ON CONNECTIONG ∆ρν

e the type and the quality of the con

L t is impossible to have the right information, becausInections are variable. With calculation of the total loses of pressure, it is from 3% to

5%.

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S Nom. height

Resistance coefficient

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NOMOGRAM OF FLOWING

or rude calculating of the sF peed of flowing, loses of pressure and quantity, the par

Internal diameter Quantity of Speed of flowing Loses of pressure

ameters are given in the following nomogram of flowing. By the average speed of flowing to 20 m length, for every TEE socket, reducer and

elbow 90°, add about 10 m of pipe length. For every curve r=d and about 5 m of pipe for every radius r=1,5 x d, add about 10 m of pipe.

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

v (m/s)

to meter of pipe ∆p/L (mbar/m)

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INSTALLATION INSTRUCTIONS FOR PIPELINES

l displace is impossible, critical len

Lkn - Distance between the holders for bending

l (mm2)

Notes: xed system is working on higher temperature, the distance between the

hol

CALCULATION POSSIBILITIES

y for calculation of the holder distance:

re ture

ST PES MADE OF PPR AND PE

l, dimension of the pip

istance between the holders Lkn for fixed systems D

f the pipe lines are installed on this way, than axiaI

gth of bending is basic of system of calculation. Calculated distance of holders for every pipe must to provide factor of safety of

minimum 2.0. If Lkn is smaller, than the distance between the holders L must be changed.

Lkn is calculated with the following formula for minimal safety factor 2.0:

(mm) JR - moment of inertia (mm4)

RA - Ring surface of pipe’s walε - Preventive heating expansion

If the fiders must be reduced on 20%. High temperature is: For PEHD > 45°C For PP > 60°C

ollowing parameters are necessarF

• Pipes material ) • Dimensions (da x s

• Installation temperatu• Maximum operating tempera• Maximum operating pressure • Density of the flowing media

I ANCE OF HOLDERS FOR PID

istance of holders depends of characteristics of the pipe materiaDe, weight of the flowing media, operation temperature and position of the pipes.

Distance of the holders is given in the table below. The values are given on the base of flowing media with density of 1 gr/cm3 and horizontal pipes. Based on calculation of distance of holders, maximal bend of L/500 between two holders on the pipe can be taken as basis.

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

pressures:

Distance between the holders must be reduced for 4% for fluids with density of 1,0 g/c

PN 6 +47%

Distance for pipes made of ppr

holders of pipes made of PPR, for holders made of PP

CHANGING FACTOR FOR PIPES MADE OF PEHD AND PPH

istance of the holders, given in the table, can be used for other D

PN 3,2 -2,5% PN 6 9%

PN 16 +7%

m3 to 1,25 g/cm3. Distance between the holders must be increased as below in transportation of gas

with density < 0,01 g/cm3:

PN 10 +30% PN 16 +21%

alculation of the distance for C

H, must be reduced for 25%.

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Distance of holders L (cm) for

29

INSTALLATION INSTUCTIONS FOR PIPE LINES

thermo plastic material, it means that increasing of the line

esistance on temperature R

ecause the polyethylene isB

ar dimension is expected. So, till planning of the project, project team must take into consideration the factor of changing of length of pipeline. It is useful for new construction of pipeline, the final connections to be done after adapting of the pipes on the air temperature.

Calculation of the operating pressure according the temperature and expected time is given below:

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temperature Life timeSeries

Permitted operational pressure PH 2.5 PH 3.2 PH 4 PH 6 PH 10 PH 16

30

Base for calculation

Curve of pressure for pipes made of

Curve of pressure for pipes made of

PE 80

PE 100

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Time of slacking

Time of slacking in years

Stra

inin

g S

train

ing

Time of slacking

Time of slacking in years

31

Calculation of the changes of length

ference

use following formula: temperature

ficient of expansion (mm/m*K)

ifference (K)

For determination of the ∆T, the highe perature to the

nal pressure influence

d and fricative pipe system is:

L - Length of the pipe system (mm)

hanges of the length by temperature difC

or calculation of the length changes of the pipe, F

∆LT - Changes of length till the change (mm) α - Linear coefL - Pipe length (m) ∆T - Temperature d

st difference of the installation tem highest operation temperature is used. Average value of α: PP∼0,15; PEHD∼0,20

Linear expansion coefficient α for PP Linear expansion coefficient α for PEHD Calculation of length changes inear changes causes of interL

ith internal pressure, expansion of the length of closeW

p - Operational pressure (bar) cientµ - Transferal contractive coeffi

Ec - Crawl module r of the pipe da - Outer diamete

di - Internal diameter of the pipe

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Temperature

Temperature

Exp

ansi

on c

oeffi

cien

t

Exp

ansi

on c

oeffi

cien

t

32

Changes of the length causes of chemical influence

hanges of the length into the pipe system can be hC igher, as much as the diameter of t

∆Lch=Fch*L L - Length of the pipe system (mm)

rrect calculation, factor of distortion can be determinate with individual test for diff

tion

nsole can be caused of change of the operational or air tem

e (mm)

Specific constant of the material:

tion temperature of 20° is based on calculation of k-value. ture.

he pipe increases under chemical influence. Simultaneously, mechanical features are reduced. Expected change of the length under influence of the chemical mixture can be calculated with main factor of the distortion. Till testing of the drain pipe made of PEHD and PP that are transporting chemical mixture, factor of distortion is useful.

ch=0,025...0,040 (depending of planned pipe line) F

hange of length in this test approximately is: C

Fch - Distortion factor Note: For coerent material.

onsole calculaC

hanges of the coCperature. Big attention must be taken of the installation of the pipe line on the ground

because of the axial motion are quite compensated. In most cases, change of the direction of the pipeline can cause contracting of pipeline length. Also, change of the direction can be used for compensation of length expand.

Depend of the construction, compensators can be axial, lateral or angled. Distance to the fixed point (length of the banded end of the pipe - console) easily can be calculated as:

Ls - Length of the console (mm) ∆L - Change of length (mm) da - Outer diameter of the pip

k - Specific constant of the material

Note: InstallaShock strength has to be taken into calculations when low temperaK - Value can be reduced to 30% for pipes without pressure (ventilation).

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On unit temperature change

33

Compensation of the changes with compensation console (left)

t)

len

ompensation of the changes of the length with elastic arch (righC

- Fixed point LP - slide point F

Console length in cm for pipes made of PP and PE depended of the change of the gth ∆L

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Changes of height ∆L (cm)

34

CHEMICAL CHARACTERISTICS

E pipes have great resistance on P many chemicals and different temperature.

_____ Full resistance ce

e

egend: L

________ --- --- Limited resistan --- No information B.P. Water mixture

r3.V.P. Saturated mixtuH.K. Low concentration

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S Che ubstancemical s Concentration Temperature (°C) Gases that contain Acetic acid Acetic acid Anhydrid of Acetic acid Acetone Alum Amonia gas Amonia liquid

Traces

Animal and vegetable oil Beer Benzol Sodium preborath (borax) Boric acid Butanone Calcium hipochlorideCarbon dioxide Carbon monoxide Carbon tetrachlorideCarbon bisulfate Chloride of different metals Chloroacetic acid Chloroform Chromium acid Lemon acid Oil Detergent Dextrin Dichlore ethane Dichlore ethylene Diesel oil Diethyl ether Dry chlorine Ethyl oil Ethyl alcohol Ethyl acetate Fatty oil Phenol

35

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Chemical substance Concentration Temperature (°C)

Formaldehyde Formic acid Fruit juices Dairy acid Glucose Glycerin Chloral carbonic acid Chloral carbonic acid Chloral carbonic acid (gas, hard or liquid) Fluorite carbonic acid Carbon

Traces

Bromine carbon Carbon peroxide Carbon peroxide Carbon sulfide Ferro chloride Ketenes Vinegar Mercury Methanol Methyl chloride Molasses Oil Naphthalene Nitrite of different metals Nitric acid Nitric acid Nitro benzene Nitric steam Nitric steam Mineral oil Ozone Paraffin oil Per chloride acid Gasoline Petroleum Phosphoric acid Phosphoric acid Phosphoric acid Photograph regencies Cilium borate Cilium bromide Cilium dichromate Cilium hydroxide

36

ADVANTEGES OF POLYETHYLENE PIPES

lye t flexibility that cau

moving on the ground

us used in cha

al hits

lye e on mechanical hits. However, testing on me

Big flexibility - small weight •

o thylene pipes have greaP

ses easy and fast installation and makes reducing of use of special fittings (packs of the pipes with long length in contours). Next table gives possibilities of curling of the pipes dependent on nominal diameter, SDR and temperature.

Resistance on •

a es of the elastics, PE pipes are C areas with bad seismologic

racteristics and overloaded roads. Great resistance on mechanic•

o thylene pipe shows very big resistancP

chanical hits is not present in the international standards of this kind. Smaller friction coefficient than any other material of same use •• High nonporous pipes High quality of the lines

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Clean

Radius of curling R according the diameter

37

Chemical substance Concentration Temperature (°C)

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

col

stance on chemical corrosion - no need of additional cover on the ipe

ng nectors. Welding out of the ditch. Smaller installation depth. Tin

ack V radiation and freezing.

Co

ACKAGING

Packaging of pipes to Φ90 mm is in con

Packaging of pipes to Φ1

TRANSPORTATION AND STORAGE

have to be handled with care, so none of the kno

gh temperature

ora ength loading, ca causes deformation (ov

Ecological material - protection of quality of the water without changes of taste and or of the water. High resi•

p s • Fast installation o length without conL

ny ditches. Continuing on and with any kind of pipeline without problems. Possibilities for installation of outer pipelines •

l colored HDPE - pipes are specially resistant on UB

lored pipes have some UV stabilizer that makes them more resistant.

P

tours and look like this:

10 mm looks like this:

ransportation and storage of PE pipesT

wn damages to become as: Incorrect handle on hi•

t ge on high temperature, combined with lS

al pipes).

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• Scrape with sharp object

pes ped or set on rude surface... If the pipes are ove

ese se of incorrect load or unload and hits by the

the transportation

raig urface on the whole length of the pip

rent kind of pipes (types and diameters), the har st

. If need of mo ng

pro cte

i can be pulled and dropP

rloaded, or unloaded with metal wires, handled care is needed. Deformation caused of outer load •

h kinds of damages usually are becauT

transportation. For best protection by•

t ht pipes must lie on the bottom, on clean sS

e as it is on the picture below. Transportation of diffe•

de pipes must be on the bottom • Avoid to put one on another pipe, except when transportation. • Contours must be storage as they come from the manufacturervi - protect the pipes of mechanical hits. • Ends of the pipes that are rounded and ready for connection have to be te d.

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WRONG

CORRECT

CORRECT

TRANSPORTATION

39

INSTALATION t is recommendI ed for installation of pipes to be putted into the ditch with minimal

dep

ted on many ways. Frequently used:

ST G

(Melt Flof Index)

fittings made of thermoplastic:

Who can welt?ined and qualified persons. Welding can be done only with the

ma

lding place must be protected of air conditions (wind, humidity, inte

d so any kind of strain to be avoided.

Str

th of 45 - 60 cm depends of freezing zone. Installation of the pipes is allowed on air temperature from -5°C to +60°C.

ETHODS OF CONNECTION M

he polyethylene can be connecT• Frontal welding

lding • Electrofusion we• Mechanical connecting N RUCTIONS FOR WELDINI

asic information about MFI groupB

hese instructions are used for welding of pipes and TMaterial substance Welting compatibility

Only special trachines according the DVS 2208/part 1 standards. Used parameters for every welt

must be noticed in the welding report.

asic instructions BSurrounding of wensive UV radiation, temperature <5°C). Parts that are welding must be not damaged

and clean. Also the surrounding must be clean.

se is limited of different types of connectionUIf it is possible - all connections to be isolateain that can be caused of difference of temperatures between the ditch and

operational conditions must be as much as possible on lower level. In the table are given permitted types of connection for appropriate class of pipes.

Polyethylene PE 80,

PE 100 MFI group 005 with 010

Polypropylene PPH, PPR MFI group 003 with 006

PPH with PPR

Especial types PE 80 - el PPR - el PPR - s - el

PE 80 - el with PE 80 PPR - el with PPH and PPR PPR - s - el with PPH and PPR

MFI group MFI value PP (230/2,16)

MFI value PE (190/5)

003 005 006 010

0,2 - 0,4 g/10 min 0,4 - 0,8 g/10 min

0,3 - 0,7 g/10 min 0,7 - 1,3 g/10 min

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40

Legend:

INSTRUCTIONS FOR FRONTAL WELDING t 11 from PP)

welding is integral part of welding equipment. Tw

ure (bar) or the power of heating (Kp) has

Parameters of welding e (Pspec)

a re

hen use of hydraulic equipment, calculated welding power (Kp) has to be con

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

(By DVS 2207, part 1 and 2 for PEHD and par

elding method WElement for frontalo ends of (pipe and fitting) bring with pressure on the heating

plate. So the parts are heating up to the temperature of fusion with reduced pressure (pre warming) and than take off the heating plate and connect the ends with pressure.

pecific heating pressure S

In most cases, heating press to be set from the table for welding machine. For check of use or

if you don’t have table for pressure, wanted pressure of heating can be calculated with the formula:

alculation of power of heating: C

Specific heating pressurPPH, PPR (el) 0,10 N/min2PE 80 (el) 0,15 N/min2

perWelding tem tu (T) /205°C PPH, PPR (el) 195

PE 80 (el) 200/210°C

Wverted on permitted adjustable hydraulic pressure.

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Type of connection

Mechanical connection Frontal welding

With covered welding

Flange welding

Electro fusion welding

41

Welding parameters

1 - time needed to set the pipes ating

welding parameters:

Units with determination of the power: Fconn. = Fw + Ftable :

Instructions for successful welding

achine) and if needed set a tent.

TT2 - time needed for continued heT3 - Time for taking off the heating plateT4 - Time needed to reach the pressure T5 - Cooling time

Common table of

Units with determination of the pressure Pconn. = Pw + Ptable

repare the operational place (tools, mP

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Temperature Pressure

Setting by the connection pressure

e heating essure

Prpr

Setting time Time of pre heating Cooling time Connection pressure

Time of taking off the heating plate

Welding time Total connection time

Type of material Thickness of wall (mm)

Height of the welt (mm)

Time of pre heati(sec)

ng Time of change (sec)

Pressure of connection Cooling time

42

Setting of the machine for welding

ing holders, so ends to be parallel. Insure free mo

e process at lea

aper.

d it to the

erformance of the process of frontal welding

re. welding surfaces are set for the heating plate. With this

set

Visual control of finished weld and possible defect

ide

ight of the edge

etting of the appropriate pipe and fittS

ve of the end that will be welded. Clean internal and outer surface of the welding part with acetone or alcohol. Smoothing of the two ends and removing of any kind of edges or trash. Once again check the parallelism of the two ends.

the process (start thCheck the heating temperature before the start ofst 5 min after the reaching of given welding temperature). Keep the heating plate on special holders, before and after the welding.

lean the heating plate before start of welding with appropriate towel or pCSet the needed parameters.

for moving the part into the welding zone and adMeasure the pressure needed pressure needed for pipe welding. P

ut the heating plate. PSet the needed pressuKeep the pressure till the ting, latter formed edge must be equal for whole section of the pipe. Reduce the pressure on P=0,01 H/mm2 and keep it for pre warming time (by the

table). Remove the heating plate and connect the welding surfaces in short time. Easily

increase the pressure to the asked value. Keep this pressure for the cooling time. Take off the holders after the cooling time.

fter the connection the weld must be formed A

ntically to whole circumference of a pipe. For every case, welt must be visually controlled, so put

attention on: Equal he•

• Slide surface of the edge

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43

Possible failures and reasons for their appearance

TESTING UNDER PRESSURE All welded joints should be completely

cold before testing under pressure (in principle 1 hr after the last weld).

Testing under pressure should be

undertaken in compliance to the valid standard regulations (VS 2210 part 1, DVGW work list w 210).

Thus, the maximal pressure applied

here is 1.5 h PH, where no leakage should occur during testing (at least 10 minutes).

The pipe system should be protected

from environmental temperatures changes (UV radiation).

Failure Appearance Possible reasons

INSUFFICIENT FUSION

Low temperature of heating plate, great amount of high pressure resulting in material pressing out

Crack inside the welding area

Pipe overheating or overloading prior the required cooling time

Hole within the fusion area

Insufficient joining pressure or too short pressure action

Porosity

Welding edges improperly cleaned

Unclean welding edges Dust, sand or metal shavings

44 TEC

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ELECTROFUSION WELDING OF PEHD PIPES AND FITTINGS Preparation of the welding spot: Adjustment of the equipment: (Preparation of tools and machine), welding control unit. Preparation of welding edges (refers to any item prior welding

process begins). Cut the right angle pipe by means of an appropriate cutting tool.

Clean the pipe alongside L + 50 mm minimum with dry cloth (L= length entering the electric fitting).

The shiny surface inside and outside the pipe edge is carefully removed using peeling tool or scraping knife inserted on a suitable device around the pipe diameter.

Having cleaned the welding area (both pipe and fitting) with acetone (or alike) and with soft tissue making sure no traces remain (piles etc.)

from its case making sure not to touch its inside and prepared pipe - it is then inserted into the pre e pipe edge. Welding areas should be dried before pipe is inserted into the fitti

paper. Having fixed the device supports around the pipe thu

t and fasten both ends with special support, thus avo

elding process

again to make sure there is no axial displacement of the socket and connector is then connected to the welding cord. Proper connection of the welding equipment is shown on the device.

Pre-welding preparations Fitting to be welded is removed

pared pipe end until front end of the fitting connects to th

ng. This means removing any moisture or cleaning residues with absorbing

s indirectly fixing the el. fitting edges. Prepare the second part to be welded in the same way. Insert the other part of the pipe or the fitting into the socke

iding pressure increase in the welding area. Electrofusion w Having completed preparations as mentioned above, check once

WELDING INSTRUCTIONS Electrofusion welding of PE This method is used for welding pipes and fittings by means of a

resistant wire. The resistant wire is built within the fitting wall. Electric current is used to do the welding. During heating period

the inside of both the fitting and the pipe are melted.

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45

The fitting shrinking is precisely measured during heating which guarantees that the joining pressure, previously unnecessary shall be modified.

The completed welding process results in a homogenous joint that guarantees a 100% tightness. The complete electrofusion welding process shown in the picture.

1,3g/10 min. Only universal tools subject to bar-code can be used on the butt welding machine. Pipe

tions and record these.

y inserting this card (or manually entering e

or scanner. A

of data entering

elding voltage are

FUNDAMENTAL APPLICATION OF THIS WELDING TECHNIQUE

Only parts of same material can be welded. The electrofusion fittings flow index is in the range of 0,7 -

oval shape should not exceed 1.5%. ELECTROFUSION WELDING DEVICE

Appropriate machines are being used for electrofusion welding manufactured by numerous producers. These machines monitor all the welding

rocess funcp

Each fitting should have its code card showing all elding data. Bw

th data) the machine receives all the welding parameters required and welding process begins on basis of this information.

Having loaded the data, it is erased from the card thus making sure it can be used only once.

elding parameters are entered with pen Wsound beep shall register the completion

rocess. pHaving entered the welding parameters, the size

and outside temperature are displayed. These values must be known. Welding process begins with pressing the green start button. At the same time the welding time required and current time as well as wdisplayed.

Joint supports should remain in position during complete welding process (including the cooling time). There is a sound beep at the end of the welding process.

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46

WELDING PROCESS

WELDING PREPARATION

HEATING

CONNECTING AND COOLING

STICKING AND PRE

Supports can be removed after the cooling.

parameters can be printed thus providing the welding report.

Cooling time should be observed. In case of interruptions in welding process for any reasons (power failure) it is not recommended to use the same fitting again.

Visual inspection and documentation The welding indicator makes a visual weld inspection on the fitting itself. All welding

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47

POLYPROPYLENE PIPES

FLOOR HEATING Thanks to the PP - Pa specific flexibility and the option of applying concrete, the

system is suitable for floor hea

ADIATOR HEATING thermal radiation in particular, the material is

suitable for designing radiator heating systems.

gas, liquid food products etc.

IONS

ed the average operating temperature. Energy savings amount from 10 to 20%.

equirements in view of application of plastic materials in potable water delivery.

re manufactured of treated Ms - 58, plated protected (Ni) and guarantee watertight layers within all other metal components of the sys

rties of the system. All system parts can be joined by means of semi-fusion or electric socket welding technique.

d handling. he system can be easily composed at the construction site or placed in front of the

wa

POTENTIAL OF APPLICATION SANITARY INSTALLATION The PPR system has been developed for application in sanitary installations in

construction, in compliance to DIN 8078 prescribing operating pressure of PN 25 forpipes and fittings.

ting also. RConsidering the parameters, the

INDUSTRY Thermal and chemical resistance of the material allows its application in the transport

of compressed air, SPECIAL APPLICATSmall weight, persistency to salt water and vibration adjustments open opportunities

for usage in ships and camping vehicles. ENERGY SAVING Low thermal dispersion within the fitting with low thermal inertia enables quick hot

water delivery even if the piping has not yet reach

HARMLESS TO HEALTH The PPR system meets in full international r

METAL THREADED INSERTS All threaded inserts built in fittings a

tem. WELDING This is one of the fundamental prope

VERSATILITY Low specific weight enables transport anTll.

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48

FROST RESISTANCE The elasticity of PP-Pa enables increase of pipe cross-section in

ing

RESISTANCE TO FRICTION AND CORROSION

and acidic substances to pH 1-14.

s a very poor heat conductor, condensation and thermal leakages are minimized.

REMOR ZONES APPLICATIONS ce to hits the PP-Ra pipelines

can

hanks to its smooth surface inside the pipe, no deposits occur whmaterials used for the same purpose.

nces the PP-R represents a sound insulator, elastic and absorbing all water changes causing vibrations and building noises.

p to 50 years depending on operating temperature and pre

case of increasing the liquid delivered volume occurring in freezconditions.

SURFACE ELECTRICITY Thanks to the low electric conductivity this system is protected

from so called astray currents.

This property enables high flow velocities of the transport medium

(up to 7 m/sec) with no risk of erosion even in the presence of alkali

LOW THERMAL CONDUCTIVITY Since PP-R i

RESISTANCE TO ABRASION The pipes allow high water velocity without any corroding

problems. TThanks to its flexibility and resistan be laid in tremor zones also. LOWER PRESSURE LOSSES Tich in turn result in lower pressure losses in relation to other

NOISE FREE As all plastic substa

LONG DURATION Ussure.

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49

SEMIFUSION WELDING

PREPARATION External pipe surfaces and fitting part must be alike

and smooth. Pipe ends must be cut at right angle. Prior welding begins the device operation and reached welding tem

ould be imprinted straight and with no axial movement into the heating accessories (casing and prickle) up to the spacer. When the heating time has elapsed, the heated pipe and fitting part to be rem

spacer.

Welding is carried out by means of a welding device with simultaneous heating of both joining elements of the system. When welding temperature has been reached the elements imprint one into another thus creating an absolute closed connection.

perature should be checked. PERFORMANCE Pipes and fitting parts sh

oved from the device and immediately with no movements to be inserted one into the other. It is very important to observe the prescribed insertion depth in order not to exceed the fitting part

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50

ELECTRIC SOCKET WELDING

the connection must not be overloaded until completely cooled. Cooling agents are not

per

amage.

only

t to

8 X diameter.

• ipes with no protection from external

xygen.

nts

be

don ation

up to 30 deg maximum

The electric socket is mainly used in repairing and welding the existing installations.

The procedure is simple and safe provided some simple rules are observed. Connection

parts must be headed axially. After the parts have been inserted into the E-socket they

are connected to the welding device. Subsequent procedure follows automatically only

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To avoid disruption of PP-R pipes quality it is

recommended to follow these instructions:

• Do not use open flame to create a curve,

since temperature can not be controlled and

it can lead to molecular temperature d

It is possible to make a 90 deg elbow

care should be taken the bending radius no

be less than

NO

NO

NO

NO

51

P

conditions can lead to outside damages

caused by UV rays in combination with

o

• It is not recommended to use metal eleme

causing abrasion. In case metal elements are

of satisfying quality the connection is done

with Teflon band.

• Avoid hits, sharp bending especially at pipe

ends and edges

• Not to use broken and damaged pipes

Any movements of pipes and fittings can

e only during or immediately after install

rubber inserts composition is specially adapted to the PPR pipes. Two types of supports are used in pipeline construction:

• rigid (fixed support)

T

used as holder support, one should bear in mind the short d a all these are fixed to. Swinging tapping saddles are not sui bl o upports. In principle vertical distributions can be rigidly fitted. Compensation arcs of perpendiculars elongation are not required. Tapping saddle and support must be stable and fixed in a satisfactory manner to be able to accept forces occurring following pipe elongation.

ting. Cold fluid pipelines are not prone to elo

METHOD OF PIPELINE CONSTRUCTION TECHNICAL FIXATION PP-R pipelines holders should be inserted according to PP-R pipe diameter. Care should be taken fixing material not to cause any technical damage to the

external surface of PP-R pipes. Tapping saddles with rubber inserts represent ideal pipe fixation elements whereby

• sliding (guide support)

IGID (FIXED) SUPPORR Even placement of the rigid support (fixed spots) divide the pipeline into separately

controlled distances. This construction type allows avoiding uncontrolled movements inside the pipeline and secures pipe guidance.

Fixed support size and design should allow any extension and possible additional loading forces of pipes to be received and compensated.

Wh eingen threaded rods are bist nces to the roof and we f r construction of fixed sta

PP-R pipe tapping saddles meet above mentioned conditions and when fitting

instructions are observed, these are ideal for construction of fixed and sliding supports. When metal tapping saddle with specific rubber insert is used mechanical damage to pipes is excluded.

When positioning the sliding support care should be taken not to prevent axial movements to the pipe parts placed too close, such as fitting parts, armatures etc.

ELONGATION Pipeline elongation depends on its heangation and therefore not of interest in this respect. In hot fluids and heating pipelines

installation however, the pipeline length changes due to temperature differences affecting the material behavior should be taken into account. Each material should be considered separately in accordance with the method of pipeline construction.

• Pipelines within walls, floor etc (mortar, concrete) • Pipelines and canals • Pipelines in open space

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52

o

h

PIPELINE CANALS When placing PP-R pipelines in various canals, modifications in view of length

should be taken into account, i.e. branching arms to have sufficient space to follow the elongation.

LINES WITHIN WALLS, FLOOR When laying pipelines within walls, floor etc. PPR pipes elongation is not taken into

account. By insertion of pipeline into the concrete, mortar and alike elongation caused by temperature conditions is prevented. Thus generated forces are being equalized with the elasticity of the material and therefore not critical.

PIPELINE CANALS When placing PP-R pipelines in various canals, modifications in view of length

should be taken into account, i.e. branching arms to have sufficient space to follow the elongation.

PIPELINES WITHIN WALLS, FLOOR When laying pipelines within walls, floor etc. PPR pipes elongation is not taken int

account. By insertion of pipeline into the concrete, mortar and alike elongation caused by temperature conditions is prevented. Thus generated forces are being equalized witthe elasticity of the material and therefore not critical.

This can be achieved in various ways:

This can be achieved in various ways: 11. By proper placement of perpendiculars in the canal. 2. By proper sizing of the hole for finding the branching pipeline through the canal

wall, i.e. by pipe covering size for finding the wall. 3. By making knots enabling torsion compensation

. By proper placement of perpendiculars in the canal. 2. By proper sizing of the hole for finding the branching pipeline through the canal

wall, i.e. by pipe covering size for finding the wall. 3. By making knots enabling torsion compensation

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PIPELINES IN OPEN SPACE In line structures including cold and hot distributions (such as cellars, boiler rooms

etc.) great attention is paid to the external appearance and stable form of the pipeline.

PP-R pipe elongation coefficient is:

0,15mm x m x *C

ion in practice. The difference between operating temperature and temperature at the moment of placement of pipe is very important in calculating the elongation value.

Below examples show elongation calculat

CALCULATION OF ELONGATION VALUES KNOWN AND REQUIRED VALUES

Designation Significance Value Unit

∆L Elongation ? mm

α Linear elongation of PP-R pipes 7 0.15 mm / m°C

L Pipe length 10 m

tr Operating temperature 50 °C

tm Temperature at fitting 25 °C

∆t Temperatu tM ∆t=tR-tM re difference between tR and 25 °C

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

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ELONGATION (mm)

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S ONGATIONS

Supports are easily fitted and fixed to PP-R as well as metal pipes. In open space installation elongation has to be taken into consideration even during pipeline designs. Pipe cons a way to allow elongation and unobstructed movement of pipe within the elongation calculation values….

Only two simple options can be considered regarding compensation modification of length.

ELASTIC ARC MODIFICATION

In most cases the change of direction can be used to compensate the elongation. The distance to the fixed support, i.e. to the pipe bending end (bracket) can be easily calculated using the following formula.

COMPEN

ATION EL

line truction must be designed in

COMPENSATORS Not all compensator types for metal pipelines are recommended for PP-R pipelines. CHANGE OF DIRECTION

Calculation example: Bracket length Known and required values


LK Bracket length ? mm

L Spec. const, mat. PP-R pipe 20 /

D Outside diameter of the pipe 32 mm

∆L Elongation 20 mm

Bracket length is calculated using the following formulas:

KT - slide point FT - fixed point

On basis f the example as calculated above the bracket length LK is 506 mm.

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CHANGE OF DIRECTION ELASTIC ARC

55

LIRA)

ssary to insert an elastic a s and additional four 900 elbows are required to make this.

C lation ASTIC ARC (LIRA) K n and

IRA)

ssary to insert an elastic a s and additional four 900 elbows are required to make this.

C lation ASTIC ARC (LIRA) K n and

ELASTIC ARC (

ation is not possible it is nece

ation is not possible it is neceIn case elongation compensertain quantity of pipe

In case elongation compensertain quantity of piperc (lira). Crc (lira). C

alcualcu example: EL example: ELnownow required values required values

Desi tion gna Significance Value Unit

Amin MIn. width of the elastic arc ? mm

∆ L Elongation 20 mm

SA Safe distance 100 mm

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Calculation of the electric arc width is performed using the following formulas:

mm minimum.

KT - slide point FT - fixed point

since movements due to elongations are practically invisible. e elastic arc is determined as follows:

Amin = L + SA Amin = 2 x 2mm + 100mm Amin = 140mm Elastic arc width in this case is 140

VOLTAGE ELASTIC ARC This type of construction can provide less bracket length on the arc itself which is

convenient in limited space during construction. Proper design of this method leads to improved pipeline optical appearance also

Bracket length of voltagCalculation example: Bracket length of voltage elastic arc Known and required values.


LKp Bracket length of voltage elastic arc ? mm

K Spec. const, mat. PP-R pipe 20 /

D Outside diameter of the pipe 32 mm

∆L Elongation 20 mm

racket length is determined using the following formulas:

m.

B

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

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NCE ORTS The method and frequency of PP-R pipeline fixation depends also on the amount of

elong ion cau rences. Fixed support enables pipeline to be divided into several individual sections providing

an elongation possibility. lacing of pipes inside individual sections is made possible by inserting sliding

sup ns the pipeline is used in, pipe material, pipe nces in the table below have shown the best performances in practice.

especially in potable water installations it is necessary the system to be thoroughly wa n clearance without restrictions the following pr

ity;

onal defects of armatures and devices;

• Washing with water/air mixture

nce of fitters, requests of the investor as well as manufacturer's recommendations of the system materia account when making the decision on which method of cleaning to use.

Condition under 1 above - washing with water, is absolutely satisfactory in drinking water installations completely constructed of PP-R system.

No additional substances (glue, tinol) are used in pipelines constructed against the PPr system.

Connection is made exclusively by fusion. The system remains clean of additional

substances after connection. For these reasons it is rather satisfactory to wash the

system with clean water.

CE ORTS The method and frequency of PP-R pipeline fixation depends also on the amount of

elong ion cau rences. Fixed support enables pipeline to be divided into several individual sections providing

an elongation possibility. lacing of pipes inside individual sections is made possible by inserting sliding

sup ns the pipeline is used in, pipe material, pipe nces in the table below have shown the best performances in practice.

SYSTEM CLEANING (WASHING) Having completed the pipeline, irrespective of the used system materials and

especially in potable water installations it is necessary the system to be thoroughly wa n clearance without restrictions the following pr

ity;

onal defects of armatures and devices;

• Washing with water/air mixture

he nce of fitters, requests of the investor as well as manufacturer's recommendations of the system materia account when making the decision on which method of cleaning to use.

Condition under 1 above - washing with water, is absolutely satisfactory in drinking water installations completely constructed of PP-R system.

No additional substances (glue, tinol) are used in pipelines constructed against the PPr system.

Connection is made exclusively by fusion. The system remains clean of additional

substances after connection. For these reasons it is rather satisfactory to wash the

system with clean water.

DISTA BETWEEN PP-R PIPE SUPP BETWEEN PP-R PIPE SUPP

atat sed by temperature diffesed by temperature diffe

PPports. Distance between supports depends also on conditio

line weight including the filling medium weight. The distaports. Distance between supports depends also on conditio

line weight including the filling medium weight. The dista

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Temp. Pipe diameter

Difference Support distance in cm.

SYSTEM CLEANING (WASHING) Having completed the pipeline, irrespective of the used system materials and

shed. In order the system to receive its applicatioerequisites must be fulfilled:

shed. In order the system to receive its applicatioerequisites must be fulfilled:

• Making sure on the potable water qual

• Making sure on the potable water qual• Removing corroding effects; • Removing functi• Removing corroding effects; • Removing functi• Cleaning the pipe inside surface.

These prerequisites can be fulfilled in the following two ways:

• Washing with water

• Cleaning the pipe inside surface. These prerequisites can be fulfilled in the following two ways:

• Washing with water

T The experieexperie

l must be taken intol must be taken into

57

No electricity breaks can occur in PP-R pipelines armature connections such as bath taps, fa c provide for grounding.

he same goes for acrylic tubs and showers of plastic materials.

Storage area should be flat so

hould be avoided. In case of temperatures below 00C there is a possibility pip in

tant,

pipes and fittings contain UV

• stabilizer enabling storage in open space up to 6 months FINDAMENTAL CALCULATIONS Numerous parameters are required in determination of drinking water pipe diameter

in buildings. The simplified method includes all pipes resistances and other individual resistances. This method offers the best possible accuracy and coming very near the real exploitation conditions.

Following parameters are required for pipe diameter determination:

• The lowest supply overpressure or outlet pressure of the pressure control

fteners etc.;

ind the friction within pipe material; parts.

POTENTIAL LEVELLING (EARTHING)

u ets etc. thus it is not required to TIn case of metal tubs grounding should be provided for. TRANSPORTATION AND STORAGE PP-R pipes can be stored at any external temperatures. that pipes lie across all their length on basement. Bending of pipes during transport

and storage ses to be damaged when strongly hit; careful handling is therefore recommended

very low temperature ranges. In spite of the fact that PP-R pipes are very resiscareful handling is nevertheless recommended. UV radiation affects all high polymeric plastic substances. PP-R

valve (pressure increase or decrease); • Geodetic level difference; • Pressure losses in devices such as: water meters, filters, so• Minimal flow pressures used for floor armatures; • Pressure drop value bearing in m• Losses coefficient of used fittings

Fittings part Value Socket 0.25 Reduction 0.40 - 0.80 Elbow 90° 1.20 Elbow 45° 0.50 TEE part 0.25 - 3.00 Socket with UN 0.50 Socket with SN 0.70 Elbow with UN 1.40 Elbow with SN 1.60 TEE part UN 1.60 TEE part SN 1.80 Flat permeable valve 9.50 - 7.60 Outlet valve 0.25

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TECHNICAL CHARACTERISTICS

TECHNICAL SPECIFICATIONS OF

OLYTHENE AND POLYPROPYLENE PIPES

AND FITTINGS

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P

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PE 100 - PIPES

ISO 4427

*admissible operating pressure. see “technical information“

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PE 80 - PIPES

ISO 4427

*admissible operating pressure. see “technical information“

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PE 63 - PIPES

ISO 8077

*admissible operating pressure. see “technical

information“

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and F20 mm.

PP - R PIPES

ISO 8077

*admissible operating pressure. see “technical

information“

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

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Weight (kg/m) Weight (kg/m)

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STUB FLANGE

* molded out of PE100 * black

*admissible operating pressure see “technical

information “

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

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Weight (kg)

Weight (kg)

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

END KAP

* elongated * molded out of PE100

* admissible operating pressure see “technical

information“

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Weight (kg)

Weight (kg)

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REDUCER

* elongated * molded out of PE 100 * black


information“

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Weight (kg)

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S2) reducer diameter SDR 11/ISO S-

REDUCER



information“

O S-8.3 1) from dimension 250: SDR 17.6/I5

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Weight (kg)

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REDUCER



information“

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Weight (kg)

68

REDUCER



information“

1) branch SDR 11/ISO S-5

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Weight (kg)

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SDR 17.6/ ISO S-8.3

TEE



information“

1) from dimension 250:

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Weight (kg)

Weight (kg)

70

ELBOW 90°


* admissible operating pressure see “technical information“

SDR 17.6 / ISO S -8.31

1) from dimension 250:

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Weight (kg)

Weight (kg)

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* ated * molded out of PE 100 * black


6

ated * molded out of PE 100 * black


1) from dimension 250: SDR 17.6

ELBOW 45°

elongg

/ISO S-8.3 /ISO S-8.3 1) from dimension 250: SDR 17.

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Weight (kg)

Weight (kg)

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ELBOW 90°



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Weight (kg)

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REDUCER CONCENTRIC



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Weight (kg)

Weight (kg)

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

20*C)

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

20*C)

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ELECTROFUSION TEE REDUCED

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

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

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

20*C)

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ELECTROFUSION ELBOW 90°

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

* admissible operating pressure for water (at

20*C)

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

20*C)

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80

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

20*C)

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ELECTROFUSION ADAPTER

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

20*C)

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ELECTROFUSION ADAPTER ELBOW 45° INTEGRATED WELDING MODULE MALE THREAD OUT OF BRASS * elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at

20*C)

1) Thread according to DIN 2999

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ELECTROFUSION ADAPTER ELBOW 90° INTEGRATED WELDING MODULE MALE THREAD OUT OF BRASS * elongated * molded out of PE 100 (PE 80 on request) * black * admissible operating pressure for water (at

20*C)

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TAPPING SADDLE

INTEGRATED WELDING MODULE WITH ELECTROFUSION SELAING CAP


* admissible operating pressure for water (at

20*C)

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UNIVERSAL TAPPING VALVE INTEGRATED WELDING MODULE WITH TREAD INSER OUT OF BRASS


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

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PLASTIC TAPPING VALVEINTEGRATED WELDING MODULE WITH INTEGRATED CUTTER


* admissible gas operating pressure 4 bar, for

water 10 bar

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BACKING RING

* molded out of PP * black

* On request

* admissible gas operating pressure according

DIN (16962/5)

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Eng. Katalog Gema Plast - Km

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Transcript of Eng. Katalog Gema Plast - Km