dip absdata

8/10/2019 Dip ABSdata

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Introduction

1

EURAPIPE DURAFLO 1-1

CONTENTS

SCOPE 1-2

DURAFLO 1-2

FREEFLO 1-2

MANUFACTURING STANDARDS 1-3

CUSTOMIZED FABRICATION 1-3

QUALITY ASSURANCE 1-4

LIMITATIONS OF LIABILITY 1-4


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Introduction


SCOPE

The Eurapipe ABS Pressure Pipe Systems catalogue has been designed to assist designers, installers and end users to gain the

maximum available benets when using the Eurapipe ABS Pipe Systems.Many piping applications are subject to special operating conditions, which may fall outside the scope of catalogues such as this.

It is strongly recommended in these instances that qualied engineers experienced in thermoplastic pipe system design should be

consulted.

Note: Technical data contained in this catalogue supersedes all previously published data by Eurapipe.

The piping systems covered, including typical jointing methods, are shown in the following table:

DURAFLO

For small bore applications,Eurapipe ABS piping systems

have traditionally been based on an inch nominal bore system

e.g. a 150 Nominal Bore ABS pipe has an equivalent outside

diameter to a 6 NB steel pipe i.e. 168.3mm.

For large bore applications in which Eurapipe has pioneered

the use of ABS piping systems, Eurapipe has adopted

International Standard pipe sizes for large bore pipe systems.

This combined system has wide industry acceptance and is

the system used by Eurapipe for its DURAFLOpiping system

in this size range.

Currently, Standards Australia is updating the Australian

Standard for ABS pressure pipes and ttings which will include

this combination of pipe sizes. DURAFLO will be nominated

as the Series 1 size range.

FREEFLO

Eurapipe has recently developed a new size range of pipe to

be compatible with ductile iron and FRP ttings, in addition to

legacy materials such as asbestos cement and cast iron.

This range of pipes and ttings is available under our

FREEFLO range of products.

Currently, Standards Australia is updating the Australian

Standard for ABS pressure pipes and ttings and will also

include this range of pipe sizes. FREEFLO will be nominated

as the Series 2 size range.

JOINT SYSTEM

PIPE SYSTEM

COLD SOLVENTCEMENT

WELDING (SWJ)

ELASTOMERICSEAL

JOINTS (RRJ)

FLANGE WITHBACKING

RING

DUCTILEIRON

FITTINGS

SHOULDERSTYLE

COUPLING

THREADEDJOINTSAS1722

DURAFLO

FREEFLO


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Introduction

1


MANUFACTURING STANDARDS

All products manufactured by Eurapipe comply with AS/NZS

3518:2004 and other relevant Australian and internationalstandards.

Products not covered by these standards are manufactured

to Eurapipe Quality Plans, drawings and manufacturing

specications.

Eurapipe holds the following licences and certicates:

StandardsMark Licence to AS/NZS 3518:2004 ABS pipes

and ttings for pressure applications

Germanischer Lloyd Type Approval Certicate for ABS

pressure pipes and ttings (GL)

U.S. Food and Drug Administration (FDA)

Japan Electrical Safety & Environment Technology

Laboratories (JET)

National Sanitation Foundation International (NSF)

The Reliable Contract Research Laboratory with the

Comprehensive Service, Switzerland (RCC).

CUSTOMIZED FABRICATION

Eurapipe has a highly skilled and innovative fabrica-

tion team able to translate client sketches in to complete,

nished assemblies ready for site installation. Using

techniques sometimes only available in a quality controlled

factory environment, th prefabricated assemblies generate

considerable savings by reducing both costs and installation

time.

Contact Eurapipe for further information regarding fabrica-

tion of manifolds, headers, non-standard bends and other

customized products and assemblies.


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Introduction


QUALITY ASSURANCE

Eurapipe is committed to a Total Quality

Management System, being a Quality Endorsed

Company to AS/NZS ISO 9001 : 2000.

Eurapipes Quality Control Laboratory features some of the

most modern test equipment and is able to conduct all product

testing necessary for compliance with the relevant standards.

LIMITATIONS OF LIABILITY

All information contained in this catalogue has been compiledand presented in good faith and is subject to change without

notice. Eurapipe makes no express or implied warranty of

any kind regarding the accuracy of the information contained

herein.

Eurapipe reserves the right to withdraw or alter the

specication of any product without notice. The products listed

in this catalogue have been designed and manufactured to

be in accordance with the instructions guiding their use, care

and maintenance. The products should not be used for any

purpose other than those for which they were designed.

For further information regarding these products, reference

should be made to the instructions and the guidelines for care

and use issued by Eurapipe. Alternatively please contact your

nearest Eurapipe representative listed on this publication.

ISO 9001

Reg. Lic.No. 1105


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ABS Pipe Systems

2


CONTENTS

ABS 2-2

ENVIRONMENTAL ADVANTAGE 2-2

IMPACT STRENGTH 2-2

CHEMICAL RESISTANCE 2-2

ABRASION RESISTANCE 2-2

WEATHER RESISTANCE 2-2

NON TOXIC/ TAINT FREE 2-3

EXCEPTIONALLY SMOOTH BORE 2-3

SIZE AND PRESSURE RANGE 2-3

TEMPERATURE RANGE 2-3

LIGHT WEIGHT 2-3

JOINING SYSTEMS 2-3


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2

ABS Pipe Systems


ABS

ABS (Acrylonitrile - Butadiene - Styrene) is a modern

thermoplastic polymer found in everyday applications such asconstruction site safety helmets.

Piping Systems manufactured from this polymer display

outstanding properties and so makes ABS pipes the rst

choice for many of the most demanding piping applications.

ABS pipe and ttings are designed and manufactured by

Eurapipe to suit extreme climatic conditions.

Both theDURAFLOand the FREEFLOpiping systems are

manufactured from ABS polymer.

ENVIRONMENTAL ADVANTAGE

The use of ABS contributes positively to the environment as

it takes approximately one sixth of the energy to manufacture

compared to metal products. This has direct savings in green

house gas emissions.

Additionally ABS is lead and chlorine free and can be readily

recycled.IMPACT STRENGTH

The butadiene constituent in ABS affords unrivalled resistance

to impact. This means that DURAFLOand FREEFLOABS

Piping Systems may be used in more critical applications

where other types of plastics could not be considered.

CHEMICAL RESISTANCE

DURAFLOandFREEFLOABS is unaffected by both internal

and external chemical attack by a wide range of acids, alkalis,

ground water salts and other environmental factors.

ABRASION RESISTANCE

DURAFLOandFREEFLOABS offers outstanding resistance

to abrasion and erosion from aggressive slurries, which can

rapidly damage steel or other traditional pipe materials.

WEATHER RESISTANCE

DURAFLOand FREEFLOABS is one of the most weather

resistant polymers available today. Successful eld tests have

been completed on piping systems having been exposed to

weathering for over 30 years.

Not accounted forin Green Star orNABERS ratingtools.


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ABS Pipe Systems

2


NON-TOXIC/TAINT FREE

The ABS formulation contains no harmful metallic stabiliz-ers

and it has been widely used for many years in piping systemsfor high purity water, medical preparations, food products and

soft drinks.

DURAFLOand FREEFLOABS systems are ideal for potable

cold water. They conform to World Health Organisation, E.E.C.

and AS 4020 requirements for potable water reticulation and

distribution.

EXCEPTIONALLY SMOOTH BORE

DURAFLOand FREEFLOABS does not suffer from internal

corrosion and provides a smooth bore for the life of the pipingsystem.

The smooth bore does not support the formation of scale and

slime as do cement based lined products.

SIZE AND PRESSURE RANGE

DURAFLOand FREEFLOABS piping systems are

manufactured in sizes ranging from 15mm to 900mm.

Standard pressure ratings at 20C start at 450 KPa and go to

2000 KPa (PN4.5 to PN 20). Refer to EURAPIPE for further

details.

TEMPERATURE RANGEA great advantage of DURAFLOandFREEFLOABS

over other plastic systems is its ability to perform over a

wide temperature range from -30C to +70C. This makes

DURAFLOandFREEFLOABS very versatile and capable of

handling a wide variety of uids from refrigerants to moderately

hot corrosive liquids

LIGHT WEIGHT

ABS is one-sixth the weight of steel systems, making

DURAFLOand FREEFLOeasy to handle and install. This

reduces the cost of installation, handling and transport .

JOINING SYSTEMS

Cold Solvent Weld Joining

The DURAFLOsize range also utilizes the proven traditional

method of joining ABS pipes, cold solvent cement welding,

which provides an homogenous bond between pipes and

ttings (SWJ).

Elastomeric Seal Joining

Both the FREEFLOand DURAFLOsize ranges utilise an

elastomeric seal joining systems (Rubber Ring Joint, or RRJ).

Other Joint Systems

Other joint systems are also available as standard for both

DURAFLOand FREEFLOsystems and are detailed further in

this catalogue.


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ABS Material

3


CONTENTS

INTRODUCTION 3-2

THE MATERIAL 3-2

MATERIAL PROPERTIES 3-3

IMPACT STRENGTH 3-4

MODE OF FAILURE 3-4

THERMAL EXPANSION 3-5

TOXICITY AND TAINT 3-5

RIGIDITY AND STIFFNESS 3-5

WEATHERING 3-6

ABRASION RESISTANCE 3-6

CHEMICAL RESISTANCE 3-7


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3

ABS Material


INTRODUCTION

Because of a unique balance of properties, modern ABS

copolymers are being used on an ever increasing scale for themanufacture of many industrial and domestic products.

The material is very tough and resilient, has high impact

strength, good chemical resistance and is non toxic and taint

free. These advantageous properties have attracted engineers

in many industries to the use of ABS piping systems rather

than traditional materials, which do not have these distinctive

benets.

ABS piping systems are replacing many failed piping systems

made from other materials.

The Eurapipe ABS system comprises a range of matched

pressure pipes and ttings, joined together by a wide variety of

methods including cold solvent cement welding or our rubber

ring joint system.

THE MATERIAL

Acrylonitrile - Butadiene - Styrene (ABS) identies a family of

engineering thermoplastics with a broad range of performancecharacteristics.

The copolymeric system is alloyed to yield the optimum

balance of properties suited to the selected end use.

ACRYLONITRILE- imparts chemical resistance and rigidity.

BUTADIENE - endows the product with impact strength,

toughness and abrasion resistance.

STYRENE - contributes to the lustre, ease of processing and

rigidity.


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ABS Material

3


MATERIALS PROPERTIES

The formulation used by Eurapipe has been developed

in conjunction with polymer manufacturers to optimiseperformance in respect to tensile strength, chemical

resistance, ductility, resistance to weathering, heat stability,

low toxicity, taint free and ease of processing from raw material

to nished product.

ABS is tough and strong over the recommended temperature

range of -30C to +60C.

The outstanding properties of ABS are:

High impact strength and ductility, which combine to give

exceptional toughness.

Good chemical resistance.

Abrasion resistance.

High strength solvent weld jointing which allows efcient

system assembly and modication.

Rubber Ring jointing methods, allowing compatible systems

jointing techniques.

Nontoxic and non-taint properties.

Withstands aggressive ground waters.

High strain tolerance for buried applications.

Good resistance to ultraviolet light.

Lower celerity and extreme tolerance to water hammer

surges.

Property* Reference Temperature S.I.Unit Other Units

Ultimate tensile strength (strain rate 50mm/min)

ASTM D638 Type I

20 C 40 MPa 5800 lbf/in2

Elongation at break 20 C 50% 50%

Instantaneous Flexural Modulus 20 C 2200 MPa 319 072 lbf/in2

Compressive strength 20 C 42 MPa 6100 lbf/in2

Izod impact strength (notched)

ASTM D256 (method A)

23 C 340 J/m notch 6.4 ft lb/in notch

Specic gravity 1.05 x 103

Kg/m3

65.5 x 10-3

lb/ft3

Vicat softening point ASTM D1525 95 C 203 F

Coefcient of thermal expansion 10.1 x 10-5

m/mC 5.6 x 10-5

ft/ftF

Maximum operating temperature 60 C 140 F

Poissons ratio 0.35

Thermal conductivity 0.2 W/mC 1.3 BTU/ft

2

/in/FSpecic heat 1.47 KJ/KgC 0.35 BTU/lbm/F

Volume resisitivity 3.5 x 1016V cm

Dielectric constant 3.20 @ 60 Hz

3.12 @ 103

Hz

2.90 @ 106

Hz

*Test pieces machined from moulded specimens yielded to the above mentioned typical properties


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3

ABS Material


IMPACT STRENGTH

ABS is a relatively ductile thermoplastic, which exhibits very

high impact strength compared to other thermoplastics suchas uPVC particularly at low temperatures. It is for this reason

ABS is used in demanding applications requiring exceptionally

high impact strength material such as construction site safety

helmets.

As part of the Eurapipe Quality Assurance programme, sample

lengths of pipe are routinely impact tested at 0C as required

by AS 3518.

ABS is unique in retaining high levels of impact strength at sub

zero temperatures and is signicantly superior to most other

thermoplastics used in pipe systems.

The graph shows the relatively small reduction in impact

strength of ABS between 20C and 0C compared with

another thermoplastic pipe systems.

MODE OF FAILURE

ABS is a relatively ductile material and the mode of failure

resembles that of soft copper. Failure is by ductile distortion

and tearing, the localised nature minimising the loss of pipe

contents.

In contrast, crack propagation and hazardous material

fragmentation accompany the failure of brittle material.


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ABS Material

3


THERMAL EXPANSION

All thermoplastics expand at a greater rate than metals as

shown in the diagram above.

Expansion need not cause undue concern in design or

installation of an ABS piping system provided that due

recognition is taken at the design stage. The reduced exural

modulus of ABS over that of steel results in reduced loads on

supports and equipment arising from thermal strains.

The linear coefcient of thermal expansion of ABS is 10.1 x

10-5

m/m C.

TOXICITY AND TAINT

ABS is free from heavy metal stabilisers such as lead which are

often used in the processing of other thermoplastic materials.Therefore, there is no possibility of any toxic heavy metals

substances being leached from the ABS pipe material into the

uid being conveyed by the pipe.

Eurapipe ABS conforms to AS4020 and has been safely used

for many years with potable water, grade I distilled water

for medical use, renal dialysis uid and many foods and

beverages.

ABS is regarded as taint free and has been used for conveying

potable water, beer, soft drinks, caramel, wines, sauces,

chocolate, custard cream and other similar products. It is

recommended that food and drink manufacturers test for taste

tainting on their own product before installation commences.

RIGIDITY AND STIFFNESS

ABS is classied as a rigid thermoplastic over its working

temperature range -30C to +60C.

With increased temperature, pipe rigidity decreases thus

necessitating more frequent support.


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3

ABS Material


WEATHERING

Eurapipe ABS piping systems are suitable for external

installation under extreme conditions without additional surfaceprotection.

When ABS products are exposed to the weather, they will

suffer some minor degradation of the exposed surface. The

degradation results in a reduction of surface gloss, and shift in

surface colour to light grey. The degradation is conned to the

exposed surface only.

The effect of long-term exposure to sunlight over prolonged

periods has minimal effect on the physical properties of ABS

systems.

Because of the relatively high exural modulus of ABS, the

stresses induced in a component whilst in service result

in smaller strains, therefore minimising the possibility of

environmental stress cracking of the exposed surface.

This resistance to failure is further improved by the inherently

high impact strength of ABS, particularly at low temperatures,

and the ability of the polymer to withstand long term heat

exposure with little change to physical properties.

ABRASION RESISTANCE

ABS piping systems have long been successfully employed

in applications where abrasion resistance is the prime

consideration. The conveying of slurries in the mining, food,power generation and waste water industries is a typical

example where ABS has been demonstrated to outlast steel

and stainless steel pipes previously employed.

The chemical resistance of ABS combined with impact

resistance makes it an ideal choice for such corrosive and

erosive environments.

It is these conditions which lead to reduced life of metal pipe

systems.

The rubber-like butadiene phase in ABS provides this piping

material with outstanding resistance to abrasive media.

Eurapipe sales engineers have the experience to advise on

the suitability of ABS pipe for slurry or abrasive applications.

For gravity ow systems the long term low surface roughness

enables less steep slopes to be used. Lower slopes can mean

reduced building heights which has a great effect on capital

costs. Additionally, lower slopes reduce transport velocity,

which in turn reduces the wearing of the piping material.


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ABS Material

3


CHEMICAL RESISTANCE

The information given on the following pages is based on the

recommendations of the manufacturers of the polymers, eldexperience and subsequent tests by Eurapipe.

The chemical resistance information has been obtained from

numerous sources and it is primarily based on plastic material

test specimens that have been immersed in the chemical (not

combination of chemicals) and on eld experience. Under no

circumstances is to be assumed that a mixture of individually

acceptable chemicals may be safely used with ABS or any

other product.

The effect of the combination of chemicals on the ABS

components has to be assessed in conjunction with other

factors that have a signicant impact upon the lifecycle of the

system i.e. temperature, internal pressure, exural stresses,

cyclic loads etc. Any chemical attack is increased when

temperature or stress are increased or when temperature or

stress are varied.

It is the design engineers responsibility to assess the materials

and the exposure under such conditions.

Specic data on industrial chemical applications of ABS can be

given by the Eurapipe organisation. Such enquiries are invited

for applications not shown here.

Under no circumstances is it to be assumed that a mixtureof individually acceptable chemicals may be safely used with

ABS or any other product.

Absence of notation indicates the substance has not been

tested.

Unless stated, all concentrations are 100% or saturatedaqueous solution. Reference to saturated solutions is at 20C.

Resistance Key Information

1. RESISTANT=Little or no attack

2. CONDITIONAL RESISTANCE=Some attack, however may

still be suitable when used with a higher pipe class or reduced

service life.

3. NOT RECOMMENDED=Little or no resistance. Not suitable

for use with ABS pipe.

4. REFER TO EURAPIPE

The information given here is based upon various sources

available at the time this manual was created. We reserve the

right to revise this information from time to time in the light

of subsequent research and experience. The information is

to be used as a general guide and there is no warranty or

representation, either expressed or implied, that this data is

free from errors.

We shall not be liable for any damages of any kind that mayresult from the use of this data.

QUICK REFERENCE CHEMICAL RESISTANCE

Chemical Resistance

Weak acids Good resistance

Strong acids Limited resistance

Weak alkalis Good resistance

Strong alkalis Good resistance

Aggressive soils Excellent resistance

Metal salts Good resistance

Sea water Excellent resistance

Aromatic hydrocarbons Poor resistance

Organic solvents Poor resistance


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3

ABS Material


Chemical or Agent Formula Concentration (%W/V)

Working

temperature

20C 50CAcetamide CH

3CONH

2% 1

Acetic Acid CH3COOH

Up to 10

10-20

Over 20 (including Glacial)

1

2

3

1

3

Acetone CH3COCH

33 3

Acetyl Chloride CH3COCI 3 3

Alcohols:

Allyl CH2=CHCH

2OH 3 3

Amyl CH3(CH

2)

3CH

2OH 3 3

Benzyl C6H

5CH

2OH 3 3

Butyl (Butanol) CH3(CH

2)

2CH

2OH 3 3

Ethyl (Ethanol) CH3CH

2OH Up to 50% aq. soln. 1 1

Ethyl (Ethanol) CH3CH

2OH 95% aq. soln. 3 3

Furfuryl C4H

3OCH

2OH 3 3

Methyl (Methanol) CH3OH 3 3

Iso Propyl (propanol) (CH3)2CHOH 3 3

Alum AI2(SO

4)

3K

2SO

4.H

2O 1 1

Aluminium Chloride AICI3

1 1

Aluminum Sulphate AI2(SO

4)

31 1

Ammonia Solution NH4OH 35% 1 1

Ammonium Carbonate (NH4)

2CO

31 1

Ammonium Molybdate (NH4)

6Mo

7O

2.H

2O 1 1

Ammonium Nitrate NH4NO

31 1

Ammonium Sulphate (NH4)

2SO

41 1

Ammonium Thiocyanate NH4SCN 1 1

Amyl Acetate Ch3COO(CH

2)

4CH

33 3

Aniline C6H

5NH

23 3

Aromatic Hydrocarbons 3 3

Barium Bromide BaBr 2

1 1

Barium Carbonate BaCO3

1 1

1=RESISTANT 2=CONDITIONAL RESISTANCE 3=NOT RECOMMENDED 4=REFER TO EURAPIPE


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ABS Material

3



Working

temperature

20C 50CBarium Chloride BaCI

21 1

Barium Hydroxide Ba(OH)2

1 1

Battery Acid H2SO

41 1

Benzene C6H

63 3

Benzoic Acid B6H

5COOH 3 3

Boric Acid H3BO

31 1

Brake Fluids 3 3

Brine NaCIH2O Saturated 1 1

Bromic Acid HbrO3

1 1

Bromine (Gas + Liquid) Br 2

3 3

Butane Gas C4H

101 1

Butyric Acid C3H

7COOH 20% aqueous 3 3

Calcium Compounds Refer to respective sodium compound

Carbon Dioxide CO2

40% aq. soln. 1 1

Carbon Disulphide CS2

95% sq. soln. 3 3

Carbon Monoxide CO 1 1

Carbon Tetrachloride CCI4

3 3

Castor Oil 1 1

Chlorine Gas Dry CI2

2 3

Chlorine Wet 3 3

Chlorine Aqueous Solution

Up to 3% free chlorine 1 1

Over 3% free chlorine 4 4

Chlorobenzene C6H

5CI 3 3

Chloroform CHCI3

3 3

Chromic Acid CrO3+H

2O 10%

25%

2

3

3

3

Citric Acid HOC(COOH)(CH2COOH)

2H

2O 1 1

Cresols C6H

4(OH)CH

33 3

Copper Chloride CuCI2

1 1

Copper Fluoride CuF2

1 1

Copper Sulphate CuSO4

1 1



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3

ABS Material



Working

temperature

20C 50CCreosote 3 3

Cyclohexane C6H

123 3

Detergents 4 4

Dextrose C6H

12O

6H

121 1

Dichloroethane CH2CICH

2CI 3 3

Dichloromethane CHCI2

3 3

Diethylamine (C2H

5)

2NH 3 3

Diethyl Ether C2

H5

OC2

H5

3 3

Ethylene Glycol HOCH2CH

2OH 1 1

Ferric Chloride FeCI3

3 3

Ferric Nitrate Fe(NO3)

31 1

Ferrous Chloride FeCI2

Saturated 1 2

Ferrous Sulphate FeSO4

40% aqueous 1 1

Formaldehyde (Formalin) HCHO (+H2O) 10% 1 1

Formic Acid HCOOH 3% 1 3

Freon R11, R12, R22, R113, R114 4 4FruitJuices 1 2

Gelatine 1 1

Glucose C6H

12O

61 1

Glycerine HOCH2-CHOH-CH

2OH 1 1

Hydrochloric

Acid

HCI

HCI

HCI

0-10%

10-30%

30%-37%

>37%

1

1

1

3

1

1

3

3

Hydrouoric

Acid

HF

HF

0-10%

>10%

1

3

2

3

Hydrouorosilicic Acid H2SiF

63 3

Hydrogen H2

1 3

Hydrogen Peroxide H2O

2

1%

3%

5%

10% (30 vol)

1

1

1

3

1

2

3

3



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ABS Material

3



Working

temperature

20C 50C

Iodine Solution in KI I2

1 3

Kerosene 3 3

Ketones 3 3

Lanolin 1 1

Lead Acetate Pb(CH3OO)

21 1

Linseed Oil 1 3

Magnesium CompoundsRefer to respsective sodium

compound

Mesityl Oxide (CH3)

2C=CHCOCH

33 3

Methane CH4

1 3

Methoxyethanol CH3OCH

2CH

2OH 3 3

Methyl Acetate CH3COOCH

33 3

Methyl Cyclohexanone C6H

9CH

3O 3 3

Methyl Ethyl Ketone CH3COCH

2CH

33 3

Methyl Methacrylate CH2C(CH

3)COOCH

33 3

Methylated Spirits 3 3

Milk 1 1

Mixed AcidsLimited resistanceDependent onConcentrations

4 4

Molasses Commercial 1 1

Nickel Sulphate NISO4

1% 1 1

Nitric Acid HNO3

1%

5%

1

2

3

3

Nitrogen N2

3 1 1

Oleic Acid C8H

17-CO=CH- 1 3

Oxalic Acid HO2CCO

2H 1 4

Oxygen O2

1 1

Ozone O3

20PPM SolutionSaturated SolutionGaseous

1

3

3

1

3

3



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3

ABS Material


Chemical or Agent Formula Concentration (%W/V) Working

temperature

20C 50CPetrol 3 3

Phenol C6H

5OH 3 3

Potassium Compounds

Refer to respective

Sodium compounds

Propane C3H

81 1

Pyridine C5H

5N Trace 3 3

Soap solutions (aqueous) 1 1

Sodium Acetates Na(CH3COO) 1 1

Sodium Borate Na2B

4O

71 1

Sodium Carbonate NaCO3

1 1

Sodium Chlorate NaCIO3

1 1

Sodium Chloride NaCI 1 1

Sodium Chromate Na2CrO

41 1

Sodium Cyanide NaCN 1 1

Sodium Ferrocyanide Na4F

e(CN)

61 1

Sodium Fluoride NaF 1 1

Sodium Hydrogen Carbonate NaHCO3

1 1

Sodium Hydrogen Sulphate NaHSO4

1 1

Sodium Hydrogen Sulphite NaHSO3

1 1

Sodium Hydroxide NaOH Saturated 1 1

Sodium Hypochlorite NaOCI >3% available chlorine 3 3

Sodium Iodide NaI 1 1

Sodium Nitrate NaNO3

1 1

Sodium Permanganate NaMnO4 3 3

Sodium peroxide Na2O

23 3

Sodium Persulphate Na2S

2O

81 1

Sodium Phosphate Na4P

2O

71 1

Sodium Salicylate NaC7H

5O

31 1

Sodium Silicate NaSiOl3.9

H2O 1 1



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ABS Material

3


Chemical or Agent Formula Concentration (%W/V) Working

temperature

20C 50CSodium Sulphate Na

2SO

41 1

Sodium Sulphite Na2SO

31 1

Sodium Sulphide Na2S 1 1

Sodium Thiosulphate NaS2O

41 1

Stannic Chloride SnCI4

1 3

Stannoous Chloride SnCI2

1 3

Sulphur Dioxide (Gas)

Dry

Wet

SO2 1

1

2

2

Sulphuric Acid H2SO

4

Under 30%

30%-50%

50%+

1

1

3

1

2

3

Toluene C6H

3=5CH

33 3

Trichlorobenzene C6H

3CI

33 3

Trichloroethylene CI2C=CHCI

33 3

Triethanolamine N(CH2CH

2OH)

31 3

Triethylene Glycol (Trigol) HOCH2O)

2CH

2CH

2OH 1 2

Turpentine 3 3

Uric Acid CO(NH)2COC

2CO(NH)

21 2

Urine 1 1

Vegetable Oils 1 2

Vinegar 1 2

Water

Chlorinated

Deionized

Distilled

Fresh

Sea

H2O

1

1

1

1

1

1

1

1

1

1

1

1

Wines 1 2

Xylene C6H

4(CH

3)

43 3

Zinc Orthophosphate Zn3(PO

4)2

2 2

Zinc Stearate Zn(C18

H35

O2)

21 1



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DURAFLO Design

4


CONTENTS

INTRODUCTION 4-2 PIPE SUPPORT CENTRES 4-14

SYSTEM SELECTION CRITERIA 4-2 DEFLECTING PIPES ON A CURVE 4-15

VALVE SELECTION CRITERIA 4-3 COLLAPSE RESISTANCE 4-16

PIPE DESIGN CRITERIA 4-4 PRESSURE TESTING 4-16

PRESSURE TEMPERATURE DERATING 4-5

FLOW CALCULATION FOR LIQUIDS 4-6

THERMAL EXPANSION 4-8

DESIGNING FOR PIPE EXPANSION 4-9

PIPE ROUTE PLANNING 4-9

EXPANSION LOOPS 4-10

EXPANSION COMPENSATOR 4-11

RUBBER BELLOWS 4-11

PIPE WALL STRESSING 4-11

PIPE SUPPORT 4-12

PIPE CLIP RADIAL CLEARANCE 4-12

PIPE SUPPORT PADS 4-12

PIPE ANCHORS 4-13

SUPPORT OF HEAVY PIPE LINE

ACCESSORIES 4-14

EQUIPMENT CONNECTIONS 4-14


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INTRODUCTION

Thermoplastic pressure piping systems show considerable

cost savings compared with traditional materials, particularlywhen chemical resistance, external coating, internal lining,

resilience and installation time is taken into account.

The modern engineer sees the many advantages that ABS

systems bring to the end user. In applying design principles

to the specic criteria of thermoplastic materials the engineer

can take advantage of the database of case histories, modern

industry standards and use the physical properties of the

material.

SYSTEM SELECTION CRITERIA

A basic process specication for the piping system should be

engineered. In many cases this can be a very informal study,

but where the application of service is of a more critical nature,

this should involve some careful research into the exact or

anticipated process conditions.

Some points to be considered are:

Operating temperature and pressure

Composition of media

Support system design

Design to accommodate thermal expansion

External conditions

From this information the following decisions may be made:

Pipe material to be used

Diameter, pressure class and stiffness of pipe to be used

Jointing system, e.g. cold solvent cement welding, rubber

ring joints, anges etc.

Supporting arrangements for pipes and valves

Trench design

Route details


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DURAFLO Design

4


VALVE SELECTION CRITERIA

The table below will assist with the selection of suitable

thermoplastic valves.

Ball Diaphragm Buttery

Size range DN15 - DN100 DN15 - DN50 DN50 - DN200

Clean liquid Good Good Good

Slurry Refer to Eurapipe Suitable Refer to Eurapipe

Flow control Off/On Good Moderate

Position indicator Yes Yes Yes

Vacuum proof Yes No Yes

Pressure surge behaviour Good Refer to Eurapipe Good

Sealing materials FPM / PTFE Natural rubber FPM

EDPM / PTFE Butyl rubber EDPM

PTFE

EDPM

Max. pressure range @ 208C 1000 kPa 1000 kPa 1000 kPa

Suitable for electric or pneumatic actuator Yes Yes Yes

End connection Socket, thread, ange Spigot, socket, thread, ange Wafer style


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DURAFLO Design


PIPE DESIGN CRITERIA

Eurapipes pipe design is in accordance with the requirements

set out in AS3518.

Design Factor of Safety (F)

This factor is applied to the minimum ultimate strength of

material to establish safe (conservative) working loads.

Eurapipe has designed its standard range of pipes using a

minimum design safety factor of 1.6. This degree of safety

margin in the design of pipes means that the standard

DURAFLO and FREEFLO range of pipes are suitable for

application in critical services such as permanent urban water

supply applications and where high security is required for the

transport of hazardous chemicals.

Design Basis

This is a period, usually a minimum of 50 years accord-

ing to convention, which is used to determine the long term

hydrostatic strength of ABS pipe. Obviously, this does not

mean that the pipe will fail

Hydrostatic Design Stress

This hydrostatic design stress (HDS) is the minimum required

strength (MRS) divided by the Design Safety Factor. For the

minimum design safety of 1.6 used in the DURAFLO and

FREEFLO pipe ranges, the maximum HDS of 10 MPa is used.

Long Term Hydrostatic Strength (sLCL)

This is the 97.5% lower condence limit value of hoop stress,

continuously applied at a specied temperature that the pipewall material can support for a specied time. This value

is calculated using the statistical procedures detailed in the

standard extrapolation method of ISO/TR 9080.

Minimum Required Strength (MRS)

This is the minimum value ofsLCL for a temperature of 20Cand for the conventional period of 50 years. The ABS material

used to manufacture DURAFLO and FREEFLO has an MRS

of 16 MPa.

PN ValueThis is the nominal working pressure at 20C, in bar

(10 bar = 1 MPa).

Stress Regression

At a constant temperature the time to failure due to stress of a

thermoplastic pipe is inversely proportional to the magnitude

of the stress. By conducting a series of burst tests on ABS

material at different stress levels, a graph of stress versus time

to fracture can be plotted. This is always shown as a log-log

plot and is known as the Stress Regression Characteristic

for the pipe. It is representing a possible life for the pipe

manufactured from the selected ABS raw material compound.

See gure below.


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DURAFLO Design

4


PRESSURE/TEMPERATURE DERATING

All thermoplastic piping system pressure ratings apply at the

standard mid-wall temperature of 20C. Where systems arerequired to operate at higher continuous mid-wall temperatures,

pressure ratings must be adjusted in accordance with the

following graph. The pressure values from 10 C up to 50C

are for 50 years design life, whereas for 60C are for 20 years

design life.

OPERATING PRESSURE BASED ON TEMPERATURE RERATING

PN4.5

PN6

PN9

PN12

PN15

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

-30C 10C 20C 30C 40C 50C 60CPIPE MID-WALL TEMPERATURE (C)

OPERATINGP

RESSURE(bar)

As the tempincreases you needthe operatingpressure.


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DURAFLO Design


FLOW CALCULATIONSFOR LIQUIDS

The extreme smoothness of the Eurapipe pipe wall and the

chemical resistance of the material prevent internal corrosion.Consequently, the hydraulic characteristics of an ABS

DURAFLO andFREEFLO pipe generally remain constant

for the life of the system . Eurapipe ABS DURAFLO and

FREEFLO pipes do not need to be over-sized in the design

stage to allow for future performance losses due to corrosion.

For gravity pipe systems where the ow regime may be

partially full, the engineer should refer to the procedure in AS

2200 - Design charts for water supply and sewerage.

PRESSURE LOSS CALCULATION PROCEDUREPressure drops due to friction may be determined for practi-

cal purposes using nomograms (ow charts). Full range of

nomograms for applications where the media is water can be

found at the end of this catalogue. (Absolute roughness for

ABS pipe in operation, = 0.007mm.)

The uid pressure loss through ttings may be included in

the overall system pressure loss by calculating the equivalent

length of pipe equal to the pressure loss through individual

ttings.

The calculations of pressure loss in ttings is:Ef = F3D

where:

Ef = equivalent length of straifht pipe for ttings, m

F = ttings constant (see adjacent column)

D = ttings diameter,mm

To calcualte the total pressure loss in the system, the

equivalent straight pipe length for ttings is added to the total

measured straight pipe length:

ALTERNATIVE PROCEDURE

The aforementioned method will provide a conservative

selection of pipe diameter and class for an application. A more

rigorous approach will derive signicant savings in the design

of a pipe system.

ABS FITTINGS CONSTANTS

Fittings F

Elbow 90 0.017

Elbow 45 0.009

Bend 90 Short Radius 0.004

Bend 45 Short Radius 0.002

Bend 90 Long Radius 0.002

Bend 45 Long Radius 0.001

Tee Through 0.011

Tee Branch 0.042

Loss in straight lengths of pipe

The head loss in straight lengths of pipe can be calculated as

follows :

where

L =length of pipe, m

Hp=head loss, m

f =Darcy friction factor, dimensionless

d =inside diameter of pipe, m

v =mean velocity of media, m/s

g =9.81 m/s2, acceleration due to gravity

The Darcy friction factor is dependent upon the Reynolds

number, Re, and the relative roughness of the pipe surface,

where

=density, Kg / m3

=dynamic viscosity, Kg / ms

=absolute roughness, mm

=0.003 mm, the absolute roughness for clean ABS

This method usesEquivalent Lengththat we add to thepipe length for out

index runcalculations.Or Kf on next page.


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DURAFLO Design

4


Laminar ow In this type of ow Re2000 is calculatedusing the Colebrook White equation :

Head loss in ttings

where

SKf= N

bendsK

bends+ N

elbowsK

elbows+ N

teesK

tees+...

where

Kf=coefcient of friction for each type of tting, shown in

the adjacent table

N =number of ttings of each type

Total head loss

Using the head loss calculations above, the pressure drop in

the pipeline is calculated using the formula :

Dp= g(H

p+ H

f), N/m2

Notes :

The Reynolds number range between 2000 and 4000 is

called the critical zone. Flow in this zone is unstable, and this

must be taken into account.

The methods shown above can be used with various types

of newtonian uids.

COEFICIENT OF FRICTION FOR FITTINGS, Kf

Type of tting Kf

Elbows 90 1.2

45 0.35

Bends Sweep

90 0.5

45 0.2

22 0.1

Tees

Flow through 0.6

Flow to branch 1.8

Flow from branch 1.5

Entries

Square 0.65

Protruding 0.75

Slightly rounded 0.21

Bellmouth 0.06

Outlets (all) 1.0

Sudden enlargements

Inlet to outlet ratio 4:5 0.15


Inlet to outlet ratio 1.2 0.6



Sudden contractions



Inlet to outlet ratio 1.2 0.35



Valves fully open

Gate 0.2

Buttery 0.3

Ball 0.5

Swing check 1.3

Diaphragm 2.4


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DURAFLO Design


THERMAL EXPANSION

Expansion is not a problem during the installation of an

ABS DURAFLO and FREEFLO pipe systems provided theappropriate provisions are made during the design stage.

The linear coefcient of thermal expansion for Eurapipe ABS

pipe is 10.1 x 10-5

m/m C (5.6 x 10-5

ft/ft F).

The variation in pipe wall temperature should be used in the

following equation to calculate the maximum pipe thermal

movement. (Pipe operating and shut down conditions

should be considered when evaluating extreme temperature

variations.)

DL = L C DT

whereDL=pipe expansion/contraction, mL = original pipe length, m

C = linear coefcient of thermal expansion, m/m 8CDT = pipe wall temperature variation, 8C

The mid-wall temperature is dependent on the internal and

external environmental temperatures with the temperature of

the owing media having the greater inuence.

The variation in pipe wall temperature can be calculated as :

DT =0.65DTL10.10DT

A

where

DT =pipe wall temperature variation,8C

DTL=maximum temperature variation in pipe content, 8C

DTA

=maximum temperature variation of external air, 8C

Example :

Calculate the thermal expansion of a 50 metre section of Eura-

pipe ABS pipe with an expected variation in the temperature of

the uid conveyed from 208C to 308C and an expected varia-tion of the ambient temperature from 108C to 408C.

DTL

=30

-20 = 108

DTA

=40 - 10 = 30 8CDT

=0.65DT

L+0.10DT

A= 6.5 + 3 = 9.5 8C

DL= LC DT

DL =50 10.1 10-5 9.5 = 0.047975mDL =47.98mm

The following graph allows you to read directly total pipe

expansion from a known pipe length and temperature range.


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DURAFLO Design

4


DESIGNING FOR PIPE EXPANSION (ABOVEGROUND)

Pipe expansion of a cold solvent cement welded pipelinemay be accommodated using any one or combination of the

following techniques:

Pipe route planning

Expansion loops

Expansion joints (rubber bellows)

Pipe wall stressing

PIPE ROUTE PLANNING

In the vast majority of cases, effective route planning can

eliminate the requirement of expansion loops, or expansion

bellows etc with consequent nancial savings.

The basic principle of design is to allow pipe runs to move

axially from a xed point (anchor) and then guide this

movement into a change of pipe direction ensuring that the

pipe is free to ex as shown in g. 1.

An inappropriate installation is shown in Fig 2. The pipe run

is xed at on end (A) and constrained at the other (B). As thetemperature increases the pipe will try to expand but will have

nowhere to go as the ends are constrained by clip (B). Thus

the pipe will snake between supports as indicated.

In Fig 3, effective route leg planning has

eliminated the need for expansion loops etc by a simple

redesign of pipe supports. By utilising a suitable pipe support

to allow free lateral pipe movement, the pipe can be installed

with sufcient exibility to expand and contract. The support

at (C) remains but the clip at pipe support (B) is eliminated to

give sufcient length for exibility.


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DURAFLO Design


Calculate the expansion

Establish an anchor point midway along the straight length of

pipe to control the direction of any movement.

-Position pipe supports away from change of direction to allow

required movement.

-The extent of movement to be accommodated at each end

from the neutral position will be + 25% of the total expansion.

Example, if total calculated expansion is 100mm, 50mm of this

is to be accommodated at each end, which is + 25mm from the

neutral position, see Fig 5.

EXPANSION LOOPS (ABOVE GROUND)

Length of the expansion loop legs, (H) for sizes up to

DN 400 can be determined using the adjacent table. Please

refer to Eurapipe for further information.

The expansion loop table can also be used for calculating

exibility required at changes in direction.

Expansion loop dimensions can be reduced considerably by

the use of tandem bellows. Refer Eurapipe for details.

Expansion loop leg length, H (mm)

Pipe

SizeDN

Expansion DL/2 (g .4) DL (g.5) (mm)

25 50 75 100 150 200

15 650 920 1130 1300 1595 1840

20 730 1030 1265 1460 1785 2065

25 815 1155 1415 1635 2000 2310

32 915 1300 1590 1835 2250 2595

40 980 1390 1700 1960 2400 2775

50 1095 1550 1900 2200 2690 3105

65 1225 1735 2125 2450 3005 3470

80 1330 1885 2310 2665 3260 3765

100 1510 2135 2615 3020 3700 4270

125 1675 2365 2900 3345 4100 4730

150 1835 2590 3175 3665 4490 5185

200 2120 3000 3675 4240 5195 6000

225 2500 3535 4330 4995 6120 7065

250 2645 3740 4580 5290 6475 7480

300 2805 3965 4860 5610 6870 7930

350 2980 4210 5155 5955 7290 8420

375 3160 4470 5475 6320 7740 8940


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DURAFLO Design

4


EXPANSION COMPENSATORS

Where space does not permit a exible route, or the use of

expansion loops, rubber bellows should be considered.

RUBBER BELLOWS

Rubber bellows are able to accommodate angular, lateral

and small axial movements as shown below. Bellows should

be located in adjacent pipe legs to benet from the lateral

movement. Bellows in pressure service should be tied to

prevent excessive forces being applied to anchors, nozzles or

structures. Tandem bellows can be used to meet large thermal

movements.

PIPE WALL STRESSING

In many cases expansion may be taken up by variations in

pipe wall stresses. Contact Eurapipe for further detailed design

procedures should this method be adopted.

Expansion compensator operating range*

Pipe Size

DN

Travel

Axial

Compression/

Extension

mm

Lateral

Deection

mm

Angular

Deection

32 8 - 4 8 15

40 8 - 4 8 15

50 8 - 5 8 15

65 8 - 6 10 15

80 12 - 6 10 15

100 18 - 10 12 15

125 18 - 10 12 15

150 18 - 10 12 15

200 25 - 14 22 15

225 25 - 14 22 15

250 25 - 14 22 15

300 25 - 14 22 15

350 25 - 14 22 15

375 25 - 14 22 15

400 25 - 14 22 15

500 25 - 14 22 15

575 25 - 16 19 15

650 25 - 16 19 10

750 25 - 16 19 10

*Values shown are for the single sphere bellows

Guide to expansion unit selection

Bellows Dual BellowLoop

Loop

Accommodate

Angular/Lateral

Movement

Yes Yes Yes

Vibration Isolation Good Very good Moderate

Axial Expansion

Range

Very

small

Very high Good

Installation Space Small High Large

Maintenance Minimum Minimum Minimum

Pressure Rating High High HighSize range, DN 32 - 750 300 - 750 32 - 750

Cost/mm Expansion High Moderate High


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DURAFLO Design


PIPE SUPPORT

The basic principle of correct pipe supporting is to allow

controlled axial movement of the pipe while providing lateralrestraint and adequate support for the pipe.

The hanger type support does not provide lateral restraint to

the pipe and therefore encourages snaking and so should

be avoided except where located adjacent to the changes in

direction where exibility may be required.

Thus pipe supports should:

Be rigid in construction to adequately support pipe

(fabricated mild steel angle being ideal).

Have a wide bearing area, to allow pipe to move easily over

support.

Resist deection, thus transferring loads to the structure.

Be free from sharp burrs or edges to avoid cutting or

damaging pipe wall.

Allow controlled axial movement of the pipe.

Provide lateral restraint, where required.

Pipe clips should:

Allow controlled axial pipe movement

Be free from burrs or sharp edges

Provide required lateral restraint

All clips shall be corrosion- resistant.

Pipe clips, other than anchor clips shall be so constructed

that, when they are securely xed, longitudinal movement of

the pipe is permitted.

Anchor clips for xed points shall be constructed so that

when they are tightened, the tting or pipe is securely and

evenly clamped to prevent movement. The bearing width shallbe 25 mm minimum.

Metal clips shall be used in conjunction with resilient

material to protect the pipe and shall have a nished clearance

across the diameter to allow for radial and longitudinal

movement. All materials shall be compatible with ABS, and be

smooth and free from protrusions.

Eurapipe manufactures a range of suitable pipe clips for pipe

sizes up to 100mm. For sizes 125mm and above fabricated

mild steel clips with a radial clearance as per the following

table are suitable.

PIPE SUPPORT PADS

The use of pipe support pads between pipe and support is

strongly recommended where there is likely to be considerable

movement of the pipe or chang of the pipe from vibration.

High density polyethylene sheet 6 -10 mm is suitable for thispurpose and should be installed as indicated in g.6.

Width of pipe supports must be sufcient to allow free axial

movement of the pipe without binding.

The following table gives recommended pipe support widths.

Pipe diameter Minimum clearance

Up to DN150 2 mm

DN200 - DN450 5 mm

DN500 - DN750 10 mm

Pipe Diameter Minimum support width

Up to DN300 25 mm

DN350 - DN375 60mm

DN400 - DN450 100 mm

DN500 - DN750 300 mm


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DURAFLO Design

4


PIPE ANCHORS

Pipe anchors should be provided in systems where thermal

expansion occurs.Anchors ensure that pipe movement occurs in a controlled and

predictable manner.

In addition, pipe anchors will absorb axial pipe pressure thrust

in those systems tted with expansion joints.

Where possible, a anged pipe connection may be used as an

anchor point by the use of a valve support in lieu of one of the

backing rings. Refer to g.7.

Where suitable ange connections are not convenient, pipe

anchors may be constructed by solvent cementing split ttings

to pipe as shown in g.8.

An alternative method for pipe diameters up to 50mm is shown

in g.9.

Anchor points located at mid length of a straight section

need not be as robust as those associated with expansion

compensators which must be able to withstand the total

pressure thrust plus frictional resistance to movement.

Note: Under no circumstances should a tightened pipe clip be

used as an anchor.

The action of tightening the clip imposes a crushing load on

the pipe which may damage the pipe and affect its structural

stability.


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DURAFLO Design


SUPPORT OF HEAVY PIPE LINE ACCESSORIES

Valves, lters, or other heavy items should always be

independently supported or anchored to prevent undue loadingand stress being applied to the pipe. Eurapipe valve support

plates can be used in place of ange backing rings to provide

necessary support.

Equipment Connections

ABS pipe may be connected directly to pipe or other

equipment using anges or threaded connections. Flanges

are the recommended method for all sizes, however threaded

connections maybe used for sizes 50mm or below.

PIPE SUPPORT CENTRES

ABS is classied as a strong thermoplastic over its working

temperature range of -308to +708C.With increasing temperature pipe stiffness decreases requiring

frequent support.

The spacing of supports shall be such that the midspan

deection does not exceed 1/500th of the span.

As a guide, horizontal support centres for Eurapipe ABS pipe

at various temperature as given in the adjacent table. For

verticle pipes support centres may be increased by 50%. For

more details contact Eurapipe.Pipes operating at higher temperatures, up to 608C, must becontinuously supported.

PIPE SIZE

DN

Support centers (m)

based on PN15 pipe

Average pipe wall temperature

208 C 408C

15 0.80 0.60

20 0.90 0.70

25 1.00 0.75

32 1.20 0.90

40 1.30 0.95

50 1.50 1.10

65 1.80 1.35

80 2.00 1.50

100 2.30 1.70

125 2.60 1.90

150 3.00 2.20

200 3.50 2.60

225 4.00 2.95

300 4.20 3.10

350 4.50 3.35

375 4.80 3.55

400 5.00 3.70

450 5.50 4.10500 6.00 4.45

575 6.20 4.60

650 6.40 4.75

750 6.60 4.90

Pressure

rating PN6 PN9 PN12 PN15 PN18 PN20

Correction

factors0.71 0.88 0.92 1 1.05 1.07

The following correction factors should be applied for

other pipe classes.


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DURAFLO Design

4


DEFLECTING PIPES ON A CURVE

The exibility of ABS pipes can often be used to an advantage

when installing pipe work where a curve is required. Thefollowing table gives minimum bending radii without undue

stress being placed on a pipe.

It is possible for pipes to be curved to a lesser radius than in

the table below depending on the design pressure/temperature

relationship. Contact Eurapipe for further information.

ANGULAR DEFLECTION

In addition to the ability to curve ABS pipes, the elastomeric

sealed sockets available (RRJ/RRJ) will give further capability

for changes in direction.

The following table shows the designed deection angle for

both the DURAFLO and the FREEFLO ranges of sockets.

ABS PIPE MINIMUM BEND RADIUS (m)

DN Up to 65 80 100 125 150 175 200 225 300 350 375 400 500 575

RADIUS 6.5 10 12 15 18 21 28 32 37 43 50 53 56 74

ANGLE

OVER 6M 53 34 29 23 19 16 12 11 9 8 7 6 6 6

PIPE SIZETOTAL DEFLECTION

ANGLE PER JOINT

DURAFLO/

FREEFLO

DN300 4.58

DN375 to DN500 48

DN575 to DN750 3.58


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DURAFLO Design


COLLAPSE RESISTANCE

Critical collapse pressure (differential pressure) for above

ground pipelines may be calculated using the followingformula:

where :

E = Modulus, MPa

D = Outside diameter of the pipe, mm

t= Pipe wall thickness, mm

n= Poissons ratio, dimensionlessn= 0.35 for ABS

Note:For temperatures above 20C Modulus must be derated

accordingly (see adjacent table). The values in the table are

for long term Modulus of Elasticity. The instantaneous Modulus

of Elasticity for Eurapipe ABS is 2200 Mpa.

For buried pipelines, design for buckling should be based upon

AS2566 - Buried exible pipelines - Design.

Eurapipe ABS pipelines are particularly suitable for below

atmospheric applications. Contact Eurapipe for further advice.

PRESSURE TESTINGThe recommended test pressure for ABS DURAFLO and

FREEFLO pipe used in above ground systems is 1.5 times the

designed operating pressure of the system for a maximum of

one hour, less allowance for temperature derating.

Pressure testing above these limits is not recommended as it

can reduce the maximum life of the system.

Pressure testing of ABS DURAFLO and FREEFLO buried

pipelines shall be in accordance with AS2566 - Buried exible

pipelines.

Variation of long term Modulus of

Elasticity with temperature

Temperature(C) Modulus(MPa)20 1580

30 Contact Eurapipe

40 Contact Eurapipe

50 Contact Eurapipe

60 Contact Eurapipe


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ABS Installation

5


CONTENT

INTRODUCTION 5-2

HANDLING AND STORAGE 5-2

JOINING SYSTEMS 5-3

COLD SOLVENT CEMENT WELDING 5-4

COLD SOLVENT CEMENT WELDINGPROCEDURE 5-6

INSTALLATION OF BOLT ON SADDLES 5-11

ELASTOMERIC SEAL JOINING PROCEDURE 5-11

FLANGED JOINTS 5-12

THREADED CONNECTIONS 5-13

BURIED PIPELINES 5-14

REPAIR OF DAMAGED PIPES 5-15

ABOVE GROUND PIPELINES 5-17

HYDROSTATIC PRESSURE TESTING 5-17


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ABS Installation


INTRODUCTION

Eurapipe ABS pipe systems are easy to install. It requires

minimum trade skills and training of personnel for a successfulinstallation.

A complete certication package comprising training manual,

Quality Assurance program, on site training and certication of

personnel is available from Eurapipe.

HANDLING AND STORAGE

ABS pipes and ttings are relatively light and easily handled.

However, care must be taken during handling to prevent

scoring or gouging of the pipes and ttings:

Pipes and ttings shall not be dropped, indented,crushed or impacted.

Metal slings, hooks, or chains shall not come into

direct contact with the pipe surface. Fabric slings shall be

used and shall be attached at two points on the load.

Do not sling from the middle of the pipe.

Spreader bars may be necessary to prevent slings

slipping during lifts.

Care shall be taken to prevent damaging the

external surfaces of pipes by rough handling or by dragging

along the ground.

Pipe packs and individual pipes can be lifted by

forklift or by using slings in conjunction with a crane or other

lifting device such as a backhoe or other suitable equipment.

Lengths in excess of 6 metres must be lifted fromtwo points at least 3 metres apart. This can be achieved by

using a forklift with wide tynes or by using slings and spreader

bar at least 3 metres long.

If mechanical lifting equipment is not available, large

diameter pipes may be rolled down planks from the transport

unit. Ropes shall be employed to control the pipes on the way

down.

Smaller diameter pipes can be lifted and carried

manually.

Pipes shall be stored in the packs supplied.

Packs shall be stored on level ground free from

stones or projections, which could damage the pipe.

For short term, storage packs can be stacked to a

height of maximum 2.8 meters.

Multiple packs are not to be lifted.

For longer term storage- more than 3 months -packs

shall be stacked to a height of maximum 1.8 meters.

Where pipes are to be stored individually or without


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ABS Installation

5


being strapped in packs, they shall be supported with 75mm

wide horizontal timber supports at 1.5 m spacing.

Unpacked pipes shall not be stacked higher than 1.8

m without vertical support.

When stacking pipes with solvent cement welded

sockets tted to one end, alternate and stagger the pipe end to

end so that the sockets do not bear upon each other.

Eurapipe ABS pipes need not to be stored under

cover except when storage period is likely to exceed 6 months.

When extended storage periods are expected, pipes shall

be covered with a light colour screening, which allows airowbetween layers.

Fittings shall be stored in the original packaging until

ready for use.

Under high solar radiation, pipe should be shaded at

least 24 hours prior to joining.

JOINING SYSTEMS

Pipes and plain ended ttings may be joined by the following

methods:

Sockets - cold solvent cement welded (SWJ)

- elastomeric sealed (RRJ)

Flanges

Shoulder style coupling (e.g. Victaulic)

Threaded adaptors

Tapping saddles

Unions

Mechanical couplings (e.g. Gibaults, Straub, Wang

etc.)

Elastomeric sealed sockets (RRJ)

There are two types of elastomeric sealed sockets:

- one side cold solvent cement weld type and the

otherside elastomeric seal type (SWJ/RRJ),

- both sides elastomeric seal type (RRJ/RRJ).

Cold solvent cement welded sockets (SWJ/SWJ)

Cold solvent cement welded sockets are the quickest, most

economical joining method for ABS pipes and plain endedttings and are available for all pipe sizes.

Cold solvent cement welding eliminates the need for thrust

blocks as the longitudinal stress is taken in the pipe wall.

This type of joint is permanent and cannot be disassembled.

Cementing ABS to PVC

The cementing of these two dissimilar materials is not

recommended.

A Rubber Ring socket or a mechanical connection such as a

threaded connection or a ange is recommended where such

joints are necessary.

Branch connections

The preferred branch connection is by use of tees.

Tapping saddles, which permit branch connections to be made

without removing a section of the main pipe are useful where

additions are required to an existing installation.

Contact Eurapipe for further details regarding the use and

installation of ABS tapping saddles.


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Connecting ABS to other pipe systems

There are several recommended methods of connecting other

pipe systems directly to ABS pipe.Elastomeric sealed sockets (RRJ sockets)

Composite unions

Flanges

Threaded adaptors

Shouldered end style couplings

COLD SOLVENT CEMENT WELDING

Correctly made joints using this technique are stronger than

either pipe or tting.

The cold solvent cement welding of ABS is a welding

process and not a glueing process.

The solvent acts by temporarily disolving the two surfaces to

be welded. When they are brought together, the two surfaces

reconstitute into a single homogenous solid mass as the

solvent quickly evaporates.

Sustained axial loading of pipe into the tting is required to

form a satisfactory joint.

The axial loading for the welding is provided by ensuring that

the two parts being welded together have an interference t. It

is for this reason that sockets are designed with a taper (g.1)

Tools required

Coarse le or other tools suitable for chamfering the

pipe.

Emery paper.

Felt tipped pen.

Tape measure.

Cutting tools e.g. pipe cutters, hack saw, ne tooth

wood saw or circular saw with tungsten tipped blade.

Clean paint brushes (natural bristles and unpainted

wooden handle).

Eurapipe ABS solvent cement and MEK cleaner.

The recommended brush size for ease of use is shown in the

following table:

Pipe diameter Brush Size

Up to DN50 20 mm

DN 50 - DN 200 50 - 80 mm

DN200 and above 100 mm

Mechanical device for joining pipe sizes above

150NB e.g. hand operated lever winch, two fabric lifting slings

or two chain slings (min. 12mm link length).

Clean, lint free rags.

Safety glasses and protective gloves.

g. 1 Typical cold solvent cement socket design


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Safety precautions

The following requirements are in addition to any govern-ment

safety legislation or established company work practices: Read safety precautions on ABS cement and MEK

cleaner tins.

Work area must be well ventilated.

As cement and cleaner are ammable liquids ensure

work area is clear of falling sparks or other sources of ignition

e.g. smoking.

Wear safety glasses and protective gloves at all

times when using ABS cement and MEK cleaner.

Material Safety Data Sheets are available from Eurapipe.


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COLD SOLVENT CEMENT WELDING PROCE-DURE

Preparation

Prepare and inspect the pipe.

Scratches, gouges or dents shall be less than 10%

of the pipe wall thickness.

Joining surfaces must be clean and free from water,

dirt, oils or any foreign matter to ensure a good weld.

The ends of the pipes shall be cut square and

chamfered and all burrs shall be removed.

Dry t the joint without forcing the pipe into the

sochet (g.1). If the pipe cannot be entered into the socket or

does not bind up before reaching the end of the socket, do not

continue with the joint.

Refer to the Training and Accreditation Program for Installation

of ABS Pipelines. Alternatively, contact Eurapipe for further

information.

Add Witness Marks (g.2) at distance from the end

of the pipe equal to:

the socket depth, rst witness mark

the socket depth plus 100 mm, second

witness mark

For pipe sizes 150 NB and above, set up mechanical

joining device to ensure sufcient axial load is exerted to the

joint (g.3).

fg. 2

fg. 3

fg. 1


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Abrade and clean joining surface of the pipe (g.4),

no further than the rst witness mark, using emery paper.

This will help absorption of MEK into the wall.

Abrade and clean the inside surface of the socket

(g.5) using emery paper. This will help absorption of

MEK into the wall.

Wipe over the surfaces with a clean dry rag to

remove any dust (g.6).

Immediately before joining, thoroughly wipe the

abraded surfaces with a clean rag moistened with MEK to

initiate the chemical reaction (g.7).

fg. 4

fg. 5

fg. 6

fg. 7


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Joining

Stir solvent cement before use.

Using a clean brush, apply solvent cement to the

pipe (g. 8) and the socket (g. 9).

Brush strokes should be rm and alternatively

circumferential and longitudinal, nishing with continuous

longitudinal strokes to redistribute any excess from the socket

root and end of the pipe.

For sizes under 150mm only one person is

required for the welding process. Apply one coat to the pipe

surface rst, then one coat to the socket and then apply a

second coat to the pipe (when required-see table below).

For larger sizes, 200mm and above, two people

are required for this process. One person is applying solvent

cement to the pipe -two coats, see table below-while,

simultaneously, another person is applying solvent cement to

the socket (g. 10)

Excess solvent cement can adversely effect the joint.

Do not apply solvent cement onto the pipe overthe rst witness mark.

Do not pour the solvent cement onto the pipe orallow puddles to form.

Pipe size Coats required

Pipe Socket

Up to DN 50 1 1

DN 50 and above 2 1

fg. 8

fg. 9

fg.10


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Without delay, push the pipe in a smooth even

motion, until the end of the socket reaches the rst witness

mark (g.11).

Ensure that the joining process is completed as quick

as possible, while the solvent cement surface is still wet.

Do not attempt to make the joint if the solvencement has dried.

The second witness mark shall be 100 mm from the

end of the socket.

Wipe thoroughly excess solvent cement from all

around the socket mouth and, where possible, from inside of

the joint.

Replace the lids on solvent cement and MEK

cleaner.

Clean brushes in MEK.

Where joining is to continue, brushes can be stored

in a covered tin of MEK cleaner to prevent hardening.

Always ensure excess MEK cleaner is removed from brushes

before using with solvent cement.

Excess solvent cement must be removed

Do not use MEK to clean up excess solventcement.

Continue to exert axial load until the joint sets. As

the sockets are tapered the pipe will initially try to slide out of

the socket.

See the following table.

Pipe size Holding time

DN 15 - DN 50 20 - 60 sec.

DN 80 - DN 200 1 -5 min

DN 225 - DN 350 5 - 10 min.DN 375 - DN 500 10 - 20 min.

DN 575 - DN 650 20 - 30 min.

DN 750 30 - 45 min.

Do not disturb joints for 60 minutes after joining.

fg. 11

fg. 12

fg. 13


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Important notes on cold solvent cement welding

Work in a well ventilated area clear of hazards.

Use only Eurapipe ABS solvent cement and MEK

cleaner.

PVC solvent cement and primer are not suitablefor use with Eurapipe ABS pipe and ttings.

Treat ABS cement and MEK cleaner with care, as

they are volatile ammable liquids. Replace lids tightly

after use.

An indication of the number of joints likely to be

made with Eurapipe ABS Solvent cement when following the

recommended procedure is as follows:SOLVENT CEMENT USAGE*

SIZE SOLVENT WELD

JOINTS PER LITRE**

DN 50 S1 135

DN 80 S1 45

DN 100 S1 35

DN 125 S1 20

DN 150 S1 20

DN 200 S1 10

DN 225 S1 4

DN 300 S1 4

DN 350 S1 3

DN 375 S1 2

DN 400 S1 1

DN 450 S1 1

DN 500 S1 0.5

DN 575 S1 0.5

DN 650 S1 0.3

DN 750 S1 0.3* The usage of MEK is approximately 50% that of ABS cement

** A socket counts as 2 joints, a tee as 3 joints etc.

The usage of MEK is approximately 50% that of ABS

cement

ABS cement shall be stirred before use.

If solvent cement becomes thickened through

evaporation of solvents or becomes contaminated dispose

cement safely and use a fresh tin.

Do not thin cement with MEK.

Ensure there is no contamination to the solvent

cement joint from dirt, dust and oil.

Solvent cement may be removed from your handswith soap and water or industrial hand cleaning soaps.

Do not use MEK for removing ABS solventcement from your skin.

The key to fast efcient joining, particularly with large

pipe diameters is preparation.

Solvent cement joining must be completed as quickly

as practicable, typically within 2 minutes of applying the rst

coat of cement.

Pipe and socket must be dry for effective joining.

Use only clean cotton rags and clean brushes.

Check alignment of ttings before making the joint.

When using a lever winch, have everything ready

before applying solvent cement.

When installing ttings, ensure that winching

operations do not bear on branches of tees.

A canopy over the joining area is desirable when

working in full sun.

In hot conditions shading of joining areas of pipefor a

minimum of 1 hour before joining will enable easier joining.

In hot or wet conditions a canopy over the joining

area to prevent direct sunlight or precipitation on the joining

process will enable easier joining. Ensure adequate ventilation.

Where a lever winch is used, leave it connected

applying the axial load until the joint sets.

It is good practice to leave the tension on the winch


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until it is needed for the next joint (g. 14).

Full rated pressure shall not be applied for 48hours after joining.

Testing must not be carried out until thefollowing times have elapsed since completionof the last joint:Sizes DN 10 DN200 48 hours

Sizes DN225 DN350 72 hours

Sizes DN400 DN750 96 hours

INSTALLATION OF BOLT ON SADDLES

Assemble clean elastomeric seal carefully into band,

making sure no dirt is in the tapping band groove.

Extra care must be taken when tting curved E-lips. Match any positioning lug into the mating notch in

the band groove to ensure they are aligned correctly.

Position band on a clean section of pipe, tighten

bolts until band is secure. Over tightening is not necessary and

could cause the stainless steel nuts to gall.

Tap the pipe trough the band being careful not to

damage the band or force swarf under the seal. It is good

practice to mark the pipe so that if the band is removed it may

be replaced exactly and centrally over the tapped hole.

The take-off branch is a plain socket. Reduced or

threaded branch congurations may be formed by using the

appropriate Eurapipe tting.

Ensure that all take-off pipes are aligned and free to

ex with expansion to avoid undue stress on the saddle.

Ensure that any instrument connected by this

method is independently supported and not presenting any

concentrated load to the main pipe.

ELASTOMERIC SEAL JOINING PROCEDURE

Preparation

Pipe: Inspect pipe for surface defects, which may affectperformance or function of the pipe in service.

Scratches, gouges or dents shall be less than 10% of the pipe

wall thickness. The spigot end of the pipe shall be cut square,

chamfered, free from chips and cracks and all burrs removed.

Socket: If rubber ring gasket is pre-tted, remove and

inspect both gasket and socket housing to ensure the surfaces

are clean and free from dirt, oils or any foreign matter.

Where cleaning is required a dry brush is a suitable method of

removing dust followed with the use of a clean lint free cloth

and water to remove all dirt and contaminants from the sealing

surfaces.

Trench: A bedding layer of a minimum thickness (refer

AS2566-1) shall be laid in the bottom of the trench, compacted

according to the required specications and graded to

continuously support the pipe.

Where the socket will lay on the trench bottom, scallop out a

bell hole in the bedding. The bell hole shall be twice the length

of the socket to allow sufcient room for joining.

After joining ll and compact the bell hole ensuring that pipe

and socket are fully supported.

fg.14


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Joining

Reduce the diameter of the rubber ring gasket by

folding in the form of a heart shape and insert into the socketring groove. Ensure it is the right way round with the bulb

inserted rst and the taper section facing towards the socket

mouth. Check the rubber ring gasket is correctly positioned

with the external groove located on the retaining bead in the

socket.

Add two witness marks to the spigot end of the pipe

using a pencil or felt tipped marking pen:

-rst witness mark: socket depth less 15 mm

-second witness mark: socket depth. Lower the pipe into the trench and support in

accordance with the procedures on Handling. Check the pipe

is aligned correctly and able to enter the socket freely.

Use only lubricant supplied by Eurapipe

Apply a thin lm of lubricant to the inside surface of

the rubber ring gasket

Apply a thin lm onto the outside surface of the

spigot, especially the chamfer, for a minimum distance of

100mm from the spigot end. Lubricant can be applied using a glove, rag or brush,

Realign the pipe and enter the spigot carefully into

the socket until it makes contact with the gasket.

Using approved means of providing mechanical assistance

and maintaining a straight line push the spigot into the socket

until the rst witness mark remains just visible ush with the

socket face.

Do not push the pipe to the bottom of the socket. If

the pipe is inserted too far, withdraw immediately until the two

witness marks are visible again, the rst being ush with the

socket face. In this position clearance is automatically allowed

for expansion. The socket of the joint being made should be

restrained to prevent backward movement, which would close

up joints already made.

FLANGED JOINTS

Eurapipe manufacture two styles of anged joining systems.

Full face anges, available in sizes 15mm to 150mm.

Stub anges, available in sizes DN 50 to DN 750.

Stub anges are the preferred style as they offer a more

economical tting and are easier to install than the full face

style. Stub ange assemblies have the same pressure rating

as full face anges assemblies.

Backing rings must be used with both full face and stub

anges and are available in all standard drilling congurations.

Gaskets must be used with anges.

ABS stub ange and full face ange assemblies may be bolted


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directly to other anged pipe systems of the same ange

drilling i.e. ANSI 150, AS 2129 etc.

Flange bolt torque values for ABS pipes will not be as high asthose commonly used on steel pipe systems.

The recommended torque values are suitable for the maximum

pressure rating of ABS pipe systems.

Higher torque values may result in distortion of the ange face.

Standard buttery valves may be placed between ABS stub

ange or full face ange assemblies without modication.

Valves should be checked for full and free movement prior to

nal tightening of ange bolts.

Care needs to be exercised as the valve disc

may interfere with the bore of the pipe.Spacers or special stub anges can be provided.

THREADED CONNECTIONS

Eurapipe manufactures a range of threaded ttings up to

100NB (4).

All threaded ttings are rated 1500kPa at 20C.

For high-pressure installations it is preferable to use adaptors

or ttings with male ABS threads in preference to female ABS

threaded ttings.

Composite unions, available in male and female threaded

RECOMMENDED BOLT TORQUES AND BOLT SIZESFOR AS 2129 TABLE E FLANGES(ABS TO ABS

FLANGES)

PIPE SIZE BOLT SIZE TORQUE(N/m)

BOLTS/FLANGE

DN 15 S1 M12 X 50 7 4

DN 20 S1 M12 X 50 10 4

DN 25 S1 M12 X 50 14 4

DN 32 S1 M12 X 50 13 4

DN 40 S1 M12 X 50 16 4

DN 50 S1 M16 X 65 22 4

DN 65 S1 M16 X 65 25 4

DN 80 S1 M16 X 70 33 4

DN 100 S1 M16 X 80 25 8

DN 125 S1 M16 X 90 34 8

DN 150 S1 M20 X 90 42 8

DN 200 S1 M20 X 100 63 8

DN 225 S1 M20 X 130 80 12

DN 250 S1 M20 X 150 108 12

DN 300 S1 M20 X 150 108 12

DN 350 S1 M24 X 160 133 12

DN 375 S1 M24 X 170 163 12

DN 400 S1 M24 X 180 157 16

DN 450 S1 M24 X 190 185 16

DN 500 S1 M27 X 230 191 16

DN 575 S1 M27 X 240 190 16

DN 650 S1 M27 X 280 200 20

DN 750 S1 M33 X 300 200 20

*Torque values ar ebased upon the use of lubricated bolts complying withthe relevant standards. Care should be taken with galvanized bolts asincreased friction may be encountered

congurations to 50NB are recommended for joining ABS pipe

to metal threads particularly in systems subject to thermal

cycling.

Tightening shall 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 however this only causes

distortion and leaks.

If a threaded connection is leaking disassemble the thread

and if not damaged remake the connection taking care not to

overtighten.

PTFE tape is the recommended thread sealant.

Do not use liquid thread sealants, e.g. Loctite orPTFE paste, as they contain chemicals which may attack

plastic materials.


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BURIED PIPELINES

Trench preparation

Trenches shall be excavated in accordance with AS2566 -

Buried exible pipelines -Installation and the specied design

and relevant installation codes.

The bottom of the trench shall be even and stable and

prepared in accordance with the prescribed pipeline gradient

and depth.

A bedding layer of a minimum thickness as determined by the

code shall be laid in the bottom of the trench.

Ensure that the bedding is free from hard objects or sharp

projections.

The bedding shall be graded to continuously support the pipe.

The bedding shall be compacted according to the required

specications.

Where the joining tting will lay on the trench bottom, scallop

out a bell hole in the bedding. The bell hole shall be twice the

length of the socket joiner to allow sufcient room for joining.

After joining, the bell hole shall be lled and compacted.

Ensure that after joining has been completed joining sockets

are neither unsupported nor on points of concentrated load.

Pre-assembly of cold solvent cement welded

pipes and laying

Joining above ground and snaking into the trench is suitable

for solvent cement welded pipes in sizes up to 200NB.

With this method, the pipes are joined together in a continuous

length of several hundred metres alongside the trench.

Care must be taken not to strain the pipe or pipe joints.

If this method is to be considered, refer to Eurapipe.

Joining in trench

This method is appropriate for all joining methods and for all

sizes of pipe.The pipes shall be laid in the trench so that the socketed end

of the pipe is facing in the direction of laying.

The next pipe is then placed in the trench and inserted into the

socket.

Pipes can be supplied with one joining socket tted to one end

and the other end chamfered. Where this is not the case, or

the pipe is cut to a specic length, a chamfer shall be formed

(see procedure for cutting) and a socket shall be welded to

one end of the pipe above ground before laying in trench.

Where it is necessary to t a joining socket to a pipe in a

trench, the trench will need to have sufcient room around the

end of the pipe to perform joining.

When solvent cement welding in trenches, ensure that any

spillage of solvent cement or MEK is completely removed

immediately.

Thrust blocks

Thrust blocks are not required for solvent cement jointed

buried pipelines at changes of direction, terminations, changes

in pipe diameter or tees.

Thrust blocks may be required where elastomeric seal joints,

valves or other equipment is positioned in the pipeline and are

not independently supported.

Backlling and Tamping

Backlling and compaction of embedment material, overlay

and backll shall be in accordance with AS 2566.


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REPAIR OF DAMAGED PIPES

Above ground

For above ground repairs, the recommended method is to

remove the damaged section of pipe and replace with a new

section.

Sockets, anges, socket unions, or shoulder style joints are all

suitable methods to rejoin the pipe. Metal couplings are also

suitable where pipe has adequate restraint against axial thrust.

Below ground

Where damage to the pipe is minimal (less than 25-30% of

circumference of pipe) a repair saddle may be used. These are

available from Eurapipe. A temporary repair may

dip absdata

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