utility planning fundamentals - gf piping systems

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Technical Manual

Piping Systems in Utilities

Technical ManualPiping Systems in Utilities

Schaffhausen, November 2018

GF Piping Systems – Piping Systems in Utilities – (11.18) 5

Technical ManualPiping Systems in Utilities

I How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Plastic Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Application Solutions for Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V Design and Laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VI ELGEF Plus System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 GF Piping Systems – Piping Systems in Utilities – (11.18)

Content

I How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 How to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

II Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 GF Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

III Application Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Water Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Gas Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

IV Plastic Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Properties of Plastic Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Approvals and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

V Design and Laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Basic knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Hydraulic Calcuation and Pressure Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 Laying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 Jointing Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

VI ELGEF Plus System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1091 The ELGEF Plus electrofusion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1102 Couplers and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1163 Saddles and pressure tapping valves (PTVs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1194 Spigot fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1225 Installation guidelines - error prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1236 Electrofusion units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1257 Tools and accessories for electrofusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

A Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129


PrefaceGF Piping Systems is a major global provider of complete piping solutions for many

demanding applications in various market segments. Founded in 1802, Georg Fischer started

the first production of malleable iron fittings in 1864 and today is recognized as the pioneer in

the development of corrosion-free plastic piping systems for the safe and reliable conveyance

of liquids and gases. This technical handbook reflects more than 60 years of our experience

and know-how in the designing and manufacturing of plastic piping systems. Today, our

product portfolio consists of more than 60’000 products and we are supporting our

customers with products and services day to day around the globe.

The scope of these planning fundamentals is to offer a valuable support in planning and

selection of the proper materials and the most suitable product range for all main industrial

applications. In addition, the handbook provides extensive information about all jointing

technologies for plastic materials and gives technical advises in the installation of pipes,

fittings, valves, measurements and control, as well as actuation.

We strongly believe that the professional planning and the proper use of our comprehensive

product range are the base for reliability, safety and high quality.

We hope that, in this handbook, you will find the qualified support that you need for your daily

work. In case of special applications our worldwide technical engineers will be glad to assist

you.

We would like to thank everyone, who continues to support GF Piping Systems in its mission

to delivering more value to customers, through superior piping systems.

Schaffhausen, November 2018

Preface


How to Use

Content

1 How to use ................................................................................................................................10

2 List of abbreviations ................................................................................................................11


How to use

1 How to useThis handbook describes and explains the basic fundamentals for planning, product

selection, processing and installation of pressure pipes in industrial applications.

It is suitable as a reference book as well as documents for training and education or to

support the consultation. All specifi cations are based on the relevant international ISO and

EN standards, on various national standards, DVS guidelines and additional information from

raw material suppliers. In addition, the results of extensive internal investigations are

incorporated. Thus the designer, engineer and installer should be given the necessary

assistance to properly plan and install their piping system.

Selection and weighting of the topics are focused on the explanation of the design-relevant

areas. Detailed instructions of the products are to be taken from the corresponding

installation and operating instructions.

Planning aids for utility and building-technology systems are available in separate

handbooks. For further information, please contact your local country representative or refer

to: www.gfps.com

Overview of symbols

General symbols

General information Note

Example Online calculation tools and mobile applications

Symbols of materials

Abrasion resistance Electrical properties

Combustion behavior Mechanical characteristics

Chemical resistance Physiological properties

High-purity properties UV and weather resistance

Application limits


How to UseList of abbreviations

2 List of abbreviationsAbbrevia-tions

Description

BGA German health authorityBgVV Federal Institute for Consumer health protection and veterinary medicine

DIBt German Institute for construction technology

DVGW German association of gas and water e.V.

DVS German association of welding technology

EPDM Ethylene propylene diene rubber

FAR Federal Aviation Regulations

FDA Food and Drug Administration

FKM Fluororubber

GFK Fiberglass reinforced plastics

KTW Plastic drinking water recommendation by the Federal Health Office

MFR Melt Flow Rate

MRS Minimum Required Strength

NBR Nitrile rubber (Buna-N)

NR Natural rubber

PB Polybutene

PE Polyethylene

PE-X Crosslinked Polyethylene

PP Polypropylene

PTFE Polytetrafluorethylene

PVC Polyvinyl chloride

PVC-C Polyvinyl chloride, chlorinated

PVC-U Polyvinyl chloride, unplasticized

PVDF Polyvinylidene fluoride

SDR Standard Dimension Ratio

TG Malleable iron

UP-GF Unsaturated polyester resin, glass fiber reinforced


How to use

GF Piping Systems – Piping Systems in Utilities – (11.18) 1 · 13

Introduction

Content

1 GF PipingSystems ...................................................................................................................14

2 Services ....................................................................................................................................15

3 Quality .......................................................................................................................................173.1 Qualityassuranceatalllevels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2 Managementsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3 Accreditedtestcenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Sustainability ...........................................................................................................................194.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2 Socialaspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 Training .....................................................................................................................................20

I

1 · 14 GF Piping Systems – Piping Systems in Utilities – (11.18)

GF PipingSystems

1 GF Piping SystemsGlobal presence

Ourglobalpresenceensurescustomerproximityworldwide.Salescompaniesinover

25 countriesandrepresentativesinanother80countriesprovidecustomerservicearound

theclock.With50productionsitesinEurope,AsiaandtheUSAweareclosetoourcustomers

andcomplywithlocalstandards.Amodernlogisticsconceptwithlocaldistributioncenters

ensureshighestproductavailabilityandshortdeliverytimes.GF PipingSystemsspecialists

arealwayscloseby.

Complete solutions provider

Withover60,000products,weofferindividualandcomprehensivesystemsolutionsfora

varietyofindustrialapplications.Havingtheprofitabilityoftheprojectsinfocus,weoptimize

processesandapplicationsthatareintegratedintothewholesystem.Continuallysetting

standardsinthemarket,wedirectlyprovideourcustomerswithtechnologicaladvantages.

Duetoourworldwidenetworkofqualifiedcontactpartners,customersbenefitdirectlyfrom

our50years+experienceinplastics.

Fromstarttofinish,wesupportourcustomersasacompetent,reliableandexperienced

partner,activelycontributingtheknow-howofanindustrialcompanythathasbeensuccess-

fulinthemarketforover200years.


IntroductionServices

I

2 ServicesFrom planning support to implementation – our specialists are always close by

Asaleadingproviderofpipingsystemsinplastic,weofferourcustomersnotonlyreliable

products,butalsoacomprehensivepackageofservices.Oursupportrangesfroma

comprehensivetechnicalmanualortheextensiveCADlibrarytoaninternationalteamof

experts,whoworkcloselytogetherwithlocalsalescompanies.Andwhenitcomesto

implementingaproject,ourcustomersadditionallybenefitfromawiderangeoftraining

courses,eitheronsiteorinourmoderntrainingcentersworldwide.

a Chemical resistance

Ourspecialistteamshavedecadesofexperienceintheareaofchemicalresistance.Theycan

offerindividualsupportandadviceinselectingtherightmaterialforthecorresponding

plasticssystemsolution.Onrequest,ateamwillexamineandselecttheappropriatematerial

forspecialapplications.

s CAD library

TheextensiveCADlibraryisthemostfrequentlyusedplanningtoolatGF PipingSystems.The

databasecomprisesover30,000drawingsandtechnicaldataregardingpipes,fittings,

measurementandcontroltechnologyaswellasmanualandactuatedvalves.Thebig

advantageoftheCADlibraryisthatthedatacanbeintegrateddirectlyinCADmodels.

d Technical support

Technicalsupportandmaterialselectionarekeyfactorsforasuccessfulinstallation.Ateam

ofspecialistsheadquarteredinSwitzerlandisavailabletosupporttheGF PipingSystems

salescompaniesaroundtheworld.Fortechnicaladviceorforgeneralinformation,our

customersaresupportedindividuallybythespecialistteaminthecorrespondingsales

company.

f Online and mobile calculation tools

Ournumerous,multilingualonlinecalculationtoolsareveryusefulforconfiguringand

calculating.Bymeansofpressure/temperaturediagrams,thepressureofliquidmedia

recommendedforpipesandfittingsatvarioustemperaturescanbeeasilydefined.FlowCalc

App,themobileapplicationofGF PipingSystems,isanon-siteplanningtoolforpipediameter

andflowvelocitycalculationtoselecttherightdimensionofpipingsystems.

g On-site training

Ourexpertsareavailabletosupportourcustomerslocallyandconducttrainingindiverse

fusionandjointingtechniquesonlocation.Thedurationandstructureofthetrainingdepends

ontheprojectandthesystembeinginstalled.

h Customizing

ThecustomizingteamsatGFPipingSystemsworkcloselytogetheraroundtheglobe.The

focusofourteamsisontheproductionofcustom-madespecialpartstocomplete

installations.Inaddition,awidevarietyofspecialsolutionscanbeproducedinsmallseries.

Standardizedprocessesguaranteeourcustomersthehighestquality,evenforindividual

solutions.


Services

j Rental pool

Inmanycountries,GF PipingSystemsprovidesmachinesandtoolstorentforvariousjoining

techniquessuchasbuttwelding,electrofusionandmechanicalconnections.

k Training courses

GF PipingSystemsoffersawiderangeoftrainingcoursesthatallowparticipantstogain

confidenceinworkingwithourproductsandprovenjointingtechnologies.Thepractical

trainingisclearlydefined,structuredandadaptedtothevariouslevelsofexperienceofthe

participants.

l Fit for Service NDT

Usingultrasoundtechnology,weareabletoprovideourcustomerswithtop-qualitynon-

destructivetesting(NDT)forecoFIT(PE),PROGEF(PP)buttweldsandELGEF(PE)

electrofusionwelds.ImportantprojectsacrossthegloberelyonNDTtechnologytoensure

thegreatestsecurityandqualityofweldedjointsonmetallicpipes.GF PipingSystems’

approachtoholisticqualitymanagementhasresultedintheworld’sfirstNDTserviceforbutt

weldsandelectrofusionweldsonecoFIT(PE),PROGEF(PP)andELGEF(PE)withan

operationalfitnessreport(pass/fail).Onceanitemhaspassed,weprovideaten-year

guarantee.

OuruniqueNDTsolutionguaranteesyourweldqualitywithapass/failreport.

; Track and Trace

TrackandTraceisacompletemanagementpackagethattakescareofpreparation,dataentry

anddataarchivingatallcriticalphasesonaconstructionsite.State-of-the-artapps,Internet

platforms,onlineclouds,mobiledevicesandGPShardwareareusedforthis.Theserviceis

availableasanannuallicenceandcontainsalltherequiredelementstoplan,manageand

implementinstallationsinanintelligent,quality-drivenandsmoothprocess.

A Advanced Engineering Services

Inordertosupportkeyprojectsacrossallprojectphases,weprovideadvancedengineering

servicesforthedesign,installationandverificationofsystems.Advancedengineering

servicesprovidesupportforeverycustomerrequirement:

• Modificationofparts

• Materialselection

• Designreviews

• Detailingofstandards

• Hydraulicmodeling

• Dynamic-mechanicaltensionanalysis

• Calculationofstaticanalyses

• FEA/FEM

Toguaranteesafe,highperformanceplasticpipingsystems,allinvolvedcalculationsare

performedusingprofessionalprogramssuchasROHR2.


IntroductionQuality

I

3 Quality

3.1 Quality assurance at all levelsQualitycreatessafetyandisthebasisfortrust.Incustomerrelationshipsaswellasin

projectwork,development,productionandinthespecificapplicationofproducts,quality

awarenessandstandardsdecideonsustainedsuccess.Thefundamentalimportanceof

qualitydeterminesouractions,shapesourunderstandingofquality,andisreflectedinour

ownclaimtoquality.

Thesystematicintegrationofpartnersandsuppliersispartofourcomprehensive

understandingofqualityandguaranteesthebindingassuranceofthequalitystandardalong

theentirevalueaddedchain.

GF PipingSystemsisboundtothehighqualitystandardsofitscustomersandconsidersitself

activelyresponsibleformeetingthecustomerrequirementsaswellasensuringlegal

standards.Therigorousimplementationofourqualitypolicyrepresentsanobligationfor

everysingleperson.Consequently,theorientationtowardsqualitywhenprovidingaservice

goeswithoutsayingforallemployeesworkinginthecompany.

3.2 Management systemsQuality,environment,occupationalsafetyandhealthprotectionhavealwaysplayedavery

importantroleintheGeorgFischergroup.Inlinewiththat,allproductioncompaniesaswell

asmanysalescompaniesofGF PipingSystemsarecertifiedinaccordancewiththeISO9001

qualitymanagementsystem.Furthermore,allofourproductionsitesarecertifiedin

accordancewithISO14001.Thestandarddefinescriteriathatareapplicablethroughoutthe

worldforefficientenvironmentalmanagementsystemsand,asaresult,isconsideredtobe

thebasisforoptimizingenvironmentallyrelevantprocesses.

Aspartofoursustainabilityactivities,allproductionsiteshavealsobeencertifiedin

accordancewithOHSAS18001,theinternationalstandardintheareaofoccupationalhealth

andsafety.Newlyacquiredornewlyfoundedproductioncompaniesareboundtoestablisha

quality,environmentalandoccupationalsafetymanagementregimewithinaperiodofthree

years.

3.3 Accredited test centerThetestcenterofGF PipingSystemsisatestcenteraccreditedinaccordancewithISO/IEC

17025forcomponentsofpipingsystems.Itinspectsalltypesofpipes,pipeconnections,

connectingelements,fittings,manualandautomaticvalvesaswellasflowmetersaccording

torelevantstandardsanditsownexternalaswellasinternalspecifications.

CustomersfortestlaboratoryprogramsaretheR&Ddepartments,manufacturingplants,as

wellasend-usersofGF PipingSystemscomponentsandotherexternalcustomers.

DevelopmentandproductreleasetestsarecompletedforR&Ddepartments(TTtypetesting,

ITTinitialtypetesting),batchreleasetests(BRT)andprocessverificationtests(PVT)forour

ownproductionunitsaswellasothertestsforexternalcustomers.

Thecontinuoustrainingandspecificexperienceofouremployees,thetechnicalstateofour

testingsystems,aswellasproperlydocumentedtestsequencesarebasicprerequisitesto

accreditingthetestcenterinaccordancewithISO/IEC17025.TheaccreditationbySAS(Swiss

AccreditationOffice)isconfirmedintheformofacertificate.Averificationtakesplace

annuallyaswellasarenewaloftheaccreditationevery5years.


Quality

TheSAS,whichisresponsibleforandhasissued

ouraccreditation,isamemberoftheInternatio-

nalLaboratoryAccreditationCooperation(ILAC).

AlllaboratoriesaccreditedbytheILACare

obligedtoformallyrecognizeanytestreport

issuedbyafellowmember.Thispermitsus,and

ourcustomers,touseallaccreditedtestreports

originatingfromourlaboratorytoobtainproduct

approvalsandqualitycertificates,etc.There-

fore,potentialexpenditureandtimeconsump-

tionisconsiderablyreduced.

Theaccreditedtestprogramalsoincludes:

• Long-terminternalpressuretesting(ENISO

10931,ENISO15493,ENISO15494,ISO9393)

• Bursttestsonfittingsandpipes

• Crushtests(ISO9853)

• Impactresistancetests(ISO13957)

• Decohesiontest(ISO13955,ISO13956)

• Peelingtest(ISO13954)

• Tensilestrengthandfailuremodeonbutt-

fusedtestspecimens(ISO13953)

• Pressuredroptest(EN12117)

• Determinationofdensity(ENISO1183)

• MeltflowrateMFR(ENISO1133)

• OxidationinductiontimeOIT(ENISO11357-6)

Acompletelistingofaccreditedtestscanbe

seeninatable.Thistable,whichisconstantly

updated,canbereferredtobyconsultingthe

followinginternetsite:www.sas.ch

B Accredited bodiesBSearchBSTS094.


IntroductionSustainability

I

4 SustainabilityAs an internationally operating industrial group, GF is in the midst of society. It is, therefore, important to harmonize economy, ecology and social aspects. In accordance with this responsibility, our industrial and social activities carry a long-term and long-range orientation. It is our endeavor to anchor sustainability in all of our sales companies. Our sustainability goals, whose attainment we communicate regularly and transparently, drive our actions.

4.1 EnvironmentForGF PipingSystems,ourownenvironmentalresponsibilityisanintegralaspectinallofour

businessactivities.Becauseweregardenvironmentalawarenessasoneofthemost

importantvaluesofourcompany,allinternalstructuresandprocessesareorientedtowards

sustainability.Westrivetosavenaturalresourcesandworkrelentlesslyonoptimizingthe

eco-friendlinessofourproductsandtheirapplications.Outstandingmaterialpropertiesand

innovativetechnologiesformthebasisofourenvironmentallyfriendlyandenergy-saving

solutions.Bysupplyingourcustomerswithcompletepipingsystems,wesupportand

promoteecologicalandcost-efficientoperatingprocessesinmanyindustriesandindaily

routine.Toobtaindetailedinformationabouttheenvironmentalcompatibilityofourproducts,

wemonitorallphasesoftheproductlifecycleindetail,whichalsoallowsusultimatelyto

improvethelifecycleassessmentofourproducts.

4.2 Social aspectsAttractiveworkplaces,interestingtasks,agoal-orientedtrainingandprofessional

development,aswellasafairsalaryandgoodsocialbenefitscontributetosecuringthe

futureofthecompany.GF PipingSystemsoperateswiththisresponsibilityasitspremise.

Withlocationsinover30countries,GF PipingSystemsviewsthemultitudeofcultures,

religions,nationalities,gendersandagegroupsasavaluablesourcefortalent,creativityand

experience.Thismakespossibletheextraordinaryservicesperformedbyapproximately

16,000staffmembersemployedbyGF PipingSystemsthroughouttheworld.

Additional information about sustainability can be found at

www.gfps.com/sustainability.


Training

5 TrainingQualifiedpersonnelisoneofthekeyfactorsforthesuccessofacompany.Onlyhighly

motivatedandwell-trainedemployeeswiththeappropriateknow-howandcustomerfocus

arereliablepartners.

GF PipingSystems,asaprofessi-

onalsystemandsolutionprovider,

offersyoutrainingcourseswitha

focusonproducts,applications,

salesargumentsanddifferent

customerrequirements.

Thejointingtechnologies,aswell

asmeasurementandcontrol

technologyareincreasingly

innovative.Tostayup-to-date,you

needcontinuingeducation.

GF PipingSystemsmakesan

essentialcontributiontoyour

know-how.Nomatterwhatyour

fieldofexpertisemaybe–utili-

ties,buildingtechnologyorindust-

rialapplications–youcanbenefit

fromthetrainingcourses,which

areadaptedtothedifferent

marketsegmentsandapplica-

tions.

Weofferacustomizedprogram

forsalespersonnelandoccupati-

onalgroupssuchasinstallers,

plannersandplantbuilders.

Besidesthetheory,weattach

greatimportancetohands-on

practice.Ourroomsareespecially

equippedforpracticaltraining.

Theyaresuitableforsimulta-

neoustrainingofupto100

personsunderidealconditions.

Weworktogethercloselywithour

salespersonnelwhenselecting

trainers.Therearebasic,advan-

cedandmastercourses,which

areallstructuredinacoordinated

fashion.

For additional information about the current training program, visit www.gfps.com.


Application Solutionsfor Supply

Content

1 Water Utilities ..........................................................................................................................221.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2 LeadingSystems(Samples) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2 Gas Utilities ..............................................................................................................................242.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 LeadingSystems(Samples) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3 Automation ...............................................................................................................................263.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

II


WaterUtilities

1 Water Utilities

1.1 OverviewHygienicdrinkingwater,pureintaste,smellandappearanceisoneofthefundamentalhealth

requirements.Thedemandforasecuresupplyofcleanwaterisincreasingworldwide.For

thefullspectrumofwatersupply,GF PipingSystemshasavarietyofinnovativetechniques

andspecializedproductsdesignedspecificallyforthewaterdistributionindustry.Ourleading

know-howandexpertiseforallwaterdistributionapplicationshelpsfindingtherightsolution

foryourapplication.

a Water transportation lines

Whentransportingwater,asafeandreliableconnectionisthekeysuccessfactor.Butatthe

sametimeitcanbeachallengingtask,especiallyatlargedimensions.GF PipingSystems

understandstheneedforpropertooling,highperformancejointingtechnologiesand

connectionpartsaswellasexpertsupportonsite.

s Water distribution lines

Forthereliable,economicalandsustainablewaterdistributionitisessentialthatallpiping

componentslikepipes,fittingsandvalvesareconnectedsafeandreliable.GF PipingSystems

offersacomprehensiverangeofjointingtechnologies.TheelectrofusionsystemELGEFPlus

ensuresamaterialhomogeneousconnectionofpipeandfittingthatcontributestoareliable

network.WiththeMULTI/JOINTsystemallkindsofmaterialscanbeconnectedinaquick,

safeandsimpleway.

d Water service lines and house connections

Inthelaststageofthewatergrid,servicelinesbringwatertothemeter.Duetoitsflexibility

andmaterialhomogeneousjointingtechnologies,amongstmanyotherpositive

characteristics,PEistoday’smainusedmaterialfornewinstallations.Thankstothemodular

ELGEF Pluselectrofusionsystemanappropriatesolutioncanbefoundforeveryapplication.

EachindividualELGEFfittingandsaddleismadetomatchandwhenputtogethertheyform

reliableleak-proofconnections.Manydifferentcombinationscanbedevisedusingjustafew

products.AlsoPEvalveswillcontributetoareliableandsafenetworkaspartofthe

ELGEF Plussystem.


Application SolutionsWaterUtilities

II

f Pressure sewage lines

Ratherthangravity,thepressuresewagesystemisusingpumpstomovethewastewater

alongtothewastewatertreatmentplant.Pressuresewagesystemsareusinggenerally

smallerdiameterpipesthatarelessexpensiveandeasiertoinstall.ChoosingheretheGFPE

system,areliablenetworkfor100yearscanbebuilt.

g Irrigation

Agrowingworldpopulationandthechangingclimateenhancethefoodandwaterscarcity.

Moreandmorefoodproductionwillbeseparatedfromthelocalweatherbybuildinglarge

glasshousesordoingextendedirrigationincreasingtheoutputoffoodperm2.Systems

simpletoinstallandensuringasecurewaterdistributionoverthetotalproductlifespanwill

becomeanimportantattribute.GF PipingSystemsprovidesacomprehensiveproductrange

forirrigationaswellasonthelocaltrainingandfastdeliveries.

1.2 Leading Systems (Samples)ELGEF Plus MULTI/JOINT iJOINT Machines Tools

d160–d2000mm,PN10d20–d1200mm,PN16

DN50–DN600mm d16–d110mm Butt fusiond40mm–d1600mm(withCNCtechnologyuptod630mm)

d20–d2000mm

Electrofusionfittings,spigotfittings,seamlessbendsandsegmentedfittingsandpipes

Widerangerestraintcouplings,reductioncouplings,wide-rangeflanges,curves,endcapsPEadapters,footbends

Couplings,tees,bends,reducersandsaddles,transitionfittings,universalfittings

ElectrofusionMSA125,230,330,340(Transformer)

MSA2.0,2.1,4.0,4.1,2.0MULTI(Invertertechnology)

Rotationpeelers,clampingdevices,top-loadtools,cuttingtools,re-roundingtools,squeeze-offtools,tappingdevices


GasUtilities

2 Gas Utilities

2.1 OverviewFordecades,gashasbeendeliveredthroughanetworkofburiedtransmissionanddistribu-

tionpipestohomesandindustriesthroughouttheworld.Ithasgrowntobecomethemost

dependableformofenergyandbeingoneofthecleanest,safestandmostusefulofallenergy

sources.

Duringrecentyearsthegassupplyindustryhasinvestedgreatlytoensureandenhance

consistentqualityintheoperationandmaintenanceofgassupplynetworks.GF Piping

Systemscontinuestoprovidehighqualitysystemsandservicesforbuildingandmaintaining

thesenetworksthuscontributingtothetransportationofgasinthesafest,mostsecureand

reliableway.

a Gas transportation lines

Whentransportinggas,asafeandreliableconnectionisthekeysuccessfactor.Butatthe

sametimeitcanbeachallengingtask,especiallyatlargerdimensions.GF PipingSystems

understandstheneedforpropertooling,highperformancejointingtechnologiesandconnec-

tionpartsaswellasexpertsupportonsite.

s Gas distribution lines

Forthereliable,economicalandsustainablegasdistributionitisessentialthatallpiping

componentslikepipes,fittingsandvalvesareconnectedsafeandreliable.GF PipingSystems

offersacomprehensiverangeofjointingtechnologies.TheelectrofusionsystemELGEFPlus

ensuresamaterialhomogeneousconnectionofpipeandfittingthatcontributestoareliable

network.WiththeMULTI/JOINTsystemallkindsofmaterialscanbeconnectedinaquick,

safeandsimpleway.

d Gas service lines and house connections

Inthelaststageofthegasgrid,servicelinesbringgastothemeter.Duetoitsflexibilityand

materialhomogeneousjointingtechnologies,amongstmanyotherpositivecharacteristics,

PE istoday’smainusedmaterialfornewinstallations.ThankstothemodularELGEFPlus

electrofusionsystemanappropriatesolutioncanbefoundforeveryapplication.Each

individualELGEFfittingandsaddleismadetomatchandwhenputtogethertheyform

reliableleak-proofconnections.Manydifferentcombinationscanbedevisedusingjustafew

products.AlsoPEvalveswillcontributetoareliableandsafenetworkaspartofthe

ELGEF Plussystem.


Application SolutionsGasUtilities

II

2.2 Leading Systems (Samples)ELGEF Valves MULTI/JOINT Machines Tools

d160–d2000mm,PN10d20–d1200mm,PN16

PE-ballvalvesuptod225mm

DN50–DN600mm Butt fusiond40–d1600mm(withCNCtechnologyuptod630mm)

d20–d2000mm

Electrofusionfittings,spigotfittings,seamlessbendsandsegmentedfittingsandpipes

PressureTappingValvesuptod63mmoutlet,mainsuptod400mm

Widerangerestraintcouplings,reductioncouplings,wide-rangeflanges,curves,endcaps PEadapters,footbends

ElectrofusionMSA125,230,330,340(Transformer)

MSA2.0,2.1,4.0,4.1,2.0MULTI(Invertertechnology)

Rotationpeelers,clampingdevices,top-loadtools,cuttingtools,re-roundingtools,squeeze-offtools,tappingdevices


Automation

3 Automation

3.1 OverviewPEpipingsystemsarenotjustusedforsupplyinggasandwater,butincreasinglyalsoin

industrialapplications.

Beitformeasurement,controlorpropulsion,ourtechnologiesarenotonlyfullycompatible

withoneanother,but–regardlessoftheirdimensions–canalsobeseamlesslyintegrated

intoyourpipingsystemsusingsuitablesystemcomponentsfromGF PipingSystems.

3.2 MeasurementProduct categories• Flowmeasurement

• (ultrasound,paddlewheel,

electromagnetic,turbine,float)

• pH/ORP

• Conductivity/resistivity

• Pressure/filllevel

• Temperature

• Clouding

• Chlorine/chlorinedioxide

• Dissolvedoxygen

3.3 Control

Precise control

Intelligentdesignmakeslifeeasier.Alloursensorscanbeconnectedtothesametransmitter.

Our9900single-channel,multi-parametercontrollerensuressecureandefficientoperation

ofyourentirecontrolcircuit.Thankstoitsmodulardesign,additionalfunctionssuchasbatch

controlorcommunicationtechnologiescanbeaddedatanytimewithoutanyproblems.The

parametersofthecurrentlyconnectedsensorsaredisplayedataglanceonthelarge,well-lit

display.

Reliable drive technology for fi ttings

Themodulardesignofourdriverangeallowsyouthegreatestflexibilityforyourconfigura-

tion.Valvesanddriveelementscanbecombinedflexiblyandadditionalfunctionssuchas

positioncontrolormonitoringsystemscanbeaddedasoptions.Dependingonyourrequire-

ments,youcanchoosebetweenelectric,magneticorpneumaticdrives.Madeentirelyfrom

plastic,ourwholedriverangeisdesignedforthetoughestenvironmentalconditionsandis

resistanttoaggressivechemicalsandseawater.• Easytoinstall:clamp-onflowratemeterscanbe

directlyattachedtotheoutsideofthepipewhilethe

systemisrunning.

• Easytooperate:anintuitivemenustructureandthe

clearparameterdisplayareintegralcomponentsofour

user-friendlycontroltechnology.

• Easytocombineandretrofit:thefastandeasyconfigu-

rationisakeybenefitthatprovesthattheflexibilityof

ourautomationsolutionsknownolimits.

GF Piping Systems – Piping Systems in Utilities –(11.18) 3 · 27

Plastic Piping Materials

Content

1 Properties of Plastic Piping Materials ...................................................................................281.1 Polyethylene (PE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 Approvals and Standards ........................................................................................................332.1 Approvalsofproducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.2 Standardsandguidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 III


PropertiesofPlasticPipingMaterials

1 Properties of Plastic Piping Materials

1.1 Polyethylene (PE)

PE properties (reference values)

Property PE 80Value1

PE100 / PE100 RC Value1

Units Test standard

Density 0.93 0.95 g/cm³ EN ISO 1183-1Yieldstressat23°C 18 25 N/mm² ENISO527-1

Tensilee-modulusat23°C 700 900 N/mm² ENISO527-1Charpynotchedimpactstrengthat23°C

110 83 kJ/m² ENISO179-1/1eA

Charpynotchedimpactstrengthat-40°C

7 13 kJ/m² ENISO179-1/1eA

Crystallitemeltingpoint 131 130 °C DIN51007Thermalconductivityat23°C 0.43 0.38 W/m K EN12664Waterabsorptionat23°C 0.01 - 0.04 0.01 - 0.04 % ENISO62Color 9005 9005 RALLimitingoxygenindex(LOI) 17.4 17.4 % ISO 4589-1

1Typicalcharacteristicsmeasuredatthematerialshouldnotbeusedforcalculations.

General

PolymerswhichconsistofhydrocarbonswithformulaCnH2nwithadoublebond(ethylene,

propylene,butene-1,isobutene)arecollectivelyreferredaspolyolefin.Polyethylene(PE)

belongstothisgroup.Itisasemi-crystallinethermoplastic.Polyethyleneisthebestknown

polymer.Thechemicalformulais:-(CH2-CH2)n,makingpolyethyleneanenvironmentally

friendlyhydrocarbonproduct.PEaswellasPPbelongtothenon-polarmaterials.Becauseof

this,itdoesnotdissolveincommonsolventsandhardlyswells.Asaresult,PEpipescannot

besolventcemented.Theappropriatejointingmethodforthismaterialiswelding.

HighmolecularPEgradesofmediumtohighdensityhavebecomestateoftheartfor

industrialpipinginstallations.Thegradesareclassifiedinaccordancewiththeirinternal

pressureresistanceinPE80(MRS8MPa)andPE100(MRS10MPa).Inthiscontext,wealso

talkaboutPEgradesofthe3rdgeneration,whilePE80gradesbelong,inmostcases,tothe

2ndgeneration.PEgradesofthe1stgeneration–PE63accordingtocurrentclassifications–

havepracticallynoapplicationanymore.Theinternalpressureresistanceistestedaccording

toISO1167andcalculatedincompliancetoISO9080.Inpipingconstruction,PEismostlyused

forburiedgasandwaterlines.Forthisrangeofapplications,polyethylenehasbecomethe

dominantmaterialinnumerouscountries.Butalsobuildingtechnologyandindustrialpiping

installationsmakeuseoftheadvantagesofthismaterial.

Alternative,trenchlessinstallationmethodssuchasrelining,trenchcuttingandflushdrilling

requirenewmaterials:PE100RC(raisedcrackresistance)madefrommodifiedPE100hasa

greaterresistancetoslowcrackgrowthandstresscracks.TheadvantageofPE100RCasa

materialisthatnotchesandgroovesinthepipehavelessofanimpactonthelifetimeinthe

longterm.Forthisreason,thismaterialisoftenusedfortrenchlesspipeinstallation.The

requirementsforpipesmadefrompolyethyleneforalternativeinstallationtechniquesare

specifiedinPAS1075.


Plastic Piping MaterialsPropertiesofPlasticPipingMaterials

III

Advantages of PE

• Lowweight

• Excellentflexibilityduringstorageandinstallationaswellasresistancetoearth

movements

• Goodabrasionresistance(abrasionresistance)

• Corrosionresistance,noadditionalmeasuresrequired

• Highimpactstrengthevenatlowtemperatures

• Goodchemicalresistance

• Smoothpipesurfaceresultinginhigherflowrate,lessincrustationandlowerenergycosts

• Suitablefortrenchlessinstallationtechniques

UV and weather resistance

Becauseoftheblackpigmentsused,blackpolyethyleneisveryweather-resistant.Even

longerexposuretodirectsunlight,windandrainhardlycausesanydamagetothematerial.

Chemical resistance

Polyethyleneshowsagoodresistanceagainstabroadrangeofmedia.Studiesby

independentinstituteshaveshownthattheexpectedlifetimeofPEpipes,evenunderextreme

conditions,exceedsthelifetimerequiredbystandards.Fordetailedinformation,observethe

listofchemicalresistancefromGF PipingSystemsorcontacttheresponsibleGF Piping

Systemsrepresentative.

Abrasion resistance

PEshowsexcellentresistancetoabrasivestress.Dependingonthesize,geometryandspeed

ofthesolidsbeingtransported,PEhasgreatadvantages,inparticularovermetallic

materials.PEpipingsystemsarethususedinmanyapplicationsfortransportingmediawith

solidcontents.

Application limits

Theapplicationlimitsofthematerialontheonehanddependonembrittlementandsoftening

temperaturesandontheotherhandonthenatureandtheexpectedservicelifeofthe

application.Thepressure-temperaturediagramsgivedetailsonapplicationtemperatures

andpressures.

Combustion behavior

Polyethylenebelongstotheflammableplastics.Theoxygenindexamountsto17%.Withan

oxygenindexbelow21%,aplasticmaterialisconsideredtobeflammable.PEdripsand

continuestoburnwithoutsootafterremovingtheflame.Basicallytoxicsubstancesare

releasedthroughallburningprocesses,particularlycarbonmonoxide.WhenPEburns,

primarilycarbondioxide,carbonmonoxideandwaterareformed.

Thefollowingclassificationsinaccordancewithdifferentcombustionstandardsareused:

• AccordingtoUL94,PEisclassifiedasHB(horizontalburning)andaccordingto

DIN53438-1asK2.

• AccordingtoDIN4102-1andEN13501-1,PEislistedasB2(normalflammable).

IntheFrenchclassificationofbuildingmaterials,polyethylenecorrespondstoM3(ofaverage

flammabilityrating).Theself-ignitiontemperatureis350°C.Suitablefire-fightingagentsare

water,foam,carbondioxideorpowder.



Electrical properties

Likemostthermoplastics,polyethyleneisnon-conductive.Thismeansthatno

electrochemicalcorrosiontakesplaceinPEsystems.

However,thenon-conductivepropertieshavetobetakenintoaccountbecausean

electrostaticchargecanbuildupinthepipe.Polyethyleneprovidesgoodelectricalinsulation

properties.Thespecificvolumeresistanceis3.5x1016Ωcmandthespecificsurface

resistanceis1013Ω.Thesefigureshavetobetakenintoaccountwhereverthereisahazardof

ignitionorexplosion.

Physiological properties

TheblackpolyethylenematerialsfromGF PipingSystemsareauthorizedforuseinfood

applications.Theorganolepticpropertiesofthefittingsareinaccordancetotherelevant

standards.Usageinallrelatedareasisthuspossible.Fordetailsregardingexisting

approvalsforapplicationswithdrinkingwaterorfoodstuffs,pleasecontacttheresponsible

GF PipingSystemsrepresentative.

1.2 SustainabilityTheworldisfacingmajorchallengesintheenergysector.Thisincludestheincreasing

consumptionofenergy,thefinitenatureoffossilresources,theincreasingpricesforenergy

andclimatechange.Inordertosatisfytheneedsoftoday‘saswellasfuturegenerations,

sustainabledevelopmentisneeded.Plasticscontributetomasteringthesechallenges.

TheproductsofGF PipingSystemshavebeeninuseatcustomersformanyyears,insome

casesevendecades.Evenminorincreasesinefficiency–suchasthoseachievedbyasuitable

design–cansignificantlyinfluencetheenvironmentalbalance.Forthisreason,GF Piping

Systemspursuesacomprehensiveapproachinthedevelopmentofpipingsystems.

Sustainablesolutionsarepossibleonlyiftheentirelifeoftheapplicationsandproductsis

considered.

Plastics save energy

Besidestheirgenerallyknowntechnicaladvantages,suchascorrosionresistance,plastics

alsopresentecologicalbenefits.Withtheirlightweightandinsulatingeffect,plasticsare

suitableforanumberofenergy-efficientapplications:invehicles,forpackaging,in

insulationsandforpipingsystems.Plasticsareproducedprimarilyoutofcrudeoil.Roughly

fourpercentofthecrudeoilproducedworldwideisprocessedintoplastics.Effortstoreduce

theconsumptionofcrudeoilandotherfossilfuelsdonot,however,meananabandonmentof

plastics–onthecontrary:Energyissavedbyusingplastics!

Inastudy1,PlasticsEuropequantifiedwhattypeofeffectenergyconsumptionand

greenhouseemissionshavewhenplasticproductsweretobereplacedbyothermaterials.

The results of the study

• Productsmadeofplasticenablesignificantsavingsinenergyandgreenhouseemissions.

• Inmostcases,replacingplasticproductswithothermaterialsleadstoanincreaseof

energyconsumptionandgreenhouseemissions.

Ifasmanyplasticproductsaspossibleweretobereplacedwithothermaterials,morethan

50%moreenergywouldberequiredthantheenergycurrentlybeingconsumedduringthe

entirelifecycleofallplasticproducts.Inotherwords:Theplasticproductsthatarecurrently

onthemarkethaveenabledanenergysavingsof2,400millionGJperyear.Thisisthe

equivalentofanamountof50milliontonsofcrudeoilthatcouldbedistributedonto200very

largeoiltankers.

1 Pilz,H.,Brandt,B.,Fehrin-ger,R.(2010):Theimpactofplasticsonlifecycleenergyconsumptionandgreen-housegasemissionsinEuropeDenkstattGmbHundertheauthorityofPlasticsEurope,Brussels,Belgium.


Plastic Piping MaterialsPropertiesofPlasticPipingMaterials

III

Life cycle assessment of pipes

GF PipingSystemshadalifecycleassessment2commissionedofpipesforbuilding

technology,industryandutilities.Inthisassessment,theenvironmentaleffectsofonemeter

ofpipeeacharecomparedfortheplasticsusedbyGF PipingSystemsandtheirmost

importantcompetingmaterials(forDN25,DN80,DN150andDN400).Thestudywascalculated

byindependentSwisslifecycleassessmentexpertsandisbasedontheinternationally

leadinglifecycleassessmentdatabase„Ecoinvent“.

TheresultisthatplasticpipesintheapplicationsanddimensionsdeliveredbyGF Piping

Systemsalmostalwaysshowbetterresultsthanthecompetingmaterials.Forexample,the

CO2footprint,i.e.thatistheaddedgreenhouseemissionsduringmanufacturing,transport

anddisposalofonemeterofPEpipeofdimensionDN80isroughlyfivetimeslowerthanfora

pipemadeofstainlesssteel.Decisivefactorsforthelifecycleassessmentofpipesarethe

typeandquantityofthematerialused.Foreverykilogramofmaterial,manyplasticsandalso

copperandstainlesssteelshowasimilarhighenergydemand.Low-alloyedsteelandcast

ironwithanaverageshareofregrindsaresignificantlylowerperkilogram.Theresultsdiffer

whenreferencedtoonemeterpipe.Basedonthesignificantlylowerweight,plasticpipesfare

verywellcomparedtometals,particularlyforthesmallandmediumdimensions.

PlasticpipesmadeofPEshowasignificantlybetterlifecycleassessmentthanmetalpipes.

Reducingmaterialdemandisatthecenteroffurtherimprovementofthelifecycle

assessmentofplasticpipes.Thisappliestoproductdevelopmentaswellastousersand

planners:

• Reducematerialdemandfurther

• Useofregrindsforpartswithlowloads

• Nooverdimensioningduringplanning(e.g.diameter,pressurelevel)

2 Büsser,S.,Frischknecht,R.(2008):Lifecycleassess-mentofpipes-comparisonofdifferentpipingmaterialsforbuildingservices,industryandutilities.ESU-ServicesLtd.onbehalfofGeorgFischerPipingSystems,UsterandSchaffhausen.

G3.1 Life cycle assessment of plastic pipes



Comparative life cycle assessments of GF Piping Systems industrial systems

IncollaborationwiththeindependentBelgianinstituteVITO,theGlobalQuality&

SustainabilitydepartmentofGF PipingSystemscalculatedthelifecycleassessmentsforfour

selectedGF-specificindustrialpipingsystemsandcomparedeachonewithasystemfrom

thecompetitionofthesameapplication.

GF PipingSystemsandVITOanalyzedtheenvironmentalimpactsofthesystemsoverthe

entirelifecycle–fromcradletograve.Thecalculationoftheenvironmentalimpactsofthe

plasticsystemsisbasedonspecificdataofGF PipingSystems.

Thefollowingmaterialsandapplicationswerecompared:

Plastic Comparative material Anwendung

PP Stainlesssteel TransportofchemicalsPVC-U Stainlesssteel Dosing

PE Glassfiberreinforcedplastic(GRP) Coolingwatertransporttoapowerplant

PB Copper Waterdistributiononaship

Basedonthecomparisonmaterials,theindustrialpipingsystemsfromGF PipingSystems

aregivenalowerenvironmentalimpactthanthesystemsfromthecompetition.The

conductedlifecycleassessmentsconfirmtheresultsfromotherinvestigationsand

underscoretheimportantsignificanceofplasticsinecologicallyconsciouspipingsystem

construction.

Thefollowinggraphicsshowstheresultsintheimpactcategory„globalwarming“(excluding

theutilizationphase):

T3.1 Comparison of materials and applications

G3.2 Results of “global warming” for PE

TheCO2savingsof5 991 kg

correspondtotheemissions

thatarecausedbydrivingacar

for37 500 kmor1timesaround

theequator.


Plastic Piping MaterialsApprovalsandStandards

III

2 Approvals and Standards

2.1 Approvals of productsVariousapprovalsareinplaceforallpipingsystemsfromGF PipingSystems.Themost

importantapprovalsarelistedinthefollowingoverview.Thecurrentstatusoftheapprovals

canbeobtainedfromanauthorizedGF PipingSystemsrepresentative.

Abbreviation Approval authority Approved product range

Material

ABS AmericanBureauofShipping Pipes,fittings,valves

ABS,PE,PVC-U,PVC-C

ACS AttestationdeConformitéSanitaire

Fittings PE

BSI BSIGIS

BSIAssuranceUKLimited Fittings PE,malleablecastiron

BULGARKONTROLLA BulgarkontrolaS.A., Fittings PE

BV BureauVeritas Pipes,fittings,valves

ABS,PE,PP-H,PVC-C,PVC-U

NF CERTIgaz Fittings PE

DIBt DeutschesInstitutfürBautechnik

Pipes,fittings,valves

PVC-U,PP-H,PVDF,PE (Fittings)

DNV DetNorskeVeritas Pipes,fittings,valves


DVGW DeutscherVereindesGas-undWasserfaches

Gaskets EPDM,NBR


PE,PP-H,PVC-C,PVC-U,malleablecastiron

EANDIS Eandiscvba Fittings PE

ETI EstoniaTechnicalInspecto-rate

Fittings,valves PE

FM FMApprovals Pipes,fittings PE

GAS GASs.r.o. Fittings PE

GL GermanischerLloyd Pipes,fittings,valves


GlobalMark GlobalMark Fittings PE

GOST-R Rosstandart Pipes,fittings,valves

ABS,PB,PE,PP,PVC-C,PVC-U,PVDF

GRDF GazRéseauDistributionFrance

Fittings PE

IGH InstitutIGHd.d. Fittings PE

IKRAM IkramQAServicesSDNBHD Fittings PE

IIP InstitutoItalianodeiPlastici Fittings PE,PVC-U

INSTA-CERT DancertS/A Fittings PE

ITC Institutprotestovániacertifikaci

Fittings PE

KCW KoreaWaterandWastewaterWorksAssociation

Fittings PE

KIWAKIWAGastec

KeuringsinstituutvoorWaterleidingsartikelen

Fittings PE,PVC-UPE,malleablecastiron

KTW/W270 Kunststoff-Trinkwasser- Empfehlungen

Dichtungen EPDM,NBR

Fittings PE,PVC-U

LR Lloyd'sRegisterofShipping Pipes,fittings,valvese

ABS,PE,PVC-U,PVC-C,PP-H

NK NipponKaijiKyokai Pipes,fittings,valves

ABS,PB,PE,PP,PVC-C,PVC-U

NIGC NationalIranianGasCo. Fittings PE

NSF NationalSanitaryFoundation Fittings PE

ON ÖsterreichischesNormungs-institut

Fittings PE

T3.2 Abbreviations of appro-vals (edition: June 2016)


ApprovalsandStandards

Abbreviation Approval authority Approved product range

Material

ÖVGW ÖsterreichischeVereinigungfürdasGas-undWasserfach

Gaskets EPDM,NBR


PE,PP,PVDF,malleablecastiron

PAEW PublicAuthorityforElectricityandWaterOman

Fittings,machines PE

PROM PromatomnadzorWeissruss-land

Fittings,machines PE

PROMNAZOR Promnazor,Kazakhstan Fittings,machines PE

RINA RegistroItalianoNavale Pipes,fittings,valves


RMROS RussianMaritimeRegisterofShipping


ABS,PE,PVC-C,PVC-U

RTN ROSTECHNADZOR Pipes,fittings,valves,machines

ABS,PB,PE,PP,PVC-C,PVC-U,PVDF

SEPRO NikoSeproOS,Ukraine Fittings,Valves PE

SVGW SchweizerischerVereindesGas-undWasserfaches

Gaskets EPDM,NBR

Fittings,valves PB,PE,PP,malleablecastiron

TSSA TechnicalStandards&SafetyAuthority


PVC-U,PVC-C,PP-H

VUSAPL Vusapl,Slowakia Fittings PE

VUZ VyskumnyUstavZvaracsky,Slowakia

Machines -

WRAS WaterRegulationsAdvisorySchemeWaterByelawsScheme

Gaskets EPDM,NBR

Pipes,fittings ABS,PE,PVC-U,PVC-C

2.2 Standards and guidelines

2.2.1 Relevant standards and guidelines for pipes and fittings of PE

Standard Name

ISO4427-1 Plasticspipingsystems–Polyethylene(PE)pipesandfittingsforwatersupply–Part1:General

ISO4427-2 Plasticspipingsystems–Polyethylene(PE)pipesandfittingsforwatersupply–Part1:General

ISO4427-3 Plasticspipingsystems–Polyethylene(PE)pipesandfittingsforwatersupply–Part3:Fittings

ISO4427-5 Plasticspipingsystems–Polyethylene(PE)pipesandfittingsforwatersupply–Part5:Fitnessforpurposeofthesystem

ISO4437-1 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part1:General

ISO4437-2 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part2:Pipes

ISO4437-3 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part3:Fittings

ISO4437-5 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part5:Fitnessforpurposeofthesystem

ISO9623 PE/metalandPP/metaladaptorfittingsforpipesforfluidsunderpressure-Designlengthsandsizeofthreads-Metricseries

ISO17885 Plasticspipingsystems–Mechanicalfittingsforpressurepipingsystems–Specifi-cations

EN ISO 15494 Plasticspipingsystemsforindustrialapplications-Polybutene(PB),polyethylene(PE)andpolypropylene(PP)-Specificationsforcomponentsandthesystem-Metricseries

EN 1555-1 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part1:General

EN1555-2 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part2:Pipes

T3.3 Standard and guidelines for pipes and fittings of PE (edition: June 2016)



III

EN1555-3+A1 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part3:Fittings

EN 1555-5 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part5:Fitnessforpurposeofthesystem

CEN/TS1555-7 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part7:Guidanceforassessmentofconformity

EN12201-1 Plasticspipingsystemsforwatersupply-Polyethylene(PE)-Part1:General

EN12201-2+A1 Plasticspipingsystemsforwatersupply-Polyethylene(PE)-Part2:Pipes

EN12201-3+A1 Plasticspipingsystemsforwater-Polyethylene(PE)-Part3:Fittings

EN12201-5 Plasticspipingsystemsforwatersupply,andfordrainageandsewerageunderpressure-Polyethylene(PE)-Part5:Fitnessforpurposeofthesystem

CEN/TS12201-7 Plasticspipingsystemsforwatersupply,andfordrainageandsewerageunderpressure-Polyethylene(PE)-Part7:Guidancefortheassessmentofconformity

AS/NZS4129 Fittingsforpolyethylene(PE)pipesforpressureapplications

2.2.2 Relevant standards and guidelines for processing

Standard Name

ISO/TS 10839 Polyethylenepipesandfittingsforthesupplyofgaseousfuels-Codeofpracticefordesign,handlingandinstallation

ISO12176-1 Plasticspipesandfittings–Equipmentforfusionjointingpolyethylenesystems–Part1:Buttfusion

ISO12176-2 Plasticspipesandfittings–Equipmentforfusionjointingpolyethylenesystems–Part2:Electrofusion

ISO12176-3 Plasticspipesandfittings-Equipmentforfusionjointingpolyethylenesystems-Part3:Operator‘sbadge

ISO12176-4 Plasticspipesandfittings–Equipmentforfusionjointingpolyethylenesystems–Part4:Traceabilitycoding

EN12007-2 Gasinfrastructure-Pipelinesformaximumoperatingpressureuptoandincluding16bar-Part1:Generalfunctionalrequirements;GermanversionEN12007-1:2012

PAS1075 PipesmadefromPolyethyleneforalternativeinstallationtechniques–Dimensions,technicalrequirementsandtesting

DVS2202 Evaluationofjointsbetweenthermoplasticsonpipingpartsandpanels-Characteristics,description,evaluation

DVS2202Supplement-1

Evaluationofimperfectionsinjointsofthermoplasticmaterialstopipingpartsandpanels.–heatedplatewelding(HS,IR)

DVS2202Supplement-2

Evaluationofjointsbetweenthermoplasticsonpipingpartsandpanels-Sleeveweldingwithanincorporatedheatingelement(HM)

DVS2205-1Supplement6

Calculationoftanksandapparatusmadeofthermoplastics-Weldingfactors

DVS2207-1 Fusioningofthermoplastics-Heatedtoolfusionofpipes,pipelinecompo-nentsandsheetsmadeofPE

DVS2210-1 Industrialpipelinesmadeofthermoplastics-Planningandexecution-Abo-ve-groundpipesystems


Industrialpipingmadeofthermoplastics-Designandexecution-Abo-ve-groundpipesystems-Calculationexample


Industrialpipingmadeofthermoplastics-Designandexecution-Abo-ve-groundpipesystems-Recommendationsfortheinternalpressureandleaktests


Industrialpipingmadeofthermoplastics-Designandexecution-Abo-ve-groundpipesystems-Flangeconnections:Description,requirementsandassembly

DVS2210-2 IndustrialPipingmadeofThermoplastics -Design,StructureandInstalla-tionofTwo-pipeSystems

T3.4 Relevant standards and guidelines for processing (edition: June 2016)



2.2.3 Relevant standards and standards met for valves

Standard Name

EN 1555-4 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)-Part4:Valves

EN12201-4 Plasticspipingsystemsforwatersupply-Polyethylene(PE)-Part4:Valves

EN 593 Industrialvalves-MetallicbutterflyvalvesENISO16135 Industrialvalves-BallvalvesofthermoplasticmaterialsENISO16136 Industrialvalves-ButterflyvalvesofthermoplasticmaterialsENISO16137 Industrialvalves-CheckvalvesofthermoplasticmaterialsENISO16139 Industrialvalves-GatevalvesofthermoplasticmaterialsENISO21787 Industrialvalves-ValvesofthermoplasticmaterialsISO4437-4 Plasticspipingsystemsforthesupplyofgaseousfuels-Polyethylene(PE)

-Part4:Valves

2.2.4 Relevant standards and guidelines for flanges and gaskets

Standard Name

EN681-1 Elastomericseals-Materialrequirementsforpipejointsealsusedinwateranddrainageapplications-Part1:Vulcanizedrubber

EN681-2 Elastomericseals-Materialrequirementsforpipejointsealsusedinwateranddrainageapplications-Part2:Thermoplasticelastomers

ISO7005-1 Pipeflanges-Part1:Steelflangesforindustrialandgeneralservicepipingsystems

ISO7005-2 Metallicflanges-Part2:Castironflanges

ISO7005-3 Metallicflanges-Part3:Copperalloyandcompositeflanges

ISO7483 DimensionsofgasketsforusewithflangestoISO7005

ISO7483TechnicalCorrigendum1

DimensionsofgasketsforusewithflangestoISO7005;TechnicalCorrigendum1

ISO9624 Thermoplasticspipesforfluidsunderpressure-Matingdimensionsofflangeadaptersandloosebackingflanges

EN ISO 15494 Plasticspipingsystemsforindustrialapplications-Polybutene(PB),polyethylene(PE)andpolypropylene(PP)-Specificationsforcomponentsandthesystem-Metricseries

EN558+A1 Industrialvalves-Face-to-faceandcenter-to-facedimensionsofmetalvalvesforuseinflangedpipesystems-PNandClassdesignatedvalves

EN1092-1+A1 Circularflangesforpipes,valves,fittingsandaccessories,PNdesignated–Part1:Steelflanges

EN1092-2 Flangesandtheirjoints-Circularflangesforpipes,valves,fittingsandaccessories,PNdesignated-Part2:Castironflanges

EN 1514-8 Flangesandtheirjoints-DimensionsofgasketsforPN-designatedflangesPart8:PolymericO-ringgasketsforgroovedflanges

EN 1515-1 Flangesandtheirjoints-Bolting-Part1:Selectionofbolting

ASMEB16.5 PipeFlangesandFlangedFittings:NPS1/2throughNPS24Metric/InchStandard

BS10:2009 Specificationforflangesandboltingforpipes,valvesandfittings

DVS2205-4 Calculationofthermoplastictanksandapparatuses-Flangedjoints


Calculationofthermoplastictanksandapparatuses-Fusionedflanges,fusionedcollars-Constructivedetails


Industrialpipingmadeofthermoplastics-Designandexecution-Above-groundpipesystems-Flangeconnections:Description,requirementsandassembly

JISB2220 Steelpipeflanges

JISB2239 Castironpipeflanges

T3.5 Standards and guidelines for valves (edition: June 2016)

T3.6 Standards and guidelines for flanges (edition: June 2016)



III

2.2.5 Relevant standards and guidelines for threads

Standard Name

ENISO228-1 Pipethreadswherepressure-tightjointsarenotmadeonthethreads-Part1:Dimensions,tolerancesanddesignation

EN10226-1 Pipethreadswherepressuretightjointsaremadeonthethreads- Part1:Taperexternalthreadsandparallelinternalthreads-Dimensions,tolerancesanddesignation

EN10226-2 Pipethreadswherepressuretightjointsaremadeonthethreads– Part2:Taperexternalthreadsandtaperinternalthreads–Dimensions,tolerancesanddesignation

2.2.6 Relevant standards and guidelines for malleable cast iron connectors

Norm Bezeichnung

ISO17885 Plasticspipingsystems.Mechanicalfittingsforpressurepipingsystems.Specifications

EN10284 Malleablecastironfittingswithcompressionendsforpolyethylene(PE)piping systems

EN 10344 Malleablecastironfittingswithcompressionendsforsteelpipes

T3.7 Standard and guidelines for threads (edition: June 2016)


Design and Laying

Content

1 Basic knowledge ......................................................................................................................411.1 Metric and British system of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2 Abbreviations and units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.3 SI-units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.4 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2 Design .......................................................................................................................................462.1 Long-termbehaviorofthermoplasticmaterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.2 Rangeofapplicationsforpipesandfittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.3 Calculationofallowablepressure/requiredwallthickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Water hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.5 Pipelines under vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3 Hydraulic Calcuation and Pressure Losses ...........................................................................653.1 Hydrauliccalculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.2 Pressureloss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4 Laying .......................................................................................................................................734.1 Pipe trenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.2 Trenchless laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.3 Processingandhandling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.4 Internalpressureandleaktest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.5 Disinfection of pipeline systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

IV


5 Jointing Technology .................................................................................................................825.1 Integralconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.2 Butt fusion jointing (heating element fusion conventional butt fusion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.3 Electrofusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.4 Basicinformationaboutweldingpreparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.5 Installationprocess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

5.6 CoolingtimesELGEFPluscoupler&fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.7 CoolingtimesforELGEFPlussaddles&PVTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.8 Mechanical joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.9 Transitionadapterwiththread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

5.10 Flange connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

5.11 MULTI/JOINT3000Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.12 iJOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.13 PRIMOFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.14 UNI-Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108


Design and LayingBasicknowledge

IV

1 Basic knowledge

1.1 Metric and British system of unitsTheessentialdifferencebetweenthemetricandtheBritishsystemofunitsliesinthefact

that one is based on the nominal diameter and the other on the outside diameter. The metric

system of units utilizes the outside diameter and the values are given in mm. The British

system utilizes the nominal diameter of the pipe and uses the inch system of units and

fractions thereof.

Conversions of metric and British system of units

Metric sizes Inch sizes

Pipe outer diameterdn (mm)

Nominal diameterDN (mm)

Nominal diameterDN (inch)

Pipe outer diameterdn (mm)

10 6 ⅛ 10.2

12 8 ¼ 13.5

16 10 ⅜ 17.2

20 15 ½ 21.3

25 20 ¾ 26.9

32 25 1 33.7

40 32 1¼ 42.4

50 40 1½ 48.3

63 50 2 60.3

75 65 2½ 75.3

90 80 3 88.9

- - 3½ 101.6

110 100 4 114.3

125 100 - -

140 125 5 140.3

160 150 6 168.3

180 150 - -

200 200 8 219.1

225 200 8 219.1

250 250 9 244.5

280 250 10 273.0

315 300 12 323.9

355 350 14 355.6

400 400 16 406.4

450 450 18 457.2

450 500 20 508.0

500 500 20 508.0

560 600 22 558.2

630 600 24 609.6

- - 26 660.4

710 700 28 711.2

- - 30 762.0

800 800 32 812.8

- - 34 863.6

900 900 36 914.4

1000 1000 40 1016.0

1200 1200 48 1219.2

1400 1400 56 1422.4

1600 1600 64 1625.6

2000 2000 80 2032.0


Basicknowledge

1.2 Abbreviations and units of measure

1.2.1 Abbreviations for materials

Abbreviation Name

ABS Acrylonitrile-butadiene-styreneCR Chloroprene rubber, e.g. neoprene

EPDM Ethylenepropylenerubber

FKM Fluororubber

GFK Glass-fiberreinforcedplastics

Ms Brass

NBR Nitrilerubber

NR Naturalrubber

PB Polybutylene

PE Polyethylene

PE-X Crosslinkedpolyethylene

PP Polypropylene

PTFE Polytetrafluorethylene

PVC Polyvinylchloride

PVC-C Polyvinylchloride postchlorinated (increased chlorine content

PVC-U Polyvinylchlorideplasticizer-free

PVDF Polyvinylidenefluoride

TG Malleable cast iron

UP-GF Unsaturatedpolyesterresin,fiberglass-reinforced

POM Polyoxymethylene (Polyacetal)

1.2.2 Abbreviations for procedures

Abkürzung Bezeichnung

C Design factor Coefficientwithavaluegreaterthanone,whichtakesaccountofboththeoperatingconditionsand the properties of the components of a pipelinesystemnotyetrecordedinthelowerconfidencelimit.

S Pipe series Dimensionlesskeyfigurefordesignatingpipes; S=(SDR-1)/2

SDR Standard dimension ratio Whole-numbernumerickeyfigureforapipeseries that approximately corresponds to the ratiobetweenthenominaloutsidediameterofapipeanditsnominalwallthickness

MFR Meltmass-flowrate Valuethatrelatestotheviscosityofameltedmassthatispressedthroughadiewithaparticularweightatapredefinedtemperature

MRS Minimumrequiredstrength ValueofσLCL(lowerconfidencelimitofthepredicted resistance to internal pressure) at 20 °C and 50 years



IV

1.2.3 Abbreviations for Dimensions and units

Abkürzung Bezeichnung

d,d1,d2,d3,d4

Outerdiameter

DN Nominaldiameter

dn Nominalouterdiameter(EN1555/EN12201)

SC Size of hexagon head bolts

AL Numberofboltholes

s Wrench size

g Weight in grams

e Wallthicknessofpipe

PN Nominalpressureat20°C,water

Rp Cylindricalinnerpipethreadacc.toISO7-1

R Conicalouterpipethreadacc.toISO7-1

ppm Parts per million

1 bar =0.1N/mm²= 0.1 MPa= 14.504 psi

1.3 SI-units

1.3.1 SI base units

Basis sizeName Sign

SI base unitsName Sign

Length l Meter mMass m Kilogram kg

Time t Second sElectriccurrent l Ampere AThermodynamic temperature

T Kelvin K

Amount of substance n Mole molLuminous intensity ln Candela cd

1.3.2 Internationally defined prefixes

MeaningPrefixName Sign

Factor asDecimal power Decimal number

Quintillion exa E 1018 = 1 000 000 000 000 000 000Quadrillion peta P 1015 = 1 000 000 000 000 000

Trillion tera T 1012 = 1 000 000 000 000Billion giga G 109 = 1 000 000 000Million mega M 106 = 1 000 000Thousand kilo k 103 = 1 000Hundred hecto h 102 = 100Ten deca da 101 = 10Tenth deci d 10-1 = 0.1Hundredth centi c 10-2 = 0.01Thousandth milli m 10-3 = 0.001Millionth micro μ 10-6 = 0.000 001Billionth nano n 10-9 = 0.000 000 001Trillionth pico p 10-12 = 0.000 000 000 001Quadrillionth femto f 10-15 = 0.000 000 000 000 001Quintillionth atto a 10-18 = 0.000 000 000 000 000 001

Dimensions must be listed in mmand/orinchandrefertonominal or standard dimension. Subject to construction and design changes.


Basicknowledge

1.3.3 Units

Size Sign SI unit Permissible units outside of SI

Conversion into corresponding SI unit and relationships

Units and conversions no longer permissible

Length I m 1” = 0.0254 m1 Sm = 1852 m

Area A m2 1 b = 10-28 m2

1 a = 102 m2

1 ha = 104 m2

sqm,sqdm,sqcm

Volume V m3 l 1 l = 10-3 m3

Solid angle Ω SR 1 sr = 1 m2/m2 1°=3.046•10-4 sr1g=2.467•10-4 sr

Time t s minhd

1 min = 60 s1h=3600s1 d = 86 400 s

Frequency f Hz 1Hz=1/s

Speed, rotationalfrequency

n s-1 min-1

U/min1 min-1(1/60)s-1

1U/min=1(1/min)

Velocity v m/s km/h 1km/h=(1/3.6)m/s

Acceleration g m/s2 Standard gravitational acceleration gn=9.80665m/s2

1 Gal = 10-2m/s2

Mass m kg t 1t=10³kg 1q=50kg

Density ρ kg/m3 t/m3 kg/l

1t/m3=1000kg/m3

1kg/l=1000kg/m3

Moment of inertia J kg•m2 1kp•ms2=9.81kg•m2

Force F N 1N=1kg•m/s2 1 dyn = 10-5N1p=9.80665•10-3N1kp=9.80665N

Torque M N•m 1kpm=9.80665Nm1Nm=0.7375lb-ft

Pressure p Pa bar 1Pa=1N/m2

1 bar = 105 Pa1atm=1.01325bar1at=0.980665bar1Torr=1.333224•10-3 bar1mWS=98.0665•10-3 bar1mmHg=1.333224•10-3bar

Stress σ N/m2 Pa

1N/m2 = 1 Pa 1kp/m2=9.80665N/m2

1kp/cm2=98.066510-3N/m2

1kp/mm2=9.80665•10-6N/m2

Dynamic viscosity Pa•s 1Pa•s=1N•s/m2 1 P (Poise) = 10-1Pa•s

Kinematic viscosity m2/s 1 m2/s=1Pa•s•m3/kg 1St(Stokes)=10-4 m2/s

Workenergy W E

J eVW•h

1J=1Nm=1WS1W•h=3.6KJ

1cal=4.1868J1kpm=9.80665J1 erg = 10-7J

Electriccharge Q C 1C=1A•s

Electricvoltage U V 1V=1W/A

Electriccurrent I A

Electricresistance R Ω 1Ω=1V/A 1Ωabs=1Ω

Power P W 1W=1J/s=1Nm/s 1W=1V•A

1PS=735.498W1kcal/h=1.163W1kpm/s=10W

Electriccapacitance C F 1F=1C/V

Magneticfieldstrength H A/m 1Oe=79.5775A/m

Magneticflux Φ Wb 1Wb=1V•s 1 Mx = 10-8 Wb

Magneticfluxdensity B T 1T=1Wb/m2 1 G = 10-4 T

Inductance L H 1H=1Wb/A

Electricconductance G S 1S=1/Ω

Thermodynamic temperature

T K Δ1°C=Δ1KO°C=273.15K

Celsius temperature t, δ °C Δ1°C=Δ1KOK=-273.15°C

Thermal capacity C J/K 1Kcl/grad=4.186810-3J/K1Cl=4.1868J/K



IV

1.4 Conversion tables

1.4.1 Viscosities

Kin

emat

ic v

isco

sity

C

enti

stok

es d

ensi

ty

Abs

olut

e vi

scos

ity

cent

ipoi

se

Deg

ree

Eng

ler

Say

bolt

Uni

vers

al

seco

nd (S

SU

)

Red

woo

d

1 se

cond

(sta

ndar

d)

Say

bolt

Fur

ol

seco

nd

Ford

Cup

no.

4

seco

nd

Deg

ree

Bar

bey

Cup

no.

15

seco

nd

Abs

olut

e vi

scos

ity

pois

e de

nsit

y 1.

0

Kin

emat

ic

visc

osit

y m

²/s

1.0 1.0 1.0 31 29 - - - - 0.01 1.0 x 10-6

2.0 2.0 1.1 34 30 - - 3640 - 0.02 2.0 x 10-6

3.0 3.0 1.2 35 33 - - 2426 - 0.03 3.0x10-6

4.0 4.0 1.3 37 35 - - 1820 - - 4.0 x 10-6

5.0 5.0 1.39 42 38 - - 1300 - 0.05 5.0 x 10-6

6.0 6.0 1.48 45.5 40.5 - - 1085 - 0.06 6.0 x 10-6

7.0 7.0 1.57 48.5 43 - - 930 - 0.07 7.0 x 10-6

8.0 8.0 1.65 53 46 - - 814 - 0.08 8.0 x 10-6

9.0 9.0 1.74 55 48.5 - - 723 - 0.09 9.0x10-6

10 10 1.84 59 52 - - 650 - 0.10 1.0 x 10-5

20 20 2.9 97 85 15 - 320 - 0.2 2.0 x 10-5

40 40 5.3 185 163 21 - 159 - 0.4 4.0 x 10-5

60 60 7.9 280 245 30 18.7 106 5.6 0.6 6.0 x 10-5

80 80 10.5 370 322 38 25.9 79 6.7 0.8 8.0 x 10-5

100 100 13.2 472 408 47 32 65 7.4 1.0 1.0 x 10-4

200 200 26.4 944 816 92 60 32.5 11.2 2.0 2.0 x 10-4

400 400 52.8 1888 1632 184 111 15.9 18.4 4.0 4.0 x 10-4

600 600 79.2 2832 2448 276 162 10.6 26.9 6.0 6.0 x 10-4

800 800 106 3776 3264 368 217 8.1 35 8.0 8.0 x 10-4

1000 1000 132 7080 4080 460 415 6.6 68 10 1.0 x 10-3

5000 5000 660 23600 20 400 2300 1356 1.23 240 50 5.0 x 10-3

10 000 10 000 1320 47 200 40 800 4600 2713 - 481 100 1.0 x 10-2

50 000 50 000 6600 236000 204 000 23000 13560 - 2403 500 5.0 x 10-2

1.4.2 Flow volume

m3/h l/min l/s m3/s Imp. gal/min US gal/min cu. ft./h cu. ft./s

1.0 16.67 0.278 2.78•10-4 3.667 4.404 35.311 9.81•10-3

0.06 1.0 0.017 1.67•10-5 0.220 0.264 2.119 5.89•10-4

3.6 60 1.0 1.00•10-3 13.20 15.853 127.12 3.53•10-2

3600 60 000 1000 1.0 13200 15838 127 118 35.3110.2727 4.55 0.076 7.58•10-5 1.0 1.201 9.629 2.67•10-3

0.2272 3.79 0.063 6.31•10-5 0.833 1.0 8.0238 2.23•10-3

0.0283 0.47 0.008 7.86•10-6 0.104 0.125 1.0 2.78•10-4

101.94 1699 28.32 2.83•10-2 373.77 448.8 3600 1.0

1.4.3 Pressure and heads

bar kg/cm2 lbf/in2 atm ft H2O m H2O mm Hg in. Hg kPa

1.0 1.0197 14.504 0.9869 33.455 10.197 750.06 29.530 100

0.9807 1.0 14.223 0.9878 32.808 10 735.56 28.959 98.07

0.0689 0.0703 1.0 00609 2.3067 0.7031 51.715 2.036 6.89

1.0133 1.0332 14.696 1.0 33.889 10.332 760.0 29.921 101.3

0.0299 0.0305 0.4335 0.0295 1.0 0.3048 22.420 0.8827 2.99

0.0981 0.10 1.422 0.0968 3.2808 1.0 73.356 2.896 9.81

13.3•10-4 0.0014 0.0193 13.2•10-4 0.0446 0.0136 1.0 0.0394 0.133

0.0339 0.0345 0.4912 0.0334 1.1329 0.3453 25.40 1.0 3.39

1.0•10-5 10.2•10-6 14.5•10-5 9.87•10-6 3.34•10-4 10.2•10-5 75.0•10-4 29.5•10-5 1.0

Absolute viscosity (centipoise) = kinematicviscosity(centistokes)•densityover50centistokes-conversiontoSSUàSSU=centistokes•4.62

atm Internationalstandardatmosphere

kg/cm2 Metric atmosphere


Design

2 Design

2.1 Long-term behavior of thermoplastic materialsOneofthemostimportantcharacteristicsofplasticpipesistherealisticservicelifeofapipe

thatissubjectedtointernalpressure.Thischaracteristicisreferredtoaslong-termbehavior.

Whendeterminingthelong-termbehavior,thetemperatureandtheflowmediumplayan

essential role.

2.1.1 MRS-values

Wedifferentiatebetweenthepropertiesrelatingtothecreepbehaviorofthepressurepipe

plasticsusingastandardizedclassificationsystem.Thestartingpointforclassificationisthe

determinationofthechartsforlong-termfailureunderinternalhydrostaticpressureandthe

evaluation of these charts based on standard extrapolation methods. The maximum stress

overtimeatconstanttemperatureisdetermined.TheLTHS(long-termhydrostaticstrength)

expected value forms the theoretical curve for the determined test values. The stress

determinedinthiswayat50years(roundedtothenext-loweststandardpreferrednumber)

formstheMRS(minimumrequiredstrength)value–thematerial-specificminimumstrength.

ClassificationofPEmaterials:

Material MRS-Wert(MPa)

σLCL

PE63 6 6.3-7.99PE80 8 8.0-9.99

PE100/PE100RC 10 10.0-11.19


Design and LayingDesign

IV

2.1.2 Long-term behavior of PE

Calculation (based on EN ISO 15494: 2015)

Thefollowingrepeatoflong-termbehaviorsofPE80andPE100.Forthetemperaturerange

from+10°Cto+80°C,linesoffracturearedisplayed.ThesearecalledLPLcurves(Lower

PredictableLimit);thismeansaccordingtothedefinitionthat97.5%ofallfracturepointsare

on or above the corresponding curve.

StraightlinesrepresentthelongtermpropertiesofPEinthehoopstressdiagram.

Thecurvesareplottedinadoublelogarithmicdiagram(notlinear),pleasetakethisinto

accountwhenreadingvaluesforstressortime.Thepressure-temperaturediagramthatwe

provideforpipesandfittingsmadeofPE80andPE100isderivedfromthelong-termbeha-

vior, including the design factor, for a service life of 25 years.

Thelong-termvalueshavebeencalculatedbyusingtheextrapolationmethodaccordingto

ENISO9080.Withthefollowingequation(3-parametermodel),whichwasderivedfromthat

diagram, stress, temperature or time can be calculated for the temperature range of

+10 °C to 80 °C.

First branch(left-handportionofthecurvesasshowninthefollowinglong-termbehaviors)

PE100

log t = –45.4008 + 28444.734 ⋅ – 45.9891 ⋅ log σ1T

PE80

log t = –42.5488 + 24078.8 ⋅ – 37.5758 ⋅ log σ1T

t Time to failure (h)T Medium temperature (K)σ Hoopstress(MPa)(1MPa=1N/mm2)


Design

Long-term behavior PE100 / PE100 RC (EN ISO 15494:2015)

X1 Time to failure, in hours (h)X2 Time to failure, in yearsY Hoopstress(MPa)

(1MPa=1N/mm²)



IV

Long-term behavior von PE80 (EN ISO 15494: 2015)

X1 Time to failure, in hours (h)X2 Time to failure, in yearsY Hoopstress(MPa)

(1MPa=1N/mm²)


Design

2.2 Range of applications for pipes and fittings

2.2.1 In general

The choice of material and the pressure rating of the pipe components are important for both

operatingsafetyandforattainingthespecifiedminimumservicelifeofthesystem.

Thedecisiveinfluencingfactorsarethefollowing:

• Operatingpressure

• Operatingtemperature

• Medium transported

• Duration of stress

Separatecalculationsarenecessaryifdesignfactorsaredifferentortheservicelifeis

modified.Thesuitabilityofthematerialfortheflowmediumcanbedeterminedfromthelist

of chemical resistance provided separately by GF Piping Systems.

2.2.2 Pressure-temperature diagram for PE

PE100

APEsystemisdesignedbasedonaverageoperatingconditionstakingaccountofthe

maximumvalues.Incontrasttometalpipelines,PEpipelinesaredesignedwiththeaimofa

guaranteed life. The average operating conditions must be used as the basis for this.

If,forexample,alineisexposedtoatemperatureof40°Cforonemonthatthehottesttime,

this is not the temperature used as the basis for the calculation. A more accurate value is the

annual average temperature. As a result, the line is not overdimensioned and is instead

designedexactlytomeettheoperatingconditionrequirements.Thedesignfactors,described

later, provide additional reliability.

Thefollowingpressure-temperaturediagramforPE100pipesandfittingsisvalidfora

service life of 50 years.

Thedesignfactorof1.25forwaterand2.0forgashasbeenincorporated.

Thediagramcanbeusedforwaterormediaresemblingwater,inotherwords,mediathat

have no reduction factor for chemical resistance.

Please take into account the pressure-temperature diagrams for valves and special

fittings. Because of the construction and/or sealing material used, differences are

possible when compared to pipes and fittings. More information is available in the

Planning Fundamentals of the relevant types of valves and special fittings.

In case of long-term operating pressure at temperatures above 40 °C, please contact

your authorized GF Piping Systems representative.



IV

G4.3 Pressure-temperature diagram for PE100, water

1 Design factor C = 1.25, S5, SDR11for20°Cwater, 50 years

2 DesignfactorC=1.25,S8.3,SDR17.6 and S8, SDR17 for 20°Cwater,50years

P Permissible pressure (bar, psi)

T Temperature (°C, °F)

G4.4 Pressure-temperature diagram for PE100, gas

1 Design factor C = 2.0, S5, SDR11 fr 20 °C gas, 50 years

2 DesignfactorC=2.0,S8.3,SDR17o.6 and S8, SDR17 for 20 °C gas, 50 years




Design

PE80

Thefollowingpressure-temperaturediagramforPE80pipesandfittingsisvalidforaservice

life of 50 years.

Thedesignfactorof1.25forwaterand2.0forgashasbeenincorporated.

Itcanbeusedforwaterormediaresemblingwater,inotherwords,mediathathaveno

reduction factor for chemical resistance.

Please take into account the pressure-temperature diagrams for valves and special

fittings. Because of the construction and/or sealing material used, differences are

possible when compared to pipes and fittings. More information is available in the

Planning Fundamentals of the relevant types of valves and special fittings.

In case of long-term operating pressure at temperatures above 40 °C, please contact

your authorized GF Piping Systems representative.

G4.5 Pressure-temperature diagram for PE80, water

1 Design factor C = 1.25, S5, SDR11for20°Cwater,50years

2 DesignfactorC=1.25,S8.3,SDR17.6 and S8, SDR17 for 20°Cwater,50years



G4.6 Pressure-temperature diagram for PE80, gas

1 Design factor C = 2.0, S5, SDR11 for 20 °C Gas, 50 years

2 DesignfactorC=2.0,S8.3,SDR17.6 and S8, SDR17 for 20 °C Gas, 50 years





IV

2.3 Calculation of allowable pressure/required wall thickness

2.3.1 Selecting plastic piping components

Dimensioning of thermoplastic pipes subjected to internal pressure strictly adheres to

strengthrequirementsandiscalculatedbyusingthevesselformula.Allpipedimensions

listedinthestandardsarebasedonthisformula.Deviationsonlyoccurinthelowerrangeof

diameters,sincepracticalandmanufacturingconsiderationsmakeitnecessarytomaintain

certainminimumpipewallthicknesses.

e =p ⋅ d

20 ⋅ σzul + p

e Pipewallthickness(mm)d Pipe outer diameter (mm)p Permissible operating pressure (bar)σzul Allowablehoopstress(N/mm²)

Nominal pressure PN

Thedesignation„nominalpressure“PN(alsoknownaspressurelevel)byitselfisnolonger

sufficient.ThePNclassificationgenerallyusedallovertheworldasinformationforpipe

dimensioningisratherconfusingwherebuttfusionisconcerned.

Inthecaseofplasticpipesestablishedpracticeistousepressure-neutraldescriptionsfor

pipesofthesamepressurecapacity.Thisavoidsincorrectuseofpipesindifferentapplica-

tionsorunderdifferentconditions.

ISO4065classifiespipesbyseriesaccordingtopressurerating,sothatpipeswiththesame

series number have the same pressure rating, as is also the case in designations according to

nominal pressure levels. The pipe series are denoted by the letter S. The series designation is

basedonthefollowingformula:

S is a dimensionless value.

S =10 ⋅ σzul

p ⋅ C =

d – e2 ⋅ e

e Pipewallthickness(mm)d Pipe outer diameter (mm)p Operatingpressure(bar,psi)C Design factor

Hence,aPPpipewithdimensiond110andwallthickness=10mmresultsin:

S = = 5(110 – 10)

(2 ⋅ 10)

ThedesignationSDR(StandardDimensionRatio)ismuchmorecommononthemarket.SDR

indicatestheratioofoutsidediametertowallthickness.

SDR =de

ThepipeseriesdesignationandtheSDRdesignationareconnectedbythisformula:

SDR = 2 ⋅ S + 1


Design

Inthecaseoftheexampleabove,thisresultsin:

SDR = 2 ⋅ 5 + 1 = 11

ThemarketprimarilyfeaturesthedesignationsPNandSDR.GFPipingSystemsrecommends

theuseofdimensionandwallthickness,aswellasSDRatalltimes.

2.3.2 Calculating the effective design factor / permissible operating pressure

Tocalculatethedesignfactorandallowableoperatingpressure,itisnecessarytoknowthe

long-termbehaviorofthematerial.Suchadiagramallowsthelong-termcreepstrengthtobe

readdependingonthedesiredservicelifeandoperatingtemperature.Forfittingsandvalves,

thewallthicknessisusuallygreaterthanforpipesofthesamepressurelevel.Forthis

reason,theoutsidediameterandwallthicknessofthepipeareusedtocalculatethedesign

factor.Thedesignfactoristhencalculatedbyusingthefollowingformula:

C =σs ⋅ 20 ⋅ e p ⋅ (d – e)

C Design factorσ Hoopstress(N/mm²)e Pipewallthickness(mm)d Pipe outer diameter (mm)p Operatingpressure(bar)

Similarly, the maximum permissible operating pressure is calculated by rewriting the formula above as:

20 ⋅ e ⋅ σs

Cp =

d – e

Example – Calculating the design factor and operating pressure

Intendedservicelife

Max. operating temperature

Max. operating pressure

Material

Intendedpressurelevel

Outsidediameter

Wallthickness

Hoopstress

50Jahre

+20 °C

10 bar

PE100

PN16bar

110 mm

10 mm

8.52N/mm2

C = = 2.0 > 1.2510 ⋅ 20 ⋅ 10 10 ⋅ (110 – 10)

Forthesakeofclarity,thecalculationsarecarriedoutusingtheexampleabove,but

usingtheusualminimumdesignfactorforPE100.

p = = 16 bar(110 – 10)

20 ⋅ 10 ⋅ 101.25



IV

The calculation shown applies only to freely moving pipelines. Pipes that are fi xed in

the axial direction (fi xed installation) must be checked for buckling. In most cases such

a check leads to a reduction of maximum inner pressure, as well as shorter distances

between the support brackets. Furthermore, the forces that act on the fi xed points

must be taken into account. Contact your authorized GF Piping Systems representative

for additional information.

2.4 Water hammerWater hammer is a term used to describe dynamic surges caused by pressure changes in a

pipingsystem.Theyoccurwheneverthereisadeviationfromthesteadystate,e.g.whenthe

flowrateischanged,andmaybetransientoroscillating.

Waterhammersmaybegeneratedbythefollowing:

• Openingorclosingavalve

• Pumpstartuporshutdown

• Change in pump or turbine speed

• Waveactioninafeedtank

• Trapped air

Thepressurewavecreatedbywaterhammerscausesthepipingsystemtoexpandand

contract.Intheprocessthepropagationspeedofthepressurewaveislimitedbythespeedof

soundinthecorrespondingmedium.Theenergycarriedbythewaveisdissipatedinthe

pipingsystemandthewavesareprogressivelydamped,seethefollowingfigure:

Themaximumpositiveornegativeadditionofpressureisafunctionofflowrate,bulk

modulusofelasticityofthefluid,pipedimensionandthemodulusofelasticityofthepipe

material.Itcanbecalculatedbyusingthefollowingsteps.

G4.7 Damped pressure wave

l Wave lengthp Pressure change


Design

a Determine the velocity of the pressure

Vw =K

ρ ⋅ 1 + K ⋅ di

e ⋅ EVw Velocityofpressurewave(m/s)K Bulkmodulusofelasticityoffluid(Pa)ρ Fluiddensity(kg/m³)E Modulusofelasticityofpipewall(Pa)di Innerdiameterofpipe(mm)e Pipewallthickness(mm)

Themodulusofelasticityofpipesmadeofthermoplasticpolymersvarieswiththeoperating

durationandtemperature.Hence,operatingdurationandtemperaturemustbeknownfora

precisecalculationofwaterhammers.

s Calculate maximum pressure change due to water hammers

∆p = Vw ⋅ ∆v ⋅ ρ / 10000

Δp Maximumpressurechange(bar)Vw Pressurewavevelocity(m/s)(seestep1)Δv Changeinfluidvelocity(m/s)=(v1-v2)v1 Velocityoffluidbeforechange(m/s)v2 Velocityoffluidafterchange(m/s)ρ Fluiddensity(kg/m³)

Allpressureincreasesinducedbyaflowreductionwillhaveacorrespondingpressuredrop

ontheotherside(vacuum).Ifthisexceedstheexpectedstaticminimumoperatingpressure,

thecalculatedpressuremustbecomparedtothepressureatwhichthepipecollapsesin

order to evaluate the safety factor in step 4.

d Calculate the maximum and minimum total pressure

pmax = p + ∆p

pmin = p – ∆p

pmax Maximum total pressure (bar)pmin Minimum total pressure (bar)p Expectedoperatingpressure(bar)Δp Changeduetowaterhammer(calculatedinstep2)

f Calculate the effective safety factor

Cmax =20 ⋅ σ ⋅ e

pmax ⋅ (d – e)

Cmax Safety factor (dimensionless)σ Circumferentialstress(N/mm²)t Pipethickness(mm)d Outsidediameterofpipe(mm)pmaxMaximumtotalpressure(bar)(calculatedinstep3)

Thevalueforthecircumferentialstresscanbefoundinthecreepcurves.Asmostwater

hammers last for a matter of seconds, the value for a load duration of 0.1 h can be used. The

exceptiontothisruleiswhenthewaterhammersareoscillating(e.g.fromapositivedispla-

cementpump).Inthiscasethesystemmustbetreatedasifaloadequaltothemaximumtotal

pressure (pmax) existed throughout the entire service life of the pipe.



IV

g Safety factors

Forinfrequentwaterhammersthecommonminimumvaluescanbeusedassafetyfactors.

Forperiodicwaterhammersthefactorshouldbeatleast3.

Ifthesafetyfactorfoundinstep4doesnotmeetthesecriteriaforsafeoperation,anincrease

inpipediametershouldbeconsidered,ormeasuresshouldbetakentoreducetheoccur-

renceofwaterhammers(e.g.poweredvalves,surgetanks,slowstart-uppumps).

Whenusingpoweredvalves,valvesarecommonlydesignedwithclosuretimesgreaterthan

the critical period Tctoreducewaterhammer.Thecriticalperiodisthetimeapressurewave

needs to complete one cycle in the pipeline.

Tc =2 ⋅ LVw

Tc Critical period (s)L Pipe length (m)Vw Pressurewavevelocity(m/s)(seestep1)

Example

Awaterpipelinefromastoragetankisconnectedtoamainvalvethatishydraulically

activatedwithanelectricalremotecontrol.Thevalveclosingtimeis1.5sandthewater

flowrateisQ=35m³/h.

Material

Outsidediameter

Wallthickness

Nominalpressure

Pipeline length

Operatingtemperature

Modulus of elasticity

Water density

Bulkmodulusofelasticityof

water

PE100

110 mm

10 mm

PN16(SDR11)

500 m

20 °C

E=1320N/mm2=1320x106 Pa

ρ = 103kg/m3

K = 2.05 GPa

a Calculating the velocity of the pressure wave

Vw = = 370 m/s2.05 ⋅ 109

103 ⋅ 1 + 90 ⋅ 2.05 ⋅ 109

10 ⋅ 1320 ⋅ 106

s Calculating the fluid velocity before the change

v1 =VolumendurchsatzQuerschnittsfläche

353600 m3/s

v1 =π ⋅ m20.09

2

2 = 1.53 m/s


Design

Assumewatervelocitygoestozeroafterthevalveisclosed,i.e.Δv=1.53m/s.

Pressure change∆p = 370 ⋅ (1.53) ⋅ 1000/1000 = 5.65 bar

d Calculating the maximum pressure

pmax = 16 + 5.65 = 21.65 bar

Δpislessthenp.Hence,theminimumpressuredoesnothavetobetakenintoaccount.

f Calculating the circumferential stress

FindthecircumferentialstressinthePP-Hlong-termbehavior.Takethevalueforaload

durationof0.1has,fornon-oscillatingwaterhammers,thepipeneedstowithstandthisextra

pressure for only a matter of seconds.

σ=13.9N/mm2

C =20 ⋅ σ ⋅ e

pmax ⋅ (d – e)

C = = 1.2820 ⋅ 13.9 ⋅ 10

21.65 ⋅ (110 – 10)

g Calculating the maximum safety factor

TheminimumsafetyfactorforPE100canbesetto1.25.Here,C=1.28>1.2,sothispipingis

suitableforinfrequentwaterhammers.Howeveritwouldnotbesuitableifperiodicwater

hammersoccurred,becauseinthatcasewewouldneedC>3.Pipedimensionsorvalve

closingtimewouldneedtobeadjustedinordertoreducewaterhammer.

Calculating the critical period

Tc = = = 2.70 s2 ⋅ LVw

2 ⋅ 500 m370 m/s

Inthisexample,thevalveclosingtimeislessthanthevalueofthecriticalperiod.Byincrea-

singtheclosingtimeabovethiscriticalperiod,waterhammerwouldbereduced.Thepiping

wouldthenbesuitableforallsituationsinvolvingperiodicwatersurges.



IV

2.5 Pipelines under vacuumThemechanicalloadatabsolutevacuumcorrespondstoadifferentialpartialvacuumof1bar,

i.e.theeffectivepressureonthepipe‘sinnerwallis1barlessthanthepressureontheouter

wallatstandardatmosphericpressure.

Incaseofadifferentialpartialvacuumspecialattentionmustbepaidtothedimensional

stabilityofthepipe.Itcanbecalculatedwiththeclassicbucklingformulaforcylindrical

pipes:

Pk = ⋅Ec

4 ⋅ (1 – µ2)er

3

Pk Criticalbucklingpressure(N/mm²)(1N/mm²=10bar)Ec Long-termcreepmodulus(N/mm²)μ Poisson‘sratioe Pipewallthickness(mm)r Mean pipe radius (mm)

Apipeatabsolutevacuum(differentialpartialvacuum1bar)isadequatelydimensioned

againstbucklingwhenthecriticalbucklingpressurePk=2bar,i.e.whenaminimumdesign

factorof2isusedforcalculation.Anyinfluencecausedbyout-of-roundnessandeccentricity

mustbetakenintoaccountseparately.Undertheseassumptions,thefollowingmaximum

applicationtemperaturesariseforthevariouspipematerials(takingintoaccountthegeneral

applicationtemperaturelimitsforthespecificmaterial),seethetablebelow.Thinner-walled

pipe series are unsuitable for these conditions.

(25yearvalues:Poisson‘sratioμ=0,4;designfactor=2)

2.5.1 Pipes and fittings

Maximum application temperatures under vacuum (1 bar differential partial vacuum)

Material PN(bar)

SDR Temperature(°C)

PE80 10 11 50PE100 / PE100 RC 16 11 60

2.5.2 Mechanical connections

Similartofittings,mechanicalconnectionsfeatureasignificantlygreaterwallthickness

comparedtopipes.However,thevacuumresistanceofthegasketsmustbeobserved.The

permissiblevacuumformechanicalconnectionsislistedinthefollowingtable:

Connection type Permissible vacuum (differential partial vacuum) (bar)

Union 1Threaded connection 1

Flangeconnection,flatgasket Notpossible

Flangeconnection,profileseal 1

Flangeconnection,O-ringseal 1


Design

2.5.3 Laying in industrial applications

Intheclassicalapplicationof“pipelinesystemsforutilities,”pipelinesareusuallylaidinthe

groundandthetrenchesarerefilledoncethepipelineconstructionworkhasbeencompleted.

As a result, the ambient temperatures are very constant and changes in length are prevented

by the surrounding earth.

Incontrast,whenlinesarelaidinindustrialapplications,particularattentionmustalsobe

paidtothefollowingpoints:

• Changesinlengthasaresultoftheeffectsoftemperature

• Deflections

• Choice of suitable connection technology

Special construction measures must be investigated and implemented to counteract this

influencingfactor.Thesecanincludetheinstallationofbends,pipebracketsandcompensa-

tors. Detailed documents relating to pipeline systems made of polyethylene and other

materialscanbefoundinthe“IndustrialPipelineSystems”planningfundamentals.

2.5.4 Calculation of length changes

Thechangeinlengthcausedbytemperaturecanbecalculatedusingthefollowingformula:

∆L = L ⋅ ∆T ⋅ αΔL Temperature-relatedlengthchange(mm)L Length of the pipe section (m)ΔT Differenceoftemperature(K)α Coefficientoflinearexpansion(mm/mK)

Coeffi cients of linear expansion of polymers

Material α = mm/m K

PE 0.15 – 0.20

ExactvaluescanbecalculatedusingGFPipingSystems‘onlinetool

(www.cool-fit.georgfischer.com)orrequesteddirectlyfromtheauthorizedGFPipingSystems

representative.

If the operating temperature is higher than the installation temperature, then the pipe

expands. If, on the other hand, the operating temperature is lower than the installation

temperature, then the pipe contracts in length.

The installation temperature must therefore be incorporated into the calculations as

wellasthemaximumandminimumoperatingtemperatures.

Itispreferabletouse“+”toindicateexpansionofthepipeand“-”toindicate

contraction.

Thelargerchangeinlengthistheonetobeusedfordeterminingtherequiredlength

oftheflexiblesection.



IV

2.5.5 Calculation of flexible sections

Therequiredlengthoftheflexiblesectioncanbecalculatedusingthefollowingformula:

LB =3 ⋅ da ⋅ ∆L⋅ Ecm

σb

LB Lengthofflexiblesection(mm)da Pipe outer diameter (mm)ΔL Lengthchange(mm)Ecm Averagebendingcreepmodulusfort=25a(N/mm²)σb Permissiblebendingstressfort=25a(N/mm²)

Because Ecm and σb are dependent on time, temperature and stress, it is difficult to

calculate LB. Therefore the following diagrams should be used instead of the formula.

2.5.6 Pipe clamping distance and fastening of installation of pipes

Overview

Installation of plastic pipes

Plasticpipesshouldbeinstalledusingsupportsdesignedforusewithplasticsandshould

thenbeinstalledtakingcarenottodamageoroverstressthepipe.

Arranging loose brackets

Aloosebracketisapipebracketwhichallowsaxialmovementofthepipe.Thisallows

stress-freecompensationoftemperaturechangesandcompensationofanyotheroperating

condition changes.

Movementofthepipeinthepipebracket.

Pipebracketfirmlyinstalledonthepipe,

movementinthebracketsuspension.

Movement of the pipe in 2 axes.

Theinnerdiameterofthebracketshouldbelargerthantheouterdiameterofthepipeto

allowfreemovementofthepipe.Theinneredgesofthebracketsshouldbefreefromany

sharp contours to avoid damaging the pipe surface.

Anothermethodistousebracketswithspacersintheboltswhichalsoavoidsclampingthe

bracketonthepipe.


Design

Anothermethodistousebracketswithspacersintheboltswhichalsoavoidsclampingthe

bracketonthepipe.

Theaxialmovementofthepipingmaynotbehinderedbyfittingsarrangednexttothepipe

bracketorotherdiameterchanges.

Slidingbracketsandhangingbracketspermitthepipetomoveindifferentdirections.

Attachingaslidingblocktothebaseofthepipebracketpermitsfreemovementofthepipe

alongaflatsupportingsurface.Slidingandhangingbracketsareneededinsituationswhere

thepipelinechangesdirectionandfreemovementofthepipemustbeallowed.

Arranging fixed points

Afixedpipebracketisabracketwhichpreventsthepipefrommovinginanydirection.The

purposeofafixedpointistocontrolsystemstressescausedbytemperaturechanges.

Fixed point design

Thepipemustnotbefixedbyclampingitinthepipebracket.Thiscancausedeforma-

tion and physical damage to the pipe, damage that sometimes does not appear until

very much later.

Ifitisnecessarytorestrictthelengthchangeofthepipeatbothends–asitisusuallythecase–thenthepipebracketshouldbearrangedbetweentwofittingsordesignedasadoublebracket(two-sidedfixedpoint).

Placingapipebracketimmediatelyadjacenttoafittingrestrictsmovementduetochangesinlengthtoonedirection(one-sidedfixedpoint).

Onesidedfixedpoint

Twosidedfixedpoint

Pipe brackets must be robust and mounted firmly to be able to take up the forces arising from changes in length in the pipeline. Hanging brackets or KLIP-IT pipe brackets are unsuitable for use as fixed points.

G4.8 Spacers prevent clamping the pipe



IV

KLIP-IT pipe brackets

Theserobustplasticpipebracketscanbeusednotonlyunderrigorousoperatingconditions,

butalsowherethepipeworkissubjecttoaggressivemediaoratmosphericconditions.Pipe

bracketsandpipeclampsfromGFPipingSystemsaresuitableforallpipematerialsused.

DonotuseKLIP-ITpipebracketsasfixedpoints!

Startingfromthedimensiond90,theKLIP-ITbracketsmustbeinstalledstanding,asshown

inthefollowingassemblyexamples.

T4.8 Pipe brackets for cold insulation MIP

Openhandle Insertpipe,closehandlewithquickactionclamp

Assemble insulation1.Peelofffoil2. Press on contact area

Pushinsulationintothebracket.Caution:Makesuretherigidfoamispositionedcorrectly.

Tightenthescrew Coatcontactareaswithadhesiveandbond the insulation

Using information for pipe spacing

Plastic pipelines must be supported at certain intervals depending in the material, average

pipewalltemperature,densityoftheflowmedium,pipediameterandpipewallthickness.

Thedistancesbetweenthepipeclmapswerecalculatedbasedonaparticularpipedeflection

(regardedaspermissible)betweentwobrackets.

Pipelines that are clamped in an axially rigid manner and permanently laid must be tested for

resistancetobuckling.Inmostcases,thistestleadstoareductionofthemaximuminternal

pressureandareductionofthespacingbetweensupports.Furthermore,theforcesactingon

thefixedpointsmustbetakenintoconsideration.


Design

Bracket spacing for PE pipes

Liquids with a density of 1 g/cm3

d(mm)

Bracket spacing L for SDR11 pipes(mm)

≤ 20 °C 30 °C 40 °C 50 °C 60 °C

16 500 450 450 400 35020 575 550 500 450 400

25 650 600 550 550 50032 750 750 650 650 55040 900 850 750 750 65050 1050 1000 900 850 75063 1200 1150 1050 1000 90075 1350 1300 1200 1100 100090 1500 1450 1350 1250 1150110 1650 1600 1500 1450 1300125 1750 1700 1600 1550 1400140 1900 1850 1750 1650 1500160 2050 1950 1850 1750 1600180 2150 2050 1950 1850 1750200 2300 2200 2100 2000 1900225 2450 2350 2250 2150 2050250 2600 2500 2400 2300 2100280 2750 2650 2550 2400 2200315 2900 2800 2700 2550 2350355 3100 3000 2900 2750 2550400 3300 3150 3050 2900 2700450 3550 3400 3300 3100 2900500 3900 3650 3500 3350 3100

ForotherSDRvalues,multiplythevaluesbythefollowingfactors:

• SDR17andSDR17.6:0.91

• SDR7.4:1.07

Thepipebracketspacinggiveninthetablemaybeincreasedby30%inthecaseofvertical

piperuns,i.e.,multiplythevaluesgivenby1.3.

Liquids with a density other than 1g/cm3

Iftheliquidtobetransportedhasadensityotherthan1g/cm³,thenthebracketspacingsin

thetableaboveshouldbemultipliedbythefactorgiveninthefollowingtabletoobtain

differentsupportspacings.

Density of medium(g/cm3)

Type of medium Factors for bracket spacing

1.00 Water 1.001.251.501.752.00

Othermedia 0.960.920.880.84

≤0.01 Gaseous media 1.30forSDR111.21 for SDR7.4


Design and LayingHydraulicCalcuationandPressureLosses

IV

3 Hydraulic Calcuation and Pressure Losses

3.1 Hydraulic calculation

3.1.1 Required pipe diameter

Formulas

Thefollowingformulacanbeusedforafirstapproximationofthepipediameterrequiredfor

agivenflowrate:

18.8 ⋅di =Q1

v or 35.7 ⋅di =

Q2

v

v Flowvelocity(m/s)di Pipe inner diameter (mm)Q1 Flowrate(m³/h)Q2 Flowrate(l/s)18.8 Conversion factor for units Q1 (m3/h)35.7 ConversionfactorforunitsQ2(l/s)

Theflowvelocitymustbeapproximatedaccordingtotheintendeduseofthepipeline.

Standardvaluesfortheflowvelocityare:

Liquids

• v=0.5–1.0m/sforthesuctionside

• v=1.0–3.0m/sforthepressureside

Gases

• v=10–30m/s

Thecalculationsofpipediameterhavenottakenintoaccounthydrauliclosses.Theyhaveto

becalculatedseparatelyasdescribedinthefollowingsections.

(m3/h) (l/min) (l/s) (m3/s)

1.0 16.67 0.278 2.78 x 10-4

0.06 1.0 0.017 1.67 x 10-5

3.6 60 1.0 1.00 x 10-3

3600 60 000 1000 1.0

T4.9 Conversation table with units for flow rate


HydraulicCalcuationandPressureLosses

Example for calculating the inner diameter di

PE100pipe

FlowvolumeQ2

Flowvelocity

SDR11

8l/s

1.5m/s

35.7 ⋅di = = 82.4 mm8

1.5

ApipewithDN80(3”inch)isused.Afterdefiningtheinnerdiameter,therealflow

velocitycanbecalculatedwiththefollowingformula:

354 ⋅v = = 1.9Q1

di2

ms

1275 ⋅v = = 1.9Q2

di2

ms

v Flowvelocity(m/s)di Pipe inner diameter (mm)Q1 Flowrate(m3/h)Q2 Durchflussmenge(l/s)354 ConversionfactorforunitsQ1(m3/h)1275 ConversionfactorforunitsQ2(l/s)

Correlation of outer diameter – Inner diameter

TofindtheoutsidediameterusingtheinsidediameterandtheapplicableSDR,usethe

followingformula:

di ⋅d =SDR

SDR – 2

di

(mm)SDR11d (mm)

di

(mm)SDR17/17.6d (mm)

16 20 16 2020 25 21 25

26 32 28 3233 40 35 4041 50 44 5052 63 56 6361 75 66 7574 90 79 9090 110 97 110102 125 110 125115 140 124 140131 160 141 160147 180 159 180164 200 176 200184 225 199 225205 250 221 250229 280 247 280258 315 278 315290 355 313 355327 400 353 400368 450 397 450409 500 441 500458 560 494 560515 630 556 630581 710 626 710655 800 705 800

T4.10 Correlation of outside diameter to inside diameter for SDR11 and SDR17/17.6



IV

3.1.2 Nomogram for easy determination of diameter and pressure loss

Thefollowingnomogramsimplifiesthedeterminationoftherequireddiameter.Inaddition,

thepressurelossofthepipespermeterpipelengthcanbereadoff.

The determined pressure loss from the nomogram applies only to a density of the fl ow

medium of 1,000 kg/m³, e.g. for water. Further pressure losses of fi ttings, valves, etc.

have to be considered as shown in the following.

Using the nomogram

Basedonaflowvelocityof1.5m/s,alineisdrawnthroughthedesiredflowrate(e.g.30m³/h)

totheaxiswithaninnerdiameterofdi(≈84mm).Thenselectadiameternearby

(74mmforSDR11)anddrawa2ndlinethroughthedesiredflowrateuptothepressureloss

axisΔp(5mbarpermeterpipe).



Nomogram for pipes SDR11, SDR17/17.6, SDR33 using the metric system (water, H2O)



IV

Nomogram for inch pipes



3.2 Pressure loss

3.2.1 Pressure loss in straight pipes

Whencalculatingthepressurelossinstraightpipelengthsthereisadistinctionbetween

laminarandturbulentflow.TheimportantunitofmeasurementistheReynold‘snumber(Re).

Thechangeoverfromlaminartoturbulentflowoccursatthecriticalvalue,Reynold’snumber

Recrit=2,320.

Laminarflowoccurs,inpractice,particularlyinthetransportofviscousmediasuchas

lubricatingoils.Inthemajorityofapplications,includingmediasimilartowater,aturbulent

flow,havinganessentiallysteadiervelocitythanlaminarflowinacross-sectionofpipe,

occurs.

The pressure loss in a straight length of pipe is inversely proportional to the pipe diameter

andiscalculatedbythefollowingformula:

Ldi

∆pR = λ ⋅ρ

2 ⋅ 102⋅ ⋅ v2

ΔpR Pressure loss in a straight length of pipe (bar)λ Pipe friction factorL Length of the straight length of pipe (m)di Pipe inner diameter (mm)ρ Densityofflowmedia(kg/m3)(1g/cm³=1000kg/m3)v Flowvelocity(m/s)

In practice, when making a rough calculation (i.e. smooth plastic pipe and turbulent

flow) it is enough to use the value λ = 0.02 to represent the hydraulic pressure loss.

3.2.2 Pressure loss in fittings

Coefficient of resistance

Thepressurelossesdependuponthetypeoffittingaswellasontheflowinthefitting.The

so-calledcoefficientofresistance(ζ-value)isusedforcalculations.

Fitting type Coefficient of resistance ζbending radius R ζ-value

90°bend 1.0•d 0.511.5•d 0.41

2.0•d 0.344.0•d 0.23

45° bend 1.0•d 0.341.5•d 0.272.0•d 0.204.0•d 0.15

90°elbow 1.245°elbow 0.3Tee 1 1.3Reduction (contraction) 0.5Reduction (extension) 1.0Connections(flanges,unions,fusioningbetweentwopipes)

d>90mm:0.120≤d≤90mm:1.0to0.1:d20:1.0 d50:0.6d25:0.9 d63:0.4d32:0.8 d75:0.3d40:0.7 d90:0.1

1 Foramoredetailedview,differentiatebetweencoalescence and separa-tion.Valuesforzuptoamaximumof1.3canbefound in the respective literature. Usually the part of a tee in the overall pressure loss is very small, therefore in most cases ζ = 1.3canbeused.



IV

Calculation of pressure loss

Tocalculatethetotalpressurelossinallfittingsinapipeline,takethesumoftheindividual

losses, i. e. the sum of all the ζ-values.Thepressurelosscanthenbecalculatedaccordingtothefollowingformula:

∆pFi = Σζ ⋅v2

2 ⋅ 105 ⋅ ρ

ΔpFi Pressurelossoffittings(bar)Σζ Sum of the individual lossesv Flowvelocity(m/s)ρ Densityofthemediumtransportedinkg/m3(1g/cm3=1000kg/m3)

3.2.3 Pressure loss in valves

Thekv factorisaconvenientmeansofcalculatingthehydraulicflowratesforvalves.Itallows

forallinternalresistancesandforpracticalpurposesisregardedasreliable.Itisdefinedas

theflowrateofwaterinlitersperminutewithapressuredropof1baracrossthevalve.The

technicaldataoftheGFPipingSystemsvalvescontainsthekvvaluesaswellaspressureloss

charts.Thelattermakeitpossibletoreadoffthepressurelossdirectly.Butthepressureloss

canalsobecalculatedfromthekvvalueaccordingtothefollowingformula:

∆pAr =ρ

1000⋅Q

kv

2

ΔpAr Pressure loss of valve (bar)Q Flowrate(m3/h)ρ Densityofthemediumtransported(kg/m3)(1g/cm3=1000kg/m3)kv Valveflowcharacteristic(m3/h)

3.2.4 Pressure different from static pressure

Ifthepipelineislaidvertically,ageodeticpressuredifferencemustalsobecalculated.This

pressuredifferenceiscalculatedasfollows:

∆pgeod = ∆Hgeod ⋅ ρ ⋅ 10–4

Δpgeod Geodeticpressuredifference(bar)ΔHgeod Differenceinelevationofthepipeline(m)ρ Densityofmedia(kg/m3)(1g/cm3=1000kg/m3)



3.2.5 Sum of pressure losses

Thesumofallthepressurelossesinthepipelineisgivenby:

Σ∆p = ∆pR + ∆pFi + ∆pAr + ∆pgeo

Example of a pressure loss calculation

Thefollowingexampleshowsthecalculationtodeterminethepressurelossofa

pipeline:

PEpipe

SDR11flowrate

Medium

Density of medium

Length of straight pipe sections

Elevationdifference

d110 mm

10l/s

Wasser

1g/cm3

15 m

2.0 m

Number of fittings

12xelbow90°

4xelbow45°

3xtees

3xunions

2xflangeconnections

1xdiaphragmvalveTyp039,

100%opened

ThewallthicknessofthispipelinecanbecalculatedasfollowswiththeSDR:

e = = = 10 mmd

SDR110 mm

11

Theinnerdiameterofthepipelineisasfollows:

di = d – 2 ⋅ e = d – = 90 mm2 ⋅ dSDR

Withtherequiredflowrateof10l/s,theflowvelocityisasfollows:

v = 1275 ⋅ = 1275 ⋅ = 1.57 Q2

di2

msec

msec

10902

Pressure loss Formula

Pressure loss of strait pipes∆pR = 0.02 ⋅ ⋅ 1.572 = 0.04 bar

1590

10002 102

Pressurelossoffittingsandjoints

Σζ = (12 ⋅ 1.2) + (4 ⋅ 0.3) + (3 ⋅ 1.3) + (5 ⋅ 0.1) = 20

∆pFi = 20 ⋅ 1000 = 0.25 bar1.572

2 105

Pressurelossofvalve,100%opened.Withtheflowcharac-teristics diagram of diaphragm valve,type039,kv-value 702.6l/min(flowrate10l/s=36m3/h)

∆pAr = = 0.0026 bar10001000

36702.6

2

⋅

Pressure loss oh height difference

∆pgeod = 2.0 ⋅ 1000 ⋅ 10–4 = 0.2 bar

Total pressure loss of the pipeline

Σ∆p = 0.04 bar + 0.25 bar + 0.0026 bar + 0.2 bar = 0.4917 bar

T4.11 Formulas for calculation of pressure losses


Design and LayingLaying

IV

4 Laying

4.1 Pipe trenchesTherelevantnationalandregionallayingguidelinesandregula-

tions for underground pipelines apply for construction of the

requiredpipetrenchandforlayingofthepipes.Thepipetrench

must be constructed such that all parts of the line can be laid at a

frost-proofdepth.Thepipecoverage(coverageheight)his0.6-1 m

forgasand1-1.8mforwater,pursuanttoDVGW.

The trench base must be prepared so that the pipeline lies on it

evenly.Ifthesub-surfaceisrockyorstony,thetrenchbasemust

bedugoutatalowerdepthandtheexcavatedmaterialreplacedby

suitablegroundmaterialwithagrainsizethatcausesnodamage

to the pipes.

Perfectpreparationofthepipelinezoneisdecisivefortheload-carryingcapacityofthePE

pipesandfittingsintheground.ThepipelinezoneisthebackfillintheregionofthePEpipe

andconsistsofthebedding,sidefillandcoverzone.

Thepipelinezonemustbecreatedinaccordancewiththeplanningrequirementsand

structuralanalysiscalculation.Theregionbetweenthetrenchbaseandsidefillingistermed

“bedding”.Asaresultofearthreplacement,aload-bearingsub-surfacemustbeensured,i.e.

fornormalgroundconditions,EN1610specifiesaminimumthicknessfortheregionofthe

lowerbeddingasa=100mmandforrockorveryhardgroundasa=150mm.Inadditionto

theminimumthickness,requirementsarealsomaderegardingthebuildingmaterialstobe

used for the bedding.


Laying

Nobuildingmaterialsshouldbeusedwithcomponentsgreaterthan:

• 22mmatDN≤200

• 40mmatDN>200uptoDN≤600

Theupperlayerthicknessbresultsfromthestructuralanalysiscalculation.Furthermore,it

is necessary to ensure that no cavities occur under the pipe. The purpose of the pipe bedding

istoreliablyandevenlytransferalltheloadsbornebythepipetotheground.ThelaidPE

pipe must therefore be fully supported over the complete length. The upper limit of the

pipelinezoneisdefinedinEN1610at150mmoverthepipecrownor100mmoverthepipe

connection. When installing the cover and the earth layers above this, it is necessary to

ensurethatthepipecannotbedamagedbyinfillingandsealing.

4.2 Trenchless layingTrenchlesslayingallowscoststobesavedcomparedtoanopen-trenchmethod.Potential

savings are generated by the reduction in construction time and the protection of resources,

suchassurfaces,backfillmaterialsandstoragespace.Indirectcostscanbereducedby

avoidingadverseeffectsonresisdentsandtheinfrastructure.Afurtheradvantageof

trenchlesslayingisthereductionindust,noiseandCO2emissionsthankstolessexcavation

workandfewertransportjourneys.SafelayingispossiblebyusingPEpipeswithprotective

and test properties.

Therearedifferentkindsoftrenchlesslaying:

• Relining

• Horizontaldirectionaldrilling

• Burst lining

• Close-fitlining

• Displacement hammer (for trenchless laying of house connections)

4.3 Processing and handlingSuccessfulprocessingstartswiththehandlingofthecomponents.Theaimhereistobring

thecomponentstotheplaceofprocessingcleanlyandwithoutdamageacrossthecomplete

supply chain.

4.3.1 Oxide layer

Initsmeltedstate,thepolymerissusceptibletooxidativereaction.Duringtheextrusion

process,themeltcomesintocontactwithairandformsanoxidelayer.Thiscanadversely

affecttheconnectionqualityandmustbemechanicallyremovedduringprocessing

(seechapter“5.13.2Connectiontechnology”onpage108).

Incontrast,thefittingcoolsintheclosedmoldintheinjectionmoldingprocess,andthereis

thereforenooxidativereactionhere.Thisistrueaslongasthefittingisinitsoriginal

packaging(bagandbox).

UVirradiationcausesachangetothemolecularstructureonthePEsurface.Thisalsoleads

totheformationofanoxidelayerandtheconnectionmechanismintheweldingprocessis

restricted. Protection against direct sunlight is important to prevent the formation of an oxide

layer on the surface of the components.



IV

4.3.2 Packaging concept

Forsafeandreliabletransport,theELGEFPlusproductsarepackedindividuallyorin

packagingunitsinaplasticbagandabox.

Theboxescanbestackedandprotectthefittingagainstsunlight,dirtanddamage.AllELGEF

Pluselectrofusioncomponentsarealsoindividuallypackedinbags.Aircirculationinthe

packagingisreducedtoaminimum.Thispreventsareactiveenvironmentfromoccurring.

Thepackagingprotectsagainstdirt.

Injection-moldedELGEFPlusproductsarepackedinbagsandboxesdirectlyafterproduc-

tion.PEballvalvesandspigotfittingsinlargerdimensions(>d315und>d280T90°reduced)

arepackedinboxes.

SeamlesselbowsaremadeofPEpipeandpackedonpalletswithoutaboxandplasticbag.

4.3.3 Storage

Pipes

Thepipestoragesurfacemustbelevelandfreeofstones.Pipesmustbelayeredandstacked

inawaythatavoidstheriskofdamageorpermanentdeformation.Larger-diameter,thin-wal-

ledpipesmustbefittedwithstiffeningrings.Avoidsingle-pointornarrowlongitudinal

supports.

Thefollowingtablegivesrecommendedmaximumstackingheightsfornon-palletpipe

storage.Providedpipesarestackedonpalletsandprotectedagainstsidewaysmovement,

thenominalstackingheightsspecifiedinthetablemaybeincreasedby50%.

Pipestorageareasshouldbeaswell-protectedaspossible.Absorptionofoil,solventsand

other chemicals must be avoided at all costs during storage.

Stored pipes must not be exposed to the elements more than absolutely necessary, i.e. they

shouldbekeptinacoveredwarehouse.Ifstoredoutdoors(e.g.onaconstructionsite),they

shouldbecoveredwithsheetingforprotectionagainsttheweather(e.g.UVradiation).

One-sidedwarmingfromexposuretothesuncouldcausedeformations.

Pipesandpartsshouldbeusedintheorderofmanufacture/delivery,toensureproper

warehouseturnoveroftheplasticmaterial.

Material Permissible stacking height(m)

PE100/PE100RC 1.0


Laying

Fittings

ELGEFPlusfittingsandPEballvalvesmustbeprotectedagainstmoistureandcontamination

throughout the entire duration of storage. The maximum recommended storage duration is

tenyears.Inordertoreachthismaximumduration,theELGEFPluscomponentsmustbe

storedintheoriginalpackaging(box+bag)atatemperaturebelow+50°C.Thestoragetime

begins on the date of production.

ThePEbagfilmprotectstheELGEFPlusfittingseffectivelyagainstUVlight.Storagewithout

a box but in the undamaged bag is possible for a maximum of up to two years. During this

time,thefittingscanbeweldedsafely.Theprocessorisresponsibleforindicatingthetime

thatthefittingintheplasticbagwasremovedfromthebox.

Largerdimensions(>d315),whichareusuallyalsoheavyandbulky,mustbestoredinthebox

in order to protect against damage.

Seamlesselbowsshouldbeprotectedfromdirectsunlight.Toavoiddeformation,palletswith

seamlesselbowsmustnotbestacked.

ELGEFPlusfittingsmustnotcomeintocontactwithsolvents,greases,paints,silicone,or

similar substances.

4.3.4 Transportation

PipesVehiclesusedtotransportpipesmustbecapableof

accommodating the full pipe length. The pipes must

be supported to prevent them bending or deforming.

Theareawherepipesrest(includingsidesupports)

shouldbelinedwithpaddedsheetingorcorrugated

cardboard to avoid damage by protruding rivets or

nails.

Toprotectagainstdamage,pipesandfittingsmust

notbeslidoverthetransportvehicle’sloadingarea,

nor should they be dragged along the ground to their

place of storage.

Duecaremustbetakenwithloadingandunloading.

Ifliftinggearisused,thismustbefittedwithspecial

pipegrips.Throwingpipesandpartsdownfromthe

cargo surface is unacceptable.

Impactsmustbeavoidedatallcost,especiallyat

ambienttemperaturesbelow0°Cwheremany

plastics(e.g.PVC)havesignificantlylowerimpact

resistance.

Pipesandfittingsmustbetransportedandstoredso

thattheycannotbesoiledbyearth,mud,dirtywater,

etc.Werecommendsealingpipeswithprotective

endcaps to prevent the ingress of dirt.



IV

Fittings

Topreventtransportdamage,thefittingsshouldbewellprotectedduringtransportation.We

recommendleavingtheproductsintheoriginalpackaginguntilinstallation.Ifsmaller

quantitiesneedtoberemoved,theseshouldbetransportedinaboxthatprotectsthemwell

againstUVradiationandcontamination.

Duringunpacking,caremustbetakentoplacetheproductssothattheplasticbagsarenot

damaged by sharp or protruding edges, e.g. plug contacts. To avoid damage, products should

notbethrown.

Seamlesselbowsshouldbetransportedonpallets.

WerecommendonlyremovingfittingsandvalvesfromGFPipingSystemsfromthepackaging

immediately before use.

4.3.5 Use on building sites

To prevent the products from becoming contaminated and damaged, they should be removed

fromthepackagingimmediatelybeforeprocessing.

Theweldedareasmustbecleanedif:

• The plastic bag has been opened or damaged

• Theproductisnotpackedinaplasticbag

• Theproductwasproducedfromapipe,e.g.seamlessorsegment-weldedelbows

• Theweldedareaiscontaminated

Peelingisrequiredif:

• Theproductisnotpackedinaplasticbag

• Theproductwasproducedfromapip,e.g.seamlessorsegment-welded

4.3.6 Pipe bending

Itispossibletotakeadvantageoftheelasticityofthepipematerialstoanextent,meaningthe

PEpipescanbelaidinacurveduringinstallation.Thespecifiedvaluesforthesmallest

permitted bending radius must not be undershot.

Thepermissiblebendingradiiatdifferenttemperaturesareamultipleofthepipeoutside

diameter:

Pipe wall temperature 20 °C 10 °C 0 °CMinimum bending radius for PE

20d 35d 50d

WhenlayingPEpipesSDR11and17inadepressurizedstate(20°C),aminimumbending

radius of 10d may be used for a short time.

Valuesbetweenthetemperatu-res can be interpolated linearlySource:DVGWworksheetGW321(TableA.3)

Source:DVGWworksheetGW320-1(AppendixA)


Laying

4.4 Internal pressure and leak test

4.4.1 Introduction to pressure testing

Overview of the different testing methods

Testing method

Internal pressure test Leak test

Medium Water Gas* Compressed air1)

Gas/air(oil-free)

Gas/air(oil-free)

Type Incompres-sible

Compressible Compressible Compressible Compressible

Test pressure (overpres-sure)

Pp (perm)

or0.85 • Pp (perm)

Operatingpressure+ 2 bar

Operatingpressure+ 2 bar

0.5 bar 1.5 bar

Hazardpotentialduring pressure test

Low High High Low Medium

Material All plastics PE PE All plastics ABSInformativevalve

High:Proof of resistance to pressure including tightness against test medium



Low Mittel Medium

Varioustestmethodsforpressureandtightnesstestsareuseddependingonnationaland

internationalstandardsandguidelinesaswellaslocalconditions.Theseincludeforexample

contractionmethods,pressurelossmethods,pressuredifferencemethodsorvisual

methods. They vary in the test process, test time and test pressure.

Thepurposeofapressuretestis:

• Ensuretheresistancetopressureofthepipeline,and

• Showtheleak-tightnessagainstthetestmedium

Usually,theinternalpressuretestisdoneasawaterpressuretestandonlyinexceptional

cases(underconsiderationofspecialsafetyprecautions)asagaspressuretestwithairor

nitrogen.

Thefollowingcomparisonattemptstopointoutthedifferencebetweenwaterandairasatest

medium:

Waterisanincompressiblemedium,i.e.settinga1mPEpipewithadiameterofd160undera

pressureof3barresultsinanenergyofapprox.1joule.Incontrast,airisacompressible

medium.Thesamepipewithtestpressureof3baralreadystoresanenergyof5,000joule.If

therewereafailureduringtheinternalpressuretest,thewater-filledpipewouldjumpup

0.02m,theair-filledpipe100m.

1) Observetheapplicablesafety precautions. More information is available in DVS2210-1addendum2.



IV

Fracture behavior of plastics

Incaseofafailure,thermoplasticmaterialsshowdifferentbehaviors.Hence,PEandPB

exhibitaductilebehavior(andABSslightlylower),sothatbrittlefracturecannotoccur.

Nevertheless,thefollowingsafetyprecautionsmustbetakenintoconsiderationduringthe

internalpressuretest.Asmentionedbefore,thepressuretestisthefirstloadingplacedon

thepipelineandisintendedtouncoveranyexistingprocessingfaults(e.g.insufficient

fusioning).

Gasleak-tightnesscannotbedemonstratedbyawaterpressuretest,notevenwithincreased

testpressure!

4.4.2 Internal pressure test with water or a similar incompressible test medium overview

Overview

Theinternalpressuretestisdonewheninstallationworkhasbeencompletedandpresuppo-

ses an operational pipeline or operational test sections. The test pressure load is intended to

furnish experimental proof of operational safety. The test pressure is not based on the

operatingpressure,butratherontheinternalpressureloadcapacity,basedonthepipewall

thickness.

Addendum2ofDVS2210-1formsthebasisforthefollowinginformation.Thisreplacesthe

datainDVS2210-1entirely.Themodificationsbecamenecessarybecausethereference

value„nominalpressure(PN)“isbeingusedlessandlesstodeterminethetestpressure

(1.5 •PN,bzw.1.3•PN)andisbeingreplacedbySDR.Inaddition,ashort-termoverloador

evenareductionintheservicelifecanoccurifthepipewalltemperatureTR = 20 °C is

exceeded by more than 5 °C in the course of the internal pressure test based on the nominal

pressure.

Testpressuresare,therefore,determinedinrelationtoSDRandthepipewalltemperature.

The100-hvaluefromthelong-termbehaviordiagramisusedforthetestpressure.

Test parameters

Thefollowingtableprovidesrecommendedmethodsforperformingtheinternalpressuretest.

Object Pre-test Main test

Test duration (depends on the length of the pipeline sections)

≤Pp (perm) ≤0.85Pp (perm)

Prüfdauer (abhängig von der Länge der Rohrleitungsabschnitte)

L≤100m:3h100m<L≤500m:6h

L≤100m:3h100m<L≤500m:6h

Checksduringthetest(testpressureandtemperature progression must be recorded)

Atleast3checks,distributed over the testdurationwithrestoring the test pressure

Atleast2checks,distributed over the testdurationwithoutrestoring the test pressure

Pre-test

Thepre-testservestopreparethepipingsystemfortheactualtest(maintest).Inthecourse

ofpre-testing,atension-expansionequilibriuminrelationtoanincreaseinvolumewill

developinthepipingsystem.Amaterial-relateddropinpressurewilloccurwhichwill

requirerepeatedpumpingtorestorethetestpressureandalsofrequentlyare-tighteningof

theflangeconnectionbolts.

Theguidelinesforanexpansion-relatedpressuredecreaseinpipesare:

Material Pressure drop(bar/h)

PE 1.2


Laying

Main test

Inthecontextofthemaintest,amuchsmallerdropinpressurecanbeexpectedatconstant

pipewalltemperaturessothatitisnotnecessarytopumpagain.Thecheckscanfocus

primarilyonleakdetectionattheflangejointsandanypositionchangesofthepipe.

Observe if using compensators

Ifthepipelinetobetestedcontainscompensators,ithasaninfluenceontheexpectedaxial

forcesonthefixedpointsofthepipeline.Becausethetestpressureishigherthanthe

operatingpressure,theaxialforcesonthefixedpointsincreaseproportionately.Thishasto

betakenintoaccountwhendesigningthefixedpoints.

Observe if using valves

Whenusingavalveattheendofapipeline(endorfinalvalve),thevalveandthepipeend

shouldbeclosedbyadummyflangeorcap.Thispreventsaninadvertentopeningofthevalve

and exit of the medium or any pollution of the inside of the valve.

Filling the pipeline

Beforestartingwiththeinternalpressuretest,thefollowingpointsmustbechecked:

• Was installation done according to the available plans?

• Allpressurereliefdevicesandflaptrapsmountedintheflowdirection?

• All end valves shut?

• Valvesinfrontofotherdevicesareshuttoprotectagainstpressure?

• Visualinspectionofalljoints,pumps,measurementdevicesandtanks?

• Hasthewaitingperiodafterthelastfusion/cementingbeenobserved?

Nowthepipelinecanbefilledfromthegeodeticlowestpoint.Specialattentionshouldbe

giventotheairvent.Ifpossible,ventsshouldbeprovidedatallthehighpointsofthepipeline

andtheseshouldbeopenwhenfillingthesystem.Flushingvelocityshouldbeatleast1m/s.

Adequatetimeshouldbeallowedbetweenfillingandtestingthepipeline,sothattheair

containedinthepipingsystemcanescapeviathevents:approx.6-12h,dependingonthe

nominal diameter.

Determining the test pressure

Thepermissibletestpressureiscalculatedaccordingtothefollowingformula:

Pp(zul) = ⋅20 ⋅ σv(T, 100 h)

Sp ⋅ AG 1

SDR

σv(T, 100 h) Long-termcreepstrengthforpipewalltemperatureTR (at t = 100 h)Sp Minimumsafetyfactorforlong-termcreepstrengthAG Processingorgeometry-specificfactorthatreducestheallowabletestpressureTR Pipewalltemperature:averagevalueoftestmediumtemperatureandpipe

surface temperature

Material Sp Minimum safety factor

PE80,PE100 1.25



IV

To make things easier, the permissible test pressures can be taken directly from the following diagrams.

P Permissible test pressure (bar)T Pipewalltemperature(°C)

Checks during testing

Thefollowingmeasurementvaluesmustberecordedconsistentlyduringtesting:

• Internalpressureattheabsolutelowestpointofthepipeline

• Medium and ambient temperature

• Water volume input

• Water volume output

• Pressure drop rates

4.5 Disinfection of pipeline systemsDisinfection measures in pipeline systems are needed if contamination is too great. This state

canoccurduringnewinstallationsorrepairswherethesystemwasopenedandbasic

disinfectioniscarriedoutshortlybeforethesystemisputintooperation.However,amoreor

lesslongstagnationofthewaterphase(potableorindustrialwater)canalsoleadtoan

impermissiblyhighnumberofgerms.Inmanycases,ahighernumberofgermsalsobuilds

up over time in normal operation.

Inanycase,thequestionarisesregardingthesuitabledisinfectionprocess,themostimport-

antaspectsofwhichincludetherightchoiceofdisinfectant.

Most disinfectants are, by their chemical nature, aggressive to plastics and the compatibility

andusabilityofplasticpipelinesdependstoasignificantdegreeonthetypeofdisinfectant,

its concentration and the operating conditions.

The most common disinfectants are based on chlorine as gaseous chlorine or commercially

available sodium hypochlorite (also chlorine bleaching lye). They are comparable in terms of

theirbacterialeffectandpotentialdamagetothepipesystem,andtheirimpactonpipeline

materialsisverywell-knownandforeseeable.

Innumeroustestsonthelong-termbehaviorofpolyolefinswithrespecttochlorine/hypoch-

lorite,itcouldbeshown,forexample,thatPEhasaverygoodresistancetochlorineconcent-

rationsthatarepermittedinpotablewater.Asarule,thelifeofthepipesystemisnot

restricted by the disinfectant here.

PEevendemonstratesgoodresistanceatconcentrationscommoninswimmingpools

(approx.2ppm).However,nogeneralstatementsonresistancecanbemadeatthispoint

becauseintheseareasofapplication,regularorirregularshockchlorinationiscommon

practice,inadditiontohighertemperatures.Anindividualanalysisanddesignarerequired

here to ensure the life is not impacted.

Ifchlorinedioxideisusedtodisinfectwaterpipelines,anindividualanalysismustbecarried

out.


JointingTechnology

5 Jointing Technology

5.1 Integral connections

Overview

FromthewiderangeofsolutionsofferedbyGFPipingSystemsonthesubjectofmaterial-to-

materail connections, the methods commonly used in underground pipeline construction are

describedinmoredetailbelow:

Connection type Butt fusion ElectrofusionDimension range d40-d1600 d20-d1200

5.2 Butt fusion jointing (heating element fusion conventional butt fusion)

5.2.1 Overview

Material: PE

Fusion machine Jointing cross section Macro view

5.2.2 Fusion procedure

Forheatingelementbuttfusion(HB),thefusionareasofthepartstobejoined(pipes,fittings

or valves) are heated to fusion temperature and joined by means of mechanical pressure,

withoutusingadditionalmaterials.Ahomogeneousjointistheresult.Buttfusionjointsfor

pressurepipelinesmustonlybecreatedwithafusiondevicethatallowsthejointingpressure

to be regulated. When building pressure pipelines, the components to be jointed must have

thesamewallthicknesses.


Design and LayingJointingTechnology

IV

Principle of the fusion procedure

Advantages and properties

Heatingelementbuttfusionjointsareinexpensiveconnectionsthatcanbemadeon

corresponding systems up to large diameters (2,000 mm and more). Professionally prepared

buttfusionsmeetthesamerequirementsasthecomponents.Onspeciallyequippedbutt

fusiondevices,itisalsopossibletofusepartsatananglesothatsegment-fusedelbowsor

T-piecescanbemadefrompipesegments.Awiderangeofdevicesisavailablefor

conventionalbuttfusion;thesearedesignedforworkshops,pipetrenchesorfittingfusion

and can be operated manually, electrically or hydraulically.

For additional information about using the fusion procedure for corresponding materials, see www.gfps.com

5.2.3 Installation process

ThefollowinginstallationprocessisrepresentativeforallGFbutt-weldingmachines.For

detailedandspecifiedmachinehandling,pleaseseetherelevantoperatinginstructions.

Fordetailedinformation,pleaseseeourhomepagewww.gfps.comorcontactyourregional

GFsalesoffice.

Prerequisites

Onlymaterialsofthesamekindcanbeweldedtoeachother(PEtoPE).Fordetailed

informationonPEtypematerialcompatibility,seesection1.2.“Areaofuse–suitablepipes”

on page 111.

Inbuttwelding,onlypipeendswiththesamewallthickness(SDRclass/pipeseries)canbe

weldedtoeachother.

Makesureyouhavesufficientspaceintheweldingareaandtheworkingenvironmentpermits

professionalwork.

1 Pipe2 Heatingelement3 Fitting


JointingTechnology

a Clean heating element

Beforeeveryweldingoperation,cleanheatingelementwith

dry,clean,lint-freepaper.

• Beforeheating,cleanwithpapertowelsandPEcleaner.

• Inwarmstate,cleanwithdrypapertowels.

Caution–riskofburning

s Align and clamp pipes

To minimize the displacement caused by pipe ovality, the pipes

mustbealignedinaccordancewiththeirsignatures.

Clamppipes/fittingssecurely.Clampwithtwojawsonthefixed

andmoveablesideoftheweldingmachine.

Positionandsupportpipeendssecurelyonrollerblocks,this

makesiteasiertoensureflushalignmentandsecureclamping.

d Planing

Checkwhetherplaneriscleanandfreeofgreaseonbothsides.

Donotplaneuntilimmediatelybeforewelding.

Planeweldingendsflat;even,uninterruptedmachiningatleast

1-1.5xcircumference.

Makesurechipsareremovedeffectivelyandremovechips

continuously. Stop planing intermittently. Remove chips and

checkresultofplaning.

Check:samewallthicknessofweldingends.

f Off set and gap check

Offsetcheck:Maximumpermittedoffset≤10%ofwallthick-

ness

Δsmax.=0.1xs

However,maximumof5mmforwallthicknessesof>30mm

anddiameters>dn630

Gapcheck(valuesasperDVS2207-1):

dn [mm] Gap A [mm]

≤d355 0.5400-630 1.0630-800 1.3800-1000 1.5>1000 2.0

Thencleantheplanedpipeends(pipe,fitting)with100%

vaporizingPEcleanerandlint-free,cleanpapertowels.



IV

g Check heating element temperature

Heatingelementsurfacetemperature(inaccordancewith

DVS 2207):

220°±10°C

Measurementwithcalibratedthermocontactmeasuringdevice

withintheweldingareaatatleasteightpointsonthecircumfe-

rence of the heating element.

Weldingstartattheearliest30min.aftertargetheating

element temperature has been reached (time to heat through

heatingelementevenlyeverywhere).

Thensetheatingelementinheatingelementtake-offunit.

h Equalize/check bead height

Equalizewithequalizingpressure=0.15N/mm2 until minimum

bead height is achieved.

Inmanuallycontrolledweldingmachines,seethemachine

operating instructions to determine the hydraulic pressure that

needstobeset.InthecaseofCNCcontrol,themachine

automatically applies the correct parameters in accordance

withthepipewallthickness.

j Heating

For heating, the contact pressure is reduced such that a

transfer of heat from the heating element to the pipe ends is

stillensuredwithoutuncontrolledopeningasaresultofthe

melt expansion.

Heatingpressure≤0.01N/mm2

Inprinciple,itisnecessarytoensurethatthepipeendsarestill

justincontactwiththeheatingelementhere.

k Changeover

Wait until joint surfaces have been detached on both sides from

theheatingelementbythetake-offunit.

Swingtheheatingelementoutoftheweldingareawithout

damaging or dirtying the joint surfaces.

Keepthechangeovertimeasshortaspossible(keepthe

coolingofthejointsurfacesaslowaspossible).

l Joining and cooling

Bringthejointsurfacestogetherquicklyuntilshortlybefore

theymakecontact.

Shortlybeforecontact,bringthejointsurfacestogetherwitha

speed close to zero.

Applyrequiredjointpressureof0.15N/mm2 as linearly as

possible(takeaccountofjointpressureset-uptime).

Maintain joint pressure during entire cooling period.


JointingTechnology

; Check and welding log

Theweldedconnectionmustbecheckedovertheentire

circumferenceforbeadformation.Theweldingbeadshouldbe

as even and smooth as possible over the complete

circumference.

Nounweldedpoints,beaddiscolorationsornotchesare

permittedintheweldedconnection.Additionalfaultssee

DVS 2202supplementarysheet1.

Labelweldedconnectionwith:

• Welding number

• Cooling time (unclamping)

• Date

• Visa/signature

ThencreatemanualweldinglogorsavetheelectroniclogwiththeWeldinOnesoftware.

A Tightness check

Inallcases,thecoolingtimeasperDVS2207-1orspecific

manufacturerspecificationsmustbeadheredto.

Apressuresamplecanonlybetakenonehouraftertheendof

cooling at the earliest.

An overview of welding parameters

TheweldingparametersinaccordancewithDVS2207-1(August2015)aresummarized

below:

Equalize Heat Changeover Joins

Nominal wall thickness s (mm)

Minimum bead height* (mm)

Heating time (s)

Changeover time (mm)

Joint pressureset-up time (s)

Cooling time (min)

<15°C 15°-25°C 25-40°C

≤4.5 0.5 ≤45 5 5 4.0 5.0 6.5

4.5 – 7 1.0 45 – 70 5 – 6 5 – 6 4.0-6.0 5.0 – 7.5 6.5–9.5

7 – 12 1.5 70 – 120 6 – 8 6 – 8 6.0–9.5 7.5 – 12 9.5–15.5

12–19 2.0 120–190 8 – 10 8 – 11 9.5–14 12 – 18 15.5 – 24

19–26 2.5 190–260 10 – 12 11 – 14 14–19 18 – 24 24–32

26–37 3.0 260–370 12 – 16 14–19 19–27 24–34 32–45

37–50 3.5 370-500 16 – 20 19–25 27–36 34–46 45 – 61

50 – 70 4.0 500 – 700 20 – 25 25–35 36–50 46 – 64 61 – 85

70–90 4.5 700–900 25–30 35 50-64 64 – 82 85–109

90–110 5.0 900–1100 30–35 35 64 – 78 82 – 100 109–133

110–130 5.5 1100–1300 max.35 35 78–92 100 – 118 133-157

(Intermediatevaluesmustbeinterpolated)* Equalizeminimumbeadsizeonheatingelementattheendoftheequalizationtime,join

andcoolwithp=0.15N/mm2,heatwithp≤0.01N/mm2



IV

5.2.4 Butt welding devices

Characteristics TM160 TM250 TM315 GF400 GF500 GF630 GF800 GF1000 GF1200 GF1600Max. jointing diameter (mm)

160 250 315 400 500 630 800 1000 1200 1600

Jointing material PE,PP,PB PE,PP,PB PE,PP

Working range (°C) -10/+45 -10/+45 -10/+45Input voltage (V) 230/115 230 230 400/230 400 400 400 400 400 400

Operation control Manual,CNC Manual,CNC Manual

Performance (W) 1900 3250 3850 5700 6300 11000 15000 19500 20500 55000

Reduction inserts / Flange adapter clamp

Optional Optional Optional

Hoist unit Optional Optional

Chamfered upper clamp Optional Optional

Fusion protocols, transfer via USB stick

WR,CNCversion WR,CNCversion WR version

Traceability via barcode scanner

Optional(CNCversion) Optional(CNCversion)

Weight - base machine(kg)

22 47 53 65 169 222 690 1238 1346 3350

Workingrange


JointingTechnology

5.3 Electrofusion

5.3.1 Overview

Material

• PE

Fusion machine Jointing cross section Macro view

5.3.2 Fusion procedure

Byelectrofusion,plasticpipeandelectrofusionfittingarepermanentlyconnectedwitheach

other by a restraint and homogenuous joints.

Theelectrofusionfittingsareequippedwithinternalresistancewirestowhichelectric

currentisappliedduringthefusionprocess.Thisheatstheinsideofthefittingsandthe

outside of the pipe to the fusion temperature and melts them. The dimensions of the pipe end

andfittingsocketcorrelateinsuchawaythatafusionpressureisobtainedduringjointing,

resultinginahomogeneousjoint.Thejointingforceinthepolymermeltrequiredforthe

fusionistheresultofthevolumeincreaseofthemelt.Afteritcoolsoff,theresultisa

permanent, homogenous joint.

Principle of the fusion procedure

A PipeB Fitting

a Connecting areas Inserationdepthd Jointinglevel



IV

5.3.3 Advantages and properties

Theuseofelectrofusiontoconnectpipesandfittingsallowssafe,rational,economicand

efficientinstallationofundergroundandabovegroundPEpipingsystems.

Advantages

• IntegralconnectionsPE-PE,meaningnosealingelementisrequired

• Restraintpresent,sonocounter-supportisrequiredforundergroundlines

• ConnectionofpipesmadeofPE80,PE100aswellasacombinationofPE80andPE100

• DifferentSDRclassescanbeweldedtogether

• Nofusionbeadoninsideofthepipe

• Smallspacerequirementforexecutionbecauseoflightweightandcompactfusiondevices

• Fastpipe-layingspeed(comparedtoconventionalbuttfusion)becausefusiondeviceis

barelyfixed

• Fully automatic fusion process (high process reliability)

• Gap-freetraceabilitythroughweldinglogsandidentificationoftheweldedcomponents

• Lowinvestmentneedbecausealldimensionsarefusedwithonefusiondevice

For additional information about using the fusion procedure for corresponding materials, see www.gfps.com

5.4 Basic information about welding preparation

Insuffi cient preparatory measures can lead to a faulty welded connection. The

functionality and life of the product can be adversely aff ected.

5.4.1 Cutting pipe endsCoarsedirtmustbecleanedfromtheworkingareaonthe

pipe.Ifwaterisused,thepipesmustbecompletelydry

prior to separation. Then separate the pipe ends at a right

anglewiththepipeseparatingdeviceanddeflashthecut

surfaces. The tools must neither permanently deform nor

damage the pipe. The use of lubricants during separation is

not permitted. Suitable tools for this are pipe cutters or a

guidedelectronicpipesaw.

5.4.2 PeelingPEpipesareoftenstoredwithoutprotectionagainstdirect

sunlightordirt.Theymustbepeeledwithasuitablepeeling

tooldirectlybeforethestartofwelding.Intheinjecti-

on-moldedproducts,peelingisnotrequirediftheywere

stored correctly.

Itisinprinciplepossibletopeelspigotendsonfittings(spigotfittings,ballvalvesortransition

adapters)ifthisisrequiredbytheprocess.Thisdoesnothaveanegativeimpactonthe

weldingresult,providedthatpeelingiscarriedoutcorrectlyandtheresultingdiameterofthe

spigotendiswithinthetoleranceofthepermitteddiameterafterpeeling(seetablebelow).

Intheareaoftheweldingzone,thepipesurfacemustbemachinedwithoutgaps.Forthe

reliableremovaloftheoxidelayer,arotatingpeelershouldbeusedwithaconstantwall

thicknessremoval≥0.2mm.Thepeelingresultistobecheckedforevenchipformationand

min.cutdepth.Thepeeledareamustnotbesubsequentlytouched.


JointingTechnology

Ensureasmallannulargapformationbetweenfittingandpipe.Thereforeregularlycheckthe

qualityandwearofthepeelingbladeonthepeeler.Incasesofdoubtregardingtoomuchwall

removal,seetheminimumpermittedpipediametersbelow.

Flatspots,bulges,scratchesandgroovesarenotpermittedontheweldedareaafterpeeling.

Forverificationofpeelingafterwelding,atleast1cmmustbeaddedtotheinsertiondepthof

couplersandfittingsand4cmtothelengthofasaddle.

Nominal pipe outside diameter dn

(mm)Min. permitted pipe outside diameter after peeling (mm) at 20°C*

20-25 dn-0.432-63 dn-0.575-225 dn-0.6250-315 dn-0.7>315 dn-0.8

Example for d225:

dn = 225.0

Min.perm.pipeØafterpeeling=225.0mm-0.6mm=

224.4 mm

(measurewithcircometer)

5.4.3 Ovality

Duringwelding,theovalitymustbewithinthetolerancesdefinedinthestandards.Asa

generalrule,thevaluesfromDVS2207-1canbeused.

Ifthevaluesareoutsidethetolerancerange,measuresmustbetaken,e.g.theuseof

re-roundingtools.

DVS2207-1permitsamaximumpipeovalityof1.5%ora

maximumof3mm.Forlargerovalities,usere-rounding

clamps.

* Ifambienttemperaturevaries greatly, the nominal diameter dn is to be convertedwithformulaΔd= d * (1+α/3*ΔT).

f Fittingg Pipe



IV

5.4.4 Pipe end reverse

Ifthereisexcessivereverseonthepipeends,theheatingcoilzonesmustbesufficiently

covered.Incasesofdoubt,visuallycheckthepipeendswithaspiritlevelandcompare

reversedendswithhalfinnercoldzone.Ifnecessary,cutpipeendstosizeatrightangles

directlybeforewelding.

5.4.5 CleaningAs a result of the manufacturing process, the heating coil is

completelyembeddedinthefitting.Asaresultoftheclosed

andsmoothsurface,residue-freecleaningofbuildingsite

dirt(dust,sand,mud)ifeasilypossibleonELGEFPlus

electrofusionfittings.

ThePEcleaner(e.g.TangitPEcleaner),orPEcleaningcloths

dampenedwithcleanerbythemanufacturerinaclosable

plasticboxmustbea100%rapidlyvaporizingliquid.Agents

testedinaccordancewithDVGWVP603orNTA8828meet

thisrequirement.Theuseofalcohol/watermixtures

availablecommerciallycan,asaresultofthewaterthey

contain,leadtoareductioninqualityandthereforemust

not be used. The paper for cleaning must be clean, unused,

absorbent,lint-freeandnotcolored.Cleaningclothssoaked

withTangitPEcleanerarepermitted.

Cleaningcanonlybecarriedoutonthepeeledweldedarea.

Otherwise,thereistheriskofdirtbeingtransferredtothe

cleanedsurface.Ifmarkingpensareused,itisessentialto

ensurethatnoinkgetsintotheweldingzonearea.If

subsequentcleaningisrequired,theinkmustnotbewiped

intotheweldingzone.Inkthatgetsintotheweldingzone

cannot be completely removed even by repeated cleaning.

Thepipemustbere-machinedorreplaced.

Duringwelding,thecontactsurfacesmustbecleananddry.

Itisnecessarytoensurethatcleaningagentsarecomple-

telyvaporizedwithoutresiduepriortowelding.Thisapplies

in particular for cold temperatures, as the cleaning agent

vaporizesmoreslowlythaninwarmtemperatures.

a Heatingcoilzones Cold zoned Permitted pipe end reversef Impermissiblepipeend

reversel


JointingTechnology

5.4.6 Mark fi tting positionItmustbepossibletocheckboththeinsertiondepthfor

socketsandfittingsandthepositionforsaddlemoldingsby

meansofamarking.

• Alwaysperformmarkingaftercleaning

• Fromd110,makeatleast3marksonthecircumference.

5.4.7 Stress-free installationDuringinstallationofthefitting,stress-freeassemblyofall

componentsmustbeensured.Electrofusionfittingsmaybe

neithertiltednorpushedwithforceontothepipeend.

Ifnecessary,usesuitablere-rounding,clampingorholding

devices (for example on coiled pipes in house connections).

Stress-freeassemblybymeansoftheclampingdevice

must then be maintained up to the end of the cooling period.

5.4.8 Avoid air fl ow & visual check

Beforethestartoftheweldingprocess,thepipeendsmustundergoavisualcheck,in

particular also of the interior. At this point in time, foreign bodies such as loose stones or

other foreign matter can still be removed easily.

The pipe ends must then be closed by suitable means, e.g. end caps. This can prevent

disruptiveairflows(“chimneyeffect”).Thisappliestoelectroandbuttweldings.Thiseffectis

particularly strong in vertically installed pipelines.

5.4.9 Welding & checkUsefusionmachinesthatarecompatiblewithELGEFPlus

fittings

• Connecttheweldingcabletothefittinginload-relieving

way

• Readintheweldingbarcodeusingascannerorbarcode

reader

• Starttheweldingprocedure

• Pay attention to special occurrences

• Checktheweldingdisplay

• Checktheweldingdeviceforerrormessages,createa

weldingprotocolifnecessary

Forgeneralsafety,weldingshouldbesupervisedupuntil

the end of the cooling period and a distance of at least 1m to

theweldingshouldbemaintained.



IV

5.4.10 Temperature-compensated welding times

AllELGEFPluselectrofusionfittingshaveabarcodethatautomaticallyadaptsthewelding

timetotheambienttemperatureoftheweldingdevice.

Electrofusionfitting,pipeandweldingdevicemustbeatthesametemperaturepriorto

welding.Takeaccountofthetimeforequalizingthetemperature.Werecommendstoringthe

componentsforweldinginthesameareaforapproximately20min.beforewelding.

5.5 Installation processThefollowinginstallationprocessisrepresentativeforallELGEFPluscouplersandfittings.

The detailed, individual installation process can be accessed on a smart phone by scanning

theQRcodeonthebagpackaging.

Fordetailedinformation,pleaseseeourhomepagewww.gfps.comorcontactyourregionalGFsalesoffice.

a Cut pipes

Cleanpipeendsroughly,cutatrightanglewithpipecutter

and if necessary deburr edges.

The pipe ends must be cut at an exact right angle. The

insertion depth of the electrofusion coupler must be

completelyfilledout.

s Determine peeling length

Measureareawhichmustbepeeledonthestillpacked

productwithayardstickandthenmarkonthepipewithan

addition of approx. 1 cm.

d Peel pipes

Peelpipewitharotarypeeler.Checkthepeelingresilt.Note

min.peelingof0.2mmaswellasmax.allowablewallthick-

ness reduction.

f Clean pipe

CleanpipeonlyinthepeeledareawithTangitPEcleaner

andlint-free,colourlessandcleanclothincircumferential

direction, let the cleaner exhaust. Do not touch the fusion

zone and avoid contamination.

g Mark the fi tting position

Markinsertiondepthwithyardstickandpermanentmarker

onthepipe.Toavoidcontaminationdonotsubsequently

touchtheweldingzone.


JointingTechnology

h Fitting installation

Directlybeforeassembly–andwithouttouchingthewelded

area–taketheELGEFPlusfittingoutofitspackagingand

pushitontothepipe.Theinsertiondepthmarkingsonthe

pipeareusedtocontrolandadjusttheposition.Toallow

installationwithouttensionuseclampingtools.

h a.)

Inverticalinstallationsoranenvironmentinwhichan

airflowcanoccur,thepipeendsmustbeclosed.

h b.)

Inverticalinstallationsorinpositionsinwhichaclamping

toolcannotbeused,suitablemeasuresmustbetakento

eliminate installation stress.

h c.)

Inverticalinstallationsorinpositionsinwhichaclamping

toolcannotbeused,suitablemeasuresmustbetakento

holdthepipesandfittingsinpositionandpreventany

movement of the components.

j Fusion

Fuse in accordance to the user manual of the fusion unit.

Control and supervise fusion process.

k Check

Duringandafterfusion,checkfusionindicators*onthe

product.Afterfusioncheckmessageonthefusionunit.

l Cooling time

Also ensure there is no stress during the cooling period,

therefore do not move the connection until the minimum

cooling time (CT) as per barcode label has passed.

* The popping up of fusion indicators is the visual confirmationthatweldingpressure occurred. They do not enable conclusions to bedrawnregardingthequalityoftheconnection.The height of the fusion indicators can vary.



IV

5.6 Cooling times ELGEF Plus coupler & fittingsAfter the fusion process, our MSA electrofusion units directly display the cooling time after

whichtheclampingtoolcanberemoved.Ifotherelectrofusionunitsareused,thecooling

timeuptoremovaloftheclampingtoolisindicatedonthebarcodelabelwith“CT”.Afterthis

coolingtime,theweldedconnectioncanbemoved.

Thelongercoolingtimesinthetablebelowapplyfortheload-bearingcapacityforthe

tightness test.

T4.12 Cooling times for ELGEF Plus coupler and fittings

dn

(mm)Remove clamping tool(min.)

Tightness test*

STP ≤ 6 bar(min.)

STP ≤ 18 bar(min.)

20-63 6 10 3075-110 10 20 60

125-160 20 30 75180-225 20 45 90250-315 30 60 150355-400 60 120 180450-630 60 150 210710-800 90 150 240900-1200 60 150 240

Thecoolingtimespecifieshowlongittakesfortheweldedconnectiontocooltoa

corresponding reference temperature. The reference temperature is a measure for the

stabilityoftheconnectionandthuswhatloads/stressestheconnectioncanbesubjectedto.

For removal of the clamping tool, Georg Fischer uses a ref. temp. of 110 °C, a ref. temp. of 80

°C for an internal pressure of 6 bar and a ref. temp. of 20 °C (ambient temperature) for an

internal pressure of 18 bar.

5.7 Cooling times for ELGEF Plus saddles & PVTsAfter the fusion process, our MSA electrofusion units directly display the cooling time after

whichtheweldedconnectioncanbemechanicallyloaded.Ifotherelectrofusiondevicesare

used, the cooling time up to removal of the clamping tool is indicated on the barcode label

with“CT”.Afterthiscoolingunits,theweldedconnectioncanbemoved.Thelongercooling

timesinthetablebelowapplyfortheload-bearingcapacityforthetightnesstest.

T4.13 Minimum cooling time for ELGEF Plus saddles and pressure tapping valves (PTVs)

dn

(mm)Mechanical load,Pressureless tapping

(min.)

Tightness test / tapping under operating pressure

STP ≤ 6 bar(min.)

STP ≤ 18 bar(min.)

40, 50 Monobloc 10 20 3063-160Monobloc 20 30 90

63-400Duobloc 20,30* 30 90110-630branchsaddle 30 45 90Branch saddle topload315-1000xoutlet160/225

45 90 180

Branch saddle topload500-2000xoutlet315/500

60 120 240

Thecoolingtimespecifieshowlongittakesfortheweldedconnectiontocooltoa

corresponding reference temperature. The reference temperature is a measure for the

stabilityoftheconnectionandthuswhatloads/stressestheconnectioncanbesubjectedto.

For removal of the clamping tool, Georg Fischer uses a ref. temp. of 110 °C, a ref. temp. of 80

°C for an internal pressure of 6 bar and a ref. temp. of 20 °C (ambient temperature) for an

internal pressure of 18 bar.

* Includingthecoolingtimetoremovalofclampingtool;STP = system test pres-sure.

* With injection molded bottom part for dn110 and dn160

STP System test pressure


JointingTechnology

5.8 Mechanical joints

Overview

OfthemanydiversesolutionsofferedbyGFPipingSystemsformechanicaljoints,the

followingtableoffersinformationontheconventionalmethodsusedinindustrialpiping

systemconstruction:

Figure Connections typre Gasket Connection of plastic with

Transitionadapterwiththread

PTFETape Plastic/metal

Flange connection O-ring Plastic or metalProfileseal

MULTI/JOINT®Widerangefitting

Special seal Suitable for all pipe materials

iJOINTCompressionfitting

Lip seal plastic

PRIMOFITCompressionfitting

Profileseal Plastic or metal

Universal coupling Special seal Plastic or metal

T4.14 Overview of mechanical connections



IV

5.9 Transition adapter with threadThetransitionadaptersaresystem-compliantandonlycompatiblewithELGEFPluscoupler

andfittings.

Thread types

Thefollowingthreadtypesareused:

Designation of the thread

Standard Description Application

Rp ISO7-1,EN10226-1

Parallel internal (female) thread,wherepressu-re-tightjointsaremadeon the threads

Transitiol and threaded fittings,Malleablecastironfittings

R ISO7-1,EN10226-1

Conical external (male) thread,wherepressu-re-tightjointsaremadeon the threads

Transition and threaded fittings,Steelpipes

5.10 Flange connectionsFlangeswithsufficientthermalandmechanicalstabilitymustbeused.Thedifferentflange

typesbyGFPipingSystemsfulfilltheserequirements.Thegasketdimensionsmustmatch

theouterandinnerdiameteroftheflangeadapterorvalveend.Differencesbetweenthe

innerdiametersofgasketandflangethataregreaterthan10mmmayresultin

malfunctioningflangeconnections.

a Pipes Boltd Washerf Flangeg Valveend/flangeadapterh Flange sealj Nut


JointingTechnology

5.10.1 Comparison of fl ange connections

Flange connection Properties

PP-Vflange • Corrosion-freeall-plasticflangemadeofpolypropylenePP-GF30(fiber-glassreinforced)

• Highchemicalresistance(hydrolysis-resistant)• Maximumpossiblebreakresistanceduetoelasticity(deformsifitis

tightened too much)• Use for ambient temperatures up to 80 °C• The temperature of the medium is restricted by the material of the

plastic piping system• UV-stabilized• Withintegratedbolt-fixing• Self-centeringaidfortheflangesontheflangeadapter• Symmetricdesignallowsassemblyoneitherside:A„reverse“

installation is never possible. All important information is readable• V-groove(patented)• Evendistributionofforcesacrosstheflange(preserveslifeexpec-

tancy of components)• Supportsalonger-lastingtorqueforasafejoint

PPsteelflange • Veryrobustandstiffduetothesteelinlay• Corrosion-freeplasticflangemadeofpolypropylenePP-GF30

(fiber-glassreinforced)withsteelinlay• Highchemicalresistance(hydrolysis-resistant)• Maximum ambient temperature 80 °C• UV-stabilized

Steel, galvanized • ExtremelyrobustandrigidBlindflange • CombinationofabackingflangeandaPE100endblank.

• Combinesendblanksinthedimensionsd63tod315withthePP-Vbackingflange.

• Dimensionsd355tod630arecombinedusingaloose-typeflangemadefromPPwithasteelinsert.

• Withtheblankingflangeset,thepipingsystemcanbeclosedoffusing the same material.

• Ifthepipingsystemisextended,thebackingflangecanbeusedagain,cuttingdownonadditionalcosts.

• Suitable for pressure piping• Easyassemblyoftheblankflangeset:Theendblankiscenteredon

theinnerdiameterofthebackingflange.



IV

5.10.2 Creating fl ange connections

Whenmakingaflangeconnection,thefollowingpointshavetobetakenintoaccount:

Usage information

Backingflangesareidentifiedwiththefollowingpictogramsoftheusableflanges:

Butt fusion

Orientation of bolts beyond the two main axes

• Forhorizontalpipelines,theorientationshownoftheboltsbeyondthemainaxes(seethe

followingfigure)ispreferredsincepossibleleaksattheflangeconnectiondonotcausethe

medium to run directly onto the bolts.

Flangewithmainaxes

(centered,crosswise)

• Flangeadapter,valveendorfixedflange,gasket,aswellasbackingflange,mustbe

aligned centered on the pipe axis.

• Beforepre-tighteningthebolts,thejointingfacesmustbeflushwitheachotherandmust

fittightlyagainstthegasket.Pullingbadlyalignedflangestogetherwithintheflange

connection must to be strictly avoided because of the resulting tensile stress.

Selecting and handling bolts

• Thelengthoftheboltsshouldbeselectedinsuchawaythattheboltthreaddoesnot

protrudemorethan2to3turnsofthethreadatthenut.Washersmustbeusedatthebolt

headaswellasthenut.

• To ensure that the connecting bolts can be easily tightened and removed after a lengthy

periodofuse,thethreadshouldbelubricated,e.g.withmolybdenumsulphide.

• Tighteningtheboltsbyusingatorquewrench.

• Theboltsmustbetighteneddiagonallyandevenly:First,tightentheboltsbyhandsothat

thegasketisevenlycontactingthejointingfaces.Thentightenallboltsdiagonallyto50%

oftherequiredtorque,followedby100%oftherequiredtorque.Therecommendedbolt

tighteningtorquesarelistedinthetable“BolttighteningtorqueguidelinesforISOflange

connections”,page102.However,deviationsmayoccurinpractice,e.g.throughtheuseof

stiffboltsorpipeaxesthatarenotaligned.TheShorehardnessofthegasketcanalso

influencethenecessarytighteningtorque.

• Werecommendcheckingthetighteningtorques24hoursafterassemblyaccordingtothe

specifiedvaluesand,ifnecessary,retightenthem.Alwaystightendiagonallyhere,aswell.

• Afterthepressuretest,thetighteningtorquesmustbecheckedinanycaseand,if

necessary, retightened.

For more information on fl ange connections, see DVS 2210-1 Supplement 3.


JointingTechnology

Tightening the bolts using a torque wrench

However,deviationsmayoccurinpractice,e.g.throughtheuseofstiffboltsorpipeaxesthat

arenotaligned.TheShorehardnessofthegasketcanalsoinfluencethenecessarytightening

torque.

In the area of flexible sections and expansion loops, no bolt connections or flange connections should be used since the bending stress may cause leaks.

5.10.3 Bolt tightening torque guidelines for metric (ISO) flange connections with PP-V, PP- steel and PVC flanges

TheindicatedtorquesarerecommendedbyGFPipingSystems.Thesetorquesalreadyensure

asufficienttightnessoftheflangeconnection.TheydeviatefromthedataintheDVS2210-1

Supplement3,whicharetobeunderstoodasupperlimits.Theindividualcomponentsofthe

flangeconnection(valveends,flangeadapters,flanges)byGFPipingsystemsare

dimensioned for these upper limits.

Pipe outer diameter dn (mm)

Nominal diameter DN (mm)

Bolt tightening torque MD (Nm)

Flat ring maximum pressure10 bar / 40 °C

Profile gasket maximum pressure16 bar

O ring maximum pressure 16 bar

d16 DN10 10 10 10

d20 DN15 10 10 10d25 DN20 10 10 10d32 DN25 15 10 10d40 DN32 20 15 15d50 DN40 25 15 15d63 DN50 35 20 20d75 DN65 50 25 25d90 DN80 30 15 15d110, 125 DN100 35 20 20d140 DN125 45 25 25d160, 180 DN150 60 35 30d200, 225 DN200 701) 45 35d250, 280 DN250 651) 35 30d315 DN300 901) 50 40d355 DN350 901) 50 -d400 DN400 1001) 60 -d450, 500 DN450,DN500 1901) 70 -d560,630 DN600 2201) 90 -

Please observe the special bolt tightening torques listed for butterfly valves DN25 and

DN300. See also the section “Planning fundamentals for butterfly valves, hand-

operated”.

1) Maximum operating pressure6 bar

Bolttighteningtorque guidelinesforISOflange connections



IV

5.10.4 Bolt tightening torque guidelines for ASME fl ange connections with PP-V, PP- steel and PVC fl anges

Flange size(inch)

Nominal diameterDN (mm)

Bolt tightening torques(lb-ft)

Flange ring maximum pressure 10 bar / 40 °C

Profi le gasket maximum pressure 16 bar

½” DN15 15 10

¾” DN20 15 101” DN25 15 101¼” DN32 15 101½” DN40 15 102” DN50 30 202½” DN65 30 203” DN80 40 304” DN100 30 206” DN150 50 338” DN200 50 3310” DN250 601) 4012” DN300 751) 53

5.10.5 Length of bolts

Inpractice,itisoftendifficulttospecifythecorrectboltlengthforflangeconnections.Itcan

bederivedfromthefollowingparameters:

• Thicknessofthewasher(2x)

• Thicknessofthenut(1x)

• Thicknessofthegasket(1x)

• Flangethickness(2x)

• Thicknessofflangecollar(valveendorflangeadapter)(2x)

• Valveinstallationlength,ifapplicable(1x)

Thefollowingtablesareusefulindeterminingthenecessaryboltlength.Duetothevarious

combinationsoftheindividualcomponents,onlythicknessesoftheindividualpartsofflange

connectionscanbeprovided.However,yousimplyaddthemtogethertodeterminethe

necessary bolt length.

According to DVS 2210-1, you should dimension the necessary bolt length for fl ange connections so that 2-3 turns of the thread protrude beyond the nut.

Online tool „Bolt lengths and tightening torques“ located at www.gfps.com/tools

1) Maximum operating pressure6 bar


JointingTechnology

Washer(mm)

Thickness(mm)

DN10–DN25 3

DN32–DN600 4

Nuts(mm)

Pitch(mm)

Height of nut (thickness)(mm)

DN10–DN25 M12 SW19(18) 1.7 10.4 DN32–DN125 M16 SW24 2.0 14.1

DN150–DN350 M20 SW30 2.5 20.2 DN400–DN500 M24 SW36 3.0 20.2 DN600 M27 SW 41 3.0 23.8

Flat gasket(mm)

Thickness(mm)

DN10–DN80 ca. 2

DN100–DN600 ca.3

Profile seal(mm)

Thickness(mm)

DN10–DN40 ca.3

DN50–DN80 ca. 4DN100–DN125 ca. 5DN150–DN300 ca. 6DN350–DN600 ca. 7

Flange PP-V PP steel Stahl (hole circle PN16)

Stahl (hole circle PN10)

DN10 – – – –DN15 16 12 – –

DN20 17 12 – –DN25 18 16 – 12DN32 20 20 – 14DN40 22 20 – 14DN50 24 20 – 16DN65 26 20 – 16DN80 27 20 – 18DN100 28 20 – 18DN125 30 24 – 25DN150 32 24 – 20DN200 34 27 24 20DN250 38 30 30 22DN300 42 34 34 26DN350 46 40 35 28DN400 50 40 38 32DN450 – – – 36DN500 – 54 46 38DN600 – 64 42



IV

Metric flange adapters for butt fusion joints

Thickness (mm)

PE SDR11 PE SDR17/17.6

d16/DN10 – –d20/DN15 7 –

d25/DN20 9 –d32/DN25 10 –d40/DN32 11 –d50/DN40 12 12 d63/DN50 14 14 d75/DN65 16 16 d90/DN80 17 17 d110/DN100 18 18 d125/DN100 25 25 d140/DN125 25 25 d160/DN150 25 25 d180/DN150 30 30d200/DN200 32 32d225/DN200 32 32d250/DN250 35 25 d280/DN250 35 25 d315/DN300 35 35d355/DN350 40 30d400/DN400 46 33d450/DN500 60 60 d500/DN500 60 60 d560/DN600 60 60 d630/DN600 60 60

Valves installed in flange connection (mm)

Installation length(mm)

ButterflyvalveType567/578

ButterflyvalveType038/039

DN32 – –DN40 – –

DN50 45 43DN65 46 46 DN80 49 46 DN100 56 52 DN125 64 56 DN150 72 56 DN200 73 60 DN250 113 68 DN300 113 78 DN350 129 78DN400 169 102DN450 179 113DN500 190 126DN600 209 146


JointingTechnology

5.10.6 Selection of gaskets for fl ange connections

Whenselectingsuitableflangesealsforthermoplasticpipingsystems,thefollowingfactors

mustbetakenintoaccount:

• Operatingconditions

• Sealing forces

• Gasketform

• Dimension

• Material

Type of gasket

Flat gasket Profi le gasket O-Ring

Inapplicationswithlowoperatingpressures,thecustomaryflatgasket,whichismadeof2to

5mmthicksheetmaterial(dependingonthenominalwidth),issufficient.Flangeconnections

withflatgasketsrequireflangeswithsufficientstiffness.AllflangesbyGFPipingSystems

meettheserequirements.

Forhigheroperatingandtestingpressures,profileflangegasketsandO-ringshaveproven

useful.Comparedtoflatgaskets,profileflangegasketsconsistoftwoparts.Oneisthe

crownedflatgasketpart,whichisreinforcedwithsteel,andtheotheristheprofilegasket

part(O-ring,lipseal)ontheinnersideofthegasket.

Stabilizedprofileflangegaskets,aswellasO-ringgaskets,havethefollowingadvantages:

• Reliablesealwithlowbolttighteningtorque

• Usable at higher internal pressures and internal vacuum

• Minorinfluenceofflangeorcollarsurface

• Safeoperationwhenconnectingpipesmadeofdifferentmaterials

Asuitablegasketformcanbefoundbyusingthetablebelow.

Gasket form Recommended application limits

Flange or collar design

Flatgasket p≤10bar,aboveDN200only≤6barTto40°C

With sealing grooves

Profilegasket Vacuum(p=0barto16barT = entire application range

Withorwithoutsealinggrooves

O-ring Vacuum(p=0barto16barT = entire application range

Onesidewithgroove

Gasket material

Thechoiceofagasketmaterialisbasedontheflowmedia.Detailsaboutthesuitabilityofthe

gasketmaterial,orspecificallyitschemicalresistance,canbefoundintheGFPipingSystems

resistance tables.

Theuseofgasketmaterialswithahighdegreeofhardness,asinsteelpipes,isnot

recommendedforthermoplasticpipingsystemsbecausetheflangeortheadaptorcould

becomedeformedduetotherequiredhighsealingforces.Elastomermaterials,suchas

EPDM(forwaterapplications)orFPM(forgasapplications),withaShore-Ahardnessofupto

75° are preferable.

Gasket dimension

Thedimensionsofthegasketsaresetinthegeneralstandardsforpipejointingcomponents.

Excessivedimensionaldeviationsintheinsideoroutsidediameterofthegasketcomparedto

theflangeadapterorvalveendcauseincreasedmechanicalstressoftheflangeconnection,

acceleratedwearoftheinnersideofthegasket,aswellasdepositsinsidethepipe.



IV

5.11 MULTI/JOINT 3000 Plus

5.11.1 Overview

Material

• All pipe materials

Wide range fi tting Sealing system cross section Suitable for all pipe materials

5.11.2 Connection technology

Widerangefittingsconnectpipesbymeansofcompression.Whentheboltsaretightened,a

sealispressedontothepipesurface.Intherestraintversion,aUni/Fiksringsecuresthe

connection.TheUni/Fiksringisprovidedwithgrippingelements(“Fiksers”),whichtransfer

the axial forces (through the internal pressure) or tensile forces that occur, to the pipe surface

andasaresultcreatearestraintconnection.Asaresultofthisuniquedesign,useispossible

on all pipe materials.

TheMULTI/JOINT3000Plusfittingshaveawiderangeofupto43mmandconnectpipeswith

apipeoutsidediameterof46mmto637mm(DN50-600).Thiswiderangeallowsdifferent

pipematerialstobeconnectedwithease.


• Easilyaccessibleboltswithantigallingcoating–thispreventscoldwelding

• Maximumangulardeflectionof±8˚persocketside.Foracoupling,thismeansatotal

maximumangulardeflectionof16˚

• Restraint for aboveground and underground installation

• FlangeswithseparateflangeboresforPN10orPN16.(DN425-600combi-flanges)

• ThetechnicaldesignlifeofallMULTI/JOINT3000Plusproductsis50years

• Allfittingsaresuppliedwithhygienicprotection.Thismeansthefittingsareoptimally

protectedagainstexternalinfluenceanddamageuntiltheyreachtheconstructionsite

For more information see www.waga.nl


JointingTechnology

5.12 iJOINTCompression fitting Connection cross-section Easy assembly


TheiJOINTcompressionfittingconnectsPEpipesbycompressingtheseal.Whenthenuts

are tightened, a lip seal is pressed onto the pipe surface. A grip ring secures the connection.

The grip ring transfers the axial forces (through the internal pressure) or tensile forces that

occur to the pipe surface and as a result creates restraint.

Body and thrust ring Properties

Body and thrust ring UV-stabilizedpolypropyleneimpact-resistantcopolymerwithhighlong-termageresistanceinaccordancewithISO9080.

Coupling nut UV-stabilizedbluepolypropyleneimpact-resistantcopolymer

Clamp ring Polyoxymethylene(POM)Seal NBRlipsealtod63

NBRprofilesealfromd75tod110Reinforcing ring (for internal thread)

StainlesssteelAISI430

Thread Externalthreadconical/internalthreadcylindricalin accordancewithISO7


• Forwaterinstallationsupto16bar

• Temperaturerange:-10°Cto+45°C

• Fast and easy installation

• Nopipepreparationrequired(e.g.chamfering)

• Nospecialtoolsrequired

• Thespeciallipgasketallowsasmootpipeinsertionandprovidesatthesametimethebest

possible tightness also in case of out of roundness or slightly scratched pipes.

• Reusable

For more information on using iJOINT, see www.gfps.com



IV

5.13 PRIMOFIT

5.13.1 Overview

Material

• Steelpipes,buttweldtubesandleadpipes

• PE-,PE-Xapipes

Compression fi tting Connection cross section


PRIMOFITisacompressionfittingwhichoffersfullendloadcapability.Additionallyitallowsa

misalignmentoftheconnectedpipesupto3°percompressionjoint.Inpre-assembled

conditionofPRIMOFITcompressionfittings,theinnerdiameteroftheinternalcomponents

seal,washerandlockingringarebiggerthanthemaximumouterdiameterofthepipe.

Thereforepipeinsertionwithoutdismantlingisgranted.Bytighteningthenutthesealis

pressedintothespacebetweenconicalsurfaceofthefittingbodyandtheoutersurfaceofthe

pipe.Atthesametimeaclampingeffectisappliedonthelockingring,whichenablesfullend

loadresistance.ForconnectingPEandPE-Xapipesaninsertstiffenerthatisdesignedtofit

intotheinnerdiameterofthepipeisrequired,whichincreasestheresistanceofthe

PE / PE-Xapipetotheradialforces.


• Mainapplications:water,gas,oil,compressedair,fuel

• Pressure/temperature:uptomaximum16bar,-20to150°C(dependingonsealing

material)

Material:

• Nutandbody:whitemalleablecastironEN-GJMW-400-5inaccordancewithEN1562with

blackorhot-dipgalvanizedsurface

• Seal:NBR,EPDMorFKM

• Pre-assembledreadyforinstallation–noneedfordismantling

• Individuallypackagedwithcolorcodesystem,barcode(EAN)andassemblyinstructions

• Spare-packsystem(sealingkits)forflexiblesolutionsandreuse

• Nospecialtoolsorskillsnecessary

• Nospecialpipepreparationneeded(e.g.cuttingthreads)

• Fastassembly,nocoolingtimes–time-savinginstallation

• Non-destructivedismantlingpossible

• Smallandcompactfittingcanbeusedinawkwardplaces

For more information on using PRIMOFIT, see www.gfps.com and www.fi ttings.at

A PEconnectionB Steel connectiona PEpipes LockingringforPEpiped Washerf Rubber sealg Insertstiffenerh Lockingringforsteelpipej Steel pipek Nutl Coupling body


JointingTechnology

5.14 UNI-Coupling

Material

• PE,PVC,PP,ABS,GFK

• Steel, rubber coated steel, galvanized steel, ductile cast iron, copper1,copper-nickel,

aluminum2

UNI-Coupling Connection cross section


Stainlesssteelcouplingsconnectpipesbymeansofcompression.Whenthescrewsare

tightened,asealwithaconicalstructureispressedontothepipesurface.Inthetension-

resistant design, an anchoring ring secures the connection. The anchoring ring transfers the

axial forces (through the internal pressure) or tensile forces that occur to the pipe surface.

Thiscreatesrestraint.Asaresultofthisuniquedesign,useispossibleonvariouspipe

materials.


Thiscouplingmadeofstainlesssteeloffersnumerousadvantagesoversimilarconnection

elements.Thisisbecausethiscouplingcontainstwospecialcomponentsthatmakeitso

unique.Apatentedsealpreventsleaksandaspeciallyshapedanchoringringensuresa

reliable and permanent connection. As a result of the uncomplicated structure, the coupling is

quicktoinstall.Thankstothetypediversity,itcanbeusedasaconnectorbetweenpipesof

differentmaterialsandwithdifferentoutsidediameters.Better,fasterandmorereliablethan

youhaveknownbefore.UNI-Couplingoffersyouaneasy-to-installsolutionthatsavestime

and money.

• Materialthroughout:W51.4571

• Patentedsealwithcompensationprinciple

• Nostripinsertrequired(exceptiononlywithvacuum>0.5barnegativepressure)

• Anchoring ring for maximum tensile strength

• Bridgingofgreaterpipedimensionswithlargerclampingrange

• Upto5%angulardeflectionpossible

• Continuousweldseamonhousing(nocorrosion)

• Upto35mmgapbetweenpipeendspossible

• Angulardeflectionupto5°

• 3mmtoleranceforconnectionwithdifferentpipeoutsidediameters

For more information on using UNI-Coupling, see www.gfps.com

1 Soft annealed copper pipes onlyinconjunctionwithreinforcement rings

2 Dependentonpipewallthickness


ELGEF Plus System

Content

1 The ELGEF Plus electrofusion system ................................................................................. 1101.1 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.2 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1.3 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

1.4 CAD library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

2 Couplersandfittings ............................................................................................................. 1162.1 System advantages of ELGEF Plus couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.2 SystemadvantagesofELGEFPlusfittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

2.3 System advantages of ELGEF Plus transition adaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3 Saddlesandpressuretappingvalves(PTVs) ...................................................................... 1193.1 System advantages of ELGEF Plus saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

3.2 System advantages of tools - tapping saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.3 Stop-offadaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.4 Spigots saddle with cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.5 Excessflowvalves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4 Spigotfittings .........................................................................................................................1224.1 SystemadvantagesofELGEFPlusspigotfittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5 Installationguidelines-errorprevention ...........................................................................123

6 Electrofusion units .................................................................................................................1256.1 Overview of electrofusion units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.2 Demands on generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

7 Tools and accessories for electrofusion ..............................................................................127

V


The ELGEF Plus electrofusion system

1 The ELGEF Plus electrofusion systemELGEF stands for ELektroschweissen GEorg

Fischer and has been the brand name of the

electrofusionsystemfromGFforover30years

now. The system consists of electrofusion

fittingsandsaddlesaswellasPEballvalvesand

spigotfittings.

1.1 QualityELGEFPlusproductsundergostrictqualitycontrolasdefinedintheinternalqualityplan.

Thisqualityischeckedandconfirmedbymeansofinternalandexternalaudits.

Thequalityplandefinestheprocedure,themeansandthechronologicalsequencesneces-

sarytoverifyanddocumentthespecifiedqualitytargetsfortheELGEFPlusproducts.

ISO10005andtheapprovalsandstandardslistedinChapter4serveasthespecification.

Interrelationship and chronological sequence of the TT/AT/BRT/PVT tests

TT Type Test; a test performed in order to prove that the material or the parts meet the requirements listed in the relevant standards.

AT AuditTest;atestperformedbyoronbehalfofacertificationbody.BRT Batch Release TestPVT ProcessVerificationTest;theplannedrandomsamplingofpartsandmaterialsin

order to verify the process continuity.


ELGEF Plus SystemThe ELGEF Plus electrofusion system

V

1.2 Field of applicationELGEFPluselectrofusionandspigotfittingsaredeveloped,approved,manufacturedand

monitoredaccordingtotheapplicablestandardsEN12201,ISO4427(water),EN1555,

ISO4437(gas),ENISO15495(industrialapplication)aswellasotherlocalstandards.

Suitable pipes

ELGEFPluselectrofusionandspigotfittingsaresuitableforweldingPEstandardpipesmade

ofPE63,PE80,PE100andPE100RCwhosemeltflowrate(MFR)isbetween0.2and

1.4 g/10 min.andcorrespondswiththecommonpipestandardsEN12201-2,EN1555-2,DIN

8074/75,ISO4427-2andISO4437-2.TherestricteddiametertoleranceclassBandtheupper

limitdimensionofovalityarerecommendedforstraightlengths.Separateproduct-specificor

manufacturer-specificapprovalsapplyforPE-Xpipes.

For pipes with a minimum wall thickness smin≥3,0mm,ELGEFPluselectrofusionfittingscan

generally be welded in the following SDR and dimensional range:

• d20–d800mmSDR11

• d90–d1200mmSDR17/17.6

ELGEFPlusfittingscanalsobeweldedcompatiblywithotherSDRclasses.Thepermissible

SDRrangeisshownonthebarcodeattachedtothefittingandmustbeconfirmedbythe

responsible GF branch in doubtful cases.

WhendifferentSDRclassesareusedinonesystem,thehighestSDRleveldeterminesthe

maximum operating pressure.

Ambient temperature

ELGEFPluselectrofusionfittingscanbeinstalledusingGFelectrofusionmachinesatambient

temperaturesofbetween-10°Cand+45°C.ThemeasuresdescribedinDVS2207-1mustbe

takeninthecaseofadverseweatherconditions(rain,frost,insolationetc.).

Examples: Protection from adverse weather conditions

Protecting the welding zone using a tent Waterresiduesmustbepumpedoff



Maximum operating pressure

Afterinstallationinapipingsystem,ELGEFPluselectrofusionandspigotfittingsareexclusi-

velyintendedforallowingmediasuchasgasorwatertoflowthroughthepipewithinthe

permissiblepressureandtemperaturelimitsorforcontrollingthisflow.

Water (20 °C) Gas (20 °C)

PE100 Max.operatingpressureatC=1.25 PFA [bar]

Max.operatingpressureatC=2.0MOP[bar]

SDR11 16 10*

SDR17 10 5*

* Pleasenotedeviationsaccordingtonationalregulations(e.g.CH)orproduct-specificrestrictions!

PFA Maximumpermissibleoperatingpressureforwater(pressiondefonctionnementadmissible)

MOP Maximumpermissibleoperatingpressureforgas(maximumoperatingpressure)

1.3 Identification

1.3.1 Batch no. (production batch)

Importantinformationonlogistics(articleno./EANcode/batch/weight),applicability(stan-

dards/approvals/application)andsimplifiedinstallation(onlineoperatingmanual/manual

welding data) can be found on the bag or box packaging. The batch no. (production batch) is

also permanently moulded into the product in the form of a series marking providing infor-

mation on production year and production batch.

18 Year of production1 Production batch

Inthiscase:batchno.1801 Meaning:1stproductionbatchproducedin2018



V

1.3.2 Welding data and traceability

Welding data

Therearevariousdifferentwaysoftransmittingtheweldingdatatotheweldingunit.The

most widespread (and recommended) method is by reading in a welding barcode. The

contentsofthisweldingbarcodearedescribedinthestandardISO13950.Inputerrorsare

avoided by reading in the welding barcode. The welding parameters are automatically

transmitted to the welding unit.

Ifitisnotpossibletoreadintheweldingdataautomaticallybymeansoftheweldingbarcode,

the welding data can be entered manually.

Temperature-compensated welding times

AllELGEFPluselectrofusionfittingshaveabarcodewhichautomaticallyadaptsthewelding

timetotheambienttemperatureoftheweldingunit.Electrofusionfitting,pipeandwelding

unit have to be on the same temperature level before welding begins. Please note the time

necessary for adapting the temperature!

Traceability

Continuoustraceabilitysafeguardstheoperationofthepipingsystem.Foreachcomponent,

the entire processing chain can be traced back to the production of the raw materials.

ThesystemoftraceabilityisdescribedinthestandardISO12176,Part4.

Besidestheweldingbarcode,thestickerattachedtotheELGEFPluselectrofusionfittingalso

includes the traceability barcode. The information on the cooling time and the applicability of

thepermissibleSDRclassesofthepipecompletetheweldingdata.Inaddition,themanual

welding data in various temperature ranges is displayed on the bag label.

Documentation

The documentation of the work sequence for pipe installations is becoming more and more

important.Inthisconnection,theWeldinOnesoftwareassistsyouinweldingorsystem

maintenance. The Welding Book software extends the data about the joint beyond the welding

records gathered by the electrofusion and butt welding units. The software automatically

combines images made using any smartphone camera with the welding records in each case

in order to document all preparatory activities such as peeling and using clamp holders as

wellasusingthecorrectfittingsandpipes.TheBarcodeCreatorhelpsyoutocreatethe

OperatorIDsforyourfittersinaccordancewithyourcompetencesandtheISO12176-3

standard. It creates the order number in a transparent way in order to trace the installation or

the construction site and allows the automatic assignment of your joint to a certain code. The

Barcode Creator creates certain codes for the tools used at the construction site and even for

pipes(manufacturer,type,diameteranddateofpurchase).



Barcode label

Further information to each product can be downloaded with the unitary QR-Codes from the

database of our online-services. In this way a consolidation of all information from production

and installation is possible in order to generate complete network documentation.

a Product names Code numberd Dimensionf Materialg Traceability code ISO 12176h Unitary QR-Codej Product picturek SDR-Classofthefittingl Max.operatingpressure; Norms/ApprovalA Number of itemsS Batch-No.D Productionmonthandyear,

YY.XXXXF ManualWeldingdataG Nominal welding time and

welding voltageH Welding-BarcodeISO13950J Min.CoolingtimeK SDR-Class of the PipesL Colorbar:yellow=Gas,

blue = Water

Bag label



V

1.4 CAD library

Product library of GF Piping Systems

WiththisCADlibrary,GFPipingSystemsaimstoprovidedesignersandengineerswitheven

betterandmoreefficientsupportforthedesignofpipingsystems.

Three-dimensional models (3-D models) of all piping components by GF Piping Systems in the

area of industrial applications can be called up via the database. The user creates two

dimensional drawings (2-D drawings) on his own in the desired views.

Thelibrarydoesworkindependentlyfromtheuser’sCADsystem.Manysystemsand

interfaces are supported.

Thedatabasecomprisesover30,000drawingsandtechnicaldataregardingpipes,fittings,

measurement and control technology as well as manual and actuated valves.

The CAD library offers:

• Data packets with all the drawings of a system

• Over30,000drawings

• Pipes,fittings,valves,measurement&control

• Presentation in 2-D and in 3-D

• Optimized user interface

• MultifunctionaldriversforthemostcommonCADsystems

• Quick access

G5.9 Sample presentation of a CAD library

Direct access to the online CAD library at http://cad.georgfischer.com


Couplersandfittings

2 Couplers and fi ttings

2.1 System advantages of ELGEF Plus couplersELGEF Plus couplers d20-63 – integrated pipe fi xation

ELGEFPluselectrofusioncouplersd20-63areequippedwithan“integratedpipefixation”.

This facilitates pipe installation for:

• Vertical pipe sections

• Thepreinstallationoffittings,metaladaptersorvalvemodules

• Theprefixationofcoiledpipeends(doesnotreplacetheuseofclampingdevices)

ELGEF Plus couplers d20-160 – easy-to-remove center stop

AllELGEFPluselectrofusioncouplersd20-160areequippedwitharemovablecenterstop.

This facilitates pipe installation:

• An end stop can be felt when the pipe is inserted

• Whenthecouplerispushedoverthepipe,thecenterstopcanbe„ejected“easilybythe

pipe

ELGEF Plus couplers - number of welding zones

ELGEFPluselectrofusioncouplersd20-500havetwointerconnected(monofilar)welding

zones,i.e.bothweldingzonesareweldedinoneweldingprocess.

Asaresultofthenecessarypowerinput,twoseparate(bifilar)weldingzonesarerequired

forELGEFPluscouplers≥d560.Thismeansthateachpipeendcanbeweldedseparately

using these electrofusion couplers.

ELGEF Plus couplers – easy to install and easy to push over pipes

Thankstothecoveredwiresandthespeciallydevelopedelectricaldesign,allELGEFPlus

electrofusioncouplersareabletobridgearelativelylargegap.Forthisreason,thecouplers

have a larger internal diameter. This facilitates pipe installation:

• When the coupler is pushed onto the pipe end

• Whenthecouplerisslidedoverthepipe,thusreducingtheinstallationtime

ELGEF Plus couplers d355-800 – active reinforcement

ELGEFPluselectrofusioncouplersd355-800areequippedwithan„activereinforcement“.

The outer PE ring expanded in the manufacturing process exerts its tension when heated

during the welding process and actively presses onto the internal ring during welding. This

causesthegapbetweenpipeandfittingtobeclosedactivelyandexpansionofthecouplerto

be inhibited.

In other words:

• Thecouplersareeasiertopushoverthepipe,thusfacilitatinginstallation

• Reduced installation times are possible without preheating or additional equipment


ELGEF Plus SystemCouplersandfittings

V

2.2 System advantages of ELGEF Plus fi ttingsELGEF Plus fi ttings d20-63 – integrated pipe fi xation

ELGEFPluselectrofusionfittingsd20-63areequippedwithan„integratedpipefixation“.

These facilitate pipe installation for:

• Vertical pipe sections

• Thepreinstallationoffittings,metaladaptersorvalvemodules

• Theprefixationofcoiledpipeends(doesnotreplacetheuseofclampingdevices)

ELGEF Plus fi ttings – easy to install and easy to push onto pipes

Thankstothecoveredwiresandthespeciallydevelopedelectricaldesign,allELGEFPlus

electrofusionfittingsareabletobridgearelativelylargegap.Forthisreason,thefittings

havealargerinternaldiameter.Thisfacilitatespipeinstallationwhenthefittingsarepushed

onto the pipe end and reduces the installation time.

ELGEF Plus fi ttings d75-250 – insertion depth marking

ThereisaninsertiondepthmarkingonELGEFPluselectrofusionfittingsd75-250.This

facilitatesthemeasurementoftheweldingzonelengthwithoutthepackagingofthefitting

havingtobeopenedatanearlystage,allowingthefittingtobecomecontaminated.

ELGEF Plus fi ttings d75-180 – angle marking

ThereisananglemarkingonELGEFPluselectrofusionfittingsd75-180atthecoupler

openingofthefitting.Thisfacilitatesthealignmentofthefittingwithregardtoangleand

position during installation without additional measuring equipment being required.

ELGEF Plus fi ttings – number of welding zones

ELGEFPluselectrofusionfittingsd20-180havetwointerconnected(monofilar)welding

zones,i.e.bothweldingzonesareweldedinoneweldingprocess.Tofacilitateinstallation,

ELGEFPluselectrofusionfittings≥d200havetwoseparate(bifilar)weldingzones.

Thismeansthat,withtheseelectrofusionfittings,eachpipeendcanbeweldedseparately.


Couplersandfittings

2.3 System advantages of ELGEF Plus transition adaptors

ELGEF Plus transition fi ttings d20-63 – modular system

ELGEFPluselectrofusiontransitioncouplersandfittingsd20-63arestructuredasamodular

system.Awiderangeoftransitionvariantscanbecreatedfromonecouplerorfitting.This

flexibilitymakesinstallationeasierandfaster–andreducesyourinstallationcosts.These

transition adaptors can only be used in conformity with the system in connection with ELGEF

Pluselectrofusionfittings.

Thisincreasesyourinstallationflexibilityandreducesthenecessarywarehousespace:

• Complete system with few individual parts

• Reductionofwarehousestoragebyupto50%invalueterms

• Flexible mounting to valves as a result of being able to rotate and screw the adaptor until

just before welding begins

• Materialsapprovedforusewithdrinkingwater–optionallyinbrassorstainlesssteel

Duringinstallation,itshouldbenotedthatthepipingmustwithstandmechanicalstresses

andtheexpectedcorrosivestressescomingfromtheoutside.Ifnecessary,thetransition

adaptors must be coated or covered. The existing soil conditions and the installation and

operating conditions are crucial for the selection of the pipe covering.

The outer coating or covering has to meet the various requirements in a suitable way as

follows:

Excellentstabilityagainstexternalinfluencesafterinstallation,suchasaggressivesoils,

straycurrents,microorganisms,plantgrowthetc.


ELGEF Plus SystemSaddles and pressure tapping valves (PTVs)

V

3 Saddles and pressure tapping valves (PTVs)

3.1 System advantages of ELGEF Plus saddlesELGEF Plus saddles d63-400 – modular system

ELGEFPluselectrofusionDuoblocsaddlesd63-400arestructuredasamodular

system. It is possible to create a wide range of variants from one Duobloc saddle

-suchastappingsaddles,tappingsaddleswithagasstop,PTVs,stop-off

saddlesandspigotsaddleswithcutter-fordifferentoutletdimensions.

Thisincreasesyourinstallationflexibilityandreducesthenecessarywarehouse

space:

• Complete system with few individual parts


• Variableassemblypossibleastheoutletcanberotatedby360°

• Vertical or horizontal installation possible

Thisflexibilitymakesinstallationeasierandfaster–andthisinturnreduces

yourinstallationcosts.Inthemodularsystem,onlyadditionalcomponents

conforming to the system are permitted!

ELGEF Plus saddles d63-400 – large tapping diameter

ELGEF Plus electrofusion saddles have extra large tapping diameters (d2). They

also have considerably larger cross-sections than the usual commercially

available products.

This causes a lower pressure loss and gives the operator the following advanta-

ges:

• Morepressurearrivesattheconsumeratthesameinputpressureor

• The pressure in the supply pipe can be reduced

ELGEF Plus saddles – outlet spigot no longer needs to be peeled

We lay particular emphasis on cleanliness during the production of the electro-

fusionfittings,andeachfittingis„cleanly“packedinabag.Asaresult,the

connecting spigots to the electrofusion saddle or to the outlet pipe do not need to

be peeled - on condition that they are used immediately upon removal from the

protective bag:

• This saves valuable installation time

• There are no expenses for special peeling tools

Inthisway,youcanreducethecostsofyourhouseconnectingproject,making

youmorecompetitive.Iftheoutletspigotsarepeeledcorrectly,thisstilldoesnot

reduce the quality. The usability is ensured. We recommend cleaning the outlet

spigot using Tangit PE cleaner.

ELGEF Plus saddles - length of the outlet spigot

Intheunfavorableeventofaninstallationerror,thelengthoftheoutletspigot

allows a second welding process to be carried out. The outlet spigot of the

ELGEF Plus electrofusion saddles can be shortened in the case of an installation

orweldingerror,andtheremaininglengthallowstheoutlettoberewelded*:

• Whennecessary,thissavesconsiderableinstallationtimeandreconditioning

costs

• This saves you from trouble with the residents and the network operator*Thisdoesnotapplywhenanintegratedexcessflowvalveisused

d2


Saddles and pressure tapping valves (PTVs)

ELGEF Plus branch saddles – effi cient installation of reduced outlets

ELGEFPlusbranchfittingsareanextremelyreliableandhugelyeconomicalway

ofinstallingreducedoutletsandofferyouthefollowingadvantageswhenthey

are newly installed:

• Variable positioning on the main pipe

• 1 weld less in comparison with a T-piece

• Formainpipesd63-d2000withoutletsolutionsd63-d500

• Full pressure class possible

• Considerably lower material costs

• Overall installation costs are reduced considerably as a result of the shorter

installation time and the smaller size of the trench

When integrated later:

• Can be integrated under operating pressure

• The usual common not tapping methods can be used

• Smaller trench size in inner city areas

• OptimumalternativetotheT-piecefornewinstallation,laterintegrationand

renovation/repairs

3.2 System advantages of tools - tapping saddlesArticle no. Installation tools

799198047 Installationandtappingkeysforsaddles(externalhexSW8,internalhex10and17)

799150378 Hexkeyforsaddlesandbranchsaddles(externalhexSW8)

T5.15 Monobloc tapping saddles d40, d50

dn Tapping key Test cap Tapping adaptor*

4050

Notnecessary!

T5.16 Monobloc tapping saddles with sprayed lower section


6390110125160

Notnecessary!

T5.17 Duobloc tapping saddles with rotatable outlet


63-400

S54 for outletd20-40S67 for outletd50-63

S54 for outletd20-40S67 for outletd50-63

* Tappingwithnogaslosses.

* Tappingwithnogaslosses.

* Tappingwithnogaslosses


ELGEF Plus SystemSaddles and pressure tapping valves (PTVs)

V

T5.18 Pressure tapping valves (PTVs):


63-400

RatchetExternal hexSW14

Notnecessary!

Notnecessary!

13 revolutionsOutlet d3228 revolutionsOutlet d63

3.3 Stop-off adaptorsELGEF Plus stop-off adaptors – the repair solution for shut-off under gas pressure

Fortheshort-termshut-offofgaspipeswhilerepairsarebeingmade,stop-offadaptorsare

oftenusedinthelow-pressurerange.UsinganELGEFPlusstop-offadaptorandanELGEF

Plussaddle,theshut-offadaptorcanbeconnectedtothepipingquicklyandeasily.

Thisincreasesyourinstallationflexibilityandreducesthenecessarywarehousespace:

• Complete system with few spare parts


3.4 Spigots saddle with cutterELGEF Plus spigot saddles with cutter – a cost-effi cient solution for new buildings

A PE spigot with cutter can also be integrated into the modular system of ELGEF Plus

electrofusion saddles:

• Indoubtfulcases,thisreducestheheightofthepipecovering

• It also saves you money on the components

3.5 Excess fl ow valvesExcessflowvalvesareforemergencyshut-offafterdamagetoorthedestructionofbranch

pipes and prevent gas from escaping uncontrollably. This makes them an active protective

element designed to reduce the risk of accident.

Excess fl ow valves in the ELGEF Plus saddles

The modular ELGEF Plus range of tapping saddles also includes variants with an excess

flowvalve:

• Reducedwarehouseandcomponentcoststhankstoflexibilityandmodularsystem

• Variantsforallpressurelevelsupto10baravailable

Standard variants:

• TypeADUE25mbar–1barwithoverfloworifice

• TypeBUE200mbar–5barwithoverfloworifice

• Type1-5barwithoutoverfloworifice

* Tappingwithnogaslosses


Spigotfittings

4 Spigot fi ttingsThePE100rangeofspigotfittingsfromGeorgFischeristheidealadditiontotheELGEFPlus

electrofusionrange,offeringproventechnologyinanenormousrangeofvariants.

Angles,curves,T-pieces,reductions,endcapsandflangeadaptorareavailableinthe

dimensionalrangebetweend20andd1000mm.TheyareeasytointegrateintotheELGEF

PlussystemusingELGEFPluscouplersorfittings.Dependingontheinstallationsituation,

these can also be butt-welded.

4.1 System advantages of ELGEF Plus spigot fi ttingsGeorg Fischer spigot fi ttings d20-1000 – comprehensive range

Firstandforemost,therangeofspigotfittingsfromGeorgFischerincludesa

wide range of variants. The width and depth of the range are crucial for their

main applications. Numerous reductions and T-pieces with reduced outlets can

help you out in special situations.

Thisincreasesyourinstallationflexibilityandlowersyoureffortonsite,thus

saving costs.

Georg Fischer spigot fi ttings d20-315 – individually packed in PE protective bags

Immediatelyafterproduction,thespigotfittingsfromGeorgFischerarepacked

inPEprotectivebagsandboxes.AswiththeELGEFPluselectrofusionfittings,

thispreventsoxidationofthesurfaceduetoUVlight.Inotherwords,whenthe

spigotfittingsaretransportedandstoredcorrectly,youcandispensewith

peelingthefittingsonsite:

• This reduces your installation time

• It also saves installation costs

Georg Fischer spigot fi ttings d20-315 – complete traceability

AllspigotfittingsfromGeorgFischerareconsistentlyequippedwiththe

traceability barcode.

Thisincreasesyourinstallationflexibilityandlowersyourinputonsite,thus

saving costs:

• You feel secure in the knowledge that all quality-relevant factors of the

welding joint have been sustainably documented

• Reduced search costs when damage occurs

Georg Fischer Spigot fi ttings d355-800 - Designed for BIG ideas

Large dimensions are a challenge for users and installers. Injection-moulded

socketfittingsuptod500mmsupportinstallationwithfeaturessuchas:

• Angle/insertiondepthmarkingsonthespigot

• Supporting surfaces for a spirit level

• Centringaidforflanges

Uptodimensiond800mm,GeorgFischeroffersspigotfittingswhicharefully

pressure rated and have no pressure reduction factor.


ELGEF Plus SystemInstallation guidelines - error prevention

V

5 Installation guidelines - error prevention

Frequent causes of error and remedial measures

Hereisalistofcauseswhichcanleadtoerrorsduringelectrofusionasaresultofcareless

preparation,butareeasyfortheexpertpersonneltopreventbyobservingasmallnumberof

principles:

TheerrorsinweldingjointsforheatingcoilsaredescribedindetailInDVS2202,Supplement

2.Inthefollowing,weprovideashortdescriptionofthemostfrequentcausesoferroraswell

asremedialmeasureswithoutgoingintothedetailsofthedescription,thetestmethodsor

the evaluation criteria.

Figure Cause of error Remedial measures

G5.10 External welding error – insertion depth

Insertion depth not seribed or incorrectly Markcorrectlyandfollowinstructions

G5.11 External welding error – inadequate peeling

Thereisnovisiblemachiningextendingbeyondthefittingbody

The visible machining is:• irregular• inadequate (chip thickness)• not continuous• non present• excessive (pipe undersized)• impermissible(manualscrapingforPE-X)

Markcorrectlyandfollowinstructions.Suitable peeling device and regular maintenance

G5.12 Internal welding error - twisting

Angular deviation with displacement of heating spiral and melt withorwithoutseparationsinthejoiningplane,increasedmaterialflow,forexamplethrough• non-flushpipeends• inadequate curvature radii in the case of ring coils• bending moment on the sleeve• movement during the weldingInextremecases,thisincorrectinstallationcanleadtolocaloverheatingwithsmokeandflamedevelopment.

Use of clamping devices

G5.13 Internal welding error – shape inaccuracy

Channelformationlocally,overlargeaxialareasorradiallyaroundthecircumference,e.g.dueto:• notchesand/orgroovesinthepipesurface• deviating diameter tolerance (pipe undersized)• incorrect machining• mechanical damage• flaking

Suitable peeling device and regular maintenanceReplacement of the peeling blade

G5.14 Internal welding error – incomplete pipe insertion

Pipeendsoffsetornottouchingeachotherorthestopononeorboth sides in the sleeve and melt emergence on the inside or outside,e.g.dueto:• insufficientpipeinsertiononbothsides/oneside(noadequate

coverage in the joining plane)• unequal pipe insertion • pipeendnotcutoffatarightangleInextremecases,thisincorrectinstallationcanleadtolocaloverheatingwithsmokeandflamedevelopment.

Cutting of the pipe ends at right angles.Use a suitable pipe cutter


Installation guidelines - error prevention

Figure Cause of error Remedial measures

G5.15 Internal welding error – inadequate material bond

Incomplete joint locally or over large areas with or without separationinthejoiningplane,e.g.dueto:• insufficientweldingenergy(e.g.prematureweldingtermination)• moisture• contaminated surface• impermissible material combinations

• Precleaningofthepipe,cleaning in the peeled area only;clean,lint-freepaper;solvent evaporates comple-tely,avoidtouchingthecleaned pipe surface.

• Usedataoffittingtobewelded only

• Comply with cooling time and avoid time pressure

G5.16 Internal welding error - SDR class not permissible

WallthicknessofthepipeisoutsideoftheSDRrangespecifiedbythefittingmanufacturer.Inextremecases,thisincorrectinstalla-tioncanleadtolocaloverheatingwithsmokeandflamedevelop-ment.

• Check compatibility on the barcode label before welding

• Usedataoffittingtobewelded only

Rewelding

Ifweldingisaborted,e.g.asaresultofexternalinfluences(suchasgeneratorbreakdown),rewelding can be carried out after the materials have completely cooled down to the ambient temperature. The following points must be complied with here:

• Checking and correction of the cause of error. The relevant error message from the

electrofusion unit gives indications as to the possible cause of error.

• It is not permitted to remove the clamping devices holding the joint.

• Thefittingmustbeprotectedfromcontaminationandmoisture.Itisnotpermittedtouse

additional coolants (cold water etc.) to accelerate the cooling process.

Checkingofthefittingresistanceattheelectrofusionunit:fittingresistancemusthavetheinitial value again after cooling. It is not permitted to reweld joints if the tightness test was unsuccessful.


ELGEF Plus SystemElectrofusion units

V

6 Electrofusion units

6.1 Overview of electrofusion unitsMSA 125 MSA 230 MSA 330 MSA 2.0 MSA 340 MSA 2.1 MSA 2 MULTI MSA 4.0 MSA 4.1

Material PE/PP PE PE/PP PE/PP PE/PP PE/PP PE/PP/PB/PVDF

PE/PP PE/PP

Electrical data

Protection class IP54 IP54 IP54 IP65 IP54 IP65 IP65 IP65 IP65

Switch

Output voltage 8-42V 39-40V 8-48V 8-48V 8-48V 8-48V 3.6-40V 8-48V 8-48V

Output current max (A) 50 90 110 90 110 90 90 110 110

Display Graphical Alphanum Alphanum Graphical Alphanum Graphical Graphical Graphical Graphical

Data and operating control system

Protocols 350 350 500 350 1000 1000 500 5000 5000

Export protocols

Welding data format CSV/PDF CSV CSV/PDF CSV/PDF PDF/BIN PDF/BIN PDF/BIN PDF/BIN

Language variants 4 9 11 Symbols 11 Symbols Symbols 27 27

Mechanical data

Weight (kg) 13 19 23 11.9 23 11.9 11.9 12.5 12.5

Power cable length (m) 4 4 4 4 4 4 4 4 4

Welding cable length (m) 3 3 4 3 4 4 4 4 4

Functions

Order number

Manualweldingdatainput

Traceability

GPS

Workflowconfiguration

WeldinOne-compatible

QR code Optional

WLAN scanner

Online service apps

Mobilenetworkcomm.


Electrofusion units

6.2 Demands on generators

Generators

Generators are used to ensure a reliable supply of electricity to the electrofusion unit at

construction sites. The following requirements must be taken into account here:

• Generatormaintainedregularly(onceyearlyaccordingtoDVS)withsufficientoutputpower

fortheelectrofusionunitandtheelectrofusionfittingstobewelded

• Sufficientfuelforthegeneratorforthetimeittakestomakethenecessarywelds

• The generator supplies the electrofusion unit only (no other consumers)

The generator provides the electrofusion unit with a safe and stable electrical network - even

under load - with the following basic conditions:

• Power output >3.5 kVA (or from d355 >6 kVA)

• Voltage230V±10%

• Frequency50Hertz±10%

• Current(back-upfuse)13to20A

6.2.1 Accessories

Adaptors

As the connectors on the cable of the electrofusion unit are subject to wear due to frequent

insertionandremoval,adaptorsshouldbeused.Thisreducesthecostsandprevents

unnecessary failure of the electrofusion unit. Worn-out adaptors must be replaced.

Angle adaptors

Someinstallationswhicharelocatedininner-cityareasorusemultifunctionalpipesoffer

verylittlespace.Inordertohavesufficientroomforthepowersupplyoftheelectrofusion

fittingwhileminimizinginstallationheight,itcanbehelpfultouseangleadaptors.

Extension cables

Maximum20mwithacross-sectionof2.5mm2.

6.2.2 Practical tips

Strain relief of welding cable

Intherestrictedspaceavailableinthetrench,youcouldtripovertheweldingcable.Ifthe

weldingcableisattachedbetweenelectrofusionunitandELGEFPlusfittingwithstrainrelief

(bywrappingthecableoncearoundthepipe),theweldingprocessisnotinterruptedinspite

of this occurrence.

Unwinding the cable roll

Asaresultoftheelectromagneticeffectofacoil,cabledrumsbetweengeneratorand

electrofusion unit must be unwound completely at all times.


ELGEF Plus SystemTools and accessories for electrofusion

V

7 Tools and accessories for electrofusion

Overview

The tools used for electrofusion must be coordinated with the electrofusion system. The

following table is an overview of the tool groups and accessories including a representative

example:

Figure Tool group and accessories

Dimensional ranges

Purpose

Rotary peelers d20-1200 Remove the oxide layer through peeling of the pipe or spigot end when preparing for welding

Cleaning agents - Residue-free cleaning of the welding surfaces when preparing the pipe

Cutting tools d10-1600 Allow plastic pipes to be separated at right angles

Tapping tools - For the tapping of tapping saddles

Clamping and align-ment tools

d20-630 Allow stress-free installation during the welding and cooling process

Installation tools (topload)

d280-630 For welding tapping saddles and branch saddles

Installation tools (topload)

d315-2000 Welding branch saddles

Re-rounding tools d25-2000 Mechanicalcompensationofpipe ovalities during the welding and cooling process

Squeeze-offtools d20-250 Mechanicalsqueeze-offtoolsaresuitableforshuttingoff(squeezingoff)PEpipesduringrepair and extension work.

Markingandmeasuring - Determining the diameter of the components to be welded.Markingthepeelingareaandthe insertion depth

T5.19 Overview of tools and accesso-ries for electrofusion


Electrofusion units

GF Piping Systems – Piping Systems in Utilities – (11.18) A · 129

A

IndexAAbbreviations and units of measure 42Abrasion resistance PE 29Accredited test center 17Application solutions 21Approvals and Standards 33Automation 26

BBarcode and bag label 114Basic information about welding seam preparation 89Basic knowledge 41Batch-No. 112Blind flange 98Butt fusion jointing (heating element fusion conventional

butt fusion) 82

CCAD 115Calculation of allowable pressure/required wall thickness

53Chemical resistance 29Combustion behavior 29Control 26Conversion tables 45Couplers and fittings ELGEF Plus 116

DDesign and Laying 39Design factor 54

EElectrical properties PE 30Electrofusion (heating element fusion joints) 88Electrofusion units 125ELGEF Plus brackets and pressure tapping valves (PTVs)

119ELGEF Plus electrofusion unit 125ELGEF Plus Identification 112ELGEF Plus installation guidelines – error prevention 123ELGEF Plus range of application 111ELGEF Plus sockets 116ELGEF Plus spigot fittings 122ELGEF Plus System 109, 110Environment 19

FFlange connections 97Flow volume 45

GGaskets 104Gas Utilities 24GF Piping Systems 14

HHydraulic Calculation and Pressure Losses 65

IIdentification ELGEF Plus 112iJOINT 106Installation guidelines – error prevention ELGEF Plus

123Installation process 93Integral connections 82Internal pressure and leak test 78

JJointing Technology 82

LLaying 73Leak test 78Length of bolts 101Long-term behavior of PE 47Long-term behavior of thermoplastic materials 46Long-term behavior PE80 49Long-term behavior PE100 48

MMeasurement 26Mechanical joints 96Metric and British system of units 41MRS-values 46MULTI/JOINT 105

NNomogram 67

OOuter diameter 66Oxide layer 74

PPackaging concept 75Physiological properties PE 30Pipe diameters 65Pipelines under vacuum 59Pipe trenches 73Plastic piping materials 27Polyethylene (PE) 28Pressure and heads 45Pressure loss 70Pressure-temperature diagram for PE 50PRIMOFIT 107Processing and handling 74Product library 115Properties of Plastic Piping Materials 28

QQuality 17, 97

A · 130 GF Piping Systems – Piping Systems in Utilities – (11.18)

RRange of applications for pipes and fittings 50

SSaddles and pressure tapping valves (PTVs) ELGEF Plus

119Safety factors 57SDR 42Selecting plastic piping components 53SI-units 43Spigot fittings ELGEF Plus 122Standards and guidelines 34Storage 75Sustainability 19, 30

TThe ELGEF Plus electrofusion system 110Threaded fittings 97Tightening torque 100Tools for electrofusion 127Training 20Transition adapter with thread 97Transition fittings 118Transport 76Trenchless laying 74

UUNI-Coupling 108

VVacuum 59Viscosities 45

WWall thickness 53Water hammer 55Water Utilities 22Welding data and traceability 113

GF Piping Systems – Piping Systems in Utilities – (11.18) A · 131

A

A · 132 GF Piping Systems – Piping Systems in Utilities – (11.18)

700.671.677GFDO_P-UT_01_EN (12.18)© Georg Fischer Piping Systems Ltd. CH-8201 Scha� hausen/Switzerland, 2018

UtilityBuilding Technology

Industry

GF Piping Systems

The information and technical data (altogether “Data”) herein are not binding, unless explicitly confirmed in writing. The Data neither constitutes any expressed, implied or warranted characteristics, nor guaranteed properties or a guaranteed durability. All Data is subject to modification. The General Terms and Conditions of Sale of Georg Fischer Piping Systems apply.

Worldwide at homeOur sales companies and representatives ensure local customer support in more than 100 countries.

www.gfps.com

Argentina / Southern South AmericaGeorg Fischer Central Plastics Sudamérica S.R.L.Buenos Aires / ArgentinaPhone +54 11 4512 02 [email protected]/ar

AustraliaGeorge Fischer Pty LtdRiverwood NSW 2210Phone +61 (0) 2 9502 8000 [email protected]/au

AustriaGeorg Fischer Rohrleitungssysteme GmbH3130 HerzogenburgPhone +43 (0) 2782 856 [email protected]/at

Georg Fischer Fittings GmbH3160 TraisenPhone +43 (0) 2762 [email protected]

Belgium / LuxembourgGeorg Fischer NV/SA1600 Sint-Pieters-Leeuw / BelgiumPhone +32 (0) 2 556 40 20Fax +32 (0) 2 524 34 [email protected]/be

BrazilGeorg Fischer Sist. de Tub. Ltda.04571-020 São Paulo/SPPhone +55 (0) 11 5525 [email protected]/br

CanadaGeorg Fischer Piping Systems LtdMississauga, ON L5T 2B2Phone +1 (905) 670 8005Fax +1 (905) 670 [email protected]/ca

ChinaGeorg Fischer Piping Systems Ltd Shanghai 201319Phone +86 21 3899 3899 [email protected]/cn

Chinaust Plastics Corp. Ltd.Songlindian, Zhuozhou city, Hebei province, China, 072761Phone +86 312 395 2000Fax +86 312 365 [email protected]

Denmark / IcelandGeorg Fischer A/S2630 Taastrup / DenmarkPhone +45 (0) 70 22 19 [email protected]/dk

FinlandGeorg Fischer AB01510 VantaaPhone +358 (0) 9 586 58 25 Fax +358 (0) 9 586 58 [email protected]/fi

FranceGeorg Fischer SAS95932 Roissy Charles de Gaulle CedexPhone +33 (0) 1 41 84 68 [email protected]/fr

GermanyGeorg Fischer GmbH73095 Albershausen Phone +49 (0) 7161 302 [email protected]/de

IndiaGeorg Fischer Piping Systems Pvt. Ltd400 083 MumbaiPhone +91 22 4007 2000 Fax +91 22 4007 [email protected]/in

ItalyGeorg Fischer S.p.A.20063 Cernusco S/N (MI)Phone +39 02 921 [email protected]/it

Georg Fischer TPA S.r.l.IT-16012 Busalla (GE)Phone +39 010 962 47 [email protected]/it

JapanGeorg Fischer Ltd530-0003 Osaka Phone +81 (0) 6 6341 [email protected]/jp

KoreaGeorg Fischer Korea Co. LtdUnit 2501, U-Tower120 Heungdeok Jungang-ro (Yeongdeok-dong) Giheung-gu, Yongin-si, Gyeonggi-do Phone +82 31 8017 1450Fax +82 31 217 [email protected]/kr

MalaysiaGeorge Fischer (M) Sdn. Bhd.41200 Klang, Selangor Darul EhsanPhone +60 (0) 3 3122 5585Fax +60 (0) 3 3122 [email protected]/my

Mexico / Northern Latin AmericaGeorg Fischer S.A. de C.V.CP 66636 Apodaca, Nuevo Leon / MexicoPhone +52 (81) 1340 8586Fax +52 (81) 1522 [email protected]/mx

Middle EastGeorg Fischer Piping Systems (Switzerland) LtdDubai / United Arab EmiratesPhone +971 4 289 49 [email protected]/int

NetherlandsGeorg Fischer N.V.8161 PA EpePhone +31 (0) 578 678 222 [email protected]/nl

Georg Fischer Waga N.V.NL-8160 AG EpePhone +31 (0) 578 678 [email protected]

New ZealandGeorg Fischer Ltd5018 Upper HuttPhone +04 527 9813Fax +04 527 [email protected]/nz

NorwayGeorg Fischer AS1351 Rud Phone +47 67 18 29 [email protected]/no

PolandGeorg Fischer Sp. z o.o.05-090 Sekocin Nowy Phone +48 (0) 22 31 31 0 50 [email protected]/pl

RomaniaGeorg Fischer Piping Systems (Switzerland) Ltd020257 Bucharest - Sector 2Phone +40 (0) 21 230 53 [email protected]/int

RussiaGeorg Fischer Piping Systems (Switzerland) LtdMoscow 125040Phone +7 495 748 11 [email protected]/ru

SingaporeGeorge Fischer Pte Ltd528 872 SingaporePhone +65 6747 0611Fax +65 6747 [email protected]/sg

Spain / PortugalGeorg Fischer S.A.28046 Madrid / SpainPhone +34 (0) 91 781 98 [email protected]/es

SwedenGeorg Fischer AB117 43 StockholmPhone +46 (0) 8 506 775 [email protected]/se

SwitzerlandGeorg Fischer Rohrleitungssysteme (Schweiz) AG8201 SchaffhausenPhone +41 (0) 52 631 [email protected]/ch

TaiwanGeorg Fischer Co. LtdSan Chung Dist., New Taipei CityPhone +886 2 8512 2822Fax +886 2 8512 2823www.gfps.com/tw

United Kingdom / IrelandGeorge Fischer Sales LimitedCoventry, CV2 2ST / United KingdomPhone +44 (0) 2476 535 [email protected]/uk

USA / CaribbeanGeorg Fischer LLC92618 Irvine, CA / USAPhone +1 714 731 88 00 Fax +1 714 731 62 [email protected]/us

Georg Fischer Central Plastics LLCShawnee, OK 74801 / USAPhone +1 (405) 273 63 [email protected]

VietnamGeorge Fischer Pte LtdRepresentative OfficeHo Chi Minh CityPhone + 84 28 3948 4000Fax + 84 28 3948 [email protected]/vn

International Georg Fischer Piping Systems (Switzerland) Ltd8201 Schaffhausen / SwitzerlandPhone +41 (0) 52 631 3003Fax +41 (0) 52 631 [email protected]/int

170106-backcover-A4-utility_blue.indd 1 11.09.2018 11:08:40

GF Piping Systems

The information and technical data (altogether “Data”) herein are not binding, unless explicitly confirmed in writing. The Data neither constitutes any expressed, implied or warranted characteristics, nor guaranteed properties or a guaranteed durability. All Data is subject to modification. The General Terms and Conditions of Sale of Georg Fischer Piping Systems apply.

Worldwide at homeOur sales companies and representatives ensure local customer support in more than 100 countries.

www.gfps.com

Argentina / Southern South AmericaGeorg Fischer Central Plastics Sudamérica S.R.L.Buenos Aires / ArgentinaPhone +54 11 4512 02 [email protected]/ar

AustraliaGeorge Fischer Pty LtdRiverwood NSW 2210Phone +61 (0) 2 9502 8000 [email protected]/au

AustriaGeorg Fischer Rohrleitungssysteme GmbH3130 HerzogenburgPhone +43 (0) 2782 856 [email protected]/at

Georg Fischer Fittings GmbH3160 TraisenPhone +43 (0) 2762 [email protected]

Belgium / LuxembourgGeorg Fischer NV/SA1600 Sint-Pieters-Leeuw / BelgiumPhone +32 (0) 2 556 40 20Fax +32 (0) 2 524 34 [email protected]/be

BrazilGeorg Fischer Sist. de Tub. Ltda.04571-020 São Paulo/SPPhone +55 (0) 11 5525 [email protected]/br

CanadaGeorg Fischer Piping Systems LtdMississauga, ON L5T 2B2Phone +1 (905) 670 8005Fax +1 (905) 670 [email protected]/ca

ChinaGeorg Fischer Piping Systems Ltd Shanghai 201319Phone +86 21 3899 3899 [email protected]/cn

Chinaust Plastics Corp. Ltd.Songlindian, Zhuozhou city, Hebei province, China, 072761Phone +86 312 395 2000Fax +86 312 365 [email protected]

Denmark / IcelandGeorg Fischer A/S2630 Taastrup / DenmarkPhone +45 (0) 70 22 19 [email protected]/dk

FinlandGeorg Fischer AB01510 VantaaPhone +358 (0) 9 586 58 25 Fax +358 (0) 9 586 58 [email protected]/fi

FranceGeorg Fischer SAS95932 Roissy Charles de Gaulle CedexPhone +33 (0) 1 41 84 68 [email protected]/fr

GermanyGeorg Fischer GmbH73095 Albershausen Phone +49 (0) 7161 302 [email protected]/de

IndiaGeorg Fischer Piping Systems Pvt. Ltd400 083 MumbaiPhone +91 22 4007 2000 Fax +91 22 4007 [email protected]/in

ItalyGeorg Fischer S.p.A.20063 Cernusco S/N (MI)Phone +39 02 921 [email protected]/it

Georg Fischer TPA S.r.l.IT-16012 Busalla (GE)Phone +39 010 962 47 [email protected]/it

JapanGeorg Fischer Ltd530-0003 Osaka Phone +81 (0) 6 6341 [email protected]/jp

KoreaGeorg Fischer Korea Co. LtdUnit 2501, U-Tower120 Heungdeok Jungang-ro (Yeongdeok-dong) Giheung-gu, Yongin-si, Gyeonggi-do Phone +82 31 8017 1450Fax +82 31 217 [email protected]/kr

MalaysiaGeorge Fischer (M) Sdn. Bhd.41200 Klang, Selangor Darul EhsanPhone +60 (0) 3 3122 5585Fax +60 (0) 3 3122 [email protected]/my

Mexico / Northern Latin AmericaGeorg Fischer S.A. de C.V.CP 66636 Apodaca, Nuevo Leon / MexicoPhone +52 (81) 1340 8586Fax +52 (81) 1522 [email protected]/mx

Middle EastGeorg Fischer Piping Systems (Switzerland) LtdDubai / United Arab EmiratesPhone +971 4 289 49 [email protected]/int

NetherlandsGeorg Fischer N.V.8161 PA EpePhone +31 (0) 578 678 222 [email protected]/nl

Georg Fischer Waga N.V.NL-8160 AG EpePhone +31 (0) 578 678 [email protected]

New ZealandGeorg Fischer Ltd5018 Upper HuttPhone +04 527 9813Fax +04 527 [email protected]/nz

NorwayGeorg Fischer AS1351 Rud Phone +47 67 18 29 [email protected]/no

PolandGeorg Fischer Sp. z o.o.05-090 Sekocin Nowy Phone +48 (0) 22 31 31 0 50 [email protected]/pl

RomaniaGeorg Fischer Piping Systems (Switzerland) Ltd020257 Bucharest - Sector 2Phone +40 (0) 21 230 53 [email protected]/int

RussiaGeorg Fischer Piping Systems (Switzerland) LtdMoscow 125040Phone +7 495 748 11 [email protected]/ru

SingaporeGeorge Fischer Pte Ltd528 872 SingaporePhone +65 6747 0611Fax +65 6747 [email protected]/sg

Spain / PortugalGeorg Fischer S.A.28046 Madrid / SpainPhone +34 (0) 91 781 98 [email protected]/es

SwedenGeorg Fischer AB117 43 StockholmPhone +46 (0) 8 506 775 [email protected]/se

SwitzerlandGeorg Fischer Rohrleitungssysteme (Schweiz) AG8201 SchaffhausenPhone +41 (0) 52 631 [email protected]/ch

TaiwanGeorg Fischer Co. LtdSan Chung Dist., New Taipei CityPhone +886 2 8512 2822Fax +886 2 8512 2823www.gfps.com/tw

United Kingdom / IrelandGeorge Fischer Sales LimitedCoventry, CV2 2ST / United KingdomPhone +44 (0) 2476 535 [email protected]/uk

USA / CaribbeanGeorg Fischer LLC92618 Irvine, CA / USAPhone +1 714 731 88 00 Fax +1 714 731 62 [email protected]/us

Georg Fischer Central Plastics LLCShawnee, OK 74801 / USAPhone +1 (405) 273 63 [email protected]

VietnamGeorge Fischer Pte LtdRepresentative OfficeHo Chi Minh CityPhone + 84 28 3948 4000Fax + 84 28 3948 [email protected]/vn

International Georg Fischer Piping Systems (Switzerland) Ltd8201 Schaffhausen / SwitzerlandPhone +41 (0) 52 631 3003Fax +41 (0) 52 631 [email protected]/int

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