21 - 22 November 2012

Middle East Water Leakage Summit 2012, Dubai, UAE

Water Leakage

a Thing of the Past short comings and solutions

Paul Hutchings

Water Leakage

1. The Scenario and the Analysis

2. The Solutions

PE to Metal Connections (special flange)

PE to PE or Metal Connections (HP flange)

3. Conclusion

The Scenario

Testing performed - flanged couplings in Gothenburg

THE FUNCTIONING OF FLANGE JOINTS — FINDINGS FROM FULL SCALE EXPERIMENTS AND FEM ANALYSES Lars Jacobsson, Hans Andersson, Daniel Vennetti and Sven-Erik Sällberg

SP Technical Research Institute of Sweden, Göteborg, Sweden Presented at the Plastic Pipes XVI Conference in Barcelona, September 2012

Successive relaxation in previously tightened bolts as tightening goes on (in four rounds) Much lower forces than expected from the generally used formula Unevenly distributed forces (yet the flange pressure is distributed more evenly by the steel flange)

The main causes are that – the plastic relaxes during

tightening (just a few minutes are of significance)

– higher friction than expected in the threads and bolt heads/washers

Analyses performed - flanged couplings in Gothenburg

SP Technical Research Institute of Sweden, Göteborg, Sweden Presented at the Plastic Pipes XVI Conference in Barcelona, September 2012

PE – Metal Connections with the special flange

On-site example with standard flange DN 500/450mm

steel/ cast iron PE

Standard stub end with backing ring Special flange connection

SPECIAL FLANGE CONNECTION

SPECIAL FLANGE CONNECTION

DN dsteel/cast iron PE

200 250mm250 315mm*300 355mm

350 400mm400 450mm400 500mm*

500 560mm500 630mm*600 710mm*

700 800mm*800 900mm*900 1000mm*

1000 1200mm** special solution

Connection with identical internal diameters of PE-HD / PP pipe and steel / cast iron fittings

SPECIAL FLANGE CONNECTION

AIRBUS Hamburg - Firewater Main (14bar) - DN 600 / d710mm

EDEWECHT (Germany) - Branch 45° d 710/500/500 mm (10bar)

DELMENHORST - Branch d900mm SDR17, 10bar, 45°

PE – PE or Metal Connections with the HP-flange

STANDARD backing ring connection - unloaded

expansion of pipetilting seal area

STANDARD backing ring connection - under pressure

Cut A-A

A

A

alternative to F-pieces and stub ends with backingrings

HP-FLANGE - connection PE to accessories - DN 50 - DN 600

HP-FLANGE, up to 25bar

HP-FLANGE, up to 25bar

a SAFE flange connection also needs as well aSAFE SEALING !

PROFILE GASKET

Most of the relaxation occurs during the first 50-100 hours => re-tightening after one or two days is relevant

The gaskets help to - distribute the pressure more evenly and - possibly smooth uneven flange surfaces

Lars Jacobsson, Hans Andersson, Daniel Vennetti and Sven-Erik Sällberg

SP Technical Research Institute of Sweden, Göteborg, Sweden Presented at the Plastic Pipes XVI Conference in Barcelona, September 2012

PROFILE GASKET

HP-SC Flange, stress compensation version

Conclusions

Concluding Statement

• PE 100 pipe is a wonderful material for laying long lengths of pipe

• PE 100 fittings give problems due to the same characteristics that make it wonderful to lay

• The definition and selection of the fittings to create a sustainable and beneficial pipe system can ensure marked reduction in water losses

solutions are readily available

Thank you very muchfor your attention

EXTRA SHEETS DEALING WITH TEES / BRANCHES

1. design and practice examples2. how not to do it3. full pressure rated equal tee d900mm, under test4. full pressure rated equal tee d900mm5. full pressure rated equal tee d900mm, profile version6. full pressure rated reduced tee d1200mm/DN 1507. hydrostatic testing, equal branch, at 25bar8. you need it, we can do it – multi-branch tee

• Increasing trend to larger diameter for PE pressure systems

• Economic development of fittings(more stability, reduced costs)

• Design, construction and rating

PE and PP fully pressure rated large bore fittings, design and practice examples

EXTRA SHEETS DEALING WITH TEES / BRANCHES

20°C, 15bar, < 1 Hour,

2pc out of 3pcfailed

Hydrostatic Pressure Test - Mitred tees, d 900mm SDR17

BECETEL, Belgium - Hydrostatic Pressure Test

Test parameters

EN 12201-320°C, σ 12,4MPa, 100h

80°C, σ 5,5MPa, 165h

VMW- Water Company Antwerp (Belgium) d 900mm SDR17

d 560mm

d 630mm

d 710mm

d 900mm

PROFILE TEE - NEW GENERATION

410mm

DN 150

REDUCED TEE - d 1200mm / DN 150

HYDROSTATIC STRENGTH TEST - TENSILE test, 25bar

FREE FLOW X-CROSS - for connection to hydrant