ABS Pipe Design Manual

EURATECH (MALAYSIA) SDN BHD (527494-K)
Address Lot 1478 Nilai Industrial Estate Phase II 71800 Nilai Negeri Sembilan MALAYSIA Telephone (60 6) 799 8989 Facsimile (60 6) 799 8626 Email euratech@euratech.com.my Website www.euratech.com.my
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CONTENTS
1 Introduction 4
Pipe Systems
Material
Design
17
Installation
31
Pipes & Fittings
45
Flow Nomograms
63
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INTRODUCTION
Euratech (Malaysia) Sdn Bhd, a wholly owned by Tyco Flow Control Group of Companies, has within itself a group of highly trained and dedicated staff in the design, manufacture, installation and operation of its products. The company is committed to a continuing program of quality and reliable products and services. A comprehensive technical advisory service is available from the companys technical service engineers including design of special customers requirements, application advice and other information. Our ABS products are manufactured and conformed to the highest international engineering quality standard such as the Australian Standard AS3518, the British Standard BS5391 and Malaysian Standard MS1419. Euratech (Malaysia) Sdn Bhd is also accredited to ISO9002 Quality System. Euratech (Malaysia) Sdn Bhd is principally engaged in the manufacturing and sales of ABS pressure pipes and fittings. Our products are widely used in a variety of industries such as:1) 2) 3) 4) 5) 6) 7) Water reticulation Domestic plumbing Water treatment plants Waste water treatment and recycling plants Power generation plants Industrial plants such as electronics, food processing, chemical, paper mills, palm oil and rubber mills. HVAC
It is Euratechs corporate objective to be the preferred supplier for high quality advanced thermoplastic piping system by meeting our customers need in a timely and effective manner by giving full technical support and advice.
LIMITATIONS OF LIABILITY All information contained in this catalogue has been compiled and presented in good faith and is subject to change without notice. Euratech (Malaysia) Sdn Bhd makes no express or implied warranty of any kind regarding the accuracy of the information contained herein. Euratech (Malaysia) Sdn Bhd reserves the right to withdraw or alter the specification of any product without notice. The products listed in this catalogue have been designed and manufactured to be in accordance with the instructions guiding their use, care and maintenance. The products should not be used for any purpose other than those for which they were designed. For further information regarding these products, reference should be made to the instructions and the guidelines for care and use issued by Euratech (Malaysia) Sdn Bhd representative listed on this publication.
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APPROVAL AUTHORITIES
Lloyds Register Quality Assurance
Sirim & Sirim QAS
Ikram QA Services Sdn Bhd
BE RS E K
UT U
BE RS E K
UT U
BER
T A MB A
H MU T U
BER
T A MB A
H MU T U
JABATAN PERKHIDMATAN PEMBETUNGAN
JABATAN BOMBA DAN PENYELAMAT MALAYSIA
Jabatan Perkhidmatan Pembetungan
Jabatan Bomba dan Penyelamat Malaysia
American Bureau of Shipping
Syabas
SAJ Holdings Sdn. Bhd. (Syarikat Air Johor)
Perbadanan Air Melaka
Lembaga Air Perak
Syarikat Air Terengganu Sdn. Bhd.
Jabatan Bekalan Air Negeri Sembilan
Perbadanan Bekalan Air P.Pinang Sdn Bhd
Jabatan Bekalan Air Kedah
Jabatan Bekalan Air Pahang
Jabatan Bekalan Air Sarawak
Jabatan Bekalan Air Kelantan

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PIPE SYSTEMS
GENERAL OVERVIEW ABS ABS (acrylonitrile, butadiene, styrene) is a modern thermoplastic polymer found in everyday applications such as construction site safety helmets. Piping Systems manufactured from this polymer display outstanding properties and so makes ABS pipes the first choice for many of the most demanding piping applications. ABS pipe and fittings are designed and manufactured by EURATECH to suit local conditions. The EURAPIPE piping systems is manufactured from ABS polymer.
ENVIRONMENTAL ADVANTAGE The use of ABS contributes positively to the environment as it takes approximately one sixth of the energy to manufacture compared to metal products. This has direct savings in green house gas emissions. Additionally ABS is lead and chlorine free and can be readily recycled.
IMPACT STRENGTH The butadiene constituent in ABS affords unrivalled resistance to impact. This means that Eurapipe ABS Plastic Piping Systems may be used in more critical applications where other types of plastics could not be considered.
CHEMICAL RESISTANT EURAPIPE ABS is unaffected by both internal and external chemical attack by a wide range of acids, alkalis, ground water salts and other environmental factors.
ABRASION RESISTANT EURAPIPE ABS offers good resistance to abrasion and erosion from aggressive slurries which can rapidly damage steel or other traditional pipe materials.
WEATHER RESISTANT EURAPIPE ABS is one of the most weather resistant polymers available today. Successful field tests have been completed on piping systems having been exposed to weathering for over 30 years.
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NON-TOXIC/TAINT FREE The ABS formulation contains no harmful metallic stabilizers and it has been widely used for many years in piping systems for high purity water, medical preparations, food products and soft drinks. EURAPIPE ABS systems is ideal for potable cold water. They conform to World Health Organisation, E.E.C. and AS 4020 requirements for potable water reticulation and distribution.
TEMPERATURE RANGE A great advantage of EURAPIPE ABS over other plastic systems is its ability to perform over a wide temperature range from -40C to + 70C. This makes EURAPIPE ABS very versatile and capable of handling a wide variety of fluids from refrigerants to moderately hot corrosive liquids.
LIGHT WEIGHT ABS is one-sixth the weight of steel systems, making EURAPIPE easy to handle and install. This reduces the cost of installation, handling and transport.
JOINING SYSTEMS Cold Solvent Weld Joining The EURAPIPE size range also utilizes the proven traditional method of joining ABS pipes, cold solvent cement welding, which provides an homogenous bond between pipes and fittings (SWJ).
EXCEPTIONALLY SMOOTH BORE EURAPIPE ABS does not suffer from internal corrosion and provides a smooth bore for the life of the piping system. The smooth bore does not support the formation of scale and slime as do cement based lined products.
SIZE AND PRESSURE RANGE EURAPIPE ABS piping systems is manufactured in sizes ranging from 15mm to 630mm. Standard pressure ratings at 20C start at 450 KPa and go to 1500 KPa (PN4.5 to PN 15). Larger sizes and heavier classes are in development and reference should be made to Euratech.
Elastomeric Seal Joining The EURAPIPE size ranges utilise an elastomeric seal joining systems (Rubber Ring Joint, or RRJ). Other Joint Systems Other joint systems are also available as standard for EURAPIPE systems and are detailed further in this catalogue.
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MATERIAL
INTRODUCTION THE MATERIAL Because of a unique balance of properties, modern ABS copolymers are being used on an ever increasing scale for the manufacture of many industrial and domestic products. The material is very tough and resilient, has high impact strength, good chemical resistance and is non toxic and taint free. These advantageous properties have attracted engineers in many industries to the use of ABS piping systems rather than traditional material, which do not have these distinctive benefits. ABS piping systems are replacing many failed piping systems made from other materials. STYRENE The Euratech ABS system comprises a range of matched pressure pipes and fittings, joined together by a wide variety of methods including cold solvent cement welding or our rubber ring joint system. Acrylonitrile - Butadiene - Styrene (ABS) identifies a family of engineering thermoplastics with a broad range of performance characteristics. The copolymeric system is alloyed to yield the optimum balance of properties suited to the selected end use. ACRYLONITRILE BUTADIENE - imparts chemical resistance and rigidity. - endows the product with impact strength, toughness and abrasion resistance. - contributes to the lustre, ease of processing and rigidity.
ACRYLONITRILE
A
Ageing Resistance Heat Resistance Chemical Resistance
ABS
Low Temperature Property Retention Impact Strength Lustre Mouldability Rigidity
B BUTADIENE
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S STYRENE
MATERIALS PROPERTIES The formulation used by Euratech has been developed in conjunction with polymer manufacturers to optimise performance in respect to tensile strength, chemical resistance, ductility, resistance to weathering, heat stability, low toxicity, taint free and ease of processing from raw material to finished product. ABS is tough and strong over the recommended temperature range of -40 C to + 70 C. Rubber Ring jointing methods, allowing compatible systems jointing techniques. Non Toxic and non-taint properties. Withstands aggressive ground waters. Good chemical resistance. High strain tolerance for buried applications. Abrasion resistance. Good resistance to ultraviolet light. High strength solvent weld jointing which allows efficient system assembly and modification. Lower celerity and extreme tolerance to water hammer surges.
The outstanding properties of ABS are: High impact strength and ductility, which combine to give exceptional toughness.
Property* Ultimate tensile strength (strain rate 50 mm/min) ASTM D638 Type 1 Elangation at break Instantaneous Flexural Modulus ASTM P750 Compressive strength Izod impact strength (notched) ASTM D256 (method A) Specific gravity Vicat softening point ASTM D1525 Coefficient of thermal expansion Maximum operating temperature Poissons ratio Thermal conductivity Specific heat Volume resistivity Dielectric constant
Reference Temperature
S. I. Unit
Other Units
20C 20C 20C
30 MPa 25% 2000 MPa
4350 lbf/in2 25% 290 000 ibf/in2
20C 23C
42 MPa 340 J/m notch
6 100 ibf/in2 6.4 ft ib/in notch
1.04 x 10 3 Kg/m3 104C 10.1 x 10 -5 m/m C 80C 0.35 0.25W/mK 1.47 KJ/kgK
1.04 x 10-3 ib/ft3 219F 5.6 x 10-5 ft/ft F 176F 0.35 1.7 BTU/ft2/in/F 0.35 BTU/Ibm/F
3.5x10 16cm 3.2 at 60Hz 3.12 at10 3Hz 2.9 at 10 6Hz
* Test pieces machined from moulded specimens yielded to the above mentioned typical properties.
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IMPACT STRENGTH ABS is a relatively ductile thermoplastic which exhibits very high impact strength compared to other thermoplastics such as uPVC particularly at moderate low temperatures. It is for this reason ABS is used in demanding applications requiring exceptionally high impact strength material such as construction site safety helmets. As part of the EURATECH quality assurance programme, sample lengths of pipe are routinely impact tested in accordance with AS3518. Samples are chilled to 0C to stimulate field operating conditions. ABS is unique in retaining high levels of impact strength at sub zero temperatures and is significantly superior to most other thermoplastics in this respect. The graph shows the relatively small reduction in impact strength of ABS between 20C and 0C compared with another thermoplastics pipe systems. 25
20 UPVC @ 20C
IMPACT ENERGY (Kgm)
15
ABS @ 0C ABS @ 20C
10
0 20 32 50 100 200
PIPE SIZE (mm)
MODE OF FAILURE ABS is a ductile material and the mode of failure resembles that of soft copper. Failure is by ductile distortion and tearing, the localized nature minimizing the loss of pipe contents. In contrast, the failure of brittle material is accompanied by crack propagation and hazardous material fragmentation. The photograph illustrates an impact failure in ABS pipe under pressure which may be compared to the brittle failure mode exhibited by another common thermoplastic pipe work material subjected to the same test and displayed alongside.
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TOXICITY AND TAINT 18 16

HDPE
ABS is free from heavy metal stabilizers such as lead which are often used in the processing of other thermoplastic materials. Therefore, there is no possibility of any toxic heavy metals substances being leached from the ABS pipe material into the fluid being conveyed by the pipe. EURATECH ABS conforms to AS4020 and has been safely used for many years with potable water, grade I distilled water for medical use, renal dialysis fluid and many foods and beverages. ABS is regarded as taint free and has been used for conveying potable water, beer, soft drinks, caramel, wines, sauces, chocolate, custard cream and other similar products. It is recommended that food and drink manufacturers test for taste tainting on their own product before installation commences.
COEFFICIENT OF EXPANSION (x 10-5 ) m/mC
14 12 10 8 6 4 2 0
18/18SS MILD METAL COPPER EURATECH ABS PP
uPVC
RIGIDITY AND STIFFNESS ABS is classified as a rigid thermoplastic over its working temperature range - 40C to +70C. With increased temperature, pipe rigidity decreases thus necessitating more frequent support. At 70C. continuous support is required on the horizontal.
THERMAL EXPANSION All thermoplastics expand at a greater rate than metals as shown in the diagram above. Expansion need not cause undue concern in design or installation of an ABS piping system provided that due recognition is taken at the design stage. The reduced flexural modulus of ABS over that of steel results in reduced loads on supports and equipment arising from thermal strains. The linear coefficient of thermal expansion of ABS is 10.1 x 10-5 m/mC.
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WEATHERING EURATECH ABS Piping systems are suitable for external installation under extreme conditions without additional surface protection. When ABS products are exposed to the weather, they will suffer some minor degradation of the exposed surface. The degradation results in a reduction of surface gloss, and shift in surface colour to light grey. The degradation is confined to the exposed surface only. The effect of long-term exposure to sunlight over prolonged periods has minimal effect on the physical properties of ABS systems. ABRASION RESISTANCE ABS piping systems have long been successfully employed in applications where abrasion resistance is the prime consideration. The conveying of slurries in the mining, food, power generation and waste water industries is a typical example where ABS has been demonstrated to outlast steel and stainless steel pipes previously employed. The chemical resistance of ABS combined with impact resistance makes it an ideal choice for such corrosive and erosive environments. It is these conditions which lead to reduced life of metal pipe systems. The rubber-like butadiene phase in ABS provides this piping material with outstanding resistance to abrasive media. EURATECH sales engineers have the experience to advise on the suitability of ABS pipe for slurry or abrasive applications. For gravity flow systems the long term low surface roughness enables less steep slopes to be used. Lower slopes can mean reduced building heights which has a great effect on capital costs. Additionally, lower slopes reduce transport velocity, which in turn reduces the wearing of the piping material.
Because of the relatively high flexural modulus of ABS, the stresses induced in a component whilst in service result in smaller strains, therefore minimising the possibility of environmental stress cracking of the exposed surface. This resistance to failure is further improved by the inherently high impact strength of ABS, particularly at low temperatures, and the ability of the polymer to withstand long term heat exposure with little change to physical properties.
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CHEMICAL RESISTANCE The information given on the following pages is based on the recommendations of the manufacturers of the polymers, field experience and subsequent tests by EURATECH. The data is based on the exposure of tensile bars to the environment, and associated weight changes, tensile strength and elongation determination. These results are augmented by environmental stress cracking tests. Specific data on industrial chemical applications of ABS can be given by the EURATECH Organization. Such enquiries are invited for applications not shown here.
Chemical Weak acids Strong acids Weak alkalis Strong alkalis Aggressive soils Metal salts Sea water Aromatic Hydrocarbons Organic solvents
Resistance Good resistance Limited resistance Good resistance Good resistance Excellent resistance Good resistance Excellent resistance Poor resistance Poor resistance
ABS Quick Reference Chemical Resistance
Resistance Key Information 1. RESISTANT Little or no attack. 2. CONDITIONAL RESISTANCE Some attack however may still be suitable when used with a higher pipe class or reduced service life. Under no circumstances it is to be assumed that a mixture of individually acceptable chemicals may be safely used with ABS or any other product. The information is to be used as a guide and is not a guarantee, either expressed or implied. Absence of notation indicates the substance has not been tested. Unless stated, all concentrations are 100%, or saturated aqueous solution. Reference to saturated solutions is at 20C. 3. NOT RECOMMENDED Little or no resistance. Not suitable for use with ABS pipe. 4. REFER TO EURATECH It should be noted that production of substances might involve process upsets which subject piping systems to varying pressures, temperatures and chemicals. It is the design engineers responsibility to assess the materials and exposure conditions. It is likely that the positive characteristics of ABS make it a more suitable choice than other materials.
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DESIGN
INTRODUCTION Thermoplastic pressure piping systems show considerable cost savings compared with traditional materials, particularly when chemical resistance, external coating, internal lining, resilience and installation time is taken into account. The modern engineer sees the many advantages that ABS systems bring to the end user. In applying design principles to the specific criteria of thermoplastic materials the engineer can take advantage of the database of case histories, modern industry standards and use the physical properties of the material.
From this information the following decisions may be made: Pipe material to be used Diameter, pressure class and stiffness of pipe to be used Jointing system, e.g. cold solvent cement welding, rubber ring joints, flanges etc. Supporting arrangements for pipes and valves Trench design SYSTEM SELECTION CRITERIA A basic process specification for the piping system should be engineered. In many cases this can be a very informal study, but where the application of service is of a more critical nature, this should involve some careful research into the exact or anticipated process conditions. Some points to be considered are: Operating temperature and pressure Composition of media Support system design Design to accommodate thermal expansion External conditions Route details
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VALVE SELECTION CRITERIA The table below will assist with the selection of suitable thermoplastic valves
Ball DN15 - DN100 Good Refer to Euratech Off / On Yes Yes Good FPM / PTFE EDPM / PTFE Diaphragm DN15 - DN50 Good Suitable Good Yes No Refer to Euratech Natural rubber Butyl rubber PTFE EDPM 1000 kPa Yes Spigot, socket, thread, flange Butterfly DN50 - DN200 Good Refer to Euratech Moderate Yes Yes Good FPM EDPM 1000 kPa Yes Wafer style
Size range Clean liquid Slurry Flow Control Position indicator Vacuum proof Pressure surge behaviour Sealing materials Max. pressure range @ 20C Suitable for electri or pneumatic actuator End connection
1000 kPa Yes Socket, thread, flange
PRESSURE / TEMPERATURE DERATING All thermoplastic piping system pressure ratings apply at the standard midwall temperature of 20C. Where systems are required to operate at higher continuous mid-wall temperatures, pressure ratings must be adjusted in accordance with the following graph.
1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 -40 PN 15
The maximum normal operating temperature for an ABS EURATECH pipeline under continuous pressure is 70C.
PRESSURE / TEMPERATURE DERATING
PN 12
WORKING PRESSURE (kPa)
PN 9
PN 6 PN 4.5
20
30
40
50
60
70
PIPE MID-WALL TEMPERATURE (C)
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PIPE DESIGN CRITERIA Euratechs pipe design is in accordance with the requirements set out in AS3518. Design factor of Safety (F) This factor is applied to the minimum ultimate strength of material to establish safe (conservative) working loads. Euratech has designed its standard range of pipes using minimum design safety factors of 1.6 and 2.1. This degree of safety margin in the design of pipes means that the standard EURAPIPE range of pipes are suitable for application in critical services such as permanent urban water supply applications and where high security is required for the transport of hazardous chemicals. Design Basis This is a period, usually a minimum of 50 years according to convention, which is used to determined the long term hydrostatic strength of ABS pipe. Obviously this does not mean that the pipe will fail. Hydrostatic Design Stress This hydrostatic design stress (HDS) is the minimum required strength (MRS) divided by the Design Safety Factor. For the minimum design safety of 1.6 used in the EURAPIPE pipe ranges, the maximum HDS of 10 MPa is used.
Long Term Hydrostatic Strength (
LCL
This is the 97.5% lower confidence limit value of hoop stress, continuously applied at a specified temperature that the pipe wall material can support for a specified time. This value is calculated using the statistical procedures detailed in the standard extrapolation method of ISO / TR 9080. Minimum Required Strength (MRS) This is the minimum value of LCL for a temperature of 20C and for the conventional period of 50 years. The ABS material used to manufacture EURAPIPE has an MRS of 16 MPa. PN Value This is the nominal working pressure at 20C, in bar (10 bar = 1 MPa). Stress Regression At a constant temperature the time to failure due to stress of a thermoplastic pipe is inversely proportional to the magnitude of the stress. By conducting a series of burst tests on ABS material at different stress levels, a graph of stress versus time to fracture can be plotted. This is always shown as a loglog plot and is known as the Stress Regression Characteristic for the pipe. It is representing a possible life for the pipe manufactured from the selected ABS raw material compound. See figure below.
STRESS REGRESSION CHARATERISTIC FOR EURATECH ABS PIPE

100.00 MEAN / HP STR
LWR 97.5 / HP STR
16.08 50 YR LCL
HOOP STRESS, MPa
50 YRS
10.00 1 10 100 1000 10000 100000 1000000
HOURS
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FLOW CALCULATIONS FOR LIQUIDS The extreme smoothness of the EURATECH pipe wall and the chemical resistance of the material prevent internal corrosion. Consequently, the hydraulic characterstics of an ABS EURAPIPE pipe generally remain constant for the life of the system. Euratech ABS EURAPIPE pipes do not need to be oversized in the design stage to allow for future performance losses due to corrosion. For gravity pipe systems where the flow regime may be partially full, the engineer should refer to the procedure in AS2200 - Design charts for water supply and sewerage.
ABS FITTING CONSTANTS Fittings Elbow 90 Elbow 45 Bend 90 short radius Bend 45 short radius Bend 90 long radius Bend 45 long radius Tee through F 0.017 0.009 0.004 0.002 0.002 0.001 0.011 0.042
PRESSURE LOSS CALCULATION PROCEDURE Pressure drops due to friction may be determinde for practical purposes using nomograms (flow charts). Full range of nomograms for applications where the media is water can be found at the end of this catalogue. The fluid pressure loss through fittings may be included in the overall system pressure loss by calculating the equivalent length of pipe equal to the pressure loss through individual fittings. The calculation of pressure loss in fittings is: E = F x D where E = equivalent length of straight pipe for fittings, m F = fittings constant (see adjacent column) D = fittings diameter, mm
Tee branch
Loss in straight lengths of pipe The head loss in straight lengths of pipe can be calculated as follows: L v2 HP = x d 2g where L = length of pipe, m HP = head loss, m = Darcy friction factor, dimensionless d = inside diameter of pipe, m v = mean velocity of media, m/s g = 9.81m/s2, acceleration due to gravity The Darcy friction factor id dependent upon the Reynolds number, Re, and
To calculate the total pressure loss in the system, the equivalent straight pipe length for fittings is added to the total measured straight pipe length. Etotal = E + EP where E P = the pipeline length, m ALTERNATIVE PROCEDURE The aforementioned method will provide a conservative selection of pipe diameter and class for an application. A more rigorous approach will derive significant savings in the design of a pipe system.
the relative roughness of the pipe surface, d vd Re =
where = density, Kg / m3 = dynamic viscosity, Kg / m s = absolute roughness, dimensionless = 0.003, the absolute roughness for clean ABS
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Laminar flow In this type of flow Re < 2000 and the Darcy factor yields: 64 = Re Turbulent flow The friction factor for Re > 2000 is calculated using the Colebrook White equation: 1 d 2.51 = -2log10 + 3.7 Re Head loss in fittings H =
COEFFICIENT OF FRICTION FOR FITTINGS, Kf Type of fitting Elbow 90 45 Bends Sweep 90 45 22 Tees Flow through Flow to branch Flow from branch Entries Square Protruding 0.65 0.75 0.21 0.06 1.0 0.6 1.8 1.5 0.5 0.2 0.1 1.2 0.35 Kf
K x
v2 2g
where K = Nbends Kbends + Nelbows Kelbows + Ntees Ktees+... where K = coefficient of friction for each type of fitting, shown in the adjacent table N = number of fittings of each type
Total head loss Using the head loss calculations above, the pressure drop in the pipeline is calculated using the formula: p =g (HP + H ), N/m
2
Slightly rounded Bellmouth Outlets (all) Sudden enlargements Inlet to outlet ratio 4:5 Inlet to outlet ratio 3:5 Inlet to outlet ratio 1:2 Inlet to outlet ratio 2:5 Inlet to outlet ratio 1:5 Sudden contractions Inlet to outlet ratio 4:5 Inlet to outlet ratio 3:5 Inlet to outlet ratio 1:2 Inlet to outlet ratio 2:5 Inlet to outlet ratio 1:5 Valves fully open Gate Butterfly Ball Swing check Diaphragm
0.15 0.4 0.6 0.75 0.9
Notes : The Reynolds number range between 2000 and 4000 is called the critical zone. Flow in this zone is unstable, and this must be taken into account. The methods shown above can be used with various types of newtonian fluids.
0.45 0.38 0.35 0.28 0.15
0.2 0.3 0.5 1.3 2.4
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THERMAL EXPANSION Expansion is not a problem during the installation of an ABS EURAPIPE pipe systems provided the appropriate provisions are made during the design stage. The linear coefficient of thermal expansion for Euratech ABS pipe is 10.1 x 10-5 m/mC (5.6 x 10-5ft/ftF). The variation in pipe wall temperature should be used in the following equation to calculate the maximum pipe thermal movement. (Pipe operating and shut down conditions should be considered when evaluating extreme temperature variations.) L = where L = L = C = T = L x C x T pipe expansion/contraction, m original pipe length, m linear coefficient of thermal expansion, m/mC pipe wall temperature variation, C The variation in pipe wall temperature can be calculated as : T = 0.65TL+0.10TA where T = pipe wall temperature variation, C TL = maximum temperature variation in pipe content, C TA = maximum temperature variation of external air, C Example : Calculate the thermal expansion of a 50 metre section of Euratech ABS pipe with an expected variation in the temperature of the fluid conveyed from 20C to 30C and an expected variation of the ambient temperature from 10C to 40C. TL = 30 - 20 = 10C TA = 40 - 10 = 30C T = 0.65T L + 0.10TA = 6.5 + 3 = 9.5C L = L x C x T L = 50 x 10.1 x 10-5 x 9.5 = 0.047975m L = 47.98mm The following graph allows you to read directly total pipe expansion from a known pipe length and temperature range.
The mid-wall temperature is dependent on the internal and external environmental temperatures with the temperature of the flowing media having the greater influence.
THERMAL EXPANSION
500
50
PIPE EXPANSION ( L)
400
40
300
30
200
20 15
100
10 5
0 0 20 40 60 80 100
PIPE LENGTH (M)
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VARIATION IN MID-WALL TEMPERATURE
T (C)
600
60
DESIGNING FOR PIPE EXPANSION (ABOVE GROUND) Pipe expansion of a cold solvent cement welded pipeline may be accommodated using any one or combination of the following techniques: Pipe route planning Expansion loops Expansion joints (rubber bellows) Pipe wall stressing
Fig. 2 Fixed point A Pipe Clip C Pipe deflection Pipe Clip B
PIPE ROUTE PLANNING In the vast majority of cases, effective route planning can eliminate the requirement of expansion loops, or expansion bellows etc. with consequent financial savings.
Pipe Movement
An inappropriate installation is shown in Fig 2. The pipe run is fixed at on end (A) and constrained at the other (B). As the temperature increases the pipe will try to expand but will have nowhere to go as the ends are constrained by clip (B). Thus the pipe will snake between supports as indicated.
Fixed Point
Pipe free to move
Fixed point A Pipe Clip B Removed Allowing Pipe Lateral Movement Pipe Clip C
Pipe Clip
Fig. 1
Fig. 3
The basic principle of design is to allow pipe runs to move axially from a fixed point (anchor) and then guide this movement into a change of pipe direction ensuring that the pipe is free to flex as shown in fig. 1.
In Fig 3, effective route leg planning has eliminated the need for expansion loops etc. by a simple redesign of pipe supports. By utilising a suitable pipe support to allow free lateral pipe movement, the pipe can be installed with sufficient flexibility to expand and contract. The support at (C) remains but the clip at pipe support (B) is eliminated to give sufficient length for flexibility.
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Calculate the expansion Establish an anchor point midway along the straight length of pipe to control the direction of any movement. Position pipe supports away from change of direction to allow required movement. The extent of movement to be accommodated at each end from the neutral position will be 25% of the total expansion. Example, if total calculated expansion is 100mm, 50mm of this is to be accommodated at each end, which is 25mm from the neutral position, see Fig 5. PIPE SIZE (DN) 15 20 25 32 40 50 65 80 100 125 150 200 225 250 300 350 375 400 25 600 700 800 900 1000 1100 1200 1300 1400 1700 1800 2100 2500 2600 2800 3400 4400 5200
EXPANSION LOOP LEG LENGTH, H (MM) EXPANSION L/2 (fig.4) L (fig.5) (mm) 50 900 110 1150 1300 1400 1500 1650 1800 2200 2400 2600 3000 3600 3700 4200 5100 6400 7400 75 1100 1300 1400 1600 1800 1900 2000 2200 2500 2800 3100 3800 4700 4800 5200 6000 8000 9000 100 1300 1450 1600 1800 2000 2100 2300 2500 2900 3100 3700 4400 5300 5400 6000 7000 9300 10000 150 1500 1750 1950 2150 2400 2600 2800 2900 3500 3800 4500 5200 6200 6300 7100 8000 10300 200 1800 2000 2200 2500 2800 3000 3100 3200 4200 4500 5000 5900 7200 7300 8800 9800
H/2 max
L/2 Fig. 4
L/2
EXPANSION LOOPS (ABOVE GROUND) Length of the expansion loop legs, (H) for sizes up to DN 400 can be determined using the adjacent table. Please refer to Euratech for further information. The expansion loop table can also be used for calculating flexibility required at changes in direction. Expansion loop dimensions can be reduced considerably by the use of tandem bellows. Refer Euratech for details.
H Intermediate Pipe Support without Clip
Fig. 5
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EXPANSION COMPENSATORS Where space does not permit a flexible route, or the use of expansion loops, rubber bellows should be considered.
RUBBER BELLOWS Rubber bellows are able to accommodate angular, lateral and small axial movements as shown below. Bellows should be located in adjacent pipe legs to benefit from the lateral movement. Bellows in pressure service should be tied to prevent excessive forces being applied to anchors, nozzles or structures. Tandem bellows can be used to meet large thermal movements. EXPANSION COMPENSATOR OPERATING RANGE* Travel PIPE SIZE DN 32 40 50 65 80 100 125 150 200 250 300 350 375 400 450 500 575 650 750 Axial Compression / Extension mm 8-4 8-4 8-5 8-6 12 - 6 18 - 10 18 - 10 18 - 10 25 - 14 25 - 14 25 - 14 25 - 14 25 - 14 25 - 14 25 - 14 25 - 14 25 - 16 25 - 16 25 - 16 Lateral Deflection mm 8 8 8 10 10 12 12 12 22 22 22 22 22 22 22 22 19 19 19 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 Angular Deflection GUIDE TO EXPANSION UNIT SELECTION Dual Bellow Bellows Loop Accommodate Angular / Lateral Movement Vibration Isolation Axial Expansion Range Installation Space Maintenance Pressure Rating Size Range, DN Cost / mm Expansion Yes Good Very small Small Minimum High 32 - 750 High Yes Very good Very high High Minimum High 300 - 750 Moderate
Loop
Yes Moderate Good Large Minimum High 32 - 750 High
PIPE WALL STRESSING In cases where relatively small amounts of pipe expansion occur, expansion may be taken up by variations in pipe wall stresses. Contact Euratech for further detailed design procedures should this method be adopted.
* Values shown are for the single sphere bellows.
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Pipe Clip
PIPE SUPPORT The basic principle of correct pipe supporting is to allow controlled axial movement of the pipe while providing lateral restraint and adequate support for the pipe. The hanger type support does not provide lateral restraint to the pipe and therefore encourages snaking and so should be avoided except where located adjacent to the changes in direction where flexibility may be required. Thus pipe supports should: Be rigid in construction to adequately support pipe (fabricated mild steel angle being ideal). Have a wide bearing area, to allow pipe to move easily over support. Resist deflection, thus transferring loads to the structure. Be free from sharp burrs or edges to avoid cutting or damaging pipe wall. Allow controlled axial movement of the pipe. PIPE SUPPORT PADS Provide lateral restraint, where required. Pipe clips should: Allow controlled axial pipe movement Be free from burrs or sharp edges Provide required lateral restraint Pipe Diameter Up to DN150 OD225 - OD500 OD560 - OD826
Fig. 6
Radial Clearance Between Pipe & Clip
Pipe Support Pad
Min. Clearance 2 mm 5 mm 10 mm
The use of pipe support pads between pipe and support is strongly recommended where there is likely to be considerable movement of the pipe or chafing of the pipe from vibration. High Density polyethylene sheet 6-10 mm is suitable for this purpose and should be installed as indicated in fig. 6. Width of pipe supports must be sufficient to allow free axial movement of the pipe without binding. The following table gives recommended pipe support widths.
Clearance between the pipe and pipe clip is important. Euratech manufactures a range of suitable pipe clips for pipe sizes up to 100mm. For sizes 125mm and above fabricated mild steel clips with a radial clearance as per the following table are suitable. Pipe Diameter Up to DN150 OD225 - OD315 OD355 - OD400 OD450 - OD500 OD560 - OD826 Min. Support Width 20 mm 25 mm 40 mm 50 mm 60 mm
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PIPE ANCHORS
Backing Ring Valve Support Plate
Pipe anchors should be provided in systems where thermal expansion occurs. Anchors ensure that pipe movement occurs in a controlled and predictable manner. In addition, pipe anchors will absorb axial pipe pressure thrust in those systems fitted with expansion joints. Where possible, a flanged pipe connection may be used as an anchor point by the use of a valve support in lieu of one of the backing rings. Refer to fig. 7. Where suitable flange connections are not convenient, pipe anchors may be constructed by solvent cementing split fittings to pipe as shown in fig. 8. An alternative method for pipe diameters up to 50mm is shown in fig. 9.
Pipe Clip Anchor Sleeve Secure with stainless steel straps Anchor Flange connected onto pipe Fig. 8 Gusset Plates as required
Anchor points located at mid length of a straight section need not be as robust as those associated with expansion compensators which must be able to withstand the total pressure thrust plus frictional resistance to movement. Note: Under no circumstances should a tightened pipe clip be used as an anchor. The action of tightening the clip imposes a crushing load on the pipe which may damage the pipe and affect its structural stability.
Alternative Pipe Anchor Detail Fig. 9
Backing Ring
Valve Support Plate
Gusset Plates as required
Fig. 7
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SUPPORT OF HEAVY PIPE LINE ACCESSORIES Valves, filters, or other heavy items should always be independently supported or anchored to prevent undue loading and stress being applied to the pipe. Euratech valve support plates can be used in place of flange backing rings to provide necessary support. Equipment Connections ABS pipe may be connected directly to pipe or other equipment using flanges or threaded connections. Flanges are the recommended method for all sizes, however threaded connections maybe used for sizes 50mm and below. PIPE SIZE DN DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150 DN195 DN200/OD225 DN225/OD250 DN300/OD315 DN350/OD355 DN375/OD400 DN400/OD450 DN450/OD500 DN500/OD560 DN575/OD630 DN650/OD710 DN750/OD826 DN850/OD900
Support centres (m) Based on PN15 pipe Average pipe wall temperature 20C 1.0 1.1 1.2 1.3 1.4 1.6 1.7 1.8 2.2 2.3 2.5 2.9 3.0 3.1 3.4 3.7 4.1 4.7 4.7 5.1 5.1 5.2 5.4 5.5 50C 0.8 0.8 0.9 1.0 1.1 1.2 1.4 1.5 1.8 1.9 2.0 2.4 2.5 2.7 2.7 2.9 3.2 3.6 3.6 3.9 4.0 4.2 4.4 4.5 60C 0.6 0.7 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.2 1.3 1.5 1.6 1.8 1.8 2.0 2.2 2.4 2.4 2.6 2.7 3.0 3.2 3.4
PIPE SUPPORT CENTRES ABS is classified as a strong thermoplastic over its working temperature range of -40 to + 70C. With increasing temperature pipe stiffness decreases requiring frequent support. The spacing of supports shall be such that the midspan deflection does not exceed 1/200th of the span. As a guide, horizontal support centres for Euratech ABS pipe at various temperatures is given in the adjacent table. For vertical pipes support centres may be increased by 50%. For more details contact Euratech (Malaysia) Sdn. Bhd. Pipes operating at higher temperatures, up to 70C, must be continuously supported.
The following correction factors should be applied for other pipe classes.
Pressure rating Correction factors
PN4.5 0.63
PN6 0.71
PN9 0.88
PN12 0.92
PN15 1.00
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DEFLECTING PIPES ON A CURVE The flexibility of ABS pipes can often be used to an advantage when installing pipe work where a curve is required. The following table gives minimum bending radii without undue stress being placed on the pipe. It is possible for pipes to be curved to a lesser radius than in the table below depending on the design pressure/temperature relationship. Contact Euratech for further information.
ABS PIPE MINIMUM BEND RADIUS Pipe Size Up to 65 (DN) Bend Radius 6.5 (m) 80 10 100 12 125 15 150 18 175 21 195 25 200 28 225 32 300 37 350 43 375 50 400 53 450 56 500 62 575 74 650 85 750 100
ANGULAR DEFLECTION In addition to the ability to curve ABS pipes, the elastomeric sealed sockets available (RRJ/RRJ) will give further capability for changes in direction. EURAPIPE The following table shows the designed deflection angle for EURAPIPE ranges of sockets.
PIPE SIZE DN 300 DN 375 TO DN 500 DN 575 TO DN 750
TOTAL DEFLECTION ANGLE PER JOINT 4.5 4 3.5
DEFLECTION ANGLE
DEFLECTION ANGLE
RUBBER RING TO RUBBER RING SOCKET WITH DEFLECTION ALLOWANCE
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COLLAPSE RESISTANCE Critical collapse pressure (differential pressure) for above ground pipelines may be calculated using the following formula: Pcr= 2xE t x Dt 1 v2
3
Variation of long term Modulus of Elasticity with temperature Temperature (C) 20 30 40 50 60 Modulus (MPa) 1330 1160 990 830 660
where : E = D = t = V = V = Note:
Modulus, MPa Outside diameter of the pipe, mm Pipe wall thickness, mm Poissons ratio, dimensionless 0.35 for ABS For temperatures above 20C Modulus must be derated accordingly (see adjacent table). The values in the table are for long term Modulus of Elasticity. The instantaneous Modulus of Elasticity for Euratech ABS is 2000 Mpa.
For buried pipelines, design for buckling should be based upon AS2566 Buried flexible pipelines - Design. Euratech ABS pipelines are particularly suitable for below atmospheric applications. Contact Euratech for further advice.
PRESSURE TESTING The recommended test pressure for ABS EURAPIPE pipe used in above ground systems is 1.5 times the designed operating pressure of the system for a maximum of one hour, less allowance for temperature derating. Pressure testing above these limits is not recommended as it can reduce the maximum life of the system. Pressure testing of ABS EURAPIPE buried pipelines shall be in accordance with AS2566 - Buried flexible pipelines.
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INSTALLATION
INTRODUCTION Euratech ABS pipe systems are easy to install. It requires minimum trade skills and training of personnel for a successful installation. A complete certification package comprising training manual, Quality Assurance program, on site training and certification of personnel is available from Euratech. Care shall be taken to prevent damaging the external surfaces of pipes by rough handling or by dragging along the ground. Pipe packs and individual pipes can be lifted by forklift or by using slings in conjunction with a crane or other lifting device such as a backhoe or other suitable equipment. Lengths in excess of 6 metres must be lifted from two points at least 3 metres apart. This can be achieved by using a forklift with wide tynes or by using slings and spreader bar at least 3 metres long. If mechanical lifting equipment is not available, large diameter pipes may be rolled down planks from the transport unit. Ropes shall be employed to control the pipes on the way down. Smaller diameter pipes can be lifted and carried manually. Pipes shall be stored in the packs supplied. Packs shall be stored on level ground free from stones or projections, which could damage the pipe. For short term, storage packs can be stacked to a height of maximum 2.8 meters. Multiple packs are not to be lifted. For longer term storage-more than 3 months-packs shall be stacked to a height of maximum 1.8 meters.
HANDLING AND STORAGE ABS pipes and fittings are relatively light and easily handled. However, care must be taken during handling to prevent scoring or gouging of the pipes and fittings: Pipes and fittings shall not be dropped, indented, crushed or impacted. Metal slings, hooks, or chains shall not come into direct contact with the pipe surface. Fabric slings shall be used and shall be attached at two points on the load. Do not sling from the middle of the pipe.
Spreader bars may be necessary to prevent slings slipping during lifts.
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Where pipes are to be stored individually or without being strapped in packs, they shall be supported with 75mm wide horizontal timber supports at 1.5m spacing. Unpacked pipes shall not be stacked higher than 1.8m without vertical support. When stacking pipes with solvent cement welded sockets fitted to one end, alternate and stagger the pipe end to end so that the sockets do not bear upon each other.
JOINING SYSTEMS Pipes and plain ended fittings may be joined by the following methods: Sockets - cold solvent cement welded (SWJ) - elastomeric sealed (RRJ) Flanges Shoulder style coupling (e.g. Victaulic) Threaded adaptors Tapping saddles Unions Mechanical couplings (e.g. Gibaults, Straub, Wang etc.) Elastomeric sealed sockets (RRJ) There are two types of elastomeric sealed sockets: - one side cold solvent cement weld type and the other side elastomeric seal type (SWJ/RRJ), - both sides elastomeric seal type (RRJ/RRJ).
Euratech ABS pipes need not to be stored under cover except when storage period is likely to exceed 6 months. When extended storage periods are expected, pipes shall be covered with a light colour screening, which allows airflow between layers. Fittings shall be stored in the original packaging until ready for use. Under high solar radiation, pipe should be shaded at least 24 hours prior to joining.
Cold solvent cement welded sockets (SWJ/SWJ) Cold solvent cement welded sockets are the quickest, most economical joining method for ABS pipes and plain ended fittings and are available for all pipe sizes. Cold solvent cement welding eliminates the need for thrust blocks as the longitudinal stress is taken in the pipe wall. This type of joint is permanent and cannot be disassembled. Cementing ABS to PVC The cementing of these two dissimilar materials is not recommended. A Rubber Ring socket or a mechanical connection such as a threaded connection or a flange is recommended where such joints are necessary. Branch connections The preferred branch connection is by use of tees. Tapping saddles, which permit branch connections to be made without removing a section of the main pipe are useful where additions are required to an existing installation. Contact Euratech for further details regarding the use and installation of ABS tapping saddles.
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Connecting ABS to other pipe systems There are several recommended methods of connecting other pipe systems directly to ABS pipe. Elastomeric sealed sockets (RRJ sockets) Composite unions Flanges Threaded adaptors Shouldered end style couplings Clean paint brushes (natural bristles and unpainted wooden handle). Euratech ABS solvent cement and MEK cleaner. The recommended brush size for ease of use is shown in the following table: Pipe diameter Up to DN 50 DN 50 - DN 195 DN 200 and above COLD SOLVENT CEMENT WELDING Correctly made joints using this technique are stronger than either pipe of fitting. The cold solvent cement welding of ABS is a welding process and not a glueing process The solvent acts by temporarily disolving the two surfaces to be welded. When they are brought together, the two surfaces reconstitute into a single homogenous solid mass as the solvent quickly evaporates. Sustained axial loading of pipe into the fitting is required to form a satisfactory joint. The axial loading for the welding is provided by ensuring that the two parts being welded together have an interference fit. It is for this reason that sockets are designed with a taper (fig. 1)
MAX. SOCKET ID MIN. SOCKET ID
Brush size 20 mm 50 - 80 mm 100 mm
Mechanical device for joining pipe sizes above 150DN e.g. hand operated lever winch, two fabric lifting slings or two chain slings (min. 12mm link length). Clean, lint free rags. Safety glasses and protective gloves.
X.
PIP
EO
DIAMETER
PIP
EO
Safety precautions The following requirements are in addition to any government safety legislation or established company work practices: Read safety precautions on ABS cement and MEK cleaner tins. Work area must be well ventilated.
MAX. INTERFERENCE FIT MIN. INTERFERENCE FIT

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
MI
N.
MA
Do Dm
SOCKET DEPTH
Dr
fig. 1 Typical cold solvent cement socket design Tools required Coarse file or other tools suitale for chamfering the pipe. Emery paper. Felt tipped pen. Tape measure. Cutting tools e.g. pipe cutters, hack saw, fine tooth wood saw or circular saw with tungsten tipped blade.
As cement and cleaner are flammable liquids ensure work area is clear of falling sparks or other sources of ignition e.g. smoking.
Wear safety glasses and protective gloves at all times when using ABS cement and MEK cleaner.
Material Safety Data Sheets are available from Euratech (Malaysia) Sdn. Bhd.
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COLD SOLVENT CEMENT WELDING PROCEDURE Preparation Prepare and inspect the pipe. Scratches, gouges or dents shall be less than 10% of the pipe wall thickness. Joining surfaces must be clean and free from water, dirt, oils, or any foreign matter to ensure a good weld. The ends of the pipes shall be cut square and chamfered and all burrs shall be removed.
For pipe sizes 150 DN and above, set up mechanical joining device to ensure sufficient axial load is exerted to the joint (fig. 3)
Fig. 3
Abrade and clean joining surface of the pipe (fig. 4), no further than the first witness mark, using emery paper. This will help absorption of MEK into the wall.
Fig. 1
Dry fit the joint without forcing the pipe into the socket (fig. 1). If the pipe cannot be entered into the socket or does not bind up before reaching the end of the socket, do not continue with the joint. Refer to the Training and Accreditation Program for Installation of ABS Pipelines. Alternatively, contact Euratech for further information.
Fig. 4
Abrade and clean the inside surface of the socket (fig. 5) using emery paper. This will help absorption of MEK into the wall.
Fig. 2
Add Witness Marks (fig. 2) at distance from the end of the pipe equal to: the socket depth, first witness mark the socket depth plus 100 mm, second witness mark
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Fig. 5
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Brush strokes should be firm and alternatively circumferential and longitudinal, finishing with continuous longitudinal strokes to redistribute any excess from the socket root and end of the pipe.
Fig. 6
Wipe over the surfaces with a clean dry rag to remove any dust (fig. 6)
Fig. 9
For sizes under 150mm only one person is required for the welding process. Apply one coat to the pipe surface first, then one coat to the socket and then apply a second coat to the pipe (when required-see table below).
Fig. 7
Immediately before joining, thoroughly wipe the abraded surfaces with a clean rag moistened with MEK to initiate the chemical reaction (fig. 7)
JOINING Stir solvent cement before use. Using a clean brush, apply solvent cement to the pipe (fig. 8) and the socket (fig. 9).
Fig. 10
For larger sizes, 200mm and above, two people are required for this process. One person is applying solvent cement to the pipe - two coats, see table below - while, simultaneously, another person is applying solvent cement to the socket (fig. 10) Excess solvent cement can adversely effect the joint. Do not apply solvent cement onto the pipe over the first witness mark. Do not pour the solvent cement onto the pipe or allow puddles to form. Pipe size Coats required Per Joint Socket 1 1 2 1
Fig. 8
< DN 50 > DN 50
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Without delay, push the pipe in a smooth even motion, until the end of the socket reaches the first witness mark (fig. 11). Ensure that the joining process is completed as quick as possible, while the solvent cement surface is still wet. Do not attempt to make the joint if the solvent cement has dried.
Excess solvent cement must be removed Do not use MEK to clean up excess solvent cement.
The second witness mark shall be 100 mm from the end of the socket.
Fig. 13
Continue to exert axial load until the joint sets. As the sockets are tapered the pipe will initially try to slide out of the socket. See the following table.
Fig. 11
Pipe size Wipe thoroughly excess solvent cement from all around the socket mouth and, where possible, from inside of the joint. DN 15 - DN 50 DN 80 - DN 200 DN 225 - DN 350 DN 375 - DN 500 DN 575 - DN 650 DN 750
Holding time 10 - 60 sec. 1 - 3 min. 3 - 5 min. 5 - 10 min. 10 - 15 min. 20 - 30 min.
Do not disturb joints for 30 minutes after joining.
Fig. 12
Replace the lids on solvent cement and MEK cleaner. Clean brushes in MEK. Where joining is to continue, brushes can be stored in a covered tin of MEK cleaner to prevent hardening. Always ensure excess MEK cleaner is removed from brushes before using with solvent cement.
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Important notes on cold solvent cement welding Work in a well ventilated area clear of hazards. Use only Euratech ABS solvent cement and MEK cleaner. UPVC solvent cement and primer are not suitable for use with Euratech ABS pipe and fittings. Treat ABS cement and MEK cleaner with care, as they are volatile flammable liquids. Replace lids tightly after use. An indication of the number of joints likely to be made with Euratech ABS Solvent cement when following the recommended procedure is as follows:
The usage of MEK is approximately 50% that of ABS cement ABS cement shall be stirred before use. If solvent cement becomes thickened through evaporation of solvents or becomes contaminated dispose cement safely and use a fresh tin. Do not thin cement with MEK. Ensure there is no contamination to the solvent cement joint from dirt, dust, and oil. Solvent cement may be removed from your hands with soap and water or industrial hand cleaning soaps.
Pipe diameter DN 50 DN 80 DN 100 DN 125 DN 150 DN 195 DN 200 DN 225 DN 300 DN 350 DN 375 DN 400 DN 450 DN 500 DN 575 DN 650 DN 750
Solvent weld joints per liter * 135 45 35 20 20 10 10 4 4 3 2 1 1 0.5 0.5 0.3 0.3 Use only clean cotton rags and clean brushes. Check alignment of fittings before making the joint. Do not use MEK for removing ABS solvent cement from your skin The key to fast efficient joining, particularly with large pipe diameters is preparation. Solvent cement joining must be completed as quickly as practicable, typically within 2 minutes of applying the first coat of cement. Pipe and socket must be dry for effective joining.
* A socket counts as 2 joints, a tee as 3 joints etc.
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When using a lever winch, have everything ready before applying solvent cement. When installing fittings, ensure that winching operations do not bear on branches of tees. A canopy over the joining area is desirable when working in full sun. In hot conditions shading of joining areas of pipe for a minimum of 1 hour before joining will enable easier joining. In hot or wet conditions a canopy over the joining area to prevent direct sunlight or precipitation on the joining process will enable easier joining. Ensure adequate ventilation. Where a lever winch is used, leave it connected applying the axial load until the joint sets. It is good practice to leave the tension on the winch until it is needed for the next joint (fig. 14). Full rated pressure shall not be applied for 24 hours after joining. Test pressures above working pressure shall not be applied for 48 hours after joining.
Fig. 14
INSTALLATION OF BOLT ON SADDLES Assemble clean elastomeric seal carefully into band, making sure no dirt is in the tapping band groove. Extra care must be taken when fitting curved E-lips. Match any positioning lug into the mating notch in the band groove to ensure they are aligned correctly. Position band on a clean section of pipe, tighten bolts until band is secure. Over tightening is not necessary and could cause the stainless steel nuts to gall.
Tap the pipe trough the band being careful not to damage the band or force swarf under the seal. It is good practice to mark the pipe so that if the band is removed it may be replaced exactly and centrally over the tapped hole. The take-off branch is a plain socket. Reduced or threaded branch configurations may be formed by using the appropriate Euratech fitting. Ensure that all take-off pipes are aligned and free to flex with expansion to avoid undue stress on the saddle. Ensure that any instrument connected by this method is independently supported and not presenting any concentrated load to the main pipe.
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FLANGED JOINTS Eurapipe manufactures two styles of flanged joining systems. Full face flanges, available in sizes 15mm to 150mm.
Stub flanges are the preferred style as they offer a more economical fitting and are easier to install than the full face style. Stub flange assemblies have the same pressure rating as full face flanges assemblies. Backing rings must be used with both full face and stub flanges and are available in all standard drilling configurations. Gaskets must be used with flanges.
Fixed Backing Ring
ABS Pipe
ABS stub flange and full face flange assemblies may be bolted directly to other flanged pipe systems of the same flange drilling i.e. ANSI 150, AS 2129 etc.
Gasket Backing Ring Full Face Flange Steel Flange ABS Pipe
Full Face Flange Assembly
Gasket
Stub Flange
Stub flanges, available in sizes DN 50 to DN 750. Flange Assembly Steel to ABS Stub Flange
Loose Backing Ring
ABS Pipe
Flange bolt torque values for ABS pipes will not be as high as those commonly used on steel pipe systems.
Gasket
Stub Flange
Stub Flange Assembly
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The following recommended torque values are suitable for the maximum pressure rating of ABS pipe systems. Higher torque values may result in distortion of the flange face. Recommended bolt torques and bolt sizes for AS 2129 Table E Flanges (for ABS to ABS Flanges) Pipe size Bolt size Recommended torque* Bolts per Nm Flange DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 DN 195 DN 200 DN 225 DN 250 DN 300 DN 350 DN 375 DN 400 DN 450 DN 500 DN 575 DN 650 DN 800 M12 x 50 M12 x 50 M12 x 50 M12 x 50 M12 x 50 M16 x 65 M16 x 65 M16 x 70 M16 x 80 M16 x 90 M20 x 90 M20 x 100 M20 x 100 M20 x 130 M20 x 150 M20 x 150 M24 x 160 M24 x 170 M24 x 180 M24 x 190 M27 x 230 M27 x 240 M27 x 280 M33 x 300 7 10 14 13 16 22 25 33 25 34 42 63 63 80 108 108 133 163 157 185 191 190 200 200 4 4 4 4 4 4 4 4 8 8 8 8 8 12 12 12 12 12 16 16 16 16 20 20
Standard butterfly valves may be placed between ABS stub flange or full face flange assemblies without modification. Valves should be checked for full and free movement prior to final tightening of flange bolts. Care needs to be exercised as the valve disc may interfere with the bore of the pipe. Spacers or special stub flanges can be provided.
THREADED CONNECTIONS Euratech manufactures a range of threaded fittings up to 100DN (4 ). All threaded fittings are rated 1200kPa at 20C. For high-pressure installations it is preferable to use adaptors or fittings with male ABS threads in preference to female ABS threaded fittings. Composite unions, available in male and female threaded configurations to 50DN are recommended for joining ABS pipe to metal threads particularly in systems subject to thermal cycling. Tightening shall only be done by hand with a maximum of an extra quarter turn with a pipe wrench. There is often a tendency to over-tighten threads however this only causes distortion and leaks. If a threaded connection is leaking disassemble the thread and if not damaged remake the connection taking care not to over-tighten. PTFE tape is the recommended thread sealant. Do not use liquid thread sealants, e.g. Loctite or PTFE paste, as they contain chemicals which may attack plastic materials.
,,
* Torque values are based upon the use of lubricated bolts complying with the relevant standards. Care should be taken with galvanized bolts as increased friction may be encountered.
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BURIED PIPELINES Trench preparation Trenches shall be excavated in accordance with AS2566 - Buried flexible pipelines - Installation and the specified design and relevant installation codes. The bottom of the trench shall be even and stable and prepared in accordance with the prescribed pipeline gradient and depth. A bedding layer of a minimum thickness as determined by the code shall be laid in the bottom of the trench. Ensure that the bedding is free from hard objects or sharp projections. The bedding shall be graded to continuously support the pipe. The bedding shall be compacted according to the required specifications. Where the joining fitting will lay on the trench bottom, scallop out a bell hole in the bedding. The bell hole shall be twice the length of the socket joiner to allow sufficient room for joining. After joining, the bell hole shall be filled and compacted. Ensure that after joining has been completed joining sockets are neither unsupported nor on points of concentrated load. Pre-assembly of cold solvent cement welded pipes and laying Joining above ground and snaking into the trench is suitable for solvent cement welded pipes in sizes up to 200DN. With this method, the pipes are joined together in a continuous length of several hundred metres alongside the trench. Care must be taken not to strain the pipe or pipe joints. If this method is to be considered, refer to Euratech.
Joining in trench This method is appropriate for all joining methods and for all sizes of pipe. The pipes shall be laid in the trench so that the socketed end of the pipe is facing in the direction of laying. The next pipe is then placed in the trench and inserted into the socket. Pipes can be supplied with one joining socket fitted to one end and the other end chamfered. Where this is not the case, or the pipe is cut to a specific length, a chamfer shall be formed (see procedure for cutting) and a socket shall be welded to one end of the pipe above ground before laying in trench. Where it is necessary to fit a joining socket to a pipe in a trench, the trench will need to have sufficient room around the end of the pipe to perform joining. When solvent cement welding in trenches, ensure that any spillage of solvent cement or MEK is completely removed immediately. Thrust blocks Thrust blocks are not required for solvent cement jointed buried pipelines at changes of direction, terminations, changes in pipe diameter or tees. Thrust blocks may be required where elastomeric seal joints, valves or other equipment is positioned in the pipeline and are not independently supported.
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Backfilling and Tamping Backfilling and compaction of embedment material, overlay and backfill shall be in accordance with AS 2566.
REPAIR OF DAMAGED PIPES Above ground For above ground repairs, the recommended method is to remove the damaged section of pipe and replace with a new section. Sockets, flanges, socket unions, or shoulder style joints are all suitable methods to rejoin the pipe. Metal couplings are also suitable where pipe has adequate restraint against axial thrust. Below ground Where damage to the pipe is minimal (less than 25 - 30% of circumference of pipe) a repair saddle may be used. These are available from Euratech. A temporary repair may be quickly prepared on site from a sectioned ABS socket with the centre stop removed. A repair saddle properly fitted will restore the pipe to its maximum rated working pressure. Where the damage is more extensive, the damaged section of pipe must be replaced. The joining method may be selected from the following table.
Rubber ring coupling repair procedure Preparation and removing the damaged section Note: All dimensions in this section are for pipe DN 500. The repair kits, which are available for all sizes, contain detailed method and procedure. Please contact Euratech for other sizes. The length of the trench should be extended by 2 metres at each end from where the damaged section is to be removed; this is to allow sufficient pipe length for attaching the ABS RRJ slip couplings and Thrust Restraint Collars (if needed). Cut out the damaged section using the tungsten tipped circular saw.
Method Slip Coupling Shoulder Style Coupling Mechanical Coupling
REPAIR METHOD Size Range DN 250 - DN 750 DN 50 - DN 450 DN 15 - DN 750
Axial Restraint* NO NO NO
It will be necessary to remove a minimum pipe length of 1200 mm to effect the correct installation of the ABS RRJ slip coupling. Inspect the existing pipe for surface defects, which may affect performance of the rubber rings. Ensure the pipe is free of any dirt and debris and clean the surface using rags dampened with water. Do not use the MEK cleaner. The following chamfers need to be applied (approximate only): - On the existing pipe, a chamfer of 15 x 15mm back along the pipe. - On the new section, a chamfer of 15 x 30mm back along the pipe. Measure the old section of pipe that has been removed and cut the new section to be installed 100 mm shorter, this is to ensure there is no interference of the new and existing pipe sections and for ease of installation.
* Temporary restraint may be required.
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Positioning the new pipe section Apply a thin film of the RRJ lubricant to the inside surface of the ABS RRJ slip coupling rings and to the outside surface of each end of the replacement pipe for a distance of 400mm. Fit ABS RRJ slip couplings to each end and using a mechanical device (comea-long etc) slide to the length of the coupling, as shown on the following drawing, (a). Position the new section of pipe in the trench, using the marking pen place a witness mark 200mm back from the ends of the existing pipe and apply lubricant to chamfer and pipe ends. Slide the slip-couplings over the existing pipe ends back to these marks as shown on the following drawing, (b). Important If needed, a detailed procedure of installing Thrust Restraint Collars is provided with the repair kit. The Thrust Restraint Collars require a minimum curing time before recommissioning the line. Contact Euratech for the recommended time required for each application. Repairs made with repair sockets or metal couplings may be returned to service immediately. After pressure testing, backfill excavation ensuring pipe is suitably bedded and tamped. ABOVE GROUND PIPELINES Euratech ABS pipe is particularly suitable for installation as an above ground line. Typical examples are in tailings disposal or de-water applications. Contact Euratech for information. Repairs made using shoulder ends may be returned to service immediately for gravity lines, or after the recommended solvent cement drying time for pressure lines.
REPAIR ASSEMBLY ABS REPLACEMENT PIPE PRE-ASSEMBLED WITH ABS SLIP COUPLINGS
(a)
ABS SLIP COUPLINGS
EXISTING PIPE
REPLACEMENT PIPE
EXISTING PIPE
(b)
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HYDROSTATIC PRESSURE TESTING The test procedure outlined in AS2566 should be followed where installations must be pressure tested. Alternatively, the following procedure may be employed. Note: Testing must not be carried out until the following times have elapsed since completion of the last joint: Sizes DN 15 - DN200 Sizes OD225 - OD355 Sizes OD400 - OD630 24 hours 36 hours 48 hours
If there are no leaks remove any remaining air and increase pressure to 300kPa. Leave at this pressure for 15 minutes and inspect for leaks. If pressure remains constant, increase pressure to recommended test pressure. Leave pressurised for a period not exceeding one hour. During this time pressure should hold almost constant. Recommended test pressure is 1.5 times the operating pressure, less the allowance for temperature/pressure derating at the current test temperature and maximum static head. Note: If extended times are required to achieve the test pressure either leakage is occurring or there is air trapped in the system. Inspect for leakage and if none apparent, reduce the pressure and check for trapped air which must be removed before the test can continue.
For large installations split the system into sections for testing. Fill section with clean ambient temperature water (20C is ideal). Do not pressurise. Ensure no air is trapped in the system. Inspect system for gas leaks. Allow the system to stand for one hour to allow temperature to stabilise and an equilibrium reached.
CAUTION: Under no circumstances should pressure tests be carried out using high pressure gas. Water is the preferred pressurizing medium. If air is used, a maximum pressure of 7kPa should not be exceeded. When testing above ground lines, the Poissons effect may reduce the length of line. This may impose excessive loads on bulk heads or equipment greater than the design. It is recommended that final closures are made after the hydrotest and inservice test.
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PIPES & FITTINGS

EURAPIPE ABS PIPE DIMENSION TABLE
PIPE SIZE (mm)
1/2 (15DN) 3/4 (20DN) 3/4 (20DN) 3/4 (20DN) 1 (25DN) 1 (25DN) 1 (25DN) 1 1/4 (32DN) 1 1/4 (32DN) 1 1/4 (32DN) 1 1/2 (40DN) 1 1/2 (40DN) 1 1/2 (40DN) 2 (50DN) 2 (50DN) 2 (50DN) 2 1/2 (75mm) 2 1/2 (75mm) 2 1/2 (75mm) 2 1/2 (75mm) 3 (80DN) 3 (80DN) 3 (80DN) 3 (80DN) 4 (100DN) 4 (100DN) 4 (100DN) 4 (100DN) 4 (100DN) 4 (100DN) 6 (150DN) 6 (150DN) 6 (150DN) 6 (150DN) 6 (150DN) 6 (150DN) 15 9 12 15 9 12 15 9 12 15 9 12 15 9 12 15 6 10 12 15 6 9 12 15 3 4.5 6 9 12 15 3 4.5 6 9 12 15
PIPE CLASS
MAXIMUM OPERATING PRESSURE (kPa)

1500 900 1200 1500 900 1200 1500 900 1200 1500 900 1200 1500 900 1200 1500 600 1000 1200 1500 600 900 1200 1500 300 450 600 900 1200 1500 300 450 600 900 1200 1500
ORDER CODE
01 513 015 01 511 020 01 512 020 01 513 020 01 511 025 01 512 025 01 513 025 01 511 032 01 512 032 01 513 032 01 511 040 01 512 040 01 513 040 01 511 050 01 512 050 01 513 050 11 510 075 11 511 075 11 512 075 11 513 075 01 510 080 01 511 080 01 512 080 01 513 080 01 508 100 01 509 100 01 510 100 01 511 100 01 512 100 01 513 100 01 508 150 01 509 150 01 510 150 01 511 150 01 512 150 01 513 150
OUTSIDE DIAMETER (mm)

21.4 26.8 26.8 26.8 33.6 33.6 33.6 42.3 42.3 42.3 48.3 48.3 48.3 60.4 60.4 60.4 75.1 75.1 75.1 75.1 88.9 88.9 88.9 88.9 114.3 114.3 114.3 114.3 114.3 114.3 168.3 168.3 168.3 168.3 168.3 168.3
INSIDE DIAMETER (mm)

17.0 23.4 22.4 21.4 29.3 28.1 26.9 37.0 35.5 34.0 42.3 40.5 38.8 53.0 50.7 48.6 68.8 65.0 63.1 60.5 81.5 78.1 74.8 71.7 109.4 107.1 104.9 100.5 96.3 92.2 161.1 157.7 154.4 148.0 141.8 135.9
WALL THICKNESS (mm)

2.2 1.7 2.2 2.7 2.1 2.7 3.3 2.6 3.4 4.1 3.0 3.9 4.7 3.7 4.8 5.9 3.1 5.1 6.0 7.3 3.7 5.4 7.0 8.6 2.5 3.6 4.7 6.9 9.0 11.0 3.6 5.3 6.9 10.1 13.2 16.2
MASS (kg/m)
0.14 0.14 0.18 0.21 0.22 0.28 0.33 0.34 0.44 0.52 0.44 0.57 0.68 0.69 0.88 1.06 0.75 1.17 1.36 1.63 1.04 1.49 1.90 2.28 0.91 1.32 1.71 2.45 3.13 3.76 1.94 2.82 3.68 5.28 6.75 8.12
1. All values quoted are average and are subject to manufacturing tolerances. 2. Standard pipe length supplied 5.8 m. Lengths up to 12 m available upon request.
4. Other sizes and pressure ratings are available upon request 5. Pipe is supplied plain ended.
Dimension stated as guide, for detail dimension, please refer to Euratech (M) Sdn Bhd
Issue 1 Revision 1
45

300 450 600 900 1200 1500 450 600 900 1200 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450
PIPE SIZE (mm)

8 (200DN) 8 (200DN) 8 (200DN) 8 (200DN) 8 (200DN) 8 (200DN) 140 mm 140 mm 140 mm 140 mm 225 mm 225 mm 225 mm 225 mm 225 mm 225 mm 250 mm 250 mm 250 mm 250 mm 250 mm 250 mm 315 mm 315 mm 315 mm 315 mm 315 mm 315 mm 355 mm 355 mm 355 mm 355 mm 355 mm 355 mm 400 mm 400 mm
PIPE CLASS
3 4.5 6 9 12 15 4.5 6 9 12 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5
ORDER CODE
01 508 200 01 509 200 01 510 200 01 511 200 01 512 200 01 513 200 11 509 140 11 510 140 11 511 140 11 512 140 11 508 225 11 509 225 11 510 225 11 511 225 11 512 225 11 513 225 11 508 250 11 509 250 11 510 250 11 511 250 11 512 250 11 513 250 11 508 315 11 509 315 11 510 315 11 511 315 11 512 315 11 513 315 11 508 355 11 509 355 11 510 355 11 511 355 11 512 355 11 513 355 11 508 400 11 509 400

219.1 219.1 219.1 219.1 219.1 219.1 140.2 140.2 140.2 140.2 225.3 225.3 225.3 225.3 225.3 225.3 250.3 250.3 250.3 250.3 250.3 250.3 315.4 315.4 315.4 315.4 315.4 315.4 355.5 355.5 355.5 355.5 355.5 355.5 400.5 400.5

209.9 205.5 201.2 192.8 184.8 177.0 133.5 131.5 127.5 123.6 218.1 214.7 211.4 202.9 198.7 192.7 242.3 238.6 234.9 225.4 220.8 214.2 305.4 300.7 296.0 284.1 278.3 269.9 344.2 338.9 333.7 320.2 313.7 304.2 387.9 381.9
WALL THICKNESS (mm)

4.6 6.8 9.0 13.1 17.2 21.0 3.3 4.4 6.4 8.3 3.6 5.3 6.9 11.2 13.3 16.3 4.0 5.9 7.7 12.5 14.7 18.1 5.0 7.4 9.7 15.7 18.6 22.7 5.6 8.3 10.9 17.6 20.9 25.6 6.3 9.3
MASS (kg/m)
3.27 4.77 6.21 8.93 11.43 13.75 1.50 1.95 2.81 3.61 2.63 3.85 5.00 7.92 9.29 11.22 3.23 4.72 6.16 9.77 11.45 13.84 5.10 7.47 9.76 15.49 18.17 21.96 6.47 9.48 12.39 19.66 23.06 27.87 8.20 12.02
46
Issue 1 Revision 1

600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 1200 1500 300 450 600 1000 300 450 600
PIPE SIZE (mm)

400 mm 400 mm 400 mm 400 mm 450 mm 450 mm 450 mm 450 mm 450 mm 450 mm 500 mm 500 mm 500 mm 500 mm 500 mm 500 mm 560 mm 560 mm 560 mm 560 mm 560 mm 560 mm 630 mm 630 mm 630 mm 630 mm 630 mm 630 mm 710 mm 710 mm 710 mm 710 mm 826 mm 826 mm 826 mm
PIPE CLASS
6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 12 15 3 4.5 6 10 3 4.5 6
ORDER CODE
11 510 400 11 511 400 11 512 400 11 513 400 11 508 450 11 509 450 11 510 450 11 511 450 11 512 450 11 513 450 11 508 500 11 509 500 11 510 500 11 511 500 11 512 500 11 513 500 11 508 560 11 509 560 11 510 560 11 511 560 11 512 560 11 513 560 11 508 630 11 509 630 11 510 630 11 511 630 11 512 630 11 513 630 11 508 710 11 509 710 11 510 710 11 511 710 11 508 826 11 509 826 11 510 826

400.5 400.5 400.5 400.5 450.6 450.6 450.6 450.6 450.6 450.6 500.7 500.7 500.7 500.7 500.7 500.7 560.7 560.7 560.7 560.7 560.7 560.7 630.8 630.8 630.8 630.8 630.8 630.8 710.9 710.9 710.9 710.9 825.5 825.5 825.5

376.0 360.8 353.4 342.8 436.4 429.6 423.0 405.9 397.6 385.7 484.9 477.4 470.0 451.0 441.9 428.6 543.1 534.7 526.4 505.2 494.9 480.0 611.1 601.6 592.3 568.3 556.8 540.0 688.7 678.0 667.5 640.5 799.7 787.3 775.1
WALL THICKNESS (mm)

12.3 19.9 23.5 28.9 7.1 10.5 13.8 22.3 26.5 32.4 7.9 11.6 15.3 24.8 29.4 36.0 8.8 13.0 17.1 27.8 32.9 40.4 9.9 14.6 19.3 31.2 37.0 45.4 11.1 16.5 21.7 35.2 12.9 19.1 25.2
MASS (kg/m)
15.71 24.95 29.26 35.37 10.35 15.19 19.86 31.55 37.01 44.75 12.77 18.74 24.51 38.95 45.69 55.24 15.99 23.48 30.72 48.83 57.28 69.27 20.22 29.70 38.86 61.78 72.48 87.65 25.65 37.70 49.33 78.45 34.58 50.85 66.55
Issue 1 Revision 1
47
EURAPIPE ABS PRESSURE PIPE SERIES 1
PLAIN SOCKET CODE 100
STUB FLANGE CODE 135
FULL FACE FLANGE CODE 129, 130, 317, 319, 322
SHOULDER END CODE 954
SHOULDER STYLE COUPLING CODE 953
BLANK FLANGE STUB STYLE CODE 136
BLANK FULL FACE FLANGE CODE 131, 313, 315, 316
BACKING RING CODE 415, 416, 425
VALVE SUPPORT PLATE CODE 460
GASKET (FULL FACE STYLE) CODE 410
GASKET (STUB FLANGE STYLE) CODE 431
ELBOW 90 CODE 115
ELBOW 45C CODE 119
FAUCET ELBOW 90C CODE 116
MOULDED BEND 90C CODE 118
BEND 90 R=1.2D (SP-SP) CODE 301
BEND 90 R=5D (SP-SP) CODE 309
BEND 45 R=5D (SP-SP) CODE 310
EQUAL TEE CODE 122
REDUCING TEE SPIGOT OFFTAKE (So-SoxSP) CODE 120
48
Issue 1 Revision 1
REDUCING TEE SOCKET OFFTAKE (So-SoxSp) CODE 122
TEE THREADED OFF TAKE (So-SoxTh) CODE 121
Y PIECE 45 CODE 128
SADDLE STRIPS CODE 146
SADDLE CODE 126
TAPPING SADDLES CODE 127
REDUCING SOCKET CODE 114
REDUCING BUSH CODE 109
FAUCET SOCKET CODE 101
VALVE ADAPTOR / HEXAGON NIPPLE CODE 107
VALVE SOCKET / MALE ADAPTOR CODE 151
FAUCET ADAPTOR CODE 153
END CAP CODE 140
THREADED PLUG CODE 155
SOCKET UNION CODE 205
SADDLE CLIP CODE 455
PIPE CLIP CODE 434
RUBBER EXPANSION JOINT CODE 452
ANCHOR SLEEVE CODE 272
ANCHOR FLANGE CODE 137
BALL CHECK VALVE DOUBLE UNION CODE 836, 838
BALL VALVE DOUBLE UNION CODE 880
ABS SOLVENT CEMENT CODE 461
MEK CLEANER/PRIMER CODE 463
Issue 1 Revision 1
49
PLAIN SOCKET
SIZE (mm) 15 20 25 32 40 50 75 80 100 150 200 225 250 315 355 400 450 500 560 630
CODE 01.100.015 01.100.020 01.100.025 01.100.032 01.100.040 01.100.050 11.100.075 01.100.080 01.100.100 01.100.150 01.100.200 11.100.225 11.100.250 11.100.315 11.100.355 11.100.400 11.100.450 11.100.500 11.100.560 11.100.630
ID (mm) 21 27 34 42 48 60 75 89 114 168 219 225 250 315 355 400 450 501 561 631
A (mm) 27 33 41 52 59 74 93 111 141 203 250 247 275 341 384 440 493 548 593 688
B (mm) 43 47 53 61 67 77 91 112 139 192 246 252 276 307 347 392 440 490 549 620
Z (mm) 3 3 3 3 3 3 3 6 6 6 6 6 6 6 6 6 10 10 12 14
STUB FLANGE TO AS 2129
SIZE (mm) 50 75 80 100 150 200 225 250 315 355 400 450 500 630
CODE 01.135.050 11.135.075 01.135.080 01.135.100 01.135.150 11.135.200 11.135.225 11.135.250 11.135.315 11.135.355 11.135.400 11.135.450 11.135.500 11.135.630
ID (mm) 60 75 89 114 168 219 225 250 315 355 400 450 501 631
A (mm) 96 106 127 159 214 270 270 331 376 440 488 539 613 708
B (mm) 40 50 57 70 100 134 127 139 169 189 220 245 270 335
C (mm) 15 15 18 20 24 25 25 30 35 37 50 50 50 64
D (mm) 74 91 108 133 191 250 250 287 350 400 435 514 548 685
Z (mm) 3 3 5 5 8 8 8 8 8 8 14 14 14 16
Backing ring required
FULL FACE FLANGE UNDRILLED TO AS 2129 TABLE D/E
SIZE (mm) 15 20 25 32 40 50 75 80 100 150
CODE 01.129.015 01.129.020 01.129.025 01.129.032 01.129.040 01.129.050 11.129.075 01.129.080 01.129.100 01.129.150
ID (mm) 21 27 34 42 48 60 75 89 114 168 Drilled Table D - 317 Series DIN 16/3 - 319 Series
A (mm) 95 100 115 140 150 165 184 200 220 285
B (mm) 23 25 27 32 34 40 49 57 70 100
C (mm) 10 10 10 10 10 10 12 12 17 22
Z (mm) 3 3 3 3 3 3 3 5 5 8
Drilled ANSI 150 - 322 Series Undrilled - 129 Series
Other Drilling available on request
SHOULDER END
SIZE (mm) 50 80 100 150 200 250 315 355 400 450 500
CODE 01.160.050 01.160.080 01.160.100 01.160.150 01.160.200 11.160.250 11.160.315 11.160.355 11.160.400 11.160.450 11.160.500
ID (mm) 60 89 114 168 219 250 315 355 400 450 501
A (mm) 73 104 141 208 269 308 355 425 477 527 585
B (mm) 70 90 108 140 170 213 241 273 505 555 605
Z (mm) 34 39 45 50 55 66 65 69 286 311 336
50
Issue 1 Revision 1
SHOULDER STYLE COUPLING

SIZE (mm) 50 80 100 150 200 250 315 355 400 450 500 CODE 01.953.050 01.953.080 01.953.100 01.953.150 01.953.200 01.953.250 01.953.315 01.953.355 01.953.400 01.953.450 01.953.500 A (mm) 140 175 205 275 340 410 489 555 568 619 698 B (mm) 98 131 162 214 280 348 395 448 482 539 597 Z (mm) 44 46 50 52 63 69 69 76 73 79 76
Shoulder couplings are manufactured from galvanised mild steel with EPDM gasket
BLANK FLANGE STUB STYLE AS 2129 TABLE E
SIZE (mm) 15 20 25 32 40 50 75 80 100 140 150 200 225 250 315 355 400 450 500 630
CODE 01.136.015 01.136.020 01.136.025 01.136.032 01.136.040 01.136.050 11.136.075 01.136.080 01.136.100 11.136.140 01.136.150 01.136.200 11.136.225 11.136.250 11.136.315 11.136.355 11.136.400 11.136.450 11.136.500 11.136.630
A (mm) 50 56 66 70 81 95 106 127 159 192 214 270 270 331 376 440 488 539 613 708
B (mm) 10 10 10 10 10 12 12 12 17 20 22 25 25 32 38 43 52 58 64 81
BLANK FULL FACE FLANGE UNDRILLED AS 2129 TABLE E
SIZE (mm) 15 20 25 32 40 50 75 80 100 140 150 200 225 250 315 355 400 450 500 560 630
CODE 01.131.015 01.131.020 01.131.025 01.131.032 01.131.040 01.131.050 11.131.075 01.131.080 01.131.100 11.131.140 01.131.150 01.131.200 11.131.225 11.131.250 11.131.315 11.131.355 11.131.400 11.131.450 11.131.500 11.131.560 11.131.630
A (mm) 95 100 115 140 150 165 184 200 220 255 285 335 335 405 455 525 580 640 705 760 825
B (mm) 10 10 10 10 10 12 12 12 17 20 22 25 25 32 38 43 52 58 64 73 81
Issue 1 Revision 1
51
BACKING RING
PCD SIZE (mm) 15 20 25 32 40 50 75 80 100 140 150 200 225 250 315 355 400 450 500 560 630 CODE 03.***.015 03.***.020 03.***.025 03.***.032 03.***.040 03.***.050 13.***.075 03.***.080 03.***.100 13.***.140 03.***.150 03.***.200 13.***.225 13.***.250 13.***.315 13.***.355 13.***.400 13.***.450 13.***.500 13.***.560 13.***.630 ID 33 39 47 56 65 77 91 108 137 167 195 255 255 312 355 405 440 519 553 694 690
AS 2129 TABLE D CODE *415 B A PCD H D (mm) (mm) (mm) (mm) 6 95 67 4 14 6 102 73 4 14 6 115 83 4 14 6 120 87 4 14 6 134 98 4 14 8 150 114 4 18 8 165 127 4 18 8 185 146 4 18 8 215 178 4 18 10 255 210 8 18 10 280 235 8 22 10 335 292 8 22 20 335 292 8 22 20 405 356 12 22 20 455 406 12 22 20 525 470 12 22 20 580 521 12 26 25 640 584 12 26 30 705 641 16 26 32 760 699 16 30 32 825 756 16 30
AS 2129 TABLE E CODE *416 A PCD H D (mm) (mm) (mm) 95 67 4 14 102 73 4 14 115 83 4 14 120 87 4 14 134 98 4 14 157 114 4 18 165 127 4 18 185 146 4 18 215 178 8 18 255 210 8 18 280 235 8 22 335 292 8 22 335 292 12 22 405 356 12 22 455 406 12 22 525 470 12 26 580 521 12 26 640 584 16 26 705 641 16 26 760 699 16 30 825 756 16 33
ANSI 150 CODE*425 A PCD H D (mm) (mm) (mm) 89 60 4 18 99 70 4 18 108 79 4 18 118 89 4 18 127 98 4 18 152 121 4 18 178 140 4 18 191 152 4 18 229 191 8 18 254 216 8 22 279 241 8 22 343 299 8 22 343 299 8 25 406 362 12 25 483 432 12 25 533 476 12 29 597 540 16 29 635 578 16 33 699 635 20 33 813 749 20 35
Material: Hot dipped galvanised mild steel
VALVE SUPPORT PLATE
SIZE CODE A B (mm) (mm) (mm) 15 03.***.015 95 86 20 03.***.020 100 89 25 03.***.025 115 95 32 03.***.032 140 99 40 03.***.040 150 105 50 03.***.050 165 127 75 13.***.075 184 140 80 03.***.080 200 143 100 03.***.100 220 159 140 13.***.140 255 189 150 03.***.150 285 216 200 03.***.200 335 246 250 13.***.250 335 298 315 13.***.315 405 348 Material: Galvanised mild steel. Stainless steel also available
C D E (mm) (mm) (mm) 51 14 16 76 14 16 76 14 16 76 14 16 76 14 16 102 14 22 109 14 22 126 14 22 152 14 22 192 14 22 229 14 33 280 14 33 340 14 40 390 22 40 Code 465 - AS 2129 Table D Code 470 - ANSI 150 Code 458 - DIN 16/3 ID (mm) 18 23 30 39 45 57 69 84 110 119 164 214 214 242 307 347 392 440 490 549 620 A (mm) 95 100 115 140 150 165 184 200 220 255 285 335 335 405 455 525 580 640 705 760 825
F (mm) 8 8 8 8 8 8 8 8 8 10 10 10 12 12
GASKET (FULL FACE STYLE)

SIZE CODE (mm) 15 04.***.015 20 04.***.020 25 04.***.025 32 04.***.032 40 04.***.040 50 04.***.050 75 14.***.075 80 04.***.080 100 04.***.100 140 14.***.140 150 04.***.150 200 04.***.200 225 14.***.225 250 14.***.250 315 14.***.315 355 14.***.355 400 14.***.400 450 14.***.450 500 14.***.500 560 14.***.560 630 14.***.630 Standard material - EPDM others materials are also available B (mm) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
52
Issue 1 Revision 1
GASKET (STUB FLANGE STYLE)
SIZE (mm) 50 75 80 100 140 150 200 225 250 315 355 400 450 500 630
CODE 04.431.050 14.431.075 04.431.080 04.431.100 14.431.140 04.431.150 04.431.200 14.431.225 14.431.250 14.431.315 14.431.355 14.431.400 14.431.450 14.431.500 14.431.630
ID (mm) 57 69 84 110 119 164 214 217 242 307 347 392 440 490 620
A (mm) 96 106 127 159 192 214 270 270 331 376 440 488 539 613 708
B (mm) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
ELBOW 90
SIZE (mm) 15 20 25 32 40 50 75 80 100 150 200 225 250 315 355 400
CODE 01.115.015 01.115.020 01.115.025 01.115.032 01.115.040 01.115.050 11.115.075 01.115.080 01.115.100 01.115.150 01.115.200 11.115.225 11.115.250 11.115.315 11.115.355 11.115.400
ID (mm) 21 27 34 42 48 60 75 89 114 168 219 225 250 315 355 400
A (mm) 27 33 41 52 59 74 92 111 142 207 259 259 284 355 439 439
B (mm) 31 36 43 51 56 69 83 102 129 180 260 235 258 322 408 408
Z (mm) 11 14 18 22 25 32 39 50 64 88 116 116 127 158 202 202
Elbows in larger sizes available on request
ELBOW 45
SIZE (mm) 15 20 25 32 40 50 75 80 100 150 225 250 315 355 400 CODE 01.119.015 01.119.020 01.119.025 01.119.032 01.119.040 01.119.050 11.119.075 01.119.080 01.119.100 01.119.150 11.119.225 11.119.250 11.119.315 11.119.355 11.119.400 ID (mm) 21 27 34 42 48 60 75 89 114 168 225 250 315 355 400 A (mm) 27 33 41 52 59 74 91 112 135 206 259 284 355 439 439 B (mm) 27 30 35 42 45 54 62 72 89 132 171 190 232 289 289 Z (mm) 7 8 10 13 14 17 18 21 26 40 52 58 64 83 83
FAUCET ELBOW 90
Elbows in larger sizes available on request
SIZE 15 20 25 20 X 15
CODE CODE 01.116.015 01.116.020 01.116.025 01.116.020015
A (mm) 28 34 43 35
B (mm) 29 35 42 32
C (mm) 31 36 43 36
D (mm) 18 21 24 18
ID (mm) 21 27 34 27
Z (mm) 11 14 18 14
Issue 1 Revision 1
53
MOULDED BEND 90
SIZE (mm) 15 20 25 32 40 50 75 80 100
CODE 01.118.015 01.118.020 01.118.025 01.118.032 01.118.040 01.118.050 11.118.075 01.118.080 01.118.100
ID (mm) 21 27 34 42 48 60 75 89 114
A (mm) 29 35 43 64 54 64 93 113 137
B (mm) 40 50 64 100 80 100 150 180 220
C (mm) 58 71 88 131 109 131 195 231 284
BEND 90 R= 1.2D (Sp-Sp)
SIZE CODE (mm) 50 01.301.050 75 11.301.075 80 01.301.080 100 01.301.100 140 11.301.140 150 01.301.150 200 01.301.200 225 11.301.225 250 11.301.250 315 11.301.315 355 11.301.355 400 11.301.400 450 11.301.450 500 11.301.500 630 11.301.630 Bends supplied plain ended. Non standard bend angles available. SIZE CODE (mm) 50 01.302.050 75 11.302.075 80 01.302.080 100 01.302.100 140 11.302.140 150 01.302.150 200 01.302.200 225 11.302.225 250 11.302.250 315 11.302.315 355 11.302.355 400 11.302.400 450 11.302.450 500 11.302.500 630 11.302.630 Bends supplied plain ended. Non standard bend angles available.
R (mm) 72 90 107 137 168 202 263 270 300 378 426 481 541 601 721
A (mm) 127 155 182 232 282 337 436 448 497 624 702 790 887 985 1180
B min (mm) 157 193 227 289 353 421 546 561 622 782 880 990 1113 1235 1480
R (mm) 72 90 107 137 168 202 263 270 300 378 426 481 541 601 721
A (mm) 84 103 120 152 184 219 282 290 321 402 452 508 571 633 758
B min (mm) 97 118 138 175 213 254 328 337 373 468 526 591 664 737 882
SIZE CODE (mm) 50 01.308.050 75 11.308.075 80 01.308.080 100 01.308.100 140 11.308.140 150 01.308.150 200 01.308.200 225 11.308.225 250 11.308.250 315 11.308.315 355 11.308.355 400 11.308.400 450 11.308.450 500 11.308.500 630 11.308.630 Bends supplied plain ended. Non standard bend angles available.
R (mm) 151 188 222 286 351 421 548 563 626 789 889 1001 1126 1251 1502
A (mm) 205 253 298 380 465 556 721 741 823 1034 1164 1311 1473 1636 1961
B min (mm) 235 291 342 438 535 640 831 854 948 1192 1342 1511 1698 1886 2261
54
Issue 1 Revision 1
SIZE CODE (mm) 50 01.312.050 75 11.312.075 80 01.312.080 100 01.312.100 140 11.312.140 150 01.312.150 200 01.312.200 225 11.312.225 250 11.312.250 315 11.312.315 355 11.312.355 400 11.312.400 450 11.312.450 500 11.312.500 630 11.312.630 Bends supplied plain ended. Non standard bend angles available. SIZE CODE (mm) 50 01.309.050 75 11.309.075 80 01.309.080 100 01.309.100 140 11.309.140 150 01.309.150 200 01.309.200 225 11.309.225 250 11.309.250 315 11.309.315 355 11.309.355 400 11.309.400 450 11.309.450 500 11.309.500 630 11.309.630 Bends supplied plain ended. Non standard bend angles available.
R (mm) 151 188 222 286 351 421 548 563 626 789 889 1001 1126 1251 1577
A (mm) 117 143 168 213 259 310 400 411 456 572 644 724 813 903 1135
B min (mm) 129 159 186 237 288 344 446 458 508 638 717 807 907 1006 1266
BEND 90 R= 5D (Sp-Sp)
R (mm) 302 376 445 572 701 842 1096 1127 1252 1577 1777 2003 2253 2503 3153 A (mm) 365 425 533 672 834 999 1298 1334 1482 1864 2099 2363 2657 2951 3716 B min (mm) 395 489 577 739 904 1083 1407 1447 1609 2021 2276 2564 2882 3201 4031
BEND 45 R= 5D (Sp-Sp)
SIZE CODE (mm) 50 01.310.050 75 11.310.075 80 01.310.080 100 01.310.100 140 11.310.140 150 01.310.150 200 01.310.200 225 11.310.225 250 11.310.250 315 11.310.315 355 11.310.355 400 11.310.400 450 11.310.450 500 11.310.500 630 11.310.630 Bends supplied plain ended. Non standard bend angles available. R (mm) 302 376 445 572 701 842 1096 1127 1252 1577 1777 2003 2253 2503 3153 A (mm) 188 232 273 347 424 506 656 674 748 940 1058 1190 1338 1485 1864 B min (mm) 201 247 291 371 453 541 701 721 800 1005 1131 1273 1431 1589 1999
Issue 1 Revision 1
55
EQUAL TEE (So-SoxSo)
SIZE (mm) 15 20 25 32 40 50 75 80 100 150 200 225 250 315 355 400 450 500
CODE 01.122.015 01.122.020 01.122.025 01.122.032 01.122.040 01.122.050 11.122.075 01.122.080 01.122.100 01.122.140 01.122.200 11.122.225 11.122.250 11.122.315 11.122.355 11.122.400 11.122.450 11.122.500
ID (mm) 21 27 34 43 48 60 75 89 114 168 219 225 250 315 355 400 450 501
A (mm) 63 72 85 102 112 137 167 204 258 360 365 472 520 652 891 990 1083 1272
B (mm) 31 36 43 51 56 69 84 102 129 180 235 247 326 326 421 471 524 562
Z1 (mm) 11 14 18 22 25 32 40 49 64 88 118 124 162 162 263 289 310 380
Z2 (mm) 11 14 18 22 25 32 40 49 64 88 118 124 162 162 239 265 292 306
TYPE (mm) M M M M M M M M M M M M M M M M F F
REDUCING TEE SPIGOT OFFTAKE (So-SoxSp)
Sizes 15mm - 315mm are moulded Reduced branch sizes are available in sizes 355 - 630
SIZE 200-100 250-150 315-150 315-200 355-150 355-200 400-150 400-200 400-250 450-150 400-200 450-250 450-315 500-150 500-200 500-250 500-315
CODE 01.120.200100 11.120.250150 11.120.315150 11.120.315200 11.120.355150 11.120.355200 11.120.400150 11.120.400200 11.120.400250 11.120.450150 11.120.450200 11.120.450250 11.120.450315 11.120.500150 11.120.500200 11.120.500250 11.120.500315
REDUCING TEE SOCKET OFFTAKE (So-SoxSo)

SIZE (mm) 20x15 25x15 25x20 40x25 50x25 50x40
ID (mm) 219 250 315 315 355 355 400 400 400 450 450 450 450 500 500 500 500
A (mm) 277 339 387 387 450 450 500 500 500 559 559 559 559 618 618 618 618
B (mm) 420 500 600 650 650 700 700 750 800 750 800 850 900 800 850 900 950
C (mm) 250 325 350 375 375 400 400 425 450 425 475 500 525 450 500 525 550
CODE 01.122.020015 01.122.025015 01.122.025020 01.122.040025 01.122.050025 01.122.050040
A (mm) 33 41 41 59 74 74
B (mm) 67 73 78 97 109 125
C (mm) 34 38 40 50 56 62
ID1 (mm) 27 34 34 48 60 60
ID2 (mm) 21 21 27 34 34 48
Z1 (mm) 12 12 14 18 18 26
Z2 (mm) 14 18 18 25 31 31
TEE THREADED OFFTAKE (So-SoxTh)
SIZE (mm) 15 20x15 20 25x15 25
CODE 01.121.015 01.121.020015 01.121.020 01.121.025015 01.121.025
ID (mm) 21 27 27 34 34
A (mm) 29 35 35 44 43
B (mm) 62 67 72 73 85
C (mm) 29 32 35 35 42
D (mm) 18 18 21 18 24
Z (mm) 11 14 14 17 17
56
Issue 1 Revision 1
Y PIECE 45
SIZE (mm) 20 25 32 40 50 80 100 150 200 250 Larger sizes
ID (mm) 01.128.020 27 01.128.025 34 01.128.032 42 01.128.040 48 01.128.050 60 01.128.080 89 01.128.100 114 01.128.150 168 01.128.200 219 11.128.250 250 are available on request
CODE
A (mm) 28 33 41 50 60 140 220 277 277 339
B (mm) 68 81 98 117 140 400 550 700 700 750
C (mm) 43 52 65 77 95 250 375 475 475 575
Z1 (mm) 6 7 9 11 12 273 370 468 462 458
Z2 (mm) 26 29 42 51 63 186 285 359 356 429
Z3 (mm) 34 55 52 65 78 60 100 126 123 108
TYPE (mm) M M M M M F F F F F
SADDLE STRIPS
SIZE (mm) 80 100 140 150 200 225 250 315 355 400 450 500
CODE 01.146.080 01.146.100 11.146.140 01.146.150 01.146.200 01.146.225 11.146.250 11.146.315 11.146.355 11.146.400 11.146.450 11.146.500
(mm) 120 120 120 120 120 60 60 60 60 60 60 60
A (mm) 300 300 300 300 300 300 300 300 300 300 300 300
B (mm) 7 9 11 13 17 17 19 24 28 30 35 38
D* (mm) 1/2 1 1/4 1 1/4 1 1/4 2 2 2 2 2 2 2 2
* Maximum sizes of threaded tapping
TAPPING SADDLES
SIZE (mm) 80 x 50 100 x 50 CODE 01.127.080050 01.127.100050 A (mm) 150 175 B (mm) 96 108 ID1 (mm) 89 114 ID2 (mm) 60 60
REDUCING SOCKET
SIZE (mm) 20 x 15 25 x 15 25 x 20 32 x 25 40 x 25 40 x 32 50 x 40 80 x 50 100 x 80 150 x 100 250 x 225 315 x 250 355 x 315 400 x 355 450 x 400 500 x 450 630 x 500
CODE 01.114.020015 01.114.025015 01.114.025020 01.114.032025 01.114.040025 01.114.040032 11.114.050040 01.114.080050 01.114.100080 01.114.150100 11.114.250225 11.114.315250 11.114.355315 11.114.400355 11.114.450400 11.114.500450 11.114.630500
A (mm) 34 42 42 52 59 59 74 110 141 204 275 341 384 440 493 548 668
A1 (mm) 27 27 34 43 43 52 62 74 110 142 -
B (mm) 46 52 52 64 71 68 81 112 138 204 275 328 382 427 479 530 596
ID (mm) 27 34 34 42 48 48 60 89 114 168 251 316 356 401 451 501 632
ID1 (mm) 21 21 27 34 34 42 48 60 89 114 226 251 316 356 401 451 501
Z (mm) 4 7 5 10 15 8 13 23 21 47 13 19 20 23 24 25 38
TYPE (mm) M M M M M M M M M M F F F F F F F
Issue 1 Revision 1
57
REDUCING BUSH
SIZE (mm) 20 x 15 25 x 15 25 x 20 32 x 15 32 x 20 32 x 25 40 x 15 40 x 25 40 x 32 50 x 25 50 x 40 80 x 20 80 x 50 100 x 50 100 x 80 150 x 100 200 x 150 250 x 225 315 x 250 355 x 315 450 x 400 500 x 450 560 x 500 630 x 500
CODE 01.109.020015 01.109.025015 01.109.025020 01.109.032015 01.109.032020 01.109.032025 01.109.040015 01.109.040025 01.109.040032 01.109.050025 01.109.050040 01.109.080020 01.109.080050 01.109.100050 01.109.100080 01.109.150100 01.109.200150 11.109.250225 11.109.315250 11.109.355315 11.109.450400 11.109.500450 11.109.560500 11.109.630500
ID (mm) 21 21 27 21 27 34 21 34 42 34 48 27 60 60 89 114 168 225 250 315 400 450 500 500
A (mm) 27 34 34 42 42 42 48 48 48 60 60 89 89 114 114 168 219 250 315 315 450 500 560 630
B (mm) 22 25 25 29 29 29 31 31 31 37 37 52 52 65 65 92 120 135 168 188 235 260 275 288
Z (mm) 2 5 3 9 9 4 11 6 2 12 6 31 15 28 13 28 3 12 33 20 22 25 15 28
FAUCET SOCKET (PLAIN THREADED SOCKET)
SIZE (mm) 15 20 25 32 40 50
CODE 01.101.015 01.101.020 01.101.025 01.101.032 01.101.040 01.101.050
A (mm) 31 38 47 57 65 79
B (mm) 41 47 54 61 65 73
C (mm) 18 20 24 27 27 30
ID (mm) 21 27 34 42 48 60
OD (mm) 27 34 42 53 60 75
Z (mm) 19 22 25 29 29 34
REDUCING HEXAGON NIPPLE

RED. HEX. NIPPLE SIZE (mm) 20 x 15 25 x 15 25 x 20 32 x 25 40 x 25 40 x 32 50 x 25 50 x 40 CODE 01.107.020015 01.107.025015 01.107.025020 01.107.032025 01.107.040025 01.107.040032 01.107.050025 01.107.050040 A (mm) 27 27 34 42 43 52 43 59 B (mm) 44 47 48 55 58 61 64 68 C (mm) 15 15 16 19 19 22 19 21 ID (mm) 21 27 27 34 48 48 OD (mm) 27 34 34 42 48 48 60 60 Z (mm) 21 21 23 26 27 30 27 32
HEXAGON NIPPLE
RED. HEX. NIPPLE SIZE (mm) 15 20 25 32 40 50 CODE 01.107.015 01.107.020 01.107.025 01.107.032 01.107.040 01.107.050 A (mm) 27 34 42 52 59 74 B (mm) 41 46 51 59 62 73 C (mm) 15 17 19 21 21 26 ID (mm) 21 27 34 48 OD (mm) 21 27 34 42 48 60 Z1 (mm) 26 29 34 36 Z (mm) 21 24 26 29 31 36
58
Issue 1 Revision 1
MALE ADAPTOR
SIZE (mm) 15 20 25 32 40 50 CODE 01.151.015 01.151.020 01.151.025 01.151.032 01.151.040 01.151.050 A (mm) 27 34 42 52 59 74 B (mm) 38 42 49 56 58 70 C (mm) 15 17 19 21 21 26 ID (mm) 21 27 34 42 48 60 Z (mm) 18 20 24 27 27 33
ID
FEMALE ADAPTOR
SIZE SPIGOT (mm) 15 20 25 32 40 50 SOCKET 15 20 25 40 CODE 01.153.015 01.153.020 01.153.025 01.153.032 01.153.040 01.153.050 A (mm) 32 38 47 57 65 79 B (mm) 42 47 53 62 64 75 Z (mm) 22 25 28 33 33 39 Z1 (mm) 27 31 37 42 C (mm) 18 21 24 27 28 30
CAP
SIZE (mm) 15 20 25 32 40 50 75 80 100 140 150 200 225 250 315 355 400 450 500 560 630
CODE 01.140.015 01.140.020 01.140.025 01.140.032 01.140.040 01.140.050 11.140.075 01.140.080 01.140.100 11.140.140 01.140.150 01.140.200 11.140.225 11.140.250 11.140.315 11.140.355 11.140.400 11.140.450 11.140.500 11.140.560 11.140.630
ID (mm) 21 27 34 42 48 60 75 89 114 140 168 219 225 250 315 355 400 450 500 560 630
A (mm) 27 33 41 52 59 74 93 105 138 173 203 264 272 302 380 428 482 542 602 674 758
B (mm) 8 9 13 17 17 21 27 77 101 114 127 164 169 186 232 260 291 326 361 382 415
C (mm) 29 33 39 46 50 61 71 111 139 170 200 250 247 275 341 384 440 493 548 593 688
TYPE M M M M M M M M M M F F F F F F F F F F F
THREADED PLUG
SIZE (mm) 15 20 25 32 40 50
CODE 01.155.015 01.155.020 01.155.025 01.155.032 01.155.040 01.155.050
A (mm) 27 33 41 51 58 71
B (mm) 21 23 26 30 31 36
C (mm) 15 16 19 22 22 26
Issue 1 Revision 1
59
SOCKET UNION
SIZE (mm) 15 20 25 32 40 50 80 100 Seal material
CODE 01.205.015 01.205.020 01.205.025 01.205.032 01.205.040 01.205.050 01.205.080 01.205.100 - EPDM
A (mm) 35 43 60 74 83 103 158 182
B (mm) 43 47 59 70 73 86 113 142
ID (mm) 21 27 34 42 48 60 89 114
Z (mm) 10 12 12 12 12 12 12 14
SADDLE CLIP
SIZE CODE (mm) 15 01.455.015 20 01.455.020 25 01.455.025 32 01.455.032 40 01.455.040 50 01.455.050 80 01.455.080 100 01.455.100 * Clip thickness Material - Black polypropylene
ID (mm) 21 27 34 42 48 60 89 114
A (mm) 13 18 21 29 34 38 50 65
B (mm) 37 41 45 65 67 87 122 156
C (mm) 14 14 16 16 16 22 24 38
PIPE CLIP
SIZE (mm) 15 20 25 32 40 50 80 100
CODE 05.434.015 05.434.020 05.434.025 05.434.032 05.434.040 05.434.050 05.434.080 05.434.100
B (mm) 26 29 32 36 39 50 105 120
C (mm) 10 10 10 10 10 10 -
D (mm) 6 6 6 6.5 6.5 10 15 15
d1 (mm) 21 27 34 42 48 60 89 114
d2 (mm) 10.5 10.5 10.5 14 14 17 -
d3 (mm) 5.5 5.5 5.5 6.5 6.5 8.5 9 9
Z1 (mm) 16.5 19 24 33.5 37 44.5 89 99
Z2 (mm) 19 21.5 26.5 33.5 37 44.5 71 81
TYPE (mm) B B B C C C G G
Material - Black polypropylene
60
Issue 1 Revision 1
RUBBER EXPANSION JOINT
SIZE 32 40 50 80 100 150 200 250 315 355 400 450 500 560 630
CODE 01.452.032 01.452.040 01.452.050 01.452.080 01.452.100 01.452.150 01.452.200 11.452.250 11.452.315 11.452.355 11.452.400 11.452.450 11.452.500 11.452.560 11.452.630
A (mm) 95 95 105 130 135 180 205 240 260 265 265 265 254 254 354
C (mm) 8 8 8 12 18 18 25 25 25 25 25 25 25 25 25
D (mm) 15 15 15 15 15 15 15 15 15 15 15 15 15 10 10
E (mm) 4 4 5 6 10 10 14 14 14 14 14 14 16 16 16
ANCHOR SLEEVE
SIZE (mm) 50 75 80 100 140 150 200 225 250 315 355 400 450 500 560 630
CODE 01.272.050 11.272.075 01.272.080 01.272.100 11.272.140 01.272.150 01.272.200 11.272.225 11.272.250 11.272.315 11.272.355 11.272.400 11.272.450 11.272.500 11.272.560 11.272.630
ID (mm) 60 76 89 115 141 169 220 227 251 316 356 401 451 502 562 632
A (mm) 74 93 104 140 173 208 268 268 275 347 390 441 501 550 616 710
B (mm) 40 40 50 60 90 90 90 120 120 120 120 120 120 180 180 180
ANCHOR FLANGE
SIZE (mm) 50 75 80 100 140 150 250 315 355 400 450 500 560 630
CODE 01.273.050 11.273.075 01.273.080 01.273.100 11.273.140 01.273.150 11.273.250 11.273.315 11.273.355 11.273.400 11.273.450 11.273.500 11.273.560 11.273.630
ID (mm) 62 76 91 116 141 170 252 317 357 402 452 502 562 632
A (mm) 96 115 127 159 201 214 334 380 440 493 556 613 665 720
B (mm) 40 53 57 70 77 100 137 170 190 214 241 266 285 300
C (mm) 14 16 18 20 22 24 32 35 37 40 42 45 50 70
D (mm) 74 88 118 134 162 192 305 362 415 450 506 561 615 669
Issue 1 Revision 1
61
BALL CHECK VALVE SINGLE UNION
SIZE
CODE
15 01.***.015 20 01.***.020 25 01.***.025 32 01.***.032 40 01.***.040 50 01.***.050 80 01.***.080 Code 836 - EPDM seal Code 838 - FPM seal
A (mm) 48 59 69 96 96 103 178
B (mm) 95 112 124 148 148 177 215
Z (mm) 62 73 79 94 88 105 114
BALL VALVE DOUBLE UNION
SIZE CODE (mm) 15 01.***.015 20 01.***.020 25 01.***.025 32 01.***.032 40 01.***.040 50 01.***.050 80 01.***.080 100 01.***.100 Code 880 - EPDM seal Code 882 - FPM seal
A (mm) 51 63 73 105 105 135 182 217
B (mm) 101 119 134 161 160 191 260 314
C (mm) 48 65 69 88 88 108 138 165
D (mm) 81 87 101 127 127 151 191 241
Z (mm) 67 79 86 101 98 118 158 187
SOLVENT CEMENT USAGE*
ABS SOLVENT CEMENT
MEK CLEANER / PRIMER
SIZE (mm) 50 80 100 125 150 195 200 225 300 350 375 400 450 500 575 650 750
SOLVENT WELD JOINTS PER LITRE** 135 45 35 20 20 10 10 4 4 3 2 1 1 0.5 0.5 0.3 0.3
* The usage of MEK is approximately 50% that of ABS cement ** A socket counts as 2 joints, a tee as 3 joints etc.
62
Issue 1 Revision 1
FLOW NOMOGRAMS
EURAPIPE METRIC PIPE SERIES 1 DN100 TO DN950
Issue 1 Revision 1
63
64
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66
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68
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70
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Notes
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71
Notes
72
Issue 1 Revision 1

ABS Pipe Design Manual

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ABS Pipe Design Manual

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EURATECH (MALAYSIA) SDN BHD (527494-K)

Pipes & Fittings

Lloyds Register Quality Assurance

Sirim & Sirim QAS

Ikram QA Services Sdn Bhd

JABATAN PERKHIDMATAN PEMBETUNGAN

JABATAN BOMBA DAN PENYELAMAT MALAYSIA

Jabatan Perkhidmatan Pembetungan

Jabatan Bomba dan Penyelamat Malaysia

American Bureau of Shipping

SAJ Holdings Sdn. Bhd. (Syarikat Air Johor)

Perbadanan Air Melaka

Lembaga Air Perak

Syarikat Air Terengganu Sdn. Bhd.

Jabatan Bekalan Air Negeri Sembilan

Perbadanan Bekalan Air P.Pinang Sdn Bhd

Jabatan Bekalan Air Kedah

Jabatan Bekalan Air Pahang

Jabatan Bekalan Air Sarawak

Jabatan Bekalan Air Kelantan

20C 20C 20C

30 MPa 25% 2000 MPa

4350 lbf/in2 25% 290 000 ibf/in2

42 MPa 340 J/m notch

6 100 ibf/in2 6.4 ft ib/in notch

3.5x10 16cm 3.2 at 60Hz 3.12 at10 3Hz 2.9 at 10 6Hz

IMPACT ENERGY (Kgm)

ABS @ 0C ABS @ 20C

PIPE SIZE (mm)

TOXICITY AND TAINT 18 16

COEFFICIENT OF EXPANSION (x 10-5 ) m/mC

ABS Quick Reference Chemical Resistance

1000 kPa Yes Socket, thread, flange

PRESSURE / TEMPERATURE DERATING

WORKING PRESSURE (kPa)

PIPE MID-WALL TEMPERATURE (C)

Long Term Hydrostatic Strength (

STRESS REGRESSION CHARATERISTIC FOR EURATECH ABS PIPE

LWR 97.5 / HP STR

HOOP STRESS, MPa

10.00 1 10 100 1000 10000 100000 1000000

the relative roughness of the pipe surface, d vd Re =

0.15 0.4 0.6 0.75 0.9

0.45 0.38 0.35 0.28 0.15

0.2 0.3 0.5 1.3 2.4

PIPE LENGTH (M)

VARIATION IN MID-WALL TEMPERATURE

Pipe free to move

H Intermediate Pipe Support without Clip

Yes Moderate Good Large Minimum High 32 - 750 High

* Values shown are for the single sphere bellows.

Radial Clearance Between Pipe & Clip

Pipe Support Pad

Valve Support Plate

Gusset Plates as required

Pressure rating Correction factors

PIPE SIZE DN 300 DN 375 TO DN 500 DN 575 TO DN 750

TOTAL DEFLECTION ANGLE PER JOINT 4.5 4 3.5

RUBBER RING TO RUBBER RING SOCKET WITH DEFLECTION ALLOWANCE

Spreader bars may be necessary to prevent slings slipping during lifts.

Brush size 20 mm 50 - 80 mm 100 mm

MAX. INTERFERENCE FIT MIN. INTERFERENCE FIT

Holding time 10 - 60 sec. 1 - 3 min. 3 - 5 min. 5 - 10 min. 10 - 15 min. 20 - 30 min.