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Contents
1. INTRODUCTION .........................................................1 2. PRODUCT DESCRIPTION 2.1 General ...........................................................2 2.2 Standards of Manufacture and Quality Control.....2 2.3 Pipe Dimensions...............................................3 2.4 Other Pipe Standards ........................................6 2.5 Metric and Imperial Sizes ..................................6 2.6 Pipe Length......................................................6 2.7 Pipe Colour ......................................................6 2.8 Pipe Marking Details .........................................7 2.9 Joint Descriptions .............................................8 3. APPLICATIONS ........................................................11 4. CHARACTERISTICS OF PVC-U PIPE 4.1 Potable Water.................................................12 4.2 Weather Resistance ........................................12 4.3 Properties of PVC-u ........................................12 4.4 Working Pressure and Pressure Ratings ............13 4.5 Temperature Derating......................................13 4.6 Flow Characteristics and Head Loss..................14 4.7 Thermal Expansion..........................................16 4.8 Chemical Resistance.......................................17 4.9 Lightweight.....................................................20 4.10 Electrical Characteristics..................................20 4.11 Notch Sensitivity.............................................20 4.12 Impermeability to Gas .....................................21 4.13 Electrolytic Reaction........................................21 4.14 Behaviour in Fire ............................................21 4.15 Abrasion Resistance........................................21 4.16 Impact Strength .............................................22 4.17 Biotic Resistance ............................................22 5. WORKING CHARACTERISTICS 5.1 General .........................................................22 5.2 Handling Storage and Transport .......................22 5.3 Shipping Information .......................................24 5.4 Hazardous Shipping Details .............................24 6. JOINTING 6.1 General .........................................................26 6.2 Cutting & Chamfering ......................................26 6.3 Solvent Cement Jointing..................................26 6.4 Ring Seal Jointing ...........................................29 6.5 Threaded Joints ..............................................31 6.6 Saddle Joints .................................................31 6.7 Flange Jointing ...............................................31 7. WATER HAMMER/PRESSURE SURGES. 7.1 General .........................................................33 8. PIPE 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 INSTALLATION General .........................................................34 Temperature...................................................34 Trench Excavation ...........................................34 Trench Widths ................................................34 Trench Depth - Depth of cover .........................34 Bedding .........................................................35 Sidefill, Backfill and Compaction ......................35 Test for suitability of soil Material for surrounding Buried PVC-u Pipe ........................36 8.9 Pipe Deformation............................................37 8.10 Contaminated Ground .....................................37 8.11 Pipe Bending Radii .........................................37 8.12 Trenchless Laying............................................38 8.13 Thrusting and Anchorage .................................38 8.14 Above Ground Installation ................................39 8.15 Thermal Movement Compensation-Expansion Requirements.................................................40 8.16 Vibration ........................................................41 8.17 Effects Of Sunlight ..........................................41 8.18 Protection After Installation..............................41 8.19 Pipeline Testing ..............................................41 8.20 Water Authorities Association Guidelines ...........44 8.21 Local Authority Regulations..............................44 8.22 Technical Services ..........................................44
APPENDICES 1. Quality Standards ...........................................45 2. Abbreviations..................................................47 3. Water Authorities Association Guidelines ...........48
The information provided in this Technical Specification is given in good faith by Dyka. It is intended as a guide to the design and installation of pipeline systems using DYKA pipe, fittings and related products. The user should check that the product is suitable for the application and purpose for which it is intended and ensure compliance with Health and Safety requirements. DYKA has a policy of continual improvement of products and practices and therefore reserves the right to change specifications contained in this guide without obligation. No part of this Technical Specification may be reproduced or copied in any form without the prior permission of Dyka.
1. Introduction
Dyka have produced this PVC-u Technical Publication to assist engineers, pipeline operators and contractors in the design and installation of pressure pipelines. We believe this manual contains the best technical information available and according to our knowledge and research it is correct in all details. All information is provided in good faith and entirely without prejudice to Dyka. The use of unplasticised polyvinylchloride (PVC-u) is firmly established as the preferred material for pressure pipelines and water supply installations. Its many advantages over traditional materials have resulted in these being progressively substituted by PVC-u pipelines. Dyka are a leading manufacturer of plastic pipe systems and have pioneered many of the developments in production technology. This continuing development together with the introduction of the latest techniques and equipment ensures that Dyka products are produced to a high standard in excess of the exacting requirements of many European quality assurance organisations, including the BSI. Strict quality control through all stages of production is maintained by Dykas in house, BSI monitored laboratory. The production facility is certified to ISO9002/BS5750 (2). Dyka hold BSI kitemark licences and other approvals in relevant to the many products manufactured. Dyka are part of a European manufacturing group owned by Limburgse Vinyl Maatschapij NV (LVM), one of Europes largest PVC polymer producers. This provides Dyka with a guaranteed supply of the principle raw material at a competitive price. LVM are owned by the Belgium based multi-national company Tessenderlo Chemie NV.
2. Product Description
2.1 General
Plastics are synthetic macromolecular materials which, by processing acquire their specific functions. They are produced by chemical processes, the principle raw material being oil. The macromolecular structure of plastics is achieved by polymerisation of individual molecules or monomers into chain molecules that are between 1,000 and 100,000 times larger than those naturally occurring in water or salt. This macro molecular composition forms a spatial net-like structure with numerous internal chemical bonds. Plastics can be divided into two main groups. Thermoplastic materials which, upon heating, soften and melt and can be reheated and reformed. Thermosetting materials which soften and melt with the initial heating but then set permanently in their final shape. Polyvinylchloride or PVC-u is one of the most widely used thermoplastic materials, due to its flexibility of usage and competitive price. It is manufactured by the petrochemical industry who produce a dichloride from ethane and chloride and apply pyrolisis above 400C to cause splitting into vinylchloride and hydrochloric acid. The basic polymer is mixed with additives such as colour, filler, lubricants and stabilisers in accordance with a recipe determined by the properties of the finished product. The mix of compound is transported to either extruders or injection moulding machines to be converted into the end product. Dyka PVC-u pipe is a high quality pipe suitable for pressure pipeline systems for cold water services. It is available in imperial and metric dimensions that are produced in accordance with appropriate national and international standards. Dyka PVC-u pipe is supplied plain ended, with integral solvent weld socket or integral ring seal joint. Refer to section 6 of this catalogue for further jointing details.
Product Description
2.2.1 Production Standards
All imperial pressure pipe within the Dyka pipe system is manufactured in accordance with the requirements of BS 3505 specification for Unplasticised PVC pipe for cold water services 1986 - as amended. Dyka are permitted to affix the British Standards Institute Kitemark to these products under B.S.I. Licence numbers 8017 and 8018. Where specified Dyka, blue metric pipework is manufactured in accordance with the requirements of the water industry specification WIS 4.31.06. Unless otherwise specified, all Dyka, standard metric pipework is manufactured to the Dutch water industry standard KIWA 49 (revision 1). Dykapipe is certified to this standard by the KIWA quality organisation. Dyka have the capability to manufacture to a number of the European standards and in many cases hold quality approvals against these. Details of these and copies of all certificates are available on request.
Outside Diameter Tolerance 21.2/21.5 26.6/26.9 33.4/33.7 42.1/42.4 48.1/48.4 60.2/60.5 88.7/89.1
Class C Min/max
Wall thickness Class D Class E Min/max Min/max 1.7/2.1 1.9/2.5 2.2/2.7 2.2/2.7 2.5/3.0 2.7/3.2 3.1/3.7 3.9/4.5 5.7/6.6 7.3/8.4 9.0/10.4 10.8/12.5 12.6/14.5
2 4
1
1 1 4 112 2 3 4 5 6 8
2.5/3.0 3.5/4.1
Product Description
2.3.2 Metric KIWA BRL 502/02
A grey metric pipe system is available from Dyka, which is produced in accordance with the Dutch Water Authority Standard KIWA BRL 502/02. This standard is derived from the specifications issued by the International standards Organisation (ISO) references ISO 161/1 and ISO 4065. The Dyka production facility for this pipe system is registered by the Dutch Water Authority and the Dutch quality assurance body KIWA/NEN. All Dyka PVC-u pipe is approved by the World Health Organisation (WHO) for use with potable water. Figure 3 Table of dimensions of pipes to KIWA BRL 502/02
Outside Diameter Size mm 16 20 25 32 40 50 63 75 90 110 125 160 200 250 315 400 500 630
Outside Diameter Tolerance 16.0/16.2 20.0/20.2 25.0/25.2 32.0/32.2 40.0/40.2 50.0/50.2 63.0/63.2 75.0/75.3 90.0/90.3
6.3 bar
7.5 bar
Wall thickness 10 bar 12.5 bar 1.5/1.9 1.5/1.9 1.5/1.9 1.6/2.0 1.9/2.3 1.5/1.9 1.5/1.9 2.4/2.9 2.4/2.9 3.0/3.5 3.0/3.5 3.6/4.2 4.3/5.0 5.3/6.1 6.0/6.8 7.7/8.7 9.6/10.8
16 bar 1.5/1.9 1.5/1.9 1.9/2.3 3.0/3.5 3.0/3.5 3.7/4.3 3.8/4.4 4.5/5.2 5.4/6.2 6.6/7.5 7.4/8.4 9.5/10.7 11.9/13.3
2.0/2.4 2.0/2.4 2.2/2.7 2.7/3.2 3.2/3.8 3.7/4.3 4.7/5.4 5.9/6.7 7.3/8.3 9.2/10.4
2.4/2.9 2.4/2.9 2.9/3.4 3.5/4.1 4.2/4.9 4.8/5.5 6.2/7.1 7.7/8.7 9.6/10.8 12.1/13.6
110.0/110.4 2.7/3.2 125.0/125.4 3.1/3.7 160.0/160.5 4.0/4.6 200.0/200.6 4.9/5.6 250.0/250.8 6.2/7.1 315.0/316.0 7.7/8.7 400.0/401.0 9.8/11.0
11.7/13.1 15.3/17.1
Product Description
2.3.3 Metric DIN
A range of Dyka PVC-u pipes can also be supplied which conforms with German DIN standards. Figure 5 Table of dimensions of pipes to DIN Diameter mm 12 16 20 25 32 40 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 Nominal size (mm) 10 12 16 20 25 32 40 50 65 80 100 110 125 150 160 180 200 225 250 300 350 400 400 500 500 600 1.8 1.8 1.9 2.2 2.7 3.2 3.7 4.1 4.7 5.3 5.9 6.6 7.3 8.2 9.2 10.4 11.7 13.2 14.6 16.4 18.4 1.5 1.8 1.9 2.4 3.0 3.6 4.3 5.3 6.0 6.7 7.7 8.6 9.6 10.8 11.9 13.4 15.0 16.9 19.1 21.5 23.9 26.7 6 bar Wall thickness (mm) 10 bar 16 bar 1.0 1.2 1.5 1.9 2.4 3.0 3.7 4.7 5.6 6.7 8.2 9.3 10.4 11.9 13.4 14.9 16.7 18.6 20.8 23.4 26.3 29.7
Product Description
2.4 Other Pipe Standards
In addition to the above Dyka will manufacture pipe to most European national standards on specific request. Please refer to the technical department of Dyka for details. Copies of all quality standards mentioned are available on application to Dyka.
Product Description
2.8 Pipe Marking Details
The precise marking of Dyka PVC-u pipe is governed by various national and international standards, although to ensure traceability of pipes supplied the following information is usually included:
The markings for different classes of pipe are colour coded as below and embossed into the pipe wall to avoid accidental erasure. Class Colour C Black D Green E Brown
Product Description
2.9 Joint Descriptions
All Dyka PVC-u pressure pipe systems employ one of three jointing methods as described below. For detailed jointing and installation instructions refer to section 6 of this guide.
Product Description
Figure 6: Socket Insertion & Engagement Depth - Imperial & Metric Systems Socket depth Engagement depth
Figure 6a: Socket Insertion Depth - Imperial Systems to BS 3505 Socket insertion Depth (mm) Outside Diameter (inch) 1 114 112 2 3 4 5 6 8
Ring Seal
Figure 7: Socket Insertion and Engagement Depths. Metric Systems to WIS 4.31.06 Outside Diameter (mm) 63 90 110 160 200 250 315 400 450 500 630 Socket depth (mm) 130 147 160 187 212 239 256 285 Engagement depth (mm) 65 71 75 86 94 106 118 130
Product Description
Figure 8: Socket Insertion Depth - Metric Systems to KIWA 49 Standard Socket insertion Depth (mm) Outside Diameter (mm) 12 16 20 25 32 40 50 63 75 90 110 125 160 200 250 315 400 500 630 25 25 25 35 32 44 55 69 77 87 101 111 135 167 198 243 90 119 123 129 136 142 155 171 187 214 218
10
3. Applications
The Dykapipe PVC-u pressure pipe system is suitable for the transportation of potable water for industrial and domestic uses. Other major areas of application include:Agricultural irrigation Conveyance of processing fluids within industry Sewerage and industrial effluent disposal Conveyance of abrasive slurries Transportation of acids, alkalis and other corrosive chemicals (refer to section 4.8) Ground water transportation for land engineering Buried fire ringmain Conduit or duct for cables and fragile piping systems Venting systems Rigid PVC-u Dykapipe should not be used at ambient or liquid temperatures in excess of 60C for pressure systems. For other applications, please refer to the technical department of Dyka
11
Mechanical
Ultimate tensile strength: Compressive strength: Impact - DIN 53453: Elastic modulus in bend: Brinell hardness @ 23OC: Poissons ratio: Flexural strength: Elongation at break @ 23OC: Fracture toughness in excess of: (against method C.3..1. BS 3505:
Electrical
Volume resistivity: Breakdown voltage: Power factor: Dielectric constant:
Thermal
Processing temperature Coefficient of thermal expansion: Thermal conductivity: Specific heat: Softening point: (BS 2782 method 120B) Flammability:
kPa
Figure 9
PRESSURE - TEMPERATURE RELATIONSHIP
INTERNAL TEMPERATURE 20C VARIABLE AMBIENT TEMPERATURE
15
Cla ss E/1 6B ar
500
12
Cla ss 2.5 D1 Ba r
400
Where Dyka PVC-u pipe is to be subjected to temperatures between 20C and 60C the maximum working pressures must be derated to the values shown in Figures 9 and 10.
300
Cl
as
sB
/6
.3
200
Ba r
100
20
40 AMBIENT TEMPERATURE IN C
60
80
13
Cla ss C1 0 r Ba
12
400
Cl
as
300
C/
10
Cla
ss
B/6
200
.3
Ba
100
20
40 INTERNAL TEMPERATURE IN C
60
80
14
Ft hd
Ba
Where fluctuating temperatures may be experienced (as may occur with hot effluent disposal applications), the pipeline design must accommodate both the de-rated working pressure and stress induced by pipeline expansion and contraction.
s Cla 16 sE r Ba
Cl sE as /1 2. 5 r Ba
0.20 RATE OF FLOW (L/SEC) 0.25 0.30 0.40 0.50 0.60 0.80 1 1.5 0.2 0.2 35 11/4"D 40 45 50 2"D 60 70 80 90 100 4"D 20 5"D 150 6"D 30 50 100 200 8"D 200 300 250 300 350 400 450 500 600 700 800 900 1000 2,000 3,000 5,000 10,000 20,000 30,000 50,000 100,000 500,000 300,000 1500 500,000 1,000,000 500 1,000 15 20 30 40 50 5 6 8 10 3 4 3"D 1 /2"D
1
20
25 30 1"E
2 2.5 3 4
0.3 0.5
0.3 0.4 0.5 0.6 0.8 1 1.5 2 5 6 8 10 15 20 25 30 40 50 60 80 100 150 200 250 300 400 500 600 800 1,000
1 2 3 5 10
15
Q SD2.5
Where
= - 6.61 log
{(
K 3.71D
) (
+
1.053
(5.63 x 10-6) D Q
) }
0.937
Assuming that the temperature of the fluid is 20C and that it has a density of 1g per cm3. For the purposes of this calculation PVC-u pipe has a wall roughness factor (K) of 0.003 mm.
4.6.2
Point Loss
Changes in direction or abrupt changes in the internal diameter of a pipeline can give rise to the formation of eddies and other disruptive flow patterns. These can result in a head loss equivalent to a substantial length of straight pipe.
Figure 12
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 16 32 50 63
90 110
140 160
200
250
315
To simplify system design the graph in Figure 12 gives an equivalent straight meterage of pipe for various commonly used fittings. The pipe meterage calculated can then be added to the total meterage of straight pipe and the head loss determined by one calculation. For calculation purposes the following metric/imperial conversions can be used for the graph in Figure 12. Inch mm 2 16
1
1 32
114 40
112 50
2 63
Change in = Original length Maximum occurring X 0.06 X length (mm) of pipeline (m) temperature difference (K)
16
glacial Acetic anhydride (acetic acid anhydride) Acetone Acetonitrile Acetophenetidine Acetophenone Adipic acid Aliphatic hydrocarbons Allyl alcohol Allyl chloride Aluminium acetate Aluminium chloride Aluminium fluoride Aluminium hydroxide Aluminium nitrate Aluminium oxalate Aluminium oxychloride Aluminium potassium sulphate (alum) Aluminium sulphate Ammonia dry gas liquid Ammonia solution 35%(m/v)soln (ammonium hydroxide) (0.88g/ml) Ammonium bicarbonate see ammonium hydrogen carbonate Ammonium carbonate Ammonium chloride(liquid ammonia) Ammonium ferrous citrate Ammonium flouride Ammonium hydrogen carbonate
S S S* S* S S S S S* U U U U U U S* U U S* U U D U S* S* S S* S U U U U U*
S S S* S S*
S S S* S S*
17
Hydrogen sulphide Hydroquinone, see quinol Hydroxylammonium sulphate Hypochlorous acid Iodine
S* S* S U S S
S S S S U* S U* U* U* S U U* U U U* U S* S S
S* S S S U* S U* U* U*
U U* U U U* U S* U S
U* U* U
U* U* U
Fructose Fruit juices Fuel oil Furfuraldehyde (furfural) Furfuryl alcohol Gallic acid, see 3, 4, 5trihydroxybenzoic acid Gasoline, see petrol Glucose Glycerol Glycerol monobenzyl ether Glycol, see ethandiol Glycollic acid 30% alc. soln. Grape sugar Heptane Hexadecanol (cetyl alcohol) Hexanol (hexyl alcohol) Hydrobromic acid 50% (w/v) aq. soln 100% (w/v) aq. soln. Hydrochloric acid 10% (w/v) aq. soln. 22% (w/v) aq. soln. concentrated (36%) Hydrocyanic acid 10% (w/v) aq. soln. Hydrofluoric acid 4% (w/v) aq. soln. 40% (w/v) aq. soln. 60% (w/v) aq. soln. concentrated Hydrogen Hydrogen bromide anhydrous Hydrogen chloride anhydrous Hydrogen flouride anhydrous Hydrogen peroxide 3% (w/v) aq. soln.
Iso-octane (2, 2, 4-trimethylbentane) Isophorone Isopropanol, see isopropyl alcohol Lactic acid 10% (w/v) aq. soln. 100% Lanoline Latex Lauric acid, see dodecanoic acid Lauryl alcohol, see dodecanol Lead acetate Lead arsenate Lead nitrate Lead tetraethyl, see tetraethyl acid Linoleic acid Linseed oil Lubricating oil Magnesium carbonate Magnesium chloride Magnesium hydroxide Magnesium nitrate Maleic acid 25% (w/v) aq. soln. 50% (w/v) aq. soln. concentrated Malic acid Magnesium sulphate Margarine Mercuric chloride Mercuric cyanide Mercurous nitrate Mercury Mesityl oxide Metallic soaps (water soluble) Methanol (methyl alcohol) 100% 6% (w/v) aq. soln. Methoxybutanol Methyl acetate Methyl bromide, see bromomethane Methyl isobutyl ketone, see isobutyl methyl ketone Methyl chloride, see chloromethane Methyl ethyl ketone, see ethyl methyl ketone Methyl glycol Methyl hydrogen sulphate (methyl sulphuric acid) 50% (w/v) aq. soln. 60% (w/v) aq. soln. 75% (w/v) aq. soln. 90% (w/v) aq. soln. Methyl methacrylate Methyl sulphate, see dimethyl sulphate Methylated spirits
S U S S
S U S S
S S* S*
S S* S*
S S S S S S S S S S S S* S S S S S U S* S S S U*
S S S S S S S S S S S S* S S S S S U S* D S* S* U*
S S U* S S S S* S S S* S S S S S S D U* S S* S* S* S
S S U* S S U S* S S S* S S S S S U U* U* S S* S* S* S
S S S S S U S
S S S S S U D
18
S*
S*
S* S* S
S* S* D
Nitrobenzene Nitropropane Nitrous fumes moist Nonanol (nonyl alcohol) Octane Octanol (octyl alcohol) Octylcresol Oils & fats Oleic acid Orthophosphoric acid
20% (w/v) aq. soln. 30% (w/v) aq. soln. 50% (w/v) aq. soln. 95% (w/v) aq. soln.
S S S S S S S S S S S S S D U U U U U U U U S* S
S S S S S S S S* S S S S S S S S* S S S S* S S* S S S S S S* S* S S* S S* S* S
S S S S S S S S* S S S S S S S S* S S S S* S S* S S S S S* S* S S* S S* U* S
S S S S S* S S S S S* S S S S S S S
S S S S S* S S S S S* S S S S S S S
Paraffin Paraffin wax Pentane Perchloric acid Petrol Petrol/benzene mixture Petroleum spirit (petroleum ether) Phenol Phenylcarbinol, see benzyl alcohol Phenylhydrazine Phenylhydrazine hydrochloride Phosgene gas liquid Phosphates (see also under ammonium, potassium, sodium, etc.) Phosphine Phosphoric acid , see orthophosphoric acid Phosphorus Phosphorus pentoxide Phosphorus trichloride Phosphoryl chloride (phosphorus oxychloride) Phthalic anhydride Picric acid 1% (w/v) aq. soln.
S* S S S* S* S* S* S S S S* S* S S S S S* S
S* S S S* S* S* S* S S
S S U U S* S
U S* U U S* S*
U* U S* S*
U* U S* S*
S* S* S S S S S* S
19
10% (w/v) aq. soln. 20% (w/v) aq. soln. 30% (w/v) aq. soln. 40% (w/v) aq. soln. 50% (w/v) aq. soln. 55% (w/v) aq. soln. 60% (w/v) aq. soln. 70% (w/v) aq. soln. 80% (w/v) aq. soln. 90% (w/v) aq. soln 95% (w/v) aq. soln. 98% (w/v) aq. soln. 10% aq. soln. 30% aq. soln.
fuming Sulphurous acid Surface active agents all Tallow Tannic acid Tanning extracts
S S* S* S S
U S* S* U* U
S* S S S
S* S S S
4.9 Lightweight
The low specific gravity of Dyka PVC-u pipe means that it is much lighter than pressure pipes made from more traditional materials. The pipe is therefore easier to handle and longer or larger sections can be installed without sophisticated machinery. This results in reduced transportation and installation costs. Details of weights are available from the technical department of Dyka.
20
21
5. Working Characteristics
4.16 Impact Strength
At very low temperatures (eg 0C) the impact resistance of PVC-u is reduced. When installing pipelines at low temperatures extra care should be taken with handling and backfilling.. All Dyka manufactured pipes are rigorously tested against the impact strengths required by various national standards including BS 3505 and KIWA 49.
5.1 General
The British Standard Code of Practice CP312 Code of Practice for Plastic Pipework (Thermoplastic Material) deals in depth with many aspects of handling, installation and jointing. The following is a summary of the most important aspects of these techniques. However, Dyka recommend that the above publication is used for reference wherever possible.
5.2.1 Handling
While PVC-u pipe is light and easy to handle, it should not be maltreated. The protection of the pipe ends is particularly important. Pipes and fittings should never be dropped to the ground. They should be unloaded from the transport either by hand or using slings and lifting equipment.
5.2.2 Storage
PVC-u pipe will distort under load and this is particularly evident at elevated or uneven temperatures. Whilst this distortion will not affect the performance of the pipe it may make it difficult to joint. Stacks of pipes should therefore be protected from direct sunlight or other heat sources if stored for extended periods. Racks for long term storage should preferably provide continuous support along the pipes length, but if this is not possible then supports of 75mm (min) bearing widths at 1 metre (max) centres should be placed beneath the pipes. If side restraints are required these can be at up to 2 metre spacing. Racks should not exceed 1 metre in height. Where racks are not available pipes can be stored on a temporary basis on the ground, providing the surface is level and free from loose stones or other sharp projections.
22
Working Characteristics
Where different sizes and classes of pipe are stored in the same rack, the heaviest pipes must be at the bottom and where pipes are nested inside one another the stack height must be reduced in relation to the added weight.
1.5 metres maximum centres
1 metre maximum
Packs of pipes should remain in their packing until ready for use. The complete packs can be stored directly onto level ground that is free from loose stones and other sharp projections. Packs of pipes can be stacked, however the total stack height should not exceed 3 metres.
Support Battens
1m Spacing
Ground Level
5.2.3 Transport
Dyka PVC-u pipes should only be transported on vehicles with a flat bed that provides adequate support along the full length of the pipe. The bed of the vehicle must be thoroughly checked before loading to ensure that it is free from imperfections that may damage the pipes. Where side supports are required they should be smooth and not more than 1.5m apart. An unsupported overhang at the rear of the vehicle should not exceed 1m. As with storage the packs of pipe should be loaded with the heaviest at the bottom. Pipe that arrives on site damaged should not be used and the incident should be advised to Dyka immediately.
23
3m Maximum
Working Characteristics
Do:
Protect pipes and fittings from being exposed to direct sunlight for long periods. Store pipes on a suitable surface free from loose stones and sharp projections. Ensure pipes and fittings do not come into contact with any aggressive chemicals (refer to Figure 13) in particular beware of solvents. Use wide fabric or nylon slings for lifting. Take special care handling slippery pipes in wet or frosty conditions. Ensure adequate support is given when lifting long lengths of pipe.
Spillage instruction: absorb in sand or other inert absorbent and transfer to isolated containers for safe disposal. Marks: Flammable according I.M.C.O. regulations.
24
Working Characteristics
5.4.2 Solvent weld cement - tropical usage - brown labels
Chemical constituents; - Tetrahydrofuran - Cyclohexanon - Vinylchloride Polymer
IMCO Class 3.2 UN Number 1133 ADR Code 3.5C IATA - DGR 3.3 Flashpoint - 10 C
Spillage instruction: absorb in sand or other inert absorbent and transfer to isolated containers for safe disposal. Marks: Flammable according to I.M.C.O. regulations.
IMCO Class 3.2 UN Number 1133 ADR Code 3.5C IATA - DGR 3.3 Flashpoint - 7 C
Cleaning fluid is a de-fatting agent. Avoid contact with skin and eyes. If fluid comes in contact with the eyes seek medical attention immediately. Spillage instruction: absorb in sand or the inert absorbent and transfer to isolated containers for safe disposal. Marks: Flammable according to I.M.C.O. regulations. When transporting, handling or working with either solvent weld cement or cleaning fluid all operatives must ensure that they are acquainted with the COSHH details.
25
6. Jointing
6.1 General
One of the major benefits of Dyka PVC-u pipes is the ability to use one of the three jointing methods below. This gives a great deal of flexibility in allowing for varying installation conditions and the skill and equipment of the installers. 1. Solvent Cement 2. Ring Seal 3. Threaded Fittings see also section 7.3 for fittings specifications Before making any joint the pipe lengths and fittings should be thoroughly inspected to ensure there is no transit damage. Any damaged items should be discarded.
Using a sheet of paper with square edges, wrap it round the pipe. Ensuring that the paper is tightly wound and ends are square, cut along edge of paper
26
Jointing
Adhesives are formulated according to their usage and the type of PVC-u to be bonded, only the correct adhesive should therefore be used. It is important to check that the adhesive used is still in good condition. Tins that contain lumps or have a heavy surface film should be discarded. Under no circumstances should cleaning fluid be used as a thinner. Always use sufficient adhesive, work it in well and keep it fluid. If a less than perfect fit between the two mating surfaces has to be filled, apply several layers of adhesive, do not allow the last layer to dry before applying the next. The two surfaces must be mated in one movement while the adhesive is still wet and the PVC-u is still soft. Due to the softening power of the adhesive any excess must be removed, immediately the joint is made. Mated surfaces should be left undisturbed for 24 hours to allow the bond to cure.
1. Cut pipe end square, chamfer to a minimum of 15, deburr and smooth surface.
2. Clean external surface of spigot and internal surface of socket using DYKA Cleaning Fluid.
27
Jointing
4. Apply correct DYKA Solvent Weld Cement from figure 16 Apply cement axially to pipe surface.
Figure 16 Cement types & applications
Nominal size of pipe mm Nominal size of pipe imperial Average number joints per litre
16
3
20
1
25
3
32 1" 190
40 114" 140
50 112" 75
63 2" 70
90 3" 60
110 4" 40
140 5" 30
160 6" 25
200 8" 17
8"
2"
4"
600
350
260
Type of cement PVC cement for pressure systems up to 90mm/3" outside diameter PVC cement for pressure systems 4 and above PVC cleaning fluid
Label Yellow
Packing
Application
Tins 1 litre Small bore Tubes 125 gram pressure systems Tins 14 Litre Tins 1 litre Tins 14 Litre Tins 1 litre Tins 14 Litre Tropical use. Large diameter systems Degreasing in preparation for bonding
Brown HD
Grey
6.3.4 Caution
Ensure adequate ventilation when solvent cementing. If swallowed do not induce vomiting and seek medical attention. If splashed on face or eyes, wash liberally with clean water and seek medical attention. See Appendix 5 for health and safety guidance. Adhesive and cleaning fluid are hazardous chemicals. Ensure that empty tins, soiled cloth and paper are disposed of correctly and not left in the pipe trench.
28
Jointing
6.3.5 Possible errors when bonding PVC-u
Pipe end not cut squarely Pipe end not deburred and chamfered Moisture and dirt on glued surface Not properly cleaned or dried Brush still wet with cleaner Adhesive not evenly spread Adhesive not brushed out axially Adhesive on only one of the two surfaces Pipe and accessory not assembled in time Pipe not pushed home to shoulder Incorrect adhesive used. Adhesive type did not match the application The gap too big to be filled completely, leaving passages through the adhesive During assembly of pipe and accessories, one of the fittings has been twisted relative to the other Adjusting after jointing, occurred too late, causing the already cured adhesive to be broken apart The drying time not adhered to No attention paid to the presence of water or damp conditions (condensation) Ventilation too drastic causing adhesive to dry during application (skin forming) Adhesive no longer homogeneous, caused by the tin being left open for too long Use of incorrect cleaning agent Oil or oil containing substances contaminated joint surfaces causing bond failure Bonding took place at sub zero temperatures without the necessary precautions
29
Jointing
Apply joint lubricant in an even coating over half the spigot length (not the joint ring). Refer figure 18 for approximate coverage of rubber ring jointing lubricant. Move the spigot pipe so that the leading edge is just engaging the socket mouth before insertion. The flexibility of the pipe in sizes 4" and below may prevent correct alignment during assembly. The force required to assemble the joint should be applied as near the spigot end as possible with the socket held in position. A twisting action will ease entry. Push the spigot to the depth of entry mark. This should be done with a swift movement, the momentum gained by the spigot travelling from the socket mouth to the ring, being of assistance. CAUTION - if the pipe does not enter the socket without undue force being used, withdraw the pipe; and re-check the joint ring. PARTICULAR ATTENTION SHOULD BE PAID TO RING SEATING AND PIPE ALIGNMENT. When installing larger diameter pipework a pipe jack may be necessary to provide the impetus to make the joint. The use of a mechanical excavator to push the spigot home is not recommended as this can result in over insertion, and damage to the pipeline.
3. Mate surfaces in a single fluid movement. 2. Check that spigot end is cut square chamfered at 15. Apply Dyka Ring Seal Lubricant to spigot end only. 1. Ensure seal ring is correctly installed. Reposition as necessary using hot water to soften sealing ring
Figure 17
Nominal pipe Diameter mm Nominal pipe Diameter Imperial Average number of joints per 800mg tub
63 2" 220
90 3" 190
140 5" 90
160 6" 80
200 8" 50
A cross-sectional view of the pipe socket and the specially designed groove for the sealing ring is shown in the figure below.
CHAMFER OF 15
30
Jointing
The pipe should be marked (not with a saw) so that the spigot enters the socket to within 12-25mm of the bottom of the socket (Dimension A, figure 19 Cross section detail of ring seal joint) If installing above ground, check entry depth after installation. As with all pipe jointing, cleanliness is of prime importance and pipes, especially spigot ends, should be supported clear of the ground to prevent dirt being smeared on with the lubricant. Placing the pipes on blocks also reduces friction and consequently facilitates the making of the joint. THESE BLOCKS MUST BE REMOVED BEFORE BACKFILLING. The pipeline should be pressure tested after the first 300 to 400 metres have been installed. After this, tests should be carried out at convenient intervals preferably not exceeding 1 kilometre.
6.5
Threaded Joints
Where it is necessary to join Dyka PVC-u pipe to another type of pipe using a threaded joint, Dyka recommend the following guidelines: Wherever possible make the connection with the PVC-u pipe as the male component of the joint. Use only P .T.F.E. tape as a sealant. Tighten to firm hand tightness only using strap wrenches - do not use serrated jaw wrenches. A full range of adaptors is available to connect Dyka PVC-u pipe to other materials please contact the technical department Dyka.
Jointing
6.7.2 Standard stub and adaptor ring
This enables pipes of similar bores to be connected with no disruption to flow and therefore minimal risk of blockage occurring.
450mm
400mm
450mm
400mm
Ensure mating surfaces are clean and free from damage. Use a single rubber gasket of the correct size. Additional jointing compound should not be used. Assemble flange joints before any other joints on the pipeline. Mating surfaces must be aligned to within 5mm prior to bolting. Use only undamaged bolts, nuts and washers of the correct size. Ensure the gasket is properly aligned prior to bolting. Once nuts and bolts are finger tight, then progressively tighten as follows: Using a torque wrench work in diagonally opposite sequence. Tighten all bolts to 5% of final torque. Tighten all bolts to 20% of final torque Tighten all bolts to 50% of final torque Two operators should work together on pipe diameters above 180mm. Check final torque of all bolts after one hour. Remember a uniform tightening sequence is as important as final torque settings. Tighten all bolts to 75% of final torque Tighten all bolts to final torque.
OD X Bore (mm) nominal 63 90 125 180 225 250 x x x x x x 50 80 80 150 200 250
OD X Bore (mm) nominal 315 355 400 450 500 x x x x x 300 350 400 450 500
32
400mm
450mm
The increase in pressure due to the effect of Pressure Surge can be calculated by the formula:
H = a DV g
Where
H = Water Hammer, pressure increase in bar. a g V = = Surge wave velocity (see figure qq) Gravity
= Change in velocity
Figure 20 Showing Surge wave velocities for design purposes Pipe Material PVC-u Cast Iron Asbestos Cement Surge Wave Velocity 300m/sec 1200m/sec 900m/sec
33
8. Pipe Installation
8.1 General
The simplicity of the installation procedure for Dyka PVC-u pipe offers considerable benefits especially in terms of time and the consequent cost saving. The following is general information on installation techniques. For more specific guidance reference should be made to: CP312 Code of Practice for the Plastic Pipework and Appendix 6 Water Authorities Association Guidelines. Dyka PVC-u pipe is a semi-flexible conduit and as such can deflect considerably without damage. Its response to earth loading is not governed by pipe strength, but rather by the interaction of the soil and the pipe. It is therefore very important that all aspects of pipe laying, particularly bedding and sidefill, receive special attention.
8.2 Temperature
Particular care should be exercised when installing pipes at temperatures below 10C. Pipe laying should not be carried out when the temperature is below 0C.
34
Pipe Installation
Figure 21 Recommended minimum depth of cover
Location Roads & Streets (at maximum DOE loading) Driveways Footpaths and Gardens Open Country
8.6 Bedding
The trench should be over excavated to a depth equivalent to the nominal diameter of the pipe or a maximum of 100mm. The underbed should be filled and thoroughly compacted with bedding material which conforms to WIS 4-08-01 or meets the particle size and compaction requirements given in section 9.8 below. Care must be taken to ensure continuous support is given along the entire pipe length and not just on the joints. The bedding should be scooped out to accommodate joints and fittings. In all cases the underbed should be laid to the correct fall and gradient.
100mm minimum cover above pipe crown Fill material to conform to WIS 4-08-01
PIPE
100mm bedding
35
Pipe Installation
8.8 Test For Suitability Of Soil Material For Surrounding Buried PVC-u Pipe
The suitability of the bedding and backfilling material can be determined in one of two ways. Either by estimating the approximate particle size or by calculating the compaction fraction of the material. Under both methods it is necessary to obtain a representative sample of the proposed material. This is done by taking about 50kg of the material and heaping it on a clear surface. The pile is equally quartered and two opposing quarters are selected, the remainder is removed. The retained quarters are remixed to form a new pile and the process is repeated until the required sample size is obtained.
Method 1 Particle Size The maximum particle size should not exceed 20mm but a small percentage of particles between 20mm and 40mm is acceptable. If particles over 40mm are present the material should be rejected. In cases of doubt, a representative sample of the material weighing about 2kg should be sieved, using 20mm and 40mm British Standard approved test sieves (BS 410 Test Sieve). When sieving, clumps of material that break up under light finger pressure may be helped through the sieve, but force should not be used to squeeze oversize lumps through the mesh. The material should be rejected if: a) any particles are retained on the 40mm sieve or b) more than 5% by mass is retained on the 20mm sieve. For sharp, hard materials these particle size limitations should be halved (i.e. max. size 10mm and 20mm). Where scouring of the bed under the pipeline may be caused by adverse ground water conditions the prepared bedding material should be of a particle size smaller than 10mm to prevent loss of support to the pipeline. Method 2 Ease of Compaction 1. Place a 250mm length of 160mm O.D. pipe on a clear surface. 2. Fill the length of pipe loosely with a representative sample of the proposed material and level off to the top of the pipe. 3. Lift the pipe off the sample and place it on a clear surface. 4. Replace about a quarter of the sample into the pipe and compact it using a rammer of approximately 1kg weight. Repeat this process until all the sample has been returned to the pipe. Measure the distance the material has compacted (X) and refer to Figure 22 to determine the suitability of the material.
Figure 22 Compaction test - material suitability.
Suitability of Material Suitable Not suitable if ground is subject to waterlogged conditions after laying. Not Suitable
36
Pipe Installation
Diagrams 1-4 of compaction test. 1 2 3 4
POLYETHYLENE MEMBRANE
SAND ENVELOPE
PIPE
CONTAMINATED GROUND
37
Pipe Installation
is 150 times the nominal diameter of the pipe. The maximum deflection allowed in a mechanical joint =3. Avoid placing joints and fittings in pipes which are to be bent, preformed bends and elbows are available to eliminate stress. For further information on pipe bending for particular applications please refer to the technical department of Dyka.
80 x 65 x
100 x
Trenchless laying should only be undertaken once it has been ascertained that the soil type is suitable and damage to the pipe will not occur.
In trench 90 bend thrust details Insulating protective membrane trench poured in situ concrete thrust block ring seal jointed bend dyka ringseal joint
tee installation
flanged tee
trench wall trench wall protective membrane In situ protective membrane poured concrete
38
Pipe Installation
This is because the slight flexibility of PVC-u may cause pulsing under pressure variations which may cause the pipe to shear at the interface between the concrete anchor and the backfill. It is recommended that a thin membrane, such as bituminised paper, thin roofing felt or polythene film to a thickness of about 250 mu is applied between the concrete and the PVC pipe.
vertical plane bend anchor details restraining straps with protective membrane end cap thrust detail cross section view of thrust block
protective membrane
trench wall
protective membrane
trench wall
Diameter
3
20 75 85 90 100 110 125 140 150 165 185 215 225 250
40
50
60
70
80
90
100
50 55 65 80 95 110 120 135 155 185 200 225 50 60 70 85 95 105 120 160 170 200 55 60 70 80 110 130 160
39
Pipe Installation
Extra support should be given to accommodate the weight of heavy fittings and equipment and also to protect the pipeline from the torque applied when operating valves and hydrant tees. The pipe supports should have flat surfaces of half the diameter of the pipe or 100mm minimum width (whichever is the greater) and not be able to damage the pipe if any movement occurs. Dyka PVC-u pipe is a good insulator of the pipe contents and this helps to prevent freezing , additionally the flexibility of PVC-u allows for expansion to accommodate the increased volume of frozen liquids. However for operational reasons it is usual to insulate pipelines to minimise the risk of the contents freezing. Care should be taken that insulation is waterproof or is protected by a waterproof cover. Provision should also be made to enable drain down of pipe runs with drain valves at the lowest points. Horizontal pipe runs should incorporate a fall to facilitate drainage. PVC-u pipelines should be insulated from local intense heat sources such as boilers and steam pipes as this may cause excessive thermal movement of the pipe. In addition exposed pipelines should be protected from potential impact damage.
non-preferred no restraint
preferred no restraint
40
Pipe Installation
8.16 Vibration
Vibration - Continuous vibration, particularly where threaded joints are used (e.g. connections to water pumps) must be avoided and, where necessary, flexible joints should be used to minimise vibration effects.
41
Pipe Installation
Leave joints exposed. Test with all valves in fully open position. Test sections should not exceed 1 kilometre.
Proceed with the testing as follows: 1. Blank off all ends and bolster them against pressure. 2. Insert air bleed valves at all the highest points along the pipeline. 3. Insert a pressure gauge capable of reading pressure changes of 1% of test pressure at the lowest point of the pipeline. 4. Slowly fill the pipeline with water, take care to avoid risk of damage due to pressure surge. 5. Ensure all air bleed valves are open and operating correctly. 6. Gradually raise the pressure without shock loading to the test pressure specified in figure 29. 7. Allow the test section to stand for half an hour to equalise temperatures before proceeding with the pressure test.
42
Pipe Installation
Figure 29 Shows the Quantity of Water required to fill a 1km pipeline for pressure testing.
1000000
43
Pipe Installation
The Design and Site engineer will have final approval on acceptance of an installation, Figure 30 gives a recommended procedure. Figure 30 Recommended Pressure Testing Criteria. Simple Pressure Test Testing Pressure (x operating pressure) Test Duration 1.5 Standard Pressure Test Phase 1 Phase 2 1.5 1.3
2 hours
4 hours for Straight Runs 12 hours for pipes with branches Every 2 hours with extra pumping
Test Checks
0.5 bar/hr
0.5 bar/hr
to 0.1 bar/hr
44
BS4346 Part 2
WIS 4.31.06
WIS 4.31.07
IGN 4.31.01
IS 123 SS 1776
DS 972
ISO 4422
ISO 161
45
Appendix 1
NEN7108 BRL K-502 BRL 2013 KIWA 10 Bends for use with PVC-u pressure pipe. PVC-u pressure pipe. Rubber rings and flange gaskets for use in pressure systems. Tension proof couplers, type AMSTERDAM for use with PVC-u pipe. SBR ring seal for use in systems for the supply of potable water. Waterpipes of unplasticised polyvinyl chloride. PVC-u couplers and fittings. PVC-u fittings in nominal diameters 12mm to 90mm inclusive. PVC-u saddles and service connections for plastic pressure pipe systems. Tension proof couplers for use with PVC-u water supply pipe. Plastic pipes - general requirements PVC-u pipe for industrial use. PVC-u pipe for potable water. PVC-u socketed fittings with elastometric ring seal joints for water supply under pressure.
46
Appendix 2 - Abbreviations
PART 1
NAMES AFNOR ATA ASTM BS BSCP CIBS DIN HVCA IEC IMCO ISO KIWA NEN NFPA NFT UK UNI UNIPLAST UN Association Francaise De Normalisation Attest on Toxicology Aspects American Society for Testing and Materials British Standard British Standard Code of Practice Chartered Institute of Building Services, U.K. Deutsches Institut for Normung, e.V Heating and Ventilating Contractors Association, U.K. International Electrotechnical Commission International Maritime Conference Organisation International standards Organisation Keurings Institut Voor Waterleiding Artikelen Nederlandse Eenheids Norm National Fire Protection Association Norm Francaise United Kingdom Ente Nazionale Italiano Di Unificazione Eute Italiano Di Unificazione Nelle Materie Plastiche Universal Nomenclature
PART 2
UNITS OF MEASUREMENT - LENGTH, AREA AND VOLUME cm mm km mm2 m2 km ha m
3 2
centimetre millimetre kilometre square millimetre square metre square kilometre hectare cubic metre litre radian micron
l or lit rad u
47
Appendix 3
Water Authorities Association Guidelines
Design Criteria a) b) New mains should be designed with a minimum of dead ends. Where they are unavoidable flushing facilities should be provided. Chambers for valves, meters, hydrants and particularly air valves should be carefully sited and where practical, be provided with drains to avoid the accumulation of contaminated water. They should be located where there risk of burial is minimal. Air valves should be positioned above the highest possible level to which water could rise in the chamber so as to minimise the possibility of contamination entering through them.
c)
New Mains a) Pipes for new mains should be stored and laid as hygienically as practicable, all reasonable measures should be taken to exclude vermin, debris and dirty water. During installation the pipe ends should be capped whenever work stops. Before a main is brought into service it should be cleaned and disinfected. Any dirt and debris should be removed by flushing and swabbing. The risk of microbiological contamination remaining at joints can be reduced if this is preceded by filling the main with water containing 20mg/l of free chlorine. When the flushing water is clear the main should be charged with water containing 20mg/l of free chlorine and left for a contact period of 24 hours before it is displaced by mains water. After a further 24 hours samples should be taken for bacteriological examination at a number of points along the main and at the extremities. b) The new main may be brought into service if all the samples are found to be free of coliform organisms and after the contents of the main have been tested successfully for taste, odour and appearance. All new services should be flushed before being used for supply. Domestic service connections should be disinfected if there is any doubt about the cleanliness of the pipework. New linings drawn into existing mains should be treated as new mains.
c)
Renovated Mains a) b) Before being returned to supply, mains subject to refurbishment must be flushed and disinfected as for repaired mains. Mains refurbishments must be carried out only by restricted area and multifunctional personnel.
48
Appendix 6
Repaired Mains a) Where a main can be repaired without cutting, it should be cleaned around the fracture and this area, together with the repair collar, should be disinfected with a solution containing 1000mg/l of chlorine. The main should be flushed and samples taken for bacteriological examination. The main may be returned to service immediately. Where a main has to be cut for repair, every care must be taken to prevent contamination. If possible, it should not be emptied below the level of the fracture until it has been exposed and the trench pumped dry. Enough pumps should be available to prevent flooding while repairs are in progress. If practicable final disinfection should follow as for new mains but the period of contact may be reduced to two hours or 30 minutes if a 50mg/l concentration of free chlorine is used. In cases where this is impracticable, all surfaces which will come into contact with the potable water should be disinfected with a solution containing 100mg/l of chlorine. In all cases the main should be finally flushed and samples taken for bacteriological examination. The main may be returned to service immediately. c) If, despite precautions, a significant amount of dirty water enters the pipes, the full cleansing procedure for new mains entailing pre-disinfection, flushing, swabbing and final disinfection, should be followed as far as is practicable. Rigorous isolation, cleaning and disinfection procedures must be carried out if foul water from a fractured sewer or drain may have entered the pipes. This is a dangerous pollution hazard and any such incidents must be reported to a senior officer of the water company. The main must not be returned to supply until satisfactory bacteriological results have been obtained. Consumers should be warned not to draw water during the disinfection procedure. Mains repairs must be carried out only by restricted area and multi-functional personnel.
b)
d)
e) f)
Abandoned Mains a) Where source works, mains or services are to be abandoned they must be completely separated from the pipework remaining in use. Disused pipework or plant should not merely be isolated by means of a valve or stopcock. Where sluice valves fixed to tees cannot be removed they should be blanked off. Service pipes no longer required should be disconnected from the main. Abandoned valves and stopcocks should preferably be removed but, if left in situ, valve spindles and handwheels or crutch heads should be removed, as should surface boxes, indicator plates and posts.
b)
Contamination Incidents Water undertakings should establish procedures for dealing with incidents of contamination in distribution systems. The Guide to the microbiological implications of emergencies in the water services (WAA 1985) provides relevant advice.
49
50
51
52