Pressurised piping and fittings for gas and water supplies

Transcription

1 Pressurised piping and fittings for gas and water supplies Quality systemes for secure supply

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3 Catalog pressurised piping and fittings Introduction 1 Pushin joint products 2 Pressure pipe with pushin socket / Sewage pipe with pushin socket Adapter fittings with pushin joints Pushin joint connections Accessories for pushin joint piping Installation instructions for pushin joint piping Bicchiere innesto a vite 3 tubi pressione raccordi congiunzioni accessori istruzioni di posa per condotte a vite Flanged products 4 Pressure pipe with flanges Adapter fittings with flanges Installation instructions for piping with flange connections Tapping clamps 5 Planning and finishing work 6 Cutting pipes to length RESICOAT RS Repair Material Installation instructions for ducpurplus corrosionprotection film Information for planners and pipe fitters Transport and storage 7

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5 Introduction Piping systems As one of the most important Swiss manufacturers of piping systems made of ductile castiron, vonroll hydro develops, manufactures and sells a modular, perfectly matched system of components that meets all the needs of municipal water and gas suppliers. 1 For many years now, ductile cast iron, which, apart from its high strength, is also characterised by its elasticity, has been a popular material for the manufacture of pressurised piping. The ecosys fullprotection piping system, which features pipes coated both inside and outside with PUR as well as fittings protected by an integral coating of epoxy resin, is worth particular mention. This excellent combination of materials and the welltried sleevecoupling technology allow this system to offer the following advantages: Long service life Economic pipeline construction Optimum corrosion prevention inside and out Suitable for all types of water from soft to hard Impeccably hygienic internal lining High mechanical stability Excellent flow characteristics Easy to cut and drill SVGW certification for drinking water and gas Depending on environmental conditions, pipeclass and dimensions, vonroll s piping system with sleeve connectors can be supplied on request for projectspecific solutions for over 63 bar: see pressures for sleevecoupled piping and adapters to EN 545:2002 standards, page 6/4.3. The piping systems with sleeve connectors, screw or flange couplings are manufactured using the latest technologies and conform to EN 545 and ISO 2531 standards (or, when specially mentioned, our own standards) and have been certified by SVGW / DVGW Coatings for pipes and fittings ecopur ducpur ecofit Mechanically sturdy yet flexible pressure pipe manufactured in ductile cast iron using centrifugal casting, coated inside and out with corrosionresistant, smooth polyurethane (PUR). Perfectly suitable for all types of soil. Mechanically sturdy yet flexible pressure pipe manufactured in ductile cast iron using centrifugal casting, with a corrosionresistant, smooth polyurethane (PUR) inside lining and zinc/bitumen external coating. Together with ducpurplus PEcorrosionprevention foil, also suitable for aggressive soils. Adapter fittings manufactured in ductile castiron using sand casting, with integral epoxy resin coating. Perfectly suitable for all types of soil. phone , fax , info@vonrollhydro.ch 1/1

6 Our catalogue range of pressure pipes and adapter fittings Sleeveconnector piping system Flanged piping system Larger nominal diameters available on request DN Pipes of all diameters are 6 meters long Pipe classes according to EN 545 and ISO 2531 standards Sleevecoupled pipes K9 standard Flanged pipes K12 standard Other classes of pipe are available on request. Overview of connection techniques Sleeve connectors Flanged coupling Sealing system Tyton seal Flat seal Connection variant Electrical conductivity of the coupling system Deflection without restraint clamp Deflection with restraint clamp With or without restraint clamp Not electrically connected DN up to 5 DN up to 4 DN up to 3 DN up to 3 Not electrically connected No deflection possible No deflection possible phone , fax , info@vonrollhydro.ch 1/2

7 Ductile cast iron Material characteristics for centrifugallycast pipes and adapters according to EN Mechanical characteristic Symbol Unit Pipes Adapters Minimum tensile strength Rm MPa Yield point Rp 0.2 MPa Minimum elongation after fracture A % 10 5 Minimum vertical pressure rating MPa Burst pressure rating MPa Longitudinal bending strength MPa Density kg/dm3 7,05 7,05 Elasticity module E MPa 1,7x10 5 1,7x10 5 Thermal expansion coefficient 1/K 10x x10 6 Hardness HB < 230 < 250 Ductile cast iron Ductile cast iron with sphericallyformed graphite. (Pictured using a scanning electron microscope) phone , fax , info@vonrollhydro.ch 1/3

8 Coatings Polyurethane (PUR) Polyurethane protects piping made of ductile cast iron against corrosion and ensures meeting hygienic standards for drinking water at the same time. Polyurethane is used for both the inside lining and the outside coating. Because of polyurethane s elasticity, the coating remains intact even if the pipe is deformed. The PUR coating was developed in In comparison with other coatings, the internal polyurethane lining exhibits a high resistance to various different media such as drinking water, wastewater, demineralised water, industrial water and gas, as well as to aggressive solutions such as sulphuric acid. The PUR outside coating is suitable for all kinds of soil. Specific properties of Polyurethane Composition Wall thickness Polyurethane is composed of a twocomponent resin. Its threedimensionally linked molecular structure gives it its mechanical stability. Polyurethane is a thermosetting plastic with no solvents. It meets EN 545 and ISO 2531 standards Polyurethane PUR inside lining DN = 1.3 mm DN = 1.5 mm Polyurethane PUR outside coating (ecopur ) DN = 0.9 mm Colour inside: green outside: black Density kg/dm 3 Continuity Bonding strength Dielectric resistance continuous coating, no cracks > 14 Mpa (EMPA recommends: 2.5 Mpa on a saturated sample) Bonding strength is tested at regular intervals by our laboratories. > 108 Ωm2 Temperature Water: up to 40 C (constant); up to 80 C (short term) Air: 120 C Impact resistance 40 Nm at 20 C Effect of salt spray no effect after 1000 hours Expansion > 10% Friction coefficient k > 0.01 mm phone , fax , info@vonrollhydro.ch 1/4

9 Resistance to chemicals Acidic or basic with ph values between 1 and 14 Anorganic solvents Sulphuric acid (wasterwater) industrial wastewater 1 Thermal expansion 20 x /K Deposits Use of chlorine Quality Assurance Certification for PUR none The chlorine concentration in drinking water and the selective amount used when disinfecting have no influence on the quality of the polyurethane. Contract with EMPA in Dübendorf, Switzerland Swiss Association for Gas and Water (SVGW) Swiss Federal Office of Health (BAG) Water Byelaws Advisory Service Singapore Institute of Standards and Industrial Research for: Bulgaria, Spain, Italy, Lithuania, Poland, Czech Republic, Rumania etc. Epoxy Resin Coating The adapter fittings are provided with an integral coating of epoxy resin with a thickness of at least 250µm. Coating with epoxy resin powder is a welltried and porefree way of protecting adapters and fittings used in water and gas supplies against corrosion. The epoxy resin inside lining, which is as smooth as glass and free of pores, offers comprehensive protection of the foodstuff drinking water, and, of course, fulfils all statutory requirements on hygiene. The epoxy resin coating is an organic protective coating and is environmentfriendly in its use. phone , fax , info@vonrollhydro.ch 1/5

10 ZincBitumen external coating The ducpur pipes are provided with a zincbitumen external coating. The zinc coating is at least 150 g/m 2 according to the EN 545 standard. The zinc coating is covered with a layer of bitumen of at least 70µm. A special property of the zinc coating is its selfhealing effect if local damage occurs. A macroelement is formed at the point of damage, whereby the castiron surface represents the cathode and the galvanised surface of the pipe the anode. The zinc ions migrate to the exposed castiron surface an thus cover the damaged area with a layer of zinc once more. Pores Covering layer of bitumen Zinc Annealed surface Castiron raw material zinc ions Zn++ deposition of zinc salts current Covering layer of bitumen Zinc Annealed surface Castiron raw material damage phone , fax , info@vonrollhydro.ch 1/6

11 Permissible operating pressures for pipes, adapters and restraint clamps Without taking up lateral forces (secured against thrust using constructional means) 1 for water Sleeve connector published operating pressure PFA in bar See table Pressures according to EN 545:2002 for pushin joint pipes and adapter fittings. Page 6/4.3 for gas 1 bar (corresponds to the low to midle pressure level as defined in the SVGW guidelines) With mechanical connection that takes up lateral forces for water published operating pressure PFA in bar Sleeve connector See table Permissible pressures for thrustresistng rings. Page 6/4.4 Flange The values shown in the table (PN) are appropriate to the hole configuration according to DIN EN 1092, part 2. These values represent the permissible operating pressure. for gas 1 5 bar (corresponds to the high pressure level as defined in the SVGW guidelines) For adapter fittings with mixed types of connections (sleeve coupler/flange), the nominal pressure for the flange is decisive. phone , fax , info@vonrollhydro.ch 1/7

12 Labelling Pipes and adapter fittings according to EN 545 All pipes and adapter fittings are permanently and legibly labelled with at least the following information: Manufacturer Year of manufacture Label for ductile cast iron Nominal diameter DN Nominal pressure for flanges and indication of this standard Wall thickness class, if not K9 Cast in the sleeve for pipes Cast in the item s surface for adapter fittings Cast on the flange Printed on the pipes Sealing rings for water for gas DN, year of manufacture, manufacturer s code, name of seal, EN 6811, EPDM DN, year of manufacture, manufacturer s code, name of seal, EN 682, NBR phone , fax , info@vonrollhydro.ch 1/8

13 Standards EN 545 Pipes, adapter fittings, accessories made of ductile cast iron and their connections for water piping Requirements and testing procedures 1 EN 6811 Elastomer seals Requirements on materials for piping seals for applications in water supply and wastewater disposal EN 805 Water supply Requirements on water supply systems and their components used outside buildings ISO 2531 Ductile castiron piping, adapter fittings and accessories and their connections for water or gas applications PrEN 682 Elastomer seals Requirements on materials for piping seals for supply piping and associated components for gas and liquid hydrocarbons EN 969 Pipes, adapter fittings, accessories made of ductile cast iron and their connections for gas piping Requirements and testing procedures. Certificates and approvals Piping systems from vonroll hydro sa are SVGW / DVGW certified Only in this way can one be sure that statutory requirements concerning hygiene are perfectly fulfilled and that all standards and testing procedures are adhered to. phone , fax , info@vonrollhydro.ch 1/9

14 Abbreviations DN Nominal diameter of pipe DE Outside diameter of pipe as defined in EN 545 and ISO 2531 DI Effective calculated pipe inside diameter DI = DE 2e DM Outside diameter of sleeve T Sleeve depth in mm, identical for pipes and adapter fittings e G Wall thickness of centrifugally cast pipe made of ductile cast iron K9 according to EN 545 and ISO 2531 standards e PUR1 Wall thickness of polyurethane inside lining according to manufacturers standards e PUR2 Wall thickness of polyurethane outside coating = 0.9 mm e Wall thickness of ducpur and ecopur K9 sleevecoupled pipes e = e G + e PUR1 + e PUR2 L Pipe length in mm PFA Operating pressure PN Connection dimension equivalent to nominal pressure in bar phone , fax , info@vonrollhydro.ch 1/10

15 Pushin joint products 2 Figure Page ducpur pressure pipes with doublechamber socket /1.1 ducpur pressure pipes with singlechamber socket /1.1 ecopur pressure pipes with doublechamber socket /1.2 ecopur pressure pipes with singlechamber socket /1.2 geopur sewage pipes with doublechamber socket /1.3 2 geopur sewage pipes with singlechamber socket /1.3 vonrollrock pressure pipes with rockprotection coating ducpur /2.1 vonrollrock pressure pipes with rockprotection coating ducpur /2.1 vonrollrock pressure pipes with rockprotection coating ecopur /2.2 vonrollrock pressure pipes with rockprotection coating ecopur /2.2 vonrollrock sewage pipes with rockprotection coating geopur /2.3 vonrollrock sewage pipes with rockprotection coating geopur / bend, MMQ 2820a.90 2/ bend, MMK a.45 2/ bend, MMK a.30 2/ bend, MMK a.22 2/ bend, MMK a.11 2/3.2 5 bend, MMK a.5 2/ bend, MQ / bend, MK / bend, MK / bend, MK / bend, MK /4.2 SocketTee, UA /5.1 SocketTee, MMB /5.2 SocketTee, MMA /5.34

16 Figure Page SocketTeeT /5.4 SpigotTee, IT /5.4 Calibrechange, Taper MMR /6.1 Collars, U /7.1 Flange socket adapter, EU 2877b 2/7.1 Flange socket adapter, EU /7.1 Flange spigot adapter, F /7.2 External thrustresisting ring /8.1 External thrustresisting ring /8.1 External thrustresisting ring /8.1 Internal thrustresisting ring TytonSit for water /8.2 Internal thrustresisting ring /8.2 Tyton seal for water /8.3 Tyton seal for gas /8.3 PE100 connecting piece /9.1 Neutrex T lubricant 270 2/10.1 Transparent corrosionprotection film /10.1 Scotchrap /10.1 ducpurplus corrosionprotection film /10.1 Repairset RESICOAT RS Doublechamber cartridge Dispenser Mixing tube Installation aids and tools Set of assembly and laying tools Hammering accessory Dismantling leaf Set of assembly and laying tools Accu screwdriver / / /10.2 2/11.1 2/11.2 2/11.2 2/ /11.4 Installation instructions for pushin joint piping 2/12.110

17 Pressure pipe with pushin socket Pressure pipes and adapter fittings ducpur pressure pipe with pushin socket Made of ductile cast iron using the centrifugal casting process with PUR (polyurethane) internal lining, outer side zinc sprayed and coated with bitumen Minimal pressure loss thanks to hydraulically smooth surface, economic. Application: Drinking water, soft and aggressive water as well as media with phvalues between 1 and 14. SVGW certification for water and gas pipelines. Manufactured to ISO 2531 and EN 545 standards. Pipeclass standard K9; other classes on request. Permissible system pressure: See "permissible pressures", page 6/4.3. A thrustresisting ring fig. 2505, 2506, 2806, 2807 can be fitted. Deflection: see "Installation handbook for pushin joint piping". Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring. 2 Pipe with doublechamber socket Fig DN L DE e G e PUR1 DM T weight mm mm mm mm mm mm kg/m item no The doublechamber pipe can be fitted with internal thrustresisting ring (fig. 2807) or external thrustresisting ring (fig. 2806). Pipe with singlechamber socket Fig DN L DE e G e PUR1 DM T weight mm mm mm mm mm mm kg/m item no phone , fax , info@vonrollhydro.ch 2/1.1

18 Pressure pipe with pushin socket Pressure pipes and adapter fittings ecopur pressure pipe with pushin socket Made of ductile cast iron using the centrifugal casting process with PUR (polyurethane) internal lining, external PUR coating. Application: For demanding corrosion conditions. Secure, long service life, minimal pressure loss thanks to hydraulically smooth surface, economic. SVGW certification for water and gas pipelines. Manufactured to ISO 2531 and EN 545 standards. Pipeclass standard K9; other classes on request. Permissible system pressure: See "permissible pressures", page 6/4.3. A thrustresisting ring fig. 2505, 2506, 2806, 2807 can be fitted. Deflection: see "Installation handbook for pushin joint piping". Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring. Pipe with doublechamber socket Fig DN L DE e G e PUR1 e PUR2 DM T weight mm mm mm mm mm mm mm kg/m item no The doublechamber pipe can be fitted with internal thrustresisting ring (fig. 2807) or external thrustresisting ring (fig. 2806). Pipe with singlechamber socket Fig DN L DE e G e PUR1 e PUR2 DM T weight mm mm mm mm mm mm mm kg/m item no phone , fax , info@vonrollhydro.ch 2/1.2

19 Sewage pipe with pushin socket Sewage pipes geopur sewage pipe with pushin socket Made of ductile cast iron using the centrifugal casting process with PUR (polyurethane) internal lining, outer side zinc sprayed and coated with bitumen Minimal pressure loss thanks to hydraulically smooth surface, economic. Application: Water and wastewater as well as media with phvalues between 1 and 14. Manufactured to EN 598 standards. Pipeclass standard; K7, other classes on request. Permissible system pressure: please contact us. A thrustresisting ring fig. 2505, 2506, 2806, 2807 can be fitted. Deflection: see "Installation handbook for spigot and socket piping". Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without restraint clamp. 2 Pipe with doublechamber socket Fig DN L DE e G e PUR1 DM T weight mm mm mm mm mm mm kg/m item no The doublechamber pipe can be fitted with internal restraint clamp (fig. 2807) or external restraint clamp (fig. 2806). Pipe with singlechamber socket Fig DN L DE e G e PUR1 DM T weight mm mm mm mm mm mm kg/m item no phone , fax , info@vonrollhydro.ch 2/1.3

20 Pressure pipe with pushin socket Pressure pipes and adapter fittings vonrollrock pressure pipes with rockprotection coating ducpur vonrollrock pressure pipes with rockprotection coating. These coated castiron pipes are outstandingly suitable for use in rocky ground and are protected against damage by rocks when backfilling. The robust and hardwearing coating offers unique performance. The lightweight under castiron pipes (see table) is proven to be economical during installation in difficult ground conditions and presents no problems when coping with the most difficult pipelaying conditions. The protective coating can easily be removed with a knife so that the piping can be shortened to the required length or can be tapped or a building connection without encountering any problems. Pipe with doublechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no The doublechamber pipe can be fitted with internal restraint clamp (fig. 2807) or external restraint clamp (fig. 2806). Pipe with singlechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no phone , fax , info@vonrollhydro.ch 2/2.1

21 Pressure pipe with pushin socket Pressure pipes and adapter fittings vonrollrock pressure pipes with rockprotection coating ecopur vonrollrock pressure pipes with rockprotection coating. These coated castiron pipes are outstandingly suitable for use in rocky ground and are protected against damage by rocks when backfilling. The robust and hardwearing coating offers unique performance. The lightweight under castiron pipes (see table) is proven to be economical during installation in difficult ground conditions and presents no problems when coping with the most difficult pipelaying conditions. The protective coating can easily be removed with a knife so that the piping can be shortened to the required length or can be tapped or a building connection without encountering any problems. 2 Pipe with doublechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no The doublechamber pipe can be fitted with internal restraint clamp (fig. 2807) or external restraint clamp (fig. 2806). Pipe with singlechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no phone , fax , info@vonrollhydro.ch 2/2.2

22 Sewage pipe with pushin socket Sewage pipes vonrollrock sewage pipes with rockprotection coating geopur vonrollrock pressure pipes with rockprotection coating. These coated castiron pipes are outstandingly suitable for use in rocky ground and are protected against damage by rocks when backfilling. The robust and hardwearing coating offers unique performance. The lightweight under castiron pipes (see table) is proven to be economical during installation in difficult ground conditions and presents no problems when coping with the most difficult pipelaying conditions. The protective coating can easily be removed with a knife so that the piping can be shortened to the required length or can be tapped or a building connection without encountering any problems. Pipe with doublechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no. The doublechamber pipe can be fitted with internal restraint clamp (fig. 2807) or external restraint clamp (fig. 2806). Pipe with singlechamber socket Fig DN L DE e DM T weight mm mm mm mm mm kg/m item no. phone , fax , info@vonrollhydro.ch 2/2.3

23 Adapter fittings with pushin joints Pressure pipes and adapter fittings ecofit bend with pushin sockets Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Epoxyresin coating (min. 250 µm) to DIN 3476 standard Singlechamber socket Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring bend, 2 sockets (MMQ) Fig. 2820a.90 DN t weight mm kg itemno bend, 2 sockets (MMK 45) Fig. 2822a.45 DN t weight mm kg itemno phone , fax , info@vonrollhydro.ch 2/3.1

24 Adapter fitting with pushin joints Pressure pipes and adapter fittings 30 bend, 2 sockets (MMK 30) Fig. 2823a.30 DN t weight mm kg itemno bend, 2 sockets (MMK 22) Fig. 2824a.22 DN t weight mm kg itemno bend, 2 sockets (MMK 11) Fig. 2825a.11 DN t weight mm kg itemno phone , fax , info@vonrollhydro.ch 2/3.2

25 Adapter fittings with pushin joints Pressure pipes and adapter fittings 5 bend, 2 sockets (MMK 5) Fig. 2826a.5 DN t weight mm kg itemno phone , fax , info@vonrollhydro.ch 2/3.3

26 Adapter fittings with pushin joints Pressure pipes and adapter fittings ecofit bend with socket and spigot Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Epoxyresin coating (min. 250 µm) to DIN 3476 standard Singlechamber socket Pipes and adapter fittings are delivered with Tyton seal but without thrustresisting ring. 90 bend, socket and spigot (MQ) Fig DN t t 1 weight mm mm kg itemno bend, socket and spigot (MK 45) Fig DN t t 1 weight mm mm kg itemno bend, socket and spigot (MK 30) Fig DN t t 1 weight mm mm kg itemno bend, socket and spigot (MK 22) Fig DN t t 1 weight mm mm kg itemno phone , fax , info@vonrollhydro.ch 2/4.1

27 Adapter fittings with pushin joints Pressure pipes and adapter fittings 11 bend, socket and spigot (MK 11) Fig DN t t 1 weight mm mm kg itemno phone , fax , info@vonrollhydro.ch 2/4.2

28 Adapter fittings with pushin joints Pressure pipes and adapter fittings ecofit adapter fittings (1 branch) with pushin joints Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard Singlechamber socket (Fig doublechamber) Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring. UNIVERSAL pushin joint tee, doublechamber (UA) Fig DN 1 DN 2 PN L h weight bar mm mm kg itemno. To factory standards ,16,25, , ,16,25, , ,16,25, , ,16,25, , Construction: Doublechamber. Supply includes the adapter fitting with sealing gaskets, stud bolts with nuts and protective caps. Can be fitted with internal thrustresisting ring (fig. 2807) or external thrustresisting ring (fig. 2806). phone , fax , info@vonrollhydro.ch 2/5.1

29 Adapter fittings with pushin joints Pressure pipes and adapter fittings Teeconnector with 3 sockets (MMB) Fig DN 1 DN 2 L h weight mm mm kg itemno phone , fax , info@vonrollhydro.ch 2/5.2

30 Adapter fittings with pushin joints Pressure pipes and adapter fittings Teeconnector with 2 sockets and a flanged branch (MMA) Fig DN 1 DN 2 PN L h weight bar mm mm kg ,16,25, ,16,25, , ,16,25, , , ,16,25, , , , ,16,25, , , , , , , , , , , , , itemno phone , fax , info@vonrollhydro.ch 2/5.3

31 Adapter fittings with pushin joints Pressure pipes and adapter fittings Teeconnector with 2 sockets and a flanged branch (MMA) Fig DN 1 DN 2 PN L h weight bar mm mm kg , , itemno Teeconnector with 2 sockets and a screw branch Fig DN G L h weight mm mm kg 100 2" " " " itemno Spigot Teeconnector (IT) Fig DN 1 DN 2 L h weight mm mm kg itemno phone , fax , info@vonrollhydro.ch 2/5.4

32 Adapter fittings with pushin joints Pressure pipes and adapter fittings ecofit taper with pushin joints Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard Singlechamber sockets Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring. Taper with 2 sockets (MMR) Fig DN 1 DN 2 L weight mm kg itemno phone , fax , info@vonrollhydro.ch 2/6.1

33 Adapter fittings with pushin joints Pressure pipes and adapter fittings ecofit addin adapter, flange adapter (with pushin joint) Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard Singlechamber sockets Pipes and adapter fittings DN with standard supporting collar are delivered with Tyton seal but without thrustresisting ring. 2 Collars (U) Fig DN PN L weight mm kg itemno Flange socket adapter, adjustable (EU) Fig. 2877b DN PN L z weight bar mm mm kg 80 10,16,25, ± , ± , ± , ± ± ± ± ± ± ± ± ± ± ± itemno Flange socket adapter (EU) Fig DN PN L weight bar mm kg itemno phone , fax , info@vonrollhydro.ch 2/7.1

34 Adapter fittings with pushin joints Pressure pipes and adapter fittings Flange spigot adapter (F) Fig DN PN L weight bar mm kg 80 10,16,25, , , , itemno phone , fax , info@vonrollhydro.ch 2/7.2

35 Pushin joint connections Pressure pipes and adapter fittings Thrustresisting rings and sealing gaskets Pipes, adapter fittings and valves can be connected to pipes using thrustresisting rings that take up longitudinal forces. Thrustresisting ring (external) for vonroll support collar, with welded bead, not electrically conducting Fig DN PN DF weight bar mm kg itemno "Permissible pressures for thrustresisting rings" page 6/4.4 Thrustresisting ring (external), not electrically conducting Fig DN PN DF weight bar mm kg "Permissible pressures for thrustresisting rings" page 6/4.4 itemno Thrustresisting ring (external), not electrically conducting Fig DN PN DF weight bar mm kg External thrustresisting ring for pushin joint connections. Epoxyresin coated thrustresisting ring. itemno For pressures > 40 bar, piping of pipeclass K10 or higher should be used. See table "Permissible pressures for thrustresisting rings" page 6/4.4. phone , fax , info@vonrollhydro.ch 2/8.1

36 Pushin joint connections Pressure pipes and adapter fittings Thrustresisting ring TytonSit for water (internal) Fig DN PN* weight bar kg * 10 bar for ecopur pipes TytonSit PLUS on request itemno Thrustresisting ring (internal) Fig DN PN weight bar kg itemno Internal thrustresisting ring for doublechamber socket connections. System pressures: see "Permissible pressures for thrustresisting rings" page 6/4.4. phone , fax , info@vonrollhydro.ch 2/8.2

37 Pushin joint connections Pressure pipes and adapter fittings Tyton seal for water Fig DN weight kg itemno Rubber sealing ring for pushin joints for water, fulfils EN Tyton seal for gas Fig DN weight kg Rubber sealing ring for pushin joints for gas, fulfils EN 682. itemno phone , fax , info@vonrollhydro.ch 2/8.3

38 Pushin joint connections Pressure pipes and adapter fittings Connecting pieces PE100 connecting piece (for use in water piping) Fig DN dr di L L 1 weight mm mm mm mm kg ± ± ± ± ± ± ± ± ± itemno For use when making connections between slidevalves or piping components with pushin joints (doublechamber system) and plastic piping: The pushin joint must be fitted with a thrustresisting ring (Fig. 2807). phone , fax , info@vonrollhydro.ch 2/9.1

39 Accessories for pushin joint piping Pressure pipes and adapter fittings Installation material for pushin joint pipes Neutrex T lubricant Fig. 270 weight g itemno Lubricant for the installation of pipes made of ductile cast iron Transparent corrosionprotection film Fig DN b weight mm kg/m itemno Scotchrap Fig B length per roll weight mm m kg itemno ducpurplus corrosionprotection film Fig DN b weight mm kg/m itemno phone , fax , info@vonrollhydro.ch 2/10.1

40 Accessories for pushin joint piping Pressure pipes and adapter fittings Repairset RESICOAT RS RESICOAT RS is a readytouse, twocomponent solvent freeepoxyrepair material packed in the correct mixing ratio of 2:1. Colour: blue Doublechamber cartridge Fig. 284 weight g 100 itemno Dispenser Fig. 285 weight g 180 itemno Mixing tube Fig. 286 weight itemno phone , fax , info@vonrollhydro.ch 2/10.2

41 Accessories for pushin joint piping Pressure pipes and adapter fittings Set of assembly and laying tools, complete Fig. 254 / 15 DN weight kg itemno DN 300 auf Anfrage 2 Spigot collar Fig DN weight kg itemno Socket collar Fig DN weight kg itemno Hydraulic unit (1 pair) Fig DN weight kg itemno Groove scraper Fig DN weight kg Checking rule Fig DN weight kg itemno phone , fax , info@vonrollhydro.ch 2/11.1

42 Accessories for pushin joint piping Pressure pipes and adapter fittings Hammering accessory Fig DN weight kg itemno Dismantling leaf Fig DN Number weight kg itemno Set of assembly and laying tools, complete Fig. 293 / 16 DN weight kg itemno Spigot collar Fig DN weight kg itemno phone , fax , info@vonrollhydro.ch 2/11.2

43 Accessories for pushin joint piping Pressure pipes and adapter fittings Socket collar Fig DN weight kg itemno Openended spanner (1 pair) Fig DN weight kg itemno Groove scraper Fig DN weight kg Checking rule Fig DN weight kg itemno Extensions for the installation of VS 5000 slidevalves (1 pair) Fig DN weight kg phone , fax , info@vonrollhydro.ch 2/11.3

44 Accessories for pushin joint piping Pressure pipes and adapter fittings Accu screwdriver PIW 14.4SD Fig. 294 weight kg 2.1 Technical data 14.4.Volt / Ah Idling speed rpm Hammer blows/min Torque 158 Nm Weight without accupack 1.6 kg Weight with accupack 2.1 kg Length 193 mm Chuck 1/2" square Standard scope of supply: 2x 14.4 V / 1.4 Ah NiCd flatpack accupack RCA 7224MB charger ABS system case M20 hexagonal socketwrench insert itemno phone , fax , info@vonrollhydro.ch 2/11.4

45 Installation instructions for pushin joint piping 1. General remarks Following the instructions below will guarantee professional and correct installation work. 2. Removal of caps and dummy plugs Only remove caps and dummy plugs onsite just before the pipe is laid. 2 Environmental protection: The caps and dummy plugs are designed to be oneway material. They are made of environmentfriendly plastics (green polyethylene and black ethylenepropylene). A practical way to reuse them is to use them as a protective cushion between the pipe body and trench bottom or levelling (e.g. cement slabs). If they are disposed of in an appropriate waste incineration plant, no poisonous or corrosive pollutants are produced. 3. Cleaning the sockets Check that the insides of the socket around the retainer groove (A) and the sealing chamber (B) are clean. For ducpur pipes, bitumen residue and/or other deposits can be removed using the groove scraper. ecopur pipes, adapter fittings and slidevalves are only to be cleaned with a cloth. The use of groove scrapers is forbidden. 4. Lubricating the sockets Using a brush, apply the lubricant specially suitable for pushin joint connections to the sealing chamber (B). The retainer groove (A) should not be lubricated. phone , fax , info@vonrollhydro.ch 2/12.1

46 5. Inserting the sealing rings (Fig 2810 / 2811) 5.1 The sealing ring is inserted by hand. 5.2 Press any bulge remaining flat. 5.3 If you have trouble pressing the seal flat, make a second bulge on the opposite side. These two smaller bulges can then be easily pressed flat The hard edge of the sealing ring should not be allowed to jut out above the aligning ridge Note: Sealing rings should be stored away from sunlight and moisture (see "transport and storage"). They should only be fitted in the sockets just before pipe installation. In winter, it is recommended that the sealing rings be stored in a warm room this makes their fitting easier. right wrong 6. Cleaning and lubricating the spigots of pipes and adapter fittings and the socket 6.1 Cleaning ducpur pipes should be cleaned with a triangular scraper. If necessary, accumulations of coating material and/or other deposits should be removed from the spigots. ecopur pipes, adapter fittings and slidevalves are only to be cleaned using cloths and sponges. 6.2 Lubricating The spigots and the sealing ring in the socket should be evenly covered with installation lubricant. phone , fax , info@vonrollhydro.ch 2/12.2

47 7. Centring and alignment of pushin joint joints Attention! If the connection is to be secured with an optional thrustresisting ring, this must first be installed as described in section 12. Using a wooden roller, insert the spigot of the pipe into the socket so that it is centred in the sealing ring. In this position, the pipes will centre themselves automatically. The axes of the pipeline components (pipes, adapters and fittings) must all lie on a straight line Assembly After centring as described in section 7, the final assembly of the pipes can be carried out by using various different methods. The various methods described below are suitable for pushin joint joints with or without thrustresisting rings. During and after assembly, the depth of insertion must be checked. See sections 9 and Assembly using the assembling and laying tool (Fig. 293) for DN pipes and adapter fittings After centring, the pipeline components can be quickly and easily put together using the assembling and laying tool (Fig. 293). Two openended spanners are used to operate the appliance. Attention! When assembling a pushin joint connection with an internal thrustresisting ring (Fig. 2807), interlocking is achieved by making two or three jerky movements with the spanners in opposite directions. 8.2 Assembly using the assembling and laying tool (Fig. 293) for DN slidevalves with spigot For this, two extension pieces, 2 bolts and 2 split pins are needed. phone , fax , info@vonrollhydro.ch 2/12.3

48 8.3 Assembly using the assembling and laying tool (Fig. 254) for DN pipes and adapter fittings The assembling and laying tool is operated hydraulically and is designed for putting pushin joints together. Assembly of adapter fittings and slidevalves with socket connections using the assembling and laying tool (Fig. 254). 8.4 Assembly using the assembling and laying tool (Fig. 252) for DN pipes and adapter fittings The appliance is protected against overload by a torquelimiter on its crank. For ecopur pipes, sheathed wire rope slings must be used. If the pipeline is protected using ducpurplus protective film, installation should be carried out as shown. Assembly of adapter fittings and slidevalves with socket connections using the assembling and laying tool (Fig. 252). (sheathed wire rope slings should be used) 8.5 Assembly without assembly and laying tool Installation using a digger shovel or winch A square piece of timber should always be used to protect the pipe from damage. Assembly using a crowbar for DN For the installation of pushin joint pipes, adapter fittings (except bends) and slidevalves. The crowbar is not included in delivery. Assembly using two chainhoists in opposition To be used under difficult conditions or for large diameters. For ecopur pipes only sheathed wire rope slings and stirrups and textile belts may be used. phone , fax , info@vonrollhydro.ch 2/12.4

49 8.6 Assembly of shortened DN pipes with pushin joints Installation as in sections 8.1 to 8.5. Pipes should be shortened to the required length as described under "Shortening pipes". The short pipes can be prevented from getting out of line when being installed as follows: For DN by using an extension (e.g. pipe, piece of timber etc.) and balancing out using body weight. For DN by installing a brace across the top of the short pipe. 2 After the completion of installation work, all pieces of timber etc. used are unconditionally to be removed! 9. Inspection during and after installation During and after installation, the insertion depth should be monitored. The distance between the spigot and the bottom of the socket should be kept within a tolerance (S) of 5 10 mm. 9.1 Pushin joints with doublechamber socket DN (pipes) The position of the silvergrey marking lines for socket connections are as follows: Without thrustresisting joints If the end of the socket is flush with the first marking line, the spigot is positioned correctly in the socket. With internal thrustresisting ring Fig If the edge of the rubber sleeve of the restraining ring is flush with the second marking line, the spigot is positioned correctly in the socket. With external thrustresisting ring Fig If the end of the socket is flush with the first marking line, the spigot is positioned correctly in the socket. The thrustresisting ring may only be fitted after the sealing ring has been checked according to section Pushin joints with singlechamber socket DN (pipes and adapter fittings) DN (adapter fittings) with external thrustresisting rings Figs. 2806, 2505, 2506 DN pipes and adapter fittings with and without thrustresisting rings If the end of the socket is flush with the first marking line, the spigot is positioned correctly in the socket. DN adapter fittings Measure insertion depth and apply a marking line on the spigot as described in section 12.2 phone , fax , info@vonrollhydro.ch 2/12.5

50 10. Correct positioning of the sealing ring Immediately after installation as described in section 8, the distance (U) between the end of the socket and the sealing ring should be checked using the control gauge (A) The distance (U) must be consistent over the whole of the pipe s circumference. If the measured distance (U) is not consistent, the pushin joint connection must be dismantled and installed anew. 11. Deflection of the connection for installations without thrustresisting joints After assembling and checking have been completed, the pipe can be deflected. The permissible angles of deviation are as follows: 5 for DN (with Tyton seal) 4 for DN (with Tyton seal) 3 for DN (with Tyton seal) For connection deviation for installations with thrustresisting rings see section Fitting of external and internal thrustresisting rings External and internal thrustresisting rings can be additionally fitted to the pushin joint. These thrustresisting rings provide a secure connection under high operating pressure. For permissible operating pressures see "Information for planners and piping installers". Thrustresisting rings may only be fitted to pipes and adapter fittings with spigots that are made of ductile cast iron Internal thrustresisting rings (Fig. 2807) Preparation and installation of sealing ring as described in sections 1 6. Lubrication of the thrustresisting ring chamber. Make a bulge in the thrustresisting ring (C) by pinching it by hand. Attention! The bulge must lie between two locking segments. phone , fax , info@vonrollhydro.ch 2/12.6

51 Fit the thrustresisting ring (C) into its chamber. The number of stainlesssteel segments varies depending on the size of the thrustresisting ring. The rubber lip must be on the outside The spigot end, the sealing ring and the thrustresisting ring should be coated evenly with installation lubricant. 2 Installation and checking of the pushin joint connection as described in sections If necessary, the pipes can be deflected (α max. 3 ) after installation External thrustresisting rings (Fig. 2806) Preparation and installation of sealing ring as described in sections 1 6 Using the appropriate template, the insertion depth (I) for adapter fittings (singlechamber socket) is as follows: 80 mm for DN 80/100/ mm for DN mm for DN 200/ mm for DN 300/350 or, for pipes, UN1 and slidevalves (doublechamber socket): 110 mm for DN 80/100/ mm for DN mm for DN 200/250/300 Mark insertion depth at (A). Slide thrustresisting ring (1) and retainer ring (2) onto the end of the pipe. Insert the pipe using the assembling and laying tool (Fig. 293) up to the mark (A). Slide parts (1) and (2) up to the end of the socket to position (A). Tighten up the fang bolts (3) and nuts (4) diagonally to 120 Nm. (With spanner or accu percussion screwdriver Fig. 294) After completing installation and checking, the pipes may be deflected. The permissible angle of deviation α is max. 3. phone , fax , info@vonrollhydro.ch 2/12.7

52 12.3 External thrustresisting rings (Fig. 2506) Preparation and installation of sealing ring as described in sections 1 6. Slide thrustresisting ring (A) and retainer ring (B) onto the spigot of the pipe. Centre as described in section 7. Using the installation appliance, slide the spigot into the socket (as described in section 8) so that the end of the inserted pipe is at a distance (S) of 5 10 mm from the bottom of the socket. Make checks during the installation as described in sections Slide the retainer ring (B) up to the end of the socket. Slide the thrustresisting ring over the retainer ring. Insert the fang bolts (C) from the rear of the thrustresisting ring and screw on the nuts as tightly as possible by hand. (Pay attention that the contact areas of the screws are positioned correctly on the socket bell and the restraintclamp ring). Tighten up the fang bolts (C) and nuts (D) diagonally to 120 Nm. (With spanner or accu percussion screwdriver Fig. 294) After completing installation and checking, the pipes may be deflected. The permissible angle of deviation α is max External thrustresisting rings (Fig. 2505) for pipes with welded bead Preparation and installation of sealing ring as described in sections 1 6. Slide thrustresisting ring (A) and retainer ring (B) onto the spigot of the pipe. phone , fax , info@vonrollhydro.ch 2/12.8

53 Centre as described in section 7. Using the installation appliance, slide the spigot into the socket (as described in section 8) up to the line marked on the pipe. Make checks during the installation as described in sections Slide the retainer ring (B) up to the end of the socket and centre it (e.g. with two hardwood wedges). Insert the fang bolts (C) from the rear of the thrustresisting ring and screw on the nuts as tightly as possible by hand. (Pay attention that the contact areas of the screws are positioned correctly on the socket bell and the restraintclamp ring). Tighten up the fang bolts (C) and nuts (D) diagonally to 120 Nm. (With spanner or accu percussion screwdriver Fig. 294) After completing installation and checking, the pipes may be deflected. The permissible angle of deviation α is max Dismantling pushin joints The dismantling method varies depending on if the connection is fitted with a thrustresisting ring or not Dismantling a pushin joint without thrustresisting rings With the help of the assembling and laying tool Fig. 293 Press the openended spanners in the direction of the connection. With the help of the assembling and laying tool Fig. 254 Reverse the oilflow in the hydraulics by changing over the valve levers. The cylinders are pushed out by pumping the levers and the connection will be released. Dismantling of pushin joint connections that were made a long time ago: Push metal dismantling leaves (Fig. 2552) between the spigot and the sealing ring using the special hammering accessory (Fig. 2551) Used sealing rings should never be reused. phone , fax , info@vonrollhydro.ch 2/12.9

54 With the help of the assembling and laying tool Fig. 252 Place the steel cables and the winch as shown, Dismantle the connection by driving the rack out. In difficult cases, this appliance can also be used for pipediameters under DN Dismantling a pushin joint with internal thrustresisting ring Fig With the help of the assembling and laying tool Fig. 293, pull in the spigot until it touches the bottom of the socket. Push metal dismantling leaves (2), Fig. 2552, between the spigot and the sealing ring using the special hammering accessory (1), Fig The following number of dismantling leaves are need per dismantling operation: DN Pcs Attention! Used thrustresisting rings can be reused if they display no visual signs of damage (no broken locking elements) Dismantling a pushin joint with external Fig. 2806/2505/2506 thrustresisting ring External thrustresisting rings are to be dismounted in the reverse order of their installation. Afterwards, dismantle the joint using the installation appliances as described above. Attention! Used restraintclamp rings can be reused if they display no visual signs of damage. phone , fax , info@vonrollhydro.ch 2/12.10

55 Flanged products 4 Figur Seite ducpur pressure pipes with 2 flanges /4.111 ducpur pressure pipes with 1 flange /1.12 Wall flange 4/ bend, with foot, N 2030a.90 4/ bend, Q / bend, FFK / bend, FFK / bend, FFK / bend, FFK /2.6 Flanged T, T /3.12 Flanged cross, TT /3.3 Flanged taper, FFR / Reduction flange, stud bolts on both sides, XR /4.3 Reduction flange, stud bolts on one side, XR /4.3 Dummy flange, flat, X /5.1 Dummy flange, domed, X /5.1 Flange connection, PN10, galvanised /6.1 Flange connection, PN16, galvanised /6.1 Flange connection, PN10, V2A /6.2 Flange connection, PN16, V2A /6.2 Joint type GST PN 10 in water and gas quality zu 2007/08 4/6.3 Joint type GST PN 16 in water and gas quality zu 2007/08 4/6.3 Installation instructions for piping with flange connections 4/7.12

56

57 Pressure pipe with flanges Pressure pipes and adapter fittings ducpur pressure pipe with flange(s) Made of ductile cast iron using the centrifugal castig process with PUR (polyurethane) internal lining, outer side zinc sprayed and coated with bitumen. Minimal pressure loss thanks to hydraulically smooth surface, economic. Application: Drinking water, soft and aggressive water as well as media with phvalues between 1 and 14. SVGW certification for water and gas pipelines. Manufactured to ISO 2531 and EN 545 standards. Pipeclass K12; flanges according to EN (screwed on and bonded). PN > 16 on request Version in ecopur or with undercoat in Aluchrom on request Pipe with threaded flanges DN 80 Fig DN PN L DE e G e PUR1 weitht bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4/1.1

58 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 100 Fig DN PN L DE e G e PUR1 weitht bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4/1.2

59 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 125 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg item no. Sauissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4.1.3

60 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 150 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4/1.4

61 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 200 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4/1.5

62 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 250 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request phone , fax , info@vonrollhydro.ch 4/1.6

63 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 300 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request item no Suissetec Flange with boreholes according to DIN EN 1092 part 2 4 phone , fax , info@vonrollhydro.ch 4/1.7

64 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 350 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request Suissetec Flange with boreholes according to DIN EN 1092 part 2 phone , fax , info@vonrollhydro.ch 4/1.8

65 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 400 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request Suissetec Flange with boreholes according to DIN EN 1092 part 2 4 phone , fax , info@vonrollhydro.ch 4/1.9

66 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 500 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request Suissetec Flange with boreholes according to DIN EN 1092 part 2 phone , fax , info@vonrollhydro.ch 4/1.10

67 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with threaded flanges DN 600 Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request Suissetec Flange with boreholes according to DIN EN 1092 part 2 4 phone , fax , info@vonrollhydro.ch 4/1.11

68 Pressure pipe with flanges Pressure pipes and adapter fittings Pipe with one threaded flange Fig DN PN L DE e G e PUR1 weight bar mm mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Overall length (L): Tolerance without any special instructions ± 5 mm Tolerance on special order ± 1 mm Overall length (L): mm on request Wall flange DN weight kg item no. Suissetec Large DN on request phone , fax , info@vonrollhydro.ch 4/1.12

69 Adapter fittings with flanges Pressure pipes and adapter fittings ecofit bends with flange connectors Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard. PN > 16 on request. 90 bend with foot, 2 flanges (N) Fig. 2030a.90 DN PN t h c weight bar mm mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.1

70 Adapter fittings with flanges Pressure pipes and adapter fittings 90 bend, 2 flanges (Q) Fig DN PN t weight bar mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.2

71 Adapter fittings with flanges Pressure pipes and adapter fittings 45 bend, 2 flanges (FFK 45) Fig DN t weight mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.3

72 Adapter fittings with flanges Pressure pipes and adapter fittings 30 bend, 2 flanges (FFK 30) Fig DN PN t weight bar mm kg item no. Suissetec To works specifications Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.4

73 Adapter fittings with flanges Pressure pipes and adapter fittings 22 bend, 2 flanges (FFK 30) Fig DN PN t weight bar mm kg item no. Suissetec To works specifications Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.5

74 Adapter fittings with flanges Pressure pipes and adapter fittings 11 bend, 2 flanges (FFK 11) Fig DN PN t weight bar mm kg item no. Suissetec To works specifications Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/2.6

75 Adapter fittings with flanges Pressure pipes and adapter fittings ecofit flanged adapter fittings (with 1 or 2 branches) Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard. PN > 16 on request. FlangeTee (T) Fig DN 1 DN 2 PN L h weight bar mm mm kg item no. Suissetec * * * * Flange with boreholes according to DIN EN 1092 part * * * * phone , fax , info@vonrollhydro.ch 4/3.1

76 Adapter fittings with flanges Pressure pipes and adapter fittings FlangeTee (T) Fig DN 1 DN 2 PN L h weight bar mm mm kg * * item no Suissetec * to factory standards phone , fax , info@vonrollhydro.ch 4/3.2

77 Adapter fittings with flanges Pressure pipes and adapter fittings Flangecross (TT) Fig DN 1 DN 2 PN L h weight bar mm mm kg item no. Suissetec To works specifications Flange with boreholes according to DIN EN 1092 part phone , fax , info@vonrollhydro.ch 4/3.3

78 Adapter fittings with flanges Pressure pipes and adapter fittings ecofit taper with flange connectors Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard. PN > 16 bar on request. Taper with flanges (FFR) Fig DN 1 DN 2 PN L weight bar mm kg 80* * * * * * * * * * * * * * * * * item no Suissetec Flange with boreholes according to DIN EN 1092 part 2 phone , fax , info@vonrollhydro.ch 4/4.1

79 Adapter fittings with flanges Pressure pipes and adapter fittings Taper with flanges (FFR) Fig DN 1 DN 2 PN L weight bar mm kg item no. Suissetec 250* * * * * * * * * * * * * * * * to factory standards phone , fax , info@vonrollhydro.ch 4/4.2

80 Adapter fittings with flanges Pressure pipes and adapter fittings Reduction flange, stud bolts on both sides (XR) Fig DN 1 DN 2 PN b weight bar mm kg item no. Suissetec , , Flange with boreholes according to DIN EN 1092 part * * * to EN 545 series A Reduction flange, stud bolts on one side (XR) Fig DN 1 DN 2 PN b weight bar mm kg item no. Suissetec To work specifications , , * * * * * Flange with boreholes according to DIN EN 1092 part 2 200* * * * to EN 545 series A phone , fax , info@vonrollhydro.ch 4/4.3

81 Adapter fittings with flanges Pressure pipes and adapter fittings ecofit dummy flanges and connecting pieces with flange connectors Adapter fittings made of ductile cast iron (ENGJS) to EN 545 standard. Thick epoxyresin coating (min. 250 µm) to DIN 3476 standard. PN > 16 on request. Dummy flange, flax (X) Fig DN PN D b weight bar mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Option: with thread Dummy flange, domes (X) Fig DN PN D b weight bar mm mm kg item no. Suissetec Flange with boreholes according to DIN EN 1092 part Option: with thread phone , fax , info@vonrollhydro.ch 4/5.1

82 Adapter fittings with flanges Pressure pipes and adapter fittings Connecting pieces and gaskets Flange connection PN 10 / galvanised Fig DN D d b screws nuts weight mm mm mm kg M16x70/38 8x M M16x70/38 8x M M16x70/38 8x M M20x80/46 8x M M20x80/46 8x M M20x80/46 12x M M20x80/46 12x M M20x80/46 16x M M24x100/54 16x M M24x100/54 20x M M27x110/60 20x M item no Supply includes: Hexagonalhead bolts (DIN 931) with nuts (DIN934) in St. 8.8, galvanised 1 Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Flange connection > PN 16 on request Suissetec Flange connection PN 16 / galvanised Fig DN D d b screws nuts weight mm mm mm kg M16x70/38 8x M M16x70/38 8x M M16x70/38 8x M M20x80/46 8x M M20x80/46 12x M M24x90/54 12x M M24x100/54 12x M M24x100/54 16x M M27x110/60 16x M M30x110/66 20x M M33x130/72 20x M item no Supply includes: Hexagonalhead bolts (DIN 931) with nuts (DIN934) in St. 8.8, galvanised 1 Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Flange connection > PN 16 on request Suissetec phone , fax , info@vonrollhydro.ch 4/6.1

83 Adapter fittings with flanges Pressure pipes and adapter fittings Connecting pieces and gaskets Flange connection PN 10 / V2A Fig DN D d b screws nuts weight mm mm mm kg M16x70/38 8x M M16x70/38 8x M M16x70/38 8x M M20x80/46 8x M M20x80/46 8x M M20x80/46 12x M M20x80/46 12x M M20x80/46 16x M M24x100/54 16x M M24x100/54 20x M M27x110/60 20x M item no. Supply includes: Hexagonalhead bolts (DIN 931) with nuts (DIN934) in V2A, 1 Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality Suissetec The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Flange connection > PN 16 on request 4 Flange connection PN 16 / V2A Fig DN D d b screws nuts weight mm mm mm kg M16x70/38 8x M M16x70/38 8x M M16x70/38 8x M M20x80/46 8x M M20x80/46 12x M M24x90/54 12x M M24x100/54 12x M M24x100/54 16x M M27x110/60 16x M M30x110/66 20x M M33x130/72 20x M item no. Supply includes: Hexagonalhead bolts (DIN 931) with nuts (DIN934) in V2A, 1 Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Flange connection > PN 16 on request Suissetec phone , fax , info@vonrollhydro.ch 4/6.2

84 Adapter fittings with flanges Pressure pipes and adapter fittings Connecting pieces and gaskets Dichtung Typ GSt PN 10 in water and gas quality zu Fig. 2007/ DN D d b weight mm mm mm kg item no Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Suissetec Dichtung Typ GSt PN 16 in water and gas quality zu Fig. 2007/ DN D mm d mm b mm weight kg item no Profile joint type GST with steel reinforcement / materiel NBRDUO (DIN EN 15141), water and gas quality The tightness of fittings with flanges is only ensured by using of profile joint with steel reinforcement type GST. Suissetec phone , fax , info@vonrollhydro.ch 4/6.3

85 Installation instructions for piping with flange connections 1. General remarks Following the instructions below will guarantee professional and correct installation work. 2. Making the connection To complete the flange connection between the two pipes with their flanges (A and B), the sealing set with gasket, bolts and nuts (C) is needed. 3. Cleaning the flanges The surfaces of the seal, gasket and the threaded holes must be cleaned. Any paint residue must be removed. 4. Assembly of the connection Recommendations for the installation. Pipes and adapter fittings with flanges must be carefully beddedin. Backfilling to the sides of the piping and over the top of the pipes is to be carried out with care. Varying loads cannot be taken up by the fixed pipe connections. On no account should the pipes and adapter pieces be laid on rocks or other materials, they should be laid in ground that is free of stones. Rocky ground should be covered with at least a 15 cm thick layer of sand, gravel or loose chippings Alignment of the flange holes For flange connections in general, the holes should be positioned so that no hole lies in the vertical plane at rightangles to the plane of the pipeline. The sequence for tightening up the bolts (in the order shown by the numbered sketches) The nuts should be tightened using a torque wrench. (the torque is dependent on the size of the bolts and their class (5.6, 5.8)) We will be pleased to supply you with information on the required torque. 4 bolts 6 bolts Fitter 2 Fitter 1 8 bolts 10 bolts phone , fax , info@vonrollhydro.ch 4/7.1

86 6. Remarks concerning the installation of flanged adapter fittings (especially Fig. 2084) Because of the differing numbers of boltholes on the two sides of flanged tapers, there is a danger that pipes and adapter fittings fitted after the taper could be falsely oriented. The possible distortion (dependent on diameter) can be up to 22.5 Attention! For larger diameters, the distortion may hardly be noticeable. phone , fax , info@vonrollhydro.ch 4/7.2

87 Tapping clamps 5 Figure Page Tapping clamp /1.12 5

88

89 Tapping clamps Pressure pipes and adapter fittings Tapping clamp Special tapping fittings are often used for tapping mains piping (e.g. for domestic supplies). Using tapping valves and tapping drills, mains piping can be tapped even when under pressure Tapping clamp 5000 with male thread Fig DN R t 1 L L 1 L 2 PN weight mm mm mm mm bar kg ¼ ½ ¼ ½ ¼ ½ ¼ ½ ¼ ½ ¼ ½ ¼ ½ ¼ ½ To factory standards 5 phone , fax , info@vonrollhydro.ch 5/1.1

90 Tapping clamp Pressure pipes and adapter fittings Tapping clamp 5000 with male thread Fig DN R t 1 L L 1 L 2 PN weight mm mm mm mm bar kg ¼ ½ ¼ ½ L 1 : clamp length for castiron pipes L 2 : clamp length for steel pipes Applications: Suitable for drinking water and oilfree air, other media on request. Pressurised and vacuum operation. Castiron parts with integrated thick epoxy resin coating (min. 250 µm), colour: blue. Just one model for mains piping made of cast iron and steel (only the clamp and connection seal are different). Clamp and bolts made of stainless steel with rubber backing / earthing is SEVtested. phone , fax , info@vonrollhydro.ch.ch 5/1.2

91 Planning and finishing work 6 Page Cutting pipes to length 6/1.13 RESICOAT RS Repair Material 6/2.12 Installation instructions for ducpurplus corrosionprotection film 6/3.12 Information for planners and pipe fitters 6/

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93 Cutting pipes to length 1. Safety precautions All instructions made by the manufacturer with the aim of guaranteeing accident prevention are to be followed. Appropriate protective clothing and safety equipment must be used when work is carried out. 2. Marking the cutting point Cuts must be made at rightangles to the pipe axis. Before cutting, mark the point where the pipe is to be cut with a line around the whole circumference of the pipe. Tip: Wrap a wide steel band with straight edges around the pipe, mark along its edge. 3. Cutting Use an appropriate cutting tool, e.g. circular saw. 4. Round off sharp edges 4.1 Pushin joint pipe Bevel the spigot end of the cut pipe slightly. A hand grinder is an appropriate tool for doing this. Execution: The radius (R) depends on the size of the pushin joint pipe. DN R 5 mm DN 400 R 7 mm DN R 6 mm DN 500,600 R 8 mm Sharp edges must be sufficiently rounded off. Otherwise they make it difficult to insert the spigot and may cause damage to the sealing rings. 4.2 Threaded pipe Sharp edges should be rounded off using a file or a hand grinder Protect cut surface against corrosion Carefully clean all surfaces inside the shortened pipe. Touch up the bare metal surfaces. for ducpur pipes with a bitumen compound suiable for drinking water. for ecopur pipes using the repair kit as described under Repairing linings and outside coatings. phone , fax , info@vonrollhydro.ch 6/1.1

94 6. Markings on pushin joint pipes The marking lines should be transferred to the spigotend of the shortened pipe as appropriate to the type of piping element: 6.1 Markings for pushin joint adapter fittings (singlechamber) DN L mm Markings for pushin joint pipes and adapter fittings such as UNI 1 / slidevalve (doublechamber) with internal thrustresisting ring Fig DN L 2 mm Markings for pushin joint pipes and adapter fittings such as UNI 1 / slidevalve (doublechamber) without internal thrustresisting ring Fig DN L 1 mm phone , fax , info@vonrollhydro.ch 6/1.2

95 7. Positioning welded beads Welded beads should only be added to piping onsite only if absolutely necessary and using special welding electrodes for ductile cast iron. As a result of the heat caused by welding, both the inside and outside coatings will be damaged. These must be correctly repaired afterwards (see Repair of linings and outside coatings ) DN a mm b mm c mm / / / phone , fax , info@vonrollhydro.ch 6/1.3

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97 RESICOAT RS Repair Material 1. User Manual RESICOAT RS is a readytouse, twocomponent solvent free epoxyrepair material packed in the correct mixing ratio of 2:1. The user friendly packaging in 2chamber cartridge enables the immediate repair of damages after quick assembling. The repair kit consists of dispenser doublechamber cartridge (2:1) mixing tube Open up the frame Insert the cartridge into the frame of the dispenser Close the frame with a click Twist off the plug Assemble the mixing tube by a 1/4 twist 6 Move the plunger with the dispenser into the cartridge. This pressure causes the material flow through the mixing tube, the built in spiral elements lead to a homogenuous mixture. For further technical data please refer to the Technical Data Sheet and to the Material Safety Data Sheet. phone , fax , info@vonrollhydro.ch 6/2.1

98 RESICOAT RS 2KRepair Material 1. Usage Repair of faults caused by supporting devices during the coating process. Repair of uncoated areas after sawing drilling or milling. Repair of mechanical damage caused during transportation and installation. 2. Handling The userfriendly touchup 2chamber cartouches ensure an exact dosage of resin/hardener components in a ratio of 2:1. 3. Cartouche with piston In this case a mixing tube ensures the homogenizing of both constitents. If no mixing tube is available, both components must be homogenized thorougly. 4. Construction site If no special pistol is available on a construction site or during onsite installation, a press out unit can be used alternatively. 5. Processing instructions The substrate must be free from oil, dust and oxides. Its temperature has to be 3 C minimum above the dew point of the surrounding air, but not below 5 C. Care for a correct outcome of both components before assembling the mixingtube. Dispose the volume of approx. 3ml. 6. Curing Potlife at 23 C : 15 minutes Dustdry at 23 C : approx. 2 hours Fully cured at 23 C : 24 hours 7. Drinking water contact Contact with drinking water has been certified and approved according to the UBA Guideline. phone , fax , info@vonrollhydro.ch 6/2.2

99 Installation instructions for ducpurplus corrosionprotection film 1. General remarks DucpurPLUS corrosionprotection film is delivered as a film tube in handy rolls. It is made of environmentfriendly polypropylene. DucpurPLUS corrosionprotection film is highly resistant. Once laid, it exhibits a practically unlimited resistance to ageing effects. It is used to protect castiron piping against the following corrosive elements: Aggressive soils in acidic soils (e.g. marshy ground). In soils with a high salt content, e.g. as a result of treating roadways against frost and snow. Around roots. Formation of macroelements in the case of varying corrosion potentials between the castiron piping and other metallic parts in contact with it, e.g. iron reinforcements. in the case of different electrical potentials between the castiron piping and other metallic parts in electrical contact with it, e.g. copper. in the case of inhomogeneous bedding, e.g. when trenches are filled in with various types of earth, contact between pipe surface and lumps of clay, masonry etc. Stray currents near railways that run on direct current, e.g. tramways, too. Near metallic structures that are fitted with cathodic protection devices. Our customer service division is at your disposal for: professional instruction on the laying of ducpurplus corrosionprotection film. taking soil samples. advice on the corrosionprotection of pipelines. 2. Preparation DucpurPLUS corrosionprotection film is fitted in an ongoing manner as the pipes and adapter fittings are laid. The film should be cut about 0.3 m longer than for the total pipe length required (L1). Slide the ducpurplus corrosionprotection film over the pipe (make a bellows). Lift the pipe by hand or using lifting gear and pull the film onto the whole length of the pipe. Pushin joint should be left free Pipe connection Prepare the piping to be laid in or outside the trench as shown. Connect DN pushin joint pipes using the appropriate installation appliances (Fig. 252, Fig. 293 or Fig. 254). phone , fax , info@vonrollhydro.ch 6/3.1

100 4. Seal the connection Grasp the ducpurplus corrosionprotection film at its topmost point and fold it into the pipe. The fold must lie below the apex of the pipe and point downwards towards the bottom of the trench. Tape the fold at onemeter intervals along the pipe using SCOTCHRAP adhesive tape. Avoid pockets of air. First seal the ducpurplus corrosionprotection film onto the spigotend of the pipe about 2 3 cm away from the markings. Pull the overlapping part of the ducpurplus corrosionprotection film over the pipe connection. Using SCOTCHRAP adhesive tape, fasten the film tightly around the joint (avoid voids). Use the SCOTCHRAP adhesive tape to both fasten the film and to seal it. Adjust the ducpurplus corrosionprotection film to fit closely onto the pipe. Fasten and seal the ducpurplus corrosionprotection film onto the previously laid and already sealed section of piping using 1 1 / 2 turns of SCOTCHRAP adhesive tape. 5. Fill in the trench Embed the sealedup section of piping in using fine material. In order to protect the ducpurplus corrosionprotection film from damage when filling in the trench, place a wooden board on the top of the pipe. The board should be removed before more coarse material is filled in. Fill in the trench with fine material up to 30 cm over the top of the pipe. Only now may the trench be completely filled with excavated or coarse material using mechanical means. 6. Repairing damage to the ducpurplus corrosionprotection film Small, visible damage to the ducpurplus corrosionprotection film that can occur during the laying of the pipes can be repaired using SCOTCHRAP adhesive tape without incurring any problems. phone , fax , info@vonrollhydro.ch 6/3.2

101 Information for planners and pipe fitters 1. Beddingin and backfilling pipe trenches The following instructions must be followed unconditionally: 1.1 In city areas subsidencefree backfilling: When laying ecopur and ducpur pipes: Wellcompacted covering material, up to 32 mm grain (sandy gravel, gravel, fine excavated or recycled material). Bedding 10 cm. 1.2 Overland Full use of excavated material: ecopurpipes: Fuss use of excavated material: ducpurpipes: Homogeneous covering material, such as ravel, sand or recycled material or reuse of excavated material if ducpurplus corrosionprotection film is used. Use finer material (up to 60 mm grain) for beddingin, the coarser material to backfill. Bedding 10 cm Take the EN 805 standard into consideration. vonroll rock with rock protection coating is used in rocky ground, in order to protect the pipe against damages by rocks when filling back. vonroll rock is suitable for all applications where sharpedged back fill materiel is used. 2. Anchoring the pipeline Covering: Before making pressure tests, every pipe is to be sufficiently covered with soil, whereby the joints should be left free. 6 Anchors: Before making pressure tests on nonthrustresisting piping (i.e. without thrust resisting rings), all bends, Tpieces and the closures at both ends of the section to be tested should be sufficiently anchored. phone , fax , info@vonrollhydro.ch 6/4.1

102 Making the supports: Usually concrete anchors are used but, in special cases, stiffening with wedgedin profiles can also be used. The dimensioning of the anchors depends on the forces defined by the internal pressure and the diameter of the pipe on the one hand and on the loadcarrying capacity of the ground on the other. Adapter fittings: Adapter fittings can be secured against changes in position using anchors. The pushin joints remain free. P = axial force R = resulting force Anchors for bends: R = 2 P sin 2 in N Anchors for Tpieces: R = P in N Anchors for tapers: P = P 1 P 2 in N P = P 2 sin 2 in N Resulting forces (R) in dan (1N = kp) at 1 Mpa (10 bar) internal pressure: DN DE mm dummy flange bend 90 bend 45 bend 30 bend 22 ½ bend 11 ¼ bend 5 5 / phone , fax , info@vonrollhydro.ch 6/4.2

103 3. Permissible pressures 3.1 Pressures according to EN 545:2002 for pushin joint pipes and adapter fittings Pipe class K9 Pipe class K10 DN PFA PMA PEA PFA PMA PEA (values in bar) PFA: Permissible component operating pressure. Highest hydrostatic pressure that a pipeline component can take in continuous operation. PMA: Highest permissible component operating pressure. Highest temporarily occurring hydrostatic pressure, including the pressure surge, that a pipeline component can take in continuous operation. PEA: Permissible component testing pressure. Highest hydrostatic pressure that a newly installed pipeline component can take for a relatively short period of time, in order to test the completeness and tightness of pipework installed above or below ground. Note: This test pressure is not the same as the system test pressure (STP) which refers to the calculated pressure for the pipeline and serves to guarantee its quality and tightness. 6 phone , fax , info@vonrollhydro.ch 6/4.3

104 3.1 Permissible pressures for thrustresisting rings Internal thrustresisting rings Fig Fig (Tyton SIT) External thrustresisting rings Fig Fig Fig DN PFA PFA PFA PFA PFA * 63** * 63** * 63** * 63** * 63** on request on request 700 on request on request (values in bar) * for ecopur pipes 10 bar ** for pressures > 40 bar, class K10 or higher pipes must be used Higher pressures on demand phone , fax , info@vonrollhydro.ch 6/4.4

105 4. Table of flanges for ductile cast iron flanges in dependence of DN and PN According to ISO 2531 (EN 10922): Flanges and their connection round flanges for pipes, fittings, adapters and accessories, sorted by PN Part 2: castiron flanges. DN PN Ø D mm Ø K mm C mm n Stk Ø L mm bolts M16 M16 M16 M16 M20 M16 M16 M16 M16 M20 M16 M16 M16 M16 M20 M16 M16 M16 M16 M20 M16 M16 M20 M20 M24 M16 M16 M24 M24 M27 M20 M20 M24 M24 M30 M20 M20 M24 M27 M33 M20 M24 M27 M30 M33 M20 M24 M27 M30 M33 M20 M24 M30 M33 M36 M24 M27 M33 M36 M39 M24 M30 M33 M39 M27 M33 M36 M45 M27 M33 M39 6 phone , fax , info@vonrollhydro.ch 6/4.5

106 5. Tables for defining constructional dimensions 5.1 Table for defining the dimensions of two spigot/socket or threaded bends each with two sockets and a straight piece of pipe (L). H mm L = L 1 2t The bend s constructional dimension t can be found in the adapter fittings table: = = 11 ¼ = 22 ½ = 30 = 45 E mm L 1 mm E mm L 1 mm E mm Calculation example for H = 1312 (the dimension is put together from the individual partdimensions). L 1 mm E mm L 1 mm E m L 1 mm H mm E mm = = 11 ¼ = 22 ½ = 30 = 45 L 1 mm E mm L 1 mm E mm = L 1 mm E mm L 1 mm E mm L 1 mm phone , fax , info@vonrollhydro.ch 6/4.6

107 5.2 Dimensions for two spigot/socket or threaded bends each with one socket E = (t+t 1 )Hcos H = (t+t 1 )Hsin L = t+t 1 +E 5.3 Dimensions for two connected flanged bends E = 2(t+1)Hcos H = 2(t+1)Hsin L = 2t+E 6. Pressure tests Guidelines for carrying out pressure tests can be found under: W4/d Guidelines for the planning, design, construction, operation and maintenance of drinking water supply systems outside buildings. Available from: Swiss Association of Gas and Water Professionals SVGW Grütlistrasse 44 P.O. Box 658 CH8027 Zurich 6 phone , fax , info@vonrollhydro.ch 6/4.7

108 7. Pressure losses in water mains 7.1 Introduction The Hydraulics Laboratory at the Swiss Federal Institute of Technology in Lausanne was commissioned by us to develop pressureloss charts for water mains made of ductile cast iron with polyurethane (PUR) linings. Measured roughness of the PUR surface in the pipes k 0,01 mm (i.e. hydraulically smooth surface). The pressureloss calculations are based on COLEBROOK s formula. The pressureloss chart on the following page is valid for class K9 ducpur pushin joint pipes that are new or as good as new. It is also applicable to ecopur pushin joint pipes of the same pipe class. The altogether 1.8 mm smaller inside diameter DI must be taken account of. The use of the pressureloss chart is illustrated by the following examples. Abbreviations used in the examples: DN = nominal diameter of the pipe DI = effective calculated inside diamater of the pipe in mm Q = flow rate in l/s v = average flowspeed in m/s h = pressureloss in m water head 1) J = h = pressureloss in m water head 1) / 1000 m or slope in L 1) = 1 m water head = 0,981 bar Application example for ducpur pipes Example 1 Given: DN 200, J = 4 m/1000 m Find: Q,v From the pressureloss chart for ducpur pushin joint pipes, pipe class K9: Q = 34 l/s, v= 1 m/s Example 2 Given: DN 200, J = 4m / 1000 m Find: DN, v From the pressureloss chart for ducpur pushin joint pipes, pipe class K9: DI = 286,0 mm v = 1,56 m/s Selected for use DN 300: Q= 121,8 l/s, v=1,63 m/s Example 3 Given: Q = 100 l/s, J= 4 m/1000 m Find: DN, v From the pressureloss chart for ducpur pushin joint pipes, pipe class K9: DI= 313,0 mm v = 1,30 m/s Selectet for use DN 300 : Q= 97,5 l/s, v=1,30 m/s phone , fax , info@vonrollhydro.ch 6/4.8

109 7.2 Chart for pressure losses in water mains Flow rate Fig and Fig Pushin joint pipes, ducpur and ecopur models Hydraulically smooth inner surfaces Kinematic viscosity of the fluid = 1.3 x 10 6 m 2 s 1 ducpur / ecopur = centrifugallycast pressure pipe in ductile cast iron with polyurethane internal lining Pipe class K9 Swiss Federal Institute of Technology, Lausanne Hydraulics laboratory Average velocity of flow [ms 1 ] inside diameter nominal size or Pressureloss or gradient 6 phone , fax , info@vonrollhydro.ch 6/4.9

110 8. Planning tips for pipelines that take up longitudinal forces 8.1 General remarks At bends, junctions, branch terminations and reduction fittings, forces can be encountered that have to be brought under control by the provision of concrete anchors or by using piping that takes up longitudinal forces and so transfers such forces to the surrounding ground. The length of pipe that has to be secured is dependent on its nominal size and testing pressure as well as the coefficient of friction, covering thickness and ground pressure of the compacted trench filling. The following forces oppose the forces caused by the internal pressure: for bends, junctions, end caps and reductions: the frictional forces R between the pipe wall and the surrounding soil; for bends, the soil resistance force acting on the adjoining pipes should also be considered. 8.2 Coefficient of friction and ground pressure The following parameters are defined: Coefficient of friction = 0.5 for nonbinding sand and gravel in which there are no or very few bindings with loamy or claylike material (soil type 2.23 according to DIN 18300). = 0.25 for very loamy sand, sandy clay, marl, loess and clay (soil type 2.25 according to DIN 18300). 8.3 Dimensioning of pipelines that take up longitudinal forces (Basis: DVGW brochure GW 368) Ground pressure = 0.05 N/mm 2 for very good compacted soil = N/mm 2 for good compacted soil. Notes: When securing bends against air the length to be secured is equivalent to that of an endcap (dummy flange). When ecopur pipes or pipes protected with PEfilm are laid, a coefficient of friction of 0.25 should always be used because of the reduced ground friction. N = resulting thrust E = counteracting earth restistence R = conteracting friction I = lenght of the pipe L = length to be secured The following security measures are the minimum that must be taken: for bends: 2 socket joints on each side (see illustration) for junctions and endcaps: 2 socket joints for reductions: 2 socket joints on the side with the larger diameter. Please ask our VID for the tables showing Pipe length to be secured phone , fax , info@vonrollhydro.ch 6/4.10

111 8.1 Area of applicability In the DVGWGW368 rules, the general standard practice for pushin joint pipework is considered that involves completely filling the pipe trench even before the pressure tests. This leads to shorter pipe lengths that have to be secured against longitudinal forces. Instead of completely filling the pipe trench before carrying out pressure tests, the pipe can be partially covered with soil over 2/3 of its length 6 phone , fax , info@vonrollhydro.ch 6/4.11

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113 Transport and storage Transport and storage 7/12 Page 7

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115 Transport and storage Guidelines: For the handling of pipes and adapter fittings made of ductile cast iron The careful handling of piping components should be ensured during transport, handling and storage, as well as on site. This is, together with professional laying, one of the most important prerequisites for the perfect operation of piping networks over a period of many years. 1. Pipebundle / packaging DN pushin joint pipes made of ductile cast iron are delivered in bundles. Pipes with DN > 300 are delivered as single pipes. The wooden supports are not part of the delivery for bundled pipes. ecopur pipebundles are covered with a UVprotective film. This covering should only be opened when necessary and should always be closed again afterwards. All types of external effects, mechanical damage and improper treatment are to be avoided. Outofplace or unsuitably placed packaging elements such as steel bands, protective films, pallets etc. should be corrected. 2. Pipe bundles / permissible stacking height Permissible stacking heights or permissible number of layers for stacked pipes for pipe classes K 9 DN pipe lenght pipes per bundle pipe length per bundle bundle height bundle width bundle length weight per bundle max. no. of bundles stackable m m cm cm cm kg For each layer, the pipes are to be secured with wooden wedges against rolling apart. The wooden wedges under the outside pipes are to be nailed to the bottom and intermediate wooden supports respectively. 7 phone , fax , info@vonrollhydro.ch 7/1

116 3. Loading and unloading pipes Wide liftingbelt slings are to be used when loading and unloading pipes. Individual pipes of all dimensions should be loaded and unloaded using mechanical aids using appropriate lifting gear (belts). Chains and unsheathed wire slings that can come into contact with the pipes may not be used. Under no circumstances are crane hooks to be hooked into the steel bands or in the sockets or spigotends of the pipes. Pipes should be hooked up one at a time. Pipes should never be dragged along the ground or rolled. 4. Storage of pipes Pipe bundles should be stored on two wooden supports (A), about 20x15 cm in size. Storage direct on the ground is not allowed. When stacked, two intermediate wooden spacers, about 5x5 cm in size (B) should be placed between each layer. The pipes are to be stored so that socket and spigot ends alternate with each other. The permissible stacking height shown in the table in section 2 should be observed. Cut the steel bindings using metal shears or diagonalcutters. Chisels, crowbars, pickaxes etc. may not be used. 5. Storage of piping components made of elastomer materials (sealing rings, thrustresisting rings, retaining rings) Rubber components can be affected by the following environmental factors: oxygen heat dampness (microorganisms) ozone light solvents Storage under tension Storage of elastomer seals (>6 months) (Recommendations according to ISO 2230, DIN 7716, EN 682). Temperature under 25 C, preferably 15 C, but not under 10 C. Keep away from light, especially light with a high proportion of UVlight (sunlight). Rel. Humidity under 65%. The storage room should contain no devices that produce ozone (e.g. electric motors) or solvents, fuels or chemicals. Do not use any films containing softener for packing. The seals should be stored without tension, pressure or other deformation; they should not, for example, be hung up on any part of their circumference. phone , fax , info@vonrollhydro.ch 7/2