051159 TI e gesamt screen - agru.cn · Connection Systems General standard,Application limits ......

Index

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Approvals and Standards3rd party control and standards

Applications and ReferencesDouble containment piping systemApplicationsReference listReference projects

Connection SystemsGeneral standard, Application limitsHeating element butt weldingNon-contact butt weldingHeating element socket weldingElectrofusion weldingHot gas weldingExtrusion weldingDetachable joints

Material PropertiesGeneral propertiesSpecific propertiesPressure curves and component operating pressuresCreep modulus curvesPermissible buckling pressuresBehaviour at abrasive fluidsChemical resistancyChemical resistance factors

Installation GuidelinesTransport, Handling, StorageGeneral installation guidelinesMachining

Calculation GuidelinesSystem of unitsSDR, Component operating pressureOperating pressure for water dangerous mediaWall thickness, External pressure, necessary stiffening forpipes with buckling strainPipe cross section, Determination of the hydraulic pressurelossDog bone loadSupport distances, Support distance at fixed pipingsystems, Change in length, Minimum straight lengthBuried piping systemsFlow nomogramm

page 1 - 5page 6 - 8page 9 - 19page 20 - 23page 24 - 25page 26page 27 - 29page 30 - 33

page 34page 35page 36

page 37page 38page 39page 40 -42

page 43 -46

page 47page 48 - 53

page 54 - 55page 56

page 57 - 58page 59 - 64page 65page 66 - 69page 70 - 73page 74 - 77page 78 - 80page 81

page 82 - 89page 90page 91page 92

page 93 - 94

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Material Properties

General properties of PE

As result of continuous development of PE moldingmaterials, the efficiency of PE pipes and fittingshave been improved considerably. This fact hasbeen taken into account by the introduction of newinternational standards (ISO 9080, EN1555,EN12201), which lead to higher permissibleoperating pressures.

Polyethylene (PE) is no longer classified by itsdensity (for example PE-LD, PE-MD, PE-HD) as it isnow divided into MRS-strength classes.

In comparison to other thermoplastics PE showsan excellent diffusion resistance and has thereforebeen applied for the safe transport of gases formany years.

Other essential advantages of this material are theUV-stability (if its black coloured), and the flexibilityof the molding material ("flexible piping system").

Physiological non-toxic

With respect to its composition polyethylenecomplies with the relevant food stuff regulations(according to ÖNORM B 5014, Part 1, BGA, KTWguidelines).PE pipes and fittings are verified and registeredregarding potable water suitability accordingDVGW guideline W270.

Behaviour at radiation strain

Pipes out of polyethylene may be applied acrossthe range of high energy radiation. Pipes out of PEare well established for drainage of radioactivesewage water from laboratories and as cooling waterpiping systems for the nuclear energy industry.The usual radioactive sewage waters contain betaand gamma rays. PE piping systems do not becomeradioactive, even after many years of use.Also in environment of higher radio activity, pipesout of PE are not damaged if they are not exposedduring their complete operation time to a larger,regularly spread radiation dose of < 10 4 Gray.

Polyethylene type PE 100

These materials can also be described aspolyethylene types of the third generation (PE-3)resp. also as MRS 10 materials. .This is a further development of the PE materialswhich shows by a modified polymerisation processan amended mol mass distribution. Therefore PE100 types have a higher density and by thisimproved mechanical properties comes a raisedstiffness and hardness. Also the creep pressureand the resistance against rapid crack propagationare also increased.Consequently, this material is suitable for theproduction of pressure pipes with larger diameters.In comparison to usual pressure pipes out of PEwith less wall thicknesses the correspondingpressure rating will be achieved.

Modified polyethylene PE 80-el(Polyethylene, electro-conductable)

Due to the electro-conductibility, PE80-el is oftenused for the transport of easy combustible media(e.g. fuels) or for the conveying of dust as for thesepiping systems, a connection to earth can beperformed.

Chemical structure of polyethylene

C C

H H

H H n

C C

H H

H H n

Advantages of PE

UV-resistanceflexibilitylow specific weight of 0,95g/cm3

favourable transportation (e. g. coils)very good chemical resistanceweathering resistanceradiation resistancegood weldabilityvery good abrasion resistanceno deposits and no overgrowth possibledue to less frictional resistance less pressurelosses in comparison with e. g. metalsfreeze resistanceresistant to rodentsresistant to all kinds of microbic corrosion

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esMaterial Properties

General properties of Polypropylene(Standard types)

Behaviour at radiation strain

Against radiation of high energy, PP is generallynot durable resistant.At effect of high energy rays on poly-propylene, itmay come to a temporary resistance increase dueto cross-linking of the molecular structure. But atdurable radiation strain, it comes to a rupture of themolecular chains and therefore by the damage ofthe material to a serious resistance decrease. Thisbehaviour has to be taken into account by areducing factor which has to be determinedexperimentally.At an absorbed dose of < 10 4 Gray polypropylenepiping systems can be applied without essentialresistance decrease.

Behaviour at UV-radiation

Grey polypropylene pipe lines are not UV-stableso they must be adequately protected. As effectiveprotection against direct solar radiation, a protectionlayer (AGRU-Coating) or an insulation is possible.It is furthermore possible to compensate the arisingdamage of the surface by a corresponding wallthickness addition as the damage only occurs onthe surface. The wall thickness addition may notbe less than 2 mm.As polypropylene is not equipped with light-stablecolour pigments normally, it may come to a changeof colour (fading) by long-time weathering.As an alternative a high-temperature-resistant, blackPE-HD material can be used. The application

General properties of PP

According to DIN 8078, three, different types ofpolypropylene are recognised:Type 1: PP-H(homopolymere)Type 2: PP-B(block-copolymere)Type 3: PP-R(random-polymere)

By copolymerisating with ethylene specialproperties are achieved as in PP types 2 and 3, whichresult in an improved processability (e.g. lowerdanger of shrinkage cavitation at the injectionmolding process) and higher impact strength of theproducts in comparison to PP-H.

PP-R and copper

In direct contact with copper and PP-R deteriorates,especially at higher temperatures, the physicalproperties of PP-R. Due to the accelerated thermaloxidation, heat ageing is faster.

Physiological non-toxicity

With respect to its composition, polypropylenecomplies with the relevant food stuff regulations(according OENORM B 5014 Part 1, FDA, BGA, KTWguidelines).

AGRU pipes, sheets and round bars are made ofnucleoid PP-H (Beta (β)-PP) since the middle of theseventies.Fittings are also produced out of PP-R (poly-propylene-random-copolymere) since the end ofthe seventies.Both types have been stabilized against hightemperatures and are the best suited materials forthe production of pressure piping systems.

In comparison to other thermoplastics such as PE-HD and PVC, PP shows a thermal stability up to100°C (short-time up to 120°C for pressurelesssystems).

PP shows good impact strength in comparison toPVC. The impact strength depends on temperature,increases with rising temperatures. decreases withfalling temperatures.

Chemical structure of PP

C C

H CH3

H H

n

C C

H CH3

H H

n

Advantages of Polypropylene

low specific weight of 0,91g/cm3

(PVC 1,40g/cm3)high creep resistanceexcellent chemical resistanceTiO2 pigmentationhigh resistance to ageing by thermalstabilizinggood weldabilityexcellent abrasion resistancesmooth inside surface of the pipes, thereforeno deposits and no growth over possibledue to less frictional resistance less pressurelosses in comparison with e. g. metalsnon-conductive, therefore the structure is notaffected by tracking currentsvery good thermoplastic processable(e. g. by deep drawing)PP is a bad conductor of heat - therefore inmost cases, no thermal insulation is requiredfor hot water piping systems

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Material Properties

General properties of modified PP

On account of the most specific requirementsarising in the construction of piping systems forthe chemical indu-stry and in apparatus engineeringflame retardant and electro-conductive specialtypes have been developed.For example static charging due to the flow of fluidsor dust can arise at the operation of thermoplasticpiping systems. Electro-conductable polypropylenetypes have therefore been developed in order toenable a connection to earth can be performed.

By supplement of additives, these modifiedproperties are achieved. But there result alterationsof the mechanical, thermal and also chemicalproperties in comparison to the standard type.

It is therefore necessary to clarify all projects withour technical engineering department.

Physiological properties

Modified PP types (flame-retardant resp. electro-conductable PP) correspond in their compositiondue to the supplement of additives n o t to therelevant food stuff regulations and may thereforenot be used for potable water pipes and in contact

Differences to standard types of PP

PP-R, black:

(Polypropylene-random-copolymere, blackcoloured)The essential advantage of this black colouredmaterial type is the UV resistance which is notavailable with grey PP.However there is an insignificant decrease of theimpact strength.

PP-R, natural:

(Polypropylene-random-copolymere, natural)As PP-R natural contains no colour additives, it isapplied mainly for high purity water piping systems.However this material is not UV resistant.

PP-H-s:

(Polypropylen-homopolymere, flame-retardant)Due to the higher stiffness of PP-H-s, it is well suitedfor ventilation and degassing pipes as well as forflue lining systems. It may not be used for outdoorsapplications due to the missing UV stabilization.

PP-R-el:

(Polypropylene-random-copolymere, electro-conductable)This material is used if the application requires theconnection to earth of the piping system.Due to the high carbon black content, PP-R-el is UVresistant, but shows a reduced impact strength andcreep strength.

PP-R-s-el:

(Polypropylene-random-copolymere, flameretardant, electro-conductive)This material reconciles the positive properties ofthe flame retardant and electro-conductable PPtypes. It is therefore due to safety reasons mostlyapplied for the transport of easy ignitable mediaand replaces often expensive stainless steelductings.

There is however a reduced impact strength of PP-R-s-el as well as a slightly amended chemicalresistance (see page 16).

General properties of PP

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General properties of PVDF(Polyvinylidene fluoride)

PVDF is an extremly pure polymer and contains incomparison with a lot of other plastics no stabilizersUV-, Thermostabilizers, softener, lubricants orflame-retardant additives. Its particular suitable forultra-pure water constructions and for the transportof clear chemical liquids in the semi-conductorindustry. Due to its chemical inertness, reactionagainst most media is nearly impossible.

Pipes and components out of suitable standardtypes fulfil the high demands of the semi-conductorindustry; e. g. they are in the position to maintainthe specific resistance of deionizationed ultra-purewater over 18 MW.cm.

PVDF offers with its properties an idealcompromise, in connection with a very easyprocessing and an advantageous price-performanceratio.

Polyvinylidene fluoride (PVDF) is a thermoplasticand has the following typical properties:

- easy processing- good weldability- good heat formability

PVDF is distinguished in comparison with PTFE(Polytetrafluorethylene) by its high mechanicalstrength and the very good chemical resistance,even in connection with high temperatures.

Chemical structure of PVDF

PVDF is a halogen and also offers an excellent fireprotection without flame-retardant additives.During combustion of PVDF only a slight amountof smoke development arises. But like every otherorganic substance also PVDF is inflammable andin adequate ambientnt temperature PVDF isinflammable.

Solubility

The PVDF-homopolymere swells in high polarsolvents e.g. acetone and ethylacetat and is solublein polar solvents, e.g. dimethylformamide anddimethylacetamide.

Advantages of PVDF

wide temperature range, high heat deflectiontemperaturevery good chemical resistance, even inconnection with high temperaturesgood resistance against UV- and γ-radiationstherefore high ageing resistanceexcellent abrasion resistance (low frictioncoefficient)very good anti-friction propertiesgood mechanical propertiesexcellent insulaing characteristics inconnection with very good electrical valuesflame retardingphysiologically non-toxicgood and easy processing

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C C

FH n

C C

F

H

H n

F

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Material Properties

General properties of ECTFE(Ethylenechlorotrifluorethylene)

ECTFE has a unique combination of properties,which results due to its chemical structure - acopolymere with a changing constitution ofethylene and chlorotrifluorethylene.

Physiological properties

ECTFE is suitable for the safe application of productsin continuous contact with food stuff accoringg to"BGA Deutschland". For avoiding every influenceof smell and taste it is recommended to clean thefood with water which has direct contact withECTFE parts.

Thermal properties

ECTFE has a remarkable resistance againstdecomposition trought heat, intensive radiationand weathering. For a long time it is resistant againsttemperatures upto 150°C and it is one of the bestplastics with a good resistance against radiation.

Resistance against the weathering

ECTFE shows only a slight change of the propertiesor apperance weathering in the sunlight. Reapedweathering tests showed a remarkable stability ofthe polymers particularly the elongation at break,which is a goot indicator for the polymer-decomposition. Even after 1000 hours in a "Weather- Ometer" with xenon-light the important propertiesare hardly influenced.

Radiation resistance

ECTFE shows an excellent resistance againstdifferent radiations. It has even good values afterirridation with 200 megarad cobalt 60.

Mechanical properties

ECTFE is a solid, very impact resistant plastic, whichhardly changes its properties over a wide range oftemperatures. Besides the good impact strengthECTFE has a good breaking strain and a goodabrasion behaviour. To emphasize is also the goodbehaviour by low temperatures, especially the highimpact strength.

Advantages of ECTFE

wide temperature application range (thermalresistance up to short-term 150°C).good resistance against UV- and γ-radiation,therefore favourable ageing resistance.flame retardent (UL 94-V0-material) -oxygen index 60excellent abrasion resistanceextreme good chemical resistance againstmost technical acids, alkalies and solvents aswell as in contact with chlorine.excellent insulating properties in connectionwith very good electrical valuesphysiological non-toxicvery good surface slip characteristics

Reproduction of microorganisms on ECTFE

The surface of a product out of ECTFE isunfavourable to the proliferation of microorganisms- as with glass. This conclusion is the result of anexamination which has been executed within theframework of an test of the HP-suitability of ECTFE.Due to these properties, ECTFE is applied in thefood and drug industry and for ultra-pure waterranges.

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Chemical structure of ECTFE

C C C C

H

Cl F

H

H H n

C C C C

H

Cl F

H

H H

C C C C

H

Cl

FH

H H n

F

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Specific properties PE

Property Standard Unit PE80 (MD) PE80 (HD) PE100 PE80-elSpecific density at 23°C ISO 1183 g/cm3 0,94 0,95 0,95 0,99Melt flow indexMFR 190/5MFR 190/2,16MFR 230/5MFI range

ISO 1133

ISO1872/1873

g/10min0,9

T012

0,50

T006

0,3<0,1

T003 T001Tensile stress at yield ISO 527 MPa 20 22 25 26Elongation at yield ISO 527 % 10 9 9 7Elongation at break ISO 527 % >600 >600 >600Impact strength unnotched at +23°CImpact strength unnotched at -30°C

ISO 179 kJ/m2 no breakno break

no breakno break

no breakno break

Impact strength notched at +23°CImpact strength notched at 0°CImpact strength notched at -30°C

ISO 179 kJ/m212

4,5

12

4,5

16

6

5,0

3,0Ball indentation hardness acc. Rockwell ISO 2039-1 MPa 36 42 46Flexural strength (3,5% flexural stress) ISO 178 MPa 18 21 24Modulus of elasticity ISO 527 MPa 750 950 1100 1150Vicat-Softening point VST/B/50 ISO 306 °C 63 72 77 83Heat deflection temperature HDT/B ISO 75 °C 60 70 75Linear coefficient of thermal expansion DIN 53752 K-1 x 10-4 1,8 1,8 1,8 1,8Thermal conductivity at 20 °C DIN 52612 W/(mxK) 0,4 0,4 0,4 0,43

FlammabilityUL94

DIN 4102--

94-HBB2

94-HBB2

94-HBB2 B2

Specificvolume resistance

VDE 0303 OHM cm >1016 >1016 >1016

≤108

Specific surface resistance VDE 0303 OHM >1013 >1013 >1013 ≤106

relative dielectric constantat 1 MHz

DIN 53483 -- 2,3 2,3 2,3

Dielectric strength VDE 0303 kV/mm 70 70 70Physiologically non-toxic EEC 90/128 -- Yes Yes Yes NeinFDA -- -- Yes Yes Yes NeinUV stabilized -- -- carbon black carbon black carbon black carbon blackColour -- -- black black black black

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Material Properties

Specific properties PP

*) ......... Fire classification B1 only valid for wall thickness of 2-10mm

Property Standard Unit PP-H PP-RPP-Bblack PP-H-s PP-R-s-el

Specific density at 23°C ISO 1183 g/cm3 0,91 0,91 0,91 0,93 1,13Melt flow indexMFR 190/5MFR 190/2,16MFR 230/5MFI range

ISO 1133

ISO1872/1873

g/10min0,5

1,25M003

1,25

0,5

1,3

0,8

2,0 0,6

Tensile stress at yield ISO 527 MPa 30 25 26 30 29,9Elongation at yield ISO 527 % 10 12 10 10Elongation at break ISO 527 % >300 >300 >50 >50 43Impact strength unnotched at +23°CImpact strength unnotched at -30°C

ISO 179 kJ/m2 no break no break no break80

no break28


ISO 179 kJ/m2 50

5

25

2

3573

102,72,4

3(IZOD)

Ball indentation hardness acc. Rockwell ISO 2039-1 MPa 60 45 50 72Flexural strength (3,5% flexural stress) ISO 178 MPa 28 20 20 37Modulus of elasticity ISO 527 MPa 1300 900 1100 1300Vicat-Softening point VST/B/50 ISO 306 °C 91 65 68 85 133Heat deflection temperature HDT/B ISO 75 °C 96 70 75 85 47Linear coefficient of thermal expansion DIN 53752 K-1 x 10-4 1,6 1,6 1,6 1,6Thermal conductivity at 20 °C DIN 52612 W/(mxK) 0,22 0,24 0,2 0,2

FlammabilityUL94

DIN 4102--

94-HBB2

94-HBB2

94-HBB2

V-2B1*)

V-0


VDE 0303 OHM cm>1016 >1016 >1015 >1015 ≤108

Specific surface resistance VDE 0303 OHM >1013 >1013 >1015 >1015 ≤106


DIN 53483 --2,3 2,3

Dielectric strength VDE 0303 kV/mm 75 70 30 bis 40 30 bis 45Physiologically non-toxic EEC 90/128 -- Yes Yes Yes Yes NoFDA -- -- Yes Yes No No NoUV stabilized -- -- No No Yes No Yes

Colour -- --Ral 7032

greyRAL 7032

grey blackRAL 7037dark grey black

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Specific porperties PVDF and ECTFE

Property Standard Unit PVDF ECTFESpecific density at 23°C ISO 1183 g/cm3 1,78 1,68Melt flow indexMFR 190/5MFR 190/2,16MFR 230/5MFI range

ISO 1133 g/10min

6

0,85

Tensile stress at yield ISO 527 MPa 50 30Elongation at yield ISO 527 % 9 5Elongation at break ISO 527 % 80 250Impact strength unnotched at +23°CImpact strength unnotched at -30°C

ISO 179 kJ/m2 124 no break


ISO 179 kJ/m211 no break

Ball indentation hardness acc.Rockwell

ISO 2039-1 MPa80 90

Flexural strength ISO 178 MPa 80 47Modulus of elasticity ISO 527 MPa 2000 1690Vicat-Softening point VST/B/50 ISO 306 °C 140Heat deflection temperature HDT/B ISO 75 °C 145 90Linear coefficient of thermal expansion DIN 53752 K-1 x 10-4 1,2 0,8Thermal conductivity at 20 °C DIN 52612 W/(mxK) 0,13 0,15

FlammabilityUL94

DIN 4102--

V-0 V-0


VDE 0303 OHM cm >1013 >1016

Specific surface resistance VDE 0303 OHM >1012 >1014


DIN 53483 --7,25 2,6

Dielectric strength VDE 0303 kV/mm 22 30 bis 35Physiologically non-toxic EEC 90/128 -- Yes YesFDA -- -- Yes in preperationUV stabilized -- -- Yes YesColour -- -- natural natural

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Material Properties

Pressure curve for pipes out of PE80

0,1 1,0 10 102 103 104 105 1060,5

0,6

0,7

0,80,91,0

2,0

3,0

4,0

5,0

6,0

7,0

8,09,0

10,0

20,0

30,0

40,0

50,0

Time to fail [h]

1 10 25 50Time to fail [years]

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tres

sσ v

[N/m

m2

]

20°C

100

10°C

30°C

60°C

40°C

80°C

50°C

70°C

1010101010

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In the table stated the data apply to water. They weredetermined from the creep curve taking into accounta safety coefficient of C=1,25.

Permissible component operating pressures pB

for PE80 dependingon temperatureandoperationperiod.

1) ...We recommendfor thecalculationof theoperatingpressure in piping systems to multiply the in thetable contined operating pressure with a systemreduction coefficient fs = 0,8 (This value containsinstallation-technical influences such as weldingjoint, flange or also bending loads.).

2) ... The operating pressure has to be reduced by thecorresponding reducing coefficients (see page 39)for every application.

41 33 26 17,6 11 7,4 6

20 16 12,5 8,3 5 3,2 2,5

2,5 3,2 4 6 10 16 20

10 5 4,0 5,0 6,3 9,4 15,8 25,3 31,610 3,9 4,9 6,2 9,3 15,5 24,8 31,025 3,8 4,8 6,0 9,0 15,1 24,2 30,350 3,8 4,7 5,9 8,9 14,8 23,8 29,7

100 3,7 4,6 5,8 8,7 14,6 23,3 29,220 5 3,4 4,2 5,3 7,9 13,2 21,2 26,5

10 3,3 4,1 5,2 7,8 13,0 20,8 26,025 3,2 4,0 5,0 7,6 12,7 20,3 25,450 3,2 4,0 5,0 7,5 12,5 20,0 25,0

100 3,1 3,9 4,9 7,3 12,2 19,6 24,530 5 2,8 3,6 4,5 6,7 11,2 18,0 22,5

10 2,8 3,5 4,4 6,6 11,0 17,7 22,125 2,7 3,4 4,3 6,4 10,8 17,3 21,650 2,7 3,3 4,2 6,3 10,6 16,9 21,2

40 5 2,4 3,1 3,8 5,8 9,6 15,5 19,310 2,4 3,0 3,8 5,7 9,5 15,2 19,025 2,3 2,9 3,7 5,5 9,2 14,8 18,550 2,3 2,9 3,6 5,4 9,1 14,5 18,2

50 5 2,1 2,6 3,3 5,0 8,4 13,4 16,810 2,0 2,5 3,2 4,8 8,1 12,9 16,215 1,8 2,2 2,8 4,3 7,1 11,4 14,3

60 5 1,4 1,8 2,2 3,3 5,6 9,0 11,370 2 1,1 1,3 1,7 2,6 4,3 6,9 8,7

Temperature[°C]

Operatingperiod[years]

Diameter-wall thickness relation SDR

Pipe series S

PN

permissible component operating pressure pB1) 2) [bar]

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Material Properties

0,1 1,0 10 102 103 104 105 1060,5

0,6

0,7

0,80,91,0

2,0

3,0

4,0

5,0

6,0

7,0

8,09,0

10,0

20,0

30,0

40,0

50,0

Time to fail [h]

Ref

eren

ce s

tres

s σ v

[N/m

m2

]

20°C

40°C

60°C


10°C

50°C

30°C

80°C

70°C

100

Pressure curve for pipes out of PE100

1212121212

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For pipes and fittings out of PE 100, a smaller wallthickness than for standard Pe results due to thehigher calculation stress. They can therefore beapplied for higher operating pressures at the samewall thickness. Please find the comparison of theSDR-serie, S-serie and PN-pressure ratings in theopposite table.

In the tables stated the data apply to water. Theywere determined from the creep curve taking intoaccount a safety coefficient of C =1,25.


for PE 100 depending on temperature andoperation period.

valid for 20°C and 50 years life time

1) ...We recommendfor thecalculationof theoperatingpressure in piping systems to multiply the in thetable contained operating pressure with a systemreduction coefficient fs=0,8 (This value containsinstallation-technical influences such as weldingjoint, flange or also bending loads.).

2) ... These operating pressure have to be reduced bythe corresponding reducing coefficients (see page39) for eyery application.

41 33 26 17 11 7,4 6

20 16 12,5 8 5 3,2 2,5

4 5 6,3 10 16 25 32

10 5 5,0 6,3 7,9 12,6 20,2 31,5 40,410 4,9 6,2 7,8 12,4 19,8 31,0 39,725 4,8 6,0 7,6 12,1 19,3 30,2 38,750 4,7 5,9 7,5 11,9 19,0 29,7 38,0

100 4,6 5,8 7,3 11,6 18,7 29,2 37,420 5 4,2 5,3 6,6 10,6 16,9 26,5 33,9

10 4,1 5,2 6,5 10,4 16,6 26,0 33,325 4,0 5,0 6,4 10,1 16,2 25,4 32,550 4,0 5,0 6,3 10,0 16,0 25,0 32,0

100 3,9 4,9 6,1 9,8 15,7 24,5 31,430 5 3,6 4,5 5,6 9,0 14,4 22,5 28,8

10 3,5 4,4 5,5 8,8 14,1 22,1 28,325 3,4 4,3 5,4 8,6 13,8 21,6 27,650 3,3 4,2 5,3 8,4 13,5 21,2 27,1

40 5 3,0 3,8 4,8 7,7 12,3 19,3 24,710 3,0 3,8 4,7 7,6 12,1 19,0 24,325 2,9 3,7 4,6 7,4 11,8 18,5 23,750 2,9 3,6 4,5 7,2 11,6 18,2 23,3

50 5 2,6 3,3 4,2 6,7 10,7 16,7 24,410 2,6 3,2 4,0 6,5 10,4 16,2 20,315 2,3 2,9 3,7 5,9 9,5 14,8 19,0

60 5 1,9 2,4 3,0 4,8 7,7 12,1 15,570 2 1,5 1,9 2,4 3,9 6,2 9,8 12,5

Temperature[°C]



Pipe series S

PN

Permissible component operating pressure pB1) 2) [bar]

SDR S PE80 PE10041 20 3,2 433 16 4 526 12,5 5 6,3

17,6 8,3 7,5 9,617 8 8 1011 5 12,5 167,4 3,2 20 25

PN-pressure rate

1313131313

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Material Properties

Pressure curve for pipes out of PP-H

0,1 1,0 10 102

103

104

105

106

0,5

0,6

0,7

0,80,91,0

2,0

3,0

4,0

5,0

6,0

7,0

8,09,0

10,0

20,0

30,0

40,0

50,0

Time to fail [h]


Ref

eren

ce s

tres

sσ v

[N/m

m2

]

20°C

40°C

60°C

70°C

80°C

95°C

100

10°C

30°C

50°C

90°C

1414141414

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In the tables stated the data apply to water. Theywere determined from the creep curve taking intoaccount a safety coefficient of C (C = 1,6 from 10- 40°C, C = 1,4 from 40 - 60°C, C = 1,25 over 60°C).


for PP-Hdependingon temperatureandoperationperiond.



3) ... Operating pressures do not apply to pipesexposed toUV radiation.Within10 years ofoperation,this influence may be compensated res. essentiallyreduced corresponding additives (e.g. carbon black)to the molding material.

4) ...The values in brackets are validat proofof longertesting periods than 1 year at the 110°C test.

41 33 26 17,6 11 7,4 6

20 16 12,5 8,3 5 3,2 2,5

2,5 3,2 4 6 10 16 20

10 1 4,5 5,7 7,2 10,9 18,1 28,7 36,15 4,2 5,2 6,6 10,0 16,6 26,3 33,1

10 4,0 5,0 6,4 9,6 16,0 25,3 31,825 3,8 4,8 6,1 9,2 15,2 24,1 30,450 3,7 4,6 5,8 8,8 14,6 23,1 29,1100 3,5 4,5 5,6 8,5 14,1 22,3 28,1

20 1 3,9 4,9 6,2 9,4 15,6 24,7 31,15 3,6 4,5 5,7 8,6 14,2 22,5 28,4

10 3,4 4,3 5,5 8,3 13,7 21,7 27,425 3,3 4,1 5,2 7,8 13,0 20,6 25,950 3,1 3,9 5,0 7,5 12,5 19,8 24,9100 3,0 3,8 4,8 7,2 12,0 19,0 23,9

30 1 3,4 4,2 5,3 8,0 13,3 21,1 26,65 3,0 3,8 4,8 7,3 12,1 19,2 24,1

10 2,9 3,7 4,6 7,0 11,6 18,4 23,125 2,8 3,5 4,4 6,6 11,0 17,4 21,950 2,6 3,3 4,2 6,3 10,5 16,6 20,9

40 1 3,3 4,1 5,2 7,8 13,0 20,6 25,95 2,9 3,7 4,7 7,0 11,7 18,5 23,3

10 2,8 3,5 4,4 6,7 11,1 17,6 22,225 2,6 3,3 4,2 6,3 10,5 16,7 21,050 2,5 3,2 4,0 6,0 10,0 15,8 19,9

50 1 2,7 3,4 4,3 6,5 10,8 17,2 21,65 2,4 3,1 3,9 5,8 9,7 15,4 19,3

10 2,3 2,9 3,7 5,6 9,3 14,7 18,525 2,2 2,7 3,5 5,2 8,7 13,8 17,350 2,1 2,6 3,3 5,0 8,3 13,1 16,5

60 1 2,5 3,3 4,0 6,0 10,1 15,9 20,15 2,2 2,8 3,6 5,4 8,9 14,2 17,8

10 2,2 2,7 3,4 5,2 8,6 13,7 17,225 2,0 2,5 3,2 4,8 8,0 12,6 15,950 1,9 2,4 3,0 4,5 7,5 11,9 15,0

70 1 2,0 2,6 3,2 4,9 8,1 12,9 16,25 1,8 2,3 2,9 4,3 7,2 11,4 14,3

10 1,7 2,2 2,7 4,1 6,9 10,9 13,725 1,4 1,8 2,2 3,4 5,6 8,9 11,150 1,2 1,5 1,9 2,9 4,8 7,6 9,6

80 1 1,6 2,1 2,6 3,9 6,5 10,4 13,15 1,4 1,8 2,2 3,4 5,6 8,9 11,1

10 1,2 1,5 1,8 2,8 4,6 7,3 9,225 - 1,2 1,5 2,2 3,7 5,8 7,3

95 1 1,2 1,5 1,8 2,8 4,6 7,3 9,25 - 1,0 1,2 1,8 3,0 4,8 6,1

(10)4) - - - (1,5)4) (2,6)4) (4,0)4) (5,1)4)

Temperature[°C]



Pipe series S

PN

Permissible component operating pressure pB1) 2) 3) [bar]

1515151515

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Material Properties

Pressure curve for pipes out of PP-R

0,1 1,0 10 102 103 104 105 1060,5

0,6

0,7

0,80,91,0

2,0

3,0

4,0

5,0

6,0

7,0

8,09,0

10,0

20,0

30,0

40,0

50,0

Time to fail [h]


Ref

eren

ce s

tres

s σ v

[N/m

m2

]

20°C

40°C

80°C

100

10°C

30°C

50°C

60°C

70°C

95°C

90°C

1616161616

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The in the tables stated the data apply to water. Theywere determined from the creep curve taking intoaccount a safety coefficient of C =1,25.Due to thedifferent mechanical properties of the specificmaterial PP-s-el, the maximum operating pressurehas to be reduced to 50%!



3) ... Operating pressures do not apply to pipesexposed toUV radiation.Within10 years ofoperation,this influence may be compensated res. essentiallyreduced corresponding additives (e.g. carbon black)to the molding material.

4) ...The values in brackets are valid at proofof longertesting periods than 1 year at the 110°C test.


for PP-Rdependingon temperatureandoperationperiod.

41 33 26 17,6 11 7,4 6

20 16 12,5 8,3 5 3,2 2,5

2,5 3,2 4 6 10 16 20

10 1 5,3 6,7 8,4 12,7 21,1 33,4 42,05 5,0 6,3 7,9 12,0 20,0 31,6 39,8

10 4,9 6,1 7,7 11,6 19,3 30,6 38,525 4,7 5,9 7,4 11,2 18,7 29,6 37,350 4,6 5,8 7,2 10,9 18,2 28,8 36,3100 4,5 5,6 7,1 10,7 17,7 28,1 35,4

20 1 4,5 5,7 7,2 10,8 18,0 28,6 36,05 4,2 5,4 6,7 10,2 16,9 26,8 33,8

10 4,1 5,2 6,5 9,9 16,4 26,1 32,825 4,0 5,0 6,4 9,6 16,0 25,3 31,850 3,9 4,9 6,2 9,3 15,5 24,5 30,9100 3,8 4,7 6,0 9,0 15,0 23,8 29,9

30 1 3,8 4,8 6,1 9,2 15,3 24,3 30,65 3,6 4,5 5,7 8,6 14,4 22,8 28,7

10 3,5 4,4 5,5 8,4 13,9 22,0 27,725 3,4 4,2 5,3 8,1 13,4 21,3 26,850 3,3 4,1 5,2 7,9 13,1 20,7 26,4

40 1 3,2 4,1 5,1 7,8 12,9 20,5 25,85 3,0 3,8 4,8 7,3 12,1 19,2 24,2

10 3,0 3,7 4,7 7,1 11,8 18,7 23,625 2,8 3,6 4,5 6,8 11,3 18,0 22,650 2,8 3,5 4,4 6,6 11,0 17,5 22,0

50 1 2,8 3,5 4,4 6,6 11,0 17,5 22,05 2,6 3,2 4,1 6,1 10,2 16,2 20,4

10 2,5 3,1 3,9 6,0 9,9 15,7 19,725 2,4 3,0 3,8 5,8 9,6 15,2 19,150 2,3 2,9 3,7 5,6 9,3 14,7 18,5

60 1 2,3 2,9 3,7 5,6 9,3 14,7 18,55 2,2 2,7 3,4 5,2 8,6 13,7 17,2

10 2,1 2,6 3,3 5,0 8,3 13,2 16,625 2,0 2,5 3,2 4,8 8,0 12,6 15,950 1,9 2,4 3,1 4,6 7,7 12,1 15,3

70 1 2,0 2,5 3,1 4,7 7,8 12,4 15,65 1,8 2,3 2,9 4,3 7,2 11,4 14,3

10 1,8 2,2 2,8 4,2 7,0 11,1 14,025 1,5 1,9 2,4 3,6 6,1 9,6 12,150 1,3 1,6 2,0 3,1 5,1 8,1 10,2

80 1 1,6 2,1 2,6 3,9 6,5 10,4 13,15 1,4 1,8 2,3 3,5 5,7 9,1 11,5

10 1,2 1,5 1,9 2,9 4,8 7,6 9,625 1,0 1,2 1,5 2,3 3,8 6,1 7,6

95 1 1,2 1,5 1,8 2,8 4,6 7,3 9,25 - 1,0 1,2 1,8 3,0 4,8 6,1

(10)4) - - (1,0)4 (1,5)4 (2,6)4 (4,0)4 (5,1)4

Temperature[°C]



Pipe series S

PN

Permissible component operating pressure pB1) 2) 3) [bar]

1717171717

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Material Properties

Pressure curve for pipes out of PVDF

Time to fail [h]

Ref

eren

ce s

tres

ss

v[N

/mm

2]

1 10 25 50100

10 102 103 104 105 1060,1 1,00,5

1,0

2,0

3,0

4,0

5,0

6,0

8,0

10,0

20,0

30,0

40,0

50,0

20°C

60°C

80°C

95°C

120°C

130°C

140°C

Time to fail [years]1 10 25 50100

10 102 103 104 105 1060,1 1,00,5

1,0

2,0

3,0

4,0

5,0

6,0

8,0

10,0

20,0

30,0

40,0

50,0

20°C

60°C

80°C

95°C

120°C

130°C

140°C

Time to fail [years]

1818181818

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for PVDFdependingon temperatureandoperationperiod.

In the tables stated the data apply to water. Theywere determined from the creep curve taking intoaccount a safety coefficient of C = 1,6.



33 21 17

16 10 8

10 16 20

20 1 11,5 18,0 21,910 11,0 17,3 21,125 10,9 17,1 20,850 10,8 17,0 20,6

30 1 10,2 16,0 19,510 10,0 15,8 19,225 10,0 15,7 19,150 9,7 15,3 18,6

40 1 9,2 14,5 17,710 9,1 14,3 17,425 9,0 14,1 17,150 8,8 13,9 16,9

50 1 8,3 13,1 15,910 8,0 12,6 15,325 7,7 12,2 14,850 7,6 11,9 14,5

60 1 7,4 11,6 14,110 7,1 11,1 13,525 7,0 11,0 13,350 6,9 10,8 13,1

70 1 6,6 10,3 12,610 6,3 9,9 12,125 6,2 9,8 11,950 6,1 9,7 11,7

80 1 5,6 8,9 10,810 5,4 8,4 10,325 5,3 8,3 10,150 5,2 8,2 9,9

95 1 4,4 6,9 8,410 4,1 6,4 7,725 3,3 5,3 6,450 2,9 4,5 5,5

110 1 3,2 5,0 6,110 2,2 3,5 4,325 1,8 2,9 3,550 1,6 2,5 3,0

120 1 2,5 4,0 4,810 1,5 2,4 2,925 1,3 2,0 2,5

Temperature[°C]



Pipe seris S

PN

Permissible component operating pressure pB [bar] 1) 2)

1919191919

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Material Properties

Pressure curve for pipes of ECTFE


for ECTFE depending on temperature andoperation period.

The in the tables stated data apply to water. Theywere detemined from the creep curve taking intoaccount a safety coefficient of C = 2,0

1) ...We recommendfor thecalculationof theoperatingpressure in piping systems to multiply the in thetable contained operating pressure with a systemreduction coefficient fs=0,8 (This value containsinstallation-technical influences such as weldingjoint, flange or also bending loads).

2) ... These operating pressures have to be reducedby the corresponding reducing coefficients (seepage 39) for eyery application.

Time to fail [h]

Ref

eren

ce s

tres

s σv

[N

/mm

2]

1 101 102 103 104 105 1061

2

345

7

10

20

304050

90°C

60°C

23°C

1 5 10 25 50

Standzeit [Jahre]

1 101 102 103 104 105 1061

2

345

7

10

20

304050

90°C

60°C

23°C

1 5 10 25 50


1 101 102 103 104 105 1061

2

345

7

10

20

304050

90°C

60°C

23°C

1 5 10 25 50

Standzeit [Jahre]

1 1011 101 102 103 104 105 1061

2

345

7

10

20

304050

90°C

60°C

23°C

1 5 10 25 50

Standzeit [Jahre]

1 101 102 103 104 105 1061

2

345

7

10

20

304050

90°C

60°C

23°C

1 5 10 25 50


21 33

10 16

10 6

20 1 11,5 7,25 10,5 6,610 10,0 6,3

60 1 6,5 4,05 6,3 3,910 6,0 3,8

90 1 3,0 1,95 2,8 1,810 2,7 1,7

Temperature

[°C]



Pipe series S

PN

Permissible component operating pressure pB [bar] 1) 2)

2020202020

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Creep modulus curves for PE 80(acc.to DVS 2205, part 1)

Reducing of the creep modulus

In the stated diagrams the calculated creep modulusstill has to be reduced by a safety coefficient of ≥ 2for stability calculations.Influences by chemical attack or by eccentricity andunroundness have to be taken into accountseparately.

Creep modulus curve for PE 100

As no valid creep modulus curves are availabel forPE 100 at the moment, we recommend to raise thefrom the diagrams for PE 80 determined creepmodulus values by 10 %.

0

50

100

150

200

250

300

0 20 40 60 80

Cre

epm

o dul

us[N

/mm

2]

Operating temperature [°C]

1

2

3

4

5

1 year

350

σ = 0,5 N/mm2

0

50

100

150

200

250

300

0 20 40 60 80

Cre

epm

o dul

us[N

/mm

2]


2

3

4

5

begi

nnin

gof

agei

ng

1

10 years

σ = 0,5 N/mm2

350

0

50

100

150

200

250

300

0 20 40 60 80

Cre

epm

odul

us[N

/mm

2]


2

34

5 begi

nnin

gof

agei

ng

25 years

350

1

s = 0,5 N/mm2

2121212121

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Material Properties

Creed modulus curves for PP-H(acc. to DVS 2205, part 1)



100

200

300

400

500

20 40 60 80

Cre

epm

odul

us[N

/mm

2]


2

3

5

1 year

100

s = 0,5 N/mm2

4

1

100

200

300

400

500

20 40 60 80

Cre

epm

odul

us[N

/mm

2]


2

3

5

1 year

100

σ = 0,5 N/mm2

4

1

100

200

300

400

500

20 40 60 80

Cre

epm

odul

us[N

/mm

2]


23

10 years

100

σ = 0,5 N/mm2

4

begi

nnin

gof

agei

ng

5

1

100

200

300

400

500

20 40 60 80

Cre

epm

odul

us[N

/mm

2]


2

25 years

100

σ = 0,5 N/mm2

4

begi

nnin

gof

agei

ng5

3

1

2222222222

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Creep modulus curves for PP-R (acc, to DVS 2205, part 1)



0

100

200

300

20 40 60 80

Cre

epm

o dul

ud[N

/mm

2]


3

1 year

100

σ = 2 N/mm2

5

400

begi

nnin

gof

age i

n g

0

100

200

300

400

20 40 60 80C

reep

mod

ulus

[N/m

m2

]


3

10 years

100

σ = 2 N/mm2

5

beg i

n nin

gof

age i

n g

0

100

200

300

400

20 40 60 80

Cre

epm

o dul

us[N

/mm

2]


25 years

100

σ = 2 N/mm2

beg i

n ni n

gof

agei

ng

4

3

2323232323

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Material Properties

Creep modulus curves for PVDF(acc. to DVS 2205, part 1) in relation to thetemperature (s=2 up to 5)

0

500

20 40 60 80

Cre

epm

odul

us[N

/mm

2]


1year

100

1000

120

10years

25 years

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Permissible buckling pressures for PP-H, PP-R andPE 80

In the table stated the data apply to water. Theywere determined taken into account a safetycoefficient of 2,0 (minimum safety coefficient forstability calculations).

1) ...This buckling pressures have been calculatedaccording to formula on page 41. These bucklingpressures have to be decreased by thecorresponding reducing factors due to chemicalinfluence or unroundness for any application.

PP-H PP-R PE80 PP-H PP-R PE80 PP-H PP-R PE80 PP-H PP-R PE8020 1 0,080 0,060 0,040 0,170 0,125 0,090 1,11 0,83 0,60 5,15 3,80 2,75

10 0,060 0,050 0,035 0,130 0,110 0,070 0,86 0,73 0,47 3,95 3,35 2,20

25 0,055 0,050 0,030 0,120 0,110 0,065 0,78 0,70 0,43 3,65 3,25 1,95

30 1 0,070 0,050 0,035 0,150 0,110 0,070 0,96 0,71 0,47 4,45 3,30 2,20

10 0,055 0,045 0,030 0,115 0,100 0,060 0,75 0,64 0,39 3,50 2,95 1,80

25 0,050 0,045 0,025 0,110 0,095 0,055 0,71 0,61 0,35 3,30 2,85 1,65

40 1 0,060 0,045 0,025 0,130 0,095 0,055 0,83 0,62 0,37 3,85 2,85 1,70

10 0,050 0,040 0,020 0,105 0,090 0,050 0,68 0,57 0,32 3,15 2,65 1,50

25 0,045 0,040 0,020 0,100 0,085 0,045 0,64 0,55 0,29 2,95 2,55 1,35

50 1 0,050 0,040 0,020 0,110 0,080 0,045 0,73 0,53 0,29 3,40 2,45 1,35

10 0,045 0,035 0,015 0,095 0,075 0,040 0,61 0,49 0,25 2,85 2,30 1,15

25 0,040 0,035 0,015 0,090 0,075 0,035 0,57 0,48 0,23 2,65 2,20 1,10

60 1 0,045 0,035 0,015 0,100 0,070 0,035 0,64 0,47 0,23 2,95 2,15 1,05

10 0,040 0,030 - 0,085 0,065 - 0,55 0,43 - 2,55 2,00 -

25 0,035 0,030 - 0,080 0,065 - 0,52 0,42 - 2,40 1,95 -

70 1 0,040 0,030 0,010 0,085 0,060 0,025 0,57 0,41 0,18 2,65 1,90 0,80

10 0,035 0,025 - 0,075 0,055 - 0,49 0,37 - 2,25 1,70 -

25 0,030 0,025 - 0,070 0,055 - 0,46 0,36 - 2,15 1,65 -

80 1 0,035 0,025 - 0,075 0,050 - 0,50 0,34 - 2,30 1,60 -

10 0,030 0,020 - 0,065 0,045 - 0,44 0,31 - 2,20 1,45 -

95 1 0,030 0,020 - 0,065 0,040 - 0,41 0,27 - 1,90 1,25 -

10 0,025 0,015 - 0,055 0,035 - 0,35 0,23 - 1,65 1,05 -

8,3 5

Permissible buckling pressure 1) [bar]

PN2,5 3,2 6 10

Operationperiod[years]

Temperature[°C]

SDR-series41 33 17,6 11

S-series20 16

-

0,50

1,00

1,50

2,00

2,50

20°C 40°C 60°C 80°C 100°C 120°C

Temperature [C°]

Buc

klin

gpr

essu

re[b

ar]

SDR 21

SDR 17

SDR 33

-

0,50

1,00

1,50

2,00

2,50

20°C 40°C 60°C 80°C 100°C 120°C

Temperature [C°]

Buc

klin

gpr

essu

re[b

ar]

SDR 21

SDR 17

SDR 33

Admissible buckling pressures for PVDF

In the tables stated the data apply to water. Theywere determined taken into account a safetycoefficient of 2,0 (minimum safety coefficient forstability calculations).

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Material Properties

Permissible buckling pressures for ventilationpipes out of PP-H and PE.

100000 Pa = 1bar

This buckling pressures were calculated with theformula from page 41 . These operating pressurehave to be reduced by the corresponding reducingcoefficients through chemical influences orunroundness .

Contained in the tables the maximum permissiblebuckling pressures in Pascal were determined takeninto account a safety coefficient of 2,0 (minimumsafety coefficient for stability calculations).

Pipe dimensionØ x s Material[mm]

10years 25years 10years 25years 10years 25years 10years 25years140 x 3,0 PP-H 4200 3800 3650 3450 3350 3100 3000 2800160 x 3,0 PP-H 2750 2500 2400 2300 2200 2050 1950 1850180 x 3,0 PP-H 1900 1750 1700 1600 1550 1400 1350 1250200 x 3,0 PP-H 1400 1250 1200 1150 1100 1050 1000 900225 x 3,5 PP-H 1550 1400 1350 1300 1250 1150 1100 1050250 x 3,5 PP-H 1100 1000 1000 900 900 850 800 750280 x 4,0 PP-H 1200 1100 1050 1000 950 900 850 800315 x 5,0 PP-H 1650 1500 1450 1350 1300 1250 1150 1100355 x 5,0 PP-H 1150 1050 1000 950 900 850 800 750400 x 6,0 PP-H 1400 1250 1200 1150 1100 1050 1000 900400 x 8,0 PP-H 3400 3050 2950 2800 2700 2500 2400 2250400 x 8,0 PE80 1850 1650 1550 1400 1250 1150 1000 900450 x 6,0 PP-H 950 900 850 800 750 700 700 650450 x 8,0 PP-H 2350 2150 2050 1950 1850 1750 1650 1550450 x 8,0 PE80 1250 1150 1050 950 850 800 700 650500 x 8,0 PP-H 1700 1550 1500 1400 1350 1250 1200 1000500 x 8,0 PE80 900 850 750 700 600 550 500 450

500 x 10,0 PP-H 3400 3050 2950 2800 2700 2500 2400 2250500 x 10,0 PE80 1850 1650 1550 1400 1250 1150 1000 900560 x 8,0 PP-H 1200 1100 1050 1000 950 900 850 800

560 x 10,0 PP-H 2400 2150 2100 1950 1900 1750 1700 1600560 x 10,0 PE80 1300 1150 1100 950 900 800 700 650630 x 10,0 PP-H 1650 1500 1450 1350 1300 1250 1150 1100630 x 10,0 PE80 900 800 750 650 600 550 500 450710 x 12,0 PP-H 2000 1850 1750 1650 1600 1500 1450 1350710 x 12,0 PE80 1100 1000 900 800 750 650 600 550800 x 12,0 PP-H 1400 1250 1200 1150 1100 1050 1000 900900 x 12,0 PE80 750 700 600 550 500 450 400 350900 x 15,0 PP-H 1900 1750 1700 1600 1550 1400 1350 1250900 x 15,0 PE80 1050 950 850 800 700 650 550 5001000 x 15,0 PP-H 1400 1250 1200 1150 1100 1050 1000 9001000 x 15,0 PE80 750 700 600 550 500 450 400 3501200 x 18,0 PP-H 1400 1250 1200 1150 1100 1050 1000 9001200 x 18,0 PE80 750 700 600 550 500 450 400 3501400 x 20,0 PP-H 1200 1100 1050 1000 950 900 850 8001400 x 20,0 PE80 650 600 550 500 450 400 350 300

Permissible buckling pressures in Pascal [Pa]for different operation temperatures and periods

20°C 30°C 40°C 50°C

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For conveying of dry abrasive acting fluidspolypropylene can only be applied conditionally.There should only be used electro-conductablemate-rials (PE-el, PP-R-s-el, PP-R-el) be-cause of apossible static load.The use for each single application has to beclarified with our technical engineering department.

Abrasion behavior according to method Darmstadt

Medium: silica sand-gravel-water-mixture 46 Vol.-% silica sand/gravel, grain size up to 30 mm

Behaviour at abrasive fluids

In principle, thermoplastic pipes are better suitedfor the conveying of fluid-solid-mixtures than e. g.concrete pipes or also steel pipes. We have alreadyresulted positive experiences of differentapplications.At the of the Technische Hochschule Darmstadtdeveloped method, a 1 m long half-pipe is tiltedwith a frequency of 0,18 Hz. The local deductionof the wall thickness after a certain loading time isregarded as measure for the abrasion.The advantage of thermoplastic pipes for thetransportation of solids in open channels can clearlybe seen from the test result.

Abrasion time of HDPE- and Steel elbowsof different bending radii in dependance on solidportion

In a more practical tests the medium is pumpedthrough pipe samples which are built-in in a pipingsystem. A possibility to check the abra-sionbehaviour of such a system is to determine thetime until the arising of a hole. As it can been seenfrom the opposite diagram, thermoplastic pipes (inthis special case, PE pipes have been appliedwhereby with PP pipes the same or slightly betterresults will be achieved) have an essential advan-tage compared with steel pipes.

0 50 100 150 200 250 300 350 400 450

0,5

1,0

1,5

2,0

0

0,25PPorPEHD- pipe

PVC - pipe

stonewarepipe

withMC-DURcoatedconcretepipe

concretepipe

numberof alternations of lads

x 1000

mediumabrasionam inmm

GFK - pipe

straightpipe

30xda

20xda

15xda

10xda

6xda

120001000080006000400020000 1600014000

7% 14%14% 7%Fluid medium water with 7 resp. 14% sanddensity 1,07 bzw. 1,15 kg/lWater temperature 30 - 35°CFlow velocity approx. 7 m/s

Abrasion time in hours until the arising of a hole

bend

rad

ius

r

Steel pipe Ø63x6mm PEHD pipe Ø 63x6mm

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Material Properties

In comparison to metals where an attack ofchemicals leads to an irreversible chemical changeof the material, it's mostly physical processes atplastics which reduce the utility value. Suchphysical changes are e.g. swelling and solutionprocesses at which the composition of the plasticscan be changed in this way that the mechanicalproperties are affected. There have to be takenreducing factors into consideration at the design offacilities and parts of those in such cases.

PE und PP are resistant against diluted solutions ofsalts, acids and alkalis if these are not strongoxidizing agents. Good resistance is also givenagainst many solvents, such as alcohols, esters andketones.At contact with solvents, as aliphatic and aromaticcompound, chlorinated hydroxycarbon, you haveto reckon upon a strong swelling, especially atraised temperatures. But a destruction commencesonly rarely.The resistance can be strongly reduced by stresscracking corrosion due to ampholytiocs (chromicacid, concentrated sulphuric acid).

Lyes

AlkalisDiluted alkali solutions (e. g. caustic lye), even athigher temperature and with higher concentrationsdo not react with PP and PE and can therefore beapplied without problems, unlike to PVDF or otherfluoroplastics.

Bleaching lyeAs these lyes contain active chlorine, only aconditional resistance is given at roomtemperature.At higher temperatures and concentrations of theactive chlorine, PP and PE are rather only suitablefor pressureless piping systems and tanks.

HydrocarbonsPP is only conditionally resistant againsthydrocarbons (benzine as well as other fuels)already at ambient temperature (swelling > 3 %).PE however can be used for the conveying up totemperatures of 40°C and for the storage of thesemedia up to temperatures of 60°C.Only at temperatures > 60°C is PE conditonallyresistant as the swelling is > 3 %.

Acids

Sulphuric AcidConcentrations up to approximately 70% changethe properties of PP and PE only slightly.Concentrations higher than 80 % cause already atroom temperature oxidation. At highertemperatures, this oxidation can even go to acarbonization of the surface of the PP semi-finishedproducts.

Hydrochloric acid, hydrofluoric acidAgainst concentrated hydrochloric acid andhydrofluoric acid, PP and PE are chemically resistant.But there appears a diffusion of HCl (concentrations> 20 %) and of HF (concentrations > 40 %) at PP,which does not damage the material, but causessecondary damages on the surrounding steelconstructions.Double containment piping systems have provenfor such applications.

Nitric acidHigher concentrated nitric acid has an oxidizingeffect on the materials. The mechanical strengthproperties are reduced at higher concentrations.

Phosphoric acidAgainst this medium, PP and PE is also at higherconcentrations and at raised temperatures resistant.

For more detailed information regarding thechemical resistance of our products, our applicationengineering department will be at your disposal atany time.

General chemical properties of PE & PP

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Chemical resistance PVDF

PVDF is resistant to a wide range of chemicals.

It has an outstanding resistance to most anorganicand organic acids, oxidising media, aliphatic andaromatic hydrocarbons, alcohols and halogenatedsolvents.

PVDF is also resistant to halogens (chlorine,bromine, iodine), but not fluorine.

Generally PVDF is unsuitable for the followingmedia, because they can lead to decomposition:

- amine, basic media with a index of pH > 12- joints, which can produce free radicals under

certain circumstances- smoking sulfuric acid- high polar solvents (acetone, ethyl acetate,

dimethyl-formamide, dimethylsulphoxide, ...);here PVDF can solve or swell.

- melted alkaline metals or amalgam.

Please note that there is the possibility of tensioncrack development (stress cracking). This canhappen when PVDF is situated in a milleu with apH-factor > 12 or in the presence of free radicals(for example elemental chlorine) and it is exposedto a mechanical use in the same time.

Maximum permissible H2SO4-concentrationdepending on temperature based on the burstingstrength of the PVDF pipes.

Maximum permissible H2SO4 - concentration

Example: sulfuric acid

PVDF is exposed to the attack of concentratedsulfuric acid. Through free SO3 in the sulfuric acidtension chrack development (stress cracking) canhappen if it is also exposed to a mechanical use.Among high temperatures the concentration offree SO3 even by strong diluted sulvuric acidsolution can lead to tension chrack development.

To determine the permissible pressure in presenceof sulfuric acid and depending on the temperaturewe have analysed the behaviour of pipes out ofPVDF by different pressures and temperatures inthe DECHEMA-bracket.

The following essential paramenters should beconsidered in every cases:

100

50

60

70

80

90

1501251007550250

Temperature [°C]

Con

cent

ratio

n[%

]

Properties of the finished piece out of PVDF

Chemical structure and physical state of thejoint(s), which come in contact with the fittingout of PVDF.

Concentration

Temperature

Time

Possible diffusion or solubility

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Material Properties

ECTFE has an outstandingly good chemicalresistance and a remarkable barrier-property. Itpracticaly won´t be attacked from most ot theindustrial used corrordible chemicals, e.g. strongmineral and oxidized acids, alkaline, metal-etching-products, liquid oxygen and all organic solvents,except hot amines (z.B. aniline, dimethylamine).

The constancy datas for solvents in the followingtable were tested with undiluted solvents. Achemical attack depends on the concentration, bylower concentration of the listed media is expecteda smaller effect as shown in the table.

Like other fluorine plastics ECTFE will be attackedby sodium and potassium. The attack depends onthe induction period and the temperature. ECTFEand other fluorinepolymeres can swam in contactwith special halogenated solvents;this effect has normally no influences on theusability. If the solvent is taken away and the surfaceis dry, the mechanical properties come back to theirorigin values, which shows that no chemical attacktake place.

U-InsignificantA-Reduction by 25-50%B-Reduction by 50-75%C-Reduction by > 75%

Chemical resistance ECTFE

Chemical Temperature Weight gain Influence on Influence on[°C] [%] tensile modulus elongation at break

Mineral acidSulfuric acid 78% 23 < 0,1 U U

121 < 0,1 U UHydrochloric acid 37% 23 < 0,1 U U

75-105 0,1 U UHydrochloric acid 60% 23 < 0,1 U UChlorosulfonic acid 60% 23 0,1 U UOxidizing acidNitric acid 70% 23 < 0,1 U U

121 0,8 A CChromic acid 50% 23 < 0,1 U U

111 0,4 U UAqua regia 23 0,1 U U

75-105 0,5 U USolventsAliphates 23 0,1 U U

Hexane 54 1,4 A UIsooctane 23 < 0,1 U U

116 3,3 A UAromates

Benzene 23 0,6 U U74 7 C U

Toluene 23 0,6 U U110 8,5 C U

AlcoholesMethanol 23 0,1 U U

60 0,4 A UButanol 23 < 0,1 U U

118 2,0 A UClassical plasticsolventsDimethyl formamide 73 2,0 A U

250 7,5 C UDimethyl sulphoxide 73 0,1 U U

250 3,0 U U

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Medium 1) 2) Testing Medium 1) 2) Testing

Share strength Share strength

[%] [N/mm²] PEHD PP [%] [N/mm²] PEHD PP

aceto-acetic ester O 100 2,0...3,0 60 calcium sulfide CaSO3 A ≤ GL 60 80

acetic H 60 95 carbon dioxide, gaseous CO2 A each 60 60

air O2N2 A 100 60 95 caustic soda NaOH A/M 50 4,0...2,0 60

alum (Me(I)- Me(III)-sulfate) A ≤ GL 60 60 cider O H 60 60

aluminiumchloride AlCl3 A ≤ GL 60 80 citric acid (CO2H).CH2.CO2H O ≤ 10 60 95

aluminium sulfate Al2(SO4)3 A ≤ GL 60 80 copper (II)-chloride CuCl2 A ≤ GL 60 60

ammonia, liquid NH3 A TR 60 20 copper (I)-cyanide CuCN A ≤ GL 60 60

ammonia, gaseous NH3 A TR 60 60 copper electrolyte solution A 20/5 4,0...2,0 60

ammonia solution NH4OH A ≤ GL 60 60 copper (II)-nitrate, liquid Cu(NO3)2 A ≤ 30 60 95

ammonium acetate CH3COONH4 A ≤ GL 60 80 copper (II)-sulfate CuSO4 A ≤ GL 60 60

ammonium bromide NH4Br A ≤ GL 60 80 dextrose O ≤ 20 60 60

ammonium carbonate (NH4)2CO3 A ≤ GL 60 80 ethylene glycol CH2OH . CH2OH O 100 4,0...2,0 60

ammonium chloride NH4Cl A ≤ GL 60 80 ferric (II)- and (III)-chloride A ≤ GL 60 60

ammonium fluoride NH4F A < 10 60 80 fruit juice O H 60 95

ammonium hydrogen carbonate NH4HCO A ≤ GL 60 80 fructose O > 10 60 95

ammonium nitrate NH4NO3 A ≤ GL 60 80 hexanol C6H13OH O 100 3 60

ammonium phosphate (NH4)3PO4 A ≤ GL 60 80 hydrogel-emulsion (pH-value = 9,5) 100 95

ammonium sulfate (NH4)2SO4 A ≤ GL 60 80 hydroxyl ammonia sulfate O ≤ 12 60 60

ammonium sulfide (NH4)2S A ≤ GL 60 80 kitchen salt solution NaCl A 25 60 95

antifreezing compound M 100 5,0...3,0 60 lead acetate A ≤ GL 60

apple juice O H 60 95 lead sulfate PbSO4 A ≤ GL 60 20

bariumcarbonate BaCO3 A ≤ GL 60 80 magnesium carbonate MgCO3 A ≤ GL 60 80

bariumchloride BaCl2 A ≤ GL 60 80 magnesium chloride MgCl2 A ≤ GL 60 80

bariumhydroxide Ba(OH)2 A ≤ GL 60 80 magnesium hydrogencarbonate A ≤ GL 60 80

bariumnitrate Ba(NO3)2 A ≤ GL 60 80 magnesium salts A/M ≤ GL 60 60

barium sulfate BaSO4 A ≤ GL 60 80 magnesium sulfate MgSO4 A ≤ GL 60 80

barium sulfide BaS A ≤ GL 60 60 manuring salts A ≤ GL 60 60

barium salts A/M ≤ GL 60 95 mercury salts A/M ≤ GL 60 60

battery acid A H 60 60 methanol CH3OH O 100 4,0...2,0 60

beer O H 60 95 milk O H 60 95

borax Na2B4O7 A ≤ GL 60 60 mineral water A H 60 95

buttermilk O H 60 95 mono ethyl amine CH3.CH2.NH2 O 100 2,5...1,5 95

cadmiumchloride CdCl2 A ≤ GL 60 80 natural gas (main content CH4) O 100 4,0...2,0 60

cadmiumcyanide Cd(CN)2 A ≤ GL 60 80 natural gas condensate O 100 2 60

calcium acetate (CH3COO)2Ca M ≤ GL 60 80 nickel salts A ≤ GL 60 60

calcium bromide CaBr2 A ≤ GL 60 80 octanol C6H17OH O 100 5 40

calcium carbonate CaCO3 A ≤ GL 60 80 O 100 4,0...2,0 60

calcium chloride CaCl2 A ≤ GL 60 80 oxygen O2 A 100 4,0...2,0 60

calcium fluoride CaF2 A ≤ GL 60 80 phosphate A ≤ GL 60 60

calcium hydroxide Ca(OH)2 A ≤ GL 60 80 phosphoric acid H3PO4 A 75 4,0...2,0 60

calcium nitrate Ca(NO3)2 A ≤ GL 60 80 potassiumhydroxide KOH A ≤ 50 60 60

calcium sulfate CaSO4 A ≤ GL 60 80 potassiumborate K2B4O7 A ≤ GL 60 80

[°C] [°C]

Temperature Temperature

Media list for chemical resistance factors fCR=1(acc. DVS 2205, part 1)

The values stated are for those media for which afCR factor of 1 has to be applied due to many yearsof experiences. The in the table containedtemperatures are maximum temperatures uptowhich the resistance factor is valid.

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Material Properties


The values stated are for those media for which afCR factor of 1 has to be applied due to many yearsof experiences. The in the table containedtemperatures are maximum temperatures uptowhich the resistance factor is valid.

Medium 1) 2) Testing Medium 1) 2) Testing

Share strength Share strength

[%] [N/mm²] PEHD PP [%] [N/mm²] PEHD PP

potassium bromate, liquid KBrO3 A ≤ 10 60 60 sodium hydrogensulfate NaHSO4 A ≤ GL 60 80

potassium carbonat K2CO3 A ≤ GL 60 80 sodium hydrogensulfite NaHSO3 A > 10 60 80

potassium chlorate KClO3 A ≤ GL 60 60 sodium nitrate NaNO3 A ≤ GL 60 80

potassium chloride KCl A ≤ GL 60 80 sodium nitrite NaNO2 A ≤ GL 60 80

potassium cyanide KCN A ≤ GL 60 80 sodium phosphate Na3PO4 A ≤ GL 60 80

potassium fluoride KF A ≤ GL 60 80 sodium silicate Na2SiO3 A ≤ GL 60 80

potassium hexacyanoferrate- (II) + (III) A ≤ GL 60 80 sodium sulfate Na2SO4 A ≤ GL 60 80

potassium hydrogencarbonate KHCO3 A ≤ GL 60 80 sodium sulfide Na2S A ≤ GL 60 80

potassium iodide KJ A ≤ GL 60 80 sodium sulfite, liquid Na2SO3 A ≤ GL 60 80

potassium nitrate KNO3 A ≤ GL 60 80 sodium tetraborate Na2B4O7 A ≤ GL 60 80

potassium phosphate KH2PO4 A ≤ GL 60 80 sodium thiosulfate Na2S2O3 A ≤ GL 60 60

potassium sulfate K2SO4 A ≤ GL 60 80 sodium hydroxid NaOH A/M 50 4,0...2,0 60

salmiac NH4OH A ≤ GL 60 60 spirits O H 60 60

sulphuric acid H2SO4 A 40 3 60 95 starch O each 60 60

78 4,0...2,0 60 sugar syrup

85 3 60 tartaric acid C4H6O6 O ≤ 10 60 60

sea water A H 60 80 tin (II)-chloride SnCl2 A ≤ GL 60 80

silver nitrate AgNO3 A ≤ GL 60 60 tin (VI)-chloride SnCl4 A ≤ GL 60 80

silver salts M ≤ GL 60 60 transformer oil O 100 3 60

soda Na2CO3 A ≤ 50 60 60 100 2 60

sodium acetate CH3COONa A ≤ GL 60 80 triacethyl glycerine O 100 4,0...2,0 60

sodium bromide NaBr A ≤ GL 60 80 urea CO(NH2)2 O ≤ GL 60 60

sodium carbonate, liquid Na2CO3 A ≤ 50 60 80 water H2O A 100 60 95

sodium chlorate NaClO3 A ≤ GL 60 60 wine M H 60 60

sodium chloride NaCl A ≤ GL 60 80 yeast O each 60 60

sodium hydrogencarbonate NaHCO3 A ≤ GL 60 80 zinc salts A/M ≤ GL 60 80

[°C] [°C]

Temperature Temperature

Footnotes1)

2)

A: anorganic substanceO: organic substanzM: mixture out of anorganic and organic substances

GL: saturated ( at 20°C ) , diluted solutionTR: technical clean mediumH: commercially available composition or as present

in nature

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Medium 1) 2) Testing Testing

Share strength strength

[%] [N/mm²] 80°C 60°C 40°C 20°C [N/mm²] 95°C 80°C 60°C 40°C 20°C

acetic acid CH3COOH O 60 5,0...2,0 1,72

4,0...2,0 1,25 1,43 1,64 6) 1,85 6)

98 5,0 3,85 5,00

4,0 1,67 3,45 4,76 5,56

3,0 1,67 5,00 5,56 6,67

2,0 1,67 7,69 8,33 8,33

aceto-acetic ester O 100 4,0 1,25

aceto-acetic acid methyl ester O 100 4,0...2,0 1,18

alkaline solution 4) M 100 4,0...2,0 2,00

antifreezing compound M 50 5,0 1,67

benzine C5H12 to C12H26 O 100 4,0 1,47 1,59 1,72 6) 1,85 6)

3,0 1,28 1,33 1,39 6) 1,45 6)

2,0 1,06 1,08 1,09 6) 1,10 6)

benzol C6H6 O 100 4,0 1,33 1,37 1,41 6) 1,45 6)

3,0 1,16 1,09 1,02 6) 1,00 6)

chloroform CHCl3 O 100 4,0 2,22

3,0 2,10

2,0 1,82

chromic acid H2Cr2O4 A 10 4,0...2,0 1,43 1,61 1,89 2,04 6)

20 5,0 2,86 4,76

4,0 1,72 2,38 3,23 5,56

3,0 2,00 2,78 4,00 6,67

2,0 2,63 3,57 5,00 9,10

chromic-sulphuric acid A 100 5,0...3,0 > 100

decylhydride C10H22 O 100 4,0 1,39

2,0 1,05

desinfectant M 100 4,0...2,0 1,54

dichloroethylene CH2 = CCl2 O 100 5,0...2,0 > 100

dimethylsulfate (CH3)2SO4 O 100 4,0...2,0 1,15

etyhlene chloride C2H4Cl2 O 100 4,0...2,0 1,11

formaldehyde CH2O O 40 5,0...2,0 1,61

fuel oil O 100 4,0 1,43

3,0 1,25

2,0 1,06

hexanol C6H13OH O 100 4,0 1,11

hydraulic oil O 100 2,5...1,5 2,33

hydrochloric acid HCl A 20 3,0...1,5 1,11

30 3,0...1,5 2,13 1,75

33 4,0...2,0 1,33

methylene chloride CH2Cl2 O 100 4,0 1,49 1,47 1,45 6) 1,43 6)

3,0 1,25 1,28 1,32 6) 1,35 6)

2,0 1,05 1,06 1,08 6) 1,09 6)

natural gas condensate (mixture of O 100 5,0 > 7a 7)

aromatic and aliphatic compounds) 4,0 1,28

3,0 1,11

PE PP


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Material Properties

Medium 1) 2) Testing Testing

Share strength strength

[%] [N/mm²] 80°C 60°C 40°C 20°C [N/mm²] 95°C 80°C 60°C 40°C 20°C

nitric acid HNO3 A 15 3,0...1,5 1,67

50 3,0...1,5 3,13

53 5,0...2,0 3,30 2,00 2,00

65 4,0...2,0 3,30

nitric acid + hydrofluric acid A 15 + 4 3,0...1,5 2,00

oil, unfractionated (mixture of O 100 4,5 1,35 > 25a 7)

aromatic and aliphatic compounds) 4,0 1,25

2,8 1,00 > 25a 7)

peanut oil O 100 5,0...3,0 1,37

phosphoric acid H3PO4 A 75 3,0...1,5 1,43

polysufides MeS1+X A 100 4,0...2,0 1,33

sewage of a cellulose factory 4) M 100 4,0...2,0 1,05

sewage of a synthetic fibre fabric 3) M 100 4,0...2,0 1,33

sewage of a whey utilization 3) M 100 4,0...2,0 1,37

sodium hydroxide NaOH A 30 3,0...1,5 1,43

sulphuric acid H2SO4 A 85 2,0 3,30 3,0...1,5 1,67

90 3,0 2,00

2,0 9,09

95 3,0 10,0

2,0 > 100

98 5,0 2,86

4,0 2,44 3,33 5,56

3,0 20,0 3,85 4,17 7,14

2,0 > 100 7,69 5,56 10,0

tetrachloromethane CCl4 O 100 4,0 1,43 1,54 1,67 6) 1,79 6)

3,0 1,25 1,43 1,67 6) 1,85 6)

2,0 1,05 1,25 1,49 6) 1,75 6)

toluene C6H5CH3 O 100 4,0 1,54

3,0 1,33

2,0 1,05

transformer oil O 100 4,0 1,33 1,18 1,04 6)

3,0 1,19

trichlorofluoromethane CCl3F O 100 4,0...2,0 1,82 1,43 1,12 6)

1, 3, 5 trimethylbenzol C6H3(CH3)3 O 100 4,0 1,54

3,0 1,33

2,0 1,11

water with surface active-agent M 2 4,0...2,0 1,67

PE PP


Footnotes1)

2)

3)4)

5)

6)

A: anorganic substancesO: organic substancesM: mixture out of anorganic and organic substancesGL: saturated ( at20°C ), diluted solutionTR: technical clean mediumH: commercial available composition or as present

in the nature

not transferable to other sewage88,25 parts water, 10 parts sodiumperchlorat, 1 partsodiumhydroxid, 0,25 parts Anilin, 0,25 partsmonochlorobenzol, 0,25 parts toluoldiamineextrapolated values acc.Doc. ISO/TC 138/SC 3N 382 ( version 20.08.83 )time to fail in years

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Storage

At the storage of pipes and fittings, the below statedregulations have to be observed in order to avoid aquality decrease:

The storage area has to be even and free fromwaste, such as stones, screws, nails, etc.

At piling of pipes, storage heights of 1 m may notbe exceeded. In order to avoid a rolling away of thepipes, wooden wedges have to be situated at theoutside pipes. At pipes > OD 630mm, maximumtwo rows may be stored on top of one another.Pipes > OD 1000mm have to be stored loosely.

Pipes have to be stored flat and without bendingstress, if possible in a wooden frame.

Natural and grey coloured products have to beprotected against UV radiation at a storage outdoors.Yellow PE pipes may be stored up to 9 monthsoutdoors.

Pipes and fittings out of PP-R-s-el and PE-el have tobe protected at storage against humidity and UVradiation (no outdoor exposure, use of dry ware-houses).

Attention!As the special types PP-R-s-el and PE-el suffer thedanger of absorption of humidity at a storage period

Transport and handling

At the transport and handling of pipes and fittings,the following guidelines have to be observed inorder to avoid damages:

Pipes out of PP-H, special materials (PP-R-s-el, PP-H-s, PE-el) and prefabricated components (forexample segmented bends) may only be loadedresp. transported with special care at pipe walltemperatures below 0°C.

Impact- and bending stresses at temperatures <0°C have to be avoided.

Damages of the surface (scratches, marks, ...), asthey occur at dragging of pipes, have to be avoided.

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General Installation guidelines

Due to the lower stiffness and rigidity as well asthe potential length expansions (caused by changesin temperature) of thermoplastics in comparisonwith metallic materials, the requirements for thefixing of piping elements should be met.

On laying of pipes above ground expansion andcontractions of pipes in both radial and axialdirections must not be hindered - that means,installation with radial clearance, position ofcompensation facilities, control of changes in lengthby reasonable arrangement of fixed points.

Attachments have to be calculated so as to avoidpin-point stresses, that means the bearing areashave to be as wide as possible and adapted to theoutside diameter (if possible, the enclosing anglehas to be chosen > 90°).

The surface qualities of the attachments shouldhelp to avoid mechanical damage to the pipesurface.

Valves (in certain cases also tees) should basicallybe installed on a piping system as fixed points. Valveconstructions with the attachment devices beingintegrated within the valve body are mostadvantegous.

Fixing by means of pipe clips

Attachments made of steel or of thermoplasticsare available for plastics pipes. Steel clips have atany rate to be lined with tapes made of PE orelastomers, as otherwise the surface of the plasticspipe may be damaged. AGRU plastics pipeclips as well as pipe holders are very good suitablefor installation. These may be commonly appliedand have especially been adjusted to the tolerancesof the plastics pipes.

Therefore they serve e. g. as sliding bearing athorizontal installed piping systems in order to takeup vertical stresses. A further application range ofthe AGRU pipe clip is the function as guidingbearing which should hinder a lateral buckling ofthe piping system as it can also absorb tranversalstresses.

It is recommended for smaller pipe diameters (<da 63mm), to use steel half-round pipes as supportof the piping system in order to enlarge the supportdistances.

Installation temperatureA minimum installation temperatur of >0°C is toobserve.

Installation guidelines for electro-conductablematerials

The general installation guidelines are validfundamentally.At the installation of earthing clips it has to be takencare that the pipe surface below the clip is abraded.It is therefore absolutely necessary to remove theeventually present oxide film in order to be able toguarantee the necessary surface resistance of< 106 Ohm.

At flange joints, electro-conductable flanges or steelflanges have to be applied.

The end-installed and connected to earth pipingsystem has to be subjected to a final evaluation bycompetent pro-fessional employees regarding thebleeder resistors in any case.

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Machining of PP and PE(valid for cutting, turning, milling and drilling)

Machining of PVDF and ECTFE

The machining of PVDF and ECTFE fittings andpipes can be carried out without any particularproblems if the following guidelines are observed:

If necessary, remove remaining stresses of largersurfaces by annealing before processing.

The cutting speed, conveying and cutting geometryshould be designed in a way that any subsequentheat can mainly be removed through the shavings(too much pre-heating can lead to melding resp.discolouration of the processed surface).

All usual metal and wood processing machines maybe applied.

Cutting

Clearance angle α [°] 30 ÷ 40 Band saws are appropriate for the cuttingRake angle γ [°] 0 ÷ 5 of pipes, blocks, thick sheetsPitch t [mm] 3 ÷ 5 and for round barsCutting speed [m/min] upto 3000Cutting

Clearance angle α [°] 10 ÷ 15 Circular saws can be used for theRake angle γ [°] 0 ÷ 15 cutting of pipes, blocks and sheets.Pitch t [mm] 3 ÷ 5 HM saws have a considerablyCutting speed [m/min] upto 3000 longer working lifeTurning

Clearance angle α [°] 5 ÷ 15 The peak radius ( r ) should be at leastRake angle γ [°] 0 ÷ 15 0,5mm. High surface quality is obtainedTool angle λ [°] 45 ÷ 60 by means of a cutting tool with a wideCutting speed [m/min] 200 ÷ 500 finishing blade.Feed [mm/Umdreh.] 0,1 ÷ 0,5 Cut-off: Sharpen turning tool like a knife.Cutting depth a [mm] upto 8Milling

Clearance angle α [°] 5 ÷ 15 High surface quality is obtained byRake angle γ [°] upto 10 means of a milling machine with fewerCutting speed [m/min] upto 1000 blade - this increases cutting capacity.Feed [mm/Umdreh.] 0,2 ÷ 0,5Drilling

Clearance angle α [°] 12 ÷ 16 Spiral angles 12 - 15°. For holes withRake angle γ [°] 3 ÷ 5 diameters of 40 - 150mm, hollow drillsCentre angle ϕ [°] approx. 100 should be used; for holes < 40mmCutting speed [m/min] 50 ÷ 100 diameter, use a normal SS-twist drill.Feed [mm/Umdreh.] 0,1 ÷ 0,3

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System of units

Size Technical system SI - unit ASTM - unitof units (MKS-system)

Legal unitLength m m ft

1m = 10dm = 100cm = 1000mm 1,609km(statute) =1000m = 1km 1Meile = 1,852km (naut.)

= 1Meile0,9144m = 1yd = 3ft

25,4mm = 1 inchArea m² m² yd²

1m² = 100dm² = 10000cm² 0m836m² = 1yd1yd² = 9ft²

Volume m³ m³ yd³

1m³ = 103dm³ = 106cm³ 0,765m³ = 1yd³1yd³ = 27ft³

Force kp N

1N = 0,102kp 1N = 1kgm/s² = 105 dyn lb1kp = 9,81N 1lbf = 4,447N = 32poundals

Pressure kp/m² bar psi

1N/cm² = 0,102kp/cm² 1bar = 105Pa = 0,1N/mm² 1bar = 14,5psi

0,1bar = 1mWS 106Pa = 1MPa = 1N/mm² = 14,5lb/sq in1bar = 750Torr

1bar = 750 mmHg1bar = 0,99atm

Mechanical kp/mm² N/mm² psistress 1N/mm² = 0,102kp/mm² 1N/mm² = 145,04psi

= 145,04lb/sq inVelocity m/s m/s ft/sec.

1m/s = 3,2808ft/sec.Density g/cm³ g/cm³ psi

1g/cm³ = 14,22x10-3psiVolume m³ m³ cu ft

1m³ = 35,3147 cu ft= 1,3080 cu yd

1cm³ = 0,061 cu inTemperature °C °C °F

1°C = 1°K °F = 1,8 x °C + 32

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SDR - Standard Dimension Ratio

dadadass

sdaSDR =

SDR ... Diameter - wall thickness relation

da ... outside diameter [mm]

s ... wall thickness

Example:da = 110 mms = 10 mm

1110110 ===

sdaSDR

Component operating pressure

S - series

21−= SDRS

SDR ...Diameter - wall thickness relation

Example:SDR11

52111

21 =−=−= SDRS

Bp ... Component operating pressure [bar]

vσ ... Reference strength [N/mm²]

(see the pressure curve for each material)

SDR ... Standard Dimension Ratio

minC ... Minimum safety factor

(see following table)

Example:PE 100, 20°C, 50 years, wather (d.h. σv=10)SDR11Cmin=1,25

min)1(20

CSDRp vB ⋅−

⋅= σ 1625,1)111(

1020)1(

20

min

=⋅−

⋅=⋅−

⋅=CSDR

p vB

σ

Material10 bis 40°C 40 bis 60°C über 60°C

PE 80PE 100PP-H 1,6 1,4 1,25PP-RPVDFECTFE 2,0

Temperatur

1,25

1,251,6

1,25

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Operating pressure for water-dangerous media

In order to calculate the respective permissiblehighest operating pressure at the conveying ofwater-dangerous fluids, the operating pressure asinitial value can be looked up for the correspondingparameter in the relevant table for permissiblesystem operating pressures (valid for water).Then, this operating pressure has to be reduced bythe relevant reducing coefficients.The total safetycoefficient is thereby in all cases 2,0 at a minimum,at impact sensitive modified materials higher (atPE 80-el 2,4, at PP-R-el and PP-R-s-el 3,0).

ap ...Operating pressure of the relevant

application [bar]

Bp ...Component operating pressure, valid for

water [bar] (see page 10 to 19)

APf ....application factor

is an additional reducing factor which resultsa total safety coefficient of 2,0 at a minimumby multiplication with the C-factors according

to DIN (see following table).

CRf ....Chemical resistance factor according

to DVS (see page 30 - 33)

ZA ...Reducing factor for the specific tenacity

ZCRAP

Ba Aff

pp⋅⋅

=

Application factors fAP for water-dangerous media

Reducing factor AZ for the specific tenacity by lowtemperatures

Example:PE 100, 20°C, 50 years, water (d.h. σv=10)SDR11Cmin=1,25Chemicals: HNO3 (nitric acid), Concentration 53%,fCR = 2,0 (acc. DVS 2205, part 1)

510,26,1

16

1625,1)111(

1020)1(

20

min

=⋅⋅

=⋅⋅

=

=⋅−

⋅=⋅−

⋅=

ZCRAP

Ba

vB

Affpp

CSDRp σ

*) ... not applicable

Werkstoff-10°C +20°C

PE 80 1,2 1,0PE 100 1,2 1,0PE-el 1,6 1,4PP-H 1,8 1,3PP-R 1,5 1,1PP-R-el *) 1,5PP-R-s-el *) 1,7PVDF 1,6 1,4

BetriebstemperaturMaterial Temperature

Total securityfactor by 20°CTotal safety

factor by 20° CTotal safety factor

by 20°C(fAP x C)

PE 80 1,6 1,25 2,0PE 100 1,6 1,25 2,0PE-el 1,9 1,25 2,4PP-H 1,25 1,6 2,0PP-R 1,6 1,25 2,0PP-R-el 2,4 1,25 3,0PP-R-s-el 2,4 1,25 3,0PVDF 1,25 1,6 2,0ECTFE 1,0 2,0 2,0

MaterialC - factor

(acc. ISO 12162)

Applicationfactor

fAP

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Calculation of the permissible wall thickness smin

In general strength calculations of thermoplasticpiping systems are based on long term values. Thestrength values depanding on temperature aregiven in the pressure curves (see page 9 to 19).After calculation of the theoretical wall thicknessthe construction wall thickness has to bedetermined under consideration of the nominalpressure resp. SDR-class. Additional wall thicknesshave to be considered (e.g. application of PP pipingsystems outdoor without UV - protection ortransport abrasive media).

mins ....Minimum wall thickness[mm]

p ....Operating pressure [bar]

da ....Pipe outside diameter [mm]

zulσ ....Reference stress [N/mm2]

vσ ... Reference stress [N/mm2]

minC ...Minimum safety factor (see page 38)

If necessary, the reference stress vσ and. the

operating pressure p can also be calculted fromthis formula.

pdapszul +⋅⋅=

σ20min

minCv

zulσσ =

Example:PE 100, 20°C, 50 years, water (i.e. s v=10)Operating pressure 16barOutside diameter da=110mm

1016820

1101620

825,110

min

min

=+⋅

⋅=+⋅

⋅=

===

pdaps

C

zul

vzul

σ

σσ

( )

1025,18

81020

)10110(1620

min

min

min

=⋅=⋅=

=⋅

−⋅=⋅−⋅=

cssdap

zulv

zul

σσ

σ( )

min

min

20 ssdap

zul ⋅−⋅=σ

min

min20sdasp zul

−⋅⋅= σ

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kp ....Critical buckling pressure [bar]

cE ....Creep modulus (see tables page 20 - 23)

[N/mm2] for t=25aµ ....Transversal contraction factor

(for thermoplastics generally 0,4)s ....Wall thickness [mm]

mr ....Medium pipe radius [mm]

Load by external pressure (buckling pressure)

In certain cases, piping systems are exposed toexternal pressure:-Installation in water or buried below groundwatertable-Systems for vacuum. e.g. suction pipes

The buckling tension can then be calculateddirectly:

( )3

21410

⋅

−⋅⋅=

m

ck r

sEpµ

srp m

kk ⋅=σ

ExamplePP-R pipe SDR3340°C, 25 yearsEC=220N/mm² (creep modulus curve - page 22)outside diameter da=110Wall thickness =3,4mmAdditional safety factor 2,0 (Minimum security factorfor stability calculation).

33,14,33,53085,0 =⋅=⋅=

srp m

kkσ

085,00,217,0

17,03,534,3

)4,01(422010

)1(410

3

2

3

2

==

=

−⋅⋅=

=

−⋅⋅=

k

m

ck

p

rsEp

µ

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kp ...Critical buckling pressure [bar]

cE ....Creep modulus (see tables page 20 - 23)

[N/mm2] for t=25aµ ....Transversal contraction factor

(for thermoplastics generally 0,4)s ....Wall thickness [mm]


L ....Distance of stiffening ribs [mm]

J ....Moment of inertia [mm4]


s ....Wall thickness [mm]

h ....Height of stiffening rib [mm]

b ....Width of stiffening rib [mm]

Calculation of the necessary stiffening for pipeswith buckling strain

At higher buckling strains, there is very oftenapplied a stiffening by means of welded-on ribsdue to economic reasons in order to enableessentially thinner pipe wall thicknesses.

Basis for this is in slightly amended form theformulae for the buckling pressure calculation ofsmooth pipes.

It is necessary to know the present critical bucklingpressure at this calculation and to choose thedesired pipe wall thickness. Consequently, themaximum distance of the stiffening ribs can becalculated by help of the formula.

By means of the stiffening rib distance, the requiredmoment of inertia of the welded-on ribs can bedetermined.

Afterwards the height or width of the stiffeningribs can be calculated (one of these two parameterhas to be chosen).

There is naturally the possibility to fix the desiredstiffening ribs in their measurements at first andthen to calculate the maximum permissible criticalbuckling pressure for the desired pipe wallthickness and dimension.

( )

⋅+⋅

⋅

−⋅⋅=

23

2 5011410

Lr

rsEp m

m

ck µ

LsrJ m32

35,3 ⋅⋅=

12

3hbJ ⋅=

r

l

m

s

b

h

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Determination of the pipe cross section

Flowing processes are calculated by means of thecontinuity equation. For fluids with constant volumeflow, the equation is:

•V ....Volume flow [m3/h]

A ...Free pipe cross section [mm2]

v ....Flow velocity [m/s]

For gases and vapours, the material flow remainsconstant. There, the following equation results:

•m ....Material flow [kg/h]

ρ ....Density of the medium depending onpresure and temperature [kg/m3]

If in these equations the constant values aresummarized, the formulas used in practice for thecalculation of the required pipe cross section resultthere of:

id ....Inside diameter of pipe [mm]

Q′ ....Conveyed quantity [m3/h]

Q ′′ ....Conveyed quantity [l/s]

v ....Flow velocity [m/s]

Reference values for the calculation of flowvelocities may be for fluids:

v ~ 0,5 ÷ 1,0 m/s (suction side)v ~ 1,0 ÷ 3,0 m/s (pressure side)

Reference values for the calculation of flowvelocities may be for gases

v ~ 10 ÷ 30 m/s

vAV ⋅⋅=•

0036,0

ρ⋅⋅⋅=•

vAm 0036,0

vQdi

′⋅= 8,18

vQdi

′′⋅= 7,35

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λ ...Pipe frictional index(in most cases 0,02 is sufficient)

L ...Lenght of piping system[m]

id ...Inside diameter of pipe [mm]

ρ ...Medium density [kg/m3]

v ...Flow velocity [m/s]

Pressure loss in mountings RAp∆

Pressure loss of finished joints or couplings RVp∆

It is impossible to give exact information, becausetypes and qualities of joints (welding joints, unions,flange joints) vary.It is recommended to calculate a resistancecoefficient ζ RV = 0,1 for each joints in athermoplastic piping system, such as butt andsocket welding as well as flanges.

ζ ...Resistance coefficient for mountings [-]ρ ...Density of medium [kg/m3]

v ...Flow velocity [m/s]

The for the calculation necessary resistancecoefficients can be seen in DVS 2210, table 10(extract see page 46) or special technical literature.

Determination of the hydraulic pressure losses

Flowing media in pipes cause pressure losses andconsequently energy losses within the conveyingsystem.

Important factors for the extent of the losses:- Length of the piping system- Pipe cross section- Roughness of the pipe surface- Geometry of fittings, mountings and finishedjoints or couplings- Viscosity and density of the flowing medium

Calculation of the several pressure losses

Pressure loss in straight pipes Rp∆

The pressure loss in an straight pipe length isreversed proportional to the pipe cross section.

The whole pressure loss gesp∆ results from the

sum of the following individual losses:

Pressure loss in fittings RFp∆

There appear considerable losses regarding friction,reversion and detachment.The for the calculation necessary resistancecoefficients can been seen in the DVS 2210, table9 (extract see page 45) or special technical literature.

REMARK

For the design of piping systems out of PE-HD(OD 110 - 1200 mm) or concrete channel pipeswith PEHD inliner (up to OD 3000mm) forunpressurized applications, also the AGRUtabular compilation for the hydraulic design ofPE-HD piping systems can be looked up.

ζ ...Resistance coefficient for fittings [-]ρ ...Density of medium [kg/m3]

v ...Flow velocity[m/s]

RVRARFRges ppppp ∆+∆+∆+∆=∆

22102v

dLpi

R ⋅⋅

⋅⋅=∆ ρλ

25102vpRF ⋅

⋅⋅=∆ ρζ

25102vpRA ⋅

⋅⋅=∆ ρζ

4545454545

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positive ζ-values: pressure dropnegative ζ-values: pressure increaseVa: outgoing volume flowVd: continuous volume flowVs: total volume flowVz: additional volume flow

Hydraulic resistance coefficients of fittings(acc. DVS 2210, table 9)

Vs

Va

Vd

Vz

Vs Va

α/2

α/2

α

α

α

Kind of Parameter Resistance coefficient ζ DrawingFitting =Flow direction

bend α=90° R = 1,0 x da= 1,5 x da= 2,0 x da= 4,0 x da

bend α=45° R = 1,0 x da= 1,5 x da= 2,0 x da= 4,0 x da

ellbow α=45°30°20°15°10°

tee 90° ζz(flow collection) VZ/VS=0,0 -1,20

0,2 -0,40,4 0,100,6 0,500,8 0,70

1 0,90tee 90° ζa(flow separation) VA/VS=0,0 0,97

0,2 0,900,4 0,900,6 0,970,8 1,101,0 130

reducers Angle α 4 ... 8° 16° 24°concentric d2/d1=1,2 0,10 0,15 0,20

(pipe extension) 1,4 0,20 0,30 0,501,6 0,50 0,80 1,501,8 1,20 1,80 3,002,0 1,90 3,10 5,30

reducers Angle α 4° 8° 20°concentric d2/d1=1,2 0,046 0,023 0,010

(pipe throat) 1,4 0,067 0,033 0,0131,6 0,076 0,038 0,0151,8 0,031 0,041 0,0162,0 0,034 0,042 0,017

0,510,410,340,230,340,270,200,150,300,140,050,050,04

ζs0,06

0,200,300,400,500,60

0,100,200,35

ζd0,10

-0,10-0,05

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Hydraulic resistance coefficients of mountings(acc. DVS 2210, table 10)

Row F=Flange constructionDIN 3202-1

Reihe K=Connection flange constructionDIN 3202-3

no criteria

Legend for tables above:MV diaphragm valveSSV angle seat valveGSV straight valveS gate valveKH ball valveK butterfly valveRV check valveRK swing type check valve

Nominal width MV GSV SSV S KH K RV RKØ25 4,0 2,1 3,0 2,5 1,932 4,2 2,2 3,0 2,4 1,640 4,4 2,3 3,0 2,3 1,550 4,5 2,3 2,9 2,0 1,465 4,7 2,4 2,9 2,0 1,480 4,8 2,5 2,8 2,0 1,3100 4,8 2,4 2,7 1,6 1,2125 4,5 2,3 2,3 1,6 1,0150 4,1 2,1 2,0 2,0 0,9200 3,6 2,0 1,4 2,5 0,8

Resistance coefficient (ζ)

0,1 ... 0,3 0,1 ... 0,15 0,3 ... 0,6

Annotation: The hydraulic resistance coefficientsmentioned are reference values and are suitablefor rough calculation of pressure loss. For material-related calculations use the values of the particularmanufacturer.

Criteria for choice of gate valves(acc. DVS 2210, table 11)

Selection criteria MV/GSV/SSV S KH K RV RK

Flow resistance big low low moderate big moderateAperture- and Closing time medium long short shortOperation moment low low big moderateWear moderate low low moderateFlow regulation suitableFace-to-face length acc. row F medium big big big mittel bigFace-to-face length acc. row K low low low

Assessment

short

moderateless suitable

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Dog bone load

Dog bones should prevent a sliding or moving ofthe piping system in each direction. They servefurthermore for compensation of the reaction forcesof compensators such as sliding sockets and push-fit fittings. The dog bone has to be dimensionedfor all appearing forces:

Force by hindered thermal length expansionWeight of vertical piping systemsSpecific weight of the flow mediumOperating pressureInherent resistance of the compensators

Dog bones which have not been determinedshould be chosen in a way so as to make use ofdirection alterations in the course of the pipingsystem for the absorption of the length alterations.As dog bones, edges of fittings sockets or specialdog bone fittings are suitable.Swinging clips are not appropriate to be used asdog bones or the clamping of the pipes.

Rigid system

If the length alteration of a piping system ishindered, a fixed system is developed.The rigid or fixed piping length has no compensati-on elements and has to be considered conceringthe dimensioning as special application.

The following system sizes have to be determinedtherefore by calculation:

-Dog bone load-Permissible guiding element distance under consideration of the critical buckling length-Appearing tensile and pressure stresses

A fixed system is not recommended for this load ingeneral as due to the swelling, also a weakening ofthe material occurs (use of compensation elbows!).

Dog bone load at fixed systems

The largest dog bone load appears at the straight,fixed piping. It is in general kind:

FPF ...Dog bone force [N]

RA ...Pipe wall ring area [mm2]

cE ...Creep modulus [N/mm2] for t=100min

ε ...Prevented length expansion by heatexpansion, internal pressure or swelling [-]

Under consideration of the possible loads, ε has tobe determined as follows:

Load by heat expansion

α ..Linear heat expansion coefficient [1/°K]

T∆ ...Max. temperature difference [°K]

Load by internal pressure

p ...Operating pressure [bar]

µ ...Transversal contraction coefficient [-]

cE ...Creep modulus [N/mm2] for t=100min

da ...Pipe outside diameter [mm]

id ...Pipe inside diameter [mm]

Load by swelling

ε⋅⋅= CRFP EAF

T∆⋅= αε

( )

−⋅

−⋅⋅=1

211,0

2

2

didaE

p

c

µε

040,0...025,0=ε

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Calculation of support distances for pipes

The support distances from the thermoplasticpiping systems should be determined underconsideration of the licensed bending stress andthe limited deflection of the pipe line. Oncalculating of the support distances, a maximumdeflection of LA/500 to LA/750 has been taken asbasis. Under consideration of the previousdeflection of a pipe line between the centers oftire impact results a permissible support distanceof the pipe system.

3qJEfL Rc

LAA⋅⋅=

AL ...Permissible support distance [mm]

LAf ...Factor for the deflection (0,80 ... 0,92) [-]

cE ...Creep modulus for t=25a [N/mm²]

RJ ...Pipe inactivity moment [mm4]

q ... Line load out of Pipe-, filling- and additional weight [N/mm]

Remark: The factor fLA is determined dependingon the pipe outside diameter. There is the followingrelation valid:

80,092,0maxmin

→←→←

LAfda

Usual Support distances can be taken from thefollowing tables.

PE80, SDR11 (acc. DVS 2210, Tab.13)

PP-H, SDR11 (acc. DVS 2210, Tab.14)

da[mm] 20°C 30°C 40°C 50°C 60°C

16 500 450 450 400 350

20 575 550 500 450 400

25 650 600 550 550 500

32 750 750 650 650 550

40 900 850 750 750 650

50 1050 1000 900 850 750

63 1200 1150 1050 1000 900

75 1350 1300 1200 1100 1000

90 1500 1450 1350 1250 1150

110 1650 1600 1500 1450 1300

125 1750 1700 1600 1550 1400

140 1900 1850 1750 1650 1500

160 2050 1950 1850 1750 1600

180 2150 2050 1950 1850 1750

200 2300 2200 2100 2000 1900

225 2450 2350 2250 2150 2050

250 2600 2500 2400 2300 2100

280 2750 2650 2550 2400 2200

315 2900 2800 2700 2550 2350

355 3100 3000 2900 2750 2550

400 3300 3150 3050 2900 2700

Support distance LA in [mm] at

da[mm] 20°C 30°C 40°C 50°C 60°C 70°C 80°C

16 650 625 600 575 550 525 50020 700 675 650 625 600 575 55025 800 775 750 725 700 675 65032 950 925 900 875 850 800 75040 1100 1075 1050 1000 950 925 87550 1250 1225 1200 1150 1100 1050 100063 1450 1425 1400 1350 1300 1250 120075 1550 1500 1450 1400 1350 1300 125090 1650 1600 1550 1500 1450 1400 1350110 1850 1800 1750 1700 1600 1500 1400125 2000 1950 1900 1800 1700 1600 1500140 2100 2050 2000 1900 1800 1700 1600160 2250 2200 2100 2000 1900 1800 1700180 2350 2300 2200 2100 2000 1900 1800200 2500 2400 2300 2200 2100 2000 1900225 2650 2550 2450 2350 2250 2150 2000250 2800 2700 2600 2500 2400 2300 2150280 2950 2850 2750 2650 2550 2450 2300315 3150 3050 2950 2850 2700 2600 2450355 3350 3250 3150 3000 2850 2750 2600400 3550 3450 3350 3200 3050 2900 2750

Support distanceLA in [mm] at

4949494949

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Conversion factors for support distances(acc. DVS 2210, table 18)

For other SDR-rows, materials and fluids, the in thetable stated conversion factors can be brought in.(new support distance L = LA x f1 x f2)

Support distances for PE 100

As there are no valid creep modulus curves availablefor PE 100 at the moment, we recommend you toraise the values in the table for PE 80 containedsupport distances after eventually necessaryconversion (f1- and f2-factor) by 10%.

PVDF Ø16-50 SDR21, Ø 63-400 SDR33(acc. DVS 2210, Tab.17)

Material SDR-series Wall thicknessGases Water

< 0,01 1,00 1,25 1,50f2

PE-80 33 0,75 1,6517,6/17 0,91 1,47

11 1,00 1,307,4 1,07 1,21

PP-H 33 0,75 1,6517,6/17 0,91 1,47

11 1,00 1,307,4 1,07 1,21

PP-R 33 0,55 1,6517,6/17 0,70 1,47

11 0,75 1,307,4 0,80 1,21

PVDF 33 1,00 1,4821 1,08 1,36

1,0 0,96 0,92

1,0 0,96 0,92

1,0 0,96 0,92

1,0 0,96 0,92

Fluidothers

Density [g/cm³]

Conversion factor f1

Calculation of Support distances for pipes

da[mm] 20°C 30°C 40°C 50°C 60 °C 70°C 80°C 100°C 120°C

16 725 700 650 600 575 550 500 450 40020 850 800 750 750 700 650 600 500 45025 950 900 850 800 750 700 675 600 50032 1100 1050 1000 950 900 850 800 700 60040 1200 1150 1100 1050 1000 950 900 750 65050 1400 1350 1300 1200 1150 1100 1000 900 75063 1400 1350 1300 1250 1200 1150 1100 950 80075 1500 1450 1400 1350 1300 1250 1200 1050 85090 1600 1550 1500 1450 1400 1350 1300 1100 950110 1800 1750 1700 1650 1550 1500 1450 1250 1100125 1900 1850 1800 1700 1650 1600 1500 1350 1200140 2000 1950 1900 1800 1750 1700 1600 1450 1250160 2150 2100 2050 1950 1850 1800 1700 1550 1350180 2300 2200 2150 2050 1950 1900 1800 1600 1400200 2400 2350 2250 2150 2100 2000 1900 1700 1500225 2550 2500 2400 2300 2200 2100 2000 1800 1600250 2650 2600 2500 2400 2300 2200 2100 1900 1700280 2850 2750 2650 2550 2450 2350 2250 2000 1800315 3000 2950 2850 2750 2600 2500 2400 2150 1900355 3200 3100 3000 2850 2750 2650 2500 2250 2000400 3400 3300 3200 3050 2950 2800 2650 2400 2100

Support distance LA in [mm] at

5050505050

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Calculation of the Support distance at fixed pipingsystems

If piping systems are installed this way, that an axialmovement is not possible, the critical bucklinglength has been noticed for the security. Thecalculated distance must provide a safety factor of2,0 minimum.

Is the necessary support distance LF smaller thanthe calculated support distance LA, then LA mustbe reduced to LF.

If fixed piping systems are operating at raisedtemperatures, the calculated support destance LAhas to be reduced by 20 %. The raised operatingtemperatuers are summarized in the table below.

LF is calculated as follows for a minimum safetyof 2,0:

AR

RF L

AJerfL ≥⋅

⋅=ε

17,3

FL ... Required support distance [mm]

RJ ...Moment of inertia [mm4]

RA ...Pipe wall ring area [mm2]

ε ...Prevented heat expansion S. [47]

An simplified determining of the support distancesis possible by the help of the following table.

Material PE PP PVDFTemperature >45°C >60°C >100°C

da[mm] 0,001 0,002 0,004 0,006 0,008 0,01 0,012 0,015 0,02

16 505 355 250 205 175 160 145 130 11020 645 455 320 260 225 200 185 165 14025 805 570 400 330 285 255 230 205 18032 1030 730 515 420 365 325 295 265 23040 1290 910 645 525 455 405 370 330 28550 1615 1140 805 660 570 510 465 415 36063 2035 1440 1015 830 720 640 585 525 45575 2425 1715 1210 990 855 765 700 625 54090 2910 2060 1455 1185 1030 920 840 750 650110 3560 2515 1780 1450 1255 1125 1025 915 795125 4045 2860 2020 1650 1430 1275 1165 1040 900140 4530 3200 2265 1845 1600 1430 1305 1165 1010160 5175 3660 2585 2110 1830 1635 1495 1335 1155180 5825 4120 2910 2375 2060 1840 1680 1500 1300200 6475 4575 3235 2640 2285 2045 1865 1670 1445225 7280 5150 3640 2970 2575 2300 2100 1880 1625250 8090 5720 4045 3300 2860 2555 2335 2085 1805280 9065 6405 4530 3700 3200 2865 2615 2340 2025315 10195 7210 5095 4160 3605 3220 2940 2630 2280355 11495 8125 5745 4690 4060 3635 3315 2965 2570400 12950 9155 6475 5285 4575 4095 3735 3340 2895

Required support distance LF [mm] depending on the hindered length expansion [ε]

5151515151

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Calculation of the change in length

Changes in length of a plastic piping systems arecaused by changes in the operating or test process.There are the following differences:- Change in length by temperature change- Change in length by internal pressure load- Change in length by chemical influence

Change in length by temperature change

If the piping system is exposed to different tempe-ratures (operating temperature or ambient tempe-rature) the situation will change corresponding tothe moving possibilities of each pipe line. A pipeline is the distance between two dog bones.

For the calculation of the change in length use thefollowing formula:

TL∆ .... Change in length due to temperature

change [mm]α .... Linear expansion coefficient

[mm/m.°K]

L .... Pipe length [m]

T∆ .... Difference in temperature [°K]

TLLT ∆⋅⋅=∆ α

The lowest and hightest pipe wall temperature TRby installation, operation or standstill of the systemis basis at the determination of ∆T.

Change in length by internal pressure load

The by internal pressure caused length expansionof a closed and frictionless layed piping system is:

( ) L

didaE

pL

c

P ⋅

−⋅

−⋅⋅=∆1

211,0

2

2

µ

PL∆ ... Change in length by internal pressure

load [mm]

L ... Length of piping system [mm]

p ... Operating pressure [bar]

µ ... Transversal contraction coefficient [-]

cE ... Creep modulus [N/mm2]

da ... Pipe outside diameter [mm]

id ... Pipe inside diameter [mm]

Change in length by chemical influence

It may come to a change in length (swelling) ofthermoplastic piping system as well as also to anincrease of the pipe diameter under influence ofcertain fluids (e. g. solvents). At the same time, itcomes to a reduction of the mechanical strengthproperties. To ensure a undisturbed operation ofpiping systems out of thermoplastics conveyingsolvents, it is recommended to take a swelling factorof

fCh = 0,025 ... 0,040 [mm/mm]

into consideration at the design of the pipingsystem.

The expected change in length of a pipe line underthe influence of solvents can be calculated asfollows:

ChL∆ ... Change in length by swelling [mm]

L .......... Length of piping system [mm]

Chf ........ Swelling factor [-]

LfL ChCh ⋅=∆

Remark: For practically orientated calculations ofpiping systems conveying solvents out of thermo-plastic plastics the fCh-factro has to be determinedby specific tests.

α-average value mm/(m.K) 1/K

PE 0,18 1,8x10-4

PP 0,16 1,6x10-4

PVDF 0,13 1,3x10-4

ECTFE 0,08 0,8x10-4

5252525252

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Calculation of the minimum straight length

Changes in length are caused by changes inoperating or ambient temperatures. On installationof piping systems above ground, attention mustbe paid to the fact that the axial movements aresufficiently compensated.In most cases, changes in direction in the run ofthe piping may be used for the absorption of thechanges in length with the help of the minimumstraight lengths. Otherwise, compenstion loopshave to be applied.

If this cannot be realised, use compensators ofpossibly low internal resistance. Depending on theconstruction, they may be applied as axial, lateralor angular compensators.Between two dog bones, a compensator has tobe installed.Take care of appropriate guiding ofthe piping at loose points whereby the resultingreaction forces should be taken into account.

sL ....Minimum straight length [mm]

L∆ ....Change in length [mm]

da ....Pipe outside diameter [mm]

k ....Material specific proportionality factorAverage values: PP 30, PE 26, PVDF 20(exact values see table)

Note: An installation temperature of 20°C is basisat the calculation of the k-values. At lowtemperatures, the impact strength of the materialhas to be taken into account.The k-values can be reduced by 30% forpressureless pipes (e.g. ventilation).

Material specific proportionality factors k

The minimum straight length is expressed by:

daLkLs ⋅∆⋅=

F ...Dog boneGL ...Sliding bearing

Principle drawing U-compensation elbow

F ...Dog boneLP ...Loose point (zB pipe clips)

Principle drawing L-compensation elbow

L

L

Ls

F

L

LP

F

F

L

L

GL

Ls

Principle drawing Z-compensation elbow

F ...Dog boneGL ...Sliding bearing

0°C 10°C 30°C 40°C 60°C

PE 16 17 23 28 -PP 23 25 29 31 40

PE 12 12 16 17 -PP 18 18 20 20 24

at change in temperature

one-time change in temperature

F F

L

L L

L

F

Ls

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Calculation of straight lengths

Straight lengths in [mm] for pipes out ofpolypropylene and polyethylene 1) depending onthe change in length ∆L:

1) Minimum straight lengths in [mm] for pipes outof polyethylene

Due to the low material specific proportional actionfactor k of PE-HD (k = 26) in comparison to PP (k =30), the in the table contained minimum straightlengths can be reduced by 13 %.

The minimum straight length for PE is thereforecalculated as follows:

)()( 87,0 PPsPEHDs LL ⋅=

da[mm] 50 100 150 200 250 300 350 400 500

16 849 1200 1470 1697 1897 2078 2245 2400 268320 949 1342 1643 1897 2121 2324 2510 2683 300025 1061 1500 1837 2121 2372 2598 2806 3000 335432 1200 1697 2078 2400 2683 2939 3175 3394 379540 1342 1897 2324 2683 3000 3286 3550 3795 424350 1500 2121 2598 3000 3354 3674 3969 4243 474363 1684 2381 2916 3367 3765 4124 4455 4762 532475 1837 2598 3182 3674 4108 4500 4861 5196 580990 2012 2846 3486 4025 4500 4930 5324 5692 6364

110 2225 3146 3854 4450 4975 5450 5886 6293 7036125 2372 3354 4108 4743 5303 5809 6275 6708 7500140 2510 3550 4347 5020 5612 6148 6641 7099 7937160 2683 3795 4648 5367 6000 6573 7099 7589 8485180 2846 4025 4930 5692 6364 6971 7530 8050 9000200 3000 4243 5196 6000 6708 7348 7937 8485 9487225 3182 4500 5511 6364 7115 7794 8419 9000 10062250 3354 4743 5809 6708 7500 8216 8874 9487 10607280 3550 5020 6148 7099 7937 8695 9391 10040 11225315 3765 5324 6521 7530 8419 9222 9961 10649 11906355 3997 5652 6923 7994 8937 9790 10575 11305 12639400 4243 6000 7348 8485 9487 10392 11225 12000 13416450 4500 6364 7794 9000 10062 11023 11906 12728 14230500 4743 6708 8216 9487 10607 11619 12550 13416 15000560 5020 7099 8695 10040 11225 12296 13282 14199 15875630 5324 7530 9222 10649 11906 13042 14087 15060 16837

Change in length ∆L [mm]

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Calculation of buried piping systems

A stress and deformation proof according to ATV,instruction sheet A 127, has to be furnished forburied piping systems (e. g. drainage channels). Butthere can also serve other basis for calculation, suchas OEVGW (guideline G 52) or results of researchprojects.

There is a software program for the surchargecalculation according to ATV 127 at disposal in ourtechnical engineering department in order tofurnish the demanded proof.

Please fill in the following questionnaire ascompletely as possible. We will promptly preparea corresponding statics after receipt of thequestionnaire.

Project:

Site:

Principal:

Pipe material: Pipe inside diameter: [mm]

Pipe outside diameter: [mm] Wall thickness: [mm]

Nominal width: [mm]

Zone 1 2 3 4

Group G (1,2,3,4)

Kind of soil (gravel, sand, clay, loam)

Specific gravity [kN/m³]

Proctor density [%]

E-Modulus of the soil EB [N/mm²]

Dam" Trench "

Gravel surcharge above Width of trench b= [m]

pipe summit (min.2xda) h = [m] Gradient of slope β= [°]

Soil " Waste " Traffic load without "

Surcharge height h = [m] LKW12 "

Specific gravity γB = [kN/m³] SLW30 "

Weight on surface F = [kN/m²] SLW60 "

Unpressurized discharge piping system Pressurized piping system

Operating temperature T = [°C] Operating temperature T = [°C]

Entry cross section

at drainage systems AE = [%] Operating pressure p = [bar]

5. Surcharge

6. Operatingconditions of thepipe

1. Generally

2. Details for pipe

3. Soil

4. Installation

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E1 .... Surcharge above pipe summitE2 .... Conduit zone at the side of the pipeE3 .... Adjoining soil beside the conduit zoneE4 .... Soil below the pipe (site soil)

Dam embedding condition

E

EEE E

E

1

2 323

4

E

EEE E

E

1

2 323

4

Group Specific Anglegravity of internal

friction

γB ϕ′[kN/m³] 85 90 92 95 97 100

G1 20 35 2,0 6 9 16 23 40G2 20 30 1,2 3 4 8 11 20G3 20 25 0,8 2 3 5 8 13G4 20 20 0,6 1,5 2 4 6 10

Deformation modulus EB in[N/mm²] at

degree of compaction DPr in %

DPr

Calculation of buried piping systems

Comments to some points of the questionnaire

1. Generally:These general statements are only necessary toenable an easy assignment of the different projects.

2. Details for pipe:The most important statement is the determiningof the pipe material (polyethylene or polypropylene),as normally the pipe dimensions are given.

3. Soil / 4. Installation:There are four different groups of soil

The at the calculation applied deformation modulusof the soil has to be distinguished by the followingzones:

5. Surcharge:The surcharge height is at the trenchembedding condition the installation depth of thepipe (referring to the pipe summit) and at the damembedding condition the waste surcharge.

6. Operating conditions of the pipe: You only haveto fill in the corresponding operating parameter foreach application.

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Pipe insidediameterdi [mm]

Conveyedquantity(Flow volume)Q [l/s]

Flowvelocityv [m/s]

Pressure loss permeter pipe lengthD p/L [mbar/m]

Flow nomogramm

For rough determination of flow velocity, pressureloss and conveying quantity serves the followingflow nomogram. At an average flow velocity up to20m of pipe length are added for each tee, reducerand 90°elbow, about 10m of pipe for each bend r =d and about 5m of pipe length for each bend r = 1,5x d.

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PE and PP pipes from coils are immediately afterthe rolling action oval. Before welding the pipe endshave to be adjusted for example by heating with ahot-air blower and usage of a suitable cut pressureor round pressure installation.

The joining areas of the parts to be welded mustnot be damaged or contaminated.Immediately before starting the welding process,the joining areas have to be cleaned and must befree from e.g. dirt, oil, shavings.

On applying any of these methods, keep thewelding area clear of flexural stresses (e. g. carefulstorage, use of dollies).

The AGRU welding instructions apply to thewelding of semi-finished products, pipes and fittingsout of the in the table contained thermoplastics.

With AGRU semi-finished products, the MFR value,of which does not fall into the here stated values, itis necessary to test the weldability by performingwelding tests.

General standard

The quality of the welded joints depends on thequalification of the welder, the suitability of themachines and appliances as well as the complianceof the welding guidelines. The welding joint canbe checked through non destructive and / ordestructive methods.

The welding process should be supervised.Method and size of the supervision must be agreedfrom the parties. It is recommanded to documentthe method datas in welding protocols or on datamedium.

Each welder must be qualified and must have avalid proof of qualification. The intended field ofapplication can be determined for a type ofqualification. For the heating element butt weldingfrom sheets as well as for the industrial pipingsystem construction DVS 2212 part 1 valids. Forpipes >225mm outside diameter is an additionalproof of qualification.

The used machines and appliances mustcorrespond to the standards of the DVS 2208 part1. For the welding of plastics in the workshop thestandards of the instructions from the DVS 1905part 1 and part 2 are valid.

Measures before the welding operation

The welding area has to be protected fromunfavourable weather conditions (e. g. moisture,wind, intensive UV-radiation, temperatures < 0°C).If appropriate measures (e. g. preheating, tent-covering, heating) secure that the required pipe walltemperature will be maintained, welding operationsmay be performed at any outside temperatures,provided, that it does not interfere with the welder'smanual skill.If necessary, the weldability has to be proved byperforming sample welding seams under the givenconditions.

If the semi finished product should bedisproportionately warmed up as a consequenceof intensive UV-radiation, it is necessary to take carefor the equalization of temperature by covering thewelding area in good time. A cooling during thewelding process throught draft should be avoided.In addition the pipe ends should be closed duringthe welding process.

WeldabilityPolyethylene PE 80, PE 100 MFR (190/5) = 0,3 - 1,7 [g/10min]Polypropylene PP-H, PP-R

PP-H mit PP-R MFR (190/5) = 0,3 - 1,0 [g/10min]Special types PE 80-el with PE 80

PP-R-el with PP-H and PP-RPP-R-s-el with PP-H, PP-R and PP-R-el

Material designation

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Application limits for different kinds of joints

If possible, all joints have to executed so as to avoidany kind of stresses. Stresses which may arise fromdifferences in temperature between laying andoperating conditions must be kept as low aspossible by taking appropriate measures.The in the table contained axial conclusive jointsare permissible.

Kind of joint< PN6 >= PN6 < PN6 >= PN6 < PN6 >= PN6 < PN6 >= PN6

Heating elementbutt welding (HS) "#$ " ... & "#$ " ... & "#$ " ... &5) "#$ "#$%

Non-contactbutt welding (Infrared - IR) "% "%& " "%& " "%&

Beadlessbutt welding (IS) "#$ "#$ "#$ "#$ "#$1) "#$1)

Heating elementsocket welding "#$% "#$ "#$%

Electric socket welding(hot wedge welding) "#$% "#$ "#$ # "# #2) #2)

Hot gas welding " ... & " ... & " ... & " ... & " ... &Extrusion welding "#$% "#$% "#$% "#$%

Flange joint " ... & " ... & " ... & " ... & " ... &5) "#$% "#$%6) "#$%6)

Union " ... & " ... &

Ø20 ... 63 Ø63 ... 110 Ø110 ... 225 Ø 225 ... 1400

" ... PP-H100, PP-R80# ... PE$ ... Special types (PE80-el, PP-H-s, PP-R-s-el)% ... PVDF& ... ECTFE1) up to Ø1602) <PN6 up to Ø6003) <PN6 up to Ø4004) up to Ø255) up to Ø1606) up to Ø315

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Heating element butt welding

(following to DVS 2207, part 1 for PE-HD and part11 for PP)

Welding method discription

The welding faces of the parts to be joined arealigned under pressure onto the heating element(alignment). Then, the parts are heated up to thewelding temperature under reduced pressure (pre-heating) and joined under pressure after the heatingelement has been removed (joining).

Principle of the heating element butt weldingillustrated by a pipe.

All welding must be practised with machines anddevices which correspond to the guidelines of theDVS 2208 part 1.

Preparations before welding

Control the necessary heating elementtemperature before each welding process. Thathappens e.g. with a high speed thermometer forsurface measurements. The control measurementmust happen within the area of the heating elementwhich corresponds to the semi finished product.That a thermal balance can be reached the heatingelement should be used not before 10 minutesafter reaching the rated temperature.

For optimal welding clean the heating element withclean, fluffless paper before starting of eachwelding process. The non-stick coating of theheating element must be undamaged in theworking area.

For the used machines the particular joiningpressure or joining power must be given. They canrefer to e.g. construction information, calculated ormeasured values. In addition during the pipewelding process by slow movement of theworkpieces ocurs a movement pressure ormovement power which can be seen on theindicator of the welding machine and should beadded to the first determined joining power orjoining pressure.

The nominal wall thickness of the parts to bewelded must correspond to the joining area.

Before clamping the Pipes and fittings in thewelding machine they must be axial aligned, Theligh longitudinal movement of the parts to bewelded is to ensure for exsample throughadjustable dollies or swinging hangings.

The areas to be welded should be cleaned!

Together with the control of the gap width also thedisalignment should be checked. The disalignmentof the joining areas to one another should notoverstep the permissiple degree of 0,1 x wallthickness on the pipe outside or on the tablerespectively.Not worked welding areas shouldn´t be dirty ortouched by hands otherwise a renewed treatmentis necessary. Shavings which are fallen in the pipeshould be removed.

Pipe outside diameter die gap width[mm] [mm]< 355 0,5400 ... < 630 1,0630 ... < 800 1,3800 ... < 1000 1,5>1000 2,0

PRE-HEATING

FINISHED JOINT

Pipe PipePREPARATION

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Performing of the welding process

On heating element butt welding the areas to be joinedget warm up to the requested welding temperature withheating elements and after the removal of the heatingelement they join togehter under pressure. The heatingelement temperatures are listed in the followingtable.Generally the aim is to use higher temperatures forsmaller wall thicknesses and the lower temperatures forlarger wall thicknesses

The gradually sequences of the welding process

PE PP PVDF ECTFEHeating elementtemperature[°C]

200 up to 220 200 up to 220 232 up to 248 275 up to 285

tAg tAw tU tF tAk

Temperature

Welding-temperature

Pressure

Alignment resp.Joining pressure

Pre-heatingpressure

Alignment time Pre-heating time Ad-justingtime

Joining-pressure-build-uptime

Cooling time

Total joining time

Welding time

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sCalculation of the welding area:

or

Specific heating pressure

In most cases, the heating pressure [bar] or theheating force [N], which have to be adjusted, maybe taken from the tables on the welding machines.For checking purposes or if the table with pressuredata are missing, the required heating pressure hasto be calculated according to the following formula:

When using hydraulic equipment, the calculatedwelding force [N] has to be converted into thenecessary adjustable hydraulic pressure.

Calculation of the welding force:

sdm ⋅⋅≈ π


Welding parameters

Reference values for heating element butt weldingof PP, PE, PVDF and ECTFE pipes and fittings atoutside temperatures of about 20°C and low air-speed rates.

Type of material Wall thickness Bead height Pre-heating time tAW Adjusting time tU Joining pressure Cooling time tAk

[mm] [mm] [sec] [sec] build-up time tF [sec] [min]P=0,10 N/mm² P=0,01 N/mm²

.... 4,5 0,5 .... 135 5 6 64,5 .... 7,0 0,5 135 .... 175 5 .... 6 6 .... 7 6 .... 12

7,0 .... 12,0 1,0 175 .... 245 6 .... 7 7 .... 11 12 .... 2012,0 .... 19,0 1,0 245 .... 330 7 .... 9 11 .... 17 20 .... 3019,0 .... 26,0 1,5 330 .... 400 9 .... 11 17 .... 22 30 .... 4026,0 .... 37,0 2,0 400 .... 485 11 .... 14 22 .... 32 40 .... 5537,0 .... 50,0 2,5 485 .... 560 14 .... 17 32 .... 43 55 .... 70

P=0,15 N/mm² P≤0,02 N/mm².... 4,5 0,5 .... 45 5 5 6

4,5 .... 7,0 1,0 45 .... 70 5 .... 6 5 .... 6 6 .... 107,0 .... 12,0 1,5 70 .... 120 6 .... 8 6 .... 8 10 .... 16

12,0 .... 19,0 2,0 120 .... 190 8 .... 10 8 .... 11 16 .... 2419,0 .... 26,0 2,5 190 .... 260 10 .... 12 11 .... 14 24 .... 3226,0 .... 37,0 3,0 260 .... 370 12 .... 16 14 .... 19 32 .... 4537,0 .... 50,0 3,5 370 .... 500 16 .... 20 19 .... 25 45 .... 6050,0 .... 70,0 4,0 500 .... 700 20 .... 25 25 .... 35 60 .... 80

P=0,10 N/mm² P=0,01 N/mm²1,9 .... 3,5 .... 0,5 59 .... 75 3 3 .... 4 5,0 .... 6,03,5 .... 5,5 .... 0,5 75 .... 95 3 4 .... 5 6,0 .... 8,5

5,5 .... 10,0 0,5 .... 1,0 95 .... 140 4 5 .... 7 8,5 .... 14,010,0 .... 15,0 1,0 .... 1,3 140 .... 190 4 7 .... 9 14,0 .... 19,015,0 .... 20,0 1,3 .... 1,7 190 .... 240 5 9 .... 11 19,0 .... 25,020,0 .... 25,0 1,7 .... 2,0 240 .... 290 5 11 .... 13 25,0 .... 32,0

P=0,085 N/mm² P=0,01 N/mm²1,9 .... 3,0 0,5 12 .... 25 4 5 3 .... 53,0 .... 5,3 0,5 25 .... 40 4 5 5 .... 75,3 .... 7,7 1,0 40 .... 50 4 5 7 .... 10

PP

-H,P

P-R

PP

-H-s

,PP

-R-e

l,P

P-R

-s-e

l

P=0,10 N/mm²

PE

80P

E10

0P

E-e

l

P=0,15 N/mm²

P=0,10 N/mm²

P=0,085 N/mm²

PV

DF

EC

TFE

( )4

22 π⋅−= didaAPipe

Pipespec ApF ⋅=

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Alignment

Here adjusting surfaces to be joined are pressedon the heating element until the whole area issituated plane parallel on the heating element. Thisis seen by the development of beads. Thealignment is finished when the bead height hasreached the requested values on the whole pipecircumference or on the whole sheet surface. Thebead height indicates that the joining areascompletely locate on the heating element. Beforethe welding process of pipes with a larger diameter(>630mm) the sufficient bead development alsoinside the pipe must be controlled with a test seam.The alignment pressure works during the wholealignment process.

Pre-Heating

During the pre-heating process the areas must abutonto the heating element with low pressure. Atwhich the pressure will fall nearly to zero (<0,01 N/mm²). On pre-heating the warmth infiltrate in theparts to be welded and heat upto the weldingtemperature.

Adjustment

After the pre-heating the adjusting surfaces shouldbe removed from the heating elements. Theheating element should be taken away from theadjusting surfaces without damage and pollution.After that the adjusting surfaces must join togethervery quickly until immediately prior to contact. Theadjusting time should be keept as short as possible,otherwise the plasticised areas will cool down andthe welding seam quality would be influenced in anegative way.

Performing of pressure test

Before the pressure testing, all welding joints haveto be completely cooled down (as a rule, 1 hourafter the last welding process). The pressure testhas to be performed according to the relevantstandard regulations (e. g. DVS 2210 Part 1 - seetable pressure test).The piping system has to be protected againstchanges of the ambient temperature (UV-radiation).

Joining

The areas to be welded should coincide by contactwith a velocity of nearly zero. The required joiningpressure will rise linear if possible.

During cooling the joining pressure must bemaintained. A higher mechanical use is only afterprolongation of the cooling permissible. Underfactory circumstances and insignificant mechanicaluse the cooling times can be remain underespacialy by parts with a thick wall during the clampremoval and storage. Assembly or mechanicaltreatment is allowed after the whole cooling.

After joining, a double bead surrounding the wholecircumference must have been created. The beaddevelopment gives an orientation about theregularity of the weldings. among each other.Possible differences in the formation of the beadsmay be justified by different flow behaviour of thejoined materials. From experience with thecommercial semi finished products in the indicatedMFR-field can be assumptioned from the weldingtendency, even when this can lead to unsymetricalwelding beads. K must be bigger than 0.

Pressure test acc. DVS® 2210 Teil 1

K

PE PP PVDF ECTFESpecific 0,08heating pressure up to[N/mm²] 0.09

0,15 0,10 0,10

.

pre-test main-test short-test1,5 x PN 1,3 x PN 1,5 x PN

max. PN + 5 bar max. PN + 3 bar max. PN + 5 bar

each 1 h withoutrestore of test-

pressure

minimum 3 h minimum 1 h

piping systemswithout branchescompl. L > 100m

minimum 6 h minimum 6 h minimum 3 h

piping systemswithout branchescompl. L < 100m

minimum 3 h

special case(agreement withclient required)

material specific pressure drop(average value)

up to 0,8 bar/h up to 0,8 bar/h up to 0,8 bar/h

object

test pressure

note for the respective test standard

control during test procedureeach 1 h withrestore of test-

pressure

each 1,5 hwithout restoreof test-pressure

test period

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Requirements on the welding device used forheating element butt welding(following to DVS 2208, part 1)

Clamping device

In order to avoid high local stresses in the pipe anddeformations, the clamping devices shouldsurround at least the pipe casing as parallel aspossible to the welding plane. By their high stability,it must be provided that the geometric circular formof the pipes will be maintained. They must notchange their position in relation to the guideelements, even under the highest working forces.For fittings, such as stub flanges and welding neckflanges, special clamping devices which preventdeformations of the workpiece have to be used.

The pipe clamped at the mobile machine side haseventually to be supported and exactly adjusted bymeans of easy-running dollies so that the workingpressures and conditions required for welding canbe maintained.

It is recommendable to use clamp elementsadjustable in height to allow a better centering ofthe workpieces.

Guide elements

Together with the clamping devices, the guideelements have to ensure that the followingmaximum values for gap width (measured on coldjoining surfaces) are not surpassed due to bendingor beaming at the least favourable point in therespective working area of the machine at max.operating pressure and with wide pipe diameters(see table on page 59).

The gap width is measured by inserting a spacer atthe point opposite to the guide while the plane-worked pipes are clamped. Guide elements haveto be protected against corrosion at the slidingsurfaces, e. g. by means of hard chrome plating.

For processing in a workshop, the heating elementis in general permanently mounted to the device.In case of a not permanently attached heatingelement, adequate devices have to be provided forits insertion (e.g. handles, hocks, links).

Heating elements

The heating element has to be plane-parallel withits effective area.Permissible deviations from plane-parallelity(measured at room temperature after heating theelements to maximum operating temperature atleast once):

If the size and nature of the heating elementsnecessitates its machine-driven removal from thejoining surfaces, adequate equipment has to beprovided too.

The power supply has to be protected againstthermal damage within the range of the heatingelements. Likewise, the effective surface of theheating element has to be protected againstdamage.

Protecting devices are to be used for keeping theheating element during the intervals between thewelding processes.

Pipe outside Ø admissibleresp. edge length deviation

÷ 250 mm ≤ 0,2 mm÷ 500 mm ≤ 0,4 mm> 500 mm ≤ 0,8 mm


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Requirements on the welding device used forheating element butt welding(following to DVS 2208, part 1)

Devices for welding seam preparation

An adequate cutting tool has to be prepared withwhich the joining surfaces of the clamped pipe canbe machined in a plane-parallel way. Maximumpermissible deviations from plane-parallelity at thejoining surfaces are:

The surfaces may be worked with devices whichare mounted on or which can be introduced easily(e. g. saws, planes, milling cutters).

Control devices for pressure, time and temperature

The pressure range of the machine has to allow fora pressure reserve of 20 % of the pressure, whichis necessary for the maximum welding diameterand for surmounting the frictional forces.Pressure and temperature have to be adjustableand reproducible. Time is manually controlled as arule.

In order to ensure reproducibility, a heating elementwith electronic temperature control is to bepreferred. The characteristic performance andtolerance values have to be ensured.

Machine design and safety in use

In addition to meet the above requirements,machines used for site work should be oflightweight construction.Adequate devices for transportation andintroduction into the trench have be available (e. g.handles, links).Especially if voltages above 42 V are applied, therelevant safety regulations of VDE and UVV have tobe observed in the construction and use of themachines.

Machines used in workshops have to meet thefollowing requirements:

Stable constructionUniversal basic construction (swivelling orretractable auxiliary tools and clamps)Quick-clamping deviceMaximum degree of mechanizationIndication of pressure transmission (hydraulic/welding pressure) on the rating platePossibility to fix working diagrams in theoperating areaIn case of big machines, an undercarriage withlocking device (stable, adjustable in height,built-in level) is recommended.Pipe outside Ø deviation

da [mm] [mm]< 400 ≤ 0,5≥ 400 ≤ 1,0


""

"""

"

"

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Welding method

The method is in accordance with approvedstandard butt fusion, where the components arenot in contact with the heat source.The heating of pipe ends is performed by radiantheat. The advantage of the non contact method isthe minimal bead sizes and the elimination ofpossible contamination from the heating element(further detailed information can be taken from ourtechnical brochure "SP Series").

Welding parameters

Reference values of welding parameters for thenon-contact butt welding of PP pipes and fittingsneed not to be stated separately as this data isstored in the machine for the relevant material andof the dimensions to be welded.

New generation of welding machines for IR-welding

SP-welding equipment

This new developed welding equipment operatesfully automatic and can be used for differentmaterials (PP, PVDF, ECTFE, PFA).

There are the following sizes of welding equipmentavailable:

SP 110 (for OD 20 ÷110mm)SP 250 (for OD 75 ÷ 250mm)

Schematic sketch of the welding processIR - Non-contact butt welding for PP, PVDF andECTFE (IR-welding)

PREPARATION OF THEWELDING

PRE-HEATING

JOINING ANDCOOLING

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Heating elemet socket welding

Heating element socket welding (following to DVS2207, part 1 for PE-HD, part 11 for PP and part 15 forPVDF)

Welding method

On heating element socket welding, pipe andfittings are lap-welded. The pipe end and fittingsocket are heated up to welding temperature bymeans of a socket-like and spigot-like heatingelement and afterwards, they are joined.

The dimensions of pipe end, heating element andfitting socket are coordinated so that a joiningpressure builds up on joining (see schematicsketch).

Heating element socket weldings may be manuallyperformed up to pipe outside diameters of 40 mm.Above that, the use of a welding device because ofincreasing joining forces is recommended.The guidelines of the DVS are to be adhered toduring the whole welding process!

Welding parameters

Reference values for the heating element socketwelding of PP and PE-HD pipes and fittings at anoutside temperature of about 20°C and low air-speed rates

Schematic sketch of the welding process

1) not recommended because of too low wall thickness

Welding temperature (T)

PP-H, PP-R 250 ÷ 270 °CPE-HD 250 ÷ 270 °CPVDF 250 ÷ 270 °C

Material Pipe outside Welding temperature Adjusting time tU

type diameter [°C] fixed overallda [mm] SDR 17,6; 17 SDR 11; 7,4; 6 [sec] [sec] [min]

16 - 5 4 6 220 250 ÷ 270 - 5 4 6 2

25 1) 7 4 10 2

32 1) 8 6 10 4

40 250 ÷ 270 1) 12 6 20 4

50 1) 18 6 20 4

63 1)(PEHD); 10 (PP) 24 8 30 675 250 ÷ 270 15 30 8 30 690 22 40 8 40 6110 250 ÷ 270 30 50 10 50 8125 250 ÷ 270 35 60 10 60 8

Pipe wall thickness Pre-heating time[mm] [sec]

16 1,5 4 4 6 220 250 ÷ 270 1,9 6 4 6 225 1,9 8 4 6 232 2,4 10 4 12 440 250 ÷ 270 2,4 12 4 12 450 3,0 18 4 12 463 3,0 20 6 18 675 250 ÷ 270 3,0 22 6 18 690 3,0 25 6 18 6110 250 ÷ 270 3,0 30 6 24 8

PV

DF

Pre-heating time tAw Cooling time tAk

[sec]

PE

HD

,PP

PREPARATION OF THEWELDING

ALIGNMENT AND PRE-HEATING

JOINING ANDCOOLING

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Processing guidelinesHeating element socket welding

Preparation of welding place

Assemble welding equipment (prepare tools andmachinery), control welding devices

Preparation of welding seam

(at any rate immediately before starting the weldingprocess)

Cut off pipe faces at right angles and remove flasheson the inside with a knife.The pipe-ends should be chamfered following toDVS 2207; part 1 and the opposite table.Work the pipe faces with a scraper until the bladesof the scraper flush with the pipe face.Thoroughly clean welding area of pipe and fittingswith fluffless paper and cleansing agents (acetoneor similar).If peeling is not necessary, work the pipe surfacewith a scraper knife and mark the depth (t) on pipe.


Check temperature of heating element (on heatingspigot and on heating socket).Thoroughly clean heating spigot and heating socketimmediately before each welding process (withfluffless paper). At any rate, be careful that possiblyclogging melt residues are removed.

Performing of welding process

Quickly push fitting and pipe in axial direction ontothe heating spigot or into the heating socket untilthe end stop (or marking). Let pass by pre-heatingtime according to table values.After the pre-heating time, pull fitting and pipe offthe heating element with one heave andimmediately fit them into each other withouttwisting them until both welding beads meet.Let the joint cool down, then remove clamps.Only after the cooling time, the joint may be stressedby further laying processes.

Pipediameter

PEHD, PP PVDF PEHD, PP PVDFd [mm] b [mm] b [mm] l [mm] l [mm]

16 2 2 13 1320 2 2 14 1425 2 2 15 1632 2 2 17 1840 2 2 18 2050 2 2 20 2263 3 3 26 2675 3 3 29 3190 3 3 32 35

110 3 3 35 41

Pipe chamfer for Insert length for

On manual welding:Adjust the parts and hold them fast under pressurefor at least one minute. (see table: page 57:fixedcooling time)

ca.15°

l

b

d

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Processing guidelinesHeating element socket welding

Visual welding seam control

Check out bead of welding seam. It must be visiblealong the whole circumference of the pipes.

Performing of pressure test

Before the pressure testing, all welding joints haveto be completely cooled down (as a rule, 1 hourafter the last welding process). The pressure testhas to be performed according to the relevantstandard regulations (e. g. DVS 2210 Part 1 - seetable pressure test). The piping system has to beprotected against changes of the ambienttemperature (UV-radiation).

Requirements on the welding device used forheating element socket welding (following to DVS2208, part 1)

Devices for heating element socket welding areused in workshops as well as at building sites. Assingle purpose machines, they should allow for amaximum degree of mechanization of the weldingprocess.

Clamping devices

Marks on workpiece surfaces caused by specialclamping devices for pipe components must notaffect the mechanical properties of the finishedconnection.

Guide elements

Together with clamping devices and heatingelement, the guide elements have to ensure thatthe joining parts are guided centrically to theheating element and to each other. If necessary, anadjusting mechanism has to be provided.

Machine design and safety in use

In addition to meeting the above requirements inconstruction and design, the following pointsshould be considered for the machine design:-Stable construction-Universal basic construction (swivelling orretractable auxiliary tools and clamps)-Quick clamping device-Maximum degree of mechanization (reproducablewelding process)

Pressure test acc. DVS® 2210 part 1

pre-test main-test short-test1,5 x PN 1,3 x PN 1,5 x PN

max. PN + 5 bar max. PN + 3 bar max. PN + 5 bar

each 1 h withoutrestore of test-

pressure

minimum 3 h minimum 1 h

piping systems without branchescompl. L > 100m

minimum 6 h minimum 6 h minimum 3 h

piping systems without branchescompl. L < 100m

minimum 3 h

special case(agreement withclient required)

material specific pressure drop(average value)

up to 0,8 bar/h up to 0,8 bar/h up to 0,8 bar/h

object

test pressure

note for the respective test standard

control during test procedureeach 1 h withrestore of test-

pressure

each 1,5 hwithout restoreof test-pressure

test period

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Heating element socket welding

Requirements on the welding device used forheating element socket welding (following to DVS2208, part 1)

Heating elements

Contained in the table the values (correspond tothe draft of ISO TC 138 GAH 2/4draft, document172 E) apply to the dimensions of the heating tools.

Dimensions of heating elements for heatingelement socket welding fittingsType B (with mechanical pipe working)

1)Dimensions are valid at 260 ÷ 270°C

Heating spigot

Tools for welding seam preparation

At heating element socket welding with mechanicalpipe working (method type B), a scraper is requiredfor calibrating and chamferring the joining surfacesof the pipe. This has to correspond to the heatingelement and to the fitting socket. The scraper isadjusted with a plug gauge.

For the socket welding prepared pipe end(dimensions see table)

Calibration diameter and length for the machiningof pipe ends with method, type B

Dimensional tolerances:÷ 40 mm ± 0,04 mm> 50 mm ± 0,06 mm

Heating socket

Pipe outside Calibration

diameter diameter dx length l[mm] [mm]

20 19,9 ± 0,05 1425 24,9 ± 0,05 1632 31,9 ± 0,05 1840 39,85 ± 0,10 2050 49,85 ± 0,10 2363 62,8 ± 0,15 2775 74,8 ± 0,15 3190 89,8 ± 0,15 35

110 109,75 ± 0,20 41125 124,75 ± 0,20 44

Calibration

[mm]

R

ØD3

ØD4

L3L2L1

ØD1

ØD2

R

Heating spigot

Pipe diameter Ø D1 Ø D2 ØD3 ØD4 L 1 L 2 L 3 R[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]16 15,9 15,76 15,37 15,5 14 4 13 2,520 19,85 19,7 19,31 19,45 15 4 14 2,525 24,85 24,68 24,24 24,4 17 4 16 2,532 31,85 31,65 31,17 31,35 19,5 5 18 3,040 39,8 39,58 39,1 39,3 21,5 5 20 3,050 49,8 49,55 49,07 49,3 24,5 5 23 3,063 62,75 62,46 61,93 62,2 29 6 27 4,075 74,75 74,42 73,84 74,15 33 6 31 4,090 89,75 89,38 88,75 89,1 37 6 35 4,0

110 109,7 109,27 108,59 109 43 6 41 4,0125 124,7 124,22 123,49 123,95 48 6 46 4,0

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Welding method

On electric welding, pipes and fittings are weldedby means of resistance wires which are locatedwithin the elektofusion socket. A transformer forwelding purposes supplies electric power.

The extansion of the plastified melt and the duringthe cooling developed shrinking stress produce thenecessary welding pressure which guarantee anoptimal welding.

The method distinguishes itself by an extra-lowsafety voltage as well as by high automatization.

Welding systems

For the welding of AGRU-E-fittins the universalwelding machine Polymatic should be used.This welding device is a machine with bar codeidentification, it supervise all functions fullautomaticly during the welding process and storesthem.

After feeding of the code for universal weldingmachines with magnetic code characteristic, thecode is deleted which means that the card can onlybe used once.

Suitable welding machines

For the welding of electric weldable AGRU-fittingsthe following universal welding devices with barcode identification are suitable:

-Polymatic plus + top**-Tiny Data M + Tiny M-TWIN, LOGIC**with componet pursuit acc. ISO 12176-4

General welding suitability

Only parts made of the same material may be joinedwith one another. The MFR-value of the E-fittingaout of PE is in the range of 0,3 - 1,3 g/10min. Theycan be joined with pipes and fittings out of PE 80and PE 100 with a MFR-value between 0,30 and1,70 g/10min.

The weldable SDR-serie and the maximum ovalityare listed in the following tabel.

The welding area has to be protected againstunfavourable weather conditions (e. g. rain, snow,intensive UV-radiation or wind) The permissibeltemperature range for PE is from-10°C up to +50°C. The national guidelines must

also be considered.

Welding parameters

The welding parameters are specified by the barcode, which is directly affixed on the fitting.

* weldable with wall thickness from 2,5 mm up to 3,5 mm** weldable with wall thickness from 2,7 mm up to 3,8 mm

Pipes with thinner walls must be welded withsupport sleeves.

Electrofusion welding

(following to DVS 2207, part 1 for PE-HD andpart 11 for PP)

For AGRU electro fusion fittings is valid

SDR SDR SDR SDR SDR SDR SDROD 26 17,6 17 13,6 11 9 7,420 no no no no * - yes * - yes * - yes25 no no no no ** - yes ** - yes ** - yes32 no no no no yes yes yes40 no yes yes yes yes yes yes50 no yes yes yes yes yes yes63 no yes yes yes yes yes yes75 no yes yes yes yes yes yes90 no yes yes yes yes yes yes

110 no yes yes yes yes yes yes125 no yes yes yes yes yes yes140 no yes yes yes yes yes yes160 no yes yes yes yes yes yes180 yes yes yes yes yes yes yes200 yes yes yes yes yes yes yes225 yes yes yes yes yes yes yes250 yes yes yes yes yes yes yes280 yes yes yes yes yes yes yes315 yes yes yes yes yes yes yes355 yes yes yes yes yes no no400 yes yes yes yes yes no no

max

.Ova

lity

1,5%

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Electrofusion welding

Preparation of the welding seam( immediately before starting the welding process)


Unpack the E- fitting immediately before welding.

Never touch the inside of the socket and thescrapped pipe end.

If a pollution cannot be excepted, clean the weldingareas with PP- or PE-cleaner (or similar) and withfluffless paper.

The faces to be welded have to be dry before thesocket is put over the pipe. At any rate, removeresidues of clean-sing agents or condensationwater with fluffless, absorbent paper.Slide the socket into the prepared end of pipe rightto its center stop until it reaches the marking.


Processing guidelines

Assemble welding equipment (prepare tools andmachinery), control welding devices.

Install welding tent or similar device.

Cutt off pipe at right angles by means of a propercutting tool and mark the insert length.

Insert length= socket length/2

Clean pipe of dirt with a dry cloth at insert lengthand carefull machine pipe by means of a peelingtool or scraper knife in axial direction (cuting depthmin. 0,2mm). Remove flashes inside and outsideof pipe ends.

If a fitting is welded instead of the pipe, the weldingarea of the fitting has to be cleaned and scrappedas the pipe.

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The second part which has to be welded with thesocket (pipe or fitting) should be prepared too.Insert the second pipe end (or fitting) into the socketand clamp both pipes into the holding device, sothat no forces can raise between welding area andthe pipe (fitting) and that the socket can be turnedsmoothly.

Check:If a marking does not flush with a socket end, thepipe has not been inserted right up to the centerstop.

The clamping device has to be loosened and thepipe ends must be inserted until the markings aredirectly visible on the socket ends.

Performing the welding process

Observe the operating instructions for the weldingdevice. Only the most significant steps of thewelding procedure are described as follows.

Both plug-type socket connections should beturned upwards (however the axial position of thesocket must not be changed) and connected withthe welding cable. Position welding cable so as toprevent its weight from twisting the weldingsocket.

After the welding equipment has been properlyconnected, this is shown on the display.

The welding parameters are fed in by means of areading pencil or a scanner. An audio signal willacknowledge the data input.

After the welding parameters have been fed in, thetrademark, dimension and outside temperature areshown on the display. These values now have tobe acknowledged. Then, for control purposes, youwill be asked, whether the pipe has been worked.

Welding without clamping device:It is possible to weld AGRU electro fusion fittingswithout using a clamping device.The working instructions must correspond to DVS2207 part 1 and to the AGRU welding requirements.Keep in mind that the installation situation must bestress free. Is it not possible a clamping device mustbe used.


Electrofusion welding Processing guidelines

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Visual control and documentation

Optional is a traceability bar code is marked directlyon the fitting, so it is easy to read the code into thewelding machine. The using of the traceabilitycodeis not forcing. That means, if you don´t need thecode nothing chance at your working process. Soyou can use your standard welding machine.

The welding process is started by pressing thegreen start key. This time on the display also thedesired welding time and the actual welding timeare given as well as the welding voltage

During the whole welding process (includingcooling time) the clamping device shall remaininstalled. The end of the welding process isindicated by an audio signal.

After expiration of the cooling time, the clampingdevice may be removed. The recommendedcooling time must be observed!If a welding process is interrupted (e.g. in case ofa power failure), it is possible to reweld the socketafter cooling down to ambient temperature (<35°C).

minimum cooling time:da 20 mm - 63 mm 6 minda 75 mm - 125 mm 10 minda 140 mm 15 minda 160 mm - 180 mm 20 minda 200 mm - 280 mm 30 minda 315 mm - 400 mm 45 min

Performing the welding process

Electrofusion welding Processing guidelines

Visual weld control is performed by the weldingindicator on the socket. Moreover, all weldingparameters are stored internally by the device andcan be printed to receive a welding protocol.

Advantages of the PP E-socket

Welding indicator, which moves inside after thewelding, without outfow of the molted materials.Very long welding zoneWelding rod embed in plasticStandard welding plug Ø4mmRead the welding parameters with bar codesWelding stress 40 Volt

Remark:During the welding process of PP E-sockets takecare of the gap width (<1mm) between pipe and E-socket.

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Hot gas welding

(following to DVS 2207, part 3 for PP, PE-HD, PVDFand analogous for ECTFE)

Welding method

At hot gas welding, the edge areas and outer zonesof the welding fillers are transformed into plasticcondition - as a rule by means of heated air - andjoined under low pressure. The hot gas must befree of water, dust and oil.This guideline applies to hot gas welding of pipesand sheets out of thermoplastics, such as PP andPE-HD. In general, material thickness of the semi-finished products to be welded ranges from 1 mmto 10 mm.Fields of application of this welding method are:apparatus engineering, construction of vessels andpiping systems.

Piping systems for gas supply and water supplymust not be joined by hot gas welding!

Weldability of base material and welding fillersaccording to guideline DVS 2201, part 1, is takenfor granted.

Another requirement for high quality weldingprocesses is that the welding fillers are of the samekind and same type as far as possible. Conditionand requirement of the welding fillers have tocomply with the guideline DVS 2211.The most common welding fillers are round rodswith diameters of 3 mm and 4 mm. There are alsoused special profiles, such as oval, triangular andtrefoil rods, as well as bands. In the following, theterm "welding rods" is applied for the differentwelding fillers.

Qualification of welder and requirement on weldingdevices

The plastics welder must have obtained theknowledge and skill required for the performing ofwelding processes. As a rule, this would mean thathe is a qualified plastics worker and weldercontinuously practising or displaying of long-timeexperience. Hot gas welding machines have tocomply with the requirements according toguideline DVS 2208, part 2.

Welding parameter

Reference values at outside temperatures of about20 °C (acc. to DVS 2207)

1) measured in hot air stream approximately 5 mmin the nozzle.2) nitrogen (2 bar)

The drawing nozzle has to correspond with therespective cross section of the welding rod. In orderto apply the required heating pressure on weldingwith welding rods of larger cross sections, anadditional press handle may be required with thiskind of nozzle. Special slotted nozzles enable thewelding of bands.

Welding of ECTFE

In comparison to other thermoplastics,the heatingof ECTFE up to the required welding temperatureis not carried out with hot air but with hot nitrogen.Nitrogen is necessary as there could appear anoxidation of the plastified material in the weldingjoint area. Due to this, the quality of the weldingjoint is influenced very negatively. The temperatureof the hot nitrogen at an velocity of approx. 50 l/minshould be 340 bis 350°C at the outblow opening1).

Safety precaution

At ECTFE - melt temperatures of > 300°Chydrogen chloride and hydrofluorics arereleased. They could be toxically at higherconcentrations and should not be breathenedin.The recommended load limit acc. to TWA forHCl is 5ppm, for HF 3ppm.At breathing contact wit ECTFE-vapours, theperson should be brought out in the fresh airand medical aid should be summoned withoutdelay (danger of polymer-fever!).

The following safety measures should beconsidered:

Please consider for good ventilating of theworking place (otherwise please usebreathing protections)Please use eye protectionsPlease use hand protections

"

""Material Hot air Air quantity

temperature 1)

Rod Ø 3mm Rod Ø4mm [°C] [l/min]PEHD, PEHD-el 10 ÷ 16 25 ÷ 35 300 ÷ 350 40 ÷ 60PP-H, PP-RPP-R-el, PP-H-s 10 ÷ 16 25 ÷ 35 280 ÷ 330 40 ÷ 60PP-R-s-elPVDF 12 ÷ 17 25 ÷ 35 350 ÷ 400 40 ÷ 60

ECTFE 12 ÷ 17 25 ÷ 35 340 ÷ 350 48 ÷ 522)

Welding force

[N]

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Processing guidelines - Hot gas welding



Install welding tent or similar device.

Preparation of welding seam (at any rateimmediately before starting the welding process)

The adjusting surfaces and the adjacent areas haveto be prepared adequately before welding (e. g. byscrapping). Furthermore, it is also recommendableto scrape the welding rods, it is, however, a must,when welding PP material. Parts that have beendamaged by influences of weather conditions orchemicals have to be machined until anundamaged area appears.

The forms of the welding seams on plasticscomponents generally correspond with the formsof welding seams on metal parts.The guideline DVS2205, parts 3 and 5, are valid with respect to thechoice of welding seam forms on containers andapparatus. In particular, pay attention to the generalprinciples for the formation of welding seams. Themost important welding seam forms are:V-weld, double V-weld, HB-weld and K-weld.

With welding areas accessible from both sides, itis recommendable to make double-V-welds (sheetthickness of 4 mm and more). Generally do so whenthe thickness is 6 mm and more. The displacementof sheets may be minimized by changing the sidesof welding.

Preparations for welding

Before starting the welding process, check theheated air temperature adjusted on the weldingmachine. Mea-surement is performed by means ofa control thermocouple, inserted approximately 5mm into the nozzle, and with rod-drawing nozzlesin the opening of main nozzle. The diameter of thethermocouple must not exceed 1 mm. Air quantityis measured by means of a flow control instrumentbefore the air stream enters into the weldingmachine.

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The welder has to acquire the feeling for the speedand force he needs for welding by practising. Thewelding power may be determined by test weldingon a weighing machine.The welding rod is heated within the rod-drawingnozzle and pushed into the welding groove with itsbreak-like extension mounted on the lower part ofthe nozzle. As a consequence of the forwardmovements of the nozzle, the welding rod isautomatically being pushed on as a rule.If necessary, the welding rod has to be pushed onmanually in order to avoid stretching caused byfriction within the nozzle.

Structure of welding seam

The first layer of the welding seam is welded withfiller rod, diameter 3 mm (except for materialthickness of 2 mm). Afterwards, the welding seammay be built up with welding rods of largerdiameters until it will have completely been filled.Before welding with the next welding rod, thewelding seam which has been formed with thepreceeding welding rod, has to be adequatelyscrapped.

Additional machining of welding seam

Usually welding seams need no rewor-kinghowever, if necessary, pay atten-tion to the factthat the thickness of the base material must bemaintained.

Visual control of welding seam

Welding seams are visually checked with a view toweld filling, surface conditions, thorough weldingof welding root and displacement of joining parts.

Processing guidelinesHot gas welding

welding device

working piece

welding rod

welding seam

hot gas

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Hot gas welding

Requirements on the welding device used for hotgas welding (following to DVS 2208, part 2)

Manual welding devices (with external air supply)

The devices comprise handle, heating, nozzle, airsupply hose and electrical connecting cable.Due to their construction properties, they areparticularly suitable for longer lasting weldingprocesses.

Requirements on design

As light as possibleFavourable position of the gravity centerFunctionally formed handleIndefinitely variable power consumptionIf possible, handle with built-in control systemOperating elements arranged in a waypreventing unintentional changesMaterial of handle: break-proof, thermo-resistant, thermo-insula-ting, non-conductingCorrosion-proof hot gas supply pipes of lowscalingLight and flexible hoses without permanentchanges after squeezing

Safety requirements

The devices have to be safe with a view of all kindof personal injuries. In particular, the followingrequirements apply:

Areas endangering the risk of burning are to bekept as small as possible.Parts next to hands should not be heated totemperatures above 40°C, even after longeruse.Protection against overheating (e. g. due to lackof air) of the device has to be present.Electrical equipment has to conform with theVDE regulations.

Air supply

At hot gas welding, air is normally used which issupplied by a compressed air network, acompressor, a pressure gas bottle or a ventilator.The air supplied has to clean, free of water and oil,as otherwise not only the quality of the weldingseam but also the lifetime of the welding devicesdecreases. Therefore, adequate oil and waterseparators have to be used.The air volume supplied to the device has to beadjustable and has to be maintained constant, as itis a main factor influencing the temperature controlof the device.

Welding devices (with built-in ventilator)

The devices comprise handle, built-in ventilator,heating, nozzle and electrical connecting cable.Due to their constructional features, they can beused at sites where external air supply is notavailable.On account of their dimensions and their weight,they are less suitable for longer lasting weldingprocesse

Requirements on design

The ventilator has to supply the quantity of airrequired for welding various types of plasticsto all nozzles (see DIN 16 960, part 1).The electrical circuit has to ensure that theheating is only turned on when the ventilatoris operating. The noise level of the ventilatorhas to comply with the relevant stipulations.

Safety requirements

The nozzles used for the particular deviceshave to be securely fastened and easilyexchangeable even when heated.The material must be corrosion-proof and oflow scaling.In order to prevent heat from dissipating, thesurface of the nozzle has to be as smooth aspossible,e. g. polished.For reducing friction, the inner surface of theslide rail of the drawing nozzles have to bepolished. The same applies to the slidingsurfaces of tacking nozzles.In order to avoid strong air vortexes at the outletof the nozzle, the round nozzles have to bestraight for at least 5 x d (d = outlet diameter ofthe nozzle) in front of the outlet.

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Extrusion welding

(following to DVS 2207, part 4 andDVS 2209, part 1)

Welding method

Extrusion welding is used for joining thick-walledparts (construction of containers, apparatusengineering, piping systems), for joining of liners(for buildings, linings for ground work sites) and forspecial tasks.

This welding technique is characterized as follows:Welding process is performed with weldingfiller being pressed out of a compoundingunit.The welding filler is homogenous andcompletely plastified.The joining surfaces have been heated up towelding temperature.Joining is performed under pressure.

Weldability of base material and welding filler

Semi-finished products and welding fillers have tobe suitable for extrusion welding. Weldability ofbase material and welding fillers have to be inperfect processing condition. Assure weldability ofparts to be welded according to DVS 2207, part 4.The welding filler has to be adjusted to processingwith the particular extrusion welding device and tothe type of material used for semi-finishedproduct.The welding filler is being processed inform of pellets or rods. Pellets and welding rods ofuncontrolled composition and unknown originmust not be processed. Do not use regeneratedmaterial for welding.The welding filler has to be dry and clean (preventmoisture from falling upon cold pellets).

Qualification of welder and requirement on weldingdevices

The plastics welder must have obtained theknowledge and skill required for the performing ofwelding processes.As a rule, this would mean that he is a qualifiedplastics worker and welder continuously practisingor disposing of long-time experience.

For extrusion welding, several kinds of devices maybe used (see DVS 2209, part 1). The most commondevice is a portable welding device consisting of asmall extruder and a device for generating hot air.

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Processing guidelines - Extrusion welding





The adjusting surfaces and the adjacent areas haveto be prepared adequately before welding (e. g. byscrapping). Parts that have been damaged byinfluences of weather conditions or chemicals haveto be machined until an undamaged area appears.This has to be considered especially on performingrepair works.Do not use cleansing agents affecting plastics thusby causing them to swell.In order to equalize higher differences intemperature between the different workpieces, theworkpieces have to be stored long enough at theworking place under the same conditions.

Welding seam forms

On choosing welding seam forms for containersand apparatus , in general observe the guidelineDVS 2205, part 3 and 5. In particular, consider thegeneral technical principles for welding seamformations quoted therein.

In general, single-layer seams are welded onextrusion welding. If on welding of thicker semi-finished products it is not possible to make DV-welds, also multilayer seams can be performed.

The welding seam should laterally extend by about3 mm beyond the prepared welding groove.

T-joint with double bevelgroove

2

9

45° -

60°

T-joint with single bevelgroove with fillet weld

Double V-butt welding

V-weld without sealing run

Prepared welding groove

Welding seam forms forextrusion welding

4 5 °

9 0 ° 10

0 to 2

2

> 10

0 to

2

45° -

60°

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Processing guidelines - Extrusion welding



Lap jointIn order to guarantee sufficient heating andthorough welding, it is necessary to provide an airgap depending on wall thickness (width of air gapshould be 1 mm minimum).


Due to the hot gas passing out of the nozzle of thewelding device, the adjusting surfaces of the partsto be welded are heated up to weldingtemperature. The welding filler, continuouslyflowing out of the manually guided device, ispressed into the welding groove. The dischargedmaterial pushed the device ahead thus determiningthe welding speed. The heating of the adjustingsurfaces must be coordinated with the weldingspeed.

Basically the welding seams have to executed in away to assure that no re-working will be required. Ifnecessary, it should, however, be performed onlyafter acceptance so that eventual welding faultscan be discovered on visual inspection. Onperforming re-working, avoid the build-up ofnotches.

Lap joint with fillet weld

Lap joint with lap weld(for liners with a thickness of up to 3,5 mm )

Lap joint with extrusion welding(for liners with a thickness of up to 3,5 mm)

Visual control of welding seam

On visual inspection, surface conditions of thewelding seam, proper performance as to drawingsas well as evenness are evaluated.

Welding shoes

hand welding extruder Type K1

supplying ofwelding filler (from extruder)

welding device

hot gas

working piece

welding shoe

welded seam

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Detachable joints

Flange connections of piping systems

If pipe joints are connected by means of flanges,the following guidelines have to be adhered to:

Aligning of partsBefore applying of the screw initial stress, the sealingfaces have to be aligned planeparallel to each otherand fit tight to the sealing. The drawing near of theflange connection with the thereby occuring tensilestress has to be avoided under any circumstances.

Tightening of screwsThe length of the screws has to be chosen this waythat the screw thread possibly flushes with the nut.There have to be placed washers at the screw headand also at the nut.The connecting screws have to be screwed bymeans of a torque key (torque values see supplyprogram).

Generally

It is recommend to brush over the thread, e. g. withmolybdenum sulphide, so that the thread stays alsoat longer operation time easy-running.

Adhesive joints

With polyolefines, adhesive joints are not applicabledue to their proper chemical resistance.

The hereby achieved strength values rangeextremely below the minimum requirements madeto adhesive joints in practice.

Unions of piping systems

If pipe joints out of thermoplastics are connectedby means of unions, the following regulations haveto be adhered to:For avoiding of unpermissible loads at theinstallation, unions with round sealing rings shouldbe applied.

The union nut should be screwed manually or bymeans of a pipe band wrench (common pipewrenches should not be used).

Prevent the application of unions at areas withbending stresses in the piping systems.

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Advantages of double containment pipingsystems

Application of highly corrosion resistantmaterials such as PE, PP or PVDF (ECTFE)

Different combinations of media pipe andprotective pipe

Exact identification of the leak area by means ofan electronic detection system therefore lowrepair expenses

No succesive damages

Assignment of the system in some protectionareas - therefore higher operation flexibility

Application range of double containment pipingsystems

buried:Buried conveying piping systems of groundwater dangerous media through sensitive areas

Sewage water systems in the industry

In the landfill construction or in clarificationplants for drainage water transport

aboveground:Process systems for dangerous chemicals:

in industrial plantsin chemical manufacturingin the semiconductor production

The components of double containment pipingsystems :

Inside pipe:The media is transported through the inside mediapipe

Outside pipe:The outside- or enccasing pipe provides protectionagainst the leaking of the media

The ring gap:The gap between the inside and outside pipe. Inthe ring gap the leak detection takes place

Leak detection system:The leak detection system consists of a supervisingroom (sleeve), controlling device (z.B. sensor) andan indicator

Double containment piping system

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In practice different pipe materials have be applieddue to different operation conditions. At the doub-le containment piping system the followingpossibilities can be performed:

outside pipe(protective pipe)

inside pipe(media pipe)

welding

PP PP SPE PE SPE PP KPE PVDF KPP PVDF K

PVDF PVDF SPE ECTFE KPP ECTFE K

PVDF ECTFE KECTFE ECTFE S

S = Simultaneous weldingK = Cascade welding

Sta

ndar

dO

nde

man

d

d1 SDR1 d2 SDR2

90 17 32 11 (21)125 17 63 11 (21)160 17 90 11 (33)200 17 110 11 (33)280 17 160 11 (33)

outside pipe inside pipe

Standard dimensionscombinations for cascade welding PE/PP & ( PE/PVDF - PP/PVDF )

d1 SDR1 d2 SDR2

90 17 32 11110 33 63 11160 33 90 17160 33 90 11200 33 110 17200 33 110 11280 33 160 11315 33 200 11355 33 250 11

outside pipe inside pipe

Standard dimensionscombinations for simultaneous welding PP/PP & PE/PE

PP - PP

PE - PE

PE - PVDF

PE - PP

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The welding of a dual pipe can happen with diffe-rent welding methods. There exists also the choicebetween simultaneous welding and cascadewelding. The methode of the welding must beindicated in term of the order, because the offset ofthe inside pipe is adjusted by the welding method.

Simultaneous welding

With simultaneous welding the inside and outsidepipe are welded at the same time. Here the dualpipe can be installed or welded like a single pipebut with different welding parameters.

Advantages of simultaneous welding:

less time spent for a welding

easy and fast installation

Use of the standard - heating element (not byleak detection cables)

Disadvantages of a simultaneous welding:

no visual controll of the inside pipe weldingseam is possible

Inside and outside pipe must be made of thesame material.

1.Step: Control of the offset on the inside pipeand planning of the welding surface

2.Step: Heating of the joining areas

Simultaneous welding of a PE - PE systemSimultaneous joining with butt welding:

butt weld seam

outside pipe

inside pipe


3.Step: Welding of inside and outside pipe

offset

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1.Step: Heating and welding of the inside pipe

2.Step: Heating of the outside pipe with a splitheating element

3.Step:Welding of the outside pipe

Cascade welding

For the butt welding of the inside pipe the outsidepipe is pulled back until the inside pipe is clampedinto the clamps of the welding machine. The insidepipe is welded by heating element butt welding inaccordance with the DVS guideline 2207.

The outside pipe can be joined with split heatingelement butt welding , with sleeve or withelectrofusion welding. If a split heating element isused take care that a minimum ring gap betweeninside pipe and heating element of 10 mm is given.Further do not damage the inside pipe during theadjusting of the heating element. By the weldingof the outside pipes with an electrofusion weldingsocket the inside stop in the middle of the socketshould be removed before placement on the out-side pipe, this will allow room for welding the insidepipe. After the welding of the inside pipe the looseoutside pipe will be pulled on the to be weldedpipe and will be welded on the circumference withelectrofusion sockets. This welding is only possiblewith an outside pipe out of PEHD. A furtherpossibility for the joining of the outside pipes is thewelding with a sleeve. The procedure can becompared with the welding of electrofusionsockets. In this situation the sleeve is welded inplace by hot gas or extrusion welding .

Easier installation of the leak detection cable

The welding seam of the inside pipe can bechecked visually

This method can be applied for all materialcombinations

Higher time expenditure per welding

Varied installation and so higher installationexpenses

Advantages of the cascade welding:

Disadvantages of the cascade welding:

Cascade joining with butt welding

butt weld seam

outside pipe

inside pipe

10-15cm


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You need a leak detection system to supervisethe transport of media in double containment pipingsystems. This is installed in or through the ring gapbetween the inside and outside pipe. If a leak shouldoccur the operator immediately receives a messagefrom the permanent leack detection system. Theoutside pipe protects the environment until a repairhappends.

Today the following leak detection system in pipingsystem are applied:

Sensors

With differential pressure control the ring gap issupplied with under- or over pressure. By theoverpressure method the gas flows out of the ringgap in the inside or media pipe during pressureloose in the ring gap, as a result of this an alarm istriggered by a pressure manometer. If a leakdevelops by the under pressure or vacuum controlit will lead into a pressure loss in the media pipefollowing a pressure increase in the ring gap, whichwill also trigger an alarm. For the dimensions thestress of the different pressure in the ring gapshould be noticed.

After leaking the medium can be seen throughinspection glasses. These must be installed on alllowest points of the pipeline system. In case of aleak the leaked medium will advanceced to thelowest point and there it can be seen. Theinspection glasses should have ports to makeanalysies of the medium in case of a leak. Aconstant control of the system by the visual methodis not possible because the controls depends onthe operator.

This special leak detection method was developedto detect and show the leak places . The cables areinstalled over the whole length in the ring gap ofthe piping system. The position of the leak can belocated exactly with a system map.

In leak detection with sensors the sensors areinstalled on the lowest point of the pipelinesystem. In the case of a leaking the leaked mediumwill be advanced to the lowest point in the ringgap, where a sensor is situated. The sensors, whichdepend on different detection methods, can locatethe position of the leak. This measurement ensuresa constant control of the system, because thesensors are joined to a terminal, which makessupervising very easy. Through the application offixed points the pipeline system can be split intoseparate safety zones. A further advantage is thatin case of a leak the detection system can berenewed. Through the easy installation of the leakdetection system it is one of the most widespreadsystems in practice.

Leak detection cables

Differential control(Comparison inside pressure to ring gappressure)

Visual leak detection

outside pipe

spider clip

inside pipe

leak detectioncablel


SENSOR

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Double containment piping systems - Design

Installation systems

Fixed system

Inside, outside pipe and the surrounding are fixedtogether by dog bones on each direction change. Alength expansion of the inside or outside pipe isnot possible.

Advantages:

low expensensneed little area

Disadvantages:

high dog bone forces (note the fixingdemand)

Unimpeded heat expansion(flexible system)

The inside and outside pipe are installed such thata length expansion from both pipes and evenamong each other can happen. In term of theplanning we have to consider that the lengthexpansion of the inside pipe takes place in the out-side pipe.

Advantages:

applicable for higher operating temperatureslow stress of the double containment pipingsystem because of free expansion

Disadvantages:

higher expensesneed often much area because of thecompensation elbow

System with impeded heat expansion

The inside and outside pipe are fixed together bydog bones. The length expansion of the wholedouble containment pipe line will be picked upthrough sufficient measures (compensator,straight). This method is only sensible when theinside an outside pipe are made out of the samematerial and few temperatrue changes betweeninside and outside pipe occur.

Advantages:

low expensesusually low fixing expenses

Disadvantages:

high stress in the double containment pipingsystemneed often much area because of thecompensation elbow

With the installation of the double containmentpiping system are in comparison with theinstallation of a single pipe possible changes in thelength due to thermal expansion or contractionrequire special attention. The temperature changesof the inside and outside pipe can be different oreven opposite through the distance betweeen thepipes This can lead to considerable lengthexpansions of the pipes to one another. If it can notpicked up constructive stress will be developedwhich is an additional demand on the pipe lines.One can distinguish between three different designsystems:

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In order to be able to perform a complete and exactcalculation and design of the piping system, weneed to know the exact application and installationconditions of the respective project.

We have issued two questionnaires which shouldto be filled in by the customer and sent back to us.The questionnaires are available on demand. Afterthe analysis of the questionnaire through ourtechnical department you will receive arecommondation for the dimensions of the doublecontainment piping system.

Installation of the double containment system

Calculation

Questionnaire I

("Application and installation conditions") containsthe dimensions, materials, pressure ratings, generalapplication parameter and the leak detection system.

Questionnaire II

Excerpt from our calculation program for the double containment piping system

Excerpt from our calculation program for the double containment piping system

(Application conditions for buried piping systems")should be filled in if the piping system shall beinstalled underground and therefore a staticcalculation is necessary.

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Company: ____________________________ Phone:_____________________________________Name: ____________________________ Telefax:_____________________________________Site: _____________________________________________________________________ ___________Project: _________________________________________________________________________________

Operating conditionsFlow medium1:______________________________________________________________________________Operating temperature:inside min. ___________°C inside max. _______________________°COperating temperature:outside min. __________°C outside max. ______________________°CInstallation temperature:______________________°C Medium density: _________________kg / m³max. operating over pressure: ____________________ bar required time to fail: _________years

Requested material combination:Inside pipe O PEHD O PP O PVDF O ECTFE outside pipe O PEHD O PP O PVDF O ECTFE

Requested wall thickness combination and dimensions outside pipe / inside pipe:


Questionnaire to calculate the double containment piping systems

Please send the filled questionnaire back to the indiquated address.

Leak detection system

O selective with sensorsO constant detection with leak detection cablesO visual controlO other leakd detection methods

Installation

O aboveground system, plantO aboveground system, outdoor in the shadeO with direct UV radiationO buried piping system2

Address:

AGRU Kunststofftechnik

Ing. Pesendorfer-Strasse 31 Phone : ++43 7258 790 0E-Mail: [email protected] Bad Hall Telefax: ++43 7258 790 430 Internet: http://www.agru.at

1 For the material choic of the piping system is the exact combination of the medium necassery to control thechemical resistance.2 By buried systems please demand on our questionnaire „Application conditions for buried piping system".

PE PP PE PE PPd1 SDR d2 SDR PE PP d1 SDR1 d2 SDR2 PP PVDF PVDF90 17 32 11 # #

110 33 63 11 # #

160 33 90 17 # #

160 33 90 11 # #

200 33 110 17 # #

200 33 110 11 # #

280 33 160 11 # #

315 33 200 11 # #

355 33 250 11 # # 280 17 160 11 (33) # # #

# others: outside pipe d1_______ SDR_______ inside pipe d2_______ SDR_______

# #

17 110 11 (33) # # #

17 90 11 (33) #

## #

17 63 11 (21) # # #

17 32 11 (21)90

125

160

200

Simultaneous weldingoutside pipe inside pipe

cascade weldingoutside pipe inside pipe

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The below mentioned table gives you a shortsurvey about the different application possibilitiesof our molding materials.

Applications

Range of applications PP-H PP-R PP-H-s PP-H-s-el PE80 PE100 PE80-el PVDF ECTFE

Industrial applicationsPiping systems for conveying ofchemicalsPipes for cooling water systems ■ ■ ■ ■ ■ ■Pipes for the transport of solids ■ ■ ■ ■ ■ ■ ■Piping systems inexplosion-proof roomsHigh purity water piping systems ■ ■ ■ ■Water extraction andwater preparationPipes for swimming pools ■ ■ ■ ■Protective pipes fordistrict heating systemsProtective pipes for cables ■Apparatus engineering andvessel construction ■ ■ ■ ■ ■ ■ ■ ■Ventilation anddegassing piping systemsLining of containersand tanksConstruction of facilities ■ ■ ■ ■ ■ ■ ■ ■ ■Distribution of compressed air ■Applications for environmental protectionPipes for drainage systems ■ ■ ■ ■Lining of channels,channel reliningDual pipes ■ ■ ■ ■ ■ ■Piping systems for sewage treatment plantsand liningDegassing pipes for waste disposal facilities ■ ■ ■Drainage pipes for landfill sitesDischarge piping systems ■ ■Anwendungen im VersorgungsbereichPipes for irrigation systems ■ ■Pipes for potable water systems ■ ■ ■ ■Gas pipes ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■

■

■ ■

■

■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■

■ ■ ■ ■

■ ■

Applications for supply systems

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Reference list

ABBOTT Irland Kemira AB SwedenACERALIA Sagunto/Spanien Keramchemie GermanyADM Ireland Klinge Pharma IrelandAirbase Bitburg, D Lenzing Lowland, TNAlphen&&Rohner AG Swizerland Lenzing AG Lenzing, AArco Chemical Pittsburg, PA Leo Labs IrelandAstraZeneca AB Sweden LG Philips LCD KoreaASTURIANA DEL ZINC Spain LG Siltron KoreaAventis Germany Los Alamos Alburquerque, NMAvesta Polarit Sweden Lufthansa-dockyard Hamburg, DBASF AG Germany Mc Donnel Douglas St.Louis, MOBayer AG Germany Merck Rahway, NYBeck´s Germany Merck KgaA GermanyBioChemie Germany MVA Bielefeld, DBMW Germany Oda Plast NorwegenBoehler Vorarlberg, A Olympus IrelandBoeing Tulsa, OK Pepsi Cola IrelandBosch Germany Pfizer IrelandBoston Scientific Ireland Pharmacia AB SwedenBundeswehrkaserne Muenster, D Philips NetherlandsCAL Milk Producers Commerce, CA Pitman-Moore Burgwedel, DCelanese Shelby, NC Posco KoreaCelanese Germany Posco - Huels KoreaCessna Air Wichita, KS Powers Motor Morristown, NJCiba Geigy Swizerland Prayon SA BelgiumCNC Milsbeek Netherlands Ruwel-Werke Geldern, DDupont Niagara Falls, NY Samsung KoreaDuvel NV Belgium Samsung KoreaE.G.G. Miamisburg, OH Sandoz Cork. IrlandEMMSA Spain Schreyer Iserlohn, DFlockton Great Britain SGL GermanyFord Motor Company Detroit, MI Sharp Osaka, JapanFord Transmission Livonia, MI Siemens Arco Labs Camarillo, CAFujisawa Ireland SSAB SwedenFujitsu Gresham, OR Suedzucker GermanyGeneral Electric Evendale, OH Syntex BahamasGeneral Graphics Charleston, SC Takeda Bray IrelandGeneral Instrument Ireland Tech SingaporeGeneral Motors Trenton, NJ Tessenderlo Chemie BelgiumGrillo Germany Tiene Suikerraffinaderij NV BelgiumHenkel Ireland Tyrolean Airways (Werft) Linz, AHogovens Netherlands UCB NV BelgiumIBM Austin, TX Umicore NV BelgiumIBM Essex, JCT, VT University of IL Champaign, ILIBM LTD Ireland VASF Korea KoreaInfineon Germany Voest Alpine Linz, AInfraserv Germany VW GermanyIntel Ireland Wako Chemical Richmond, VAIrish Sugar Ireland Westing house SwedenJanssen Pharma Ireland WPF Great BritainJanssen Pharmaceutica NV Belgium Yamanuchi Ireland

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Reference projects

Bio waste treatment plant - Decomposition plant

Bio waste treatment plantZell am See, AustriaPolypropylene ventilation pipes in dimensions 63-1200mm SDR33 have been used for this project.Furthermore, reducers, bends, tees, etc. in injectionmolded and segmented design were installed. Thebutt-, socket- and extrusion welding have been usedas connection methods. Bio waste is the basis forthe extraction of compost (mixed manure) bymeans of a controlled process in this plant. Theappearing temperatures are between 0-70°C witha vacuum res. an overpressure of approx. 7000Pascal. The resistance of Polypropylene for thetransported media, e.g. ammonia and differentbacteria is excellent. The calculated life time ofthis plant is 25 years. Approximately 30.000 kg PPhave been installed in total at this project.

Double Containment pipe system - Corus bv

Double containment pipe system PVDF/PEVelsen Nord, The NetherlandsPVDF/PEHD double containment pipes indimension 90/160 SDR21/SDR17 have been usedat this project. Furthermore, bends 90°, bends 45°,tees and dog bones with and without cut-out wereinstalled. As connection method the cascade buttwelding was chosen. With this method, the insidepipe is welded by means of a standard butt weldingmirror and the outside pipe with a split heatingelement. The complete system is buried anddesigned as rigid system. In the pipeline,hydrochloric acid up to a temperature of 90°C and apressure of 3,5bar is transported. The resistance ofPVDF for the transport of this medium is excellent.The calculated life time of this plant is 25 years.Approximately 1.000m of double containment

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3rd party control

In addition to internal controls, regular tests onproducts and of internal procedures, performed byindependently accredited test institutes, are ofprime importance. This external control is oneelement of product approvals in several applicationranges and countries, where the modalities of theexternal control are regulated in registration andapproval certificates.

Presently following institutes are commissionedfor the production:

TUV-Sued-IndustrieserviceMPA-DarmstadtSKZ-WuerzburgLKT-WienOKI-Wien

Approvals

The high quality standard of our products isdocumented by a series of approvals.

The systems out of PE, PP and PVDF are approvedas per approval principles of DIBt and followingregistration numbers:

PEZ-40.23.232Z-40.23.231

PPZ-40.23.234Z-40.23.233Z-40.23.305

PVDFZ-40.23.201Z-40.23.202Z-40.23.307

The pipes and fittings out of PE, PP and PVDF areapproved according European pressure equipmentdirective 97/23/EG for the production of pressureequipment.

PPH and PVDF - fittings and valvesTUEV0206966701

Fittings PE100 and PE80TUEV0206966701

Fittings PPH and PPRTUEV0206966701

Fittings PVDFTUEV0206966701

Pipes PPH, PPR, PE80, PE100TUEV0206966701

Further approvals:

PPR-pipesON87272

PPH-pipesON83054

PE-pipes and fittingsOENORM EN 12201

PE-pipes and fittingsOENORM EN 13244

9494949494

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Standards

AGRU pipes, fittings and semi finished productsare manufactured out of standardized mouldingmaterials and produced according relevantinternational standards.

Hereafter a summary of the most importantstandards for PE, PP, PVDF and ECTFE.

OENORM B 3800Behaviour of building materials and componentsin fire

OENORM B 5014, part 1Sensory and chemical requirements and testingof materials in contact with drinking water

OENORM B 5174Polypropylene pipes

OENORM EN 12201P last ics piping systems for water supply -Polyethylene (PE)

OENORM EN 13244Plastics piping systems for buried and above-ground pressure systems for water for generalpurposes, drainage and sewerage - Polyethylene(PE)

OENORM EN ISO 1872Plastics - Polyethylene (PE) moulding and extrusionmaterials

OENORM EN ISO 1873P last ics - Polypropy lene (PP) mou lding andextrusion materials

OENORM EN ISO 15494Plastics piping systems for industrial applications- Polybutene (PB), polyethylene (PE) and poly-propylene (PP) - Specifications for components andthe system - Metric series (ISO 15494:2003)

DIN 4102Fire behaviour of building materials and buildingcomponents

DIN 8074/8075High-density polyethylene pipes

DIN 8077/8078Polypropylene pipes

DIN 16962 part 1 - part 13Pipe joints and their elements for pressure pipesof polypropylene (PP)

DIN 16963 part 1 - part 15Pipe joints and their elements for pressure pipesof high-density polyethylene (HDPE)

ISO 4065Thermoplastic pipes

ISO 10931 part 1 - part 5Plastics piping systems for industrial applications- Polyvinylidene fluoride (PVDF)

Notes

Order Sample for AGRU fittings

AGRU - CODE

Order Sample:PE 80 bend 90°, OD 63 mm, SDR 11Code: 20.001.0063.11

Material-Code No.:11 PPR grey12 PPH grey14 PPR black15 PP white16 PP natural17 PP-s grey19 PP-s-el black20 PE 80 black25 PE 100 black28 PE 80-el black29 PE 80 natural30 PVDF natural35 PVDF UHP40 ECTFE natural80 PP/PP81 PP/PVDF82 PE 80/PE 8083 PE 80/PP84 PE 80/PVDF85 PVDF/PVDF

Order Sample for AGRU sheets

AGRU - CODE

Order Sample:PVDF sheet, 2000 x 1000 mm, 2 mm thickCode: 30.600.2010.02

Material-Code No.:11 PPR grey12 PPH grey14 PPR black15 PPH white16 PP natural17 PP-s grey19 PP-s-el black20 PE 80 black21 PE 80 yellow25 PE 100 black28 PE 80-el black29 PE 80 natural30 PVDF natural35 PVDF UHP40 ECTFE natural78 PPs white

materialpart no.dimensionpipe series

xx . xxx . xxxx . xx

materialpart no.dimensionpipe series


AGRU - CODE

Bestellbeispiel:PE 80 Bogen 90°, DA 63 mm, SDR 11Code: 20.001.0063.11

Material-Code Nr.:11 PPR grau12 PPH grau14 PPR schwarz15 PP weiss16 PP natur17 PP-s grau19 PP-s-el schwarz20 PE 80 schwarz25 PE 100 schwarz28 PE 80-el schwarz29 PE 80 natur30 PVDF natur35 PVDF UHP40 ECTFE natur80 PP/PP81 PP/PVDF82 PE 80/PE 8083 PE 80/PP84 PE 80/PVDF85 PVDF/PVDF

Bestellbeispiel fuer AGRU Formteile

Notizen

AGRU - CODE

Bestellbeispiel:PVDF Platte, 2000 x 1000 mm, 2 mm dickCode: 30.600.2010.02

Material-Code Nr.:11 PPR grau12 PPH grau14 PPR schwarz15 PPH weiss16 PP natur17 PP-s grau19 PP-s-el schwarz20 PE 80 schwarz21 PE 80 gelb25 PE 100 schwarz28 PE 80-el schwarz29 PE 80 natur30 PVDF natur35 PVDF UHP40 ECTFE natur78 PPs weiss

Bestellbeispiel fuer AGRU Platten

MaterialTeil Nr.DimensionRohrreihe


MaterialTeil Nr.DimensionRohrreihe


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