4

TECHINICAL MANUAL

1.3 COMPARISION BETWEEN DIFFERENT PIPING SYSTEMSS.N. PROPERTY/PARAMETER GALVANIzED IRON METAL PVC PPR-C1. Service Life (Years) 5 - 15 10 - 30 10 >502. Standard Length (Meter) 6 5 6m 3 - 6

3. Jointing Method Threaded Joint Hard or Soft Scoldingor Welding Joint Solvent Cement Simple Thermal

Fusion

4. Skill Requires ExpertPlumber

ExpertPlumber

Do it your self-basic skill

Do it Yourself

5. Jointing Time Few Hours Few Hours Few Minutes Few Seconds

6. Strength of Joints SurfaceHomogeneity Surface Homogeneity Surface

HomogeneityFusion of Material-

Perfect Homogeneity

7. Line Commissioning Time More than 4Hrs/Half day

More Than 4 Hrs/HalfDay 24 Hours Immediate

8. Minimum Labor 2 PersonsRequired

2 PersonsRequired

2 persons required

One PersonRequired

9. Water Absorption Depends on rawmaterial used

Depends on RawMaterial Used 0.15 0.03

10. Brittleness Characteristics Resistant Resistant Poor-Resistance Highly Resistant11. Corrosion Resistant Very Weak Weak Week Non Corrosive

12. Chemical Resistance Poor Average Average Excellent

13. Installation convenience Difficult Difficult Average Simple & convenient 14. Joining Reliability Good Average Very good Excellent

15. Hygienic FactorUnhygienic due to

Zinc oxideFormation

Solvent Cement isChemicaly Unsafe

Leeches Chemically over Service Time

Food Grate-No Leeching-

Bacteriology Neutral

16. Inner Surface Smoothness Semi Smooth Semi Smooth Does not RetainSmoothness

ExcellentSmoothness

17. Easiness in Repair &Maintenance Troubleness Difficult Difficult Very Easy

18. Wall Thickness OD 20mm 2.6mm 1.5mm 1.9mm 3.4mm

19. Water Freezing Inside Pipeline Bursts Bursts Bursts Does not Burst

20. Joint Leak Proffness Average-Leaks With Time Average Average100% Leak

Proof Entire Service Life

21. Eco-Friendliness No NoHigh percentage ofChlorine & Toxic

Gases in Case of Fire

Eco Friendly, NoHarmful

SubstancesProduced During

Processing

1. Indoor & Outdoor installations of Hot & Cold water systems2. Public Utility Pipelines

3. Industries such as Chemical plants, Breweries, Petroleum & Gas plants, Oil plants, Mineral water plants, Water treatment plants, Sugar Manufacturing plants & other process industries

4. Residential & Commercial Buildings ideal for concealed piping system

5. Drinking water transportation

6. Liquid food transportation

7. Pharmaceutical plants

8. Solar water heating systems

9. Heating system inside building including floor, wall & radiator heating

10. Air Conditioning system

11. Compressed air supply systems

12. Piping systems for transportation of aggressive fluids in industries

13. Mining operations

14. Water treatment plants & distribution network

15. Sewerage networks

16. Public places such as Hospitals, Schools & Colleges, Hotels, Cinemas, Airports, Railways, Bus stations, Swimming pools etc.,

5

TECHINICAL MANUAL

2.0 PRODUCT CHARACTERISTICS2.1.1 PHYSICAL PROPERTIES

2.1.2 THERMAL PROPERTIES

2.1.3 MECHANICAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUE

Density, at 23oC ISO R 1183 g/cm3 0.897Melt Flow IndexMFI 190oC/5KgMFI 230oC/2.16KgMFI 230oC/5Kg

ISO R 1133g/10ming/10ming/10min

0.500.301.30

Viscosity ISO 1191ISO 1628 T3

cm3/g 420-430

PROPERTY TEST METHOD UNITS VALUEThermal Conductivity DIN 52612 W/m.K 0.24Specific heat, at 23oC Calorimeter KJ/Kg.K 2.0Coefficient of linear expansion DIN 53752 mm/MoC 1.5x10-4

VICAT Softening Point ISO 306 oC 132Melting Temperature Range ISO 3146 oC 140-150

PROPERTY TEST METHOD UNITS VALUETensile Stress at Yield(50mm/minute)

ISO 527-1,2 MPa 24

Tensile Strain at Yield(50mm/minute

ISO 527-1,2 % 10

Tensile Modules (Secant) ISO 527-1,2 MPa 850Flexural Modules ASTM D 790 MPa 850Tear Strength ISO 527 MPa 40Elongation at Tear ISO 527 % 800Shore D Hardness DIN 53 505 - 65Pipe Friction Factor - - 0.007CHARPY Impact Strength 23oC

0oC-30oC

2.1.4 ELECTICAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUEDie Electric Constant DIN 53483 - 2.3Volume Resistivity DIN 53482 Ohm-cm >1x1016

Die Electric Strength DIN 53481 Kv/mm 320

6

TECHINICAL MANUAL

2.2 STANDARD WORKING CONDITIONS & SERVICE LIFE

Long-term performance curve show the behavior of pipe line depending on pressure & operating temperature. It establishes the average life expectancy of a pipe line as a function of hoop stress acting on the pipe walls.

Hoop stress is in proportion with the pressure according to the following formula:-

δ = Sf X p X (d-s)/ 2s

Where:

δ = hoop stress (MPa)

Sf = Safety factor

p = Internal pressure (MPa)

d = Outside diameter of Pipe (mm)

S = Wall thickness of Pipe (mm)

If we extrapolate the hoop stress from the long term performance curve and apply the formula using 1.5 safety factor, the admissible operating pressure are obtained as given in the table.

= Recommended application-Cold water installation

= Recommended application-Hot water installation

= Recommended application-Central heating installation

* Bracketed values apply where testing can be shown to have been carried out for longer than 1 year at 110oC

Tem

per

atu

re 0 C

10 0 C

20 0 C

30 0 C

40 0 C

50 0 C

60 0 C

70 0 C

80 0 C

95 0 C

Pipe Serises accordingto DIN 8077/8078

Safety-factor 15

Nominal pressure forPP-R pipes (kgs/cm2)

SDR 11

1

1

1

1

1

1

1

1

5

5

5

5

5

5

5

5(10)* (3.4)* (4.2)*(2.1)*

2.53.93.21.04.85.54.35.15.96.06.56.46.76.97.27.77.47.78.08.28.59.28.99.29.49.8

10.110.110.610.911.211.612.0

12.812.512.913.313.7

14.1 15.0 14.8 15.2 15.6 16.1 16.6 17.6 27.8

26.4 25.5 24.7 24.0 23.4 23.8 22.3

21.7 21.1 20.4 19.820.2

19.018.317.717.316.917.116.015.615.014.514.114.513.513.112.612.211.812.211.411.010.510.110.39.59.38.06.78.67.66.35.16.14.0 5.0

7.76.48.09.6

8.510.9

10.111.711.913.012.713.313.814.315.414.915.415.916.517.018.317.818.318.819.620.221.521.221.822.323.123.9

25.524.925.726.527.3

28.130.029.530.331.132.133.235.0

10

10

10

10

10

10

10

25

25

25

25

25

25

25

50

50

50

50

50

50

100

100

100

100

15

102550

100

PN 10

SDR 74

PN 16

SDR 6

PN 20

Ser

vice

Lit

eIn

Yea

rs

ADMISSIBLE OPERATING PRESSURE

Explanations:-

7

TECHINICAL MANUAL

LONG TERM PERFORMANCE

1 5 10 25 50 100

Years

Pipe 20 x 1.9mm,4 bar internal pressure

Pipe 20 x 3.4mm,10 bar internal pressure

10 0C

20 0C

30 0C

40 0C

50 0C

60 0C

70 0C

80 0C

90 0C

95 0C

110 0C

50

40

30

25

20

15

109876

5

43.5

3

2.5

2

1.5

1

0.50,1 1 10 102 103 104

Time to failure[h]105 106

Ho

op

str

ess

[MP

a]

8

TECHINICAL MANUAL

D

S

d

3.0 PRODUCT DETAILS

3.2 PRODUCT RANGE

3.1 REFERENCE STANDARDS

3.2.1 PIPES As per DIN 8077 & DIN 8078

DIN 8077 Polypropylene (PP) pipes-Dimensions

DIN 8077 Polypropylene (PP) pipes- General quality requirements & testing

DIN 16962 Part 5 - Pipe joint assemblies & fittings for (PP) pressure pipes General quality requirements & testing

Part 6 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Elbows for socket welding

Part 7 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Tee pieces for socket welding

Part 8 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Sockets & caps for socket welding

Part 9 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Fittings for butt welding

IS 9845 Method of analysis for determination of specific and/or overall migration of constituents of plastic materials and articles intended to come into contact with foodstuffs

IS 10500 Specification for Polypropylene & its copolymers for its safe use in contact with food stuffs, Pharmaceuticals & drinking water

9

TECHINICAL MANUAL

The Pipe is used for conveying HOT and COLD water/fluids/chemicals/compressed air in various plumb-ing installations such as:

a. Single layer (Green Color) PPR Pipes for Indoor installations

b. Three layer (3) PPR Pipes for Indoor/Outdoor installations Outer Layer (Green color) PPR is UV resistant, which makes pipes suitable for use under direct sunlight Inner layer (White Color) PPR is antimicrobial which provides hygiene and protection from internal bacterial growth Middle layer (Black Color) PPR provides body strength to the pipe

The pipe can be custom manufactured in other colors for suitable quantity orders

PPR PIPE-PN10/SDR 11 (Per Meter)

PRODUCT CODE

DIMENSIONmm Inch

PRODUCTCODE

DIMENSIONmm Inch

GHI-20.10 20 1/2´´ GHI-90.10 90 3´´GHI-25.10 25 3/4´´ GHI-110.10 110 4´´GHI-32.10 32 1´´ GHI-124.10 124 47/8´´GHI-40.10 40 11/4´´ GHI-160.10 160 6´´GHI-50.10 50 11/2´´ GHI-180.10 180 7´´GHI-63.10 63 2´´ GHI-200.10 200 77/8´´GHI-75.10 75 21/2´´

PPR PIPE-PN16/SDR 7.4 (Per Meter)

PRODUCT CODE

DIMENSIONmm Inch

PRODUCTCODE

DIMENSIONmm Inch

GHI-20.10 20 1/2´´ GHI-90.10 90 3´´GHI-25.10 25 3/4´´ GHI-110.10 110 4´´GHI-32.10 32 1´´ GHI-124.10 124 47/8´´GHI-40.10 40 11/4´´ GHI-160.10 160 6´´GHI-50.10 50 11/2´´ GHI-180.10 180 7´´GHI-63.10 63 2´´ GHI-200.10 200 77/8´´GHI-75.10 75 21/2´´

10

TECHINICAL MANUAL

3.2.2 FUSION WELD

PPR PIPE-PN20/SDR 6 (Per Meter)

COUPLERPRODUCT

CODEDIMENSION

mmPRODUCT

CODEDIMENSION

mmCPL.16.20 16 mm CPL.75.20 75 mmCPL.20.20 20 mm CPL.90.20 90 mmCPL.25.20 25 mm CPL.110.20 110 mmCPL.32.20 32 mm CPL.160.20 160 mmCPL.40.20 40 mm CPL.200.20 200 mmCPL.50.20 50 mm CPL.250.20 250 mmCPL.63.20 63 mm CPL.315.20 315 mm

The COUPLER is used to join two pipes to each other by means of fusion welding. Its advantage allows for the joining of short length pipes or replacing faulty pieces of pipe.

PRODUCT CODE

DIMENSIONmm Inch

PRODUCTCODE

DIMENSIONmm Inch

GHI-20.10 20 1/2´´ GHI-90.10 90 3´´GHI-25.10 25 3/4´´ GHI-110.10 110 4´´GHI-32.10 32 1´´ GHI-124.10 124 47/8´´GHI-40.10 40 11/4´´ GHI-160.10 160 6´´GHI-50.10 50 11/2´´ GHI-180.10 180 7´´GHI-63.10 63 2´´ GHI-200.10 200 77/8´´GHI-75.10 75 21/2´´

ELBOW 90o

The ELBOW is used at corners where pipeline makes a turn of 90o.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

ELB.90.16.20 16 mm ELB.90.75.20 75 mmELB.90.20.20 20 mm ELB.90.90.20 90 mmELB.90.25.20 25 mm ELB.90.110.20 110 mmELB.90.32.20 32 mm ELB.90.160.20 160 mmELB.90.40.20 40 mm ELB.90.200.20 200 mmELB.90.50.20 50 mm ELB.90.250.20 250 mmELB.90.63.20 63 mm ELB.90.135.20 315 mm

The ELBOW 45o is used where the pipeline changes direction through 45o.

ELBOW 45o*PRODUCT

CODEDIMENSION

mmPRODUCT

CODEDIMENSION

mmELB.45.16.20 16 mm ELB.45.90.20 75 mmELB.45.20.20 20 mm ELB.45.110.20 110 mmELB.45.25.20 25 mm ELB.90.160.20 160 mmELB.45.32.20 32 mm ELB.90.200.20 200 mmELB.45.40.20 40 mm ELB.90.250.20 250 mmELB.45.50.20 50 mm ELB.90.315.20 315 mmELB.45.63.20 63 mm

11

TECHINICAL MANUAL

PLAIN UNION is used to join two pipes coaxially. It provides facility of reopening the joint, basically for maintenance.

EQUAL TEE

EQUAL TEE is used to take an outlet/branch at 90o from main pipeline.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

EQT.16.20 16 mm EQT.90.20 90 mmEQT.20.20 20 mm EQT.110.20 110 mmEQT.25.20 25 mm EQT.160.20 160 mmEQT.32.20 32 mm EQT.200.20 200 mmEQT.40.20 40 mm EQT.250.20 250 mmEQT.50.20 50 mm EQT.315.20 315 mmEQT.63.20 63 mm

PLAIN UNION*

under development*

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 mm 90 mm20 mm 110 mm25 mm 160 mm32 mm 200 mm40 mm 250 mm50 mm 315 mm63 mm

END CAP is used as a stopper at the end of pipeline. It also seals the top end of pipeline for pressure leakage test after completion of piping work.

END CAP*

under development*

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 mm 90 mm20 mm 110 mm25 mm 160 mm32 mm 200 mm40 mm 250 mm50 mm 315 mm63 mm

EQUAL CROSS TEE*

under development*EQUAL CROSS TEE is used to take two branches/outlets at 90o from pipe line at the same junction but in opposite directions.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 mm 75 mm20 mm 90 mm25 mm 110 mm32 mm 160 mm40 mm 200 mm50 mm 250 mm63 mm 315 mm

12

TECHINICAL MANUAL

PRODUCT CODE

DIMENSIONmm

PBR.90.16.20 16 x 20

PBR.90.20.20 25 x 20

PBR.90.25.20 32 x 20

PBR.90.32.20 32 x 25

PBR.90.40.20 40 x 32

PBR.90.50.20 50 x 32

PBR.90.63.20 63 x 40REDUCING ELBOW is used to joint two different sizes of pipes at 90o corner/turn.

PIPE CLAMP* REDUCER

REDUCING ELBOW 90o

PIPE CLAMP is used to secure the pipeline in it’s installed position on the wall.

REDUCER is used to joint bigger diameter pipe to smaller diameter pipe coaxially.

PRODUCT CODE

DIMENSIONmm

PBR.45.16.20 16 x 20PBR.45.20.20 25 x 20PBR.45.25.20 32 x 20PBR.45.32.20 32 x 25PBR.45.40.20 40 x 32PBR.45.50.20 50 x 32PBR.45.63.20 63 x 40

REDUCING TEE

REDUCING TEE is used to take a smaller size branch pipe at 90o from main pipe.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 x 20 63 x 2525 x 20 63 x 2032 x 20 75 x 6332 x 25 75 x 5040 x 32 75 x 4050 x 32 75 x 3263 x 40 90 x 7563 x 32 110 x 90

under development*

MALE THREADED TEE

MALE THREADED TEE is used to join a female threaded metallic fitting with PP-R line for taking Outlet.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

MTT.16.050.20 16 x 1/2 MTT.32.050.20 32 x 1/2

MTT.16.075.20 16 x 3/4 MTT.32.075.20 32 x 3/4

MTT.20.050.20 20 x 1/2 MTT.40.125.20 40 x 11/4

MTT.20.075.20 20 x 3/4 MTT.50.125.20 50 x 11/4

MTT.25.050.20 25 x 1/2 MTT.63.125.20 63 x 11/4

MTT.25.075.20 25 x 3/4

3.2.3 TRANSITION FITTINGS WITH METALLIC THREADED INSERTS

13

TECHINICAL MANUAL

FEMALE THREADED TEE is used to join a male threaded metallic fitting with PP-R line for taking Outlet.

FEMALE THREADED TEEPRODUCT

CODEDIMENSION

mmPRODUCT

CODEDIMENSION

mmFTT.16.050.20 16 x 1/2 FTT.32.050.20 32 x 1/2

FTT.16.075.20 16 x 3/4 FTT.32.075.20 32 x 3/4

FTT.20.050.20 20 x 1/2 FTT.40.125.20 40 x 11/4

FTT.20.075.20 20 x 3/4 FTT.50.125.20 50 x 11/4

FTT.25.050.20 25 x 1/2 FTT.63.125.20 63 x 11/4

FTT.25.075.20 25 x 3/4

MALE THREADED ELBOW

MALE THREADED ELBOW is used to join a female threaded metallic fitting with PP-R line at 90o corner/turn

MTE.90.16.050.20 16 x 1/2

MTE.90.16.075.20 16 x 3/4

MTE.90.20.050.20 20 x 1/2

MTE.90.20.075.20 20 x 3/4

MTE.90.25.050.20 25 x 1/2

MTE.90.25.075.20 25 x 3/4

PRODUCT CODE

DIMENSIONmm

COUPLER-MALE THREADED

COUPLER-MALE THREADED is used to join a female threaded metallic fitting with PPR line.

PRODUCT CODE

DIMENSIONmm

MTE.90.16.050.20 16 x 1/2

MTE.90.16.075.20 16 x 3/4

MTE.90.20.050.20 20 x 1/2

MTE.90.20.075.20 20 x 3/4

MTE.90.25.050.20 25 x 1/2

MTE.90.25.075.20 25 x 3/4

MTE.90.32.050.20 32 x 1/2

MTE.90.32.075.20 32 x 3/4

MTE.90.40.125.20 40 x 11/4

MTE.90.50.125.20 50 x 11/4

MTE.90.63.125.20 63 x 11/4

MTE.90.32.050.20 32 x 1/2

MTE.90.32.075.20 32 x 3/4

MTE.90.40.125.20 40 x 11/4

MTE.90.50.125.20 50 x 11/4

MTE.90.63.125.20 63 x 11/4

COUPLER-FEMALE THREADED is used to join a male threaded metallic fitting with PP-R line.

FTS.16.050.20 16 x 1/2

FTS.16.075.20 16 x 3/4

FTS.20.050.20 20 x 1/2

FTS.20.075.20 20 x 3/4

FTS.25.050.20 25 x 1/2

PRODUCT CODE

DIMENSIONmm

COUPLER-FEMALE THREADED

FTS.25.075.20 25 x 3/4

FTS.32.050.20 32 x 1/2

FTS.32.075.20 32 x 3/4

FTS.40.125.20 40 x 11/4

FTS.50.125.20 50 x 11/4

FTS.50.125.20 63 x 11/4

14

TECHINICAL MANUAL

GATE VALVE*

GATE VALVE is used to start, regulate and stop the water flow in pipeline.

3.2.4 VALVES*

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 mm 40 mm20 mm 50 mm25 mm 63 mm32 mm

under development*DESIGNER VALVE*

DESIGNER VALVE is used in concealed piping to start, regulate and stop the water flow in pipeline. It is designed to have an aesthetic look.

PRODUCT CODE

DIMENSIONmm

PRODUCTCODE

DIMENSIONmm

16 mm 40 mm20 mm 50 mm25 mm 63 mm32 mm

under development*

DOUBLE UNION BALL VALVE*

CUTTER

DUB VALVE is used to start, regulate and stop the water flow in pipeline

3.2.5 WELDING ACCESSORIES

PRODUCT CODE

DIMENSIONmm

16 mm20 mm25 mm32 mm40 mm50 mm63 mm

15

TECHINICAL MANUAL

NOTE: PRODUCTS WITH * ARE UNDER DEVELOPMENTAL STAGE

POLYFUSION DEVICES (WELDING DEVICES)PRODUCT

CODEDIMENSION

mm20 - 4040 - 6375 - 100160

3.3 QUALITY TESTS

Strict quality control of incoming raw materials and factory operations ensures the continuous production of high quality products. All pipes & Fittings are manufactured to meet or exceed the test values, frequency of testing and functional requirements of the DIN standards. All raw materials are tested and certified prior to manufacturing range of products. Release for shipment is made only after all prescribed tests are completed and the results have met GHI and the customers’ requirements.

In order to assure a high and consistent quality, we have established in-house laboratory with modern testing equipments and have highly skilled and trained technicians.The quality assurance plan covers:-

a. ACCEPTANCE TESTSi. Incoming Inspection & Testing of

• Raw Material for MFI• Product accessories for Surface Finish, Fitment & Operation• Rubber parts for Hardness & Dimensions

ii. In-process Inspection & Testing of Pipes, Fittings & Valves for Visual appearance, Fitment with Gauges & Dimensions

iii. • Final Inspection & Testing of• Pipes for Visual appearance, Dimensions, Hydraulic Test, Heat Reversion Test &

Hammer Test• Fittings for Visual appearance, Dimensions, Hydraulic Test & Hammer Test• Valves for Drip Proofness Test & Hydraulic Test

b. Type Testsi. Pipes & Fittings for Long Term Hydraulic Testii. Valves for Thermal Shock Testiii. Piping installation including assemblies of Pipes, Fittings & Valves for • Hot & Cold Water Cycle Test

• Water Hammer Testiv. Threaded Brass Inserts for Torque Test & Material Composition

16

TECHINICAL MANUAL

4.0 PRODUCT DETAILS

4.1 THERMAL EXPANSIONA pipe line which is subjected to a variation of temperatures changes its length if it is free to do so. This change in length is proportional to the unit linear coefficient of thermal expansion. Any linear expansion or contraction caused by a thermal gradient can easily be calculated using the following formula.

Where:Expansion(+) or contractor(-) in length, (mm)Intial pipe length, (Meter)Coefficient of thermal expansion( for PP-R 0.15mm/moc)

Temperature, difference ( oC)

The expansion and contraction adjustment of PPR pipeline is generally made in longitudinal direction only. Enough space shall be provided and proper type of supports shall be used to allow the free movement of pipe in axial directions.

Once the change in length of pipeline on account of thermal expansion/contraction has been calculated, a correct planning of pipelines is necessary to ensure that its effect do not cause deformation of the piping itself. PPR systems make it possible to install easy and convenient compensation for change in length using the suitable provision of following:

• Fix supports & Sliding supports

• Free flexible pipe segment; (Expansion Arm).

• Free flexible pipe loop (Compensation Loop).

Example: for 5 meter PP-R line operating between 25 to 55oC

Then,(55-25)=30oC

0.15 X 5 X 30 = 22.5mm

Fixed and Sliding supports secure external pipelines to the masonry structure of the building to prevent the movements generated by thermal expansion, totally or partially.

Fixed Supports:-are used when the axial expansion of the pipe line should be limited. Fixed support provides a rigid connection between external pipeline installations with masonry structure. The fixed supports must normally be positioned where the system changes direction (Elbows, Tees, etc.) & near to Valves, Cocks, Water meter, etc. to ensure that expansion forces are not discharged in these points. In all cases, fixed support should always be provided next to any joint in the pipeline created using any welded fitting.

Obviously the fixed supports limit the length of section of pipe free to expand, and reduce the relative change in length value.Sliding Supports:-are used to allow the pipe to move axially in both directions. They have to be positioned well away from joints made using welded fittings, on a free length of the pipes surface. The sliding support collar must be absolutely free from pipe diameter otherwise it may damage the surface of the pipe where

17

TECHINICAL MANUAL

PIPE

WALL

PERMITTED AXIAL TRAVEL

SLIDINGSUPPORT

PIPE

PIPE

WALL

FITTINGFIXED

SUPPORTFIXED

SUPPORT

PIPE

PIPE

WALL

PERMITTED AXIAL TRAVEL

SLIDINGSUPPORT

PIPE

PIPE

WALL

FITTINGFIXED

SUPPORTFIXED

SUPPORT

PIPE

it is installed.

Sliding support also ensures that the pipeline remain straight in spite of thermal stresses.

PIPEDIA.mm

Horizontal clamp spacing distance according to temperatures, cm

20 65 63 61 60 58 53 4825 75 74 70 68 66 61 5632 90 88 86 83 80 75 7040 110 110 105 100 95 90 8550 125 120 115 110 105 100 9063 140 135 130 125 120 115 10575 155 150 145 135 130 125 11590 165 160 155 145 140 130 120110 175 175 170 165 155 145 135

20oC 30oC 40oC 50oC 60oC 70oC 80oC

PIPEDIA.mm

Vertical clamp spacing distance according to temperatures, cm

20 85 82 78 78 75 69 6225 98 96 91 88 86 79 7332 117 114 112 108 104 98 9140 143 143 137 130 124 117 11150 163 156 150 143 137 130 11763 182 176 169 163 156 150 13775 202 195 189 176 169 163 15090 215 208 202 189 182 169 156110 228 228 215 215 202 189 176

20oC 30oC 40oC 50oC 60oC 70oC 80oC

Free flexible pipe segment (Expansion Arm): - with the help of free flexible pipe segment, provided at the position of change in direction, the change in length of pipeline is totally compensated. The length of free flexible pipe segment is calculated using following formula:

18

TECHINICAL MANUAL

FIXEDSUPPORT

FIXEDSUPPORT

SLIDINGSUPPORT

BB

10d

SLIDINGSUPPORT

SLIDINGSUPPORT

FLEXIBLE COMPENSATOR MADE OF PP-R PIPE AND 90%D ELBOW

SOCKET SOCKET

LS

SOCKET

FIXEDSUPPORT

FIXEDSUPPORT

LS

SLIDINGSUPPORT

PIPE

Length of free flexible segment = LS=C

WhereLS = Length of free flexible segment (mm)

C = Constant of material (for PP-R, C=30).

d = pipe outside diameter (mm).

= Expansion or contraction length (mm).

d

Free flexible pipe loop (Compensation Loop): - If the change in length cannot be compensated using expansion arm, it is necessary to install a free flexible loop (Compensation loop). Free flexible bend can be easily prepared on site with required lengths of PPR pipe & 4 nos. of 90o elbows.

FIXEDSUPPORT

FIXEDSUPPORT

SLIDINGSUPPORT

BB

10d

SLIDINGSUPPORT

SLIDINGSUPPORT

FLEXIBLE COMPENSATOR MADE OF PP-R PIPE AND 90%D ELBOW

SOCKET SOCKET

LS

SOCKET

FIXEDSUPPORT

FIXEDSUPPORT

LS

SLIDINGSUPPORT

PIPE

To prepare a free flexible loop you have to calculate:

• The length of free flexible segment (LS) with the help of formula as explained in Free flexible pipe segment (Expansion Arm)

• The minimum width (B) between two arms of the loop = 10 times the outside diameter of the pipe.

L 1

T T T T T T T

L 2 L 3 L 4

FixSupport

FixSupport

Length absorption with compensation loopin a straight section of pipe

T

T

T

T T

T

T

T

TT

TT

T

Fixed support in the middleof the vertical pipe section

L 2

L 1

L 4

L 3

L

L

L

L

L

L 5

Fixed support at baseof vertical pipe section

Fixed support

L

L

L

L

T

T T

TT

T

T

T T

T

T

L 1

T T T T T T T

L 2 L 3 L 4

FixSupport

FixSupport

Length absorption with compensation loopin a straight section of pipe

T

T

T

T T

T

T

T

TT

TT

T

Fixed support in the middleof the vertical pipe section

L 2

L 1

L 4

L 3

L

L

L

L

L

L 5

Fixed support at baseof vertical pipe section

Fixed support

L

L

L

L

T

T T

TT

T

T

T T

T

T

L 1

T T T T T T T

L 2 L 3 L 4

FixSupport

FixSupport

Length absorption with compensation loopin a straight section of pipe

T

T

T

T T

T

T

T

TT

TT

T

Fixed support in the middleof the vertical pipe section

L 2

L 1

L 4

L 3

L

L

L

L

L

L 5

Fixed support at baseof vertical pipe section

Fixed support

L

L

L

L

T

T T

TT

T

T

T T

T

T

ExAMPLES OF FIxED AND SLIDING SUPPORTS IN PIPE SECTION: -

19

TECHINICAL MANUAL

No. RECOMMENDATIONFOR PIPE CONNECTION DESCRIPTION

1

PIPE CONNECTION CAN BE MADE AT SOME DISTANCE AWAY FROM THE WALL

2

THE CONNECTION PIPE CAN BE PASSED THROUGH A HOLE MUCH LARGER THAN THEPIPE DIAMETER

3THE CONNECTION CAN BE MADE THROUGH A BRANCH PIPE TO PROVIDE FLEXIBILITY

4.2 LAYING IN SANITARY SHAFT / PIPE DUCT OF A BUILDING

When making the apartment pipe connections from main pipe going through the sanitary shaft of the building, the alternative techniques above can be applied in order to compensate for thermal expansion & contractionLS

LS

LS

LS

LS

LS

DRAWINGPIPE

DIAMETER(mm)

MINIMUM BENDINGRADIUS

(mm)

20 160

25 200

32 256

40 320

50 400

4.3 BENDING

During laying of pipeline, PPR pipes may be required to be bent. Bending shall be done by using hot air blowing at 140 oC. Direct heating by open flame must/should be avoided. Radius for PPR pipe bend should be minimum 8 times its diameter. The table indicates minimum bending radius for each size of pipe.

LS

LS

R

P

When conveying hot water through any pipe, heat is transferred through the pipe w a l l PPR pipes posses a much lower coefficient of thermal conductivity (0.24W / mK) compared to metal pipes. Therefore, most often it may not be required to insulate the pipelines which are used for hot water concealed application. However, for centralized heating systems, to prevent heat loss and to isolate the pipelines from other utilities, it is advisable to insulate these lines. The required thickness of insulation is quite small as compared with conventional lines.

20 6 1025 6 1032 10 1340 10 1350 10 1363 13 2075 20 2090 20 25

100 25 32

PipeSize mm

Thermal conductivity of Insulation material

Recommended minmium insulation thickness in mm0.030W/mk 0.035W/mk

4.4 INSULATION4.4.1 FOR HOT WATER

The above table indicates the recommended insulation thickness for different pipe sizes.

20

TECHINICAL MANUAL

4.5 RESISTANCE TO ULTRA VIOLET (UV) RAYS :-

Potable cold water plants have to be protected against heat gain and the formation of condensation. Standard value for the minimum thickness as stipulated in DIN-1988, part 2 have to be taken from the following table

(Note :- Recommended insulation for all sizes of pipes for different water temperature at various level of humidity are available on request)

PPR pipes & fittings have sufficient U.V. stability to provide protection from UV rays. The Pipes are three layers, which enables targeted UV protection.

Type of installation Insulation thickness (for 0.04 W/mk thermalconductivity material) in mm

Open installed pipes, in no heated room (i.e. celler) 4 mmOpen installed pipes, in no heated room 9 mmPipe in a duct, without warm pipe 4 mmPipe in a duct, beside warm pipe 13 mmPipe in a pipe chase riser 4 mmPipe in a pipe chase, beside warm water pipes 13 mmPipe in a concrete floor 4 mm

Minimum insulation thicknessfor the insulation of potable water pipes (10 oC) as per DIN 1988, part 2

PPR pipes & fittings meet the requirements of IS 10500-91 for drinking water and IS 10146-87 for Reachable additives as it is safe for drinking water. The product is Food Grade.

PPR pipes & fittings have combustion point 330 oC & burning point 360 oC. These conform with B2 class fire requirements of normal combustibility according to DIN 4102. On fire, PPR pipes & fittings emit carbon dioxide and water. Other than this, carbon monoxide gas, molecular hydrocarbon and oxidation products of these are also emitted in proportion to the availability of oxygen. Even if the fire is incomplete, the materials emitted are less poisonous than wood or similar materials on fire under the same conditions.

The smoke that comes out from PPR fire is non-hazardous at room temperature but fumes formed at elevated temperatures can cause irritation.

At lower temperature of 0 C and below, the flexibility of PPR pipes reduces and its impact strength also reduces. This makes pipes more prone to mechanical damages against impact loads. To avoid the damages at low temperature, it is advisable to insulate the pipe lines.(Refer ‘Insulation’ given under 4.2.2)

4.6 SUITABILITY FOR DRINKING WATER:

4.7 FIRE RESISTANCE:

4.8 LOW TEMPERATURE RESISTANCE :

4.1.2 FOR COLD WATER

21

TECHINICAL MANUAL

While designing the PPR piping system, one should be aware that PPR piping is quite different from other traditional materials like GI or Copper as well as PVC or CPVC. For good and safe design and installation, the following shall be taken into account.

5.1 GENERAL GUIDELINES

• Pipes & fittings have different dimensions from other types of pipes and fittings. Even though the bore diameter of pipe is less than the equivalent metal or plastic pipe, the flow is more due to smoothness & less friction (Refer table: “Pipe Friction Loss & Flow Rate”) Hydraulic calculation should be done each time for the best choice of pipeline diameters.

• Linear thermal expansion/contraction of PPR pipes is more as compared with metal pipes. This needs to be taken into consideration designing and installation to avoid stressing of pipeline by providing flexible free length and proper support. (Refer section 4.1 Thermal expansion).

• Refer section 2.3 for STANDARD WORKING CONDITION AND SERVICE LIFE for designing.

• Use 3 layer pipes for outdoor installations.

• Use black pipes for solar heating system.• Provide insulation for centralized heating systems and chilled water systems (Refer section 4.4

Insulation)

• Refer section 8 for Dos & Don’ts

5.2 PIPELINE DESIGN5.2.1 FLOW RATEAnalytical flow is typical for each analytical section. Draw-off point’s water quantity shall be worked out, taking into consideration water consumption (which is not simultaneous at all draw-offs). The following table gives formula for calculating the analytical flow for different types of application:-

Formula for 0.7 < Eq< 20lps Formula for Eq > 20lpsResidential buildings Q=0.682 (Eq)0.45 - 0.14 Q=1.7 (Eq)0.25 - 0.7Commercial buildings Q=0.682 (Eq)0.45 - 0.14 Q=0.4 (Eq)0.54 - 0.48

Hotels & shopping Malls Q=0.4 (Eq)0.086

Q=0.698 (Eq)0.5 - 0.12Q=1.08 (Eq)0.5 - 1.82

Q=1.08 (Eq)0.5 - 0.12Hospitals Q=0.698 (Eq)0.5 - 0.12 Q=0.25 (Eq)0.65 - 1.25Schools Q=4.4 (Eq)0.27 - 3.41 Q= -22.5.08 (Eq)0.5 - 11.5

Application Design flow rate Q12 in lps as per DIN 1988 part 3 can be calculated from following formula

Q = Standard outflow from the draw-off points, lps

Eq = Sum of all standard outflows from the draw-off points serviced by dimensional section of the installation, lps Qp = Design flow, lps • Maximum design flow velocity in service pipe should be 2 M/s. • In supply mains, the maximum flow velocity shall be between 2.5 to 5.0 M/s. • Select the size of main pipe considering the flow Eq

Where,

22

TECHINICAL MANUAL

DESIGN FLOW RATES OF COMMON WATER POINTS

0.5 Taps Without air inlet DN 15 - 0.30

0.5 Taps Without air inlet DN 20 - 0.50

0.5 Taps Without air inlet DN 25 - 1.00

1.0 Taps With air inlet DN 10 - 0.15

1.0 Taps With air inlet DN 15 - 0.15

1.0Shower heads for purfication showers DN 15

0.10 0.20

1.2 Flush Valves DN 15 (Toilet) - 0.70

0.4 F.V. DN 25 (Toilet) - 1.00

1.0 Flush Valves DN 15 (Urinal) - 0.30

1.0 Domestic dish washers DN 15 - 0.15

1.0 Domestic washing machine DN 15 - 0.25

Mixing batteries for:1.01.0

Bath Shower DN 15Bath-tubs DN 15

0.150.15

--

1.0 Kitchen sinks DN 15 0.07 -

1.0 Washstands DN 15 0.07 -

1.0 Bidet DN 15 0.07 -

1.0 Mixing battery DN 20 0.30 -

0.5 Gayser DN 30 - 0.15

1.0 Gayser DN 20 - 0.20

Minimum Pressure

Type of water Calculated flow on taking:

Mixed waterCold/warm

Only cold or warm water potable

In normal piping, two types of pressure loss can be found,

1 Distributed pressure loss related to pipe roughness, dimensions, physical properties and velocity of the liquids.

2 Local loss related to elbows, tees, valves and fittings which cause a remarkable variation in the liquid flow.

The PPR pipe has extremely smooth inner surface compared to metal pipes. Therefore, pressure loss is quite low.

Pressure loss changes are very little in the normal span of operating temperatures (up to 60oC) in potable water pipeline.

The details are available on request.

5.2.2 PRESSURE LOSS

5.2.2.1 DISTRIBUTED PRESSURE LOSS

23

TECHINICAL MANUAL

The PPR pipe has extremely smooth inner surface compared to metal pipes. Therefore, pressure loss is quite low.

Pressure loss changes are very little in the normal span of operating temperatures (up to 60oC) in potable water pipeline.

The details are available on request.

Where,R = Total local pressure loss in (mm)r = Local resistance coefficient value

as given in following tableV = Mean velocity in fluid in (m/s)g = Acceleration of gravity = 9.81 (m/s2)6 = Specific gravity of water = 1000 (kg/

m3)

In pipeline, local pressure loss takes place due to presence of fittings which can be calculated using following formula

R = ( r ) V26

2 g

5.2.2.2 LOCAL PRESSURE LOSS

Name of pp-r fittingSymbol for pp-r fitting

Coefficientvalue (r)

Coupler 0.25

Reducer Single stage reducer Double stage reducer Three stage reducer Four stage reducer

0.500.600.700.85

Elbow 90o

Elbow 45o

1.20.5

Tee 1.8

Male / Female Threaded Tee 1.8

Reducing Tee 3.0

Male/Female Treaded Adaptor

Reducing Male/Female Adaptor

0.5

0.8

Male/Female Treaded ElbowReducing Treaded Elbow

1.41.6

Valve 202532

9.58.57.6

Union 8.3

Local resistance coefficient “r” PP-R plumbing fittings.

Note :-1) These are reference values and they vary according to water temperature.

2) As fitting diameter increases, the value of ‘r’ decreases.

24

TECHINICAL MANUAL

After cooling, cut the repair bar projected outside the pipe line using pipe cutter.

4

Insert heated repair bar in the hole up till the full depth and hold it for a minute.

3

6.0 TESTING THE INSTALLATION

6.1.1 PRIMARY TEST

6.1.2 MAIN TEST

6.1 PRESSURE TESTAccording to DIN 1988, PPR Pipeline for portable water installations have to be (before concealing) hydraulically pressure tested as follows -

While carrying out the pressure test the material properties of PPR lead to expansion of pipe. This influences the test result. A further influence of the result can be caused by the thermal expansion of PPR pipes. Different temperatures of pipe & test medium lead to alteration of pressure. A temperature change of 10oC corresponds to pressure difference of 0.5 to 1 bar therefore, the highest possible constant temperature of the test medium has to be ascertained at the hydraulic pressure test of installations with PPR pipes.

For primary test, a pressure of 1.5 times of rated pressure shall be applied for a duration of 30 minutes. During this test, pressure drop shall be < 0.6 bar.

After completion of primary test, main test must be conducted, which has to be effected with a test pres-sure of alternate 1 bar and 10 bar for every 5 minutes interval for 2 hours.

In case of accidental hole formation in pipe line due to drilling or piercing of pointed object, the pipe line can be repaired as follows:

Accidental hole formation in pipe line.

1

Simultaneously heat the hole section in the pipe line and repair bar using repair section die and welding device for about 5 to 7 seconds depending upon the pipe thickness.

2

5.3 HOLE REPAIRING

25

TECHINICAL MANUAL

Acetone 100 R CAcetic Acid 100 R CAcetic Anhydride 100 R CAlum sat. R RAmmonia Aq. conc. R RAmmonium Acetate Aq. any R RAmmonium Phosphate any R RAmyl Alcohol pure R RAniline 100 R CBeer R RBenzaldehyde 100 R CBenzene 100 N RBorax Aq. R RBoric Acid Aq. sat. R RButanol 100 R RButyl Acetate 100 R NCalcium Chloride Aq. sat. R RCalcium Nitrate sat. R RCitric Acid Aq. sat. R RCoconut oil R CCyclohexanol 100 R RCyclohexanone 100 R NFormaldehyde 40 R RFormic Acid 50 R RGlycerine 100 R RHeptane 100 R NHydrochloric Acid conc. R RHydrogen Peroxide 10 R RIsopropyl Alcohol 100 R RLactic Acid 85 R RLinseed oil R RMagnesium Salts Aq. sat. R RMethyl Alcohol 100 R ROlive Oil R ROxalic Acid Aq. sat. R RPalm oil R NPeanut oil R CPhospheric Acid 50 R RPotassium Chlorate Aq. sat. R RPottacium Dichromate Aq. sat. R RPotassium Sulphate Aq. sat. R RPyridine 100 R CSalted Water any R RSea Water R RSoap R RSodium Bicarbonate Aq. sat. R RSodium Chloride Aq. sat. R RSodium Perborate Aq. sat. R RSodium phosphates Aq. sat. R RSodium Sulphate Aq. sat. R RStarch, Starch solutuion Aq. any R RSugar (dry) R RSulphuric Acid 96 R CTartaric Acids Aq. sat. R RToluene 100 C NUrea Aq. sat. R RVinegar comm. R RWater 100 R R

CHEMICAL CONC. PP-R

TEMPERATURE% 20 60

R = Recommended, Durable

C = Caution Practically durable under suitable conditions

N = Not Recommended

* For more details please ask us

26

TECHINICAL MANUAL

1.5M

No. ACTIVITY RECOMMENDATION

1

Storage Although PPR Pipe system material is stabilized for use at elevated temperature do not expose the pipes & fittings to direct sunlight.

2

Storage

PPR Pipe storage height should not be more than 1.5 meter.

3

Transporation

When transporting, PPR pipes should be loaded in proper manner, otherwise pipes may get deformed.

4 The PPR system should be protected from impact of hard and sharp objects.

5 Avoid cutting tools which create burns. Cutting should be square to pipe axis (use only provided cutters).

6

Preparation for weldingBefore welding / joining clean the surface of PPR Pipes & Fittings with clean piece of cloth and then start welding.

7

While welding of PPR Pipes and fittings check that thermostat of welding machine and dies have reached correct temperature (260oC). While welding, the pipe must not be twisted.

8 Avoid air draughts during welding to avoid stress in the welds.

9

Safe welding

Welding machines shall be earthed properly during use.

1.5M1.5M1.5M1.5M

Handling

Cutting

Heating

Welding

8.0 DOS & DON’TS FOR PP-R PIPE PLUMBING SYSTEM

27

TECHINICAL MANUAL

No. ACTIVITY RECOMMENDATION

10

Safe welding

Do not cool welding machine in water.

11 Do not over-tight threaded fittings & valves.

12Thread

joint sealing

Use only Telfon tape or Telfon thread sealant for threaded joints and avoid over wrapping with excess tape.

13

Bending

Do not apply heat directly.

14

Bending

R=8D(Min)

While bending the pipe, the bending radius should be more than 8 times the diameter of pipe.

15

Installation atlow temperature

PP-R pipes & fittings kept at temperature

16

At sub zero temperatures (0oC & below) PPR Pipe system tends to break under impact.Therefore, installation at low temperatures should be made with care, and the pipe lines should be insulated.

17

Solar systems

The black PPR pipe line.

18

Outdoor installation

Use 3 Layer Pipe for outdoor application.

Thread joint

28

TECHINICAL MANUAL

PIPEDIA.(mm)

WELDINGDEPTH(mm)

HEATINGTIME(Sec.)

WELDINGTIME(Sec.)

COOLING-TIME(Min.)

20 14.50 6 4 225 16.00 7 4 232 18.00 8 6 440 20.50 12 6 450 23.50 18 6 463 27.50 24 8 675 30.00 30 8 690 33.00 40 8 6

110 37.00 50 10 8160 55.00 60 15 10

RECOMMENDED TIME FOR PP-R FUSION JOINTS

CUTTING

• Cutpipeatrightangletoitsaxisusingburr-freecutter.

• Ensurethatpipeisfreefromburrsorcuttingchips.

• Cleanthepipe&fittingperfectlybeforewelding.

• Markweldingdepthattheendofpipe.

HEATING

• Mount thesuitablediesonheatingelementofweldingmachineaccording to the diameter of pipe and fitting to be welded.

• Connecttheweldingmachineto220voltsA.C.powersupply.

• Select2600Ctemperatureontheweldingmachinethermostat.

• Wait until the welding machine reaches the required workingtemperature.

• Insertthepipeandthefittinginthediesbyexertinglightpressure.

• Forheatingtime,refertothetablegivenfordifferentsizesofpipes.

WELDING

• After heating, quickly insert pipe into the fittingbyexerting lightpressure.

• Anymisalignmentshouldbecorrectedimmediatelyafterinsertionto avoid any stress in the weld.

• Allowthejointstocoolaspercoolingtimegivenintable.

9.0 JOINTING METHOD OF PPR PIPES & FITTINGS