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FlowtiteInstallation Guide Above Ground with non-restrained Joints
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1 Introductory Information 3 1.1Foreword................................................................................................................ 3 1.�Introduction............................................................................................................ 3 1.3FieldTechnician..................................................................................................... 3 1.4FireSafety.............................................................................................................. 3
2 Shipping, Handling and Storage 4 �.1InspectingPipe....................................................................................................... 4 �.�RepairingPipe........................................................................................................ 4 �.3UnloadingandHandlingPipe................................................................................ 4 �.4SitePipeStorage................................................................................................... 5 �.5StoringGasketsandLubricant.............................................................................. 5 �.6TransportingPipe................................................................................................... 6 �.7 HandlingNestedPipes............................................................................................ 6
3 Joining Pipes 7 3.1FLOWTITEDoubleBellCouplings......................................................................... 7 3.�OtherCouplingJoints.......................................................................................... 11 3.3FlangedJointsContactMoulded......................................................................... 12
4 Installation of Aboveground Pipes 14 4.1Introduction.......................................................................................................... 14 4.�SupportingofPipes............................................................................................. 14 4.3MaximumSupportingSpacing............................................................................. 22 4.4NegativePressure................................................................................................ 22
5 Checking the Installed Pipe 24 5.1FieldHydrotesting................................................................................................ 24 5.�InspectionPriortoFillingofPipe......................................................................... 24 5.3InspectionofFilledPipelinePriortoPressurizing............................................... 25 5.4InspectionofPressurizedPipelines..................................................................... 25
6 Thrust Restraints, Concrete Encasement and Rigid Connections Structury 26 6.1ThrustRestraints.................................................................................................. 26 6.�ConcreteEncasement.......................................................................................... 27 6.3RigidConnections................................................................................................ 28 6.4Casings(Tunnels)................................................................................................. 29
7 Field Adjustments 30 7.1LengthAdjustment............................................................................................... 30 7.�FieldCiosureswithFLOWTITE............................................................................ 30 7.3FieldClosureswidthNon-FLOWTITECouplings................................................. 31
Appendices 32 A.ApproximateWeightsforPipesandCouplings.................................................... 32 B.JointLubricantRequirements................................................................................ 33
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1IntroductoryInformation
1.1 Foreword
ThismanualisintendedtoassisttheinstallerinunderstandingtherequirementsandproceduresforthesuccessfulhandlingandinstallationofFLOWTITEpipesaboveground.Itappliesforpipesjoinedbynon-restrainedcouplingsasthedoublebellFLOWTITEcouplingorflexiblesteelcouplings.Itmayalsobeahelpfulsourceofdataforprojectengineers,althoughitisnotadesignguideorsystemengineeringmanual.
Wehavetriedtoaddresstheunusual,aswellasusual,circumstancesthatmaybeencounteredinthefield;however,itiscertainthatuniquesituationsrequiringspecialconsiderationwilloccur.Whenthishappens,askthesupplierforhelp.Also,installationsotherthanabovegroundoncradles,suchasdirectburyorsubaqueousarenotdiscussedherein.Fordirectburyuse“FlowtiteInstallationGuideforBuriedPipes”.Otherwise,consultthesupplierforsuggestedproceduresandlimitationsinthesecases.Mostimportantly,thisbookletisnotmeanttoreplacecommonsense,goodengineeringjudgement,safetyregulations,localordinancesorthespecificationsandinstructionsoftheownersengineerswhoisthefinalauthorityonalljobs.Shouldconflictsinanyofthisinformationarisethatcreatedoubtsashowtoproceedproperly,pleaseconsultthesupplierandtheowner’sengineertoobtainassistance.
1.� Introduction
TheexcellentcorrosionresistanceandmanyotherbenefitsofFLOWTITEpipecanberealizedifthepipeisproperlyinstalled.FLOWTITEpipeisdesignedconsideringthesupportthatwillresultfromtheserecommendedinstallationprocedures.FLOWTITEPipeSystemsgenerallyrecommendstheuseofstandardSN5000pipesforabovegroundpipeinstallations.TherecommendedinstallationproceduresarethereforebasedontheapplicationofstandardSN5000pipes.Theproceduresalsoapplyforpipeswithhigherstiffness,i.e.SN10000.AbovegroundinstallationofpipeswithstiffnesslowerthanSN5000requiresspecialconsideration.TheinstallationproceduresoutlinedinthisbrochureandthesuggestionsoftheFieldServiceRepresentatives,whencarefullyfollowed,willhelpassureaproper,long-lastinginstallation.Consultthesupplieronanyquestionsorwhenvariationsintheseinstructionsarebeingconsidered.
1.3 Field Technician
Thesuppliercan,attherequestofthepurchaserandwithinthetermsoftheagreementbetweenthepurchaserandthesupplier,provideaFieldTechnician.TheFieldTechniciancanadvisethepurchaserand/ortheInstallertohelphimachieveasatisfactorypipeinstallation.Itisrecommendedthat“onthejob”fieldserviceshouldbeengagedintheinitialstageofinstallationandmaycontinueperiodicallythroughouttheproject.Theservicemayrangefromcontinuous(essentiallyfulltime)tointermittentdependingonagreementbetweenpurchaserandsupplier.
1.4 Fire Safety
Glass-reinforcedpolyester(GRP)pipe,likevirtuallyallpipemadewithpetrochemicals,canburnandis,therefore,notrecommendedforuseinapplicationswhichareexposedtointenseheatorflames.Duringinstallation,caremustbetakentoavoidexposureofthepipetowelder’ssparks,cutting-torchflamesorotherheat/flame/electricalsourceswhichcouldignitethepipematerial.Thisprecautionisparticularlyimportantwhenworkingwithvolatilechemicalsinmakinglayupjoints,repairingormodifyingthepipeinthefield.
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Figure2–2Liftingpipeattwosupportpoints
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�.1Inspecting Pipe
Allpipesshouldbeinspecteduponreceiptatthejobsitetoinsurethatnodamagehasoccurredintransit.Dependingonlengthofstorage,amountofjobsitehandlingandotherfactorsthatmayinfluencethepipescondition,itisrecommendedthatthepipebere-inspectedjustpriortoinstallation.Inspecttheshipmentupondelivery,asfollows:
Makeanoverallinspectionoftheload.Iftheloadis intact,ordinaryinspectionwhileunloadingwill normallybesufficienttomakesurethepipehas arrivedwithoutdamage. Iftheloadhasshiftedorindicatesroughtreatment, carefullyinspecteachpipesectionfordamage. Generally,anexteriorinspectionwillbesufficientto detectanydamage.Whenpipesizepermits,an interiorinspectionofthepipesurfaceatthe locationofanexteriorscrapemaybehelpfulto determineifthepipeisdamaged.
Checkthequantityofeachitemagainstthebillof lading.
Noteonthebillofladinganytransitdamageorloss andhavethecarrierrepresentativesignyourcopy ofthereceipt.Claimsagainstthecarriershouldbe inaccordancewiththeirinstructions.
Ifanyimperfectionsordamageisfound,segregate theaffectedpipesandcontactthesupplier.
Donotusepipethatappearsdamagedordefective.
�.� Repairing Pipe
Normally,pipeswithminordamagecanberepairedquicklyandeasilyatthejobsitebyaqualifiedindividual.Ifindoubtabouttheconditionofapipe,donotuseit.
TheFieldTechniciancanhelpyoudeterminewhetherrepairisrequiredandwhetheritispossibleandpractical.Repairdesignscanvarygreatlyduetopipethickness,wallcomposition,application,andthetypeandextentofthedamage.Thereforedonotattempttorepairadamagedpipewithoutconsultingthesupplierfirst.Repairsmustbemadebyatrainedrepairtechnician.Improperlyrepairedpipesmaynotperformasintended.
�.3Unloading and Handling Pipe
Unloadingthepipeistheresponsibilityofthecustomer.Besuretomaintaincontrolofthepipeduringunloading.Guideropesattachedtopipesorpackageswillenableeasymanualcontrolwhenliftingandhandling.Spreaderbarsmaybeusedwhenmultiplesupportlocationsarenecessary.Donotdrop,impact,orbumpthepipe,particularlyatpipeends.
Single Pipes Whenhandlingsinglepipes,usepliablestraps,slings orropetolift.Donotusesteelcablesorchainsto liftortransportthepipe.Pipesectionscanbelifted withonlyonesupportpoint(Figure2–1)although twosupportpointsplacedasinFigure2–2isthe preferredmethodforsafetyreasonsasitmakesthe pipeeasiertocontrol.Donotliftpipesusinghooks atpipeendsorbypassingarope,chainorcable throughthesectionendtoend.SeeAppendixAfor approximateweightsofstandardpipesand couplings.
Figure2–1Liftingpipeatonesupportpoint
0.2xL 0.6xL 0.2xL
ControlRope
�Shipping,HandlingandStorage
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�.5 Storing Gaskets and Lubricant
Rubberringgaskets,whenshippedseparatelyfromthecouplings,shouldbestoredintheshadeintheiroriginalpackingandshouldnotbeexposedtosunlightexceptduringthepipejoining.Also,thegasketsmustbeprotectedfromexposuretogreasesandoilswhicharepetroleumderivatives,andfromsolventsandotherharmfulsubstances.
Gasketlubricantshouldbecarefullystoredtopreventdamage.Partiallyusedbucketsshouldberesealedtopreventcontaminationofthelubricant.Iftemperaturesduringinstallationarebelow5°C,gasketsandlubricantshouldbesheltereduntilused.
�.4Site Pipe Storage
Itisgenerallyadvantageoustostorepipeonflattimbertofacilitateplacementandremovalofliftingslingsaroundthepipe.
Whenstoringpipedirectlyontheground,besurethattheareaisrelativelyflatandfreeofrocksandotherpotentiallydamagingdebris.Placingthepipeonmoundsofbackfillmaterialhasbeenfoundtobeaneffectivewayofsitestoringthepipe.Allpipesshouldbechockedtopreventrollinginhighwinds.
Ifitisnecessarytostackpipes,itisbesttostackonflattimbersupports(minimumwidthof75mm)atquarterpointwithchocks(seeFigure2–4).Ifitisavailable,usetheoriginalshippingdunnage.
Insurethestackwillbestableforconditionssuchashighwinds,unevenstoragesurfaceorotherhorizontalloads.Ifstrongwindsareanticipatedconsiderusingropesorslingstotiepipesdown.Maximumstackheightisapproximately3metres.
Bulges,flatareasorotherabruptchangesofpipecurvaturearenotpermitted.Storingofpipesoutsideoftheselimitationsmayresultindamagetothepipes.
Figure2–4Storingpipe
Unitized Loads Unitizedloadsmaybehandledusingapairofslings asshowninFigure2–3.Donotliftanon-unitized stackofpipesasasinglebundle.Non-unitizedpipes mustbeunloadedandhandledseparately(oneata time).
Ifatanytimeduringhandlingorinstallationofthepipe,anydamagesuchasagouge,crackorfactureoccurs,thepipeshouldberepairedbeforethesectionisinstalled.
Contactthesupplierforinspectionofdamagedandforrecommendationofrepairmethodordisposal.SeeSection2.2 .
Figure2–3Liftingunitizedpackage
0.2xL 0.6xL 0.2xL
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�.7 Handling Nested Pipes
Pipesmaybenested(smallerdiameterpipesinsideoflargersizes).Thesepipesgenerallyhavespecialpackagingandmayrequirespecialproceduresforunloading,handling,storingandtransporting.Specialmeasures,ifrequired,willbecarriedoutbythepipesupplierpriortoshipment.However,thefollowinggeneralproceduresshouldalwaysbefollowed:
Alwaysliftthenestedbundleusingatleasttwo pliablestraps(Figure2–6).Limitations,ifany,for spacingbetweenstrapsandliftinglocationswillbe specifiedforeachproject.Insurethatthelifting slingshavesufficientcapacityforthebundleweight. Thismaybecalculatedfromtheapproximatepipe weightsgiveninAppendixH.
Nestedpipesareusuallybeststoredinthetransport packaging.Stackingofthesepackagesisnot advisedunlessotherwisespecified.
Nestedpipebundlescanonlybesafelytransported intheoriginaltransportpackaging.Special requirements,ifany,forsupport,configurationand/ orstrappingtothevehiclewillbespecifiedforeach project.
Packageremovalandde-nestingoftheinside pipe(s)isbestaccomplishedatade-nestingstation. Insidepipes,startingwiththesmallestsizemaybe removedbyliftingslightlywithaninsertedpadded boomtosuspendthesectionandcarefullymoveit outofthebundlewithoutdamagingtheotherpipes (Figure2–7).Whenweight,lengthand/orequipment limitationsprecludetheuseofthismethod, proceduresforslidingtheinsidepipe(s)outofthe bundlewillberecommendedforeachproject.
Figure2–6Doublesupportpointfornestedpipes
ControlRope
Figure2–7De-nestingwithpaddedboomonforklifttruck
�.6 Transporting Pipe
Supportallpipesectionsonflattimbers,spacedatmaximum4metreswithamaximumoverhangof2metres.Chockthepipestomaintainstabilityandseparation.Avoidabrasion.
Maximumstackheightisapproximately2.5metres.Strappipetothevehicleoverthesupportpointsusingpliablestrapsorrope(Figure2–5).Neverusesteelcablesorchainswithoutadequatepaddingtoprotectthepipefromabrasion.Bulges,flatareasorotherabruptchangesofcurvaturearenotpermitted.Transportofpipesoutsideoftheselimitationsmayresultindamagetothepipes.
Figure2–5Transportingpipe
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Withuniformpressure,pusheachloopoftherubbergasketintothegasketgroove.Wheninstalled,pullcarefullyintheradialdirectionaroundthecircumferencetodistributecompressionofthegasket.Checkalsothatbothsidesofthegasketprotrudeequallyabovethetopofthegroovearoundthewholecircumference.Tappingwitharubbermalletwillbehelpfultoaccomplishtheabove.
Lubricate GasketsNext,applyathinlayeroflubricanttotherubbergaskets(Figure3–3).SeeAppendixIfornormalamountoflubricantconsumedperjoint .
Clean and Lubricate SpigotsThoroughlycleanpipespigotstoremoveanydirt,grit,grease,etc.Inspectspigotsealingsurfaceforpossibledamage.Applyathinlayeroflubricanttothespigotsfromtheendofthepipetotheblackalignmentsstripe.Afterlubricating,takecaretokeepthecouplingandspigotsclean(Figure3–4).
Caution:Itisveryimportanttouseonlythecorrectlubricant.Thesupplierprovidessufficientlubricantwitheachdeliveryofcouplings.Ifforsomereasonyourunout,pleasecontactthesupplierforadditionalsupplyoradviceonalternativelubricants.Neveruseapetroleumbasedlubricant.
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FLOWTITEpipesectionsaretypicallyjoinedusingFLOWTITEcouplings.Pipeandcouplingsmaybesuppliedseparatelyorthepipemaybesuppliedwithacouplinginstalledononeend.Ifthecouplingsarenotdeliveredpre-mounted,itisrecommendedthattheybemountedatthestorageyardoratthebuildingsitebeforethepipeismountedonthesupports.
Otherjoiningsystemsuchasflanges,mechanicalcouplingsandlay-upjointsmayalsobeusedforjoiningFLOWTITEpipes.
3.1 FLOWTITE double Bell Couplings
Thefollowingsteps(1-4)aremeantforFLOWTITEPressureCouplings.
Cleaning CouplingThoroughlycleandoublebellcouplinggroovesandrubbergasketringstomakesurenodirtoroilispresent(Figure3–1).
Install GasketsInsertthegasketintothegrooveleavingloops(typicallytwotofour)ofrubberextendingoutofthegroove.Donotuseanylubricantinthegrooveoronthegasketatthisstageofassembly.Watermaybeusedtomoistenthegasketandgroovetoeasepositioningandinsertionofthegasket(Figure3–2).
Figure3–1Cleaningcoupling
Figure3–2Installinggasket
3JoiningPipes
Figure3–3Lubricantgaskets
Figure3–4Cleaningspigot
Step 1
Step �
Step 3
Step 4
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Jointing
Ifthecouplingisnotpre-mounteditshouldbemountedonthepipeinaclean,dryplacebeforethepipesarejoined.Thisisaccomplishedbyplacingaclamporaslingaroundthepipeatadistanceof1to2mfromthespigotontowhichthecouplingwillbemounted.Makesurethepipespigotisrestingatleast100mmabovethegroundsurfacetokeepawayfromdirt.Pushthecouplingontothepipespigotendmanuallyandplacea100x50mmtimberacrossthecoupling.Usetwocome-alongjacksconnectedbetweenthetimberandtheclampandpullthecouplingintopositioni.e.untilthecouplingisalignedwiththe“homeline”(seeFigure3–5).Seechapter„GapbetweenPipeSpigots“intherightcolumnforappropriatedistancetothehomeline.Thefollowingsteps(5to7)applytojoiningpipesusingclampsorslingsand“come-alongjacks”.Othertech-niquesmayalsobeusedprovidingthegeneralobjectivesoutlinedherearemet.Inparticular,insertionofthespigotendsofthepipeshouldbelimitedtothehomelineandanydamagetothepipeandcouplingavoided.
Pipe PlacementThepipewiththecouplingmountedisalignedonthepipesupports.
Fixing of ClampsClamp(orsling)Aisfixedanywhereonthefirstpipeorleftinpositionfromthepreviousjoint.FixClamp(orsling)Bonthepipetobeconnectedinaconvenientposition(Figure3–6).
Note:Clampcontactwiththepipeshallbepaddedor otherwiseprotectedtopreventdamagetothepipe andtohavehighfrictionresistancewiththepipe surface.Ifclampsarenotavailable,nylonslingsor ropemaybeused,butcaremustbetakeninthe alignmentofthecoupling.
Figure3–5Mountingofcouplingonpipe
ClampA50x100mmtimber
”Come-alongjacks”
Figure3–6Pipejoiningusingclamps
”Come-alongjacks”
ClampA
Join CouplingCome-alongjacksareplacedoneoneachsideofthepipeandconnectedtotheclamps.Thepipeispulledintopositionintothecoupling.Forappropriategapbetweenpipeendsseechapter“GapBetweenPipeSpigots”below.ClampAisthenmovedontothenextpipetobejoined.
Theapproximatemountingforcecanbecalculatedasfollows:Mountingforcesintons=(DNinmm/1000)x2
Gap Between Pipe Spigots
Abovegroundpipelineswill,ifexposedtodirectsunlight,bewarmedupbythesunandexpand.Thisappliesespeciallyforpipelinesthatareemptyduringtheinstallationphaseorforotherreasons.Toavoidexcessiveloadsonpipesandpipesupports,thepipesmustbejoinedwithsufficientgapbetweenspigotssoastoavoidcontactbetweenthespigotsevenatthehighestpossibletemperatures.Theadequategapdependsonthehighestpossibletemperaturerisethatcanbeexpectedforthepipeandthelengthofpipebetweenanchorsthatcanexpandintothejoint.Forevaluationofminimumgapbetweenspigots,alinearcoefficientofthermalexpansionofmax.28x10-6/°CcanbeassumedforFLOWTITEpipesinthelongitudinaldirection.Theminimumgapcanbecalculatedas:
gmin=(Tmax–Tinst.)Lx28x10-6
where:Tmaxisthemaximumexpectedpipetemperaturein°C.Tinst.isthepipeinstallationtemperaturein°C.Listhepipelength(anchortoanchor)expandingintothejointinmm.Agapof25mmbetweenspigotswillbesufficientformostinstallationswithpipelengthuptoandincluding12m.Thegapbetweenpipeendsshouldnotexceed30mm.Forjointswithangulardeflection,thegapwillvaryaroundthecircumferenceofthepipe.Insuchcasestheminimumgapshallbewithinthelimitationsstatedabovewhilethemaximumgapshouldundernocircumstancesexceed60mm.Thegaprequirementsaboveapplyfornon-pressurizedpipe.
Step 5
Step 6
Step 7
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ClampB
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Angular Deflection at Double Bell Couplings
Theangulardeflectionatcouplingjointsmustbelimitedinordertoavoidexcessiveloadsonpipelineandsupports.PressurizedabovegroundFLOWTITEpipesshallbeinstalledinstraightalignmentwhilechangesinlinedirectionareachievedbybendsandthrustrestraints.Unintendedangulardeflectionatcouplingjointsforpipesinstalledinstraightalignment,shallnotexceed20%ofthevaluesinTable3-1.SlightchangesinlinedirectionoflowpressurepipelineslessorequalPN6,canhowever,onspecialoccasions,beachievedbyangulardeflectionsatjoints.Suchinstallationsrequirespecialconsiderationanditmustbeassuredthatsupportsatjointswithangulardeflectionhaveadequatethrustrestraint.
! Note:Thepipesuppliershallbeconsultedpriortoinstallingpipeswithangulardeflection.
Ifpipesareinstalledwithangulardeflectionatjoints,itmustbeensuredthatthetotalangulardeflectiondoesnotexceedthenominalvaluesgiveninTable3-1.Inthatregard,normalinstallationtolerancesandtheloadinducedangulardeflections,explainedbelow,havetobeaccountedfor.Theangulardeflectionofajointshallbedistributedonbothsidesofthecoupling,seeFigure3-8.ThecouplingtopipeangulardeflectionshallundernocircumstancesexceedthevaluesgiveninTable3-1.Forabovegroundpipelines,theloadsactingonthepipelinewillcreateangulardeflectionatjointsalthoughthepipesareinstalledinstraightalignment.Normallymostoftheloadsaregravitationalforcescausingangulardeflectionintheverticalconvexdirection,seeFigure3-7.Themagnitudeofthisangulardeflectiondependsonthepipediameterandclassaswellasthesupportingandloadingconditions.Forpipesinstalledintwocradles,withmaximumsupportspacingandloadingaccordingtoTable4-5,thisloadinducedangulardeflectioncanonspecialoccasionsreach70%ofthenominalvaluesgiveninTable3-1.Forpipesinstalledinmultiplecradles,accordingtoTable4-6,thiseffectislimitedtomaximum30%ofthevaluesfromTable3-1.
FLOWTITE Sewer Coupling (FSC)
AgasketisusedfortheFSC,whichispre-equippedbythesupplierandfixedtothecouplinggroove.Withthatthesteps,describedinSection3.1 –cleaningofthegroovesandinstallingofthegasket–canbedropped.Allotherworkinginstructionsanduserdataareidenticalwiththesteps–mentionedinSection3.1 –fortheFLOWTITEPressureCoupling.
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Figure3-7Pipedeflection
Loadinducedcouplingtopipeangulardeflection
Initialangulardeflection
Loadinducedangulardeflection
Note:Anglesareexaggeratedforillustration
Table3-1AngularDeflectionatDoubleBell CouplingJoint(SeeFigure3-6)
Nominal Pipe
Diameter
Nominal Angle of
Deflection
Nominal Joint/Coupling
Offset
(mm) ( ° ) (mm)
300 3 17
350 3 20
400 3 22
450 3 25
500 3 28
600 2 21
700 2 25
800 2 29
900 2 32
1000 1 18
1100 1 20
1200 1 21
1400 1 25
1600 1 29
1800 1 32
2000 0.5 18
2200 0.5 20
2400 0.5 21
2600 0.5 23
2800 0.5 25
3000 0.5 27
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Anchoring of Pipes
Joinedpipesshallnotbeleftunanchored.Extremetemperaturevariations,e.g.causedbyexposuretosunlight,willresultinexpansionsandcontractionsinthepipes.Ifastringofseveralpipesisexposedtosuchconditionspriortoanchoringoftheindividualpipes,couplingsandpipescanbeforcedoutofposition.
Checking the Installed Joint
Thequalityofthejoiningoperationisofutmostimportancefortheperformanceofthepipeline.Thereforeathoroughcheckingoftheinstalledjointisstronglyrecommended.Angulardeflection,couplingposition,jointmisalignmentandgapbetweenpipeendsshouldbechecked.Thequalityofthejointsshouldbecheckedassoonaspossibleafterjoiningasthejointmightbedifficulttocorrectwhenthecouplinggasketshavesettled.Thequalityofthejointshouldalsobecheckedafterfillingandpressurizingthepipeline,seeSection5 .! Note:Theinstalledjointshouldbecheckedat
normaltemperatures.Highand/orunevenpipetemperatures,causedbye.g.directsunlight,willaffecttheresultsofthecheck.
Angular Deflection
Bothpipetopipeandcouplingtopipeangulardeflectionshouldbechecked,seeFigure3-8.Theangulardeflectioniseasiestcheckedwithreferencetothealignmentstripes,seeFigures3-9and3-10.Thepipetopipeangulardeflectionisforagivenpipedimension,approximatelyproportionaltothejointoffsetwhichisthedifferencebetweenthemaximumandminimumdistancebetweenthealignmentstripes,dmax–dmin,seeFigure3-11.
Thecouplingtopipeangulardeflectionisinasimilarwayapproximatelyproportionaltothecouplingoffset,amax–aminfortheleftsideandbmax–bminfortherightside,seeFigure3-9.Thepipetopipeandthecouplingtopipeangulardeflectioncanthenbecalculatedbasedonthemeasuredoffsetandthepipe’souterdiameter.Alternatively,theangulardeflectioncanbeestimatedbyproportioningthenominaljoint/couplingoffsetgiveninTable3-1.
AngularDeflection=NominalAngularDeflectionx(MeasuredOffset/NominalOffset)
ForallowableangulardeflectionseethesectiononAngularDeflectionofDoubleBellCouplings.
Coupling Position
Thecouplingshallbemountedcentricrelativetothe
jointwithinatoleranceof+/–10mm.Thecouplingpositioniseasiestmeasuredwithreferencetothealignmentstripes.Theaveragedistancefromthealignmentstripetothecouplingedgeisestimatedforbothsidesofthecouplingas:aave=(amax–amin)/2
bave=(bmax–bmin)/2
SeeFigure3-9fordefinitions.Thecouplingpositionrelativetothecentreofthejointisthencalculatedas:–10mm≤(aave–bave)/2≤10mm
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Figure3-8Angulardeflection
Couplingtopipeangulardeflection
Note:Anglesareexaggeratedforillustration
Pipetopipeangulardeflection
Figure3-9Measuringofcouplingangularoffsetandposition
Couplingoffset
amax
amin
a
bmax
bmin
b
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Joint misalignment
Maximummisalignmentofpipeendsshallnotexceedthelessof0,5%ofpipediameteror3mm.Themisalignmentcanbemeasuredwithtwoidenticalknotchedrulerspressedagainstthepipeatbothsidesofthecoupling,seeFigure3-10.Ifthedepthofthemachinedspigotsurfaceisdifferentforthetwopipes,themeasuredmisalignmentshallbecorrectedaccordingly.Forpipes700mmandlargerthemisalignmentcanbemeasuredwitharulerfromtheinsideofthepipe,seeFigure3-10.
Gap Between Pipe Spigots
Thegapbetweenpipespigotsiseasiestcheckedbymeasuringthedistancebetweenthealignmentstripes,seeFigure3-11.Thegap,g,isthencalculatedas:g=d–2sThedistancefromthepipeendtothealignmentstripes,s,canbefoundinthepipespecificationormeasuredpriortoinstallation.ForpipesDN700andlargerthegapcanbemeasureddirectlyfromtheinsideofthepipe.Forjointswithangulardeflection,bothmaximumandminimumgapshallbemeasured.Forrequirementsforgapbetweenpipespigots,seethesectiononGapBetweenPipeSpigots.
Adjusting Joints
Thejointshallbeadjustedifanyofthechecksdescribedintheprecedingsectionfallsoutsidethespecifiedlimits.Thenecessaryadjustmentsofcouplingorpipepositionshallbemadecarefully,avoidingconcentratedloadsorimpactloadsthatmightdamagepipeorcoupling.
3.� Other Joining Methods
Flexible Steel Couplings(Straub,TeeKay,Arpol,etc.–seeFigure3–12)
WhenconnectingFLOWTITEpipetootherpipematerialswithdifferentoutsidediametres,flexiblesteelcouplingsareoneofthepreferredjointingmethods.Thesecouplingsconsistofasteelmantlewithaninteriorrubbersealingsleeve.TheymayalsobeusedtojoinFLOWTITEpipesectionstogether,forexampleinarepairorforclosure.
Threegradesarecommonlyavailable: Coatedsteelmantle
Stainlesssteelmantle
Hotdipgalvanizedsteelmantle
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Figure3-10Misalignment
Figure3-11Gapbetweenpipeends
Jointoffset
Alignmentstripe
dmax
dmin
gmin
s
gmax
s
Figure3–12Flexiblesteelcoupling
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Jointmisalignment
RulerJointmisalignment
Ruler Machinedspigotsurfaces(measuregapsbetweenrulersandspigotsurface)
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Controloftheboltingtorqueofflexiblesteelcouplingsisimportant.Donotovertorqueasthismayoverstresstheboltsorthepipe.Followthecouplingmanufacturer’srecommendedassemblyinstructions,butwiththepipesupplier’srecommendedbolttorquelimits.
Note:Flexiblesteelcouplingsmustbeorderedwiththemanufacturer’sinsertforcontainmentofthegasket.
Mechanical Steel Couplings(VikingJohnson,Helden,Kamflex,etc.seeFigure3–13)
Mechanicalcouplingshavebeenusedsuccessfullytojoinpipesofdifferentmaterialsanddiametres,andtoadapttoflangeoutlets.Thereisawidevariationinthedesignofthesecouplings,includingboltsize,numberofboltsandgasketdesign.Largevariationsalsoexistinthediametertoleranceofothermaterials,whichoftenresultsinhigherbolttorquethannecessaryinordertoachieveatightsealontheFLOWTITEside.
Consequently,wecannotrecommendthegeneraluseofmechanicalcouplingswithFLOWTITEpipe.Ifamechani-calcouplingisusedtojoinFLOWTITEtoanotherpipematerialthenonlymechanicalcouplingswithadualinde-pendentboltingsystemshouldbeused(Figure3–13).ThisallowsfortheindependenttighteningoftheFLOWTITEside,whichtypicallyrequireslesstorquethanrecommendedbythecouplingmanufacturer.
ItisadvisedthatthelocalFLOWTITEpipesupplierbeconsultedwhenmechanicalcouplingsarecontemplatedforuseonaproject.Bepreparedtopresentinformationonthespecificdesign(brandandmodel).Thepipesuppliercanthenadviseunderwhatconditions,ifany,thisdesignmightbesuitableforusewithFLOWTITE.
03
Corrosion Protection
Regardlessofthecorrosionprotectionappliedtothesteelmantle,thebalanceofthecouplingneedstobecorrosionprotectedaswell.Typicallythisinvolvestheapplicationofashrinkfitpolyethylenesleeveovertheinstalledcoupling.
GRP Adapters
TheFLOWTITEcouplingcanbeusedtojoinFLOWTITEpipetoothermaterialswiththesameoutsidediameter(Table7–1)fornon-pressureapplications.Forhigherpressuresconsultthemanufacturer.
SpecialGRPadaptorsorsteppedcouplingscanbemadetoconnectGRPpipewithothermaterialsordifferentdiametres.Consultthemanufacturer.
3.3 Flanged Joints
Contact Moulded
Looseringandfixedflangesarealsoavailableforjoiningtootherpipematerials,valvesoraccessories.GRPflangesshouldbejoinedaccordingtothefollowingprocedure:(Figure3–14)
Thoroughlycleantheflangefaceandthe O-ringgroove.
Ensurethesealinggasketiscleanandundamaged.
Positionsealinggasketingroove.
Alignflangestobejoined.
Insertbolts,washersandnuts.Allhardwaremustbe cleanandlubricatedtoavoidincorrecttightening. WashersmustbeusedonallGRPflanges.
Usingatorquewrench,tightenallboltsto35Nm torque,[20NmforsmalldiameterDN250]following standardflangebolttighteningsequences.
Repeatthisprocedure,raisingthebolttorqueto70 Nm,[35Nmforsmalldiameter]oruntiltheflanges touchattheirinsideedges.Donotexceedthis torque.Todosomaycausepermanentdamageto GRPflanges.
Checkbolttorquesonehourlaterandadjustif necessaryto70Nm(35Nmforsmalldiameter).
Figure3–13Dualboltmechanicalcoupling
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Thejoiningprocedureforbothtypesoflooseringflangesisidenticalandisdescribedbelow.
Thoroughlycleantheflangefacetobejoinedand whereapplicablethe“O”-ringgroove.
Ensurethegaskettobeusediscleanand undamaged.Donotusedefectivegaskets.
Positionthegasketontotheflangeface.Forthe “O”ringseal,ensurethatthegasketispushed firmlyintothe“O”-ringgroove.Itisrecommended thatthe“O”-ringbesecuredwithsmallstripsof tapeoradhesive.
Alignflangestobejointed.
Insertbolts,washersandnuts.Allhardwaremust becleanandlubricatedtoavoidincorrecttightening. Itisimportantthatthematingsurfacebetweenthe bolthead/washersandbackingringplatearewell lubricatedtoavoidexcessivetorquebuildup.
Useatorquewrenchtotightenallboltstothe requiredtorquesettingsinTable3–2following standardflangebolttighteningsequences.
Checkbolttorquesonehourlaterandadjustif necessarytothesetbolttorque.
Note:WhenconnectingtwoGRPflangesmade withan“O”-ringgasket,onlyoneflangeshallhave agasketgrooveintheface.
Type of Gasket PN Maximum torque Nm*)
“O”-ring 6 50xPipeOD(inm)
“O”-ring 10 100xPipeOD(inm)
“O”-ring 16,20 125xPipeOD(inm)
“O”-ring 25 200xPipeOD(inm)
“O”-profilewithintegralring
6 45xPipeOD(inm)
“O”-profilewithintegralring
10 75xPipeOD(inm)
“O”-profilewithintegralring
16,20 90xPipeOD(inm)
“O”-profilewithintegralring
25 135xPipeOD(inm)
03
Loose Ring Flanges
FLOWTITEpipecanalsobesuppliedwithloosering(vanStone)flanges.Thelooseringcanberotatedtoeasilyalignwiththeboltholesinthematingflange.
Thelooseringflangecanbemanufacturedfortwotypesofgasketsealingusing
an“O”-ringseal(grooverequiredinflangeface,see Figure3–15)and
an“O”-ringprofilegasketwithsteelringforflat flangesurfaces(nogrooverequired)asshownin Figure3–16.
Figure3–16LooseringflangewithO-ringprofile gasketwithsteelring
Table3–2Torquesettingsforlooseringflanges
Figure3–15LooseringflangewithO-ringgasket
Figure3–14FlangedJoint
MetalFlange
FiberglassFlange
“O”RingGasket
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04 4.1 Introduction
ThissectionofthemanualdescribestherequirementsforinstallationofFLOWTITEpipesaboveground.Itappliesforpipesjoinedbynon-restrainedcouplingsasthedoublebellFLOWTITEcouplingorflexiblesteelcouplings.Whendesigninganabovegroundpipeinstallationitisimportanttobeawareoftheforcesthatactonthepipesystemandparticularlyforhighpressuresystems.Whenacomponentinapressurizedpipelinehasachangeincross-sectionalareaordirection,aresultantforceisinduced.Allsuchcomponents,ase.g.bends,reducers,tees,wyesorvalves,mustbeanchoredtowithstandtheseloads.Foraburiedpipeline,adequateresistanceisprovidedbythepipeembedmentandthrustblocks.Suchresistancemaynotbeprovidedatthesupportsofanabovegroundpipeline.Caremustbeexercisedtominimizemisalignmentsandallcomponentsmustbeproperlysupportedtoensurethestabilityofthepipeline.
4.� Supporting of Pipes
FLOWTITEpipesarejoinedwithcouplingsthatdonotrestrainlongitudinalexpansionandcontractionofthepipes.Tominimizetheloadsinducedinpipesandsupports,thesupportsshallnotrestrainlongitudinalexpansionofthepipes.Itis,however,essentialthatthepipemovementsareguidedandcontrolledinsuchawaythatallpipesectionsarestableandthatthecoupling’sabilitytoacceptlongitudinalmovementisnotexceeded.Thenon-restrainedcouplingsareflexibleanditisveryimportantthatthestabilityofeverypipecomponentisensuredbythesupports.Everypipeshallthereforebesupportedbyatleasttwocradlesandanchoredatoneofthese.Theremainingcradle(s)shallbedesignedasguide(s),allowinglongitudinalexpansionofthepipebutrestraininglateralmovements.Forpipessupportedinmorethantwocradles,thecradleclosesttothemiddleofthepipeshouldbeusedasananchor.Theanchorsshallbelocatedwithregularspacinginordertoensureevendistributionoflongitudinalpipeexpansiononthejoints.However,thedistancebetweentwoanchorsshallnotexceed12m.Figure4-1showstypicalsupportingofpipes.! Note: Whenapipeissupportedonmorethantwo
supports,thepipesupportsshallbeinstraightalignment.Maximumdeviationfromstraightalign-mentis0,1%ofthespanlength.Supportsshalllimitdisplacementofpipes,inalloftherestraineddirections,to0,5%ofthediameteror6mm,whicheverisless.
! Note:Itisimportantthatsupportdisplacementdoesnotresultinmisalignmentofpipeendsinjoints.Maximumallowablepipeendmisalignmentisthelesserof0,5%ofthediameteror3mm
Pipesshallbeinstalledinstraightalignmentinordertoavoidreactionforcescausedbyangulardeflectionatjoints.SeeSection3 .Thepipesmustbesupportedadjacenttothejointsinordertoensurethestabilityofthecouplings.Maximumdistancefromthecentrelineofthejointtocenterlineofasupportshallbe250mmforpipeswithDN500orlessandthelesserof0,5xDNor500mmforpipeswithDN600orlarger(Figure4-1).
4.�.1 Support Design
Anyexcessivepointorlineloadingshallbeavoidedwhenpipesareinstalledaboveground.AbovegroundFLOWTITEpipesshallthereforebesupportedincradles.Normallythecradlesaremadefromconcreteorsteel.Thecradlesshallhaveasupportingangleof150°.Thediameterofthefinishedcradlewithcradlelinersshallbe0,5%largerthattheouterdiameterofthenon-pressurizedpipe(Figure4-2).Thecradlesshallhave: aminimumwidthof150mmforallpipeswith DN≤1000mm, aminimumwidthof200mmforpipesbetween DN1100mmandDN2000mmand aminimumwidthof250mmforpipeswith DN>2000mm
Theinsideofthecradlesshallbecoveredwitha5mmthickcradlelinertoavoiddirectcontactbetweenpipeandcradle.Linersmustbemadefrommaterialsthatareresistanttotheactualenvironment.Highfrictionlinersshallbeappliedatanchorswhilelowfrictionlinersshallbeappliedatguides.SeeSection4.2.3 ,AnchordesignandSection4.2.4 ,Guidedesignforlinerspe-cifications.Figure4-2showsthecradledesign.Thepipesupportsaredesignedasanchorsorguides.Anchorsaredesignedtorestrainpipemovement.Guidesaredesignedtoallowthepipetoexpandinthelongitudinaldirectionbutrestrainitfromanylateraldisplacement.
4InstallationofAbovegroundPipes
Figure4-1FLOWTITEpipes. Typicalsupportarrangement
Guide Anchor
GuidesAnchor Anchor
MultipleCradlesMax.12m
•
•
•
Couplinganchor–ifnecessaryseeSection4.2.4
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4.�.� Loads on Supports
Thesupportsshallberigidanddesignedtowithstandtheactualloadscausedby:• Externalandenvironmentalloads• Weightofpipeandfluid• Reactionforcescausedbyinternalpressure• Frictioninducedincouplingsandagainstguides
incaseoftemperatureand/orpressurevariations.
Itistheresponsibilityoftheowner’sengineertodeterminedesignloadsforthesupports.Frictionalforcebetweenpipeandguideshallbedeterminedbasedontotalcompressionbetweenpipeandcradleandthefrictionalcoefficientbetweenthepipematerialandthecradleliner.ForthecradlelinerssuggestedinSection4.2.4 ,Guidedesign,thefrictionalcoefficientcanbeassumedtobe0.3.Table4-1providesapproximateaxialcouplingfrictionalforcesthatshouldbeconsideredinthedesignofsupportcradles.Theseloadsresultfromcontractionandelongationofpipeduringoperationandfrictionalresistanceinthegasketedjoint.Table4-1isbasedontheassumptionofsimultaneousexpansionsandcontractionsoftheneighboringpipes.Ifnon-simultaneousexpansionsandcontractionscanbeexpected,contactthepipesupplierforadequateaxialforces.
04
Figure4-3Forces
L pA
(p+∆hpq)A∝
∝
∆hpqA
Pressure
difference
Gra
vita
tion
LpgA
Resultant
∆h
Figure4-2Cradledesign
DO
min25mm
R=1.005xDO/2
min
25m
m
Cradlelinermin.thickness5mm
min.150(DN≤1000)min.200(DN≤2000)min.250(DN>2000)
150°
Table4-1SN5000FLOWTITEpipes.Axialloadsdue tofrictionalresistanceinjoints(kN)
*SewerPipesforHighPressureCleaning**StandardPipes
Fordetailedinformationpleasecontactyourlocalsupplier.
FS* FP**
DN GravityPN 1
PN6
PN 10 PN 16
300 4 5 5 6 7
350 4 5 6 6 8
400 4 5 6 7 8
450 4 6 6 7 9
500 4 6 7 8 10
600 5 7 8 9 11
700 5 7 8 10 12
800 5 8 9 11 14
900 6 8 10 12 15
1000 6 9 11 13 16
1100 7 9 12 14 17
1200 7 10 12 15 19
1300 7 11 13 16 20
1400 8 11 14 17 21
1500 8 12 15 18 23
1600 9 12 15 19 24
1700 9 13 16 20 25
1800 9 14 17 21 27
1900 10 14 18 22 28
2000 10 15 18 23 29
2100 10 15 19 24
2200 11 16 20 25
2300 11 16 21 26
2400 12 17 22 27
2500 18 22
2600 18 23
2700 19 24
2800 19 25
2900 20 25
3000 21 26
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Table4-2BracketHeight
Figure4-5Diskspringdimensions
Di
De
Lo
tFigure4-4Clampdesign
Steelstrap
Highfrictioncradleliner
Detail A
Anchorbolts
150°
Highfrictioncradleliner(fordimensions,seeFigure4-2)
h**
a*
Min.25
Steelbracket
Disksprings
Springguide
SectionA-A*ForDN≥600a=50mm
ForDN<600a=DN/8-25
**Theheightofthebracketshallbechosensuchthatthestabilityofthebracketisensured.Alinedrawntangenttothepipeattheupperedgeofthebracketmustcrossthecenterlineoftheanchorboltwellabovethebaseplateofthebracket.SeeTable4-2.
Detail A
! Note:Thereactionforces,causedbydeadweightofwater,actperpendiculartothepipe.Forpipeinstallationswithsteepslopethisresultsinasignificanthorizontalloadonthepipefoundations.
Itisacommonerrortoregardthereactionfrom waterasverticalsinceitisagravitationalforce,see Figure4-3.
! Note:Thewatercolumnwithinapressurizedpipelineoftencarriesaconsiderablecompressiveload.Itisimportenttoensurethatthesupportingstructuresarestiffenoughtoavoidcolumnbucklingofthepipeline.
4.�.3 Anchor Design
Anchorsshallbedesignedascradleswithhighfrictioncradlelinersandapretensionedsteelclamppressingthepipeagainstthecradle.Thepretensionoftheclampshallbesufficienttopreventthepipefrommovinginthecradle.
! Note: GRPpipeshavehigherdesignstrainthansteel.Thesteelclampshallthereforebedesignedwithspringelementstocompensateforthisdifference.Thespringelementsshallbedesignedsuchthatsufficientstraptensioncanbeensuredatlowpressureornopressurewithoutoverloadingthestraporthepipeinsituationsinvolvinghighworkingpressure.Thedesignofthesteelclampandthespringelementsdependsonthepropertiesofthepipeandtheloadingconditions.Figure4-4showstypicaldesignofsteelclampwithbracketanddisksprings.
ThekeydimensionsforsevendifferentstandardclampdesignsareshowninTable4-3.
Nominal PipeDiameter [mm]
Recommended Bracket Height h [mm]
300≤DN≤400 150
450≤DN≤600 200
700≤DN≤900 250
1000≤DN≤1300 300
1400≤DN≤2000 400
2100≤DN≤3000 500
04
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* TheclampingspecificationinTable4.3isbasedonhighfrictioncradlelinerwithfrictionfactoragainstpipeandcradlemin.0,7asi.e.60-70ShoreAThermoplasticPolyurethane.
** Dimensionsarebasedonthefollowingminimumsteelqualities: Steelstrap: ISO630,Fe360(DIN17100,St.37) Anchorbolt: ISO630,Fe510(DIN17100,St.52)
Table4-3Keydimensionsforstandardclampdesigns
Table4-3showsclampdesign,numberofspringelements,numberofdiskspringsinspringelementandprecompressionofspringelementsforSN5000FLOWTITEpipes.Table4-3isworkedoutforFLOWTITEpipesontwosupportsasshownonFigure4-8andmaximumpipelengthaccordingtoTable4-4.Table4-3isworkedoutbasedonthefollowingloadingconditions:• Maximumworkingpressure=Nominalpressure• Maximumsurgepressure=1.4xNominalpressure• Maximumexternalloadonpipe=2.5kN/m2
onprojectedarea• Maximumslopeofpipe10°,20°and30°,
seetableheading• JointaxialloadAccordingtoTable4-1• Minimumtemperature,emptypipe50°C
lowerthaninstallationtemperature• Maximumtemperature,emptypipe50°C
higherthaninstallationtemperature• Minimumtemperature,filledpipe20°C
lowerthaninstallationtemperature• Maximumtemperature,filledpipe20°C
higherthaninstallationtemperature
TheclampdesignisspecifiedinTable4-3withthefollowingnomenclature:Nxn/cwhere• Nisthenumberofspringelements• N=1meansspringelementononesideoftheclamp• N=2meansspringelementsonbothsidesoftheclamp• nisthenumberofdiskspringsineachspringelement• cistherequiredprecompressionofeachspring
elementinmm.Thevaluesapplyfornon-pressu-rized,pipes.TheapplicableclampdesignfromTable4-2isshowninthelastcolumnofthetable.Theclampdesignappliesfortheareaofthetablemarkedwithlines.
Figure4-6Adjustingprecompressionofdisksprings
Steelbracket
Marking
C±10%
04
Clamp Design I II III IV V VI VII
Design load 2x12kN 2x22kN 2x36kN 2x50kN 2x67kN 2x95kN 2x140kN
Steel strap** 100x5mm 100x5mm 120x5mm 120x5mm 140x6mm 140x8mm 180x10mm
Cradle liner* 100x5mm 100x5mm 120x5mm 120x5mm 140x5mm 140x5mm 180x5mm
Disk springs
Externaldiameter,De
80 80 100 100 125 125 150
Internaldiameter,De
36 36 51 51 64 61 81
Thickness,t 3 4 5 6 7 8 10
Length,l0 5.7 6.2 7.8 8.2 10.0 10.9 13.0
Max. allowable single spring compression
2.03mm 1.65mm 2.10mm 1.65mm 2.25mm 2.18mm 2.25mm
Anchor bolts** M20 M20 M25 M25 M30 M30 M36
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Table4-3aSN5000FLOWTITEPipesonTwoSupports.ClampingofPipesonAnchors.MaximumSlope10°
Table4-3appliesalsoforpipessupportedinmorethantwocradles,providedthatthecradleclosesttothemiddleofthepipeisusedastheanchor(Figure4-1).Forotherinstallationandloadingconditions,contactpipesupplier.Thespecifiedprecompressionofspringelementsisachievedbymarkingthespringguide
relativetotheclampafterhavingfingertightenedtheanchornut.Themarkingshallbemadeaspermanentaspossibleinordertoenablechecksatalaterstage.Thenthenutshallbetighteneduntilthemarkontheguidehasbeendisplacedtothespecifiedprecompression+/-10%(Figure4-6).
*SewerPipesforHighPressureCleaning**StandardPipes
***Diskspringsnotrequired.ClamppretensiongiveninkNFordetailedinformationpleasecontactyourlocalsupplier.
DNFS* FP** Clamp
DesignGravity*** PN 1*** PN 6 PN 10 PN 16
300
350
400
450
500
600
700
4
4
5
5
6
6
7
6
7
1x3/2.5
1x3/2.7
1x3/2.4
1x3/2.7
1x3/2.9
1x3/3.1
1x3/3.3
1x5/4.9
1x7/7.5
1x3/2.4
1x3/2.7
1x3/3.0
1x5/4.2
1x5/4.4
1x7/7.6
1x7/7.6
I
7 1x3/3.0
8 1x3/3.3
8 1x3/3.5
9 1x5/5.0
10 1x5/5.5
800 8 11 1x5/3.1 1x5/3.0
2x3/1.9
2x5/3.3
2x5/3.6
2x5/3.9
2x7/5.7
2x7/6.1
1x7/4.0
2x5/3.1
2x5/3.4
2x5/3.7
2x7/5.4
2x7/5.8
II
900 9 12 1x5/3.4
1000 9 13 2x3/2.2
1100 10 14 2x5/3.7
1200
1300
11 16 2x5/4.0
12 17 2x5/4.3
1400 13 18 2x7/6.2 2x5/3.5
2x5/3.8
2x5/4.0
2x7/5.8
2x7/6.2
2x7/6.5
2x9/8.7
III
1500 14 19 2x7/6.6 2x5/3.8
1600 15 20 2x5/4.1 2x5/4.0
1700 16 21 2x5/4.4 2x5/4.3
1800 17 22 2x5/4.6 2x7/6.1
1900 18 23 2x5/4.9 2x7/6.4
2000 19 24 2x7/6.9 2x7/6.8
2100 20 25 2x7/7.3 2x9/9.0
2200 20 26 2x7/7.6 2x9/9.4
2300 21 27 2x9/10.0 2x9/9.9
2400 22 28 2x9/10.4 2x11/12.5
2500 29 2x9/10.9
2600 30 2x11/13.9
2700 30 2x9/7.6 IV
2800 34 2x7/6.4
2900 35 2x7/6.6 V
3000 36 2x7/6.9
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Table4-3bSN5000FLOWTITEPipesonTwoSupports.ClampingofPipesonAnchors.MaximumSlope20°
! Note:Thetensioninthesteelstraptendstobeunevenduetothefrictionagainsttheprotectiveliner.Thetensionshallbedistributedbytappingthesteelstrapwitharubbermalletwhiletheanchornutsarebeingtightened.
*SewerPipesforHighPressureCleaning**StandardPipes
***Diskspringsnotrequired.ClamppretensiongiveninkNFordetailedinformationpleasecontactyourlocalsupplier.
DNFS* FP** Clamp
DesignGravity PN 1*** PN 6 PN 10 PN 16
300
350
400
450
500
600
700
1x3/1.6 6 1x3/2.5
1x3/2.7
1x3/2.4 1x3/2.4
I
1x3/1.8 7 1x3/2.7 1x3/2.7
1x3/2.0 8 1x3/3.0 1x5/4.8 1x3/2.7
1x3/2.2 9 1x3/3.3 1x3/2.9 1x5/4.7
1x3/2.4 10 1x5/5.8 1x5/5.1 1x5/5.1
1x3/2.8 11 1x5/6.0 1x7/8.2 1x7/8.3
1x3/3.2 12 1x7/9.5 1x5/3.3 1x7/4.5
II800 1x3/3.7 14 1x5/3.9 1x7/5.1 1x7/4.5
900 1x3/4.2 16 1x7/5.9 2x5/4.1 2x5/4.1
1000 2x3/4.4 18 2x5/4.6 2x5/4.6 2x5/2.2
III
1100 2x3/5.0 20 2x5/5.2 2x7/7.0 2x5/4.0
1200
1300
2x3/2.7 22 2x3/2.8 2x5/4.4 2x5/4.4
2x3/3.0 24 2x5/4.9 2x5/4.8 2x5/4.9
1400 2x3/3.2 26 2x5/5.4 2x5/5.3 2x7/7.3
1500 2x3/3.5 28 2x5/5.9 2x7/7.8 2x7/8.0
1600 2x3/3.8 30 2x7/8.6 2x7/8.5 2x7/5.2
IV1700 2x5/6.7 32 2x7/9.3 2x7/5.6 2x9/7.2
1800 2x5/7.2 34 2x7/6.2 2x9/7.6 2x9/7.7
1900 2x3/3.8 36 2x9/8.2 2x8/8.2 2x7/6.4
V
2000 2x3/4.0 40 2x9/8.9 2x7/6.8 2x7/6.8
2100 2x3/4.3 42 2x5/5.5 2x7/7.3
2200 2x3/4.6 45 2x7/7.9 2x7/7.7
2300 2x3/5.0 47 2x7/8.4 2x9/10.3
2400 2x3/8.5 52 2x7/8.9 2x9/11.0
VI
2500 55 2x9/11.9
2600 57 2x7/7.5
2700 60 2x7/7.9
2800 63 2x9/10.4
2900 66 2x9/10.9
3000 74 2x11/13.3
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Table4-3cSN5000FLOWTITEPipesonTwoSupports.ClampingofPipesonAnchors.MaximumSlope30°
DNFS* FP** Clamp
DesignGravity PN 1 PN 6 PN 10 PN 16
300
350
400
450
500
600
700
1x3/1.9 1x3/2.6 1x3/2.5
1x3/2.7
1x3/2.4 1x3/2.4
I
1x3/2.1 1x3/2.9 1x3/2.7 1x3/2.7
1x3/2.4 1x3/3.2 1x3/3.0 1x3/2.9 1x5/4.8
1x3/2.6 1x3/3.6 1x3/3.3 1x5/5.2 1x5/5.2
1x3/2.9 1x3/4.0 1x5/5.8 1x5/5.8 1x7/8.0
1x3/3.5 1x3/4.6 1x7/9.6 2x5/6.7 2x5/6.8
1x3/4.1 1x3/5.4 2x5/8.0 1x7/5.3 1x7/5.3
II800 1x3/4.7 1x3/3.1 1x7/6.3 2x5/4.4 2x5/4.4
900 1x5/8.6 1x3/3.6 2x5/5.1 2x5/5.0 2x7/7.0
1000 2x3/2.8 2x3/3.8 2x7/7.9 2x5/4.4 2x5/4.5
III1100 2x3/3.2 2x3/4.3 2x5/5.1 2x5/5.0 2x5/5.1
1200
1300
2x3/3.6 2x5/7.7 2x5/5.7 2x5/5.6 2x7/7.9
2x3/4.0 2x3/4.1 2x5/6.4 2x7/8.7 2x7/8.8
1400 2x5/7.1 2x3/4.5 2x7/9.7 2x7/6.8 2x7/6.9IV
1500 2x3/3.8 2x3/4.9 2x7/6.5 2x7/6.8 2x9/8.2
1600 2x3/4.2 2x3/5.4 2x7/7.1 2x9/8.8 2x5/5.0
V1700 2x3/4.6 2x3/9.4 2x9/9.7 2x5/5.4 2x7/7.5
1800 2x3/5.0 2x3/3.9 2x5/6.0 2x7/8.0 2x7/8.1
1900 2x5/8.6 2x3/4.1 2x5/6.5 2x7/8.6 2x9/11.1
2000 2x3/3.6 2x5/7.1 2x7/9.5 2x9/11.8 2x7/6.7
VI
2100 2x3/3.9 2x3/4.7 2x9/12.9 2x7/7.2
2200 2x5/6.6 2x3/5.0 2x9/13.8 2x7/7.7
2300 2x5/7.1 2x3/5.3 2x7/8.4 2x9/10.4
2400 2x3/4.7 2x3/5.7 2x7/9.0 2x9/11.1
2500 2x3/9.7 2x9/12.0
2600 2x3/4.6 2x11/15.8
2700 2x3/4.9 2x9/10.1
VII2800 2x3/5.1 2x9/10.7
2900 2x3/5.4 2x9/11.4
3000 2x3/9.2 2x11/14.4
*SewerPipesforHighPressureCleaning**StandardPipes
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4.�.4 Guide Design
Guidesshallbedesignedascradleswithlowfrictioncradleliners(Figure4-2).ThefrictionfactorbetweenFLOWTITEpipesandthelinershallbelessthan0.3.Thisrequirementisfulfilledbye.g.ultrahigh-molecularpolyethyleneandpolytetrafluorethyleneliners.Itmustbeensuredthatthelinermaterialisresistanttotheactualenvironment.Thecradlelinershallbepermanentlyattachedtotheguidecradletoensureitsstability.Inmanysituations,theweightofpipeandfluidissufficienttoensurethelateralstabilityofapipeinaguide.Theendsofshorthighpressurepipescan,however,liftupfromguidesasaresultofanunfavourablecombinationofhighpressureforcesinthefluidandpipetocouplingangulardeflection.Theneedforsecuringofpipeendsdependsonthecombinationofinternalpressure,pipetocouplingangulardeflectionandthesupportingconditions.Verticalconvexangularpipetocouplingdeflectionandinternalpressurecreatesaforcethattendstoliftthepipeend(Figure4-7).
04
Table4-4aWaterFilledPipesonTwoCradles. MinimumPipeLengthforStableEnds
n.a.=notapplicableclampcouplings
ForPN>16pleasecontactyourlocalsupplier
Table4-4bWaterFilledPipesonMultipleCradles. MinimumSupportSpacingforStableEnds
n.a.=notapplicableclampcouplings
ForPN>16pleasecontactyourlocalsupplier
Figure4-7Stabilityofpipeendsonguides
Pipetocouplingverticalconvexoffset
Note:Anglesareexaggeratedforillustration
Lift
DN
Ifsuchaliftingforcecanbecomelargeenoughtoliftuppipeend,thepipeendsmustbesecured.Thesecuringofpipeendsisbestachievedbyclampingthecouplingtothefoundationsupportingthejoint.Forinsitucastconcretesupports,seeFigure4-8.Theclampsusedforanchoringofpipes,seeSection4.2.3 ,canbeusedforclampingofcouplingstofoundations.SeeSection4.2.3 forselectionandmountingofclamps.
Nominal Pipe Diameter
Vertical Convex Angle of
Deflection
PN 1 PN 6 PN 10 PN 16
Slope Slope Slope Slope
10° �0° 30° 10° �0° 30° 10° �0° 30° 10° �0° 30°
(mm) ( ° ) m m m m m m m m m m m m
300≤DN<500 3 1.2 1.3 1.4 n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
500<DN≤900 2 0.8 0.8 0.9 4.8 5.0 5.4 n.a. n.a. n.a. n.a. n.a. n.a.
900<DN≤1800 1 0.4 0.4 0.5 2.4 2.5 2.7 4.0 4.2 4.5 6.4 6.7 7.2
DN>1800 0.5 0.2 0.2 0.2 1.2 1.3 1.4 2.0 2.1 2.3 3.2 3.3 3.6
Nominal Pipe Diameter
Vertical Convex Angle of
Deflection
PN 1 PN 6 PN 10 PN 16
Slope Slope Slope Slope
10° �0° 30° 10° �0° 30° 10° �0° 30° 10° �0° 30°
(mm) ( ° ) m m m m m m m m m m m m
300≤DN<500 3 1.6 1.7 1.8 n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
500<DN≤900 2 1.1 1.1 1.2 n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
900<DN≤1800 1 0.5 0.6 0.6 3.2 3.3 3.6 5.3 5.6 6.0 n.a. n.a. n.a.
DN>1800 0.5 0.3 0.3 0.3 1.6 1.7 1.8 2.7 2.8 3.0 4.2 4.4 4.8
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Table4-6onthenextpageshowsmaximumsupportspacingforFLOWTITEpipessupportedonthreeormorecradles.MaximumstandardFLOWTITEpipelengthis12mandthetablecoversonlysupportspacinglessthan6m.ThetableisworkedoutbasedonthefollowingloadingconditionsandsupportingasshowninFigure4-10.
• Densityoffluid=1000kg/m3
• Maximumworkingpressure=Nominalpressure• MaximumfieldtestpressureaccordingtoTable5-1• Maximumsurgepressure=1.4xnominal• Maximumexternalloadonpipe=2.5kN/m2proj.area
Forotherloadingconditions,pleaseconsultthesupplier.
4.4 Negative Pressure
Theallowablenegativepressure(vacuum)is-0.5barforSN5000and-1.0barforSN10000.
Theneedforsecuringpipeendsdependsontheangulardeflectionatjoints,thepressureinthepipesandthesupportingconditions.Bothpipetopipeandcouplingtopipeangulardeflectionmustbeconsidered.Tables4-4aand4-4bshowtheminimumsupportspacingneededtoensuresufficientreactionfromthedeadweightofpipeandfluidtocounteracttheliftingforcecreated.AverticalconvexangulardeflectioncorrespondingtothevaluesgiveninTable3-1isassumedtogetherwithworkingpressureequaltothenominalpressureofthepipe,surgepressureequalto1.4xnominalpressureandmaximumfieldtestpressureasgiveninTable5-1.Thetablesareworkedoutforpipeinstallationsindifferentslopes.
4.3 Maximum Supporting Spacing
Themaximumsupportspacingisdeterminedbasedonthepropertiesofthepipeandtheloadingconditions.Stressesinthepipewallmustbekeptwithinallowablelimitsandexcessivepipedeflectionsmustbeavoided.Table4-5onthenextpageshowsmaximumpipelengthsforFLOWTITEpipessupportedontwocradles.ThetableisbasedonthefollowingloadingconditionsandpipesupportasshowninFigure4-9.
• Densityoffluid=1000kg/m3
• Maximumworkingpressure=Nominalpressure• MaximumfieldtestpressureAccordingtoTable5-1• Maximumsurgepressure=1.4xnominal• Maximumexternalloadonpipe=2.5kN/m2proj.area
Figure4-8Anchoringofcouplingstoconcrete supports
Cradleliner·HighfrictionforAnchors·LowfrictionforGuides
Sealingcompound
Highfrictioncradleliner
Figure4-9Pipessupportedontwocradles
Guide Anchor Guide Anchor
Pipelength
250mmforDN≤500max.0.5xDNfor600≤DN≤1000500mmforDN>1000
AnchorGuides Guides
Supportspacing Supportspacing
300mmforDN≤500max.0.5xDNfor600≤DN≤1000600mmforDN>1000
Figure4-10Pipessupportedinmultiplecradles
Couplinganchor–ifnecessary,seeSection4.2.4
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Table4-6SN5000MaximumSupportSpacing, MultipleCradleInstallations[m]
*SewerPipesforHighPressureCleaning**StandardPipes
Fordetailedinformationpleasecontactyourlocalsupplier.
Table4-5SN5000MaximumPipeLength onTwoCradles[m]
*SewerPipesforHighPressureCleaning**StandardPipes
Fordetailedinformationpleasecontactyourlocalsupplier.
FS* FP**
DN Gravity PN 1 PN 6 PN 10 PN 16
300 3.4 4.0 3.9 3.0 2.6
350 3.6 4.3 4.2 3.5 3.0
400 3.8 4.5 4.5 3.9 3.3
450 3.9 4.8 4.7 4.3 3.7
500 4.1 5.0 5.0 4.8 4.1
600 4.3 5.4 5.4 5.5 4.7
700 4.6 5.9 5.9 6.0 5.4
800 4.9 ≥6.0 ≥6.0 ≥6.0 ≥6.0
900 5.1 ≥6.0 ≥6.0 ≥6.0 ≥6.0
1000 5.4 ≥6.0 ≥6.0 ≥6.0 ≥6.0
1100 5.6 ≥6.0 ≥6.0 ≥6.0 ≥6.0
1200 5.9 ≥6.0 ≥6.0 ≥6.0 ≥6.0
≥1300 ≥6.0 ≥6.0 ≥6.0 ≥6.0 ≥6.0
FS* FP**
DN Gravity PN 1 PN 6 PN 10 PN 16
300 3.4 3.5 3.2 3.0 2.6
350 3.7 3.8 3.5 3.4 2.9
400 4.0 4.1 3.8 3.7 3.3
450 4.1 4.4 4.1 4.0 3.7
500 4.3 4.7 4.4 4.3 4.1
600 4.6 5.2 4.9 4.9 4.7
700 4.9 5.8 5.5 5.4 5.4
800 5.2 6.3 6.0 5.9 6.1
900 5.4 6.8 6.5 6.4 6.6
1000 5.6 7.2 7.0 6.9 7.2
1100 5.9 7.6 7.5 7.5 7.7
1200 6.2 8.0 7.8 7.8 8.1
1300 6.4 8.3 8.0 8.0 8.4
1400 6.6 8.5 8.3 8.3 8.6
1500 6.8 8.8 8.5 8.5 8.9
1600 7.0 9.0 8.7 8.8 9.2
1700 7.2 9.1 8.9 9.0 9.4
1800 7.3 9.3 9.1 9.2 9.7
1900 7.5 9.5 9.3 9.4 9.9
2000 7.7 9.7 9.5 9.6 10.1
2100 7.8 9.8 9.6 9.8
2200 8.0 10.0 9.8 9.9
2300 8.2 10.1 10.0 10.1
2400 8.3 10.3 10.1 10.3
2500 10.4 10.3
2600 10.6 10.4
2700 10.7 10.6
2800 10.8 10.7
2900 11.0 10.8
3000 11.1 11.0
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5.1 Field Hydrotesting
Somejobspecificationsrequirethecompletedpipeinstallationtobehydrostaticallytestedpriortoaccep-tanceandservice.Thisisgoodpracticeasitcanpermitearlydetectionandcorrectionofinstallationflaws,damagedproducts,etc.Ifafieldhydrotestisspecified,itmustbedoneregularlyasinstallationproceeds.Inadditiontoroutinecare,normalprecautionsandtypicalproceduresusedinthiswork,thefollowingsuggestionsshouldbenoted:
1 PreparationPriortoTest–Inspectthecompletedinstallationtoassurethatallworkhasbeenfinishedproperly.Ofcriticalimportanceare:
•Jointsassembledcorrectly •Systemrestraints(i.e.thrustblocks,andother
anchors)inplaceandproperlycured •Flangeboltingtorquedperinstructions •Valvesandpumpsanchored. SeeSection5.2 .
� FillingtheLinewithWater–Openvalvesandvents,sothatallairisexpelledfromthelineduringfillingandavoidpressuresurges.Whenthepipelinehasbeenfilleditshallbeinspected.SeeSection5.3 .
3 Pressurizethelineslowly.Considerableenergyisstoredinapipelineunderpressureandthispowershouldberespected.
4 Insurethegaugelocationwillreadthehighestlinepressureoradjustaccordingly.Locationslowerinthelinewillhavehigherpressureduetoadditionalhead.
5 Insurethemaximumtestpressureisnotexceeded(SeeTable5-1 ).Thismaybedangerousandresultindamagetothepipesystem.
6 Ifafterabriefperiodforstabilizationthelinedoesnotholdconstantpressure,insurethatthermaleffect(atemperaturechange)orentrappedairisnotthecause.Ifthepipeisdeterminedtobeleaking
andthelocationisnotreadilyapparent,thefollowing
5Checkingtheinstalledpipe
methodsmayaiddiscoveryoftheproblemsource: •Checkflangeandvalveareas •Checklinetaplocations •Checkjointsforleakage
5.� Inspection Prior to Filling of Pipe
Thepipeshallnotbefilledwithwateruntilthecompleteinstallationhasbeeninspectedinordertoassurethatallworkhasbeenfinishedproperly.Specialattentionshallbepaidtothefollowingaspects:
1 JointsThejointsshallbecheckedasdescribedinSection3 inregardto: 1.Angulardeflection �.Couplingposition 3.Jointalignmentand 4.ThegapbetweenthepipeendsThecouplingpositionrelativetobothofthepipesshallbemarkedat4pointsaroundthecircumference(Figure5-1)asreferenceforlaterchecks.Itshallbecheckedthatthegasketsarecorrectlyseatedandthatthegapbetweenpipespigotandcouplingsleeveisfreeofconcreteorotherforeigninclusions.
� SupportsCheckthatthecradlegivesevenandcontinuoussupporttothepipeandthatthecradlediameteris0,5±0,25%largerthanthepipe.Checkthesupportangletobe150±5°.Forpipessupportedonmorethantwosupports,thealignmentofpipesupportsshallbechecked.Maximumdeviationfromstraightalignmentis0,1%ofthespanlength.Checkthatthecradlelinerisinplacebetweenthepipeandthecradleandensurethatthereisnodirectcontactbetweencradleandpipe.Checkthatthereisnoconcreteorotherforeigninclusionbetweenthepipeandthecradleliner.Checkthattherearehigh-frictionlinersatanchorsandlow-frictionlinersatguides.Checkthestructuralintegrityofthesupports.Markthepositionofthepiperelativetotheanchors,asreferenceforlaterinspection.
3 ClampsCheckthatthelineriscorrectlypositionedbetweentheclampandthepipeorcoupling.Checkthenumberandcompressionofdiskspringsagainstthespecification.
ForHigherPressurepleasecontactus.
Table5-1MaximumFieldTestPressure
Figure5-1Markingcouplingposition
Fixeddistance(15-20mm)
Pressure Class
Maximum Field Test Pressure
100kPa 150kPa
600kPa 900kPa
1000kPa 1500kPa
1600kPa 2400kPa
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Checkstructuralintegrityofthesteelclampandanchorbolts.Checkthatthesteelclampispositionedperpendiculartothepipeaxis.
4 PipesInspectthepipestoensurethattheyhavenotbeendamagedintheinstallationphase.Checkthesupportspacingagainstspecifications.
5 OtherCheckthrustblocks,anchors,valvepumps,etc.
5.3 Inspection of Filled Pipeline Prior to Pressurizing
Whenthepipehasbeenfilledwithwater,itshallbeinspectedpriortopressurizing.Specialattentionshallbepaidtothefollowingaspects:
1 JointsInspectthejointsforanysignofleakage.Checkcouplings’movementrelativetothemarksmadepriortofillingthepipe.! Note:Theweightoffluidinthepipewillcause
rotationofpipeends(Figure5-2).Checkthecouplingtopipeangularoffset,seeSection3 .
Ifacouplinghasmoved,itsnewpositionrelativetobothofthepipesshallbemarkedat4pointsaroundthecircumference(Figure5-1).Ifthereisanysignofcouplingmovementinexcessofwhatcanbeexplainedbyloadinducedpipeendrotation,thepositionofthecouplingshallbechecked.Thestabilityofthecouplingandthepipeendsupportsshallalsobeverifiedinanappropriateway.Ifthereisareasontobelievethatsupportsmighthavesettledduetotheaddedweight,thepipeendmisalignmentshallbechecked.Pipeendmisalignmentshallbelessthan0,5%ofpipediameterand3mm.
� SupportsCheckthestructuralintegrityandstabilityofthesupports.Checkiftheaddedweighthascausedsettlementordeflectionofsupports.
3 PipesMeasurethemaximumdeflectionofthepipesforeachpipespan.Thepipedeflectioncanbemeasuredbyusingatensionedstringasareference(Figure5-2).Ifthemaximumdeflectionatanypipespanexceedsthespanlengthdividedby300,thepipesuppliershallbecontactedpriortopressurizingthepipe.
5.4 Inspection of Pressurized Pipelines
Whenthepipehasbeenpressurized,thepipeshallbeinspected.Specialattentionshallbepaidtothefollowingaspects:
1 JointsInspectthejointsforanysignofleakage.Itshallbecheckedifthecouplingshavemovedrelativetothemarksmadepriortopressurizingofthepipe.! Note:InadditiontothePoisson’seffect,the
pressureincreaseinthepipecancauseslightrotationofpipeends(Figure5-2).
Checkthecouplingtopipeangularoffset,seeSection3 .IfthereisanysignofcouplingmovementinexcessofwhatcanbeexplainedbythePoisson’seffectandpressureinducedpipeendrotation,thestabilityofthecouplingandthepipeendsupportsshallbeverifiedinanappropriateway.
� SupportsCheckthestructuralintegrityandstabilityofthesupports.Checkifthepressureincreasehascausedsettlementordeflectionofsupports.Usethemarkstocheckifthepipehasmovedrelativetotheanchors.Ifapipehasmovedrelativetoanchor,thepipeshallbedepressurizedandtheanchoringrevisedpriortorepressurizing.
3 ClampsCheckthecompressionofdiskspringsandensurethatthecompressiondoesnotexceedthemaximumallowablespringcompression(Table4-2).Thespringcompressioncanbemeasuredusingthemarksonthespringguide(Figure4-6).Checkstructuralintegrityofthesteelclampandanchorbolts.
4 PipesMeasureandrecordthemaximumdeflectionofthepipesforeachpipespan.Thepipedeflectioncanbemeasuredbyusingatensionedstringasareference(Figure5-2).Ifthemaximumdeflectionatanypipespanhasincreasedbymorethan50%comparedtothedeflectionmeasuredforfilledandunpressurizedpipe,thepipeshallbedepressurizedimmediatelyandthepipesuppliershallbecontacted.Checkthepipesfordarkareasorweeping.
06
Figure5-2Pipedeflection
String Pipedeflection
05
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OneMiterBand0-30° TwoMiterBand31-60° ThreeMiterBand61-90°
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6.1 Thrust Restraints
Whenthepipelineispressurized,unbalancedthrustforcesoccuratbends,reducers,tees,wyes,bulkheadsandotherchangesinlinedirection.Theseforcesmustberestrainedinsomemannertopreventjointseparation.Determinationofneedanddesign,aswellasthelevelofsteelreinforcementofconcretestructures,istheresponsibilityoftheowner’sengineer.FLOWTITEfittingsaredesignedtowithstandthefullinternalpressure,whiletheconcretestructureshallsupportitsshapeandtransfertheload.Astheexpansionofthepressurisedfittingsistypicallygreaterthanthetensilestrengthoftheconcretewouldcarry,steelreinforcementtocontrolcrackwidthsshouldbeconsidered.Thefollowingconditionsalsoapply:
Thrust Blocks
ThrustblocksmustlimitthedisplacementofthefittingrelativetotheadjacentpipetopreservetheleaktightnessoftheFLOWTITEcouplingjoint.TheresultingangulardeflectionshallbelessthanthevaluesindicatedinTable3–1.Formoredetailsofpipeinstallationandsystemlayoutseeclauses6.2and6.3 .
Foroperatingpressuresabove10bar(PN>10)theblockmustcompletelysurroundthefitting.Forlowerpressuresspecialfittingscanbesuppliedthatallowforpartialembedding.Theblockmustbebuiltonfirmfoundation.
! Note:Itisimportantthatsupportsettlementdoesnotresultinmisalignmentofpipeendsinjoints.Maximumallowablepipeendmisalignmentisthelesserof0,5%ofthediameteror3mm.
6ThrustRestraints,ConcreteEncasementandConnectionstoRigidStructures
Figure6-1Thrustblocks
SectionA-ATee Reducer
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Pipe Anchoring
Duringthepouringoftheconcrete,theemptypipeorfittingwillexperiencelargeuplift(flotation)forces.Thepipemustberestrainedagainstmovementthatcouldbecausedbytheseloads.Thisisnormallyaccomplishedbystrappingoverthepipetoabaseslaborotheranchor(s).Strapsshouldbeaflatmaterialofminimum25mmwidth,strongenoughtowithstandflotationupliftforces,withaminimumoftwostrapspersectionlengthandwiththemaximumspacingbetweenstrapsasshowninTable6–1.Thestrapsshouldbetightenedtopreventpipeuplift,butnotsotightthatadditionalpipedeflectioniscaused(seeFigure6–2).
Pipe Support
Thepipeshouldbesupportedinsuchawaythattheconcretecaneasilyflowcompletelyaroundandfullyunderneaththepipe.Also,thesupportsshouldresultinanacceptablepipeshape(lessthan3%deflectionandnobulgesorflatareas).
Concrete Pouring
Theconcretemustbeplacedinstagesallowingsufficienttimebetweenlayersforthecementtosetandnolongerexertbuoyantforces.Themaximumliftheights,asafunctionofstiffnessclass,areasshowninTable6–2.
Maximumliftisthemaximumdepthofconcretethatcanbepouredatonetimeforagivennominalstiffnessclass.
06
Figure6–2Pipeanchoring–MaximumspacingofstrapsseetableTable6-1
Table6–1MaximumStrapSpacing Table6–2MaximumConcretePourLifts
Thrustblocksarerequiredwhenthelinepressureexceeds1bar(100kPa)forallfittingswhereunbalancedthrustoccurs,suchas:bends,reducers,bulkheads,blindflanges,tees,wyesandbifurcations.
Concentricmanways(blindflangetees),drainsandairvents,whichdonotgenerateunbalancedthrustinoperation,donotrequireencasement,butdorequirethrustresistantbranchesandfittings.
Note:Thethrustblockshapesshownaretypical forillustration.Theexactshapewillbedependent ondesignandprojectrequirement.
Valves
Valvesmustbesufficientlyanchoredtoabsorbthepressurethrust.MoredetailsonvalvesandchambersareprovidedinFlowtiteInstallationGuideforBuriedPipes.
Nozzles
Nozzlesareteebranchesmeetingallofthefollowingcriteria:
Nozzlediameter≤300mm.
Headerdiameter≥3timesnozzlediameter.
Note: itisnotnecessarytoencasenozzle connectionsinconcrete.
6.� Concrete Encasement
Whenpipes(orfittings)mustbeencasedinconcrete,suchasforthrustblocks,stressblocks,ortocarryunusualloads,specificadditionstotheinstallationproceduresmustbeobserved.
!
max.spacing
clearance
min.25mm
!
�
1
DN Maximum Spacing (m)
<400 2.5
500–600 4.0
700–900 5.0
≥1000 6.0
SN Maximum lift
2500 Largerof0.3morDN/4
5000 Largerof0.45morDN/3
10000 Largerof0.6morDN/2
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Figure6–5Rubberwrapconfiguration– Rubbershallbe50Durometer
Type A:
Type C:
10mm
150mm
20mm10mm
300mm
Rubber Wrap Placement
PositionasshowninFigures6–4and6–5.
Tapeallseamsandedgestoassurenocementcan getbetweentherubberandthepipeorbetweenthe rubberwraps.
Figure6-4AlternateB:Rubberwraps
Max.250mmforDN≤500Max.0.5DNfor600≤DN≤1000Max.500mmforDN>1000
CradleLiner
25mm 06
6.3 Rigid Connections
Whenapipepassesthroughawall,isencasedinconcrete,meetsajunctionwithamanhole,orisflangedtoapump,valve,orotherstructure,excessivebendingstressesmaydevelopinthepipeifdifferentialmovementoccursbetweenthepipeandtherigidconnection.Forallrigidconnections,actionmustbetakenbythein-stallertominimizethedevelopmentofhighdiscontinuitystressesinthepipe.Twooptionsareavailable.AlternateA(preferred)usesacouplingjointcastintotheconcrete-pipeinterface.AlternateBwrapsthepipeinrubbertoeasethetransition.
Alternate A
Wherepossible,castacouplingjointintheconcreteattheinterface(Figure6-3)sothatthefirstpipeoutsidetheconcretehascompletefreedomofmovement(withinthelimitsofthejoint).
! Caution:Whencastingacouplinginconcretebesuretomaintainitsroundnesssolaterjointassemblymaybeaccomplishedeasily.Alternatively,makeupthejointoutsidetheencasementpriortopouringtheconcrete.
Alternate B
WhereAisnotpossible,wrap(Figure6-4)aband(orbands)ofrubber(Table6-1andFigure6-5)aroundthepipepriortoplacementofanyconcretesuchthattherubberslightlyprotrudes(25mm)fromtheconcrete.LayoutthepipelinesothefirstcompletelyexposedcouplingjointislocatedasshowninFigure6-4.Precautionsmustbetakentominimizethesettlementofthereinforcedconcretestructureorpipebyprovidinganadequatefoundation.Differentialsettlementinthepipewillcausestressesinthepipeandmaycausepipefailure.
Figure6-3AlternateA
Max.25mm
Couplingcastinconcrete
CradleLiner
25mm
Max.300mmforDN≤500Max.0.5DNfor600≤DN≤1000Max.600mmforDN>1000
Table6-1ConfigurationofRubberBands
1
�
Diameter Wrap configuration
300-900 A
1000-3000 C
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Table6-2MaximumGroutingPressure(PipeInvert)withoutInternalSupports
SN MaximumGroutPressure(bar)
2500 0.35
5000 0.70
10000 1.35
Figure6–7Plasticspacerunit
Note: Iftheannularspaceisnotgroutedandthe pipewillbesubjectedtonegativepressure,the pipestiffness–installationcombinationmustbe sufficienttowithstandtheload.Consultthesupplier foradvice.
6.4 Casings (Tunnels)
WhenFLOWTITEstandardpipe(unequalexteriorflush)isinstalledinacasingthefollowingprecautionsshouldbeobserved.
Pipesmaybeplacedintothecasingbypulling (drawing)orpushing(jacking).Pleaseconsultthe supplierforthecalculationofthemaximuminsertion length/-force.
Foraneasyinsertionandforprotectionfromsliding damagethepipesshouldbeequippedwithplastic spacers,steelsleevesorwoodenskids(asshownin Figure6-6and6-7).Thesemustprovidesufficient heighttopermitclearancebetweenthecoupling jointsandthecasingwall.
Installationintothecasingismadeconsiderably easierbyusinglubricantbetweentheskidsandthe casingwall.Donotuseapetroleumbasedlubricant asitmaycauseharmtosomegaskets.
Theannularspacebetweenthecasingandpipe maybefilledwithsand,gravelorcementgrout. Caremustbetakentonotoverstressorcollapse thepipeduringthisstep,particularlywhengrouting. MaximumgroutingpressureisgiveninTable6–2
Note: Donotwedgeorbracethepipeinamanner thatcausesconcentratedorpointloadsonthepipe. Consultthesupplierpriortothisstepforadviceon suitabilityofthechosenmethod.
Figure6–6Typicalskidarrangement
Atthesametimepipesystemswithflushjointcanbeused.
Figure6-8Flushjoint
1
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3
4
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Dia- meter Series
DN
(mm)
Min. OD
(mm)
Max. OD
(mm)
Spigot width (mm)
L
(mm)
B� 300 323.4 324.5 130.0 6.0
B� 350 375.4 376.4 130.0 8.0
B� 400 426.3 427.3 130.0 10.0
B� 500 529.1 530.1 130.0 14.0
B1 600 616.0 617.0 160.0 17.0
B1 700 718.0 719.0 160.0 20.0
B1 800 820.0 821.0 160.0 20.0
B1 900 922.0 923.0 160.0 20.0
B1 1000 1024.0 1025.0 160.0 20.0
B1 1100 1126.0 1127.0 160.0 20.0
B1 1200 1228.0 1229.0 160.0 20.0
B1 1400 1432.0 1433.0 160.0 20.0
B1 1600 1636.0 1637.0 160.0 20.0
B1 1800 1840.0 1841.0 160.0 20.0
B1 2000 2044.0 2045.0 160.0 20.0
B1 2200 2248.0 2249.0 160.0 20.0
B1 2400 2452.0 2453.0 160.0 20.0
B1 2600 2656.0 2657.0 160.0 20.0
B1 2800 2860.0 2861.0 160.0 20.0
B1 3000 3064.0 3065.0 160.0 20.0
Table7-1SpigotDimensionsandTolerances
7.1 Length Adjustment
AlargemajorityofthepipesuppliedbyFLOWTITEproducershastheoutsidediameterofthebarrelofthepipewithinthetolerancerangeofthecalibratedspigot(Table7–1).ThesepipesareoftenmarkedasAdjustmentPipeorsimilar.Thefollowingprocedureswillassistincorrectlymakingthelengthadjustment:
Ensurethatthepipediameteriswithinthespigot tolerancerange.
Determinethelengthrequiredandmarkasquare cutontheselectedpipe.
Cutthepipeattheappropriatelocationusinga circularsawwithadiamondcoatedblade.Use propereye,earanddustprotection.Consultthe pipesupplierforrecommendations.
Cleanthesurfaceinthejointingarea,sandsmooth anyroughspotsandwithagrinderbevelgrindthe pipeendtoeaseassembly(seeFigure7–1).No furthergrindingisnecessary.
Thedesignofthepipesdoesnotrequireanysealingofthespigotendsafterfieldcutting.Ifnationallawdemandssealing,e.g.becauseofmaintenanceofindustrialhealthandsafetystandards,onehastocomplywithit.
Note:Inrelationtothisitisofgreatimportancethat theinterioredgeofanadjustmentpipeischamfered afterfieldcutting.
Note:SeriesB2matcheswithDuctileIronspigot O.D.SeriesB1isGRPO.D.series.Insomecountries theDuctileIron(B2)seriesmaynotbeused.
7.� Field Closures with FLOWTITE CouplingsFLOWTITEcouplingscanbeusedforfieldclosuresandrepairs.Theminimumlengthoftheclosurepipeshouldbe1metre.Theclosurepipemustbesupportedtoensureitsstability,seeSection4.2 .
Note:Forfieldclosuresection,doublethespigot width.
7FieldAdjustments
Figure7–1Pipespigotandbeveldimensions definitionforcouplingjoints
SpigotWidth
PipeWall
L
t
SpigotOD
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Procedure
Measurethedistancebetweenthepipeendswhereyouwanttosetintheclosurepipe.Theclosurepipeshouldbe50-60mmshorterthanthemeasuredlength.Thenarrowerthegaptheeasieritwillbetomaketheclosure.Forminimumgap,seeChapter3 Section“GapBetweenPipeSpigots”.
Pipe Selection
Chooseapipewhichiswithinthespigotdiametertolerance.Thesepipeswillhavetherequiredspigotoutsidedimensionforjoiningalongtheentirepipelength.Ifpossiblechooseapipewiththeoutsidedimensionatthelowendofthespigotrange(seeTable7–1).
Pipe Preparation
Markthepipelengthrequiredandmakeacutperpen-dicularandsquaretothepipeaxiswithacircularsaw.Useagrindingtooltomakea20degreebevelonthepipeendandround-offthecorners.Becarefulthattheremainingthicknessonthepipespigotendisnotlessthanonehalfthepipethickness.Itisalsoimportanttohaveaminimumchamferlength,L,forguidingthepipeendwithoutdamagingthegasket.FollowtherecommendedlengthsinTable7–1.Afterbevelling,usesandpapertoremoveanysharpcornersonthepipesurfacewhichmayhavebeencausedbythecutting.Smooththespigotofanyroughspots.
Note: Thespigotwidthmustbeatleastequalto thecouplingwidth.Thiswillbetwicethevalues showninTable7–1.
Pleasemakesurethatthesurfacehasnogrooves,andthatthespigotODiswithinthelimitsshowninTable7-1.
Installation
Selecttwocouplings,removethecentreregisters, andleavethegasketsinplace.Cleanthecouplings ifnecessary.Thegasketgroovemustbefreeofdirt toallowunrestricteddeformationofthegasket.
Lubricatecarefully,includingbetweenthelips.
Lubricatealsothecleanspigotendsoftheclosure pipeswithathincontinuouslayeroflubricant.Do notforgetthebevelledsurfaces.
Placeonecouplingsquareontotheendofthe closurepipesothatthegasketisincontractaround itsentirecircumference.Pushorpullthecoupling uniformlyontotheclosurepipeuntiltheentire couplingisrestingonthespigotend.Itmaybe necessarytogentlyhelpthesecondringoverthe chamferedendofthepipes.Repeatwiththe secondcouplingontheotherend.
Markhome-linesontotheadjacentpipespigot endstocontroltheuniformbackwardmovementof thecoupling.Thehome-line’slocationiscalculated asfollows: HL=(Wc-Wg)/2 HL–homeline Wc–widthofthecoupling Wg–widthofgapbetweenclosure pipeandadjacentpipe(measured).
Mountandanchortheclosurepipeonitssupports alignedwiththeadjacentpipesandwithequal clearanceoneitherside.Anyangleortiltwill complicatetheassemblingprocess.
Cleanthespigotendsoftheadjacentpipesand lubricatewithaneven,thinlayer.Installspecial toolstopullthecouplingbacktoclosingposition. (consultyoursupplierforinformationaboutthe tools).Itisrecommendedthatyoupullthecouplings overbothsidessimultaneously,keeptheclosure pipecentredandminimizepipeendcontact.Stop pullingwhenthecoupling’sedgetouchesthehome- line.Forman-entrysizepipes,anindividualinside thepipewatchingtheassemblyprocesscanbe advantageous.
Note: Afterthecouplingisinfinalposition,afeeler gaugemaybeusedtoassurethatgasketlipsare properlyoriented.
7.3 Field Closures with Non-FLOWTITE Couplings
FollowthegeneralproceduresofSection7.2 exceptthattheclosurepipewillnottypicallyneedtohavethespeciallongmachinedspigotends.Theinstallationproceduresfortheparticularcouplingusedmustbefollowed(seeSection3.2 ).
Figure7–2Closuresectionassembly
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Approximate Weights for Pipes and Couplings
AppendixAD
NFS
* - Gravity
FP** - P
N 1
PN
6P
N 10
PN
16
mm
kg/mkg/m
kg/mkg
kg/mkg/m
kg/mkg
kg/mkg/m
kg/mkg
kg/mkg/m
kg/mkg
kg/mkg/m
kg/mkg
3009.1
11.314.0
6.98.2
10.412.7
13.08.2
10.412.7
13.07.9
10.312.7
13.77.5
9.512.2
14.1
35012.2
15.118.8
8.011.1
14.317.3
15.011.1
14.317.3
15.010.6
13.817.3
15.810.0
12.616.3
16.4
40015.5
19.324.2
9.014.5
18.523.0
16.814.5
18.523.0
16.813.5
17.623.0
17.912.6
16.121.0
18.5
45019.3
24.329.6
10.018.4
24.029.0
18.818.4
24.029.0
18.816.8
22.029.0
19.615.8
19.926.0
21.0
50023.8
29.436.9
11.023.0
30.035.0
21.023.0
30.035.0
21.021.0
27.035.0
22.019.3
25.032.0
23.0
60032.4
40.349.5
12.832.0
40.048.0
32.032.0
40.048.0
32.028.0
37.048.0
34.026.0
33.044.0
35.0
70043.5
54.366.0
15.243.0
54.066.0
37.043.0
54.066.0
37.038.0
49.066.0
39.035.0
45.059.0
42.0
80056.7
70.185.9
18.155.0
69.086.0
42.055.0
69.086.0
42.049.0
64.086.0
46.045.0
58.076.0
50.0
90071.9
87.9109.4
21.070.0
87.0110.0
48.070.0
87.0110.0
48.061.0
81.0110.0
53.056.0
73.095.0
58.0
100087.8
108.0134.3
23.886.0
110.0135.0
54.086.0
110.0135.0
54.075.0
100.0135.0
60.069.0
89.0120.0
66.0
1100105.4
131.6161.8
26.6103.1
128.1160.3
53.9103.1
128.1160.3
53.989.6
119.1160.3
59.582.0
106.2140.2
63.3
1200126.1
155.6192.8
29.3125.0
155.0195.0
66.0125.0
155.0195.0
66.0110.0
145.0195.0
74.098.0
130.0170.0
81.0
1400170.9
211.1260.8
36.0170.0
210.0260.0
78.0170.0
210.0260.0
78.0145.0
195.0260.0
88.0135.0
175.0230.0
100.0
1600222.7
275.0338.9
43.1220.0
270.0340.0
90.0220.0
270.0340.0
90.0190.0
255.0340.0
105.0175.0
225.0295.0
125.0
1800280.8
347.5428.0
50.8275.0
345.0425.0
105.0275.0
345.0425.0
105.0240.0
320.0425.0
120.0220.0
285.0375.0
2000346.0
426.4527.9
60.2340.0
420.0530.0
120.0340.0
420.0530.0
120.0295.0
390.0530.0
135.0
2200416.6
514.3636.7
70.5410.0
510.0640.0
130.0410.0
510.0640.0
130.0355.0
470.0640.0
155.0
2400495.3
611.6756.1
81.6485.0
610.0750.0
145.0485.0
610.0750.0
145.0420.0
560.0750.0
170.0
2600580.8
719.6888.8
93.0570.0
710.0890.0
280.0570.0
710.0890.0
280.0
2800673.2
831.61029.6
106.0660.0
820.01030.0
310.0660.0
820.01030.0
310.0
3000769.4
951.31180.0
119.0760.0
940.01170.0
335.0760.0
940.01170.0
335.0
SN2500
SN5000
SN10000
Coupling
SN2500
SN5000
SN10000
Coupling
SN2500
SN5000
SN10000
Coupling
SN2500
SN5000
SN10000
Coupling
SN2500
SN5000
SN10000
Coupling
*Sew
erPip
esforHighP
ressureCleaning
**Stand
ardP
ipes
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Joint Lubricant Requirements
AppendixB
! Note: Lubricantsamountsarebasedonlubricatingtwogasketsandtwospigotendsperjoint.Factorypre-assembledcouplingjointswillonlyrequirehalftheaboveamountsperjoint.
Nominal Pipe Diameter (mm)
Nominal Amount of Lubricant (Kg)
Required per Joint
300to500 0.075
600to800 0.10
900to1000 0.15
1100to1200 0.20
1300to1400 0.25
1500to1600 0.30
1800 0.35
2000 0.40
2200 0.45
2400 0.50
2600 0.55
2800 0.60
3000 0.65
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