Flowtite - Thompson Pipe Group

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

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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


Pipetopipeangulardeflection

Figure3-9Measuringofcouplingangularoffsetandposition

Couplingoffset

amax

amin

a

bmax

bmin

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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 16,20 125xPipeOD(inm)


“O”-profilewithintegralring

6 45xPipeOD(inm)


10 75xPipeOD(inm)


16,20 90xPipeOD(inm)


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).


***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.


***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


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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


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]



Table4-5SN5000MaximumPipeLength onTwoCradles[m]



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°

06

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



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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

�

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

1

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3

4

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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

!

1

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3

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5

6

7

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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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IGA

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