Supermain PVC-O. Molecular Oriented For Superior Strength & Performance

Transcription

1 Supermai PVC-O Molecular Orieted For Superior Stregth & Performace HIGH FLOW CAPACITY HIGH IMPACT STRENGTH HIGH TOUGHNESS EXCELLENT DAMAGE TOLERANCE LIGHT WEIGHT CORROSION RESISTANT MATERIAL AND ENERGY EFFICIENT Quality ISO 9001 Lic 570

2 product maual Itroductio 1 Beefits 1 Product iformatio 2 Stadards for PVC-O Pipe 2 Material Classificatio 2 Pipe Classes 2 Pipe Dimesios 2 Supermai PVC-O Iteratioal Series Pipe 2 Supermai PVC-O Series 2 Pipe 3 Joitig 3 Fittigs 3 Performace 4 Tesile Stregth 4 Flow Capacity 4 For Gravity Flow Situatios 4 For Pumpig Mais 4 Impact Stregth 5 Toughess ad Notch Sesitivity 6 Embodied Eergy 7 Supermai Desig ad Istallatio 8 Geeral 8 Temperature Cosideratios 8 Fatigue Desig 9 Chemical Resistace 10 Lateral Loadigs ad Negative Pressures 10 Joitig to Ductile Iro Fittigs 11 Service Coectios 11 Istallatio 11 Orderig Iformatio - Product List 12 Limitatio of Liability This product catalogue has bee compiled by Viidex Pty Limited ( the Compay ) to promote better uderstadig of the techical aspects of the Compay s products to assist users i obtaiig from them the best possible performace. The product catalogue is supplied subject to ackowledgemet of the followig coditios:1. The product catalogue is protected by copyright ad may ot be copied or reproduced i ay form or by ay meas i whole or i part without prior coset i writig by the Compay. 2. Product specificatios, usage data ad advisory iformatio may chage from time to time with advaces i research ad field experiece. The Compay reserves the right to make such chages at ay time without further otice. 3. Correct usage of the Compay s products ivolves egieerig judgemets, which ca ot be properly made without full kowledge of all the coditios pertaiig to each specific istallatio. The Compay expressly disclaims all ad ay liability to ay perso whether supplied with this publicatio or ot i respect of aythig ad all of the cosequeces of aythig doe or omitted to be doe by ay such perso i reliace whether whole or part of the cotets of this publicatio. 4. No offer to trade, or ay coditios of tradig, are expressed or implied by the issue of cotet of this product catalogue. Nothig herei shall override the Compay s Coditio of Sale, which may be obtaied from the Registered Office or ay Sales Office of the Compay. 5. This product catalogue is ad shall remai the property of the Compay, ad shall be surredered o demad to the Compay. 6. Iformatio supplied i this product catalogue does ot override a job specificatio, where such coflict arises; cosult the authority supervisig the job. Copyright Viidex Pty Limited.

3 Itroductio Beefits INTRODUCTION Beefits Viidex Supermai Orieted PVC pressure pipe is the most advaced PVC pipe available. Supermai PVC-O is ideally suited for geeral water supply, risig mais ad other pressure applicatios. The beefits of PVC pressure pipes have bee well established over their log service history. Molecular orietatio further ehaces the mechaical properties of PVC, allowig eergy efficiet productio whilst coferrig cosiderable performace advatages. These evirometal ad egieerig advatages mea Supermai is the high-performace, cost-effective pipe material choice for pressure applicatios. Supermai is maufactured i a two stage process that comprises the iitial extrusio of a feedstock pipe followed by a expasio process that results i bi-axial molecular orietatio of the material. The radom log chai molecules of PVC become preferetially aliged i the expasio or hoop directio ad a marked icrease i stregth is attaied i this directio. For pipes, hoop stregth is the primary factor determiig resistace to iteral pressure. The sketches below illustrate the geeral priciple of orietatio. High flow capacity High impact stregth High toughess Excellet damage tolerace Light weight Corrosio resistat No adverse effect o water quality Reduced Occupatioal Health ad Safety risks Material ad eergy efficiet - more evirometally sustaiable Clusters of PVC Molecules Molecular Etaglemets Typical PVC Processig Orieted PVC Directio or Orietatio 1

4 Supermai PVC-O Guide Product iformatio Stadards for PVC-O Pipe Supermai PVC-O pipes are maufactured i accordace with AS4441 (It): Orieted PVC (PVC-O) pipes for pressure applicatios. This stadard replicates the requiremets of ISO/DIS Pipes ad joits made of orieted uplasticized poly viyl chloride (PVC-O) for water trasport specificatios, with some additioal requiremets for Australia. Material Classificatio AS4441 (It) covers a rage of PVC-O pipe materials, classified by their Miimum Required Stregth or MRS value which is specified i MPa. Supermai pipes are maufactured to MRS classes from 355 to 500. Material Class MRS (MPa) Supermai Supermai Pipe Classes Supermai pipes are classified i terms of their omial workig pressure at 20 C. Pressure classes are idetified by their PN desigatio as show i the table below. Maximum workig pressure PN10 PN12.5 PN16 PN20 MPa m head Note: Other classes may be available for special projects. Cotact Viidex for further iformatio Pipe Dimesios Pipe Dimesios Supermai pipes are maufactured i two diameter series, Iteratioal (ISO) Series dimesios ad Series 2 (DICL compatable) dimesios. Supermai pipes are supplied i stadard 6m effective legths. Refer to the Supermai Product List (page 12) for orderig codes. Supermai Supermai Supermai PVC-O Iteratioal Series Pipe DIAMETER DESIGNATION EQUIVALENT MEAN OUTSIDE DIAMETER (MM) WALL THICKNESS MIN E INSIDE DIAMETER APPROX MASS 3 DN 1 NB 2 MRS PN Mi Max (mm) (mm) (kg) DN DN DN DN DN DN DN DN DN DN Iteratioal Series pipes are desigated by the pipe outside diameter i accordace with ISO stadards covetio. 2. The equivalet Series 1 omial pipe diameter desigatios used i AS/NZS1477 PVC-U Pressure Pipe ad AS/ NZS4765 PVC-M pressure pipe are show for iformatio. 3. Approximate mass is kg per 6 m legth. 2

5 Product Iformatio Supermai PVC-O Series 2 Pipe DIAMETER DESIGNATION EQUIVALENT MEAN OUTSIDE DIAMETER (MM) WALL THICKNESS MIN E INSIDE DIAMETER APPROX MASS 3 DN 1 NB 2 MRS PN Mi Max (mm) (mm) (kg) DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN Iteratioal Series pipes are desigated by the pipe outside diameter i accordace with ISO stadards covetio. 2. The equivalet Series 1 omial pipe diameter desigatios used i AS/NZS1477 PVC-U Pressure Pipe ad AS/NZS4765 PVC-M pressure pipe are show for iformatio. 3. Approximate mass is kg per 6 m legth. Joitig Supermai pipes are supplied with itegral sockets for rubber rig joitig. The itegral joits are capable of 1 deflectio. Further deflectio ca be achieved usig deflectio coupligs. Cotact Viidex for more iformatio. Solvet cemets should ot be used with Supermai pipes. Fittigs A complete rage of pipelie fittigs is available for Supermai pipes to form a total pipelie system. 3

6 Supermai PVC-O Guide Performace Tesile Stregth Tesile Stregth The log term hydrostatic stregth of PVC-O is up to twice that of ordiary PVC-U materials Takig advatage of this superior stregth allows the same pressure class of pipe to be maufactured with a larger bore Flow Capacity Supermai pipes have excellet hydraulic performace. Their flow capacity exceeds that of ay other commoly used pressure pipe i water ad sewer applicatios A compariso of the relative hydraulic capacity of Supermai, Series 2 PVC-U ad DICL pipe is show below. The iformatio give i the flow comparisos ad flow charts is based o the Colebrook- White formula with water at 20 C ad the followig roughess coefficiets: For PVC-O ad PVC-U, k=0.003, for DICL, k=0.03. For iformatio o varyig these parameters, refer to Viidex Frictio Loss i Uiform Fluid Flow (FLUFF) software For Gravity Flow Situatios Comparig the discharge Q i Litres/secod from a 100m legth of pipe at a costat hydraulic gradiet (H/L) of 1m/100m. DN100 Supermai pipe delivers 12.1 litres per secod compared to 9.2 ad 7.5 for PVC-U ad DICL respectively. Comparative Flow Rate (%) % 82% Supermai TM PVC PN 16 PN 16 Plai Pipe 73% DICL K9 How Full is the Tak at a Give Time? DN 150 Gravity Mai For Pumpig Mais Nom. Diameter Supermai PN16 PVC-U PN16 DICL K9 Icrease over PVC-U Icrease over DICL DN L/s 9.2 L/s 7.5 L/s 31% 61% DN L/s 25.0 L/s 24.4 L/s 30% 34% DN L/s 53.4 L/s 52.2 L/s 28% 31% Comparig the head loss for a give discharge (pumpig costs are related to frictio losses). Impact Stregth Supermai PN16 PVC-U PN16 DICL K9 DN100 Q=10L/s DN150 Q=30L/s DN200 Q=40L/s Head Loss Supermai TM PVC PN 16 PN 16 Plai Pipe DICL K9 What Pumpig Power is Required? DN 150 Risig Mai 4

7 Performace Supermai exhibits extraordiary resistace to impact. Tests o Supermai show impact rupture eergies up to 10 times that of stadard PVC-U Stadard impact tests are carried out at 0 C because the mass required to test the pipe at 20 C is impracticable for ormal test equipmet. DN 375 pipes are tested usig a 16kg ball dropped from a height of 2 metres above the sample The uorthodox field test o pressurised pipe (below) illustrates the superior impact resistace of Supermai pipe Toughess ad Notch Sesitivity 5

8 Supermai PVC-O Guide Toughess is a material s ability to resist brittle crack propagatio Marshal (1989) 1 ivestigated this property. He demostrated the failure mode for Supermai was ot radial through the wall sectio as it is with stadard PVC-U pipe. The illustratios (left) depict the two failure modes Marshall also foud that a otch i the pipe wall has the effect of oly reducig the cross sectioal area The graph (below) shows that otched ad u-otched test data follow the same relatioship whe the reduced wall thickess of otched specimes is take ito cosideratio. PVC-U Pipe Supermai Pipe 1000 Stress (MPa) 100 Uotched pressure data Notched C rig data Time (hours) Marshall G P, "Report o Evaluatio of Toughess Criteria for HSPVC" (Report prepared for Water Research, UK), Notched ad Uotched Test 1 Marshall G.P. Report o Evaluatio of Toughess Criteria for HSPVC (Report prepared for Water Research, UK),

9 Embodied Eergy Embodied Eergy Embodied eergy is defied as: the quatity of eergy required by all of the activities associated with a productio process, icludig the relative proportios cosumed i all activities upstream to the acquisitio of atural resources ad the share of eergy used i makig equipmet ad i other supportig fuctios i.e. direct eergy plus idirect eergy. A recet study by CSIRO 2 demostrated the cosiderable reductio i embodied eergy for PVC-O pipes whe compared with alterative pipe materials based o equal hydraulic performace. The example below illustrates the beefit obtaied by usig Supermai pipes Embodied eergy (GL) DICL K9 PE80B PVC-U Supermai TM PN 12.5 Series 2 PVC-O 400 PN 12 PN 12.5 Embodied Eergy for 1000m of Pipe to Achieve Equal Hydraulic Performace Flow rate, Q=10.4L/s, Head Loss, H=7.84m M.D. Ambrose, G.D. Salomosso ad S. Bur, CSIRO, Australia, Pipig Systems - Embodied Eergy Aalysis. 7

10 Supermai PVC-O Guide Supermai Desig ad Istallatio Geeral With some mior exceptios, the recommeded procedures for desig ad istallatio of Supermai pipes are the same as for stadard PVC-U pipes. These are covered by AS Istallatio of PVC pipe systems. However, there are some aspects of desig ad istallatio for which either a differet approach is required or a differet respose obtaied from Supermai. These differeces are highlighted below. For detailed iformatio o the desig ad istallatio of all PVC pipes, icludig Supermai, refer to the Viidex Water Supply Maual. Temperature Cosideratios Supermai pipes are de-rated for temperature accordig to the Iteratioal practice for PVC based pipe materials as show i the below table. Supermai pipes ca be used for cotiuous service at temperatures up to 45 C 3. Higher temperatures should be avoided as Supermai will experiece reversio of the orieted structure at elevated temperatures, ad may udergo sigificat dimesioal distortio above 50 C. The operatig temperature above refers to the average across the wall. Short term exposure o oe surface to temperatures i excess of the maximum operatig temperature, such as may occur durig storage ca be tolerated. If extreme coditios are ecoutered for exteded periods durig pipe storage, some ovality may develop i the pipe or socket. This is of o cosequece i the performace of the product ad for joitig, Supermai pipes are readily re-rouded i makig the joit. If prologed storage is expected, cosideratio should be give to shadig the pipe with a material such as shadecloth or hessia, which does ot cocetrate the heat, placed so as to ot restrict the circulatio of air i the pipes, as this has a coolig effect. Fatigue Desig Where a pipelie is to be subjected to a large umber of cyclic or repetitive loads, fatigue Maximum allowable pressure (MPa) Pipe Material Temperature Re-ratig Factor PN 10 PN 12.5 PN 16 PN Water Authorities geerally require temperatures of water supplies to be kept below 40 C to prevet growth of bacteria. 8

11 Supermai Desig ad Istallatio desig must be cosidered. For Supermai pipes, de ratig may be required if the total umber of cycles i the pipe lifetime exceeds The fatigue desig procedure is fairly straightforward. Three importat factors must be cosidered. These are the loadig frequecy or umber of cycles per day, the cyclic pressure rage ad the required service life of the pipe. For a give umber of cycles, a fatigue cycle factor is refereced maximum cyclic pressure rage (MCPR) for a particular pipe material ad pressure class. The pressure rage is simply the maximum pressure mius the miimum pressure, icludig all trasiets, experieced by the system durig ormal operatios as illustrated i the diagram below. The effect of accidetal coditios such as power failure may be excluded. Note that for fatigue loadig situatios, the maximum pressure reached i the repetitive cycle should ot exceed the static pressure ratig of the pipe. The diagram also illustrates the defiitio of a cycle as a repetitive evet. I some cases, the cycle patter will be complex ad it may be ecessary to also cosider the cotributio of secodary cycles. For a more detailed discussio of fatigue desig for plastics pipes, icludig examples ad a full list of refereces, please refer to Viidex Techical Notes. To select the appropriate pipe class for fatigue loadig, the followig procedure should be adopted: Estimate the likely pressure rage, P, i.e., the maximum pressure mius the miimum pressure. Estimate the frequecy or the umber of cycles per day, which are expected to occur. Determie the required service life ad calculate the total umber of cycles which occur i the pipe lifetime. Usig the table, determie the fatigue cycle factor to be applied. Calculate the maximum cyclic pressure rage from MCPR = PN x f the followig equatio: 10 Compare MCPR with P, if MCPR is less tha P; try a higher pressure class i the equatio. Lie Pressure Oe Cycle Pressure Rage 10 1 Fatigue Re-ratig Factor Time Number Cycle/Day Supermai TM Fatigue of Cycles 100yrs Re-ratig Factor Total Number of Cycles i Pipe Lifetime Supermai Fatigue Desig 9

12 Supermai PVC-O Guide Chemical Resistace PVC-O is expected to have the same iheret chemical resistace as PVC-U, as the chemical ature of the two materials is idetical. However, sice the iformatio preseted i chemical resistace tables has bee determied for stadard PVC-U ad the effect of chemical attack o the differet molecular structure of PVC-O has ot bee extesively ivestigated, the use of Supermai pipes i chemical eviromets or for the trasportatio of chemicals is ot recommeded. Lateral Loadigs ad Negative Pressures The stiffess (lateral load for a give diametral deflectio) is related to material modulus ad the cube of the thickess. For PVC-O materials, the modulus is somewhat higher tha that for stadard PVC-U. However, the wall thickess is the overridig factor i determiig the stiffess. Supermai pipes have a sigificatly lower stiffess tha stadard PVC-U pipes of the same pressure class. This is importat i determiig the respose to lateral loadig, due to soil ad traffic, ad egative pressures due to vacuum, groud water etc. I geeral water supply works with buried pipes at ormal covers, lateral stiffess will ot be a limitig desig factor ad will ot require special cosideratio. For abormal coditios, desig should be coducted i accordace with AS/NZS Viidex recommeds the followig values be used for the rig bedig modulus for Supermai pipes: Short term rig bedig modulus at 20 C E b 4000 MPa Log term rig bedig modulus at 20 C E bl 1800 MPa Bucklig may result if the pipe is subjected to iteral vacuum, as a result of water hammer or siphoage. Other special cases iclude pump suctio lies (with or without submersio) ad cocrete ecasemet. Example: For a Supermai pipe buried with 1m cover height i sady-clay ative soil with sad used as the embedmet material, the followig supported bucklig pressures Pb kpa are calculated i accordace with AS/ NZS usig a effective combied soil modulus, E, of 6.3 MPa ad short term loadig at 20 C. Clearly, i this example, Supermai pipe has a adequate factor of safety for a full vacuum. It should be oted that to obtai support from the soil, the embedmet material must be properly placed ad compacted, ad stable agaist log term washout or leachig. For the case where a pipe has o lateral support from the soil, the usupported critical bucklig pressure must be cosidered. This may occur i above groud lies, or where a udergroud lie emerges ito a pit (usupported legth greater tha 5 diameters). Buried pipes havig cover less tha two diameters or 500 mm should also be cosidered usupported. A table comparig the usupported collapse pressures of Supermai pipe with PVC-U is give below. This compariso is made usig the short-term modulus at 20 C ad would be applicable to a egative pressure associated with water hammer. Water hammer ca ormally be readily cotrolled with air valves ad other devices to prevet egative surges, but uder some circumstaces this is ot possible. Uder these coditios, it ca be see that, despite havig a much lower collapse pressure, the Supermai pipe ca still support a full vacuum with a safety factor of 1.5. Desigers should also evaluate resistace to bucklig for applicatios with sigificat log term egative pressures eg. the presece of groudwater. Pipe Type PVC-U less tha DN150 PN16 PVC-U greater tha DN150 PN 16 Supermai 500 PN 16 Usupported Critical Bucklig Pressure, Pc (kpa) Short Term Loadig at 20 C Supermai 355 Supermai 400 Supermai 500 Supermai 500 PN 10 PN 12.5 PN 16 PN 20 Bucklig pressure

13 Supermai Desig ad Istallatio Joitig to Ductile Iro Fittigs Supermai pipes may be joited to ductile iro push fit ad compressio gasketed fittigs. As with stadard PVC-U, factory witess marks are ot applicable whe joitig to ductile iro fittigs, ad the spigots should be fully iserted to the stop. It is advisable before joitig to mark a witess lie o the spigot at the appropriate legth for the particular fittig so that full isertio ca be observed. The depth of sockets o pipes ad fittigs must be sufficiet to accommodate the axial movemets due to the combied effect of a umber of factors, such as thermal cotractio ad Poisso 4 cotractio which occurs whe a pipe is pressurised. The Poisso effect is more sigificat for PVC-O pipes because of their higher operatig stress. Viidex Superlik Ductile Iro Fittigs have socket legths adequate for all situatios ad are recommeded for use with Supermai pipe. Fittigs sockets from other suppliers may be shorter ad there may be risk of pull out depedig o operatig parameters. If ecessary, short legths or special achorage may be used to compesate for short-socket fittigs. Service Coectios Service coectios to Supermai pipes are made usig a suitable tappig bad complyig with AS/NZS 4793 (It) - Mechaical tappig bads for waterworks purposes ad the followig cosideratios: Holes should be drilled usig a hole saw Tappig bads havig full circle support, a O or V seal, ad positive stop agaist over-tighteig are recommeded for PVC-O pipes Istallatio Istallatio techiques for Supermai pipes are similar to that used for stadard PVC-U pipes. The lower wall thickess ad stiffess of PVC-O pipes compared to PVC-U pipes makes it essetial that recommeded practices for istallatio are adhered to ad the pipe is fully supported. Quality o cohesive material should be used for pipe beddig, side support ad overlay. The pipe side support material should be placed evely o both sides of the pipelie to two thirds the height of the pipe diameter ad compacted by had tampig. Side fill material should be worked uder the sides of the pipe to elimiate all voids ad provide maximum pipe hauchig. The pipe overlay material should be levelled ad compacted i layers to a miimum height of 150mm above the crow of the pipe or as specified. The field testig procedures specified i AS2032 ad the Viidex PVC Techical Maual should also be followed for Supermai pipelies. 4 Chage i dimesios i the directio perpedicular to the directio of stress. Pipes cotract i legth whe pressurised. 11

14 Supermai PVC-O Guide Orderig Iformatio Product List Product Code Size (mm) Descriptio PN Legth (m) Weight (kg) Supermai RRJ Supermai RRJ TBA 100 Supermai RRJ Supermai RRJ Supermai RRJ TBA 150 Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple TBA 225 Supermai RRJ Purple Supermai RRJ Purple TBA 250 Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple Supermai RRJ Purple

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