TECHINICAL MANUAL

1.3 COMPARISION BETWEEN DIFFERENT PIPING SYSTEMS

S.N. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. PROPERTY/PARAMETER Service Life (Years) Standard Length (Meter) Jointing Method Skill Jointing Time Strength of Joints Line Commissioning Time Minimum Labor Water Absorption Brittleness Characteristics Corrosion Resistant Chemical Resistance Installation convenience Joining Reliability Hygienic Factor GALVANIzED IRON 5 - 15 6 Threaded Joint Requires Expert Plumber Few Hours Surface Homogeneity More than 4 Hrs/Half day 2 Persons Required Depends on raw material used Resistant Very Weak Poor Difficult Good Unhygienic due to Zinc oxide Formation Semi Smooth Troubleness 2.6mm Bursts Average-Leaks With Time METAL 10 - 30 5 Hard or Soft Scolding or Welding Joint Expert Plumber Few Hours Surface Homogeneity More Than 4 Hrs/Half Day 2 Persons Required Depends on Raw Material Used Resistant Weak Average Difficult Average Solvent Cement is Chemicaly Unsafe Semi Smooth Difficult 1.5mm Bursts Average PVC 10 6m Solvent Cement Do it your self-basic skill Few Minutes Surface Homogeneity 24 Hours 2 persons required 0.15 Poor-Resistance Week Average Average Very good Leeches Chemically over Service Time Does not Retain Smoothness Difficult 1.9mm Bursts Average

PPR-C >50
3-6 Simple Thermal Fusion Do it Yourself Few Seconds Fusion of MaterialPerfect Homogeneity Immediate One Person Required 0.03 Highly Resistant Non Corrosive Excellent Simple & convenient Excellent Food Grate-No LeechingBacteriology Neutral Excellent Smoothness Very Easy

16. 17. 18. 19. 20.

Inner Surface Smoothness Easiness in Repair & Maintenance Wall Thickness OD 20mm Water Freezing Inside Pipeline Joint Leak Proffness

3.4mm
Does not Burst 100% Leak Proof Entire Service Life Eco Friendly, No Harmful Substances Produced During Processing

21.

Eco-Friendliness

No

No

High percentage of Chlorine & Toxic Gases in Case of Fire

1. 2. 3.

Indoor & Outdoor installations of Hot & Cold water systems Public Utility Pipelines Industries such as Chemical plants, Breweries, Petroleum & Gas plants, Oil plants, Mineral water plants, Water treatment plants, Sugar Manufacturing plants & other process industries Residential & Commercial Buildings ideal for concealed piping system

5. 6. 7. 8. 9.

Drinking water transportation Liquid food transportation Pharmaceutical plants Solar water heating systems Heating system inside building including floor, wall & radiator heating

12. Piping systems for transportation of aggressive fluids in industries 13. Mining operations 14. Water treatment plants & distribution network 15. Sewerage networks 16. Public places such as Hospitals, Schools & Colleges, Hotels, Cinemas, Airports, Railways, Bus stations, Swimming pools etc.,

4.

10. Air Conditioning system 11. Compressed air supply systems

TECHINICAL MANUAL

2.0 PRODUCT CHARACTERISTICS

2.1. PHYSICAL PROPERTIES 1
PROPERTY Density, at 23 C Melt Flow Index o MFI 190 C/5Kg o MFI 230 C/2.16Kg o MFI 230 C/5Kg Viscosity
o

TEST METHOD ISO R 1183 ISO R 1133

UNITS g/cm
3

VALUE 0.897 0.50 0.30 1.30 420-430

ISO 1191 ISO 1628 T3

g/10min g/10min g/10min cm3/g

2.1.2 THERMAL PROPERTIES

PROPERTY Thermal Conductivity o Specific heat, at 23 C Coefficient of linear expansion VICAT Softening Point Melting Temperature Range TEST METHOD DIN 52612 Calorimeter DIN 53752 ISO 306 ISO 3146 UNITS W/m.K KJ/Kg.K o mm/M C o C o C VALUE 0.24 2.0 1.5x10-4 132 140-150

2.1.3 MECHANICAL PROPERTIES

PROPERTY Tensile Stress at Yield (50mm/minute) Tensile Strain at Yield (50mm/minute Tensile Modules (Secant) Flexural Modules Tear Strength Elongation at Tear Shore D Hardness Pipe Friction Factor CHARPY Impact Strength 23 C o 0C o -30 C
o

TEST METHOD ISO 527-1,2 ISO 527-1,2 ISO 527-1,2 ASTM D 790 ISO 527 ISO 527 DIN 53 505 -

UNITS MPa % MPa MPa MPa %

VALUE 24 10 850 850 40 800 65 0.007

2.1.4 ELECTICAL PROPERTIES

PROPERTY Die Electric Constant Volume Resistivity Die Electric Strength TEST METHOD DIN 53483 DIN 53482 DIN 53481 UNITS Ohm-cm Kv/mm VALUE 2.3 >1x1016 3 20

TECHINICAL MANUAL

2.2 STANDARD WORKING CONDITIONS & SERVICE LIFE

Long-term performance curve show the behavior of pipe line depending on pressure & operating temperature. It establishes the average life expectancy of a pipe line as a function of hoop stress acting on the pipe walls. Hoop stress is in proportion with the pressure according to the following formula:ADMISSIBLE OPERATING PRESSURE
Pipe Serises according to DIN 8077/8078 SDR 11 SDR 74 SDR 6 PN 10 PN 16 PN 20 Safety-factor 15 Nominal pressure for PP-R pipes (kgs/cm2) 17.6 16.6 16.1 15.6 15.2 14.8 15.0 14.1 13.7 13.3 12.9 12.5 12.8 12.0 11.6 11.2 10.9 10.6 10.1 10.1 9.8 9.4 9.2 8.9 9.2 8.5 8.2 8.0 7.7 7.4 7.7 7.2 6.9 6.7 6.4 6.5 6.0 5.9 5.1 4.3 5.5 4.8 1.0 3.2 3.9 2.5 (2.1)* 27.8 26.4 25.5 24.7 24.0 23.4 23.8 22.3 21.7 21.1 20.4 19.8 20.2 19.0 18.3 17.7 17.3 16.9 17.1 16.0 15.6 15.0 14.5 14.1 14.5 13.5 13.1 12.6 12.2 11.8 12.2 11.4 11.0 10.5 10.1 10.3 9.5 9.3 8.0 6.7 8.6 7.6 6.3 5.1 6.1 4.0 (3.4)* 35.0 33.2 32.1 31.1 30.3 29.5 30.0 28.1 27.3 26.5 25.7 24.9 25.5 23.9 23.1 22.3 21.8 21.2 21.5 20.2 19.6 18.8 18.3 17.8 18.3 17.0 16.5 15.9 15.4 14.9 15.4 14.3 13.8 13.3 12.7 13.0 11.9 11.7 10.1 8.5 10.9 9.6 8.0 6.4 7.7 5.0 (4.2)* Temperature 0C Service Lite In Years

= Sf X p X (d-s)/ 2s Where:
= hoop stress (MPa) Sf = Safety factor p = Internal pressure (MPa) d = Outside diameter of Pipe (mm) S = Wall thickness of Pipe (mm) If we extrapolate the hoop stress from the long term performance curve and apply the formula using 1.5 safety factor, the admissible operating pressure are obtained as given in the table.

10

20

30

40

50

Explanations:= Recommended application-Cold water installation = Recommended application-Hot water installation = Recommended application-Central heating installation

60

70

80
* Bracketed values apply where testing can be shown to have o been carried out for longer than 1 year at 110 C

C C

95

1 5 10 25 50 100 1 5 10 25 50 100 1 5 10 25 50 100 1 5 10 25 50 100 1 5 10 25 50 100 1 5 10 25 50 1 5 10 25 50 1 5 10 25 1 5 (10)*

TECHINICAL MANUAL

LONG TERM PERFORMANCE

Hoop stress [MPa]

50 40 30 25 20 15
10 0C 20 0C 30 0C 40 0C

10 9 8 7 6 5 4 3.5 3 2.5 2 1.5 1

50 0C 60 0C 70 0C 80 0C 90 0C 95 0C 110 0C

Pipe 20 x 3.4mm, 10 bar internal pressure Pipe 20 x 1.9mm, 4 bar internal pressure

10

25

50 100

Years

0.5

0,1

10

102

103

104

Time to failure[h]

105

106

TECHINICAL MANUAL

3.0 PRODUCT DETAILS

3.1 REFERENCE STANDARDS
DIN 8077 DIN 8077 DIN 16962 Polypropylene (PP) pipes-Dimensions Polypropylene (PP) pipes- General quality requirements & testing Part 5 - Pipe joint assemblies & fittings for (PP) pressure pipes General quality requirements & testing Part 6 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Elbows for socket welding Part 7 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Tee pieces for socket welding Part 8 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Sockets & caps for socket welding Part 9 - Pipe joint assemblies & fittings for (PP) pressure pipes Injection moulded Fittings for butt welding IS 9845 Method of analysis for determination of specific and/or overall migration of constituents of plastic materials and articles intended to come into contact with foodstuffs Specification for Polypropylene & its copolymers for its safe use in contact with food stuffs, Pharmaceuticals & drinking water

IS 10500

3.2 PRODUCT RANGE

3.2.1 PIPES
As per DIN 8077 & DIN 8078

D d

TECHINICAL MANUAL

The Pipe is used for conveying HOT and COLD water/fluids/chemicals/compressed air in various plumbing installations such as: a. b. Single layer (Green Color) PPR Pipes for Indoor installations Three layer (3) PPR Pipes for Indoor/Outdoor installations Outer Layer (Green color) PPR is UV resistant, which makes pipes suitable for use under direct sunlight Inner layer (White Color) PPR is antimicrobial which provides hygiene and protection from internal bacterial growth Middle layer (Black Color) PPR provides body strength to the pipe

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

PPR PIPE-PN10/SDR 11 (Per Meter)

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

PPR PIPE-PN16/SDR 7.4 (Per Meter)

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

TECHINICAL MANUAL

PPR PIPE-PN20/SDR 6 (Per Meter)

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

3.2.2 FUSION WELD

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

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

ELBOW 90o
PRODUCT CODE ELB.90.16.20 ELB.90.20.20 ELB.90.25.20 ELB.90.32.20 ELB.90.40.20 ELB.90.50.20 ELB.90.63.20 DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm PRODUCT CODE ELB.90.75.20 ELB.90.90.20 ELB.90.110.20 ELB.90.160.20 ELB.90.200.20 ELB.90.250.20 ELB.90.135.20
o

DIMENSION mm 75 mm 90 mm 110 mm 160 mm 200 mm 250 mm 315 mm

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

ELBOW 45o*
PRODUCT CODE ELB.45.16.20 ELB.45.20.20 ELB.45.25.20 ELB.45.32.20 ELB.45.40.20 ELB.45.50.20 ELB.45.63.20
o

DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm

PRODUCT CODE ELB.45.90.20 ELB.45.110.20 ELB.90.160.20 ELB.90.200.20 ELB.90.250.20 ELB.90.315.20

DIMENSION mm 75 mm 110 mm 160 mm 200 mm 250 mm 315 mm

o

The ELBOW 45 is used where the pipeline changes direction through 45 . 10

TECHINICAL MANUAL

EQUAL TEE
PRODUCT CODE EQT.16.20 EQT.20.20 EQT.25.20 EQT.32.20 EQT.40.20 EQT.50.20 EQT.63.20 DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm
o

PRODUCT CODE EQT.90.20 EQT.110.20 EQT.160.20 EQT.200.20 EQT.250.20 EQT.315.20

DIMENSION mm 90 mm 110 mm 160 mm 200 mm 250 mm 315 mm

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

PLAIN UNION*
PRODUCT CODE DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm PRODUCT CODE DIMENSION mm 90 mm 110 mm 160 mm 200 mm 250 mm 315 mm

under development*

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

END CAP*
PRODUCT CODE DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm PRODUCT CODE DIMENSION mm 90 mm 110 mm 160 mm 200 mm 250 mm 315 mm

under development*

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

EQUAL CROSS TEE*

PRODUCT CODE DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm PRODUCT CODE DIMENSION mm 75 mm 90 mm 110 mm 160 mm 200 mm 250 mm 315 mm

under development* o EQUAL CROSS TEE is used to take two branches/outlets at 90 from pipe line at the same junction but in opposite directions. 11

TECHINICAL MANUAL

PIPE CLAMP*

REDUCER
PRODUCT CODE PBR.45.16.20 PBR.45.20.20 PBR.45.25.20 PBR.45.32.20 PBR.45.40.20 PBR.45.50.20 PBR.45.63.20 DIMENSION mm 16 x 20 25 x 20 32 x 20 32 x 25 40 x 32 50 x 32 63 x 40

PIPE CLAMP is used to secure the pipeline in its installed position on the wall. under development*

REDUCING ELBOW 90

REDUCER is used to joint bigger diameter pipe to smaller diameter pipe coaxially.
DIMENSION mm 16 x 20 25 x 20 32 x 20 32 x 25 40 x 32 50 x 32 63 x 40

PRODUCT CODE PBR.90.16.20 PBR.90.20.20 PBR.90.25.20 PBR.90.32.20 PBR.90.40.20 PBR.90.50.20 PBR.90.63.20

REDUCING ELBOW is used to joint two o different sizes of pipes at 90 corner/turn.

PRODUCT CODE DIMENSION mm 63 x 25 63 x 20 75 x 63 75 x 50 75 x 40 75 x 32 90 x 75 110 x 90
o

REDUCING TEE
PRODUCT CODE DIMENSION mm 16 x 20 25 x 20 32 x 20 32 x 25 40 x 32 50 x 32 63 x 40 63 x 32

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

3.2.3 TRANSITION FITTINGS WITH METALLIC THREADED INSERTS MALE THREADED TEE
PRODUCT DIMENSION CODE mm 1/2 MTT.16.050.20 16 x MTT.16.075.20 MTT.20.050.20 MTT.20.075.20 MTT.25.050.20 MTT.25.075.20 16 x 3/4 20 x 1/2 20 x 3/4 25 x 1/2 25 x 3/4 PRODUCT CODE MTT.32.050.20 MTT.32.075.20 MTT.40.125.20 MTT.50.125.20 MTT.63.125.20 DIMENSION mm 1/2 32 x 32 x 3/4 40 x 11/4 50 x 11/4 63 x 11/4

MALE THREADED TEE is used to join a female threaded metallic fitting with PP-R line for taking Outlet. 12

TECHINICAL MANUAL

FEMALE THREADED TEE

PRODUCT DIMENSION CODE mm FTT.16.050.20 16 x 1/2 FTT.16.075.20 FTT.20.050.20 FTT.20.075.20 FTT.25.050.20 FTT.25.075.20 16 x 3/4 20 x 1/2 20 x 3/4 25 x 1/2 25 x 3/4 PRODUCT CODE FTT.32.050.20 FTT.32.075.20 FTT.40.125.20 FTT.50.125.20 FTT.63.125.20 DIMENSION mm 32 x 1/2 32 x 3/4 40 x 11/4 50 x 11/4 63 x 11/4

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

MALE THREADED ELBOW

MTE.90.16.050.20 MTE.90.16.075.20 MTE.90.20.050.20 MTE.90.20.075.20 MTE.90.25.050.20 MTE.90.25.075.20 16 x 1/2 16 x 3/4 20 x 1/2 20 x 3/4 25 x 1/2 25 x 3/4

PRODUCT CODE

DIMENSION mm MTE.90.32.050.20 MTE.90.32.075.20 MTE.90.40.125.20 MTE.90.50.125.20 MTE.90.63.125.20 32 x 1/2 32 x 3/4 40 x 11/4 50 x 11/4 63 x 11/4

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

COUPLER-MALE THREADED

PRODUCT CODE MTE.90.16.050.20

DIMENSION mm 16 x 1/2 16 x 3/4 20 x 1/2 20 x 3/4 25 x 1/2 25 x 3/4 32 x 1/2 32 x 3/4 40 x 11/4 50 x 11/4 63 x 11/4 DIMENSION mm FTS.25.075.20 FTS.32.050.20 FTS.32.075.20 FTS.40.125.20 FTS.50.125.20 FTS.50.125.20 25 x 3/4 32 x 1/2 32 x 3/4 40 x 11/4 50 x 11/4 63 x 11/4

MTE.90.16.075.20 MTE.90.20.050.20 MTE.90.20.075.20 MTE.90.25.050.20 MTE.90.25.075.20 MTE.90.32.050.20 MTE.90.32.075.20 MTE.90.40.125.20 COUPLER-MALE THREADED is used to join a MTE.90.50.125.20 MTE.90.63.125.20 female threaded metallic fitting with PPR line.

COUPLER-FEMALE THREADED
FTS.16.050.20 FTS.16.075.20 FTS.20.050.20 FTS.20.075.20 FTS.25.050.20 16 x 1/2 16 x 3/4 20 x 1/2 20 x 3/4 25 x 1/2

PRODUCT CODE

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

13

TECHINICAL MANUAL

3.2.4 VALVES*
GATE VALVE*
PRODUCT CODE DIMENSION mm 16 mm 20 mm 25 mm 32 mm PRODUCT CODE DIMENSION mm 40 mm 50 mm 63 mm

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

DESIGNER VALVE*
PRODUCT CODE DIMENSION mm 16 mm 20 mm 25 mm 32 mm PRODUCT CODE DIMENSION mm 40 mm 50 mm 63 mm

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

DOUBLE UNION BALL VALVE*

PRODUCT CODE

DIMENSION mm 16 mm 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm

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

3.2.5 WELDING ACCESSORIES

CUTTER

14

TECHINICAL MANUAL

POLYFUSION DEVICES (WELDING DEVICES)

PRODUCT CODE DIMENSION mm 20 - 40 40 - 63 75 - 100 160

3.3 QUALITY TESTS

NOTE: PRODUCTS WITH * ARE UNDER DEVELOPMENTAL STAGE

Strict quality control of incoming raw materials and factory operations ensures the continuous production of high quality products. All pipes & Fittings are manufactured to meet or exceed the test values, frequency of testing and functional requirements of the DIN standards. All raw materials are tested and certified prior to manufacturing range of products. Release for shipment is made only after all prescribed tests are completed and the results have met GHI and the customers requirements. In order to assure a high and consistent quality, we have established in-house laboratory with modern testing equipments and have highly skilled and trained technicians. The quality assurance plan covers:a. ACCEPTANCE TESTS i. Incoming Inspection & Testing of Raw Material for MFI Product accessories for Surface Finish, Fitment & Operation Rubber parts for Hardness & Dimensions ii. In-process Inspection & Testing of Pipes, Fittings & Valves for Visual appearance, Fitment with Gauges & Dimensions iii. Final Inspection & Testing of Pipes for Visual appearance, Dimensions, Hydraulic Test, Heat Reversion Test & Hammer Test Fittings for Visual appearance, Dimensions, Hydraulic Test & Hammer Test Valves for Drip Proofness Test & Hydraulic Test b. Type Tests i. Pipes & Fittings for Long Term Hydraulic Test ii. Valves for Thermal Shock Test iii. Piping installation including assemblies of Pipes, Fittings & Valves for Hot & Cold Water Cycle Test Water Hammer Test iv. Threaded Brass Inserts for Torque Test & Material Composition

15

TECHINICAL MANUAL

4.0 PRODUCT DETAILS

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

Where:

Expansion(+) or contractor(-) in length, (mm) Intial pipe length, (Meter) Coefficient of thermal expansion( for PP-R Temperature, difference ( C)
o

0.15mm/moc)

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

o

(55-25)=30 C
o

Then,

0.15 X 5 X 30 = 22.5mm

The expansion and contraction adjustment of PPR pipeline is generally made in longitudinal direction only. Enough space shall be provided and proper type of supports shall be used to allow the free movement of pipe in axial directions. Once the change in length of pipeline on account of thermal expansion/contraction has been calculated, a correct planning of pipelines is necessary to ensure that its effect do not cause deformation of the piping itself. PPR systems make it possible to install easy and convenient compensation for change in length using the suitable provision of following: Fix supports & Sliding supports Free flexible pipe segment; (Expansion Arm). Free flexible pipe loop (Compensation Loop).

Fixed and Sliding supports secure external pipelines to the masonry structure of the building to prevent the movements generated by thermal expansion, totally or partially. Fixed Supports:-are used when the axial expansion of the pipe line should be limited. Fixed support provides a rigid connection between external pipeline installations with masonry structure. The fixed supports must normally be positioned where the system changes direction (Elbows, Tees, etc.) & near to Valves, Cocks, Water meter, etc. to ensure that expansion forces are not discharged in these points. In all cases, fixed support should always be provided next to any joint in the pipeline created using any welded fitting. Obviously the fixed supports limit the length of section of pipe free to expand, and reduce the relative change in length value. Sliding Supports:-are used to allow the pipe to move axially in both directions. They have to be positioned well away from joints made using welded fittings, on a free length of the pipes surface. The sliding support collar must be absolutely free from pipe diameter otherwise it may damage the surface of the pipe where
16

TECHINICAL MANUAL

it is installed. Sliding support also ensures that the pipeline remain straight in spite of thermal stresses.
WALL WALL

PIPE PIPE FITTING FIXED SUPPORT FIXED SUPPORT FITTING FIXED SUPPORT FIXED SUPPORT

PIPE PIPE

WALL WALL

PERMITTED AXIAL TRAVEL PERMITTED AXIAL TRAVEL

PIPE PIPE

PIPE PIPE

SLIDING SUPPORT SLIDING SUPPORT

Horizontal clamp spacing distance PIPE according to temperatures, cm DIA. o mm 20 C 30oC 40oC 50oC 60oC 70oC 80oC 65 63 61 60 58 53 48 20 25 75 74 70 68 66 61 56 32 90 88 86 83 80 75 70 40 110 110 105 100 95 90 85 50 125 120 115 110 105 100 90 63 140 135 130 125 120 115 105 75 155 150 145 135 130 125 115 90 165 160 155 145 140 130 120 110 175 175 170 165 155 145 135

Vertical clamp spacing distance PIPE according to temperatures, cm DIA. o mm 20 C 30oC 40oC 50oC 60oC 70oC 80oC 85 82 78 78 75 69 62 20 25 98 96 91 88 86 79 73 32 117 114 112 108 104 98 91 40 143 143 137 130 124 117 111 50 163 156 150 143 137 130 117 63 182 176 169 163 156 150 137 75 202 195 189 176 169 163 150 90 215 208 202 189 182 169 156 110 228 228 215 215 202 189 176

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

17

TECHINICAL MANUAL Length of free flexible segment = LS=C d Where LS = C d

FIXED FIXED SUPPORT SUPPORT

SOCKET SOCKET

PIPE PIPE

FIXED FIXED SUPPORT SUPPORT

SLIDING SLIDING SUPPORT SUPPORT

Length of free flexible segment (mm) Constant of material (for PP-R, C=30). pipe outside diameter (mm). Expansion or contraction length (mm).

= = =

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

SOCKET SOCKET

LS
B B B 10dB 10d

SOCKET SOCKET

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

SLIDING SUPPORT SLIDING SUPPORT

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

To prepare a free flexible loop you have to calculate: The length of free flexible segment (LS) with the help of formula as explained in Free flexible pipe segment (Expansion Arm) The minimum width (B) between two arms of the loop = 10 times the outside diameter of the pipe.
T T

ExAMPLES OF FIxED AND SLIDING SUPPORTS IN PIPE SECTION: T T

LS LS

LS

Fix Support

Fix Support Fix Support

T T
L1 L2

T T T
L2

Fix Support

T T

Fix Support Fix Support

T T T
L3

T
L3

T T T
L4

T T
L4 L4
L5 L5

L
T T
L5

L
T T

L L
T T T

T T

T T

T T

T
L1

T
L1

L2

T T
L3

L
L4 L3

L
T T

L
T

L L

T T

L
T

L
T T

T T

L4

L3

L4

L1

LL1 2

Length absorption with compensation loop in a straight section of pipe Length absorption with compensation loop Length absorption with compensation loop in a straight straight section of pipe in a section of pipe
L2

L3

L
T

L
T

L1

T T

T T

L
T

T T

T T

L2

L
T T

L L
T T T

L L
T
Fixed support

T T
Fixed T support

T
Fixed support

T T

Fixed support in the middle T T T T of the vertical Fixed support in the middlepipe section Fixed support in the middle of the vertical pipe section section of the vertical pipe

L L
T T

T T T Fixed support at base T of vertical Fixed support at base pipe section Fixed support at base of vertical pipe section section of vertical pipe

18

TECHINICAL MANUAL

4.2 LAYING IN SANITARY SHAFT / PIPE DUCT OF A BUILDING

No. RECOMMENDATION FOR PIPE CONNECTION
LS LS

DESCRIPTION
PIPE CONNECTION CAN BE MADE AT SOME DISTANCE AWAY FROM THE WALL THE CONNECTION PIPE CAN BE PASSED THROUGH A HOLE MUCH LARGER THAN THE PIPE DIAMETER

LS

LS LS

LS

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

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

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

PIPE DIAMETER (mm) 20 25 32 40 50 P

MINIMUM BENDING RADIUS (mm) 160 200 256 320 400

4.4 INSULATION
4.4.1 FOR HOT WATER When conveying hot water through any Thermal conductivity of Insulation material Pipe pipe, heat is transferred through the pipe 0.030W/mk 0.035W/mk Size mm wall PPR pipes posses Recommended minmium insulation thickness in mm a much lower coefficient of thermal 20 6 10 conductivity (0.24W / mK) compared to 25 6 10 metal pipes. Therefore, most often it may 32 10 13 not be required to insulate the pipelines 40 10 13 which are used for hot water concealed 50 10 13 application. However, for centralized 63 13 20 heating systems, to prevent heat loss and 75 20 20 to isolate the pipelines from other utilities, 90 20 25 it is advisable to insulate these lines. The 100 25 32 required thickness of insulation is quite small as compared with conventional lines. The above table indicates the recommended insulation
thickness for different pipe sizes.

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TECHINICAL MANUAL

4.1.2 FOR COLD WATER Potable cold water plants have to be protected against heat gain and the formation of condensation. Standard value for the minimum thickness as stipulated in DIN-1988, part 2 have to be taken from the following table
Minimum insulation thicknessfor the insulation of potable water pipes (10 C) as per DIN 1988, part 2 Type of installation Open installed pipes, in no heated room (i.e. celler) Open installed pipes, in no heated room Pipe in a duct, without warm pipe Pipe in a duct, beside warm pipe Pipe in a pipe chase riser Pipe in a pipe chase, beside warm water pipes Pipe in a concrete floor Insulation thickness (for 0.04 W/mk thermal conductivity material) in mm 4 mm 9 mm 4 mm 13 mm 4 mm 13 mm 4 mm
o

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

4.5 RESISTANCE TO ULTRA VIOLET (UV) RAYS :PPR pipes & fittings have sufficient U.V. stability to provide protection from UV rays. The Pipes are three layers, which enables targeted UV protection.

4.6 SUITABILITY FOR DRINKING WATER:

PPR pipes & fittings meet the requirements of IS 10500-91 for drinking water and IS 1014687 for Reachable additives as it is safe for drinking water. The product is Food Grade.

4.7 FIRE RESISTANCE:

PPR pipes & fittings have combustion point 330 oC & burning point 360 oC. These conform with B2 class fire requirements of normal combustibility according to DIN 4102. On fire, PPR pipes & fittings emit carbon dioxide and water. Other than this, carbon monoxide gas, molecular hydrocarbon and oxidation products of these are also emitted in proportion to the availability of oxygen. Even if the fire is incomplete, the materials emitted are less poisonous than wood or similar materials on fire under the same conditions. The smoke that comes out from PPR fire is non-hazardous at room temperature but fumes formed at elevated temperatures can cause irritation.

4.8 LOW TEMPERATURE RESISTANCE :

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

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TECHINICAL MANUAL

5.1 GENERAL GUIDELINES

While designing the PPR piping system, one should be aware that PPR piping is quite different from other traditional materials like GI or Copper as well as PVC or CPVC. For good and safe design and installation, the following shall be taken into account. Pipes & fittings have different dimensions from other types of pipes and fittings. Even though the bore diameter of pipe is less than the equivalent metal or plastic pipe, the flow is more due to smoothness & less friction (Refer table: Pipe Friction Loss & Flow Rate) Hydraulic calculation should be done each time for the best choice of pipeline diameters. Linear thermal expansion/contraction of PPR pipes is more as compared with metal pipes. This needs to be taken into consideration designing and installation to avoid stressing of pipeline by providing flexible free length and proper support. (Refer section 4.1 Thermal expansion). Refer section 2.3 for STANDARD WORKING CONDITION AND SERVICE LIFE for designing. Use 3 layer pipes for outdoor installations. Use black pipes for solar heating system. Provide insulation for centralized heating systems and chilled water systems (Refer section 4.4 Insulation) Refer section 8 for Dos & Donts

5.2 PIPELINE DESIGN

5.2.1 FLOW RATE Analytical flow is typical for each analytical section. Draw-off points water quantity shall be worked out, taking into consideration water consumption (which is not simultaneous at all draw-offs). The following table gives formula for calculating the analytical flow for different types of application:Application
Residential buildings Commercial buildings Hotels & shopping Malls Hospitals Schools

Design flow rate Q12 in lps as per DIN 1988 part 3 can be calculated from following formula
Formula for 0.7 < Eq< 20lps Q=0.682 (Eq)0.45 - 0.14 Q=0.682 (Eq)0.45 - 0.14 Q=0.4 (Eq)0.086 Q=0.698 (Eq)0.5 - 0.12 Q=0.698 (Eq)0.5 - 0.12 Q=4.4 (Eq)0.27 - 3.41 Formula for Eq > 20lps Q=1.7 (Eq)0.25 - 0.7 Q=0.4 (Eq)0.54 - 0.48 Q=1.08 (Eq)0.5 - 1.82 Q=1.08 (Eq)0.5 - 0.12 Q=0.25 (Eq)0.65 - 1.25 Q= -22.5.08 (Eq)0.5 - 11.5

Where,

Q
Eq Qp

= = =

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

DESIGN FLOW RATES OF COMMON WATER POINTS

Minimum Pressure
0.5 0.5 0.5 1.0 1.0 1.0 1.2 0.4 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0

Type of water

Calculated flow on taking: Mixed water Cold/warm Only cold or warm water potable
0.30 0.50 1.00 0.15 0.15 0.20 0.70 1.00 0.30 0.15 0.25 0.15 0.20

Taps Without air inlet DN 15 Taps Without air inlet DN 20 Taps Without air inlet DN 25 Taps With air inlet DN 10 Taps With air inlet DN 15 Shower heads for purfication showers DN 15 Flush Valves DN 15 (Toilet) F.V. DN 25 (Toilet) Flush Valves DN 15 (Urinal) Domestic dish washers DN 15 Domestic washing machine DN 15 Mixing batteries for: Bath Shower DN 15 Bath-tubs DN 15 Kitchen sinks DN 15 Washstands DN 15 Bidet DN 15 Mixing battery DN 20 Gayser DN 30 Gayser DN 20

0.10 0.15 0.15 0.07 0.07 0.07 0.30 -

5.2.2 PRESSURE LOSS

In normal piping, two types of pressure loss can be found, 1 2 Distributed pressure loss related to pipe roughness, dimensions, physical properties and velocity of the liquids. Local loss related to elbows, tees, valves and fittings which cause a remarkable variation in the liquid flow.

5.2.2.1 DISTRIBUTED PRESSURE LOSS The PPR pipe has extremely smooth inner surface compared to metal pipes. Therefore, pressure loss is quite low. Pressure loss changes are very little in the normal span of operating temperatures (up to 60 C) in potable water pipeline.
o

The details are available on request.

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TECHINICAL MANUAL

5.2.2.2 LOCAL PRESSURE LOSS The PPR pipe has extremely smooth inner surface compared to metal pipes. Therefore, pressure loss is quite low. Pressure loss changes are very little in the normal o span of operating temperatures (up to 60 C) in potable water pipeline. The details are available on request. In pipeline, local pressure loss takes place due to presence of fittings which can be calculated using following formula ( r ) V26 R= 2g Where, R = Total local pressure loss in (mm) r = Local resistance coefficient value as given in following table V = Mean velocity in fluid in (m/s) g = Acceleration of gravity = 9.81 (m/s2) 6 = Specific gravity of water = 1000 (kg/ m3)
Note :1) 2)

Local resistance coefficient r PP-R plumbing fittings.

Name of pp-r fitting Coupler Reducer Single stage reducer Double stage reducer Three stage reducer Four stage reducer Elbow 90o Elbow 45o Tee Male / Female Threaded Tee Reducing Tee Male/Female Treaded Adaptor Reducing Male/Female Adaptor Male/Female Treaded Elbow Reducing Treaded Elbow Valve 20 25 32 Symbol for pp-r fitting Coefficient value (r) 0.25 0.50 0.60 0.70 0.85 1.2 0.5 1.8 1.8 3.0 0.5 0.8 1.4 1.6 9.5 8.5 7.6 8.3

Union

These are reference values and they vary according to water temperature. As fitting diameter increases, the value of r decreases.

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TECHINICAL MANUAL

5.3 HOLE REPAIRING

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

Accidental hole formation in pipe line.

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

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

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

6.0 TESTING THE INSTALLATION

6.1 PRESSURE TEST According to DIN 1988, PPR Pipeline for portable water installations have to be (before concealing) hydraulically pressure tested as follows While carrying out the pressure test the material properties of PPR lead to expansion of pipe. This influences the test result. A further influence of the result can be caused by the thermal expansion of PPR pipes. o Different temperatures of pipe & test medium lead to alteration of pressure. A temperature change of 10 C corresponds to pressure difference of 0.5 to 1 bar therefore, the highest possible constant temperature of the test medium has to be ascertained at the hydraulic pressure test of installations with PPR pipes. 6.1. PRIMARY TEST 1 For primary test, a pressure of 1.5 times of rated pressure shall be applied for a duration of 30 minutes. During this test, pressure drop shall be < 0.6 bar. 6.1.2 MAIN TEST After completion of primary test, main test must be conducted, which has to be effected with a test pressure of alternate 1 bar and 10 bar for every 5 minutes interval for 2 hours.
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TECHINICAL MANUAL

CHEMICAL

CONC. %

PP-R TEMPERATURE 20 60
R R R R R R R R R R R N R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R C R R R C C C R R R R R C R C R R R R N R R R C R N R R R N R R R R R R R R R N C R R R R C R R R R R R R R R R C R N R R R

Acetone Acetic Acid Acetic Anhydride Alum Ammonia Aq. Ammonium Acetate Aq. Ammonium Phosphate Amyl Alcohol pure Aniline Beer Benzaldehyde Benzene Borax Aq. Boric Acid Aq. Butanol Butyl Acetate Calcium Chloride Aq. Calcium Nitrate Citric Acid Aq. Coconut oil Cyclohexanol Cyclohexanone Formaldehyde Formic Acid Glycerine Heptane Hydrochloric Acid Hydrogen Peroxide Isopropyl Alcohol Lactic Acid Linseed oil Magnesium Salts Aq. Methyl Alcohol Olive Oil Oxalic Acid Aq. Palm oil Peanut oil Phospheric Acid Potassium Chlorate Aq. Pottacium Dichromate Aq. Potassium Sulphate Aq. Pyridine Salted Water Sea Water Soap Sodium Bicarbonate Aq. Sodium Chloride Aq. Sodium Perborate Aq. Sodium phosphates Aq. Sodium Sulphate Aq. Starch, Starch solutuion Aq. Sugar (dry) Sulphuric Acid Tartaric Acids Aq. Toluene Urea Aq. Vinegar Water

100 100 100 sat. conc. any any 100 100 100 sat. 100 100 sat. sat. sat. 100 100 40 50 100 100 conc. 10 100 85 sat. 100 sat.

R C

Recommended, Durable

= Caution Practically durable under suitable conditions = Not Recommended

50 sat. sat. sat. 100 any

sat. sat. sat. sat. sat. any 96 sat. 100 sat. comm. 100

* For more details please ask us 25

TECHINICAL MANUAL

8.0 DOS & DONTS FOR PP-R PIPE PLUMBING SYSTEM

No.
Storage

ACTIVITY

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

Storage

1.5M 1.5M 1.5M 1.5M

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

Transporation

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

4
Handling

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

5
Cutting Preparation for welding

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

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

7
Heating

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

8
Welding

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

9
Safe welding

Welding machines shall be earthed properly during use.

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TECHINICAL MANUAL

No.

ACTIVITY

RECOMMENDATION

10
Safe welding

Do not cool welding machine in water.

11
Thread joint

Do not over-tight threaded fittings & valves.

12
Bending

Thread joint sealing

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

13

Do not apply heat directly.

Bending

14

R=8D(Min) Installation at low temperature

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

15

PP-R pipes & fittings kept at temperature

16

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

17

The black PPR pipe line.

Outdoor installation

18

Use 3 Layer Pipe for outdoor application.

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TECHINICAL MANUAL

9.0 JOINTING METHOD OF & FITTINGS

CUTTING

PPR PIPES

Cut pipe at right angle to its axis using burr-free cutter. Ensure that pipe is free from burrs or cutting chips. Clean the pipe & fitting perfectly before welding. Mark welding depth at the end of pipe.

HEATING Mount the suitable dies on heating element of welding machine according to the diameter of pipe and fitting to be welded. Connect the welding machine to 220 volts A.C. power supply. Select 2600C temperature on the welding machine thermostat. Wait until the welding machine reaches the required working temperature. Insert the pipe and the fitting in the dies by exerting light pressure. For heating time, refer to the table given for different sizes of pipes.

WELDING After heating, quickly insert pipe into the fitting by exerting light pressure. Any misalignment should be corrected immediately after insertion to avoid any stress in the weld. Allow the joints to cool as per cooling time given in table.

RECOMMENDED TIME FOR PP-R FUSION JOINTS

PIPE DIA. (mm) 20 25 32 40 50 63 75 90 110 160 WELDING DEPTH (mm) 14.50 16.00 18.00 20.50 23.50 27.50 30.00 33.00 37.00 55.00 HEATING TIME (Sec.) 6 7 8 12 18 24 30 40 50 60 WELDING TIME (Sec.) 4 4 6 6 6 8 8 8 10 15 COOLINGTIME (Min.) 2 2 4 4 4 6 6 6 8 10

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