Quality ISO Engineering Design and Installation Guidelines for Flowtite GRP Pressure and Non Pressure Pipes

Transcription

1 Quality ISO 9001 Engineering Design and Installation Guidelines for Flowtite GRP Pressure and Non Pressure Pipes

2 Important Disclaimer The information, opinions, advice and recommendations contained in this publication are offered only with the object of providing a better understanding of technical matters associated with pipeline design etc, with Fibrelogic Pipe Systems Pty Ltd assuring no duty of care in respect of them. This publication should not be used as the sole source of information. As it does not refer to all relevant sources of information, reference should also be made to established textbooks, and other published material. Readers should not act or rely upon any information contained in this publication without taking appropriate professional advice, which relates to their particular circumstances. Pipes and fittings are shown as typical configurations, however, in some cases, product dimensions may vary or be changed without notice. If a dimension is critical please contact Fibrelogic Pipe Systems Pty Ltd for clarification. Document # DES M th August 2009 Fibrelogic Pipe Systems Pty Ltd 1

3 Contents 1 INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES Product Benefits Manufacture Applications MATERIAL PROPERTIES Physical Properties Embodied Energy Ring stiffness Abrasion Resistance Ultraviolet solar radiation resistance Weather Resistance Chemical Properties Potable water approvals Maximum service conditions Performance in exceptional chemical environments SPECIFICATIONS AND TESTING Manufacturing Standards Standards for Fittings Test requirements for pipes Raw Materials Production testing Long Term Type Testing PRODUCT RANGE Description and classification Dimensions - pipes Dimensions - fittings HYDRAULIC DESIGN Flow and pressure capacity calculations Economic considerations Air Valves, anti-vacuum valves and scour valves Surge Capacity Water hammer surge celerities Fatigue under cyclical pressure regimes Thermal effects on pressure ratings Non pressure pipeline design STRUCTURAL DESIGN Allowable cover heights Thrust block design for pressure pipelines Angular deflection of Flowtite coupling joint Design of GRP flanges Above Ground Installation INSTALLATION Transportation and Storage Excavation and associated works Pipe laying Side support and overlay Trench and embankment fill (i.e. above embedment / overlay) Grouting Joints subject to differential settlement Cutting into or repairing installed GRP pipelines Fibrelogic Pipe Systems Pty Ltd 2

4 8 FIELD TESTING Leakage testing pressure pipelines Leakage testing non-pressure pipelines Structural assessment on installation High pressure water cleaning Fibrelogic Pipe Systems Pty Ltd 3

5 1 INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES Fibrelogic Pipe Systems Pty Ltd is a company excelling in providing the ultimate in piping solutions to its clients. We are a private, wholly Australian owned company, manufacturing in Australia. We are able to deliver the highest standard of product by incorporating our: World class facilities including Flowtite GRP Pipe continuous winding machines, Extensive QA and testing laboratories Product Engineering and Development service Global knowledge-base through the Flowtite Group (largest GRP Pipe group in the world) Experienced, professional staff...and strong ethical business principles. Globally, demand for Glass Reinforced Plastic (GRP) Pipe manufacturing is growing dramatically. Due to its high strength, low weight and corrosion resistance, clients are choosing GRP over traditional coated metallic piping. Flowtite GRP Piping has been the leading GRP Pipe manufacturing method for nearly 40 years. The technology is now being used worldwide on all continents with more than forty winding machines located in twenty licensed pipe factories. Fibrelogic Pipe Systems has licensed the Flowtite GRP Pipe manufacturing technology from Flowtite in Norway. Flowtite is a progressive organisation which supports the engineering, production and development of Flowtite GRP Pipe worldwide. Corporately, we are a leading company in Australia in growth and technology, but also in supporting the globally underprivileged through child sponsorship programs. It is a core aspect of why Fibrelogic Pipe Systems exists to help those in need, globally. We have a strong, passionate team of executives, management and staff that, when combined with our world class technology and manufacturing equipment provides a great platform for optimum product and service. Fibrelogic Pipe Systems Pty Ltd 4

6 1.1 Product Benefits Features Benefits Corrosion-resistant materials Long, effective service life No need for linings, coatings, cathodic protection, wraps or other forms of corrosion protection Low maintenance costs Hydraulic characteristics essentially constant over time Electrically non-conductive Unaffected by stray (earth) or induced currents. Cathodic protection systems do not need to be considered for either Flowtite pipes or surrounding structures. Light weight(1/4 weight of Low transport costs ductile iron1/10 weight of concrete) Eliminates need for expensive pipe handling equipment Long standard lengths Standard lengths up to 12 metres with longer lengths available on request Dimensions compatible with existing piping products Fewer joints reduce installation time Compatible with Hobas GRP, Series 2 PVCU, PVCM and PVCO, ductile iron and most existing AC pipeline applications Standard and custom fittings available Fittings are available or can be designed to suit individual requirements Extremely smooth bore Low friction loss means less pumping energy needed and lower operating costs Minimum slime build-up can help lower cleaning costs. Precision Flowtite coupling with elastomeric REKA gaskets Flexible manufacturing process Tight, efficient joints designed to eliminate infiltration and exfiltration Ease of joining, reducing installation time Accommodates small changes in line direction without fittings and can accommodate differential settlement Custom diameters can be manufactured to provide maximum flow volumes with ease of installation High technology pipe design Lower wave celerity than other piping materials can mean less cost when designing for surge and water hammer pressures High technology pipe manufacturing system High and consistent product quality worldwide which ensures reliable product performance Fibrelogic Pipe Systems Pty Ltd 5

7 1.2 Manufacture Fibrelogic Pipe Systems manufactures the Flowtite GRP Pipe at their purpose built facility in Lonsdale, South Australia. Flowtite pipes can be manufactured in a number of standard diameters ranging from DN300 up to DN3000. Flowtite pipe is manufactured using the continuous advancing mandrel process which represents the state of the art in GRP pipe production. This process allows the use of continuous glass fibre reinforcements in the circumferential direction. For a pressure pipe or buried conduit the principle stress is in the circumferential direction. Incorporating continuous reinforcements in this direction and not just chopped discontinuous roving, such as in a centrifugal casting process, yields a higher performing product at lower cost. Using the technology developed by Flowtite, a very dense laminate is created that maximizes the contribution from the three basic raw materials, namely glass fibre, silica sand aggregate and thermosetting resin. Both continuous glass fibre rovings and chopped roving are incorporated for high hoop strength and axial reinforcement. A silica sand aggregate is used to provide increased stiffness with placement near the neutral axis in the core. Thermosetting resin, delivered through a dual resin delivery system gives the equipment the capability of applying a special inner resin liner for severe corrosive applications while utilizing a less costly resin for the structural and outer portion of the laminate. Fibrelogic Pipe Systems Pty Ltd 6

8 The raw materials are applied on the continuously advancing mandrel in specific locations to ensure the optimum strength with minimum weight. The materials are applied to produce a series of layers which give both pressure resistance as well as pipe stiffness. The diagram below shows the typical wall construction of a Flowtite pipe and the table explains the layers construction and purpose. Note that all layers contain thermosetting resin. Layer Construction Purpose Interior Liner C Glass tissue Protection Barrier Layer Chopped glass fibres Protection Inner Structural Layer Continuous glass fibres and Chopped glass fibres High modulus structural reinforcement Core Silica sand aggregate and chopped Solid separating core glass fibres Outer Structural Layer Continuous glass fibres and High modulus structural Exterior Surface Chopped glass fibres Chopped glass and C glass tissue or polyester veil reinforcement Protection Fibrelogic Pipe Systems Pty Ltd 7

9 After all materials have been applied the laminate is cured completely using a number of strictly controlled mechanisms including heating the mandrel as well as infrared heating of the external surface. The cured laminate is cut to length as required. Standard lengths are 12 metre, 6 metre and 3 metre. Intermediate lengths can also be manufactured at 1 metre increments. Longer lengths are possible but can not be pressure tested. All pipes are quality inspected after manufacture. Once inspected the pipe spigots are chamfered and calibrated where necessary for fitment of couplings. Each pipe is pressure tested to twice its nominal pressure class to verify performance. Couplings are cut from specially made coupling pipes of an appropriate diameter to allow internal boring to create grooves for the rubber seals and central register. They are also proof tested at 2 x PN pressure on a hydrostatic testing machine. Fibrelogic Pipe Systems Pty Ltd 8

10 1.3 Applications With the aging of the world s infrastructure there are millions of kilometres of water and sewer pipelines needing rehabilitation. A major concern is that that the deterioration is premature and design lives predicted at the conceptual stage are not being realised. The prime cause of this problem is corrosion, typically for the following reasons: Internal attack on unprotected concrete gravity flow sewer pipes, which deteriorate rapidly in the presence of sulphuric acid as a result of the hydrogen sulphide cycle. In water supply installations, high levels of carbon dioxide in soft water from underground sources can rapidly degrade cementitious liner materials External attack can be caused by aggressive soil / ground water conditions or stray electrical currents affecting ferrous and cementitious materials. Unlike GRP, these pipes are vulnerable when buried in poorly aerated and poorly drained soils of low resistivity. Saline soils, the presence of chlorides, or sulphate-reducing bacteria also accelerate corrosion. GRP pipes are not subject to any of these problems and with the latest advances in manufacturing technology giving much higher production rates, there has been a widespread increase in their use for both new infrastructure and as replacements for corrosion prone materials. The unique properties of Flowtite pipes with high strength, combined with corrosion resistance and easier laying make them very attractive for use in many of the major infrastructure applications listed below: Water supply transmission and distribution mains Irrigation Gravity and rising main sewers Slip lining Submarine pipelines Hydro-electric power station penstocks Water and sewerage treatment plants Desalination plants Thermal power station supply and cooling systems Chemical and industrial process pipelines Storage tanks Fibrelogic Pipe Systems Pty Ltd 9

11 A range of case studies can be found on the international Flowtite website DN 250 Flowtite pipes for a corrosive bore water supply pipeline for Kogan Creek power station in Queensland. DN1000 PN16 SN Flowtite pressure pipes and special long length GRP fittings being installed on a major recycled water pipeline near Wivenhoe Dam in SE Queensland. Fibrelogic Pipe Systems Pty Ltd 10

12 DN1000 PN16 SN10,000 Flowtite pressure pipe strung out along the alignment near Wivenhoe Dam in SE Queensland Fibrelogic Pipe Systems Pty Ltd 11

13 2 MATERIAL PROPERTIES 2.1 Physical Properties As the wall construction of Flowtite pipes vary according to pipe class and stiffness, only indicative material parameter values have been given below. More specific information for any particular pipe design should be obtained by contacting Fibrelogic s engineers. Property Typical Value Density 1800 kg/m kg/m 3 Thermal coefficient of expansion (axial) x10-6 m/m.k. Thermal conductivity 0.14 to 0.22 W/m.K Tensile Strength MPa - Circumferential (hoop) Tensile Strength MPa - Longitudinal (axial) Elastic Modulus - Circumferential tensile and flexural 17,000 MPa (low pressure pipe) 24,000 MPa (high pressure pipe) Elastic Modulus 6000 MPa 12,500 MPa - Longitudinal tensile and flexural Circumferential bending creep / relaxation 60% retention after 50 years ratio Minimum ultimate circumferential tensile 1.52% initial; 0.65% long term (at 50 years) strain Minimum ultimate circumferential bending 2.30% initial; 1.30% long term (at 50 years) strain Poisson s ratio 0.22 to 0.29 Combustibility characteristics (AS Ignitability Index (0-20) ) Spread of flame Index (0-10) 0 Heat evolved Index (0-10) 2 Smoke developed Index (0-10) Embodied Energy The embodied energy of Flowtite GRP pipes is generally lower than that of equivalent nonpolymer pipe materials. For detailed information, contact Fibrelogic Pipe Systems. Fibrelogic Pipe Systems Pty Ltd 12

14 2.1.2 Ring stiffness The stiffness of a pipe indicates the ability of the pipe to resist external soil, hydrostatic and traffic loads together with negative internal pressures. It is a measure of resistance of a pipe to ring deflection determined by testing and is the value obtained by dividing the force per unit length of a specimen by the resulting deflection at 3 percent deflection. Ff S = Equation 2.1 Ld v Where: S = F = d v = D m = f = stiffness (Newtons / metre per metre length of pipe) force (N) deflection (m) mean diameter (m) a deflection coefficient including a correction factor for ovality of the deformed specimen obtained as follows: d v f = ( ) Equation 2.2 D 10 5 m According to the Australian and ISO Standards, stiffness is expressed as follows: EI S = Equation D m Where S = the pipe stiffness as determined by testing in N/m per metre length of pipe E = the apparent modulus of elasticity, in Pascals. I = the second moment of area per unit length of the pipe wall section in m 4 per m. D m = mean diameter (m) i.e. 3 t I = 12 Where t = wall thickness in m. The initial stiffness is determined using a specific test method and cannot be obtained through calculations using nominal values of E and t as Flowtite is a GRP composite. Fibrelogic Pipe Systems Pty Ltd 13

15 There are also other terms in common use internationally describing pipe stiffness. For example according to German DIN Standards and the ATV code the ring stiffness is defined as: EI S R = Equation 2.4 R 3 m Where R m = mean radius (m). This stiffness value is 8 times greater than that given by the Australian and ISO Standards, so that in order to avoid mistakes E and S R are expressed as N/mm 2 (MPa) when using this formula. According to American ASTM Standards the ring stiffness measured at 5% deflection, is expressed as: F d v (Pounds per square inch) Equation 2.5 Where F = load per unit length (pounds per inch) d v = vertical pipe deflection (inches) GRP pipes are classified by the nominal stiffness value determined from the standard initial stiffness test i.e.: Table 1 Nominal Stiffness Nominal Stiffness / Comparison of Units Unit SN 2500 SN 5000 SN S p (ISO & Aust.) N/m S R (DIN ATV) N/mm F (ASTM) psi d v Fibrelogic Pipe Systems Pty Ltd 14

16 2.1.3 Abrasion Resistance Flowtite pipes are manufactured with an external layer of reinforced resin to provide scuff resistance during the handling and installation process. The potential for bore abrasion wear can be determined using the Darmstadt method. The test used was developed at the Institute of Hydraulics and Hydrology of Darmstadt, Germany and the procedure involves axially rocking a half section of pipe through 22 degrees, so that a calibrated load of abrasive slurry slides back and forth along the invert of the pipe. When tested a Flowtite pipe specimen showed a wear rate of 0.84mm loss per 100,000 cycles Ultraviolet solar radiation resistance Flowtite pipes have a non-structural external layer of reinforced resin to provide a weathering layer when stored or installed above ground. This layer protects the structural layers from UV radiation but may discolour over time. If this is not acceptable, pipes may be coated with an acrylic (water based) paint Weather Resistance Standard Flowtite pipes can be permanently stored in the open without any detrimental effects on the structure of the pipe due to UV radiation although some superficial roughening and discolouration of the external and internal surfaces may occur. For periods over 6 months in open areas it is recommended that the rubber rings should be stored indoors. Fibrelogic Pipe Systems Pty Ltd 15

17 2.2 Chemical Properties Potable water approvals Flowtite pipes and fittings meet the requirements of AS Flowtite pipe has been tested and approved for the conveyance of potable water meeting many of the world s leading authorities and testing institutes criteria, including: NSF (Standard No. 61) United States DVGW Germany Lyonnaise des Eaux France Water Byelaws Scheme (WBS) United Kingdom Russia (Cert. No I04521A8) Oficina Técnia De Estudios Y Controles Spain Pánstwowy Zaklad Higieny (National Institute of Hygiene) Poland OVGW Austria NBN.S Belgium Copies of Flowtite Technology qualification test reports are available on the web site Maximum service conditions Normal Flowtite pipes are intended for use with water, sewage and controlled industrial wastes at temperatures of up to 35 C in the ph range 3 to 9. For temperature and chemical conditions in excess of these values Fibrelogic s engineers should be consulted for advice on re-rating and chemical suitability. With the exception of chlorinated or aromatic solvents, Flowtite pipes have a high resistance to chemical attack. Furthermore, special resin systems can be used to improve the chemical resistance at elevated temperatures. In the case of some solvents, the use of a vinyl ester resin system may be recommended Performance in exceptional chemical environments Flowtite pipes selected for use in severe environments, such as the processing industry, especially at elevated temperatures, may require special resins systems such as vinyl esters. Because of the range of factors involved, the final determination of the suitability of Flowtite for a given environment becomes the sole responsibility of the specifier. General guidance can be provided by Fibrelogic Pipe Systems as to suitable applications based on information provided by resin suppliuers. However, this advice is not intended to imply approval for any given application, as neither the resin suppliers nor Fibrelogic has any control over the conditions of usage or the means of identifying all environmental conditions that may affect the selected pipes and fittings. Fibrelogic Pipe Systems Pty Ltd 16

18 3 SPECIFICATIONS AND TESTING 3.1 Manufacturing Standards Fibrelogic Pipe Systems complies with the requirements of AS/NZS ISO 9001:2000 Quality Management Systems and has been officially certified by a 3 rd party certification body. Standards developed internationally apply to glass reinforced polyester (GRP) pipes, sometimes referred to as fibreglass or fibre reinforced polyester (FRP), when used for infrastructure, including the conveyance of potable water, irrigation water, sewage and industrial waste. Common to all modern pipe product standards is the fact that they are performance-based documents, that is, the required performance and testing of the pipe is specified rather than prescriptive requirements on the manufacturing process. Flowtite pipes have been appraised by the Water Association of Australia refer to Product Appraisal 04/06 Flowtite GRP Pipe System for Fibrelogic Pipe Systems Pty. Ltd. The following list includes standards commonly used for the manufacture and testing of GRP pipes and fittings. ISO Standards The International Standards Organization (ISO) has published a suite of GRP product standards and corresponding test methods. Flowtite Technology in Europe participated in the development of these standards; thereby ensuring performance requirements will result in reliable products. The ISO Standards for GRP pipes and fittings manufacture relevant to infrastructure works include: ISO Plastics piping systems for pressure and non-pressure drainage and sewerage - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin ISO Plastics piping systems for pressure and non-pressure water supply -Glassreinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin These Standards are essentially the same except that the sewer pipes must comply with the strain corrosion type test and water supply pipes with the requirements of AS 4020 for potable (drinking quality) water. All Flowtite pipes currently manufactured in Australia meet both standards. Australian Standards Australian practice is to use ISO based standards for GRP pipes and fittings and the following documents are in the process of being revised to meet the latest ISO Standards. Flowtite is already manufactured to the ISO equivalent. Existing standards are: GRP Pipes: - Australian Standard AS 3571 Glass Filament (GRP) Pipes Polyester Based Water Supply, Sewerage and Drainage Applications *. Australian Standard AS Plastics Glass Filament Reinforced Plastics (GRP) Methods of Test *. Fibrelogic Pipe Systems Pty Ltd 17

19 United States of America Standards Flowtite pipes manufactured in Australia are designed to meet United States Standards in addition to the ISO and AS Standards. Currently, there are several ASTM Product Standards in use that apply to a variety of GRP pipe applications. All product standards apply to pipes with diameter ranges of 200mm to 3600mm and require the flexible joints to withstand hydrostatic testing in configurations (per ASTM D4161) that simulate exaggerated in-use conditions. These standards include various qualification and quality control tests. ASTM D3262 Standard Specification for Fibreglass (Glass-Fibre-Reinforced Thermosetting- Resin) Sewer Pipe ASTM D3517 Standard Specification for Fibreglass (Glass-Fibre-Reinforced Thermosetting- Resin) Pressure Pipe ASTM D3754 Standard Specification for Fibreglass (Glass-Fibre-Reinforced Thermosetting- Resin) Sewer and Industrial Pressure Pipe ANSI/AWWA C950 AWWA Standard for Fibreglass Pressure Pipe is one of the most comprehensive product standards in existence for GRP pipe. This standard for pressure water applications has extensive requirements for pipe and joints, concentrating on quality assurance and prototype qualification testing. Like ASTM standards, this is a product performance standard. Flowtite pipe is designed to meet the performance requirements of this standard. AWWA has recently issued a new Fibreglass Pipe Design manual M-45, which includes chapters on the design of GRP pipelines for buried and aboveground installations. AWWA C950 Fiberglass Pressure Pipe AWWA M-45 Fiberglass Pipe Design Manual Other Standards Standardisation organisations such as BSI and DIN have also published performance specifications for GRP pipes to which Flowtite complies where nominated. DIN Glass Fibre-Reinforced Polyester Resin Pipes BS 5480 Pipes and Fittings for Water and Sewage Associated fittings Fittings used with Flowtite pipes may be of GRP or metallic materials. The following documents may be relevant: - International Standards ISO & Ductile Iron Pressure Fittings Australian Standard 2280 Ductile Iron Pressure Pipes and Fittings. Mild Steel Cement Lined Fittings Australian Standard 1579 Arc Welded Steel Pipes for Water and Gas and Australian Standard 1281 The Cement Mortar Lining of Steel Pipes and Fittings. Flanged joints, specifically drilling patterns in both GRP and metal Australian Standards AS 4087 Metallic flanges for waterworks purposes, AS 2129 Flanges for pipes, valves and fittings and AS (ISO 7005) Metallic flanges - Steel flanges may be applicable. Note that flange thicknesses for GRP will depend on the design but will be greater than for metal flanges. Fibrelogic Pipe Systems Pty Ltd 18

20 3.2 Standards for Fittings For water supply, sewerage rising-mains, and other pressure applications a full range of GRP fittings is available. These fittings can be custom made to specific customer requirements. In addition to GRP pressure fittings, standard ductile iron fittings, valves and hydrants are suitable for use with Flowtite pipe. The outside diameters of Flowtite GRP pipes are compatible with Australian Standard PVC-U, PVC-M, PVC-O, ductile iron, and some AC pipes and fittings of the same nominal diameter. Where pipe tapping Flowtite pipe is a flexible pipe, flexible tapping bands manufactured from gunmetal or stainless steel should be used for service connections. GRP Fittings Flowtite GRP pressure fittings are manufactured in Classes PN 6, 10, 16, 20, 25 and 32 for use with Flowtite pipes of the corresponding class. These fittings are fabricated from Flowtite pipes using proprietary wrapped laminate designs. Fittings are normally supplied spigot ended suitable for Flowtite couplings. Flanged fittings are available and can be full-faced or, for higher operating pressures, stub flanges with steel backing plates may be the preferred option. Non pressure (i.e. PN 1) fittings are also fabricated from Flowtite pipes and comply with the requirements ISO and ISO Fittings are normally supplied spigot ended suitable for Flowtite couplings. Branches for sidelines can be attached to the Flowtite mainline using saddle fittings attached with epoxy adhesive applied in-situ. Adaptor couplings for saddle branches for joining to PVC DWV Fibrelogic Pipe Systems Pty Ltd 19

21 Ductile Iron Fittings Ductile iron fittings socket joints can be used on selected Flowtite pipes of the same nominal size. Conventional socketed fittings complying with AS 2280 Ductile Iron Pressure Pipes and Fittings in sizes DN100 to DN750 are suitable. A complete range of bends, tees, reducers and flange-spigot pieces is available with Griptite* or Tyton # rubber ring sockets in sizes DN100 to DN750. Other joint designs may also be acceptable. Fibrelogic should be contacted to confirm the suitability of any particular range of fittings. These fittings may be protected from corrosion using various alternatives. Fusion bonded polymer (polyamide or epoxy) Cement lining and polyethylene wrap. *Registered Trademark of Northern Iron and Brass Foundry. # Registered Trademark of Tyco Water. Examples of fusion bonded nylon coated ductile iron fittings with Griptite seals suitable for use with Flowtite Steel fittings Fabricated steel (and stainless steel) fittings fabricated from steel plate can be used with Flowtite pressure pipes. Normally, steel fittings are protected from corrosion externally by ultra high build epoxy and internally by cement lining. Where possible these fittings are manufactured with spigots especially sized to match Flowtite outside diameters, including tolerances so that the joint can be made using standard Flowtite GRP couplings. Relevant Standards are AS 1594 Hot-rolled steel flat products AS 3678 Hot-rolled structural steel plates, floor plates and slabs AS 1579 Arc welded steel pipes and fittings for water and waste water AS 1281 Cement mortar lining of steel pipes and fittings AS 4321 Fusion bonded medium density polyethylene coatings and linings for pipes fittings AS 2312 Guide to protection of iron and steel from atmospheric corrosion and Fibrelogic Pipe Systems Pty Ltd 20

22 3.3 Test requirements for pipes A common element shared by all standards is the need for a pipe manufacturer to demonstrate compliance with the standards minimum performance requirements. In the case of GRP pipe, these minimum performance requirements fall into both short-term and long-term requirements. The short-term tests are conducted at manufacturing sites as part of daily quality control, while the latter have been conducted at Flowtite Technology s laboratory or by a certified third party. Results from quality control tests are part of a Flowtite factory s record and retained by the factory, while the type tests are carried out and archived by Flowtite Technology, which is the international parent organisation Raw Materials Flowtite Purchase Acceptance Standards (PAS) are common to the worldwide organisation and each factory maintains Technical Data Sheets and test reports for the raw material supplied. Raw materials are delivered with vendor certification demonstrating their compliance with Flowtite quality requirements. In addition, all raw materials are sample tested prior to their use. These tests ensure that the pipe materials comply with the stated specifications. Resins Flowtite pipes are normally manufactured using orthophthalic polyester resins. However where unusual environmental conditions exist, isophthalic polyester or vinyl ester can be specified. Aggregate and fillers The quartz sand used in Flowtite pipes is required to meet the specific grading curve particle sizing of the Flowtite Purchase Acceptance Standard. Elastomeric seals The elastomeric sealing rings comply with the requirements of EN 681-1: 1996,Type WA and WC and AS Unless otherwise requested EPDM rings will be supplied. However in special circumstances rings may be supplied, manufactured from other polymers - see Table 2. Table 2 Elastomers for Flowtite seals Polymer Ethylene propylene-diene* Nitrile-butadiene Styrene-butadiene rubber Abbreviation EPDM NBR SBR * The standard polymer supplied. Other types are rarely needed and can only obtained as a special order. Fibrelogic Pipe Systems Pty Ltd 21

23 3.3.2 Production testing Every pipe is subjected to the following control checks: Outside diameter Wall thickness Pipe length Visual inspection of all surfaces Hydrostatic leak tightness test (for PN6 or higher) On a sampling basis, the following control checks are performed: Pipe stiffness Deflection without liner cracking or structural failure Axial and circumferential tensile load capacity Barcol hardness Composition Outside diameter Flowtite pipes are externally controlled in accordance with Table 3 External Diameter Series of AS Normal tolerances are given in Table 3 Table 3 Tolerances on spigot outside diameters DN Outside diameter (PN1 to PN16) (mm) Outside diameter (PN20 to PN32) (mm) Min Max Min Max Pipe lengths The actual length of each pipe is equal to the nominal length with a tolerance of ± 25 mm. The effective (i.e. laying) length is equal to the pipe length plus 10 mm (an allowance for the centre register in the coupling). Surface quality The surface of the pipe shall be relatively smooth and free of exposed fibre or sharp projections. Refer to Appendix B of AS 3571 for guidance with respect to surface defects. Fibrelogic Pipe Systems Pty Ltd 22

24 Hydrostatic Leak Tightness Testing Every pipe PN6 or greater is pressure tested to 2 times the nominal pressure class of the pipe. The pipe is held at this pressure for 2 minutes allowing for inspection of the pipe. Fibrelogic Pipe Systems Pty Ltd 23

25 Specific ring stiffness A test specimen from each batch is tested in accordance with ISO 7685 and the calculated initial stiffness shall be not less than the nominal branded stiffness. A 300mm long test piece is taken once per shift of pipes manufactured in a single batch. A diametral load is applied with the pipe bearing top and bottom on flat plates. The load to achieve a 3% deflection is recorded and used to calculate the initial stiffness. Specific ring deflection When tested in accordance with ISO 10466, a test specimen from each production batch of pipes must satisfy the requirements of Table 4 at the nominated deflections. The stiffness test specimen is also used for this test. Table 4 Minimum test deflections Nominal Stiffness SN No visible damage to inside layer at % deflection of: No structural damage at % deflection of: Fibrelogic Pipe Systems Pty Ltd 24

26 Initial specific longitudinal tensile test When an axially oriented test specimen cut from each pipe batch is tested in accordance with ISO 8513, the longitudinal tensile strength indicated for the pipe shall not be less than the value given in Table 5. The mean elongation at rupture shall not be less than 0.4 percent for pipe Class 6 and above and 0.3 for lower classes and non-pressure pipes (i.e. PN 1). Table 5 Minimum axial tensile strengths (N/mm) of external circumference Nominal Diameter DN 80 Class PN 1* Class PN 6 Class PN 10 Class PN Class PN 20 Class PN 25 Class PN Note: Tensile strengths shown are for SN 2500 and comply with AS Flowtite axial strengths will be greater for higher stiffness pipes. Fibrelogic Pipe Systems Pty Ltd 25

27 Apparent initial circumferential tensile strength When a circumferentially oriented test specimen cut from each pipe batch is tested in accordance with ISO8521, the tensile strength it indicates for the pipe shall not be less than the value given in Table 6. These values may be calculated from the equation: P o = σ d m cu Where σ cu = circumferential strength (N/mm) determined from ISO 8521 P o = initial failure test pressure (MPa) determined by regression testing d m = mean diameter (m) Table 6 Initial (average) circumferential tensile strength Average apparent initial circumferential tensile strength pipes N/mm DN PN6 PN10 PN16 PN20 PN25 PN Barcol Hardness When tested in general accordance with ASTM Standard D2583 the surface Barcol Hardness of the pipe shall be greater than 35. Fibrelogic Pipe Systems Pty Ltd 26

28 3.3.3 Long Term Type Testing In addition to daily quality control testing, ISO and ISO require type testing to determine long term properties such as hydrostatic failure pressures, stiffness creep (or relaxation), and strain corrosion. These tests have duration of at least 10,000 hours to enable extrapolation to establish design values. That is, using the methods of ISO 10928, the physical parameters required can be determined for the specified nominal 50-year design period. A statistically significant number of test specimens, generally a minimum of eighteen in number, are prepared and loaded to various degrees so as to obtain a series of ultimate load (or strain) values spread over the duration of the test period. A log time log load regression line of best fit is established using the method of least squares. The 95% lower confidence limit line can then be constructed based on the 50-year minimum value. In the case of the hydrostatic design this information is needed to set values for the short-term quality control tests. Rigorous joint type tests, which include the combined effect of, draw and shear loading at normal and maximum angular deflections are also requirements of the Standards. Long term pressure testing Flowtite pressure pipe is designed on a strain basis to fulfill the requirements of ISO 10467, ISO 10639, AWWA C950, ASTM D3517 and ASTM D3754. The 50-year strain value for Flowtite pipe as determined in report T R, ε 50, is 0,65%. Current product designs comply with this value. For example on particular pipe specimens strain measurements were made and then using regression analysis the long-term strain of 0,0065 at 23.2 bar pressure was determined. That is the 50-year burst pressure, p 50, equaled 2.32 MPa. The analysis also provided the corresponding initial value, p 0, of 6.37 MPa. The minimum design pressure can be computed from equation 24 in ISO and ISO i.e.: p 0, d PN C 0.1 ηt, PN,97.5% RR, p = 1 Y LCL The Standards require that the average of the last 20 initial failure pressures during production, p 0, mean to be greater than this value for the product in question. With p p 0 C = and 6 p 50 R R, p = this equation becomes: p6 p 0, d = p p PN ηt, PN,97.5% 1 Y LCL The coefficient of variation Y, for the Flowtite process has been measured over a period of time and found to be generally within the range of 2.5% to 8%. Assuming a conservative value of 9% the expression for p 0,d becomes: Fibrelogic Pipe Systems Pty Ltd 27

29 p , d = 0.1 PN t, PN,97.5% LCL 1.21 = η PN η t, PN,97.5% LCL Using the values for safety factors in Table 3.4 of ISO and ISO the values for p 0,d are shown in the following Table 7: Table 7 η t,pn,97,5%lcl applied to to the long term 97.5% LCL η t,pnmean applied to to the long term mean Minimum long-term factors of safety PN32 PN25 PN20 PN16 PN10 PN p 0,d MPa Note: As the standards do not provide factors for PN20 this value has been interpolated. Cyclical internal hydrostatic pressure testing In accordance with Clause 5.3 of ISO and ISO the resistance of Flowtite pressure pipes to cyclic internal pressure has been verified through testing to ISO. The results are recorded in TÜV test report TÜV MP4/ and Veroc test report 13-T86. In both cases pipes were subjected to one million cycles between 0.75 x PN and 1.25 PN without showing any sign of failure. Resistance to strain corrosion The strain corrosion resistance of Flowtite pipes has been measured to a value of 0.66% (see test report T ). Using the equation in Clause 10.6 of ISO this value can be converted to deflections and compared with the requirements. By using the thickest of the pipes in each stiffness class the following deflections are obtained: Stiffness class SN 2500 SN 5000 SN Deflection % These values meet the requirements in Table 17 of ISO Joint systems Three methods of jointing Flowtite pipes have been tested i.e. both flexible and rigid joints, with or without end load resisting capability to meet the requirements of Clause 7 of ISO and ISO The following test reports are available: Flexible non-end-load-bearing joints test report T Wrapped non-end-load-bearing joints test report T Bolted non-end-load-bearing joints test report T Fibrelogic Pipe Systems Pty Ltd 28

30 4 PRODUCT RANGE 4.1 Description and classification Nominal Sizes (DN) Flowtite pipes are currently manufactured in Australia in the nominal size range 300 mm to 3000 mm. Flowtite pipes are manufactured with the same outside diameters as ductile iron of the same nominal diameter; as a result the internal diameters are approximately 10% larger than nominal size in comparable sizes in the DN300 to DN750 ranges. Nominal Pressure Classes (PN) Pressure pipes are classified according to nominal pressure and nominal stiffness; nonpressure pipes by nominal stiffness only. Table 8 Nominal pressure rating PN Working Pressure (MPa) Working Pressure (Bar) Working Head (Metres) Max. diameter for specific PN (mm) Nominal Stiffness (SN) Standard nominal stiffness is shown in Table 9. Table 9 Stiffness (SN) Other pipe pressure or stiffness classes apart from those listed may be manufactured on request. Branding and Marking All pressure pipes are branded to indicate the nominal diameter, pressure class and stiffness as shown by the following example: Couplings for non-pressure pipes are branded to indicate the nominal diameter. Because couplings are common in the non-pressure and pressure range up to Class 6 they will generally be branded Class 6, for example DN900 PN6. Fibrelogic Pipe Systems Pty Ltd 29

31 4.2 Dimensions - pipes Table 10 Pipe - available sizes and classifications for SN 2500 DN Spigot OD Pipe stiffness SN 2500 PN 1 PN 6 PN 10 PN 16 PN 20 PN 25 PN 32 t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) Fibrelogic Pipe Systems Pty Ltd 30

32 DN Table 11 Pipe - available sizes and classifications (SN 5000) Spigot OD Pipe stiffness SN 5000 PN 1 PN 6 PN 10 PN 16 PN 20 PN 25 PN 32 t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) See Table for SN Fibrelogic Pipe Systems Pty Ltd 31

33 DN Table 12 Pipe available sizes and classifications (SN 10000) Spigot OD Pipe stiffness SN PN 1 PN 6 PN 10 PN 16 PN 20 PN 25 PN 32 t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) g g g g g g g g g g g g g g g g g Fibrelogic Pipe Systems Pty Ltd 32

34 Table 13 Couplings - available sizes and classifications Coupling dimensions & Masses DN PN 1 PN 6 PN 10 PN 16 PN 20 PN 25 PN 32 Length (mm) Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg Cplg OD mass OD mass OD mass OD mass OD mass OD mass OD mass Fibrelogic Pipe Systems Pty Ltd 33

35 Table 14 Pipe spigot ends - dimensional details Nominal diameter (DN) Witness Mark P Calibration Length CL Chamfer Length N mm 140 mm 10 mm mm 140 mm 15 mm mm 150mm 20 mm 600 to mm 190 mm 20 mm Fibrelogic Pipe Systems Pty Ltd 34

36 4.3 Dimensions - fittings (Note that overall dimensions are subject to change without notice) 11.25, 22.5 & 30 BENDS Table 15 PN 1, PN 10 & PN 16 Nominal Radius Diameter of Bend Length Approx Length Approx Length Approx DN R BL Mass BL Mass BL Mass (mm) (mm) (mm) (kg) (mm) (kg) (mm) (kg) Fibrelogic Pipe Systems Pty Ltd 35