SIMONA SPC Protective-Jacket Pipes

Transcription

1 SIMONA SPC Protective-Jacket Pipes

2 Quality Reigns Supreme

3 Welcome to SIMONA 4 6 Company Profile SIMONA SPC Protective-Jacket Pipes Open Cut Pipelaying Trenchless Pipelaying Connection Methods Electrofusion Welding Butt Welding Socket Welding Service and Accessories Tender Documents Product Range PE 100 SPC-Drinking Water Pipes PE 100 SPC-Waste Water Pressure Pipes PE 80 SPC-Waste Water Pipes PE 80 SPC-Burst Lining Pipes 22 SIMONA Worldwide All information provided in this brochure is based on the state of the art and has been compiled to the best of our knowledge. All dimensions and weights are theoretical figures and are subject to standard production tolerances. Subject to change without notice, also with regard to dimensions, weights and design. 04/2005 SPC Protective-Jacket Pipes SIMONA 3

4 SIMONA Semi-finished plastics from fully-fledged professionals SIMONA AG has emerged as one of the world s leading manufacturers of semi-finished thermoplastics. Drawing on more than 40 years of experience in formulation, production and machining, we have established the credentials and unique knowhow of high-calibre specialists. That experience and the close links we maintain with our customers are your guarantee of high-quality products and superior tailor-made solutions. Fast, flexible and reliable With our main warehouses in Kirn and Ringsheim, Germany, and our worldwide network of subsidiaries and distribution partners, we can dispatch the majority of our products direct from stock. For fast, flexible and reliable service. Confirming our role as a partner that lives up to your expectations in every respect. For every challenge, we have a solution Our comprehensive selection of semi-finished products ranging from sheets and rods to pipes and fittings makes it possible to find solutions for practically any challenge. If your needs are highly specific, we will work with you to develop a customised product with exactly the properties required for your project. 4 SIMONA SPC Protective-Jacket Pipes 04/2005

5 Diverse range of applications One of the classic fields of application for SIMONA products is chemical engineering. This is mainly due to the fact that our semi-finished plastics are resistant to the majority of aggressive chemicals. Whether deployed in civil engineering, building construction, the automotive industry or mechanical engineering, our products offer a range of outstanding properties. Complemented by user-friendly processing qualities, they are the perfect solution for applications in this area. A never-ending process: Our Quality Management We know that the quality of products and services determines our business success. That is why SIMONA has an overriding commitment to Quality Management. This applies not only to our manufacturing but also to our service. Because everything we do revolves around you, the customer. From the project development stage to the purchase of raw materials, and throughout production, dispatch and on-site project consulting. A diversity of materials Our diverse portfolio of materials ranges from PE, PP, rigid PVC and foamed PVC to PETG, PVDF and E-CTFE. Including special refinements to particular materials, such as UV stabilisation and reinforcing fillers, you can choose from more than 100 different materials. Furthermore, our highquality product range has a number of outstanding features: Chemical resistance Diffusion resistance Mechanical capacity Stress crack resistance Corrosion resistance The quality management system of SIMONA AG in compliance with the Pressure Equipment Directive is certified to 97/23/EG Annex I, para The quality and environmental management system at SIMONA AG is certified to DIN EN ISO 9001 : 2000 and DIN EN ISO : /2005 SPC Protective-Jacket Pipes SIMONA 5

6 SIMONA SPC Protective-Jacket Pipes the reliable choice for state-of-the-art pipelaying When it comes to installing new pipes or repairing existing structures, efficiency both in terms of cost and time is of paramount importance. Although the method of open cut pipelaying on a bed of sand protects the pipes against external damage, it also involves a great deal of time and effort. SIMONA SPC-Protective Jacket Pipes, on the other hand, are the natural choice for highly efficient trenchless pipelaying, even in extreme conditions. Not only do they ensure rapid and highly cost-effective installation, they also provide optimum protection against external stress. PE 80 SPC-Waste Water Pipe: light grey PE inner pipe, brown PP protective jacket; PE 100 SPC-Drinking Water Pipe: black PE inner pipe, blue PP protective jacket SIMONA SPC pipes SPC-Protective-Jacket Pipes are a multi-layer solution manufactured by means of co-extrusion. They consist of a standardised inner pipe featuring a protective jacket made of modified polypropylene (SIMONA PP Protect). Inner pipe The inner pipe can be made of the PE 100 or PE 80. These two bimodal materials fulfil all the requirements with regard to slow crack growth and crack resistance, as certified by notch tests (ISO DIS 13479) and FNCTs (Full Notch Creep Tests). The inner pipe is made of materials that fulfil the quality standards promulgated by the German Plastic Pipes Association (KRV). These materials also conform to the requirements of European product standards and to the relevant codes of DVGW, WRAS and DIN CERTCO. Protective jacket The jacket is made of a specially modified polypropylene (SIMONA PP Protect), which is capable of protecting the surface of the inner pipe against potential notches and cracks generally associated with demanding installation methods such as pipe bursting or wash-boring. Even extremely deep scores in the protective jacket will not be transferred to the inner pipe when it is eventually exposed to service-related stresses. 6 SIMONA SPC Protective-Jacket Pipes 04/2005

7 SIMONA SPC pipes in action: perfect protection in all applications. Standardisation The inner pipe is manufactured in accordance with all standards, approvals and guidelines currently applicable: DIN 8074/8075 DIN DIN DVGW GW 335 T A2 TÜV Süddeutschland certified DIN EN DIN EN Processing and laying of the pipes is conducted in accordance with DVS guidelines DVS 2207 Part 1, DVS 2208 Part 1, DVS 2212 and the full range of associated standards such as DIN EN DVGW approval currently relates to the inner pipe. An application has been filed for system approval. 1 Benefits at a glance The PP protective jacket provides the inner pipe with reliable protection against external damage High resistance to crack propagation High abrasion resistance No need for subsequent sealing of welded seam Light grey interior surface of the waste-water pipe is particularly conducive to internal camera inspection Permanent protection against extreme stresses during installation and in service No risk of cracking or fracturing Reliable quality due to the use of high-grade raw materials Guaranteed processing capability in accordance with all relevant pipeline construction guidelines, without any additional cost State-of-the-art solution for environment/infrastructurefriendly and cost-effective trenchless methods Fields of application SIMONA SPC pipes are deployed within the area of drinking-water and gas supply as well as wastewater disposal. These fields of application are often associated with extreme demands on material. Laying in open trenches. Increased efficiency and potential savings with the possible use of excavated material and not the usual special bedding and sidefill materials SIMONA SPC pipes can be used in conjunction with virtually all trenchless installation technologies. Tailor-made for sewer repairs based on slip lining and pipe bursting methods. Tapping tees can be welded onto the inner pipe for service connections to buildings. If extreme stresses are expected during the insertion procedure, for example on account of indefinable, unstable or rocky soils, we recommend involving our Applications Technology Department. SIMONA PP Protect: The PP protective jacket, specially adjusted with additives, provides the entire inner pipe with protection against notches, abrasion and wear. 04/2005 SPC Protective-Jacket Pipes SIMONA 7

8 Greater efficiency in open cut pipelaying Faster open cut pipelaying The stability and service life of a pipeline is dependent to a large extent on the structural support created for the actual pipe. When laying plastic pipes without a protective jacket, the pipeline zone has to be filled with stone-free, compactible material up to a grain size of 20 mm. This area is then compacted. Generally speaking, this can only be achieved by replacing the existing soil, i.e. by embedding the pipes in sand. On account of the PP protective jacket of the SIMONA SPC pipe, the sand-bedding usually required for the supporting fill and in the pipeline zone may depending on soil conditions be replaced with processed or reused excavation material. The proportion of sharp-edged stone material can have a grain size of up to 63 mm. In addition, the protective jacket distributes the stresses exerted by the compressive loads on the pipe. SIMONA SPC pipes must be laid in accordance with DIN Appropriate verifiable structural analyses as per ATV and DWA can be provided. Live load Soil load The exclusion of sand free bedding material is possible due to the high level of resistance of the protective jacket. Excavation material up to grain sizes of 63 mm can be reused. Compressive loads on the pipe, such as live loads and soil loads, are no problem for SIMONA SPC pipes. 8 SIMONA SPC Protective-Jacket Pipes 04/2005

9 This stone poses no risk to a SIMONA SPC-Protective Jacket Pipe. Superior material properties for first-class results The modified PP protective jacket of the SIMONA SPC pipe features an increased material hardness. That considerably improves scratch resistance and resistance to penetrating objects. This property is defined by ball indentation hardness, which is measured as the resistance of a material surface to penetration by a defined body. Ball Indentation Hardness N/mm SIMONA PP Protect 70 PP Standard 40 PE-HD The protective jacket made of SIMONA PP Protect is almost twice as hard as PE-HD (high-density polyethylene). Full Notch Creep Test (FNCT) Internal creep tensile test Test specimen: 110 x 10 x 10 mm Notch: 1.6 mm, all round Test conditions: = 4,0 MPa T = 80 C 2 % Arkopal N 100 The inner pipe of the SIMONA SPC pipe achieved very high ratings (up to 3,000 h) in the FNCT. Full Notch Creep Test (FNCT) The FNCT examines creep by systematically inducing tension cracks in the test specimen by means of a wetting agent, mechanical stress and raised temperature. F F Ideal for trenchless pipelaying Alongside the deployment of conventional open cut pipelaying methods, there is a growing trend towards more cost-effective pipelaying techniques using the closed, trenchless method e.g. pipe bursting or directional drilling. In this case, the material surfaces are often subjected to even higher strains than with the open cut method. Owing to its PP protective jacket, which is extremely resistant to external damage such as notches and scratches, SIMONA SPC pipes are ideally suited to trenchless laying. 04/2005 SPC Protective-Jacket Pipes SIMONA 9

10 Maximum reliability in trenchless pipelaying Trenchless pipelaying Trenchless pipelaying encompasses a variety of methods. When it comes to slip lining, pipe bursting and directional drilling, the modified PP protective jacket provides an extremely high level of protection against all unforeseeable, potentially damaging, occurrences. 1 2 Benefits of trenchless pipelaying Minimal adverse effect on developed and paved surfaces Construction work is performed whilst largely maintaining the flow of traffic Potential use of existing pipeline routes Construction time shortened due to the absence of protracted excavation and filling work Reduction in civil engineering and recultivation costs compared with open cut pipelaying Altrohr Horizontal directional drilling (above) and pipe bursting. The SIMONA SPC protective jacket prevents the inner pipe from being damaged by sharp-edged soil fragments. Horizontal directional drilling (1) Generally speaking, this represents a controlled method of wet boring. Soil is loosened and washed out with a drilling fluid in various stages. The first step is to create the pipe duct with a pilot bore. Then, in further steps the final pipe duct is widened and the SPC pipe is introduced by an insertion device. Pipe bursting (2) Pipe bursting procedures are generally deployed wherever the repair of damaged pipelines has to be performed on the basis of a trenchless method and the hydraulic cross-section has to be retained or enlarged. As part of the bursting process, broken pieces and fragments of used pipe are displaced into the surrounding soil. Together with the in-situ soil, the broken material compacted into the ground forms an annular space, into which the new pipeline attached to the bursting unit is introduced. 10 SIMONA SPC Protective-Jacket Pipes 04/2005

11 Microtome section in the transitional zone between the protective jacket and the inner pipe PP protective jacket Shear strength of SIMONA SPC pipes In trenchless pipelaying, the pipe is subjected to extremely high shear forces. As part of the technical production process, it is possible to achieve adhesion between the two layers of material without actually creating a chemical bond between the polyethylene and polypropylene materials. Tensile force Shear plane PE inner pipe Bond and shear strength tests conducted in accordance with DIN Part 1 revealed a high level of axial strength (3.0 N/mm 2 to 5.0 N/mm 2 ) between the inner pipe and the protective jacket. Thus, the protective jacket cannot slide off the inner pipe. The SIMONA SPC protective jacket protects the inner pipe against potential damage from sharp-edged stones and burst fragments. Crack propagation from the protective jacket to the inner pipe can be ruled out entirely The innovative co-extrusion manufacturing process ensures maximum adhesion between the protective pipe and the inner pipe. As a result, the protective jacket cannot slide off. Trenchless pipelaying has many advantages, one of the foremost being the minimal impact this method has on developed and paved superstructures. 04/2005 SPC Protective-Jacket Pipes SIMONA 11

12 Best connections Pipe wall-integrated electrofusion welding Butt welding In pipe wall-integrated electrofusion welding, the tapered end of the pipe and the pipe socket are joined to one another conically. The connecting surfaces are heated electrically to welding temperature by means of a spiral embedded in the tapered end. Thus, an integral, tightly welded connection is made. After welding, the entire pipeline remains protected by the jacket without the need for any elaborate rework or sealing in the peeling area. To weld the SPC pipes, the PP protective jacket has to be removed from the PE inner pipe in the welding area using SIMONA peeling devices. Removal of the protective jacket is only performed up to approx. 1.0 cm to 1.5 cm from the end of the pipe. Consequently, there is no need to seal the welded seam afterwards because it is in full contact with the protective jacket, i.e. there is no unprotected gap. Thus, it is not possible for the protective jacket to slide off from the inner pipe. Diagram of Butt welding Diagram of pipe wall-integrated electrofusion weld For immediate welding, we can supply SIMONA SPC pipes that have been machined down at the end of the pipe, i.e. the protective jacket has already been peeled off in the requisite manner. Connection of the pipe ends is performed in compliance with DVS guidelines DVS-2207 Part 1, DVS Part 1 and DVS-2212 Part SIMONA SPC Protective-Jacket Pipes 04/2005

13 Socket welding temperature with the aid of resistance wires (heating spiral) embedded in the socket and are then welded. If tapping tees are being attached, the protective jacket must be removed depending on the shape of the valve. The protective jacket is peeled off at both ends of the pipe according to the socket insertion depth. The connecting surfaces are heated electrically to welding Diagram of socket welding An added bonus of all SIMONA SPC pipes: no need for rework or sealing at the seam after welding. 04/2005 SPC Protective-Jacket Pipes SIMONA 13

14 SIMONA one-stop solutions Tapping tee In addition to pipes, SIMONA offers a comprehensive range of fittings, flanges and valves. In fact, we are able to deliver cutting-edge solutions for practically any pipelaying project an all-embracing product range tailored to your requirements. User-friendly solutions Our SPC pipes can be supplied with processed ends ready for heated tool butt welding. Peeling devices SIMONA peeling devices have been specially developed for construction site use. They remove the protective jacket in the welding area with minimum effort, thus preparing the SIMONA SPC for subsequent welding in compliance with the relevant guidelines. SIMONA peeling devices can be deployed for pipe diameters from 110 mm to 630 mm. Tailor-made accessories SIMONA offers a range of accessories for professional processing of SPC pipes either for hire or for purchase. Our product portfolio includes peeling devices, routing machines, clamping collars, silicone heating mats and parting-off tools. Routing machines The routing machine has been designed specially for on-site welding of tapping tees to SIMONA SPC pipes. It is suitable for machining SPC pipes with outside diameters ranging from 110 mm to 630 mm. After routing, the protective jacket can be completely detached from the inner pipe with a chisel or any other suitable tool. 14 SIMONA SPC Protective-Jacket Pipes 04/2005

15 For enquiries regarding applications technology and processing, please contact us: Ph. +49 (0) 67 52/ or For enquiries about hiring or purchasing accessories, please contact us: Ph. +49 (0) 67 52/ or From left to right: clamping collars, routing machine, silicone heating mat, peeling device, chisel Silicone heating mats To facilitate detachment of the protective jacket from the inner tube, we recommend using silicone heating mats at low processing temperatures (< 15 C). The protective jacket is preheated with the aid of silicone heating mats during processing in the low temperature range. The protective jacket can then be easily removed from the inner tube with a chisel, without leaving any remnants. Clamping collars For WIDOS welding machines, we can supply you with clamping collars specially adapted to the outside diameter of our SPC Protective-Jacket Pipes for diameters from 110 mm to 630 mm. SIMONA also supplies a special manual with details of how to operate the equipment. 04/2005 SPC Protective-Jacket Pipes SIMONA 15

16 Tender documents PE 100 SPC-Waste Water Pressure Pipes PE 80 SPC-Waste Water Pipes PE 100 SPC-Drinking Water Pressure Pipes Supply PE 80/PE 100 SPC-waste water pipes and PE 100 SPCdrinking water pressure pipes consisting of an inner pipe as per DIN 8074/8075, including an additional continuous protective jacket made of modified PP (SIMONA PP Protect), and perform laying of pipe as per DIN EN 1610 and in accordance with the supplier s specifications. Pipe manufacture with proof of quality assurance in accordance with DIN EN ISO 9001 and external certification by TÜV Süddeutschland. The protective jacket shall be removed from the joint area onsite, if necessary, before the pipe ends are welded. There is no need to seal SIMONA SPC pipes after removal of the protective jacket in the welding area using SIMONA peeling devices. Please refer to the separate handling instructions for accessories. Product: SIMONA PE 80 SPC Waste Water Pipe Product code: PE ARST-SPC RO SIMONA PE 100 SPC Waste Water Pipe Product code: PE 100 ARST-SPC RO SIMONA PE 100 SPC Drinking Water Pipe Product code: PE 100 TRST-SPC RO Supplier: SIMONA AG Teichweg Kirn Telefon +49 (0 ) Fax +49(0) [email protected] Supply specification: Inner pipe dimension Wall thickness of the jacket pipe SDR, PN Colour of inner pipe Colour of jacket pipe Total quantity Pipe length Example of a tender document for SIMONA PE 100 SPC-Drinking Water Pressure Pipes Item No m /quantity Total price in Product code: PE 100 TRST-SPC RO PE 100 SPC-Drinking Water Pressure Pipe Supply PE 100 SPC-drinking water pressure pipe consisting of a black drinking water inner pipe based on TÜV Süddeutschland MUC-KSP-AO2, DVGW GW 335 AZ and DIN 8074/8075, including an additional continuous protective jacket made of blue modified PP (PP Protect), and perform laying of pipe as per DIN EN 1610 and in accordance with the supplier s specifications. Pipe manufacture with proof of quality assurance in accordance with DIN EN ISO 9001 and external certification by TÜV Süddeutschland. The protective jacket shall be removed from the joint area on-site, if necessary, before the pipe ends are welded. There is no need to seal SIMONA SPC pipes after removal of the protective jacket in the welding area using SIMONA peeling devices. Please refer to the handling instructions regarding SIMONA peeling devices. 16 SIMONA SPC Protective-Jacket Pipes 04/2005

17 Product Range

18 PE 100 SPC-Drinking Water Pressure Pipes Material Inner pipe PE 100 with drinking water approval and protective jacket made of modified PP Protect Dimensions DIN 8074, DIN Standard length 12 m; other lengths on request Colour Inner pipe: black Jacket pipe: blue Product code PE 100 TRST-SPC RO Inner pipe SDR 17 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 90 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Inner pipe SDR 11 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 90 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x SIMONA SPC Protective-Jacket Pipes 04/2005

19 PE 100 SPC-Waste Water Pressure Pipes Material Inner pipe PE 100 and protective jacket made of modified PP Protect Dimensions DIN 8074, DIN Standard length 12 m; other lengths on request Colour Inner pipe: black Jacket pipe: brown Product code PE 100 ARST-SPC RO Inner pipe SDR 17 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 90 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Inner pipe SDR 11 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 90 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x /2005 SPC Protective-Jacket Pipes SIMONA 19

20 PE 80 SPC-Waste Water Pipes Material Inner pipe PE 80 and protective jacket made of modified PP Protect Dimensions DIN 8074, DIN Standard length 12 m; other lengths on request Colour Inner pipe: light grey Jacket pipe: brown Product code PE ARST-SPC RO Inner pipe SDR 26 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 160 x x x x x x x x x x x x x x x x x x x x x x x x x x Inner pipe SDR 17.6 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m 160 x x x x x x x x x x x x x x x x x x x x x x x x x x SIMONA SPC Protective-Jacket Pipes 04/2005

21 PE 80 SPC-Burst Lining Pipes for Unpressurised Waste-Water Applications Material Inner pipe made of PE 80 and protective jacket made of modified PP Protect Colour Inner pipe: light grey Jacket pipe: brown Old pipe Inner pipe 17.6 Inner pipe Jacket thickness Inner pipe + protective jacket SPC pipe DN d e weight approx. dimensions d 2 e 2 weight mm kg/m mm mm kg/m DN x x x x DN x x DN x x DN x x x x DN x x x x DN x x x x DN x x DN x x Available in 6 or 12 m sections Short lengths on request All pipes can be supplied for the following methods of connection: - flush ends for butt welding - electrofusion welding module with heating spiral system integrated into the pipe wall Explanation d = diameter of inner pipe d 2 e e 2 = total diameter = wall thickness of inner pipe = total wall thickness SDR = Standard Dimension Ratio (equivalent to pipe outside diameter divided by wall thickness) 04/2005 SPC Protective-Jacket Pipes SIMONA 21

22 SIMONA worldwide SIMONA AG Teichweg 16 D Kirn Phone +49 (0) Fax +49 (0) Plant I/II Teichweg 16 D Kirn Phone +49 (0) Fax +49 (0) Plant III Gewerbestraße 1 2 D Ringsheim Phone +49 (0) Fax +49 (0) SIMONA S.A. Paris Z.I. 1, rue du Plant Loger F Domont Cedex Phone +33 (0) Fax +33 (0) [email protected] SIMONA S.A. Lyon Z.I. du Chanay 2, rue Marius Berliet F Saint-Bonnet-de-Mure Phone +33 (0) Fax +33 (0) [email protected] SIMONA S.A. Angers Z.I. 20, Bld. de l Industrie F Ecouflant Phone +33 (0) Fax +33 (0) [email protected] SIMONA UK LIMITED Telford Drive Brookmead Industrial Park GB-Stafford ST16 3ST Phone +44 (0) Fax +44 (0) [email protected] SIMONA AG SCHWEIZ Industriezone Bäumlimattstrasse CH-4313 Möhlin Phone +41 (0) Fax +41(0) [email protected] SIMONA S.r.l. ITALIA Via Padana Superiore 19/B I Vimodrone (MI) Phone Fax [email protected] SIMONA FAR EAST LIMITED Room 501, 5/F CCT Telecom Building 11 Wo Shing Street Fo Tan Hongkong Phone Fax [email protected] SIMONA AMERICA Inc. PO Box Oakhill Road Mountaintop, PA USA Phone Fax [email protected] SIMONA IBERICA SEMIELABORADOS S.L. Doctor Josep Castells, Polígono Industrial Fonollar E Sant Boi de Llobregat Phone Fax [email protected] SIMONA-PLASTICS CZ, s.r.o. Zděbradská ul. 70 CZ Říčany-Jažlovice Phone /-8/-9 Fax [email protected] SIMONA POLSKA Sp. z o. o. ul. H. Kamieńskiego PL Wrocław Phone +48 (0) Fax +48(0) [email protected] 22 SIMONA SPC Protective-Jacket Pipes 04/2005

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24 SIMONA AG Teichweg 16 D Kirn Telefon ( ) 14-0 Telefax ( ) K+D 04/ PD