Paling uPVC. PRESSURE PIPES PRESSURE PIPE (PLAIN END OR SOCKETED AT ONE END) PRESSURE FITTINGcS) : uPVC. PRESSURE PIPES PRESSURE PIPE Supplied in plain end or socket at one end for solvent rarceaieal aTesreaaee weld connection to pipes or fittings. MS 628 (B.S. 3505 : 1968) CLASS B Code | Nom. | Mean Outside | Well Thickness [Length | Est. Wi] No. ‘Size Dia, (ehmm__| L) | kgim mom [Min | Max. Min. | Max 1000808 | 0 | 987 891] 29 | 34 | 6m | 131 1100 1008 | 100 | 1141] 1145] 34 | 40 | 6m | 199 +1100 125B | 125 | 140.0] 1404] 38 | 44 | 6m | 280 1 1001558 | 155 | 1680} 1685] 45 | 52 | 6m | 381 1100 2008 | 200 | 2188 | 294] 53 | 61 | 6m | 584 Pressure Rating: 60 bar (60m Head of water) CLASS C Code [om [ Mean Ouse [Wal Thickness [Length TEs. Wr No, | Size (mm |) | ka/m mm_[Min_| Max | Min. | Max “r1oo06sc| 65 | 7 | 53] 30 | 35] 6m | 113 rio00soc} 80 | 88.7) 891] 35 | 41 | 6m | 156 1100 100¢] 100 | 114.1) 1145] 45 | 52 | 6m | 255 u 1100 155¢ | 155 | 1680} 1685] 66 | 76 | 6m | 549 1100 200¢ | 200 | 2188 | 2194| 78 | 9 | 6m | 850 ios 250c | 250 | 2726 | 2734] 97 | 112 | 6m | 1318 Pressure Rating: 9.0 bar (0m Head of water) —le|— CLASS D Code] Nom. | Mean Outside] Wall Thickness] Lenath | Est. Wt] No. Size Dia (mm) (| kg/m mmm_[ Min, | Max [Min [| Max. Tio 02D] 92 | 421 | 424) 22] 27 | om | 048 i100 0¢0p| 40 | 481] 484) 25] 30 | 6m | 06 11000500] 50 | 60.2] 605) 31| 37 | 6m | 09 1100068} 63 | 75 | 753) 39 | 45 | 6m | 143 1109 080} s0 | s87 | 991] 46) 53 | Sm | 18 1 1 3 1 1 300 1000 | 100 | 141 | 1145 69 | 6m | 338 300 125D| 125 | 1400 | 1404) 73) 84 | 6m | 4.98 100 155D| 155 | 1680} 1685] 88 | 102 | 6m | 7.25 joo 2000 | 290 | 2188 | 219.4} 10.3 | 119 | 6m | 1108 +1100 2500 | _250_| 2726 | 2734| 128 | 148 | 6m | 1718 Pressure Rating: 12 bar (120m Head of water)uPVC. PRESSURE PIPES CLASS E Code | Nom. | Mean Outside | Wall Thickness [Lenath ] Est. Wt No. Size | __ Dia (mm | () | kam mmm [Min [ Max | Min. T Max rio oise | 15 | 22] 21s] 17] 21] om | 018 1100020E | 20 | 266} 269] 19} 25 | 6m | 027 1100025E | 25 | 334] 337) 22| 27 | 6m | 037 + 1iooasze | 32 | 421| 42a] 27] 32] 6m | os 11000408 | 40 | 481] 484) 31] 37 | 6m | ore s11o0050E | 50 | 602] 65] 39] 45] 6m | 133 + 1100065 | 63 | 753) 753] 48 | 55 | 6m | 172 +1100 080E | 80 | 887] 891) 57] 66 | 6m | 244 1100100 | 0 | 41] 145] 73] 84] 6m | 4.00 +1100 1256 | 125 | 140.0] 1400] 90 | 104 | 6m | 610) * +1100 155E | 155 | 1680 | 1685 | 108 | 125 | 6m | 875 +1100 2008 | 200 | 2188 | 2194 126 | 145 | 6m | 13:34 ‘Pressure Rating: 15 bar (250m Head of water) CLASS 7 [Code ]Nom. | Mean Outside] Wall Thickness] Pressure |Length Est. Wt. No. ‘Size Dia, (©) mm Rating | (L) | ka/m am Meter | Min | Max | Min | Max | Bar /Meter | 11000157] 15 | 212 | 215} 37 | 4a | 40 | 400] 6m | 0.32 11000207 | 20 | 266 | 269] 39 | 43 | 32 | 320] 6m | 044 1100 0257 | 25 | 334 | 3.7] 45 | 50 | 32 | 320| 6m | 064 i100 0327 | 32.| 421] 424] 48 | 53 | 28 | 280| 6m | 0.88 111000407 | 40 | 48.1 | 484) 51 | 56 | 25 | 250) 6m | 1.10 +11000507| 50 | 602 | 605 | 55 | 61 | 22 | 22] 6m | 149 NOTE:- + Subject to availability of stock, and delivery only on application. Pipes are grey in colour.(eouing) uPVC. PRESSURE PIPE FITTINGS FAUCET ELBOW To connect faucet or ball valve to uPVC water supply line, ‘Threaded at one end and solvent weld to pipe on the other. Code | Nom. [Dimensions mm [Mean Socket [Approx. Unit | No. Size Int. Dia.d | Wh mm. A mm 2ioao1s | 15, 155 245 35 9m 2102020 | 20 199 269 50am 2102025 | 25 232 387 80 gm 2ioz0a2 | 32 218 424 115 gm 2102040 | 40 262 484 200 om 2ioz050 | 50 317 as 300 gm To solvent weld to pipes at both ends — Code | Nom. | Dimensions mm [Mean Socket | Approx. Unit’ No. Size nt. Dia.d | We mm | L [A mm aiogois | 1s [165 | 174 215 20am 2103020 | 20 | 195 | 196 269 | 45am aros0rs | 25 | 255 | 21.9 337 | 659m 2iozos2 | 32 | 270 | 22 424 | 105 gm 2103040 | 40 | 300 | 270 484 200 gm 2103050 | 50 | 360 | 309 605 300 am 2rozoso | 80 | 805 | 44.7 89.1 510 gin 2103100 | 100 | 630 | 57.7 nds LOkg To solvent weld to pipes or hitings at both ends, Code] Nom. | Dimensions mm | Mean Socket | Approx Unit No. Size Int. Di, d We ma | t [A [8 | mm Bioaois | 15 | 229] 73] 70] 215 aan 2104020 | 20 | 255] 887] 900) 269 40 gm 2ioao2s | 25 | %42| 899] a93| 337 50am aroioa2 | 32 | 435| 248! 267] 42a dig 2iogoao | 40 | 453) 1685) 1714] 48.4 0.22 ig 2ioaoso | 0 | 582] 2107|2060) 60.5 O41 kg 2ioaoss | 65 | 75.0} 2459 | 2403! 753 0. Big 2104080 | 80 | 91.0] 2007) 2593] 69.1 1 dig aioaio | 100 | 1143] 3114]3159] 1145, 2 6ha 2104155 | 155 | 1295] 5594] 650.5] 1685 8 ike 2104200 | 200 | 220 | 1200] 1200} 219.5 4. Sky (Fabricated from pipe) 45° BEND To solvent weld to pipes or fittings at both ends, Code | Nom. | Dimensions mm [Mean Socket] Approx. Unit No. | Sze int Dad | We om | tf at 8] mm g 2105015 15 | 35.6) 455 25 20 gm 2105020 | 20 | 260| 479) 565] 268 40om aioso2s | 25 | 3t6| $53] 637) 335 gm 2108032 | 32 | 386| 730] S34) 423 ozig 2ioso40 | 40 | 428] ate |ioa3| 483 0. 21g 2iososo | 50 | 635] 1201) 1397| 605 033g A 2105065 | 65 | 795|1483|1529] 753 071g 205080 | a0 | 985|1725]2050) 892 1 1g 2105100 | 100 |100" | 1855] 2075) 145 2 Lig u 2105155 | 155 | 120 | 247.0) 324.5 168.5, 6. Okg 2105200 | 200 [20 |= |=" | 298 | 11.0019 RA (Fabricated from pipe) Fete EQUAL TEE uPVC. PRESSURE PIPE FITTINGS To allow for take-off or branching of a pipeline system. Cade] Nom] Dimensions mm [Mean Socket] Approx. Urit | No. | Size | Int. Diad | Wh | om C] A [6 | mm | 2106015 | 15 | 235] 20) 12) 215 35 gm 2106020 | 20 | 222) maz] 214) 268 45 am — 2106025 | 2 | 276| 429] 224) 335 0. 1ka | p1os032 | 32 | s24| 535 | 268] 423 0.15 i & prose | 40 | 360) 492} 244) 483 0.243 | | ziocoso | 50 | a7] ors] a2] Sos 0. 44g = 2106080 | a0 | 589) 880 | 435) 89.1 O61 ks 2106100 | 100 | 674] 1175 | 598] 1145 1 6ig To allow for take-off or branching and reducing of a pipe line system, pe Code] Nom] Dimensions mm — [Mean Socket] Approx. Unit No. Size Int. Dia.d | We mm [ET A TB | mm t____| | 2107020015 | zoxis | 215 | 330 160] 266 406m 2107025015 | 25x15 | 226 | 588 |199 | 33.5 654m 2107025020 | 25x20 | 21.7 | 587 |209| 33.5 70 gm 2107032025 32x25 | 203 | 49.4 |247 | 420 | 0.13 kg 2107040025 | 40x25 | 280 | 10 32.5) 482 | 0. 2ka pet | 7107040032 dOxa2 | 332 | 546 |277 | 482 0. 2ig 2107050032 | 50x32 | 341 | 804 | 312] 606 0. 3g 2107050040 | 50x40 | 357 | 769 | 870 | 607 Ot kg DOUBLE END SOCKET 70 solvent weld to pipes or fittings Coe Nom. | Dimensions “| Mean. Socket | Approx No. Size | mm | int. Dia, (dy | Unit We. T {mm [i TA mn 208016 1) 24 | 25 a4 ion u 2108020, m | 25} 30 268 Bam le 2108025, % | 29) 23 335 35 gm | zrosos2! 32 | 369 | 59 423 35am | 7 j 108040 40 | 386 | 48 83 85 am | 2108050 so | 414 | 65 605 | O11 kg u 2108080) 80 | 765 | 225 89.1 | 0. 3kg 2ioaioo® | 100 | 1129 | 353 145 | 0. 94g 2iosiss | iss | 130 | “50 185 | 257Kg a vaosz00 (f) | 200 | 240 | — 2195 | 780k }—4— 1 sosesoiny | 250 | — | = - REDUCING SOCKET (F) (Fabricated from pivel To solvent weld 2 pipes of different diameters ic | Nom | Diversions mm | Mean Socket Int. [Approx a fee | Se Ban Ome cr | mm [TTA a | & | pi0s020015| axis | 162 | 20.1 | is9 | 212 | 268 | 20am Zioo025018| Doris | 169 | 228 | 148 | 214 | 335 | 20g Sio902s020| 25x20 | 194 | 230] 121) 266 | 335 | 30m 4 | plosoaeoas| soeas | 227 |e | 9s | sae | aes | Soan Srov0ions2| ove | 260 |306|176| 420 | 423 | 85am Jroo0s0082| Sone? | 262 | 359 | 188) 420 | 605 |ottis | uososooso| 0.40 | 502 | [ies |_as2_| 608 | otisCc) uPVC. PRESSURE PIPE FITTINGS REDUCING BUSH To solvent weld 2 pipes or fittings of different diameter oe Code [Nom. Size Dimensions mam “Approx. No. (am) |G | & | D, TD, | Unit, i arroozo01s | 20x15 | 179 | 202] 215 | 260] “10am arioo2sois | 25x15 | 205 | 274 | 215| 334] 2am 2110025020 25x20 } 163 | 227 | 260] 334] 209m i ‘2rioog2025 | 32x25 | 280 | 318 | 334] 420] 30om 1. |t [roztio0a0025 | 40x25 | 279 | 347 | 334] 483] 40am 2110040032 | 40x32 | 323 | 346] 420] 483] 65am 2110050032] s0x32 | 326 | 405 | 420| 605) 60am P/T FAUCET SOCKET | To connect faucet or ballvalves directly to uPVC pipe | am |S Dimension | Appron Unt | No (om) cL D MM. i| amos | 15 8 215 20 gm | T pitio2o | 20 25 267 30gm ainiozs | 2 21 BS om aioe | 2 a0 23 6am | Rios | us et oe | 2utt0so | 50 24 m2 02k | o | | VALVE SOCKET | To connect stop-valves to uPVC pipes t Code [Nom. Size| ___ Dimensions mmm “Approx. Unit | No._| (am) [tT A | D we i i auzois| 5 | 23 | ws | as 15am | 7 2112020 2» 283 72 | 268 25 gm 1 Fuizos| 2 «| aii | 195 | 335 40gm | Ziizos2| 3 | 354 |. 219 | 423 70 gm | Yl» \zuow) @ | 8s | 29) #2 | ote i piizoso| sd | 49 | 256 | 65 | 02k a(Pains) uPVC. PRESSURE PIPE FITTINGS END CAP To cap or seal end of uPVC pipe with solvent cement | Cote | Nom Dimendonsmm | Approx No. a i Do] Unit We l. | 21is01s 5 16 215 10 9m 2113020 2 212 268 10am 2113025 % 250 335 2% an 2ut3032 2 305 123 50 gm 213040 «0 338 483 an 2113050 50 25 5 | 01k TANK CONNECTOR WITH STRAIGHT To connect tank to faucet socket or Gl. socket BACKNUTS Nom. Dimensions mm Code ‘Size Approx oo (eam) LIA D_| Uae Wt. 2114015 15 5 | 45 | 215 | 40am 2114020 20 sto | 510 | 269 | dam 2114025, B as | @5 | 5 | 9am TAP CONNECTOR To connect to basin faucet or valve socket of pipeline for easy maintenance and repair. Nom. Dimensions am Code 7 Approx. iS in) iE Do] Unit We. 2115015 5 2 2125 | 409m 10(Peaing uPVC. PRESSURE PIPE AND FITTING SYSTEM Double end socket Reducing ce Reducing socket Equaltee Equal Ebow Reducing socket Reducing bush Reducing toe 1 XE Value socket en Jen 560 Contr va Equal bow Faucet elbow (AD en 540 Faucet socket End cap TYPICAL LAYOUT OF PALING uPVC PRESSURE PIPES AND FITTINGS Table 1. Pipe dimensions for Classes B, C, D, E and 7 ‘Nominst | Mesn eusiée Wal Thickness sae | frdmPoete som «Son at fae 40) SP hmnetnete 8S meena, 8 fmm rte «$miamtyteie 8S | pete te eo ‘nein Suto 8 § mmtndey8S|tnmton so8 eee ee oe ‘Magnesium Carbonte $$ Magesum Chiete sos faroinCebeas—-$& Ammimigowie == sg | Mummmmciammy $f aman ee ‘noun $dom Pee boas fo teres 4 — oe “K SS Merl il sor a settee voy | metaeiinnd a te fo somnuntiiioe 8 sis os 28 ost so pete wo She SE mena a wos) vo we ares too eee 88 mbt ss | omar. oi woo bam yet 88 Samsun fo st sot om a8 Smeeeoms 0d etn ve fs cn ss | rttgntmsnne UU Pes so oe so Pa 8 mngereouin 8S te ine at me) ss natant fo ‘som soo nin tote 8 enim fos fae See ss | pummocnns 3 8 humus ease 88 imygete fg | Mim res Cac pie $8 Cater ‘oa sos * ss | snes 8s Shwkene sos cote 8 a) © op | samocnose $8 Satin route oar ce Ao £8 Ghent sor | sitomonese $8 Sehmbaenae SS oe aot DU eine 53 | samme 8 setmmese so oe ag 0 cromamensn sg | Somme) SS um Dooy SS hemi 0 S$ cmmrsaaoy = sg | Samwoncnieg =F cA TONTIN SS ron 0m Sp eames 3 SunwercaTwies — $p SienatoeU re nS $5 cman fu | Stunna a0 5 sme fo ono eo ee died 0 Der 88 best oe sos | ume as Dara come mese = 88 Ly to pri sos eet ny sos en a faye so s 8 | va 58 tommy 88 ee a so ss | wietaer 5 mesa ne 2 res $3 were ogg | Mamet ve Fermalnys 40% SS Femi Aci 50% sor Des Overs $8 tae Nite aos Fruit Juices, Pp sos ‘Bae Spt aos sete 88 teem 22uPVC, PRESSURE & NON-PRESSURE PIPES INSTALLATION OF PLUMBING AND SANITARY SVSTEM Drainage F Minimum 0mm Uederground Drainage Pe “Black pipe & fittings indicate Paling uPVC Pressure Pipes & Fittings * White pipe & fittings indicate Paling uPVC SWV Pipes & Fittings 23uPVC. PRESSURE & NON-PRESSURE PIPES GENERAL PROPERTIES ‘Typical Physical Properties of uPVC pipe. Table 1 = Aver Items Test Method Unit Charatterstic Value + | Specitic Gravity ASTM D792, 142 Hardiness ASTM D785. Rockwell R 120 Water Absorption ‘ASTM D570 malem* (psi) 0.04006 (67—B5x10°) Tensile Strength at ASTM D638 kalem® (psi) 500 eC BS 7782, (7200) Elongation at Ultimate ASTM Deas 8)—150% Tensile Strenath BS 2782 Compressive Strenath ‘ASTM D685 kaler (p.si) 660 (9,400) Modulus of Elasticity ‘ASTM D638 kgler? (psi) Sxl0* (4.3410) Vicat Softening Point ASTM D155 c 100 Poisson's Ratio at - 2a 20°C (70F) Impact Strength (20d) ASTM D256 kgemjom? 6 Coofcient of ASTM D696 rnvmny"C aos Linear Expansion ‘Thermal Conductivity - Kafmh*C 045-059 Flame Resistance ASTM D635-56T Salf-extinguishing Volume Resistance ASTM D257 Q.-em (-mil) more than 105 (tmore than 25x10") Dielectric Constant ASTM D160 30-33 20°C 1KC Dielectric Strenath = KV/mm (KV) more than 40 {ore than 1.0) Dielectric Power AST, D150 - 02 Factor 20°C IKC Deflection Temperature ASTM Doss c 6 under flexural lod _L L Note: General properties have been extracted from published date 24_- uPVC. PRESSURE & NON-PRESSURE PIPES Weston Flow Diagram for Paling Pipes Up to 60 mm Diameter Head Loss in meters/1000 meters length of pipe line. Flow rate, in Litres/sec. V = Velocity in misec {= Nominal pipe size in mm, 25uPVC. PRESSURE & NON-PRESSURE PIPES Hazen & Williams Flow Diagram for Paling Pipes Up to 300 mm diameter. 8 Flow rate, in Litres/see. He ie a J 33 3 5 Head Loss in meters/1000 meters of pipe line. V_ = Velocity in misec 2 = Nominal pipe size in mm 261, PERFORMANCE PROPERTIES 1.1 RESISTANCE TO BIOLOGICAL ATTACK In nature’s endless cycle of creation, growth, decay, and re-creation (rendered somewhat more complicated by the influence of man and his technology), it has been established through experience and observation that nearly all of man’s creations and products are eventually reclaimed by nature. Metalic products are slowly des troyed and reclaimed through chemical reaction or oxidisation, Inorganic non-metallic products are even- tually reclaimed by nature through chemical reaction and various forms of erosion. Organic ot organo: chemical products are normally subjected to deteriora: tion through various forms of weathering and biological attack or degradation, Notable as an exception to nature's normal system of reclamation and recovery is a unique group of polymeric, synthetic construction materials generally termed plastics which display negli ble or no susceptibility to biolosical attack. Although not all plastics display sesistance to biological attack, some plastics have proven to be virtually indestructible through biological degradation. Polyvinyl chloride pipe such a plastic product providing nearly total resistance to biological attack. Once installed underground in normal water and sewer systems, with its exceptional resistance to corrosion, chemical attack and biological attack, PVC pipe can be considered a permanent Creation of man not susceptible to the normal processes of deterioration common in nature. Biological attack can be describedas degradation and/or deterioration caused by the action of living micro: or macro-organisms. Mirco-organisms which attack organic materials are normally classed as fungi and bacteria, Macroorganisms which can affect organic materials located underground can include an extremely broad category of living organisms from grass roots to termites to rodents. The performance of uPVC pipe in environments providing severe exposure ‘to biological attack in its various anticipated forms has been studied and evaluated since the birth of the industry in the 1930. Not only has uPVC pipes been evaluated, but alsomany other PVC products such as household implements, containers and bottles have been carefully studied in their relationship with nature’s cycle. Perhaps with some justification, environmentalists have severely criticised the fact that discarded PVC products are not reclaimed by nature through chemical, electrochemical and biolo- gical processes, Such exceptional durability tan only be considered an advantage in underground PVC piping systems. UPVC pipe will not deteriorate or break down under attack from bacteria or other micro-organisms. uPVC will not serve as a nutrient to micro-organisms, macro- uPVC. PRESSURE & NON-PRESSURE PIPES organisms, or fungi. Investigation has documented no deterioration due to biological attack. The extreme resistance offered by uPVC to bio-degradation has served as an advantage as uPVC has been used in the application of sewage treatment trickling filter media in North America since 1959. Special engineering or installation procedures are not required to protect UPVC pipe from any known form of biological attack. Elastomeric seals are also manufactured from organo: chemical materials. Elastomers are manufactured with a large variety of properties. Care must be exercised in the selection of elastomers to be used in manufacture of elastomeric seals for piping products to ensure that sufficient resistance to biological attack is provided. Various elastomers can be susceptible to such attack. ‘Such elastomers provide resistance to biological attack. ‘comparable to that inherent in polyvinyl chloride. Manu. facturers normally ensure that elastomeric compounds that provide such high resistance are used in the production of gaskets for piping products. Particularly in potable water systems, a material that will not support bacterial growth is considered a requirement. In a normal practice, when installing uPVC pipe with rubber ring joints, assembly of joints is made easier with a lubricant applied in accordance with manufacturer's instructions. Care should be exercised in selecting lubricants to ensure compatibility with the elastomeric seal and the uPVC pipe, and that the lubricant will not support the growth of fungi or bacteria, Use only Jubricant recommended by the pipe manufacturer. 1.2 WEATHERING RESISTANCE When subjected to exposure to ultra-violet (UV) radi tion from the sunlight, uPVC pipe will suffer surface damage. This effect is commonly termed ultra-violet (GV) degradation. uPVC is normally formulated to provide substantial protection from UV radiation, UV degradation incurred over an extended period of time is a destructive process of major significance in nature's ongoing process of breaking down and re claiming old materials of organic composition, e.g. plant waste, animal waste, plant fibre, wood, animal tissues, plastics, etc. The weatherbeaten appearance of old ‘wooden structures is, in great measure, caused by ultra- Violet radiation, uPVC pipe must be considered suscepti ble to UV degradation, unless shielded from sunlight. UV radiation will not penetrate even thin shields, suchas paint coatings, clothing, or wrapping. Burial of PVC pipe provides totally effective shielding from UV attack UV degradation in PVC ensues when energy from the UV radiation causes excitation of the molecular bondsin the plastic. The resulting reaction occurs only on the ‘exposed surface of the uPVC pipe and to extremely shallow depths, frequently measured at less than 0.0254 mm. Within the affected zone of reaction, the structure ‘of the polyvinyl chloride molecule is permanently altered, converting the molecule into a complex struc- 7ture typified by polyene formations. The polyene mole cule contributes a light yellow colouration to the uPVC. pipe and increases tensile strength. The effect on the uPVC pipe would be considered negligible in many product applications if no other change occurred; however, the creation ofthe thin fim of polyene material may contribute to some reduction in impact strength. The following conditions, inherent in this organo- chemical reaction, must be noted: © UV degradation results in colour change, slight increase in tensile strength, slight increase in the modulus of tensile elasticity and decreases the impact, strength in PVC pipe. © UV degradation does not continue when exposure to UV radiation is terminated. © UV degradation occurs only in the plastic material directly exposed to UV radiation and to extremely shallow penetration depth. © UV degradation of properly formulated uPVC pipe materials normally occurs only after extended ex- posure 1.3 ABRASION Investigation and observation through years of ex- perience have established that uPVC pipe provides good resistance to abrasion. The combination of PVC resin, extenders and various additives in PVC compounds and the methods of extrusion, produce a resilient piping product with an extremely high resistance to abrasion. Many investigations and tests have been conducted over the years, both in North America and Europe, by manufacturers, independent laboratories and universi- ties to define PVC pipe response to abrasion. While the approaches to the various tests and investigations have varied substantially, the data developed has been con- sistent in defining the extent of PVC pipe resistance to abrasion. The nature and resiliency of PVC pipe cause it to gradually erode over a broad area and a long time, rather than develop the characteristic, localised pitting and more rapid failure of most other piping materials. Individual tests conducted by major uPVC pipe manu- facturers to investigate the resistance of uPVC pipe to abrasion caused by mechanical cleaning have displayed insignificant evidence of wear in a wide assortment of conditions. Standard commercial cleaning and rodding equipment was usedin these tests, operating in wetlines, dry lines and lines partially filed with sand and gravel. Request for guidance from manufacturers of cleaning equipment have confirmed the results of these investiga tions. Many cleahing equipment manufacturers indi- cated that their operatinginstructions ate no different for the cleaning of PVC pipelines than for other types of pipelines — asbestos cement, cast iron, concrete, steel, or vitrified clay sewer pipes. A test conducted by the Institute for Hydromechanic and Hydraulic Structures of the Technical University of uPVC. PRESSURE & NON-PRESSURE PIPES Darmstadt in West Germany provided an interesting comparison of abrasion resistance in several piping products. Abrasion evaluation using river sand and gravel was performed with unlined concrete pipe, lined concrete pipe, glazed vitrified clay pipe, and PVC pipe producing the following results: Concrete (without lining) © Measurable wear at 150 000 cycles Concrete (with lining) © Measurable but displaying less wear at 150 000 cycles Vitrified Clay (glazed lining) © Minimal wear at 260 000 cycles (accelerated wear after glazing wore off at 260 000 cycles) PVC pipe ‘© Minimal wear at 260.000 cycles (about equal to glazed. vitrified clay, less accelerated than vitrified clay after 260 000 cycles) PVC pipe is well-suited to applications where abrasive @ conditions are anticipated. In extremely abrasive ex. posures, wear must be anticipated; however, in many conditions, PVC pipe can significantly reduce main: tenance costs due to extreme abrasion. 1.4 TUBERCULATION RESISTANCE Soluble encrustants, such as calcium carbonate in some ‘water supplies, do not precipitate on to the smooth walls of PVC pipes as they do with other materials. Since PVC. pipe does not corrode, there is no tuberculation caused by corrosion by-products as inside some other pipes. 28gerry fos 2.DESIGN DATA 2.1 BURST PRESSURE AND WORKING PRESSURE Burst pressure, which is also highly dependent on temperature, can be calculated from the following formula if either inside or outside diameter and wall thickness are known. 2tf 20 P= R= SEE (Naday’s formula)... (2) Where P : burst pressure, kg/em® t minimum wall thickness, cm D:outside diameter of pipe, em f: tensile strength, kg/cm? d.:inside diameter of pipe, cm When safety factor is now assumed as S, working foot 3 then working pressure Pp is: Bite 2tt La “30-5 tis ee compared to diameter Thus, minimum wall thickness of pipe trie when working pressure is known, from formula (2) Pd _ Peas et 2.2 RESISTANCE TO EXTERNAL PRESSURE 2.2.1 FLATTENING LOAD Though it involves extreme difficulties to calculate the resistance to external pressure of a pipe under certain conditions, it is usually judged from the following test results as a criteria Test Methods Test pipe is cut to a ring of the same length as its diameter and its both ends are finished square byalathe This is held in place between two parallel plates and is compressed under load w steadily unitlit breaks. Under this state, the load at which two points on oneside of the pipe of the broken face contacts is indicated by p,. The load is increased. The load w when the internal surface contact each other completely is indicated by p, These loads of p, and p, are converted into the values of unit cross area of pipe, which are called deflective strength F, and F; under these states: These bursting loads and deflective strength can be calculated interchangeably from the following formula. td (D — d* 31 +P mde 3a Po ++) t uPVC. PRESSURE & NON-PRESSURE PIPES where : bursting load, kg (Ib) F: deflective strength, kg/cm? (Ib/inch®) d:: inside diameter of pipe, cm (inch) D: outside diameter of pipe, cm (inch) t: wall thickness of pipe, cm (inch) 4: length of pipe, cm (inch) 2.2.2 EXTERNAL PRESSURE ‘When external pressure acts uniformly on the external periphery of pipe, a dent gradually develops on the pipe as the external pressure increases, and finally the pipe breaks. The pressure which causes this dent is called the working limit of extemal pressure, P. It can be approximately calculated by the following formula. - © barca} (S) (Southwells Formula) . where, it of pressure, ka/em® ([b/inch?) E: elastic modulus,kca/cm® (lb/inck?) t: wall thickness of pipe, cm (inch) 1/m: Poisson's ratio Tra; mean radius of pipe, cm (inch) For PALING uPVC Pipe the values at 25°C (77°F) are: E = (25—30) x 10! (kg/m?) (3.55—4.25) x 10° (Ib/inch?) 1m = 0.3—0.38 Thus, from Formula (6), the minimum wall thickness that can withstand the extemal pressure - 2.2.3 EARTH PRESSURE AND ‘WHEEL PRESSURE ‘When pipes are buried underground, those loads such as of back filled soil, liquid weight inside the pipe and moving vehicles, besides internal pressure, act on them. ‘Though internal pressure acts favourably on the pipe to the deflection of vertical direction, deformation stress by external pressure makes it extremely difficult to find the optimum wall thickness of the, pipe to insure safety, because of the complexities involved in a number of factors such as nature of soi, method of back filing, types of pavement, etc, Earth Pressure: Earth pressure significantly varies depending on nature of soil, method of back filing, the state after back filed, etc., even if pipes are buried by a trench method. Earth pressure P, (kg/cm) at depth h (m) is expressed by the following formula: train = fm o2Ktang 2Ktang “A ] (Jhansen’s Formula) . . where, 2 1+ sing where P,: earth pressure at depth h (m) or h (inch), kg/m? (Ib/inch?) overburden, m (inch) : width of trench, m (inch) 5 + specific weight of soil, kg/m* (Ib/inch’) for normal soil, itis 1700-2,000 kg/m? (0.060.072 lbinch*) 4: angle of repose of soil. (dea.) For normal soil, it is approximately 6 =-40" therefore, 2K tan @ = 0.36484 @: base of natural logarithm e = 2.71828 Wheel Pressure: For underground pipes, wheel loads are a problem too. Though it depends on types of vehicles, wheel pressure Pe (kg/m), when it acts on buried pipes, at depth hk (m) can be calculated from the following formula. =o uPV.C. PRESSURE & NON-PRESSURE PIPES where, P;; wheel pressure at depth hm (inch),kg/m? (lbfinch?) q: load per wheel, kg (tb) ‘A: buried depth,m (inch) ‘a: width of the area where the wheel contacts, m (inch) b: lengthof the area where the wheel contacts, m (inch) Note that wheel pressure is based on 30% increase over pressure caused by q. Table 2 shows the computed values of wheel pressure, P; for a truck of 20 metric tons, where q=8000kg = @=052m b= 020m W = 1920 kg/m’ @ = 40° and B = 0.7m Figure 1 is graphed from Table 2. It shows that earth pressure and wheel pressure to be incurred on the pipe buried under f > 1.2 (m), that is, under 1.2 (m) ormore, the pipe retains almost constant values (about 0.3 (kg/cm?) for 8 ton truck against heavy loads). The computed values of wheel pressure, Pp for a truck of 8 metric tons shows that the extemal pressure, P, + Pp is almost stable at 0.3 kg/cm” if the pipe is buried underground at h > 0.6 m, In other words, if pipes are buried at a depth of 0.6 m to 1.0 m, they are usually quite safe to earth pressure and wheel pressure, eas . The use of design data formulae for resistance to (a + 2h)(b + 2h) external pressure is shown in an example on page 31, Appendix 1. Table 2 Soil and Wheel Pressure able Depth of instalation h (em) 0 ® @ 7 1 10 1a Soil pressure P, (ka/m!) 190 530 Cy 1,380 1,710 2,000 2,240 Whee! pressure P (g/n®) asi | noo | aso | 2280 | 1370 920 ey P+Ps x20 | raso | sao | 3600 | 30m | 290 | 250 50 40 30 E 2 10 = 07 8 05 B O4 en a Fel & 03 3 0 Eye 5 = oa a 0.07 0.05, ce 0.04 903 Fig. 1: Au Fzample of Relation Betwoen Depth of Installation and External Pressure Caused by Truck’s Weight 30 60 90 120 150 180 Depth of installation (cm) 302.3 THERMAL STRESS When there is increase or decrease in temperatures after pipes are installed, they either expand or shrink. In such a case where both ends of the pipe are fixed, compressive stress or tensile stress will eventually be produced. ‘Stress which is accompanied with the variation of temperature is called thermal stress. Depending on the intensity of this thermal stress, it may be required to use expansion joints. This thermal stress is expressed by the following formula: +: On =aEbt =a (t— to)... +0) where, @»: thermal stress ka/em? (Ib/inch?) @: coefficient of linear expansion 1/°C At: difference of temperature °C t! working temperature °C tp: installation temperature °C 2 E: elastic modulus ka/em? (Ib/inch?) This formula shows that the thermal stress accom- panied with the variation of temperature is irrelevant to length and cross section of pipe but that itis directly proportional to elastic modulus E of pipe material. For PVC Pipe, elastic modulus & is smaller than that of metals hence it is less affected by thermal stress. In practice, however, it cannot be neglected. The coefficient of expansion can be calculated with expanded or shrinked length Ae of the pipe due to the variation of temperature, from the following formula. eae (20) Lo ag =— + (1) or RoAt — Ro (tty) where, 2 final length at temperature tC. 0: initial length at temperature te °C At: difference of temperature (°C) 8: difference of length. 2.4 TEMPERATURE CONSIDERATIONS For uPVC pipes and fittings under pressure and in continuous service at any temperature in the range 20- 60°C, the safe working pressure should be reduced in accordance with the values listed in Table 3 below. For any pipe material temperature or any pressure outside this range, the safe working pressure should be established by reference to the pipe manufacturer. 2.4.1 THERMAL LINEAR EXPANSION OF uPVC PIPE ‘The graph below shows the thermal linear expansion of UPVC pipe having a coefficient of expansion 7x10-'mm/ mm/*C, uPVC. PRESSURE & NON-PRESSURE PIPES Fig. 2 LINEAR EXPANSION men/m | ‘4 50 6) 0 Pipe material temperate vse °C. ‘THERMAL LINEAR EXPANSION OF uPVC PIPE 2.4.2 THERMAL EFFECTS An understanding of the effects of temperature variation on PVC pipe is important to engineers, installers and users. The performance of uPVC pipe is significantly related to its operating temperature. Being a thermo plastic material, PVC will display variationsin ts physical properties as the temperature changes. uPVC pipe can be installed properly over an ambient temperature range in which construction crews normally work Although the user must realise that uPVC pipe in a particular specification is rated for performance pro: perties at a temperature of 20 °C, itis recognised that operating temperatures of 1 °C to 32°C do existin water systems. As the operating temperature falls, the pipe's sliffness and tensile strength increase, thereby increasing the pipe's pressure capacity and its ability toresist earth- loading deflection. Conversely, with the drop in tem- perature, uPVC pipe decreases in impact strength and becomes less ductile, As the operating temperature rises, the impact strength and flexibility of PVC pipe increases. However, with the increase in temperature, PVC pipe decreases in tensile strength and stifiness; consequently, the pressure capacity of the pipe will be reduced and more care must be taken during installation to avoid excessive deflection. Many new users and installers of uPVC pipe may be surprised by the expansion and contraction of the pipe in response to variations in temperature. The coefficient of thermal expansion is roughly five times higher for uPVC than the normal value for cast iron or steel. Provisions must be made in design and installation to accommodate expansion and contraction ifthe pipeline is intended to provide service over a broad range of operating tem- peratures. Rubber ring joints provide excellent allow- ance and must be made for 10mm of expansion or contraction for every 30 metres of pipe for each 5.5 °C change in temperature. As a final comment on the thermal properties of PVC pipe, it should be emphasised that the average municipal LA 0 ~ ‘3090100 31water system operates at temperatures at or below 23 °C. Therefore, in the majority of common operating conditions, the actual pressure capacity of uPVC pipe would be as good or better than the manufacturer's rated pressure, The average municipal sewer system operates at temperatures at or below 23 °C. Therefore, ina similar manner, the actual pipe stiffness provided by the uPVC sewer pipe would be as good or better than the manufacturer's rated pipe stifiness. DERATING OF PRESSURE PIPES uPVC. PRESSURE & NON-PRESSURE PIPES Particularly when fluid is flowing being filed within the pipe, the formula becomes as follows: v= 0.355 CD26 [5,44 where, ++ (13.2) : velocity of flow (m/sec) coefficient of velocity (sec) ': inside diameter of pipe (m) + hydraulic gradient = head length of pipe average depth of fluid (m) FOR TEMPERATURE So a al oto 3 Tenath of periphery at cross section DC MC °C HC OC ‘area where fluid contacts OF 86°F _100°F 22°F M0" SST Caoeficient of velocity Cis the value determined by te fend @ 4 ~~ -% ~—-% 12 _SToothness ofthe interior surface ofa pipe. For PVC anPa oe 048 «036 «024 ~. 0.12 Pipe, around 140 to 150 may be employed. bs! 87 825 NNote: Since these formulas are experimental formulas, GSO btn based on water, they are not applicable tohigh Metre Hd » 2 & % 18 viscous liquids. MPa 09 «072 «(054 0.36 0.8 Pst "0 eB Figure 3 Coefficient of Velocity CLASS (D) Metre Ha fa) eos sree ces oe MPa 120 090 072 04802480 PSI im 139 «41 6D -|-= PVC pipe | . GLASS 2 zt «) = 00 5 ‘Metre Hd 100120 30 ‘Steel pine | 200 Po 1s) 120 0 060 030 Se wo a PSI 2601s, FS % 0 6 2.5 FRICTION LOSS 2.5.1 Flow Rate o 0 2» % 00 Ifthe velocity of flow in the normal pipe or watercourseis known, flow rate will be computed from the following formula. Q=Ay wee a where, ‘A: cross section area (m?) V: velocity of flow in the pipe (m/sec) : flow rate (m’/sec) There are many experimental formulae for computing velocity of flow. Of them, William Hazen formula is adequate for computing the velocity of flow for PALING PVC pipe » = 0.849 CRO Rs (William Hazen’s Formula) . (13.1) ‘Years of usage (ven) | 2.5.2 Computation of Loss Every liquid that we handle has viscosity without any exception. When viscous fluid flows on a solid surface, velocity is zero at the closest to the surface. As it leaves from the surface, velocity gradually increases and reaches its maximum at axis of the pipe. Where there is velocity of gradient like this, there is a shear stress generated by difference in velocity between pipe walls and fluid or in the fluid itself and internal energy | decreases. This is called pipe friction loss, and is calculated from the following formula. Though there are ‘a number of experiemental formulas, the one which seems to bbe most adequate for PVC Pipe is introduced here. 32auing) (a) Loss in Straight Pipes Friction factor in a straight pipe is obtained from the following formula. rg=d— eetoan Nd Be (Darcy Weisbach’s Formula) where, (4) loss of head in straight pipe (m) friction factor of pipe See Formulas (16) and (17) length of pipe line (m) inside diameter of pipe (m) gravitational acceleration (m/sec?) velocity in the pipe (m/sec) ri Formula (14) is alld fton factor of pipe, which Nvaties depending on types of pipes, and Reynolds Number Re. Re is calculated from the following formula. Eaey eel In case of circular pipe - (15) where, : density of liguid kg/m? . ¥: coefficient of kinematic viscosity of liquid (m#/sec) inside diameter of pipe (m) vi velocity of liquid (m/sec) Re less than (3-4) x 10} is called laminar flow. is: 64 " eeogboceobsdecenoenncocsacor Re mor than (3~-4) x 108s called turbulent flow. dis: x= 0.0096 + 0.0057, / + / 2:88 d Re (V. Misses’s Formula) . .. where, - (1) kx roughness coefficient of inner wall of pipe (Table 4) dd: inside diameter of pipe (cm) (b) Loss in Bends, Elbows and Valves As far as there exists fluid friction, the internal energy of fluid is consumed not only in straight pipe but also fittings and valves. These head losses are expressed by the following formula. Bend loss fy = Ky (3) uPVC. PRESSURE & NON-PRESSURE PIPES Elbow loss fh, = beeeeee (19) Valve loss hy = n = (20) Other loss fy = Kj = (21) where, thoshe t head loss of bends and elbows (m) Koko + coefficient of oss of bends, elbows, etc, et. v :velocity in the pipe (m/sec) : gravitational acceleration (m/sec) yng the number of bends, elbows, etc. = 02-03 (Those with bent radius of more than five times their diameters can be regarded as straight pipes) Ke =03—05 K, 70.720 (For fully released valves) K, 03-05 Roughness Coefficient of Internal Surface of Pipe, k Table 4 Kind of pine eer) PVC pipe 05-08 ines copper and lead pipe 2-10 Rubber pipe, ordinary en Rubber pipe, rough 530 Heavy hoses a Rubber coating hose 54 Gas pipe, welded or soba Dravn see! pipe 20-0 Kind of Pipe Kem ‘Asphaled sted pipe 00 Cement pipe, smooin 75-15 Woot nined 5 Wood pipe, ordnary 50-10 Wood sipe, rough 200-400 Cast ron pipe, new 100-200 Cast icon pipe, rusty sealea 250-500 33uPVC. PRESSURE & NON-PRESSURE PIPES Effect of Water Hammer or Pressure Surges In a general sense, surge pressures are any deviation from the normal steady state hydrostatic pressure ina piping system. Normally, positive surges are considered, but negative surges do occur and are potentially quite damaging, A detailed study of hydraulic transients is an undertaking worthy of a formal technical college course. However, certain key concepts should be familiar to those who design, install, test and operate piping systems. ‘Surge pressures commonly termed “water hammer” are generated in any piping system when a flowing liquid changes velocity. When flow velocity changes, part or all of the Kinetic energy of the fluid must be converted to potential (stored) energy and ultimately dissipated through frictional losses in the fluid or pipe wall the fluid 3 to return to its original pressure. Some of the more -ommon causes of hydraulic transients are: the opening and closing (full or partial) of valves; the starting and stopping of pumps; changes in turbine speeds; changes in reservoir elevation; reservoir wave action; liquid column separation; entrapped air. Generally, the types of surges may be divided into two categories: transient and cyclic, Transients may best be described as the intermediate conditions which exist in a system as it moves from one steady state condition to another. The closing of a single valve would be a typical example. Cyclic surging is a condition which recurs regularly in time, Surging of this type is often associated with the action of equipment such as reciprocating pumps and. pressure reducing valves, Small oscillatory surges can Grow rapidly in magnitude and can become extremely damaging if the frequency is at or near the natural resonant frequency (harmonic) of the piping system. Elastic wave theory of surge analysis has been developed bby various investigators over a number of years, and the technique will yield satisfactory answers when correctly applied. The pipeline designer should be aware that the geometry and boundary conditions of many systems are complicated and require the use of refined techniques similar to those given in tests such as Hydraulic Transients by Streeter and Wylie. ‘A common example, which is easily handled, is the calculation of the pressure rise in a pipeline due to the rapid closing of a valve. The pipelines supported against 2 longitudinal movement andis equipped with expansion joints. The maximum surge pressure is related to the maximum rate of change of the flow, while the rate of travel of the pressure wave is related to the speed of sound in the fluid (modified by the piping material). The wave velocity is then given by the following equations: GPRD EBay 7 POE 1420 a= Bares « (22) kc +O Er ere: @ = wave velocity,m/s k luid bulk modulus, 2068 MPa d_ = pipe internal diameter, m E = Modulus of elasticity of the pipe, 2758 MPa t= thickness of pipe, m Reformulating using dimensional ratios (DR) 1420 Ao K Vi te OR 2) Where: DR = pipe outer diameter/t ‘The maximum head of pressure rise may then lated. pav.. Where: V_ = velocity in pipe before valve closure, m/s g = acceleration due to gravity, 9:81 m/s P = pressure surge, head of pressure rise m (metres head) Example: A flow of 0.6 m/s is suddenly stopped in a 150 mm Pressure class D PVC pipe. Calculate the expected maximum surge pressure: 1420 ae [ik 1+ & (OR - 2) 1420 e = 383 mis (2,068 x 10°) (168 a [1 2768 KI0 ga?) Calculating the surge pressure: av g (389) (06) - 93.4 m Cn) a P Shock conditions brought about by water hammer or pressure surges must be allowed for in design, and where necessary, relief devices should be includedin the pipeline. Similar precautions may be necessary’ where high pressure surges can occur in rising mains fed by positive displacement pumps. 343. SUGGESTED CODE OF PRACTICE 3.1 Recommendations for the selection and use of uPVC pipes and Fittings. 3.1.1 SCOPE OF PART This part sets out recommendations for the selection, handling, transport and storage of uPVC pipes and fittings. It also covers safety precautions and guidance on temperature limitations. Greater detail is given in British Standard CP312 Pt. 2. 3.1.2 HANDLING AND STORAGE General Plastic pipes and fittings should not be subjected to gh ending, ertcunry during loading and un Roading operations. Where wire ropes or chains are employed, pipes should be suitably protected against scoring, Note: Pipes made from uPVC are considerably lighter than traditional materials and are characterised by tough: ness, relative flexibility, and general resistance to impact damage. However, they are subject to distortion under load, particularly at elevated temperatures, to bowing due to uneven heating, and susceptible to scoring from sharp edges. Precautions In the handling, transportation and storage of uPVC pipes and fittings, the following precautions should be observed: 1. Pipes stacked for transport should be continuously and evenly supported to minimise distortion. Alterna- tively, horizontal supports of at least 75 mm bearing width, spaced not further apart than 1.5m centre-to- centre, should be placed beneath the pipes. If the stacks are rectangular, vertical supports at twice that spacing should be provided at the sides. In such load- bearing stacks, maximum free height should not exceed 3 m. For longterm storege (more than 3 months), maximum free height should not exceed 1.5 mm. If different classes of pipes are kept in the same stacks, then the heaviest class should always be at the bottom. Avoid sharp sections bearing against the pies as these can cause indentations or scoring on the pipe walls. 2. Pipes and fittings should be protected from high temperatures and direct sunlight when stored. Note: Uneven heating around the circumference of a pipe may cause differential expansion along the length which may result in twisting and bowing. High temperatures will soften the pipes and the bottom layers of pipes stored in stacks will tend to be distorted 3. Pipes with end treatment, such as socketing, forming, flanging or with pre-assembled fittings, uPV.C. PRESSURE & NON-PRESSURE PIPES should be stacked or supported so that the ends are free from loading; if necessary, they should be protected from damage . Pipes, cut and squared by jointing, should be given special attention to ensure that they are always handled, particularly in transit, in a manner that keeps the pipe ends free from damage. If the pipes are nested (i.e. the pipes are stored inside pipes of larger diameter), the number of layers should be adjusted so that the total mass of the nested pipes does not exceed the total mass of pipes normally contained in such storage areas. When being transported, pipes should not be res trained in a manner likely to damage them. In the storage and issue of pipes, the principal of “frst in first out” should be observed 3.1.3 SAFETY The following safety precautions should be observed: 1. Normal safety precautions must be observed where inflammable or toxic solvents are used, particularly in confined areas. 2. Potable water lines must be flushed at least once before going into service to remove any extraneous matter or toxic materials Pressure testing with water provides sufficient flushing of the pipeline. 3. Being a non-conductive material, uPVC pipe cannot be used for earthing electrical installations or for dissipating static charges. When required, electricity supply authorities must be advised by the installer if any parts of existing metallic water supply pipelines are to be replaced by uPVC pipe. Where provision for electronic detection is required, suitable tracers may be buried in the pipe trench. Installers must comply with all relevant statutory safely regulations. 3.1.4 CHEMICAL RESISTANCE OF uPVC PIPE The suitability of uPVC pipe for the conveyance of a range of chemicals in non-pressure applications is tabulated where the chemical resistance of uPVC is listed. If the chemical to be conveyed is not listed in the Table, the pipe manufacturer should be consulted on the suitability of the pipe for the substance in question. Note: In drainage applications, the tables of chemical resis: tance may be vatied in accordance with the concentra tion of chemicals and the duration of contact (e.g. a laboratory drainage system). 3.1.5 INSPECTION BEFORE INSTALLATION The bore of the pipe and the fittings should be inspected to establish that it is free from foreign matter and the outside surface should be checked for damage before the pipe is installed 353.2 uPVC PIPE JOINT ASSEMBLY The assembly of one pipe to another may be performed using various methods. One of the most successful method employs a rubber ring joint, The rubber ring joint may be either of integral socket design (formed as a continuous, homogeneous entity with the pipe) or it may consist of a separate sleeve-type coupling. The joint provides the following advantages: Allowance for expansion and contraction © Reliably assembled in poor weather conditions © Consistent reliability © Flexibility and resiliency abour-saving and overall economy © Ease of installation %.2.1 ASSEMBLY OF PIPES WITH RUBBER RING JOINTS The rubber ring joint should be assembled as recom: uPVC. PRESSURE & NON-PRESSURE PIPES mended by the pipe manufacturer. The elastomeric rings may be supplied separately in cartons or pre- postioned in the socketed joint or the coupling at the factory. When rings are colour coded, besure to consult the pipe manufacturer or his literature for the signi- ficance. In all cases, clean the ring, the socket or the coupling interior, especially the groove are (except when ring is permanently installed) and the spigot area with a rag, brush or paper towel to remove any dirt or foreign material before assembling, Inspect therring, pipe spigot chamber, ring groove and sealing surfaces for damages or deformation. Use only rings which are designed for and supplied with the pipe. Insert them as recommended by the manufacturer. Lubricant should be applied as specified by the pipe manufacturer. Bacterial growth, damage to the gaskets or the pipe, may result from use of non-approved lubricants. Use only the lubricant supplied by the pipe manufacturer. JOINTING METHOD FOR RUBBER RING JOINTS (FOR BELLMOUTH PRESSURE PIPES) “jon lit and gi fr» socket ipartielarly the tng raw f [ign spigot and socket and push pipe home unit reference mark is ust use at socket Completed jin Insert the rubber ring so thal t seats every (Clean the spigot bck to reference marke and apaly lubricant to charfer. Use ork) proper hbicent, DO NOT vse mineral os fr greasos as rubber ring would be ‘versely affected, Do not apply lubecant to rubber ring ax entry of Mbrcant itoring sroove can cause misplacement of tng ‘when pip is pushed home. 36uPVC. PRESSURE & NON-PRESSURE PIPES 3.3 ASSEMBLY OF PIPES SOCKETED WITH SOLVENT CEMENT JOINTING STEP 1 Cutting and Deburring # Make a square cut using a mitre box and fine-toothed panel saw. © Remove all burrs and swarf lightly chamfer the external pipe edge. STEP 2 Degrease the Spigot and Socket (This is a very important step. The priming fluid not only cleanses the surfaces but also prepares them for a high- class joint.) * Clean the pipe and matching socket, using priming fluid to the pipe manufacturer's recommendations. © Keep the cleaned surfaces free of dirt and grease. Failure to do so could lead to failure of the joint, When a joint fails for this reason, the dirt trapped under the solvent coating is stark and indelible evidence of bad workmanship, STEP 3 Apply the Solvent Cement © Pencila line on the spigot to show the depth of socket. © Apply an even coating of approved solvent cement TO THE SPIGOT ONLY, over an area corres ponding to the socket depth STEP 4 Making the Joint * While the surface is stil wet, push the spigot home into the socket with a slight twisting motion. © Hold for 30 seconds without movement. © Remove excess cement with a soft cloth © The pipe may be handled, but not unduly strained for 1 hour. © Wait 24 hours before putting to use 3.4, SOLVENT CEMENT 3.4.1 Standard Types. — High Viscosity, Slow Drying Recommended for pipes of diameters larger than 155 mm. — High Viscosity, Quick Drying Used exclusively in normal jointing operations. Cementing and inserting the pipe should be done as quick as possible. 3.4.2, Estimated Coverage of Solvent Cement Required for Jointing Nom. | Av. No, doints [| Nom. | Av. No, Joints Pipe er 5003 Pipe er 5005 size of cement see of cement 15mm 300 80 mm 30 20 mm 175 100 mm 20 25 mm 130 155 mm 13 32 mm 95 200 mm 8 40 mm 70 250 mm 5 50 mm 38 300 min 2 65 mm 34 L Note: 1 Kg of Cement is equal to 1 Litre approx. 7 / Slightly chamfer DEBURR PALING PRIMING FLUID DEGREASE PALING SOLVENT ‘CEMENT depth APPLY SOLVENT CEMENT TO SPIGOT ONLY Push home with slight twist Wipe off ~~ solvent cement JOINTING4, INSTALLATION OF uPVC PRESSURE PIPE SYSTEMS 4.1 SCOPE This chapter sets out recommendations for the installa tion of uPVC pressure pipe. It comprises four sections as, follows: General Provisions, Installation of Pressure Pipes Below Ground, Installation of Pressure Pipes Above Ground, Testing of Pressure Pipe Systems 4.2 GENERAL PROVISIONS Laying in Direct Sunlight or in Hot Weather Precautions are necessary to minimise the distortion tused by uneven heat absorption where one side is sposed to the heat and the other is in the shade. The pipes should be shaded where possible, particularly during the jointing process so that an even heat is maintained around the circumference of the pipe. In these conditions the pipe should be free to expand and contract. The condition may be suitably overcome by rotating alternative pipes 180 degrees immediately prior to jointing, The syste must not be restrained by rid connections until it reaches ground or service tem- perature. Provision for Expansion and Contraction ‘When pipe is being installed during hot or cold weather, ‘expansion or contraction of the pipeline will take place. In these cases it is recommended that, where no rubber ting joints are included, the pipe be approximately at normal service temperature prior to final connection and back-filing, In a pressure system usingrubber-ringjoints, this may not be necessary. Electrical Earthing Being a non-conductive material, uPVC pipe cannot be used for earthing electrical installations or for dissipating static charges, Electricity supply authorities must be advised by the installer where any parts ‘of existing metal ‘water supply pipelines are being replaced by uPVC pipe. Protection from Heat UPVC pipelines must not be placed adjacent to boilers, hot water or steam lines where the temperature of the pipeline may exceed the design temperature ofthe pipe system, Hydrostatic pressure The hydrostatic pressure capacity of PVC pipeis related to the following variables: © Operating temperature under pressure ¥ Duration of stress application due to internal hydro: static pressure # The Fiydrostatic Design Stress for the PVC pipe material © The ratio between outer diameter and wall thickness The pressure rating of PVC pipe is established by uPVC. PRESSURE & NON-PRESSURE PIPES dividing the long-term pressure capacity of the pipe by the desired factor of safely. Although PVC pipe can withstand short-term hydrostatic pressure applications at levels substantially higher than pressure rating or class, the performance of PVC pipe in response to applied internal hydrostatic pressure is properly based on the product's longterm strength. Research and investigation, through the years, have accumulated vast Quantities of data clearly substantia*ng the reliability of PVC pressure pipe pressure rating and pressure class values. In PVC pressure piping systems, design of hydrostatic pressure capacity can be based with con: fidence on the pressure rating or on the pressure class at the desired factor of safety. Vibration Continuous vibration, e.g. at connections to water pumps, should be avoided, and where necessary, flexi ble joints should be installed to keep vibration to a minimum. Air Lines The use of uPVC pipe for compressed air is not recommended unless special precautionsare taken after consultation with the manufacturer and the relevant Statutory Authority. Hot Water Cylinder Supply Where uPVC pipe is used to supply cold water to a mains pressure hot water cylinder, it must not be installed in the last 1 metre of the connection and a non- return valve must be fitted in the supply ine between the cylinder and the uPVC pipe. Note: This action will ensure that tl syphoned back into the main pipe. This is particularly important where the hot water cylinders are fed directly from pressure mains, Re- ference should be made to British Standard CP 342 Pt 1; Centralized Hot Water Supply for Individual dwellings. Vacuum Conditions ‘Adequate air venting must be provided particularly with thin-walled pipes to prevent excessive vacuum con- ditions arising in pressure pipelines. Anchorage For uPVC pipelines jointed with rubber ring joints, the normal engineering practice of anchoring at changes of direction and other points of unbalanced forces must be followed. This applies to bends, valves, tees, etc. For systems that are jointed mechanically with solvent, anchorage is necessary only in special circumstances. the hot water will not be ‘The size of any necessary thrust blocks will depend on the bearing capacity of the soil or other support and should be determined according to established engineer: ing practice. The design of such anchorages should allow for the test pressure to be applied to the pipeline. 38 and cause failure of the @uPVC, PRESSURE & NON-PRESSURE PIPES ‘When concrete is being placed on a uPVC pipeline, care should be taken to avoid encasing the pipe completely; the maximum encasement should be 180 degrees, unless flexible joints are provided at each concrete face entered (see note). Note: This requirement is necessary because the slight flexi: bility of uPVC may cause pulsing under pressure varia: tion, which will do no harm to the pipe when it is clear of the concrete, but may cause it to shear at the interface between the concrete anchor and the backfill Setting of Pipes in Concrete Where scoring could occur owing to movement of the pipe relative to its surrounding, a membrane (e.g, of polyethylene, PVC or felt) should surround the pipe and fittings to permit movernent without scoring. Where @iittings are installed, sufficient space should be allowed for movement; alternatively, expansion joints should be provided to accommodate movement due to thermal expansion or contraction. Note: uPVC pipe may be totally enclosed in concrete without such protection where the installation is designed for such total enclosure. Flexible joints should be provided at the junction with the conerete. Standpi All standpipes and risers should be of approved material and should be firmly clipped to a suitable support to prevent stress being imparted to the underground pipe in the event of strain being imposed on the standpipe or riser. es and Risers Connections to Water Meters @For meter installations above ground, the uPVC pipe should be terminated approximately 1 m from the vertical risers connected to the meter. The connecting pipes at the meter should be of approved material. For underground meter installations, the meter should be firmly anchored Prevention of Flotation ‘Adequate measures should be taken to prevent flotation of the pipe due to ground water or inundation before completion of back-filling. Local Authority Requirements All installations of pressure pipe must comply with local authority by-laws and statutory regulations where these are applicable, 4.3 INSTALLATION OF PRESSURE PIPES BELOW GROUND Materials Pipes and Fittings Pipes and Fittings laid in accordance with this Section must comply with the requirements of BS 3505 & BS 3506. Bedding Material The pipe bedding material should be material as speci- fied and then approved by the installation engineer. Unless otherwise specified, one af the following ma- terials may be used as bedding material: a) Suitable sand, free from rock or other hard or sharp objects that would be retained on a 13.2 mm sieve. b) Crushed rock or gravel of approved grading up toa maximum size of 14 mm, c) The excavated material may provide a suitable pipe underlay if it is free from rock or hard matter and is broken up’so that it contains no soil lumps greater than 75 mm which would prevent adequate com: paction of the bedding, Unless otherwise specified, the side support and pipe overlay material must be identical with the pipe underlay material Back-Fill Mateiral Unless otherwise specified, excavated material from the site should constitute the backil 4.3.1 INSTALLATION PROCEDURE Cleaning The inside of all pipe and fittings should be smooth and free from sand, grease and dirt before installation. 4.3.2 PIPE INSTALLATION IN A TRENCH Provision of Trench The trench should be excavated, trimmed to the required grade and should be as narrow as practicable. ‘The bed width should not be less than 200 mm wider than the outside diameter of the pipe (see figure 4, dimension B) for pipes of 100 mm nominal size and above and not less than twice the pipe diameter for smaller pipes, Where required, the trench should be wide enough for inspection purposes. ‘The trench should be excavated deeply enough to allow for the specified grade, the required depth of underlay (see figure 4, dimension C) and the minimum cover over the pipe as Specified in table 5 which lists minimum cover requirements for various situations. 39uPVC. PRESSURE & NON-PRESSURE PIPES Backfill - Compacted pipe - overlay pipe side support Compacted | pipe underlay | B min=D+200 mm for 100 mmnom. size and above, or 2D for smaller than 100 mm. 4. PIPE INSTALLATION IN A TRENCH | Pipe overlay 180 mm min Underlay depth (C) 75 mm min af aran 4.3.3 MINIMUM COVER OVER PIPE (Dimension H of figure above) Not subject to vehicular loading 300 mm. Subject to vehicular loading — not in roadways 450 mm. in sealed roadways 600 mm, under unsealed roadways 750 mm. Pipes in embankment conditions or subject to construction equipment loading 750 mm_ Table 5 Notes: 1, Requirements of local authorities may specify dit. ferent depths for local conditions. For deformation due to external loading, designers should refer to British Standard CP312 Plastics Pipelaying Design. Underlay preparation Unless otherwise specified, a graded continuous cushion of underlay material of ‘minimum thickness 75 mm should be provided on the bottom of the trench, Chases may have to be excavated in the bedding to prevent any sockets, flanges ot similar projections from bearing on the bedding. Pipes of any diameter may be laid on the bottom of the trench without underlay provided that: i) the trench bottom will give uniform and adequate support to the pipeline; and 4) the trench is free from hard objects such as stones, sharp projecting rocks, of tree roots Where the pipeline is laid on the trench bottom, the trench bottom should be trimmed to provide continuous support for the pipe. Chases may have to be excavated in the bottom of the trench to prevent any sockets, fangs osm projections from bearing on the trench tom. 40 Where the excavation is in unstable ground or in rock, or where excessive excavation occurs, the depth of ex- cavation and underlay preparation shall be as specified to provide a uniform base to the bedding material for the support of the pipe. Removal of pegs and packing In all cases, care should be taken to remove all levelling pegs or temporary packing, such as ‘wooden blocks, before pipelaying. Pre-assembly and laying Pipes may be joined at ground level and then lowered into position without being dropped, care being taken to void straining the pipes or pipe joints. If rubber-ring joints have been used for jointing they should be checked after the pipe is positioned to ensure that the witness mark is still correctly positioned, The pipes should be positioned along the centreline of the trench. Bends of radius greater than 130 times the minimum outside diameter of the pipe may be accommodated by bending the pipes without undue stress; for curves of small radius, preformed or moulded bends should be used. Sulficient pipe side support and pipe overlay material should be placed in the trench and compacted to restrain the pipes. Joints should be left uncovered for inspection and testing unless otherwise specified. Testing ‘The testing of the pipeline must be in accordance with “Testing of Pressure Pipes Systems” in 4.5, pg. 30. Pipe side support and pipe overlay Pipe side support material should be thoroughly compacted in layers of not more than 150.mm as specified, The pipe overlay material shoilld be levelled and compacted in layers to a minimumheight of 150 mm above the top of the pipe in the trench, or as specified, care being taken to preserve the correct alignment and grade of the pipeline. Back-fill Back-fill material should then be placed on the pipe overlay and compacted as specified to refill the trench. Note: Where shoring is used, special care should be taken to maintain compaction around the pipe during and after its withdrawal, Care should be taken not to damage the Bipes during compaction of beng material ae back fil Pipe Installation in an Embarkment Condition Pipe installation in an embarkment condition should be designed in accordance with British Standard CP 312 and installed as outlined above where applicable. ®@ Flushing After installation, all pipelines should be flushed with water and chlorinated if required by the Statutory Authority before being placed in service. The water temperature should not exceed the maximum expected operating temperature, 4.4 INSTALLATION OF PRESSURE PIPES ABOVE GROUND Materials Pipes and fittings laid in accordance with this Section must comply with the requirements BS3505 /& BS 3506. 44,1 SPECIAL PRECAUTIONS ‘Temperature considerations When ambient temperatures could affect the installation of a pipe, reference should be made to Table 3. In addition, where uPVC pipe is used in cavity walls or roof spaces, particular reference should be made to Table 3. "Derating of Pressure Pipes for Temperature”, as high temperatures are likely to occur in these locations. Protection against direct sunlight uPVC pressure pipes installed in direct sunlight must be painted in light-coloured paints that do not have an oil base, or be otherwise protected. Provision for Thermal Expansion For the coefficient of thermal expansion, refer to graph in Fig. 2 Expansion Joints Expansion joints, as separate fittings, or those which ‘may be incorporated in a fitting, must comply with the uPVC. PRESSURE & NON-PRESSURE PIPES relevant requirements of MS 628 They should be installed in accordance with the manufacturer's instruc: tions in the position shown in the design for the particular installation, Sliding Supports ‘The purpose of sliding supports is to provide a guide, without restraint, for the direction of movement of pipes subject to thermal changes. The clip, or support, should be moulded from a suitable plastics material, or allow for a pipe to be surrounded with a 6 mm thick layer of suitable flexible material, or it should incorporate an approved plastics coating. Sliding supports should be provided in accordance with Table 6. Building into Floors and Walls Unless otherwise specified, any pipe or fitting built into or ‘passing through any floor or wall should be wrapped with a suitable flexible material not less than 6 mm thick; alternatively, a permanent annular space of not less than 6 mm width should be provided between the pipe or fitting and the floor or wall, and suitable measures should be taken to maintain this clearance, Fixed Supports ‘The purpose of a fixed support isto restrain movement of the pipe or fiting, either by clamping it to the structure with a fixed bracket, or by setting it firmly into the structure. Care shold be taken that pipes and fittings are not distorted by overtightening, Fixed supports should be provided at every fitting that incorporates a provision for expansion and at the lower part of every separate expansion fitting to prevent movement of the fitting. This includes the sockets of all rubber-ring jointed pipes used in the installation. Where expansion joints are required, care should be taken to see that fixed supports altemate with expansion joints throughout the installation. Rubber-ring joints on pipes ‘may be regarded as expansion joints if so recommended by the manufacturer. Spacing of Supports for uPVC Pipelines UPVC pipe should be supported at intervals which depend on the density ofthe uid being conveyed and on the maximum temperature likely to be reached by the pipe material. Table 6 shows recommended maximum spacings of support of al classes of pipe where water is the fluid being conveyed. 4luPVC. PRESSURE & NON-PRESSURE PIPES RECOMMENDED MAXIMUM SPACING OF SUPPORTS FOR ALL CLASSES (OF PIPE FOR WATER Table 6 Recommended maximum spacing of Nonsinal Size supports) j of Pipe Horizontal of Vertical pipes | graded pipes \ 7% 050 100 ® oe im 2 a0 14 % ors 150 2 oss Ln @ 090 im F 3.08 210 & 1 240 % 13 210 100 130 300 2 Ln 340 1 200 400 1% 220 oa 6 20 250 a) me 200 300 m0 ae 320 x0 500 éo0 a When ambient temperatures or the temperature of pipe lids are such that the temperature of Heer aras is Tely to be greater than 20°C, the support distances should be reduced ie minal. Where material temperatures are likely to approach 60°C and the pipe is horizontal, accor nal porto the pie is recommended: for vertical installations, the valuesin the above ‘Table for horizontal support should be used. Heavy fitings such as valves should be supported independently, and lage Pastis fitings (es Facaee pentcularly those with metal backing rings) should be supported on each ske. Where Fina ere continuously sudported, fanged connections and other protrusions shoul be allowed oom for movement. Protection Against Damage All pipes and fittings shou ‘aces where they may be damaged, onstruction. 4.5 TESTING OF PRESSURE PIPE SYSTEMS Pre-test Precautions For uPVC pipelines whic! pipe length must be part prior to the test, except otherwise specified. Solventjointed pressure pipelines should not be pres- sure tested until at least 24 hours after the last joint has been made. The manufacturer should be consulted if a shorter time is desired. General Requirements The pipeline may bs depending on the lens! availabilty of water, and valves or blanking ends. properly supported and, frubber-ring jointed, anchored during the test, Testing must not High-pressure air testing is not recommended because Anchorages areadequately of safely considerations and may not be permitted by the to prevent movement bbe done before any concrete. cured. Dam agS auately protected in Suitable water shouldbe used to fil the test section apd, sy during after a free air is removed from the section, a smoothly +h are rubber-ring jointed, each tly backfilled and restrained t for the joint itself, unless ¢ tested as a whole ot in sections, ; ested ce Or Siae the TOensure tha all permanent valves ina test section ae i ; : the spacing between sectr2S held inthe secionby iting temporary valves or blanking operating pressure pump should be used to raise the pressure to that required for the test. @ Note: Where positive displacement pumps are used for the test, they must have suitable pressure relief provisions: ‘The pressure in a test section should be read from a gauge placed as close as practicable to the lowest point ‘of that section. The gauge should allow accurate reading of pressure changes of 1 per cent of the test pressure. ‘A marked loss of test pressure, together with visual inspection of the test section for leaks, is used as ‘evidence of failure of the test section. ‘Account should be taken of the pressure loss due to pressure expansion of the pipe. ‘An increase in pipe temperature will also result in a pressure drop. tested, they should be kept open and the pressure be ends where necessary. relevant Statutory Authority. DOTesting Procedure A test pressure! of 1.5 times the design pressure®, or such lower pressure as may be required by the Statutory Authority, must be applied to the section under test. The test section should then be allowed to stand without make-up pressure. If there is no evidence of leaks of the test water after one hour under pressure or for such shorter time as agreed between supplier and purchaser, the section is deemed to have passed the fest. Requirements for this test is to CP 312 Part |: 1973. The Australian Standard AS 2032 — 1977 allows for a less stringent test of 15 minutes. Pressure Test on Valve Anchorages Sections The joints between test sections must pass the test procedure in the Rule — “Testing Procedure” above. Pressure Test on Valve Anchorages Valve anchorages must withstand the forces developed when the test pressure required in “Testing Procedure” isapplied with the valves closed. Pressure Test on Existing Pipeline Ia hydrostatic test is required on a pipeline already in service, the maximum test pressure is limited to 1.5 times the maximum design pressure for a maximum, time of 15 minutes. Notes: 1, Test Pressure — The hydrostatic pressure applied intemally to the pipe or the fiting to test strength and Wwatertightness. This pressure is the masxirmur that will ‘occur in the system during testing and is that mea- sured at the lowest point. . Design Pressure — The maximum pressure, resulting from the combination of static and dynamic pressures, that could possibly be imposed on the pipe or the fiting during its operating life. It must not exceed the maximum allowable working pressure.? Maximum Allowable Working Pressure — The maximum pressure that can be sustained, with a factor of safety, by the type or class of pipe or fing for its estimated useful life under the. anticipated working conditions, Values are as set out in the rele- vant Standards. 43 uPVC. PRESSURE & NON-PRESSURE PIPES Appendix 1 (refer to page 18) Example: To calculate the minimum wall thickness, tin required for a 200 mm class B pressure pipe sub- Jected to the following extemal conditions: © Depth of installation, h = 0.6 m © Wheel pressure from a truck of 20 metric tons. From Fig. 1 above, External pressure, P) + Pz = 0.7 Kg/emn® From pg, 17, formula (6), From pg. 4, minimum radius of 200 mm Class B 8.8mm _ e = pressure pipe, tin 109.4 mm. From pg. 4, Paling’s 200 mm Class B pressure pipe, Code No. 100.200.6B, minimum wall thickness to BS 3505 is 5.3 mm,uPVC, PRESSURE & NON-PRESSURE PIPES MALAYSIA BS 3505 (M.S 628) BS 3506 (M.S 762) BS 4346 PART 1 & 2uPVC, PRESSURE & NON-PRESSURE PIPES SALES ENQUIRIES Enquiries for PALING products should be addressed to:- PALING INDUSTRIES SDN. BED. LOT 12, JALAN PERUSAHAAN EMPAT, 68100 BATU CAVES, SELANGOR, MALAYSIA. CABLE: “PALINDUS" KUALA LUMPUR, co Contact TEL: 03-6898333 FAX: 03-6883810 ‘TELEX: MA 30824 PALING CABLE: "PALINDUS” KUALA LUMPUR, RANGE OF PRODUCTS PALING manufactures a whole range of plastic products for the building and construction industries. Call us for our catalogues on the followi 1) uPV.C. pressure and drainage pipes and fittings system. 2) uP.V.C, drainage and sewerage pipes and fittings system, 3) uP.V.C. soil, waste and vent system, 4) Electrical conduits and fittings systém. 5) Sanitary wares, fittings and accessories. 6) Building products ~ bar spacers, safety helmets, waterstops, etc. British Standards Codes of Practice When designing and installing PALING uP.V.C. pressure pipe systems, reference should also be made to BS Code of Practice CP 312 Part 1 — General Principles and choice of materials. BS Code of Practice CP 312 Part'2 ~ uPVC pipe- work for the conveyance of liquids under pressure MARCH, 1994 Edition ‘SUPERSEDES ALL PREVIOUS ISSUESSECTION 3 - DESIGN CRITERIA & STANDARDS SUB-SECTION 2 - PLUMBING & DRAINAGE CONTENTS 2.1 Introduction 2.2 Water Supply 23. Soil and Waste 2.4 Storm WaterKUALA LUMPUR SENTRAL Rail Facilities Plumbing and Drainage STATION & INFRASTRUCTURE PROJECT Page No. 7-3-2-1 PLUMBING AND DRAINAGE 2.4 Introduction This section provides the Design Criteria for plumbing and drainage systems in the station and the maintenance facility. Systems include the following : A. Water supply B. Sewerage and waste water C. Stormwater System and equipment requirements for plumbing and drainage are presented in the plumbing and drainage technical specification. 2.2 Water Supply A. Domestic Water 1. Passengers 5 litres/day/person 2. Employees 26 litres/day/person 3. Restaurants 0.5m"/day/m? 4. Dormitories 300 litres/person ‘The Detailed design should be made on fixture ratings. B. HVAC 1 Allow 2% for evaporation, drift and bleed 2. Allow for cooling water; 780 I/h RT, based on 5°C range Prepared By ZATNUDDIN PARSONS BRINCKERHOFF (M) SDN. BHD. Ist, March 996KUALA LUMPUR SENTRAL Rail Facilities Plumbing and Drainage STATION & INFRASTRUCTURE PROJECT Page No. 7-3-2-2 C. Storage The provision of cold water storage to cover interruption of supply will be based on the following —_, aeR (PRIVATE ] Demand/day | Storage (40%) Llory )Application (I/day) (litres) 180 WCIToilet 900 380 180 Urinal 400 160 | Lavatory (hand/basin) 2490 96 ge Wesh basin 960 384 Gores | Kitchen sink 1200 480 4o Cleaners sink 510 204 Geo Shower 780 304 Cleansing water bibs 600 240 Either use main storage tank with 40% of one day demand capacity, without elevated service tank, or use service tank with 30% of one day demand capacity (including HVAC) plus elevated service tank with 10% of one day demand capacity. D. Building Occupancy Offices 0.1 persons/m* Commercial Areas 0.2 persons/m? Station Depot 0.15. persons/m? Allow diversity of 35% on station areas. E. System Pressure Minimum pressure at outlet, 15m Maximum pressure at outlet, 50m Prepared By ZAINUDDIN PARSONS BRINCKERHOFF (M) SDN. BHD. Ist, March 996KUALA LUMPUR SENTRAL Rail Facilites Plumbing and Drainage STATION & INFRASTRUCTURE PROJECT Page No.7-3-2-3 F. Pipe Velocities Max velocity 2.5n/sec. 23 Soil and Waste A. Fixture units shall be based on data in the National Plumbing Code the Uniform Plumbing Code and the local code. B. Grease traps shall be sized for a 20 minute retention time C. Contaminated drainage from the Depot as shown on the drawings shall be cleaned prior to discharge to sewer. 2.4 Storm Water A. Rainfall Intensity Roof drainage systems shall be designed in accordance with rainfall intensities for 10 minutes duration for 50 year rainfall intensity, is 180mm/hour. B. Sump Pump Sizing . Q=CTAss600 Where Q- flow litres/ssecond C- constant - 1 I intensity, 180mmv/h A-collection area m? Allow flow for 10 minutes. Large seepage flows are not expected, therefore these should be ignored for sizing the peak stormwater drainage. C. Pipe Sizing Design pumped services for 2m/sec, Prepared By ZAINUDDIN PARSONS BRINCKERHOFF (M) SDN. BHD. Ist, March 996KUALA LUMPUR SENTRAL Rail Facilites Plumbing and Drainage STATION & INFRASTRUCTURE PROJECT Page No.7-3-2-4 Downpipes Wherever practical downpipes shall be located extemal to buildings. Where large roof areas require internal downpipe to be provided, these should be insulated when installed in ceilings above conditioned spaces. Typically two or three roof drains of 100mm diameter, (for 100m? roof) shall connect to a downpipe of 150mm dia. D. Maintenance Depot, Site Stormwater Drainage Planning Principle l The boundary of the maintenance depot shall be provided with a main drainage system to collect all drain or stream flows to and from it. 2 ‘The main rainwater flow shall be intercepted and led directly to the main drainage system so as not to intrude into the maintenance depot. The rainfall intensity for the purpose of designing the drainage system shall follow the relevant Authority's standards for urban drainage so as to coincide with the capacity of its existing drainage system. Prepared By ZAINUDDIN PARSONS BRINCKERHOFF (M) SDN. BHD, Ist, Mareh 996Kuala Lumpur Sentral Station and Infrastructure Project A24 WATER SUPPLY AND DRAINAGE A2.4.1 Introduction The proposed development of Kuala Lumpur Sentral is on a development of integrated office, office towers, retail and entertainment complex, hotels of international business class as well as a budget hotel and parking space. The office towers will be constructed on the concept of a Corporate Park, with stand alone buildings to be sold to corporations wishing to have their own headquarters. A241. Assumptions & Design Criteria The concept for the Water Supply & Plumbing services, has been designed to meet the following requirements: 2) There shall not be any service/equipment which requires routine maintenance to be routed/located over the train track area. However, certain piping would inevitably have to be located just below the deck structure running over the train track area. ‘Where these are unavoidable, they shall be run in services ducts. Access for replacement or inspection shall be provided from above the deck in the form of removable trench covers, ») The water supply & plumbing services for the respective decks have been based On. the normal requirements of the Uniform Building By-Laws & Jabatan Bekalan Air (IBA) as the specific usage of each deck area has yet to be defined. ©) The water supply & plumbing services for each deck area shall be of the stand alone type distinctly separated from other areas ie the Station, Maintenance Depot, etc. Integration with other areas shall only be carried out as and when the water & sanitary requirements for the adjoining areas are more clearly defined. ed) Itis assumed that all waste pipes will be drained to the under rail drainage system °) Design criteria to be adopted shall be as per the criteria set by JBA, the local - authorities and the prevailing local Malaysian Standards. _ Limitations The available space to run the water supply & plumbing services below the deck for the track & platform areas is dictated by structural elements such as the thickness of the deck slab, the depth of the proposed deck beams, etc as well as the required clearance over the railway, b) For the upper deck levels the Contractor shall determine the minimum clearance needed to accommodate the piping, fittings, etc for the above services. Over the track area, a minimum clearance from the track to the bottom of the services of 5.50m has e been confirmed by KTMB. . °) In the development of the deck, the designers shall pay particular attention to the limitations imposed due to the structural elements and the overtrack clearances, In _ ] carrying out the works, it should also be appreciated that the tracks will be fully 7 ) QD | operational and installation and servicing of the equipment will need to be carried out i | { in possession/isolations agreed with KTMB.Section C, Part II Design Concept, Appendix A . March 1996 A24.1.3 General Concept Following the applicable local authority regulations & by-laws pertaining to the Water Supply & Plumbing services, it is obligatory for the deck area that constitutes part of this Contract to be provided with a comprehensive range of such services. The water supply system for each deck area shall be 2 stand alone system with its own water storage tanks, pumpsets, etc, The storage tank for domestic water though designed to cater for landscaping water demand, shall be separated from the tanks for the HVAC system & fire protection services. It is proposed that for the deck areas, the gravitational flow system be not adopted for the moment but water be supplied to the various outlets using a pre-pressurised hydro- pneumatic system, As for hot water, itis felt that there is no requirement at the moment for a central hot water system but should hot water be required, individual hot water heaters of the instantaneous type or storage type be employed. The sanitary system shall be designed to dispose off soil & waste from all plumbing fixtures & drainage points inclusive of drainage from the landscaping of the upper decks through a vented gravity piping system either to external manholes or to the under rail drainage system. All kitchen waste shall be discharged though grease traps & separate stacks shall be also employed. For the lower car parks areas, oil interceptors shall be frovided in the drainage system to prevent fouling of the system. ‘The above system shall be replanned & reconfigured to suit the final phasing é& usage of the deck areas, ‘Water to the domestic water storage tank shall be supplied through a 200 mm mild steel concrete lined pipe tapped off from the existing water main running along the Jalan Travers/Jalan Damansara site boundary, This incoming pipe shall run along the intemal road & enter the deck area plant room, The sanitary system shall comprise 150mm UPVC soil/waste pipe stacks, rising through the deck levels & drained through 150mni ait iron soil pipes to either external manholes or under rail waste/drainage system provided by others. This system shall be a vented gravitational flow system that will also provide drainage for the landscaping of the upper deck area. Particular attention shall be placed on the horizontal runs of the sanitary system especially over the track area where the mandatory slopes required for flow é the structural elements might cause problems in achieving the specified minimum clearance of 5.5m imposed by KTMB. We propose to run the sanitary system pipes together with the pipes for the other wet services ie water supply, fire protection, etc. in defined services routes as indicated, but these need to be developed as further information is available. A242 Water supply A24.2.1 Current Situation The existing supply of water to the Kuala Lunipur Sentral is obtained from an existing 600mm dia, mild steel pipe along Jalon Travers. Other XTMB buildings and quarters on Jalan: Tun Sambanthan side get their supplies from an existing 150mm dia. pipe along Jalan Tun Sambanthan, by means of direct tappings The existing reticulation system is old and-in-a deteriorating state. Page 24 of 32Kuala Lumpur Sentral Station and Infrastructure Project For the purpose of new development, new water reticulation system has to be constructed. JBA has proposed a new source of water to be obtained from an existing 800mm dia mild steel pipe along Jalan Syed Putra ‘The Safe Water Pressure (SWP) at the proposed tapping point is 200 feet Ordinance Datum Level (ODL) of head of Water (61m ODL). Refer to JBA letter ref. Bil (2) dlm B.A. Sel. 1 16111//93 which is dated 22 February 1995, A2.4,.2.2 Future Water Demand The ultimate estimated Water Demand is 2.4 MGD (Million Gallons Per Day) for year 2001. The derivation of water demand and year required is shown inbampiranvA’y A2.4.2.3 Design concept The proposed water supply reticulation system for the development site is shown overleaf. ‘The supply of water to the development site is to be obtained from an existing 800 mm dia mild steel pipe along Jalan Syed Putra to replace the existing tapping point which shall be disconnected upon completion of the new water reticulation system. A pipe crossing is to be constructed across Sungai Kelang. The transmission pipeline is to be laid along Jalan Tun Sambanthan 4. There is a limitation of space available due to the nature of development, where in addition to commercial buildings, a central railway station and rail related facilities have to be provided. ‘Moreover with the provision of railway tracks splitting the project site, itis inevitable that all roads have to be elevated decks. Therefore the loop reticulation / transmission pipeline within the project site, feeding the individual buildings suction tanks is proposed to be buried at ground level. All high rise buildings eg. office towers, hotels or other constructions will have their own pumping, systems. The 1-day storage will shall be located at the roof top of the buildings. This is currently the subject of a planning appeal lodged with the Local Authority. The reticulation pipes shall be mild steel pipes PN 16, bituminous coated & wrapped and cement lined. Such work will be carried out strictly in accordance with KTMB regulations. The Contractor will be responsible for liaising with adjacent contractors and designers in order to determine his take off pdints from adjacent supply systems and to take into account all phasing activities. A2.4,3° Water reticulation Analysis/Communication Pipeline A2.4.3.1 Design Criteria The reticulation system characteristic shall be designed to meet the following:- a) Maximum flow velocity "V' should not exceed 0.6 m/sec, b) Peak flow factor for reticulation pipeline shalll be 2.5, °) Peak flow factor for transmission pipeline shall be 1.2. ¢) Hazen-Williams equation with Hardy-Cross analysis is used for hydraulic calculation and simplified as follows:- HL = 10.705 cy pi?Section C, Part II Design Concept, Appendix A 8) 4) i) d k) LI s) ) u) March 1996 where: HL Head Loss (m) q Design Flow ( m*/sec) c Pipe Coefficient = 1 00 D internal Diameter of pipe (ni) Minimum pipe gradient should not less than 1:500 Minimum cover to crown of pipe shall be 1.0m and maximum cover shall be 2.0m. Where these conditions cannot be met, the pipes shall be surrounded with minimum 150mm mass concrete Pipe material coefficient "C" is 100. Fire hydrants of double pillar type shall be located at approximately 90m intervals within the reticulation system and its layout shall be approved by BOMBA. Pipe materials shall be mild steel pipe (M.S) of PN 16. Alll pipes laid adjacent or under the roadway shall have minimum cover of 1.2m to the crown of pipe. Mild steel pipe laid across the railway tracks shall use pipe jacking method for construction. The cover shall be appropriate to the situation and satisfy KTMB requirements. All valve chambers shall be brick ¢hambers, except for fire hydrant valve chambers. Isolating valves shall be located within the reticulation system at suitable locations for maintenance purposes. Minimum residual pressure shall not be less than 22m of head of water. Minimum pipe size with the fire hydrants within the reticulation system shall not be less than 150mm. Minimum storage for a suction tank shall not be less than 1 hour of pumping period either not more than 1/3 of total 1-day storage capacity. 1-day storage capacity requirement shall be the combination of suction tank and storage tank capacities. All pumping system shall have 100 % stand-by pumps. Mild steel pipes of PN 16 and designed for maximum working pressure of 15 bar. Thrust blocks for bends and tees shall be designed to sustain 1.5 x working pressure with a safety factors of greater than 2.25 times working pressure. Air valves shall be installed at highest point, points which constitute changes of direction and slope. For position of long descending/ascending pipeline, the spacing shall be < 1,000mm., Scour valves shall be installed at lowest points in pipeline. ‘Minimum riser for culvert crossing shall be 300mm. Size of scour valve in pipeline shall be one third of pipe diameter, Minimum hydraulic gradient in pipeline shall not fall below 5.0m to the crown at pipe to avoid air pocket and column separation, Page 25 of 32Kuala Lumpur Sentral Station and Infrastructure Project A244 Foul Sewerage A244.1 —Introduetion : ‘The project site is within the DBKL's Pantai Sewage Catchment where the sewage will be treated at the Pantai Sewage Treatment Plant located approximately 5.4 km to the south-east of the development area, ‘The sewer trunk that carries this waste discharge is running along the Sungai Klang. 4244.2 Existing Conditions ‘The existing sewer reticulation is a continuation from Bukit Damansara and Bukit Tunku sewage catchment area and cuts through the project site. These sewers form the network with the existing system within the project site, The existing main trunk comprises of 450mm and 525mm dia sewer pipes running along the main drain. The outlet is at the Jalan tun Sambanthan/ Jalan Travers junction. Most of these sewer pipes will be abandoned and a new sewer reticulation system will be laid and combined with the existing sewers which are not affected by the development viz. Pos Malaysia and Shell Petrol Station buildings. A244.3 Design Concept ‘The sewerage system for the project site shall include the existing sewage discharge from the existing development area. The capacity of this discharge is estimated to be 9,050 P.E. (Population Equivalent). Hence, the total discharge capacity based on the project population from the proposed development and the present supply is in the figure of 59,487 P.E., This estimation is based on recommended population equivalent from Guidelines For Developers Produced by Jabatan Perkhidmatan Pembetungan, As the proposed sewage system is expected to be connected to the main publi trunk sewer line which is now operated by IWK, contribution is expected to be given to the Indah Water Konsortium (IWK) Sdn Bhd. The cost of construction of the sewer line from the project site to the main sewer can be considered for deduction from the contribution to be made to IWK. 424.44 Design Criteria ‘The sewer reticulation in the project site shall be designed to meet the requirement to M.S. 1228:1991 - Code of Practice for Design and Installation of Sewerage System by SIRIM and Guidelines for Developers on the Design and Installation of Sewerage System, Section 1 - Multi-Unit Housing and Mixed Development by Jabatan Perkhidmatan Pembetungen, Kementerian Perumahen dan Kerajaan Tempatan, Malaysia, - A244:5° > Hydraulic Desigmof Gravity Sewers @ Uniform flow equation derived by Colebrook and White has been adopted for the computation V=2(2gDi)Log ks + 251 7D D(2gDi) Q (VAX 103) ‘Where A= Cross Sectional area of flow (m*) D diameter of pipe (m) . g gravitational acceleration 9.8m/s* i Hydraulic gradient(%) ks Linear measure of roughness (m) Q Discharge (Vs) v mean velocity of flow (m/s) v Kinematic viscosity KS 0.6mm when velocity is greater than 1 M/s Design)Section C, Part II Design Concept, Appendix A March 1996 v 1.4 x 10° m2/s for water at 15°C vy Minimum velocity at full flow (m/s) Maximum velocity at full flow (m/s) (ii) Minimum Velocity at full flow = 0.8 avs/s (iii) Maximum Velocity at full low 4.0 m/s A244.6 Peak low Factor Peak Flow factor 4.7 xp*"' where p is estimated PE in thousand. A2.4.5 Surface Water Drainage) In the Kuala Lumpur Sentral development the major part of the project area is covered by tracks, These areas will be covered by elevated structures (‘decks’), comprising of parking bays and elevated road services, The surface drainage for this vast area has to be designed to prevent any ponding, This surface discharge will be collected and brought down to a storm water ground drainage system by vertical drainage pipes. Keeping in mind the aesthetics of the development, itis Proposed to conceal these vertical drainage pipes in the supporting columns or anchored to column with facade, ductile pipes or UPVC class "D’ is required for the vertical drainage pipes. As the positions of the column may vary at varjous levels, there will be constraints in running the drainage pipes vertically. These pipes may have to be linked by conerete troughs or pipes anchored to the soffit of the decks and brought down at predetermined ground columns and these to discharge into catch pits along the storm water ground drainage system. It is to have a ground Grainage system either of closed or open drain and is then to discharge into the main drainage culvert which runs across the site. The drainage system for the station roof and other areas must also meet stringent aesthetic criteria and perform its required function. : ‘The drainage in the locomotive maintenance yard will have to be accommodated at the periphery of the building as no vertical drain pipes are allowed to be constructed within the yard area. Concrete Grainage troughs have to be provided along the edge of the maintenance deck area and drainage pipes provided at vantage column points to drain the deck drainage to ground drainage system. The Contractor must be aware of the phases which will have to be considered when designing the drainage system. The performance of the drainage system must satisfy the requirements for adequate and properly functioning system at all times during the various phases namely; Phase 1 defined as the works comprising the Contract Phase 2 defined as the completed site Track Drainage all drainage relevant to track areas A25 COMPATIBILITY WITH FUTURE DEVELOPMENTS The contractor is required to be aware of future developments adjacent to the project so that the services installed for the station, depot and infrastructure do not prevent the planned extension of services, A286 DRAWINGS The design principles of the water services are shown on the drawings overleaf. Rae Ppl . Kb. easier, Foo Rife 16 [Reem he. Fox 10 0S Hog, Page 26 of 32