Professional Documents
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CONTENTS
Company Profile
Design Considerations
Accreditations
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Glossary
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COMPANY PROFILE
FLO-TEK is one of the leading manufacturers of unplasticised Polyvinyl Chloride (PVC) pipes, High Density Polyethylene (HDPE) pipes and Rotomoulded products in Southern Africa. History
Radical Investments (Pty) Ltd, trading as FLO-TEK PIPES & IRRIGATION was established in Botswana in 1998 manufacturing PVC pipes. In July 2003 and June 2004, FLO-TEK started manufacturing rotational moulded products and HDPE pipes respectively. FLO-TEK was established in South Africa in 2005. A HDPE pipe factory was started in Clayville in August 2007. FLO-TEK South Africa has since opened a branch in Cape Town and a subsidiary company in Dundee. FLO-TEK has an established company in Angola. To date, FLO-TEK has successfully qualified for numerous government, parastatal and NGO projects and tenders on grounds of its present BEE status. Progress towards a progressive but realistic strategic economic empowerment target, both directly and indirectly, is being made on a broad front. Leadership of the overall transformation programme rests with the management and the stakeholders oversee the application of the Transformation and broad-based BEE Strategies within the organization.
The Benefits
Resistance to abrasion and scouring Resistance to attack by acid or alkaline soils Impervious to chemicals found in sewerage Good flow characteristics Not damaged by modern cleaning methods Good impact properties, an important factor in installation, transportation and use Durability and toughness - resistance to handling and installation damage Corrosion resistance - greater service life Lower mass - ease of handling and installation, particularly suited to labour intensive projects Ease of repair Elastomeric, locked-in sealing ring system no specialist installation skills required Service performance in excess of 50 years Unique combination of properties Toughness Stiffness High Tensile and hoop strength Excellent resistance of creep Predictable long-term behaviour
Physical Properties
PVC is a thermoplastic material which consists of PVC polymer compounded with varying proportions of stabilizers, lubricants, fillers, pigments, and processing aids. Different formulations of these ingredients are used to obtain specific properties for different applications. Pipes can therefore be developed to meet the requirements of a wide variety of applications and conditions. The major part of each formulation is PVC resin.
DESIGN CONSIDERATIONS
Hoop Stiffness and Creep Rupture Strength
The hoop stress (from Barlows formula) is plotted against the time (in hours) to rupture, using log scales on both axes. The resultant creep rupture regression lines for PVC-M pressure pipe are given below at two temperatures, i.e. 20C and 60C.
100 90 80 70
60 50 40 30
GRAPH
20
10 0.1 1 10 100 1000 10 000 100 000 1 000 000 10 000 000
Time (hours) Stress Time Lines for PVC-O, PVC-M and PVC-U
PVC-O regression line as per SANS 1808-85 PVC-U and PVC-M regression line as per SANS 966-Parts 1&2 PVC-O design stress, SANS 1808-85 (28 MPa) PVC-U design stress, SANS 966-1 (12.5 MPa)
Notes
1. 20C Regression Line The line for PVC-U and PVC-M meets the requirements of SANS 966 while the line for PVC-O meets SANS 1808-85 2. 60C Regression Line 1000 hour failure stress (12,5MPa) as per ISO 4422 and UK Water Industry Spec No. 4-31-06 (1990).
Hydrostatic Strength
The addition of modifying agents reduces the short term strength but leads to a considerable increase in toughness in PVC-M pressure pipe, especially the resistance of the material to the propagation of cracks. The 1 hour hydrostatic strength at 20C of PVC-M is 40Mpa, compared to 42Mpa for PVC-U pipe. The failure stress of both PVC-U and PVC-M at 50 years is similar, i.e. 25/26MPa. Testing at elevated temperatures is essential for the identification of ductile-brittle transitions. Should operating temperatures rise above 25C the working pressures should be de-rated.
Impact Resistance
The measurement of the impact performance under external blows is a major requirement of SANS 966:2006. The ductility of PVC-M pipe is shown by the standard quality control test for impact; when impacted by masses of up to 30kg dropped from a height of 20m, there is no evidence of brittle failure as experienced with PVC-U.
DESIGN CONSIDERATIONS
Design Stress (os) and the Long-Term Safety Factor
The design stress is defined as the constant stress that the pipe wall can withstand for 50 years, with a defined safety factor. A safety factor or overall service (design) co-efficient (C) is applied to take into account minor variations in pipe quality, the possibility of the occurrence of brittle failure, slight surges or fluctuations in pressure or superimposed bending stresses or point loads on the pipe, or slight surface damage resulting during installation (refer SANS 966, SANS 1808-85 and SANS ISO 4427). Thus the safety factor is applied to account for any unknown loading or environmental conditions. The design stress is derived from the stress-time line which gives the minimum required strength (MRS), as follows: os = MRS C os Where MRS C - Design stress - Minimum required strength at 50 years - Design coefficient (safety factor).
NB. The maximum recommended working temperature is 60C. PVC-U pipes designed as per SANS 966 Part 1 have a safety factor of 2.5 for pipe diameters of 90mm and below, and 2.0 for pipe diameters 110mm and above. These safety factors relate to design stresses of 10.0 and 12.5 MPa respectively. DESIGNATION MRS (MPa) DESIGN STRESS SAFETY FACTOR PVC-U (< 90mm) PVC-U (< 110mm) PVC-M 26.0 2.6 2.6 10.0 12.5 18.0 2.6 2.0 1.4
Compressed Air
Normal forms of PVC pipes should NOT be used for the reticulation of compressed air there is however, a limited range of specially formulated PVC pipes with specialized couplings systems that are used in the Mining industry for compressed air. The pipes can withstand the normal pressures of compressed air but for the following reasons their use is not recommended for conventional industrial-type applications: 1. Compressed air expands violently and dangerously if allowed to. 2. PVC pipes can be accidently damaged, while pressurized, with potentially catastrophic consequences. 3. When air is compressed its temperature increases with resulting consequences for the pressure handling abilities of PVC pipes. 4. Most PVC pipes have rubber ring jointing systems which are not designed to handle thrust unless special precautions are taken.
Examples based on the above are as follows: A PVC pipe will expand or contract by 0.06mm per metre per C change in temperature. A HDPE pipe will expand or contract by 0.2mm per metre per C change in temperature. A 30 rise in temperature will cause an increase in length of 10.8mm (.06 x 30 x 6) on a 6 metre length of PVC pipe and an increase of 36mm (0.2 x 30 x 6)on a 6 metre length of HDPE pipe.
Bending
An important feature of PVC pipes is that they may be deliberately bent, within limits, thus eliminating the need, in some cases, for separate bends. As a rule of thumb the radius of such a bend must not be less than 300 times the pipe diameter. In addition each rubber ring joint can accommodate a further 1/2 of bend. This feature significantly reduces costs and speeds up installation times when compared to some traditional pipe materials.
1. Cutting
PVC pipes can be easily cut using a number of different cutting tools, such as proprietary cutting tools which cut, deburr and chamfer in one operation, circular saws or hand saws. It is important to ensure that, after cutting, the pipe end is thoroughly deburred.
20 25 32 40 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400
Jointing Procedure
Assemble all the required fittings, pipes and equipment. See below:
3.2. Chamfering
The spigot end of all rubber ring jointed pipes is chamfered at the time of manufacture. Chamfering facilitates the insertion of the spigot end into the socket of the next pipe without damaging or dislodging the rubber ring. If however, the chamfering has been cut off it is important to re-chamfer the end correctly. Re-chamfering can easily be done using a file that leaves no sharp edges which may cut the rubber ring. It should be at an angle of about 12 15 and the length of the chamfer should be such that at least half the wall of the thickness is removed. The chamfering should not be done to such an extent that a sharp edge is made at rim of the bore. a b
3.3. Lubricant
It is the most important to use correct lubricant when making a joint. The lubricant considerably reduces the effort required to insert the spigot into the socket and at the same time minimises the possibility of dislodging the rubber ring. The lubricant should be water soluble, non-toxic and of a gel consistency. Alternative lubricants such as oil, grease, diesel, dishwashing liquid, etc. must under no circumstances be used.
ACCREDITATIONS
SANS 791 / SABS 791:2004 ISO 9001:2000
Transportation
A flat-bodied vehicle is ideal for transporting pipes. Pipes with integral cuffs should be loaded and spaced so that cuffs protrude at alternate ends. When a mixed load of pipes (i.e. varying diameters) is to be transported, the larger pipes should be placed at the bottom. Pipes should not overhand the vehicle by more than 1 metre.
SAPPMA
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GLOSSARY
Circumferential Hoop Stress
The stress induced around the wall of a pipe as a result of pressure within the pipe.
Design Stress
The stress induced into the wall of the pipe when operated at its rated pressure
Factors of Safety
MRS divided by the Design Stress
Flow Rate
This is the volume of water (or other fluid) that is flowing through a pipeline. It is often measured in Litres per Second (l/s) or Litres per Minute (l/m).
Flow Velocity
The speed at which water is travelling along a pipeline. A particular volume of water will have a higher flow velocity in a small diameter pipe than in a large diameter pipe. It is measure in metres per second (m/s).
Friction Factor
Every type of pipe offers different amounts of resistance to flow (or friction) to the flow of water. Extensive research has established friction factors for each type of pipe. Pipes with low friction factors will typically be more energy efficient to operate.
Friction Losses
The friction factor for the pipe being used, the volume of water flowing through the pipeline and the length of the pipeline, will result in a specific amount of friction loss. The friction loss is measured in a number of ways, for example kPa/ 100 metres or metres per 100 metres.
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Solid Wall
The pipe-wall of these pipes consists of a single layer of solid PVC.
Water Hammer
When the flow of water in a pipeline is suddenly stopped it is possible, under specific circumstances that a shock wave of very high pressure can be caused to travel rapidly up and down the pipeline. This shock wave is known as water hammer. Severe cases of water hammer can be heard as very rapid banging in the pipeline and can cause serious damage. Proper design of the pipeline can eliminate Water hammer.
Wave Celerity
The physical properties of every type of pipe material and the dimensions of the pipe itself have an influence on the speed at which the shock wave of water hammer travels in the pipeline. This speed is known as the Wave Celerity and is measured in metres per second. Higher values of wave celerity result in higher peaks of water hammer pressure.
Working Pressure
This is the maximum pressure at which the pipe is designed to operate. It is measured in a number of different ways. e.g. Metres of water, kPa or Bar.
PN
This is the abbreviation for Pressure Nominal and is commonly used as a Pressure Classification number for a particular pressure class of pipe. For example a PN 12 pipe is designed to operate at 12 bar.
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Sales Offices
No. 31 Keramiek Street, Clayville, Extension 14, Johannesburg, South Africa, 1665 Tel. No.: +27 11 316 6891 Fax No.: +27 11 316 6896 13, 8th Avenue, Kensington, Cape Town, 7405 Tel. No.: +27 21 593 6040 Fax No.: +27 21 593 1193 45 Gray Street, Dundee, 3000 Tel. No.: +27 34 218 1236 Fax No.: +27 34 218 1237 Plot 22112, Kgomokasitwa Road, Gaborone West Industrial, Botswana Tel. No.: +267 397 2001/3/4 Fax No.: +267 397 2014 FLO-TEK Tubos e Irrigacoes KM/13, Estrada de Viana, Luanda, Angola Tel. No.: +244 2222 90662 Fax No.: +244 2222 90880
This information in this brochure is correct to the best of our knowledge. It does not constitute any form of guarantee. Specifications are subject to alteration. Subject to change without notice.