POLSAFE. Gas Distribution System

Transcription

1 POLSAFE Gas Distribution System

2 PIPELIFE INTERNATIONAL Pipelife International GmbH is one of the world's leading suppliers of plastic piping systems. Plastic pipes and fittings are produced in 34 Pipelife manufacturing plants in 24 countries in Europe, Asia and North America. Pipelife's head office is located in Vienna-Austria. Pipelife international is a joint venture between Solvay SA Belgium and Wienerberger AG Austria. Pipelife Nederland BV manufactures a wide range of products for all major pipe and fitting markets. The Dutch head office and main production plant are located in Enkhuizen-Holland. An important product line produced by Pipelife Nederland is the Polsafe Gas Distribution System. Pipelife in Europe Pipelife s core business: Water Water hot and cold drinking water Waste and sewage soil and waste sewage Energy gas distribution electrical flue gas district heating/cooling Pipelife in Asia Power and information cable protection Industry oil and gas exploitation petrochemical industry Agriculture irrigation land drainage Pipelife in North America

3 CONTENTS Polsafe system description 4 Polsafe technical information Ductile PVC Rubber seals Ductile PVC pipe installation Polsafe service line installation Polsafe balloon positioning Polsafe economics 8 Installation costs Maintenance costs Polsafe product range Ductile PVC pipes Ductile PVC fittings Polsafe fittings Service line pipes and couplers Accessories Standards 15

4 POLSAFE POLSAFE SYSTEM DESCRIPTION The Polsafe Gas Distribution System is a complete range of pipes and fittings for gas distribution. Polsafe pipes and fittings are made of Ductile PVC. The Polsafe Gas Distribution System has been approved for system pressures up to 200 mbar, however higher system pressures are possible. The Polsafe Gas Distribution System is well known for its patented self-sealing gas valve and the possibility of making house connections and repairs on live distribution mains. The Polsafe Gas Distribution System consists of a complete assortment of Ductile PVC pipe, rubber ring socket couplers, other rubber ring socket fittings and spigot fittings for distribution mains, with diameters from 50 up to 315mm. For service lines a complete range of PE80 pipe and Ductile PVC tensile tight couplers is available in diameters 25 up to 40mm. A service line connection on a main Polsafe distribution line can be realised by means of a Polsafe saddle and a Polsafe saddle tee. A balloon entry on a Polsafe distribution main can be made with a Polsafe saddle and a Polsafe saddle adapter. A by-pass can be realised easily with Polsafe components. All Polsafe Gas Distribution System components are executed in yellow, RAL1024. For Polsafe Gas Distribution Systems professional saddle tapping tools and balloon positioning equipment is available. Polsafe Gas Distribution System components are Gastec QA approved. Gastec is the Dutch Centre for Gas Technology. Polsafe stands for: high tech simplicity simple pipe installation with pipe lengths and socket couplers gas free assembly on live mains simple saddle mounting self-clamping lower saddle simple mounting of saddle tees and saddle adapters simple saddle tapping procedure removable cutter simple service line installation tensile tight connector on saddle tees tensile tight service line couplers simple balloon positioning Ductile PVC components Nitrile Butadiene Rubber (NBR) seals Gastec QA approved products 4 o c t o b e r

5 POLSAFE TECHNICAL INFORMATION POLSAFE DUCTILE PVC Polsafe pipes and fittings are made of Ductile PVC. Ductile PVC is a mixture of PVC and modified PE. The modified PE gives the material a high ductility. Ductile PVC's strength and stiffness are still at a high level, sufficient to guarantee a good performance of the rubber ring socket fittings and sufficient to resist ground loads adequately. Stiffness for Ductile PVC pipe SDR41 is 3,5 kn/mm and for Ductile PVC pipe SDR33 6,0 kn/mm. Recent studies have shown that under standard installation conditions these Ductile PVC pipes will show less than 5% deflection in the long run. Due to its high ductility Ductile PVC has a higher impact resistance and is resistant to crazing and cracking initiated by aggressive constituents in the gas. Ductile PVC is insensitive to notches due to its high fracture toughness. Therefore premature catastrophic failures are very unlikely to occur. Recent studies at Gastec, the Dutch Centre for Gas Technology, have shown that Ductile PVC will not show propagating failures up to a gas pressure of more than 4 Bar. RUBBER SEALS For the rubber ring socket fittings a special multi-lipped rubber ring has been developed, suitable to compensate long term pipe deformation. This rubber ring sealing concept has been used from the early 60's and has proved to be very successful. Rubber rings in Polsafe socket fittings and also other rubber seals in Polsafe saddles and other components are made of Nitrile Butadiene Rubber (NBR). This rubber type is very suitable for use with natural gas and gas condensate and is covered by various standards, e.g. EN682 type G. o c t o b e r

6 POLSAFE POLSAFE TECHNICAL INFORMATION DUCTILE PVC PIPE INSTALLATION POLSAFE SERVICE LINE INSTALLATION A Polsafe Ductile PVC pipeline can be installed with just one push rod and some lubricant. The system with pipe lengths and rubber ring socket fittings is very easy to install. In order to make a house connection to a Ductile PVC main pipeline a Polsafe gas saddle must be mounted on the main. The lower saddle part must be positioned on the pipe first. Because of the special design it will stay on the pipe without holding it. This allows the worker to use two hands for further assembly. The upper saddle part can be clamped to the lower one with the two saddle clamps. Afterwards a Polsafe saddle tee can be screwed into the Polsafe saddle and the saddle can be tapped. The removable cutter is designed in such a way that no bore chips can get into the main or into the service line. The self-sealing valve in the Polsafe saddle tee will prevent loss of gas during boring a live main. A PE service line pipe can be connected to the Polsafe saddle tee with the tensile tight connector on the saddle tee. self-sealing gas valve saddle tee with tensile tight connector upper saddle fits on lower saddle in both directions saddle clamps self-clamping lower saddle main pipe 36 o c t o b e r

7 POLSAFE TECHNICAL INFORMATION POLSAFE POLSAFE BALLOON POSITIONING In order to position a balloon in a Ductile PVC main pipeline a Polsafe gas saddle must be mounted on the main first. After mounting the saddle a Polsafe saddle adapter can be screwed into the Polsafe saddle and the main can be tapped. After tapping the balloon can be positioned with Polsafe positioning equipment and the balloon can be inflated. The self-sealing valve in the Polsafe saddle adapter will prevent escape of gas during boring and balloon positioning. o c t o b e r

8 POLSAFE POLSAFE ECONOMICS INSTALLATION COSTS Installation costs for a Polsafe Gas Distribution System are relatively low, due to quick and easy installation. Depending the actual situation cost reductions up to 30% compared to PE system costs can be obtained. MAINTENANCE COSTS Thorough investigations have shown that repair frequency for a Polsafe Gas Distribution System is much lower than repair frequencies for other gas distribution systems. This is shown in the following table: System material Steel Cast iron Asbestos cement PE Ductile PVC (Polsafe) Repairs per 100km per year 6, ,1 2,4 8 o c t o b e r

9 POLSAFE PRODUCT RANGE POLSAFE DUCTILE PVC PIPES DUCTILE PVC PIPE SDR 41, Gastec QA approved Size Code Meters per bundle 50 x 2, x 2, x 2, x 2, x 2, x 3, x 4, x 6, x 7, DUCTILE PVC PIPE SDR 33, Gastec QA approved Size Code Meters per bundle 110 x 3, x 4, x 6, x 7, x 9, DUCTILE PVC FITTINGS DUCTILE PVC COUPLER DUCTILE PVC REPAIR COUPLER o c t o b e r

10 POLSAFE POLSAFE PRODUCT RANGE DUCTILE PVC REDUCER 63 x x x x x x x x x x x x DUCTILE PVC TEE 63 x x x x x x x x x x x x DUCTILE PVC END CAP DUCTILE PVC END CAP o c t o b e r

11 POLSAFE PRODUCT RANGE POLSAFE DUCTILE PVC FORMED BEND DUCTILE PVC FORMED BEND 22 1 / DUCTILE PVC FORMED BEND DUCTILE PVC FORMED BEND DUCTILE PVC FORMED BEND o c t o b e r

12 POLSAFE POLSAFE PRODUCT RANGE POLSAFE GAS SADDLE 63 x 1 1 / x 1 1 / x 1 1 / x 1 1 / x 1 1 / x x 1 1 / x x 1 1 / x x 2 1 / *315 x 1 1 / *315 x *315 x 2 1 / *) type M POLSAFE SADDLE TEE, tensile tight Size SDR Code Packing 25 x SDR17,6/ x SDR17, x SDR x SDR17, POLSAFE SADDLE ADAPTER 1 1 / / /2 saddle adaptors are suitable for balloons 63 up to 110mm 2 saddle adaptors are suitable for balloons 160 up to 315mm 2 1 /2 saddle adaptors are suitable for balloons 250 and 315mm POLSAFE SADDLE PLUG 1 1 / POLSAFE CUT-OFF PLUG, for temporary service cut-off o c t o b e r

13 POLSAFE PRODUCT RANGE POLSAFE POLSAFE TESTING PLUG, for service line testing POLSAFE TESTING CAP, for Polsafe saddle tee POLSAFE TESTING CAP, for Polsafe saddle adapter 1 1 / SERVICE LINE PIPES AND COUPLERS POLVALENE PE80 PIPE YELLOW SDR17,6, Gastec QA approved Size Code 50m coils Code 100m coils 25 x 2, x 2, x 2, POLVALENE PE80 PIPE YELLOW SDR11, Gastec QA approved Size Code 50m coils Code 100m coils 25 x 2, x 3, x 3, DUCTILE PVC COUPLER PE-PE, tensile tight Size Code 50m coils Code 100m coils 25 SDR17,6/ SDR17, SDR17, o c t o b e r

14 POLSAFE POLSAFE PRODUCT RANGE DUCTILE PVC TRANSITION COUPLER PE-COATED STEEL, tensile tight Size SDR Code Packing 25 x 3 4 SDR17,6/ x 3 4 SDR17, x 1 SDR17, x 1 SDR x 1 SDR17, x SDR17, DUCTILE PVC TRANSITION COUPLER PE-COATED COPPER, tensile tight Size SDR Code Packing 25 x 15 x 25 SDR17,6/ x 22 x 32 SDR17, x 22 x 32 SDR x 28 x 40 SDR17, x 28 x 40 SDR x 35 x 40 SDR x 35 x 40 SDR Ductile PVC transition couplers PE-coated copper must be mounted with a brass thrust ring Thrust ring15mm Thrust ring22mm Thrust ring28mm Thrust ring35mm ACCESSORIES TYPICAL POLSAFE TAPPING SET TYPICAL POLSAFE BALLOON POSITIONING SET 1 4 o c t o b e r

15 STANDARDS POLSAFE NEN7230 NEN7231 Plastic piping systems for gas supply - High impact PVC pipes - Requirements and testing methods Plastic piping systems for gas supply - High impact PVC fittings - Requirements and testing methods NEN7232 Plastic piping systems for gas supply - High impact PVC saddles with clamp connection - Requirements and testing methods NEN7240 Plastic piping systems for gas supply - High impact PVC tensile tight couplers - Requirements and testing methods NEN7212 PREN1555 BRL2051 ISO6993 Rubber seals in distribution systems for natural gas Plastic piping systems for gaseous fuel supply - Polyethylene (PE) Lubricant for rubber ring seals High impact PVC pipes for gaseous fuel supply The above mentioned standards can be obtained from: Nederlands Normalisatie Instituut PO Box GB DELFT Holland 3 o c t o b c e t or b2 e0 r

16 Pipelife Nederland B.V. P.O. Box 380, 1600 AJ Enkhuizen, Holland Flevolaan 7, 1601 MA Enkhuizen, Holland Tel.: Fax: