POLSAFE Gas Distribution System
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
CONTENTS Polsafe system description 4 Polsafe technical information 5-6-7 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 9-10-11-12-13-14 Ductile PVC pipes Ductile PVC fittings Polsafe fittings Service line pipes and couplers Accessories Standards 15
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 2 0 0 0
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 2 0 0 0 5
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 2 0 0 0
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 2 0 0 0 7
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 6,9 45 21 7,1 2,4 8 o c t o b e r 2 0 0 0
POLSAFE PRODUCT RANGE POLSAFE DUCTILE PVC PIPES DUCTILE PVC PIPE SDR 41, Gastec QA approved Size Code Meters per bundle 50 x 2,0 309733 1170 63 x 2,0 307202 780 75 x 2,0 307206 500 90 x 2,2 307210 630 110 x 2,7 307214 430 160 x 3,9 307222 220 200 x 4,9 307226 140 250 x 6,1 307230 70 315 x 7,7 307234 50 DUCTILE PVC PIPE SDR 33, Gastec QA approved Size Code Meters per bundle 110 x 3,4 306791 430 160 x 4,9 306799 220 200 x 6,2 306803 140 250 x 7,7 306807 70 315 x 9,7 306811 50 DUCTILE PVC FITTINGS DUCTILE PVC COUPLER 50 318985 45 63 301144 40 75 301146 24 90 301147 16 110 301149 12 160 301152 6 200 301153 1 250 301154 1 315 301155 1 DUCTILE PVC REPAIR COUPLER 50 318986 45 63 301177 40 75 301178 24 90 301179 16 110 301180 12 160 301159 6 200 301160 1 250 301161 1 315 301162 1 o c t o b e r 2 0 0 0 9
POLSAFE POLSAFE PRODUCT RANGE DUCTILE PVC REDUCER 63 x 50 302148 1 75 x 50 301872 1 75 x 63 301279 1 90 x 63 301280 1 90 x 75 301281 1 110 x 63 301282 1 110 x 75 301283 1 110 x 90 301284 1 160 x 110 301286 1 200 x 160 301288 1 250 x 200 301289 1 315 x 250 301290 1 DUCTILE PVC TEE 63 x 63 318535 4 75 x 75 318536 6 90 x 90 318537 4 110 x 63 318538 5 110 x 75 318539 5 110 x 90 318540 3 110 x 110 318541 4 160 x 110 318542 1 160 x 160 318543 1 200 x 110 315847 1 200 x 160 315848 1 200 x 200 315849 1 DUCTILE PVC END CAP 63 312337 70 75 312338 30 90 312339 30 110 312340 30 160 312341 12 200 312342 1 DUCTILE PVC END CAP 250 301540 1 315 302068 1 1 0 o c t o b e r 2 0 0 0
POLSAFE PRODUCT RANGE POLSAFE DUCTILE PVC FORMED BEND 11 63 301054 75 301064 90 301070 110 301076 160 301090 200 301095 250 301102 315 301110 DUCTILE PVC FORMED BEND 22 1 /2 63 301056 75 301066 90 301071 110 301078 160 301091 200 301097 250 301104 315 301111 DUCTILE PVC FORMED BEND 30 63 301057 75 301067 90 301072 110 301079 160 301092 200 301098 250 301105 315 301112 DUCTILE PVC FORMED BEND 45 50 315703 63 301059 75 301068 90 301073 110 301081 160 301093 200 301099 250 301107 315 301113 DUCTILE PVC FORMED BEND 90 50 315840 63 301062 75 301069 90 301075 110 301084 160 301094 200 301101 250 301109 315 301114 o c t o b e r 2 0 0 0 1 1
POLSAFE POLSAFE PRODUCT RANGE POLSAFE GAS SADDLE 63 x 1 1 /2 320309 20 75 x 1 1 /2 320310 20 90 x 1 1 /2 320311 20 110 x 1 1 /2 320312 14 160 x 1 1 /2 320331 8 160 x 2 320334 8 200 x 1 1 /2 320332 5 200 x 2 320335 5 250 x 1 1 /2 320333 4 250 x 2 320336 4 250 x 2 1 /2 320112 4 *315 x 1 1 /2 320316 2 *315 x 2 320337 2 *315 x 2 1 /2 320111 2 *) type M POLSAFE SADDLE TEE, tensile tight Size SDR Code Packing 25 x 1 1 2 SDR17,6/11 320300 10 32 x 1 1 2 SDR17,6 320301 10 32 x 1 1 2 SDR11 320303 10 40 x 1 1 2 SDR17,6 320302 10 POLSAFE SADDLE ADAPTER 1 1 /2 320319 10 2 320320 8 2 1 /2 320325 5 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 /2 320321 40 2 320322 50 POLSAFE CUT-OFF PLUG, for temporary service cut-off 1 1 2 320317 20 2 308606 1 2 o c t o b e r 2 0 0 0
POLSAFE PRODUCT RANGE POLSAFE POLSAFE TESTING PLUG, for service line testing 320341 20 POLSAFE TESTING CAP, for Polsafe saddle tee 320318 50 POLSAFE TESTING CAP, for Polsafe saddle adapter 1 1 /2 320342 50 2 320343 50 SERVICE LINE PIPES AND COUPLERS POLVALENE PE80 PIPE YELLOW SDR17,6, Gastec QA approved Size Code 50m coils Code 100m coils 25 x 2,0 320652 308337 32 x 2,0 320653 308338 40 x 2,3 320654 308670 POLVALENE PE80 PIPE YELLOW SDR11, Gastec QA approved Size Code 50m coils Code 100m coils 25 x 2,3-309592 32 x 3,0-309593 40 x 3,7-311191 DUCTILE PVC COUPLER PE-PE, tensile tight Size Code 50m coils Code 100m coils 25 SDR17,6/11 318556 32 SDR17,6 318557 40 SDR17,6 318555 o c t o b e r 2 0 0 0 1 3
POLSAFE POLSAFE PRODUCT RANGE DUCTILE PVC TRANSITION COUPLER PE-COATED STEEL, tensile tight Size SDR Code Packing 25 x 3 4 SDR17,6/11 306925 20 32 x 3 4 SDR17,6 318559 10 32 x 1 SDR17,6 306927 10 32 x 1 SDR11 306928 10 40 x 1 SDR17,6 306929 10 40 x 1 1 4 SDR17,6 318562 10 DUCTILE PVC TRANSITION COUPLER PE-COATED COPPER, tensile tight Size SDR Code Packing 25 x 15 x 25 SDR17,6/11 320368 30 32 x 22 x 32 SDR17,6 320369 30 32 x 22 x 32 SDR11 320371 10 40 x 28 x 40 SDR17,6 320370 10 40 x 28 x 40 SDR11 320372 10 40 x 35 x 40 SDR11 320374 10 40 x 35 x 40 SDR11 320373 10 Ductile PVC transition couplers PE-coated copper must be mounted with a brass thrust ring Thrust ring15mm 304374 Thrust ring22mm 304375 Thrust ring28mm 304376 Thrust ring35mm 304377 ACCESSORIES TYPICAL POLSAFE TAPPING SET TYPICAL POLSAFE BALLOON POSITIONING SET 1 4 o c t o b e r 2 0 0 0
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 5059 2600 GB DELFT Holland 3 o c t o b c e t or b2 e0 r 0 0 2 0 0 0 1 53
Pipelife Nederland B.V. P.O. Box 380, 1600 AJ Enkhuizen, Holland Flevolaan 7, 1601 MA Enkhuizen, Holland Tel.: ++ 31.228.355555 Fax: ++ 31.228.355666 info@pipelife.nl http://www.pipelife.nl