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MECHANICAL AND
THERMAL PROPERTIES OF RAW MATERIALS
..HOSTALEN 5416 by HOECHST..
RAW MATERIAL
Pilsaterm pp3 Pipes and Fittings are made of HOSTALEN 5416 White
Polypropylene Random Copolymer
LIFE TABLE OF PİLSATHERM PIPES
CREEP
RUPTURE-INTERNAL PRESSURE TEST ON
PIPES MADE OF PİLSATHERM PIPES
Figure1
PİLSATHERM-WHITE PIPE PICTURES
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ALUMINUM FOILED PIPES/ALPP3
Dia
20
25
32 |
PIPE/PPBB
Dia
20
25
32
40
50
63
75 |
SOCKET/PPYM
Dia
20
25
32
40
50
63
75 |
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ELBOW 90O/PPYD
Dia
20
25
32
40
50
63
75 |
ELBOW 45O/PPYD
Dia
20
25
32 |
TEE/PPYT
Dia
20
25
32
40
50
63
75 |
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REDUCER/PPR
Dia
25/20
32/20
32/25
40/20
40/25
40/32
50/32
50/40
63/40
63/50
75/50
75/63 |
UNEQUAL TEE/PPRT
A B C
20 x 25 x 20
25 x 20 x 20
25 x 25 x 20
25 x 20 x 25
32 x 20 x 32
32 x 20 x 20
32 x 25 x 32
32 x 25 x 25
32 x 20 x 25
32 x 25 x 20
32 x 50 x 32
40 x 20 x 40
40 x 25 x 40
40 x 32 x 40
40 x 50 x 40
50 x 40 x 50
50 x 50 x 40
50 x 32 x 32
50 x 40 x 32
50 x 32 x 40
50 x 32 x 50
50 x 50 x 32 |
END CAP/PPYQ
Dia
20
25
32
40
50
63
75 |
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END CAP/PPDQ
Dia
20 x 1/2
25 x 3/4
32 x 1 |
FEMALE THREADED BATTERY CONNECTION
(UNDER PLASTER)
Dia
20 x 1/2 |
FEMALE THREADED ELBOW/PPID
Dia
20 x 1/2
25 x 1/2
25 x 3/4
32 x 1 |
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MALE THREADED ELBOW/PPDD
Dia
20 x 1/2
25 x 1/2
25 x 3/4
32 x 1 |
FEMALE THREADED ADAPTOR/PPIA
Dia
20 x 1/2 x 20
20 x 3/4 x 20
25 x 1/2 x 25
25 x 3/4 x 25
32 x 1
40 x 1.1/4
50 x 1.1/2
63 x 2
75 x 2.1/2 |
MALE THREADED ADAPTOR/PPDA
Dia
20 x 1/2 x 20
20 x 3/4 x 20
25 x 1/2 x 25
25 x 3/4 x 25
32 x 1
40 x 1.1/4
50 x 1.1/2
63 x 2
75 x 2.1/2 |
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FEMALE THREADED TEE/PPIT
Dia
D1
20 x 1/2 x 20
40.0
25 x 1/2 x 25
40.0
25 x 3/4 x 25
40.0
32 x 1 x 32
53.0 |
FEMALE THREADED UNION/PPIR
Dia
20 x 1/2
25 x 1/2
25 x 3/4
32 x 1
40 x 1.1/4 |
MALE THREADED UNION/PPDR
Dia
20 x 1/2
25 x 1/2
25 x 3/4
32 x 1
40 x 1.1/4 |
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BOTH END WELDED UNION/PPYR
D
20
25
32
40
50 |
BRIDGE
D
20
25
32
40 |
MALE THREADED TEE/PPDT
Dia
20 x 1/2 x 20
25 x 1/2 x 25
25 x 3/4 x 25
32 x 1 x 32 |
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OMEGA
D
20
25
32
40
50 |
VALVE
Dia
20
25
32 |
CLAMP
D
20
25
32
40
50 |
PİLSATHERM-WHITE PIPE
WELDING PRINCIPLES
JOINING PRINCIPLES OF PİLSATHERM
PIPES
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| PIPE IS CUT..
Welding machine is heated up to 260oC. When
the control light is switched off, (at 260oC)
welding process is started.
Pipe should be cut at appropriate length perpendicular
to the pipe center. Welding distance should be marked
from the pipe. |
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IF IT IS AN ALUMINUM FOILED PIPE... A special
shaver is used to take off the PP layer and Aluminum
Foil |
 PIPE AND FITTINGS ARE HEATED..
Joining surfaces of pipes and fittings should be clean.
If necessary, welding part should be cleaned with alcohol
and should be dried with a dry cloth. During welding
neither the pipe nor the fittings should be moved. Duration
of heating should be determined as shown in table three.
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|
 AND ARE JOINED NOT BE SEPARATED AGAIN.
Pipes and fittings should be heated simultaneously after
process ends, they should be taken out quickly and without
turning they should be joined by pressing one to another
axially. Welding machine should be cleaned after every
operation for the next use. |
| TECHNICAL
PROPERTIES OF PİLSA ALUMINUM FOILED PIPE
* Raw Material: PP3 and Aluminum foil.
* Ideal for central heating and plumbing systems.
* Sound resistant.
* Resistance to acids and chlorine .
* Never deflects under heat, minimum stretching.
* Pressure tolerance: for water at 200C 20
bars, for water at 900 C 10 bars .
* It is easy to scrape the outer surface and aluminum
foil by a simple pipe shaver. Permanent joint is formed
at 2600C by simple fusion welding.
* Because of the plastic property , the pipes are light
and plumbing is easy. This saves a considerable amount
of time, labour and transportation costs.
Example:
Temperature Disparity (Dt) =40K
Length of pipe (Dt)=5m
Amount of extension (Dt)=1.4 mm/m x 5,0 m = 7 mm
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| CALCULATION OF THERMAL EXPANSION
When PP3 pipe is subjected to a temperature difference,
the length of pipe changes in longitudinal direction.
The thermal coefficients of linear expansion at different
temperatures are shown in table below:
LINEAR EXPANSION ELONGATION
| Temperature Difference |
Test Method |
Unit |
Coefficient |
Elongation per meter |
| -300C 0oC |
ASTM D 696-44 |
1/0C |
0,65E-4 |
0,2 cm |
| -300C 0oC |
ASTM D 696-44 |
1/0C |
1,05E-4 |
0,3 cm |
| 300C 600C |
ASTM D 696-44 |
1/0C |
1,40E-4 |
0,4 cm |
| 600C 900C |
ASTM D 696-44 |
1/0C |
1,70E-4 |
0,5 cm |
Horizontal pipes conveying hot liquids must be straddled
at intervals not exceeding one meter. The pipe must
freely move on the straddle. Vertical pipes should be
fixed at the top end, if possible, left free at the
lower end.
EXAMPLE: When the temperature rises from 00C
to 900C,one meter pipe elongates 0.3+0.4+0.5=12
cm
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PP3 pipes are installed in the same way as conventional
galvanized metal pipes. However special attention should
be paid to the higher expansion rate of PP3 pipes
compared to the metal pipes. Pipes can be installed in/on
the wall. Since the weights of the PP3 pipes and fittings
are about one ninth of the metal pipes, installation of
PP3 pipes is easier faster and cleaner. In the PP3 pipes,
adjustment for expansion can be done in one direction.
However , one should make it certain that pipes move freely
in axial direction U bend or OMEGA compensators should
be added to the design. Fixed supports should be chosen
in such a way that they do not damage the other
surface of the pipe. |
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Expansion pipe segments can be produced
during the installation. Four elbows and certain length
of pipe are usually sufficient to do this. The pipe length
necessary for free bend (Ls) is calculated by using the
formula;
Ls=C Öd L
where
Ls=free bend length in mm.
d=outer diameter of the pipe in mm.
L=elongation in mm.
C=material coefficient (3 for PP3)
or it can directly be determined by using Figure
8.
When the length of the pipe exceeds
5 meters, it is absolutely recommended to use expansion
pipe segment. During installation, bridges are used at
the intersection points of the pipes so that they lay
in the same plane. |
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Figure 6 |
FIXED SUPPORT
Fixed supports are used to fix the pipe at certain points
against undesired pipe movements. Fixed supports should
be stronger compared to the sliding supports. Fittings
are used to construct fixed supports. At the points
where direction changes, fixed supports should not be
used. The distance between the fixed supports should be
chosen in such a way that pipe elongation is not effected.
In general elongation of the pipes is provided by free
bending sections. Figure 4 and 5 show the effect of elongation
and how it is handled in the system. 
Figure7 |
Figure 8 |
In some cases pipes are bent by heating. However, pipes
should never be allowed to contact the flame, instead
heating should be carried out by blowing air. A temperature
of 140 °C is sufficient to bend the pipes. Recommended
radius of curvatures are shown in Table 5. The distance
between the two clips in horizontal pipes depends on the
factors such as the raw material that pipe is produced
from, wall thickness, weight of the pipe and temperature.
Table 5 shows recommended distances between the clips.
Practically, same distances can be used for vertical systems.
Figure9 |
| d |
Supported Lengths (water-filled pipes)
in cm at |
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| mm |
200C |
300C |
400C |
500C |
600C |
700C |
800C |
| 16 |
75 |
70 |
70 |
65 |
65 |
60 |
55 |
| 20 |
80 |
75 |
70 |
75 |
65 |
60 |
60 |
| 25 |
85 |
85 |
85 |
80 |
75 |
75 |
70 |
| 32 |
100 |
90 |
90 |
85 |
80 |
75 |
70 |
| 40 |
110 |
105 |
105 |
100 |
95 |
90 |
85 |
| 50 |
125 |
115 |
115 |
110 |
105 |
100 |
90 |
| 63 |
140 |
130 |
130 |
125 |
1200 |
115 |
105 |
| Pipe d |
Radius, min. (R=8xd) |
| 20 |
160 |
| 25 |
200 |
| 32 |
256 |
| 40 |
320 |
| 50 |
400 |
| 63 |
500 |
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APPLICATIONS IN THE MAIN CHIMNEY:
During installation of pipes from the main line to the
apartments in a building one of the following techniques
are used to allow the pipes expand linearly
Figure 9 A: Distance a between the tee and wall
hole should be provided.
Figure 9 B: The hole diameter inside the wall should
be bigger than the pipe diameter which crosses the wall.
Figure 9 C: L shaped pipe segment is used.
ASSEMBLY OF
PIPE AND FITTINGS
Beside the raw material of the pipe, the reliability of
plumbing systems depend on the fittings and how they are
joined. Since the pipes and fittings are produced from
the same material, connections are usually homogeneous:
There are two main connections:
a- Threaded connections: Same as in galvanized
pipes
b- Fusion welding:
1- Welding done by heating
outer surface of the pipe and inner surface of the fitting.
2- Electro fusion welding.
Since the electro fusion technique is quite expensive,
socket welding is commonly used. When a tensile test is
applied to the welded pipe and fitting segment, it is
observed that welding points are not affected even when
the pipe segment reaches to the fracture point. These
welded parts are as strong as the pipe itself.
APPLICATION
OF SOCKET WELDING
1- Preparation of welding:
Both ends of pipes are cut as perpendicularity to the
pipe axis in required length. Chamfers should be given
to the outer ends of the pipe by a knife. Parts to be
welded should be cleaned by alcohol and dried by clean
fabric or paper before welding. Socket depth (welding
distance ) is marked from the end of the pipe. Temperature
is adjusted to 260 (+) 10 °C in the welding machine. Turning
off red light on the welding machine indicates that welding
temperature is reached. Heaters in the welding machine
should always be kept clean.
2- Welding :
Pipes and fittings are pushed axially towards to the heaters
of the welding machine. Then they are pulled out simultaneously
and joined to each other in axial direction. During this
the operation, pipe never should be turned radially. After
welding, heaters should be cleaned for the next use.
| Pipe Dia |
Welding Heater (R=8xd) |
| 16 |
13 |
| 20 |
14.5 |
| 25 |
16 |
| 32 |
18 |
| 40 |
20.5 |
| 50 |
23.5 |
| 63 |
27.5 |
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| STANDARDS AND CODES OF PRACTICE
E DIN 1988
Potable water pipes in private properties
Technical requirements for portable water installation
(TRWI)
EDIN 4725
Warm water floor heating systems
Part 1 Terms
Part 2 Thermal testing
Part 3 Thermal performance and design
E DIN 4726
Pipelines of plastic materials used in warm water floor
heating systems requirements special requirements and
testing
E DIN 4728
Pipelines of polypropylene type 2 used in warm water
floor heating systems; special requirements and testing
DIN 8076 Part 1
Pressure pipes thermoplastic materials
-metal compression fittings-
DIN 8077
Pipes of polypropylene, dimensions
DIN 8078
Pipes of polypropylene
General quality requirements, testing
DIN 16 928
Pipes of thermoplastic, pipe fittings elements for pipes,
laying
DIN 16 972
Pipes connections and fittings for pressure pipes of
PP
Sheet 5
General quality requirements, testing
Sheet 6
Injection molded elbows for socket welding, dimensions
Sheet 7
T-pieces injection molded for socket welding, dimensions
Sheet 8
Sockets and caps injection molded for socket welding
DIN 16 960
Welding of thermoplastic materials; principles
DVS 2203
Testing of welds of thermoplastic materials
DVS 2207 Part11
Welding of thermoplastic materials, PP Type1 and Type2,
pipes and pipe fittings
DVS 2208 Part1
Machines and equipment for the welding of thermoplastic
materials, fusion tool welding
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| WHILE USING |
| FALSE
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TRUE |
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| AVOID
OF HARD STRIKES AND
STRIKES OF THE PIPE ENDINGS |
PLACE CAREFULLY |
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| DO
NOT USE PIPES SPLIT FROM
CUTTINGS OR DAMAGED |
USE ONLY SHARP
EQUIPMENTS TO CUT THE PIPE |
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| DO
NOT TURN THE PIPES AND
PARTS AFTER WELDING |
YOU CAN TURN UP
TO 50OC
RIGHT AFTER CONNECTION |
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| DO
NOT USE CONIC THREADED ITEMS |
USE ONLY WELL THREADED
ITEMS |
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| DO
NOT EXPOSE TO THE U.V. LIGHT |
PROTECT FROM SUN
AND RAIN |
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| DO
NOT USE THE METAL LIDS TO COVER |
USE PLASTIC LIDS |
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| PROTECT
AGAINST HARD STROKES AND FROM SOLID ITEMS TO
FALL ON |
KEEP THE PIPES
COVERED |
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| DO
NOT USE HEMP THREAD WHILE WRINGING THE ARMATURES
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GLUES AND ADHESIVES
ARE ADVISED FOR WRINGING. |
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| DO
NOT HEAT BY DIRECT FLAME |
USE HEATED AIR
FOR BENDING THE MAXIMUM BENDING TEMPERATURE IS
140OC |
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| DO
NOT WELD DIRTY PIPES AND PARTS |
USE ONLY
CLEAN MATERIAL |
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