COOL-FIT™

Patent pending

Technical Information and Product Range

¥ ‡ Piping Systems Innovative technology The focus of our research is on the development of new products and improved processes. Over 4,000 patents prove our innovative strength.

Long Standing Know-how Georg Fischer is the leading supplier of piping systems in plastics.

Local support – worldwide Our sales companies in over 24 countries and an extensive, qualified network of distributors together with our modern logistics system guarantee availability at all times.

Quality management The high quality of our products is warranted by ISO 9001 certified quality management systems. In our ISO/IEC 17025 accredited test laboratory, we define the criteria for the market. Planning support Take advantage of our know-how. We are glad to share it with you.

2 ¥ ‡ COOL-FIT

Contents Page

General Information 4 Top Quality: Minimum On Site Time 5–7 System Advantages: Your Benefit 8–9 COOL-FIT ABS Pipe Technical Details 10 COOL-FIT ABS Fittings Technical Details 11 Accessory Equipment 12 Accessory Equipment for Solvent Cement Jointing, 13 Reducing Diameters and End Caps COOL-FIT ABS Reducing Diameters 14 Pressure-Temperature Parameters 15 Technical Data 16 General Comments 16 Pressure Drops 17–18 Pipe Support Distances 19 Pipe Supports and Fixed Point 20 Flexible Length 21 Plastic to Metal Connections 22 Measuring Equipment 22 Measuring Equipment, De-Venting and Curing Time 23 Pressure Testing and Insulation 24 Under-Ground Use and Storage 25 Flammability 26 ABS Metric Piping System Specification 27 COOL-FIT ABS Pipe and Fittings Specification 27 Contents Product Range 29 Black and white: Product Range Pipe 30 Black and white: Product Range Fittings 30–34 Accessory Equipment 35–37 Instructions for Solvent Cement Jointing of ABS 38–41 ABS Tangit and Cleaner: Amounts required 42 Instruction for Solvent Cementing COOL-FIT ABS 43 Jointing technique: Pipe preparation 44–45 The technical data is not binding and not an expressly Instruction for Insulating the Gap 46 warranted characteristic of the goods. It is subject to change. ABS Product Range 47 Please consult our General Conditions of Supply.

¥ ‡ 3 General Information

COOL-FIT is a complete system solution polybutadiene to produce an homoge- for secondary cooling and refrigeration neous material with excellent impact and piping systems. The system is based on low temperature characterisitcs. ABS is the tried and tested ABS plastic system halogen free with a low thermal conduc- from Georg Fischer which contains pipe tivity and non-toxic. Georg Fischer ABS fittings valves and transition fittings, now has a range of internationally recognised with the option for pre-insulated pipe approvals. Please ask if you require and fittings with outer jackets in either any details regarding approvals or raw black or white. material properties. You can adapt the system solution to your particular needs. PUR Insulation For example white pre-insulated for food COOL-FIT pre-insulated pipe and fittings production halls or standard plastic pipe are delivered ready to install using high with control valves for pump houses or density PUR L 45 kg/m3 as the insula- OEM chillers. tion material, the PUR is CFC free and recyclable. Refrigeration and Cooling plants in general using plastic pipe as the car- Jacket Pipes in White and Black rier system offer complete corrosion The outer jacket in either black or resistance and a cost effective solu- white is manufactured from high density tion compared to traditional metal polyethylene (PE). PE offers extremely materials. good impact resistance and a good resistance to oil splashes and grease or Pipe other external contamination. The PE is The ABS pipe and fittings are available smooth, non-corroding and thus easy to in 3 versions. clean with a long life-span. º standard un-insulated, to be insulated White PE offers an aesthetic and hygie- on-site with traditional insulation nic alternative for internal systems for º pre-insulated with black PE jacket instance in supermarkets or food produc- º pre-insulated with white PE jacket tion halls. Black PE is UV resistant and thus ideally Fittings suited to outdoor applications and for A complete range of fittings compatible general use. to the pipe is also available either as standard or as insulated with either Typical Working Conditions white or black outer jackets. With working temperatures ranging from The ABS range contains shut-off valves, –50 °C to +40 °C for pre-insulated and control valves, automated valves pneu- –40 °C to +60 °C for the standard ABS matic and electrical as well as a com- system with a maximum working pressure plete range of transition fittings for metal of 10 bar (water at +23 °C) COOL-FIT. to plastic connections. See standard Georg Fischer ABS litera- Typical Mediums ture for the complete range available in COOL-FIT can be used for example with dimensions d16 to d315mm. the following mediums: º chilled water and general water Georg Fischer ABS Raw Material º salt solutions ABS is a material used in a wide range º glycol solutions of general engineering applications from º alcohol solutions general housings for vacuum cleaners For compatability of ABS to non-water for instance to car bumpers. mediums please consult Georg Fischer Georg Fischer‘s ABS raw material has and see page ¢5. been specifically developed for long-life pressure bearing piping systems. Note: COOL-FIT is not for use with pri- For physical properties see ISO 15493 mary gases such as Ammonia, Propane, and Georg Fischer literature Fi 9030, R407, R22, and also not for use for com- pages 32–34. pressed air systems. Acrylonitrile Butadiene Styrene (ABS) is a styrne acrylonitrile copolymer grafted to

4 ¥ ‡ COOL-FIT Top Quality: Minimum On Site Time

Tangit Solvent Cement Reliable, Quick ABS Pipe (–40 °C to 60 °C)

COOL-FIT COOL-FIT Pipe Complete Fittings Range: for Secondary Pre-Insulated Pipe d¢6 to d3¢5 Black and White Cooling Systems 100 % water tight and Refrigeration

COOL-FIT Fittings Hand Operated Valves for jointing pipe inside including Butterfly Valves and diameters (di) Non-Return Valves No removal of PUR required

Actuated Ball, Diaphragm and COOL-FIT Fittings Butterfly Valves (Electric and Pre-insulated Pneumatic) Ready to install Black and White ABS d25 to d225 (PE jacket d90 to d3¢5)

¥ ‡ 5 Top Quality: Minimum On Site Time

Pre-Insulated pipe and fittings Standard ABS complete system; Pipe, fittings, valves, transitions

di–di

Pre-Insulated Pipe: Black and white COOL-FIT Nipple: Solvent Cemented internal diameters of pipe

Pre-Insulated Fittings: Black and white

Flanged Mechanical Joint for ABS and ABS–Metal connections

ABS Valves for example shut-off ABS Pipe ball valves

6 ¥ ‡ Shrink Sleeve, Short: Vapour tight and water tight

Sealing Tape: For location of sleeve and vapour seal, double-sided Gap Insulator: sticky for easy location of For visual check when sleeve commissioning

di–di

di–d

COOL-FIT Nipple: No removal of PUR from pipe necessary Pre-insulated Fittings; For example, Elbow 45°

Transition Unions: Copper–ABS with «O»-ring for reliable sealing, stainless steel and threaded connections also available

¥ ‡ 7 System Advantages: Your Benefit

Speed Reduce Costs for your Hanging System Fittings and Pipe are delivered direct to Simplified pipe supports on outer jacket, the site (ready to install). no need for special refrigeration pipe Simple installation technique using spee- hangers. dy solvent cementing with no need to Pre-insulated pipe requires about 30% remove the PUR using internal diameter less hangers than standard plastic pipe. jointing fittings. Lower weight compared to metals Time and cost saving handling due to means lower structural costs. the low weight of plastics. 0.04 mm/m.K expansion coefficient, helps simplify pipeline design. Zero Corrosion No maintenance, reduced down-time, Top Efficiency constant long-term efficiency. Save energy, thermal conductivity 0.026 W/m.K PUR density L 45 kg/m3 with standard thickness of ± 35 mm for excellent insulating properties. Smooth pipes: no encrustation, low pressure drops, no energy bridges due to support on outer jacket.

8 ¥ ‡ Reliability Full Technical Design Support Quality Georg Fischer products: www.cool-fit.georgfischer.com for on-line the number 1 Plastics Industrial Piping calculations of energy losses, tempera- system manufacturer in the world. ture differences and more. Tried and Tested jointing technique with CAD libraries for accurate and quicker gap filling, cold welding TANGIT ABS drawing. cement. Specialist guidelines for design and installation and design of venting equip- Innovative: Clever ment, measuring equipment, transitions. Developed for your needs. Internal pipe connections means no Full Technical Support during need to remove the PUR insulation from Installation the pipe or fitting. On-site advice and jointing technique training. Outdoor and Indoor Systems: Vapour Training Video for ABS jointing tech- Sealed nique. Black and white shrink sleeve for ¢00% vapour sealing ¢00% water tight system.

Hygienic Aesthetic Top quality in performance and looks. Smooth outer surfaces for hygienic envi- ronments. No detrimental effects under high pres- sure cleaning.

¥ ‡ 9 COOL-FIT ABS Pipe Technical Details

COOL-FIT ABS is produced using high COOL-FIT ABS Contraction Coefficient: 0.04 mm/m.K grade ABS pressure piping raw material, in use for over 20 years together with high (One system coefficient for pre-insulated ABS pipe. grade low temperature PUR produced All three materials are bonded together deliberately to in high density form to offer optimal ensure expansion and contraction as one.) insulating qualities.

Pipe Specification Product Identification; Colour, PN 10, Production Date, COOL-FIT, ABS. White has no identification on pipe.

Black RAL 9004 White RAL 9010 Carrier Pipe ABS ¢0 bar rated, cement jointed ABS plastic pipe. 5 meter lengths. ABS Pipe to ISO 15493. Jacket Pipe HD-PE to DIN 8075 in black or white. Functional require- ments to EN 253. White PE is only moderately UV resistant and is recommended for indoor applications. Black is UV resistant.

Hard Polyurethane Foam (PUR) Thermal Conductivity at 50°C l 0.026 W/m.K Foamed using polyol and isocynate Axial Shear Strength M 0.12 N/mm2 Expansion Coefficient 0.04 µm/m.K Tensile Strength M 0.2 N/mm2 Core density L 45 kg/m3 Compressive Strength M 0.3 N/mm2 Average Cell Sizes max. 0.5 mm

Code Number Carrier Pipe Jacket Pipe Weight (PE + Volume Pipe Support Heat Transfer ABS HDPE ABS + PUR) Distance * Coefficient

Black White d x e di D x e1 kg/m l/m m W/mK 169 017 182 169 017 282 25 x 2.3 20.4 90 x 2.2 1.24 0.36 1.55 0.143 169 017 183 169 017 283 32 x 1.9 28.2 90 x 2.2 1.29 0.61 1.55 0.177 169 017 184 169 017 284 40 x 2.4 35.2 110 x 2.7 1.76 0.95 1.65 0.181

169 017 185 169 017 285 50 x 3.0 44 110 x 2.7 1.89 1.49 1.65 0.230 169 017 186 169 017 286 63 x 3.8 55.4 125 x 3.0 2.48 2.34 1.75 0.264 169 017 187 169 017 287 75 x 4.6 65.8 140 x 3.0 3.17 3.36 1.90 0.290 169 017 188 169 017 288 90 x 5.4 79.2 160 x 3.0 4.11 4.80 2.05 0.316 169 017 189 169 017 289 110 x 6.6 96.8 180 x 3.0 5.22 7.21 2.20 0.368

169 017 191 169 017 291 140 x 9.2 121.6 225 x 3.2 8.16 11.69 2.55 0.382 169 017 192 169 017 292 160 x 10.5 139 250 x 3.9 10.34 15.22 2.75 0.405 169 017 193 169 017 293 200 x 13.1 173.8 280 x 4.4 13.42 24.50 3.05 0.580 169 017 194 169 017 294 225 x 14.8 195.4 315 x 4.9 17.97 30.05 3.30 0.546 COOL-FIT ABS pipe d250, d280 and d3¢5 available on request * COOL-FIT support distance are the same from –50°C to +40°C d: nominal outside diameter of ABS pipe

di: nominal internal diameter of ABS D: nominal outside diameter of PE pipe e & e1: nominal wall thicknesses

10 ¥ ‡ COOL-FIT ABS Fittings Technical Details

COOL-FIT ABS Fittings are manufactured using the same raw materials as the HD-PE pipe and are thus completely compatible with the COOL-FIT ABS pipe in terms of insulating properties and also jointing ABS technique.

PUR

COOL-FIT ABS Fitting There are 2 types of COOL-FIT ABS Fittings, namely the di type and the d type. To cement di fittings to COOL-FIT ABS ABS Pipe for d connection pipe requires a di–di fitting. i di is the designation for a joint which takes place in the internal diameter of the pipe. di25 for instance refers to the internal diameter of d25 pipe. di type fitting d is the designation for a normal socket solvent cemented joint as per the stan- dard Georg Fischer ABS range. ABS Fitting The jointing material and technique for for d connection di and d are the same, with the same cement and the same tooling. Refer to pages 36–39 for details.

d type fitting

COOL-FIT ABS pipe to pipe connections are achieved using the di–di COOL-FIT nipple, see diagram. Note: dimensions above d90 must be calibrated using the COOL-FIT Tool, see next page for details. di connection to COOL-FIT ABS Pipe COOL-FIT ABS Pipe

di–di: COOL-FIT Nipple

¥ ‡ 11 Accessory Equipment

COOL-FIT Nipple (ABS) The nipple exists in three versions:

di–di for pipe to pipe and pipe to di–di type fitting connections using the internal diameter of the pipes

d–di for pipe to d–di type fitting connections

di–d red to reduce diameter of the carrier pipe (Note: for dimensions d90 and above the COOL-FIT Calibration Tool is required before jointing the internal diameters of the pipe).

COOL-FIT Calibration Tool It is necessary to calibrate pipe in dimension d90 and above to allow join- ting using the COOL-FIT nipple. This tool calibrates the inside diameter of the pipe to an exact dimension to allow internal jointing. See page XX for order numbers and pages 42–43 for handling instructions.

COOL-FIT Shrink Sleeve, Short Used to vapour seal the outer jacket in PE. The sleeve is 85 mm wide and can only seal equal dimensioned PE jackets. To ensure a vapour and water tight joint with the same insulating properties as the pipe the mini-sleeve should be used with the gap-insulator and the sealing tape.

COOL-FIT Sealing Tape A roll of 35 mm wide, double sided mas- tic tape to vapour seal the joint. Double- sided sticky tape helps locate the shrink sleeve over the gap before shrinking and ensures a top quality seal.

COOL-FIT Gap Insulator Width ¢3 mm and a landa / heat conductivity of 0.04 W/m.K, use of this insulation ensures the same insulating properties in the gap as the pipe.

Use of other insulating and sealing methods such as tape is possible. Please consult the manufacturers of these mate- rials for application instructions, insula- ting properties and life-span.

12 ¥ ‡ Accessory Equipment for Solvent Cement Jointing, Reducing Diameters and End Caps

Tangit ABS and Cementing Equipment The solvent cementing equipment is exactly the same for internal di jointing as for standard d jointing using Tangit ABS. Code numbers can be found on page 36 in this document, see pages 36–43 for jointing instructions.

COOL-FIT Shrink Sleeve, Long This sleeve is 285 mm long, only to be used when sealing PE to PE outer jackets, not for use on ABS. For exact reducing possibilities see below.

Shrink Sleeve, Long Reducing Diameters The COOL-FIT «shrink sleeve, short» can only seal equal dimensions of PE outer jacket. The table below shows which dimensions can be sealed using which long shrink sleeve. NOTE: the sealing tape should be applied to both outer diameters of the PE pipes. PE Dims (D) 90 110 125 140 160 180 225 250 280 315 Shrink Sleeve, Long 738.0¢¢.¢67 (black) and 738.0¢¢.267 (white) 738.0¢¢.¢70 (black) and 738.0¢¢.270 (white) 738.0¢¢.¢73* (black) and 738.0¢¢.273 (white) * only for use over maximum three dimensions, for example, d3¢5 to d225 or d280 to d¢80

End-Caps End-caps are to be used for sealing the PUR against any water ingress at the transition to ABS standard.

Sealing the PUR should be achieved using a chemically compatible glue to COOL-FIT ABS Pipe ABS. Georg Fischer offers silicon glue. If silicon products are prohibited then non-solvent based glues can be used. Chemical compatability can also be Silicon Glue checked by Georg Fischer.

ABS Pipe

¥ ‡ 13 COOL-FIT ABS Reducing Diameters

Reducing Pipe Dimensions for COOL-FIT ABS To reduce the ABS carrier pipe diameter see sketches below. The example below shows how the carrier pipe dimension is reduced from COOL-FIT ABS 90/¢60 to 50/1¢0.

COOL-FIT ABS Pipe ABS Short reducer d90/D¢60 d75–d50 COOL-FIT ABS Pipe d50/D110 COOL-FIT Nipple

d–di COOL-FIT d50–di50 Nipple d–di red di90–d75

Reducing from a «d-Type» COOL-FIT ABS Fitting to COOL-FIT ABS Pipe The d type fittings have a standard ABS d joint as the fitting connection and therefore the standard ABS short redu- cers can be used to reduce the diameter

and then the d–di COOL-FIT nipple for the connection to the COOL-FIT ABS pipe.

COOL-FIT ABS Fitting «d-Type» COOL-FIT ABS Pipe

COOL-FIT Nipple

ABS d–di Short reducer

14 ¥ ‡ COOL-FIT ABS Pressure-Temperature Parameters

Pressure ratings for thermoplastic pipe General are always quoted for water at 20°C. It ABS is generally resistant to most diluted can be used at higher temperatures but inorganic acids, bases and salts and to it is a fundamental principle in thermo- most animal oils and fats. It is not resist- plastic pipework that if the working tem- ant to organic solvents, pure alcohols, perature is increased then the working petrol, acetic acid and vegetable oils. pressure must be reduced. The table below shows, for COOL-FIT Ice Slurry ABS, the maximum permissible pressures Ice slurry is a mixture of ice particles at various temperatures up to the maxi- (0.01–0.03 mm width), water and an mum allowable working temperature anti-freeze agent, usually an alcohol, of +40°C. The table is based on an salt or glycol. Georg Fischer has under- ambient temperature of 20°C with water taken extensive testing of ice slurry with as the medium. A safety factor of ¢.8 is ABS and can give recommendations Ice Slurry incorporated into all calculations with a regarding for example pipeline layout, minimum life span of 25 years. flow rates and pressure drops. Please ask your local Georg Fischer representa- Temperature °C PN ¢0 12 bar (¢45 psi) 11 tive for details. 10 –50 11.8 9 –20 11.8 8 Chemical Resistance 0 11.8 7 designates Please consult Georg Fischer for detailed 20 10.5 6 non-aqueous 30 8.9 5 solution information regarding chemical resist- 40 7 4 ance. 3 2 Georg Fischer offers written confirmation Working Pressure (bar) Working 1 on material compatibility for all chemical 0 –50 –40 –30 –20 –10 0 +10 +20 +30 +40 applications. Working Temperature (°C) Glycol Solutions For working temperatures below 0°C an ABS can be used with glycol solutions anti-freeze has to be used in the water (eg. Antifrogen L, Dowfrost) however a to prevent freezing. The above pressure- de-rating factor applies to the standard temperature curve applies only when the water based temperature – pressure medium is water, therefore for non pure curve, see example. water mediums a de-rating factor has to be applied to the above curve. This is Organic Salt Solutions standard procedure for all plastic piping These mediums are usually potassium systems. formate or acetate water based solu- For example if the medium is a water- tions, with low viscosities at low tempera- diluted glycol solutions m 50% then a tures. Tradename examples: HYCOOL, de-rating factor of 0.5 applies to the TEMPER, TYFOXIT, ANTIFROGEN KF. ABS standard pressure-temperature curve. So can be used with these types of mediums at –¢0°C for a minimum life-span of 25 however, a de-rating factor applies to years the maximum allowable working the standard water based pressure- pressure is 0.5 x ¢¢.8 = 5.9 bar. For more temperature curve. Please consult Georg details regarding these de-rating values Fischer for details. It is important that the for chemical solutions or trade named complete pipe, irrespective of pipe sys- products please consult Georg Fischer. tem material is properly devented both 12 during filling and commissioning. 11 It is very important to follow the manu- 10 9 facturers instructions for pipeline design 8 and handling of these mediums. 7 6 5 4 Antifrogen L 3 (Glycol) 2 P-T Curve Working Pressure (bar) Working 1 0 –50 –40 –30 –20 –10 0 +10 +20 +30 +40 Working Temperature (°C)

¥ ‡ 15 Technical Data

General Comments to Plastics Orien- As a general rule for designing and tated Pipeline Design and Installation installing plastics one of the major diffe- The design and installation of thermo- rences is that plastics can and should be plastic pipe systems requires designers allowed to move after commissioning i.e. and installers alike to take into account move under the influence of temperature the fact that plastics have different physi- fluctuation and pressure changes. For cal characteristics to metal. Although instance using pipe brackets that allow Georg Fischer ABS and COOL-FIT are horizontal movement and not clamping both very robust systems, nevertheless, the system in place is a must for plastic care should be taken during handling piping installations. and transport to avoid damage. Also thermoplastics have certain physical The following technical information co- characteristics, such as a high expansion vers the fundamental information re- coefficient, which need to be taken into quired to ensure an economical and account in the design phase. trouble free installation: Not all details however are published in this document, Georg Fischer has been successfully for more detailed information or if you developing and selling plastic pipe sys- have a specific question please ask your tems into a spectrum of high perfor- local Georg Fischer company, consult mance installations, such as highly con- www.cool-fit.georgfischer.com or e-mail centrated chemicals, for over 40 years, us at [email protected] for and experience has shown that when advice if you have any questions. engineers and installers take into ac- count the advice given in our technical literature plastics are an economical and reliable alternative to metals.

COOL-FIT and ABS On-Line Calcula- tion Tool Georg Fischer has developed a calcula- tion tool to calculate accurately and quickly all the necessary parameters for the engineering of secondary re- frigeration or cooling systems using On-Line via COOL-FIT ABS or standard ABS pipe. www.cool-fit.georgfischer.com

¥ ‡ Piping Systems

16 ¥ ‡ Pipe Pressure Drop For thermoplastic pipes the relative (ABS and COOL-FIT ABS) roughness is negligable and if the user is When calculating the hydraulic pressure using Moody curves the curve labelled loss in m/m in a plastic pipe the excel- «smooth pipes» gives the correct rela- lent smoothness of ABS means that when tion. The roughness factor for ABS pipes using the standard Moody Diagram the is K=0.007 mm. Using the derived f value smooth pipes curve can be used to derive the hydraulic loss, ippi can be calcula- the friction factor. ted. Unlike metal pipes no allowance need be made for corrosion and subse- Imperically it is possible to use the quent reduction of pipe bore or rough- following formulas and procedure to ness. calculate pressure loss in the pipe for any type of fluid. For ease of calculation nomograms are available in standard Georg Fischer Pressure Loss in Pipes literature. The hydraulic loss, in m/m, is given by: Pressure Drop in Fittings (ABS and COOL-FIT ABS) i 2 ppi = 2fv The pressure losses depend upon the gdi type of fitting as well as on the flow in the fitting. The so-called -value is used i for calculations. where ppi = hydraulic loss (m/m) f = friction factor (dimensionless) Page ¢8 contains the -values for common fittings. di = pipe inside diameter (m) g = acceleration due to gravity = 9.8¢ m/s2 To calculate the total pressure loss in all v = flow velocity (m/s) fittings in a pipeline take the sum of the individual losses, i.e. the sum of all the In order to determine the value of the -values. friction factor (f) the Reynolds number must be used. The Reynolds number is The pressure loss can be calculated dimensionless and may be considered according to the following formula: as the ratio of the dynamic forces of mass flow to the shear resistance due to ip =v2¢000 fluid viscosity. It may be calculated using fi the following formula: 2g i where pfi = pressure loss Re = vdi in all fittings (mm) = sum of the individual losses v = flow velocity (m/s) g = acceleration due to The Reynolds number may then be 2 related to the friction factor through an gravity = 9.8¢ m/s = density of the transported empirical formula such as Blausius’ 3 3 smooth pipe formula: medium (g/cm or t/m )

f = 0.079 Re 0.25 valid for Re between 3000 and ¢0 5.

¥ ‡ 17 Pressure Drop in Fittings Pressure Drop in Valves (ABS) Please note there is a slight difference in the coefficient of resistance factors for Flow Rate / Flow Factor standard ABS fittings or for COOL-FIT pre-insulated fittings. This is due to the The kv factor is defined as the flow rate extra fitting required, namely the internal of water in litres per minute with a special nipple and also as some COOL- pressure drop of ¢ kg/cm2 across the FIT fittings have a piece of pipe in the valve. fitting, namely the di fittings. The relationships between kv factor, flow Coefficient of Resistance for ABS rate (Q) and pressure drop (i) are Fittings given in the following formula:

Pipe outside 20 32 50 O 63 Liquids with kinematic viscosity less diameter (d) than 22 centistokes Type of fitting Coefficient of Resistance e.g. water, hydraulic oil 90° Bend 1.5 1.0 0.6 0.5 90° Elbow 2.0 1.7 1.1 0.8 45° Elbow 0.3 Tee 90° 1.5 ͱහ ͱහi Inlet 0.5 k = Q or Q = k Outlet 0.5 v ip v or ip = • Q2 Coefficient of Resistance for COOL-FIT k 2 ABS Fittings v The factors given below are for the COOL-FIT ABS fittings inclusive COOL- where Q = flow rate (litres per minute) FIT nipple. = density of the liquid (kg/dm3) i 2 Pipe outside 20 32 50 O 63 p = pressure drop (kg/cm ) diameter (d) Type of fitting Coefficient of Resistance 90° Bend 1.65 1.15 0.75 0.65 Liquids with kinematic viscosity 45° Elbow 0.45 greater than 22 centistokes Tee 90° 1.8 The effect of viscosity, caused by friction

Pipe to Pipe (di–di) 0.1 0.25 between the particles of the fluid, is no Tee 45° 0.8 1.0 longer negligable, and the flow rate is reduced. The flow factor must be multi- plied by a correction factor, c, to give a

new flow factor, kvn.

kvn = kv • c

The correction factor is given by: ͱහ c = ¢ + kv valid for cm3 only 200•Q

where = kinematic viscosity (centistokes)

kv = flow factor for water (dimensionless) Q = flow rate (litres per minute)

18 ¥ ‡ Pipe Support Distances Horizontals Pipeline Design and Layout For ABS at temperatures L+20°C refer Following are the formulas and informa- to ABS specific literature tion required to calculate change in length of the pipe and allowable flexible Standard ABS COOL-FIT ABS length. at 20°C water, metres water, metres d16 0.7 – i i d20 0.8 – L = L • T• d25 0.85 1 .55 d32 1 .0 1 .55 d40 1 .1 1 .65 i d50 1 .15 1 .65 L = change in length of pipe d63 1 .3 1 .75 L = original length of pipe during instal- d75 1 .5 1 .90 lation d90 1 .6 2.05 d110 1 .8 2.20 = coefficient of expansion (ABS 0.¢, d140 2.05 2.55 COOL-FIT ABS 0.04 mm/m) d160 2.2 2.75 iT = difference in temperatures between d200 2.3 3.05 d225 2.4 3.30 ambient temperature during installation and normal working temperature. The above values are for pipe supported using normal 360° pipe clamps. For va- Expansion and contraction in a pipe line lues using complete axial support please can only take place in a straight direc- consult the COOL-FIT on-line calculation tion; It is therefore necessary to calculate tool at www.cool-fit.georgfischer.com the change in length and then design in compensation for this to avoid unneces- Pipe supports for ABS should allow sary stresses. the system to move under the influence i of temperature, see «Pipe Supports» Example: Calculating L for the sketch page 21 for details. beside for the following assumed condi- tions would be done as follows. Heat Transfer Coefficients – Pipe L = ¢5 metres (total straight length of pipe) ABS and COOL-FIT ABS Ambient temperature during installation = +25 °C Working temperature of medium = –5 °C ABS COOL-FIT ABS W/m.K W/m.K T = –30 (working temperature–installa- d16 1 .278 – tion temperature) d20 1 .487 – = 0.1 mm/m.K (for ABS) d25 1 .742 0.13 iL = ¢5 x –30 x 0.¢ d32 2.078 0.162 d40 2.413 0.165 iL = –45 mm (minus designates a con- d50 2.81 0.213 traction of the length of pipe) d63 3.253 0.245 d75 3.643 0.27 d90 4.073 0.293 A simple and effective d110 4.637 0.341 way to compensate for d140 5.319 0.356 this change in length is d160 5.686 0.381 d200 6.385 0.513 to pre-stress the system d225 6.73 0.515 and if necessary to place a fixed point in the middle of the line to reduce the amount of lateral expansion.

Design of other types of flexible sections and use of compensators is co- Fixed vered in the standard Point Georg Fischer technical literature for plastic pipe systems.

¥ ‡ 19 Pipe Supports for ABS What is a fixed point? Plastic pipe systems should be installed A fixed pipe bracket is a bracket which using supports designed for use with prevents the pipe from moving horizon- plastics and should then be installed tally. The aim of which is to control sys- taking care not to damage or over stress tem stresses caused by temperature the pipe. changes.

KLIP-IT, Types 060 & 06¢ This should not be done by simply clam- Georg Fischer has its own specially ping the bracket onto the outside of the designed pipe support clips in PP and PE pipe ! This can cause deformation and for use with plastic pipes. See product physical damage to the pipe, damage range documentation. that sometimes only later becomes visi- ble.

It should be done either by using two sockets as per sketch below or by using a «double headed» bracket, see also sketch below.

See Georg Fischer plastic technical handbook and homepage for details regarding pipeline layout and installa- tion.

What is a loose pipe bracket? A loose pipe bracket is a bracket which allows axial movement of the pipe, to allow stress free compensation of tempe- rature changes and compensation of any other operating condition changes.

The inner diameter of the bracket should be larger than the outside diameter of the pipe to allow free movement of the pipe. The inner edges of the brackets should be free from any sharp contours which could damage the plastic. If the brackets’ inside diameter is not larger than the pipe then the bracket should not be fully tightened, thus allowing the pipe to move. Another method is to use brackets with spacers which also avoids clamping the bracket on the pipe.

spacer to avoid clamping

20 ¥ ‡ Allowable flexible length, H, for ABS where c is the material constant which is To allow the pipe to bend without stres- derived from the creep modulus of the sing it unduely there is a minimum length material which is: required between direction change and ABS 32.7 pipe support. This takes into account the flexibility of the pipe. The following table allow the flexible length a to be read from the graph once This length is called H is calculated delta L has been calculated. using the formula: Below are the H values for ABS. H = c · d · iL 200 225 160 140 110 90 10000 75 63 50 40 32 25 20 16 d

H 1000

100 110100 1000 ∆L

For COOL-FIT ABS please contact Georg Fischer Piping Systems.

¥ ‡ 21 Plastic to Metal Connections tighten the joint. Namely strap type Fundamentally three options are avail- wrenches prevent damage to the plastic able for plastic to metal connections, components. namely; threads, flanged connection and unions. Installation of Measuring Equipment Georg Fischer recommends that wher- or other Accessories ever possible mechanical connections Following is a summary of the most im- are used (unions and flanges) together portant details regarding this subject, for with a located gasket such as O-Ring. more detailed guidelines please consult www.cool-fit.georgefischer.com. Union Connections This is the most reliable and cost effec- Measuring Equipment in an ABS tive method to connect metal to plastic. System Georg Fischer has a whole range of ABS saddles are available for mid to transition unions with O-Rings specially large dimensions to be cemented to the designed to compensate for the changes pipe using a wedge to fix the parts to in length which can occur in ABS and allow curing of the cement. COOL-FIT due to temperature fluctua- Please consult Georg Fischer or tions. See ABS product range for details www.cool-fit.georgefischer.com for the ABS of the copper, brass, stainless steel and availability and fitting instructions for Copper Located malleable iron transition unions avail- these fittings. O-Ring able. Tee 90° reduced Flange connections Standard ABS tees can be fitted with a Metal to ABS and also ABS to ABS short reducer and then a threaded nipple connections using flange adaptors is or a piece of pipe with a transition possible up to DN300. union to install equipment, this should be For bolt torques, tightening sequences planned in in the design stage of the etc please refer to standard the Georg plant. We recommend use of a transition Fischer Plastics Technical Handbook. union rather than a threaded connec- Georg Fischer’s new revolutionary PN ¢6 tion. PP V-Flange is light weight, with location stubs to aid installation and is designed to avoid high stresses during tightening. ABS Nipple in an Georg Fischer recommends this type of ABS reducing Tee 90° flange for use with plastic flange con- nections. All mechanical connections including Transition Union flanges should be re-tightened after with ABS pipe commissioning if the working tempera- ture is lower than the temperature during installation.

Threaded Connections Georg Fischer recommends avoiding threaded connections for plastic wher- ever possible, solvent cementing is a very reliable and speedy method of jointing and should be preferred to threaded connections. For sealing threaded joints the mating Retro-Installation of Equipment: into parts should always be parallel to tape- an already existing system red. In the ABS range only the plastic For dimensions Ld90 it is possible to use female thread with reinforced ring the extra wall thickness in a cemented should be used for connection to metal joint to bore through pipe and fitting threads. For sealing we recommend only and install a transition union. PTFE tape. 2 layers of tape applied in a See www.cool-fit.georgefischer.com clockwise direction, the components for installation details. should then be joined carefully to avoid damage to the plastic thread. Mechani- cal wrenches should not be used to

22 ¥ ‡ Measuring Equipment in COOL-FIT SIGNET Flow Measuring Equipment ABS Georg Fischer Signet offer paddle wheel As with the ABS system Tee 90° reducers flow measuring equipment which can be are available in COOL-FIT ABS. These used to very cost effectively measure the then need to be planned into the system flow of your medium, with digital and during the design phase of the plant. analogue display devices including At present it is not possible to install cabinet housings for installation in dis- equipment into an already existing play units. COOL-FIT pipe, other than cutting the pipe and placing a Tee in the pipe. These SIGNET flow sensors can be installed using specially designed instal- De-Venting or De-aeration lation fittings, ask Georg Fischer for It is always important to remove air from installation fittings details. any piping system, for salt solutions this is particularly important due to their Curing Time corrosive nature. After jointing the components should be Summary of De-aeration process, left for 2–3 minutes before handling. º always fill the system slowly from the For detailed instructions see ABS jointing bottom up instructions or standard ABS literature. º induce a vacuum in the system The length of curing time required de- before filling pends on the ambient temperature and º install manual and/or automatic de- operating pressure. See standard ABS aerators at the highest points in the literature for details. Generally, the system waiting time after the last joint before º long horizontal runs should be pressurising the system at ¢5 bar (PN¢0) installed at a slight gradient must be at least ¢5 hours. If the pipe is º avoid low points i.e. U-configurations only subjected to the operating pressure where air can be trapped then 1 hour per 1 bar of pressure can º install de-aerators with a buffer zone be applied. of fluid below them, see sketch below º always observe the medium COOL-FIT ABS: manufacturers specific Please remember to place the shrink recommendation for filling, mixing etc sleeve over the pipe before jointing and as secondary fluids differ in their leak test the system before sealing the composition gap betwen fittings and pipe. For further information see www.cool- fit.georgefischer.com

Air release valve

ABS reduced

ABS Tee 90°

¥ ‡ 23 Pressure Testing www.cool-fit.georgfischer.com Medium: We recommend the use of Under the button «condensation» you water as testing medium. The solvent will be asked to input the system para- gases which may be left in the pipe after meters and type of insulation. The results jointing dissolve in water and thus water are guideline values based on trade- also removes all excess solvents from name published data and general physi- the system. Water also has a very low cal data regarding types of insulation. compression ratio and is thus safer as a We recommend the user consults the testing medium. insulation manufacturer for detailed If water is not practical then inert gases specific advice regarding the insulation can be used with ABS and COOL-FIT. when not using COOL-FIT. However the maximum test pressure should not exceed 6 bar. COOL-FIT ABS: Condensation, Compressed air should not be used with Yes or No? ABS or COOL-FIT. COOL-FIT has set thicknesses of insula- tion, once again via Pressures: www.cool-fit.georgfischer.com the user For water 1.5 x working pressure, to a can input his system parameters and the maximum of PN + 5 bar. program will identify whether using For pressure testing with gases maximum COOL-FIT ABS dew will appear on the pressure allowed is 6 bar. outside of the pipe or not. PUR has a thermal conductivity of 0.026 Time under Pressure Test: W/m.K and the thickness is +/–35mm We recommend that the system is left at for all dimensions so the system para- the test pressure for minimum 6 hours to meters need to be extreme for dew to ensure complete leak tightness control. appear on the outside of COOL-FIT ABS. Insulation For example: Insulating ABS Medium temperature: – 50°C ABS is not chemically resistant to sol- Temperature of the surrounding +20°C vents. Solvents are used in the jointing Relative atmospheric humidity 75% process to soften and swell the ABS to Wind velocity: 1 m/s create a weld. This use of solvent takes Under the above circumstance there will place under controlled conditions and be no condensation on the pipes. uses double wall thickness by inserting pipe in fitting. Foaming ABS with PUR On-Site Any other contact of solvents with ABS There are various types of PUR on the should be avoided. Some insulation market using different types of activators materials on the market use solvent to initiate the foaming process. All are based glues to position the insulation, as however an exothermic reaction, i.e. per manufacturers’ instructions only the generate heat, usually reaching tempe- insulation itself should be glued together. ratures of about 120°C, which can be dangerous for thermoplastics. ABS has a Any excess glue which may come into vicat point, softening point of 98°C, this contact directly with the ABS should be means that any temperatures reached removed with a cloth. above this have a detrimental effect on If insulation has been glued directly to the ABS. Also usually the foaming on-site the pipe this does not mean that the takes place in an enclosed volume which system is now dangerous. It can however then causes external pressures on the only be determined on a case to case component. For these reasons we recom- basis if the situation will have a detri- mend that ABS fittings and pipe are not mental effect on the performance of the insulated using PUR foaming on-site. pipe. Contact Georg Fischer if you re- COOL-FIT is foamed under controlled quire more information on this subject. conditions ensuring that the quality of the ABS is not affected by the PUR Insulation to avoid Dew on ABS foaming process. To calculate the necessary thickness of insulation required on ABS to avoid Dew or Condensation can be done via Georg Fischer’s on-line cooling calcu- lation program, see

24 ¥ ‡ COOL-FIT Under-Ground approximately one year, after which the COOL-FIT ABS can be used under- oxidised layer on the outside surface of ground. Standard guidelines for laying the ABS acts as a barrier and the impact of plastic pipe systems underground strength does not deteriorate further. should be followed. Although the ABS impact strength is reduced under UV light it still remains at Under normal circumstances it is not a very high level. necessary to building any expansion loops into the system. Note: avoid move- The Environment ment of the pipe before filling the trench. ABS and COOL-FIT ABS are halogen Please consult Georg Fischer for recom- free. The materials used in COOL-FIT mendations regarding underground ABS namely ABS, PE and PUR are all installation. recyclable materials. Georg Fischer as a company aims to De-Frosting understand and meet customer require- Many secondary refrigeration loops are ments regarding the environment. We not only used for normal and low tempe- design products and develop our pro- rature cooling but are also used for de- cesses taking into account the environ- frosting. Georg Fischer has many years ment and its needs. of good experience with the use of ABS in such dual de-frost / cooling systems without any detrimental effects to the system.

Long Term Life-Span of ABS Pipes One of the major differences in physical characteristics between plastics and metals is the physical characteristic creep. Creep is a time related physical property of plastics. Under a constant stress plastics strain and the amount of strain is time related. This characteristic is taken into account in the Pressure-Temperature curve which is based on a minimum Life-Span of 25 years and with a safety factor of ¢.8. This curve and further background data relating to creep, the long term hydro- static curves, and other system defining criteria can be found in ISO 15493.

Storage All plastic pipes including pre-insulated plastic pipes, i.e. COOL-FIT ABS should be stacked on a flat surface free from sharp edges, such as stones or building debris for instance. During handling care should be taken to avoid damage to the outside surface of the pipe, for instance no dragging along the ground. Avoid pipe overhangs when stored as this will cause the pipe to bend.

UV Resistance Most plastics suffer some loss of physical properties when exposed to UV light, only PE Black, used also for the outer jacket of the COOL-FIT ABS black, is UV resistant. The impact strength of ABS reduces under UV light over a time period of

¥ ‡ 25 Flammability PUR Flammability A means of measuring flammability is by Rigid polyurethane-based foams are using the limiting oxygen index (LOI) to effective insulation materials commonly ASTM 2863 or BS2782-141. These va- used in the construction industry. Polyure- lues are shown below for the COOL-FIT thane foam will burn if exposed to fla- raw materials and for comparison pur- mes. The combustibility characteristics poses some other commonly used mate- vary with chemical composition. Unlike rials. expanded polystyrene (eps), polyure- thane does not melt. It flashes into A material with a LOI value above 21 flames between 800°F and 850°F, and does not support combustion in air at only chars rather than melts at tempera- room temperature. tures below that range. The charring may in fact help protect the adjacent Material LOI foam. Some studies have indicated that ABS 18.3–18.8 Douglas Fir was more toxic than polyure- PE 17.4 thane foam. In a paper presented at the ¢985 Society of the Plastics Industry, Cotton 16 –17 annual meeting on polyurethane foam. Please consult Georg Fischer for further ABS Flammability details. According to UL-94, ABS has an HB (Horizontal Burning) flammability coeffi- cient and falls into building material class B2 (conventional inflammable, non- dripping) according to DIN 4¢02-¢. Fundamently, toxic substance are re- leased by all burning process. Carbon monoxide is generally the most impor- tant. When ABS burns, primarily carbon dioxide, carbon monoxide and water are formed. Tests have shown that the relative toxicity of the products of com- bustion are similar or even lower than those of natural products such as wood, wool and cotton. ABS combustion gases are not corrosive. That the burning nevertheless forms soot, smoke develops during combustion. Suitable fire-fighting agents are water, foam and carbon dioxide.

PE Flammability The following classifications in accord- ance with differing combustion standards: According to UL94, PE is classified as HB (Horizontal Burning) and according to DIN 53438-¢ as K2. Accord- ing to DIN 4¢02 part ¢ and ÖNORM B3800 part ¢, PE is listed as B2 (normally flammable). In the French classification of building materials, polyethylene corres- ponds to M3 (of average flammable rating). The self ignition temperature is 350°C. Suitable fire-fighting agents are water, foam, carbon dioxide or powder.

26 ¥ ‡ ABS Metric Piping System Specification

1 Scope 3 ABS Pipe This specification covers requirements for All ABS pipe shall be metric sizes manu- the Georg Fischer ABS Piping System factured in accordance with the re- intended for a wide range of applica- quirements of ISO ¢5493, supplied by tions including water and wastewater Georg Fischer. treatment as well as process cooling water and secondary refrigeration. 4 ABS Fittings The components of the ABS pipe system All ABS fittings shall be metric sizes are in accordance with the following manufactured by Georg Fischer or standards. equal, with dimensions and tolerances in accordance with ISO 727 and ISO 2 Acrylonitrile Butadiene Styrene ¢5493. All threaded connections shall Material have pipe threads in accordance with Georg Fischer ABS pipes and fittings the requirements of ISO 7-¢:¢994. shall be manufactured from acrylonitrile butadiene styrene, ABS. The raw mate- 5 ABS Valves rial used shall be material designed All ABS valves shall be metric sizes ma- for use with pressure bearing piping nufactured by Georg Fischer or equal in systems with long term hydrostatic pro- accordance with DIN 344¢ Parts ¢ to 4. perties in accordance with ISO 15493, as supplied by Georg Fischer. 6 Solvent Cement Jointing and For detailed physical properties see Installation Georg Fischer literature reference Fi9030, Should be in accordance with Georg pages 28–30. Fischer’s Guide to the Installation and Use of Plastic Pipelines.

COOL-FIT ABS Pipe and Fittings Specification

1 Scope 2.2 Physical Properties This specification covers requirements The ABS carrier pipe and fittings shall for Georg Fischer COOL-FIT ABS (pre- be manufactured to metric sizes in insulated ABS pipe and fittings), intended accordance with the requirements of primarily for use in refrigeration and ISO ¢5493, supplied by Georg Fischer. cooling plants for the secondary piping systems. The system consists of pre-insu- 3 PUR Insulation lated pipe and fittings using ABS carrier The insulating material shall be hard pipe and fittings, with insulation from polyurethane foam, PUR, with a thermal PUR and outer jacket in PE. conductivity, landa value, of l0.026 W/ The components of the COOL-FIT ABS mK and a density of L45 kg/m3. pipe and fittings are in accordance with the following standards. 4 HD-PE Outer Jacket The outer jacket shall be manufactured 2 ABS Carrier Pipe and Fittings from HDPE, high density polyethylene, 2.1 Raw Material black and white. Colours of the jacket Georg Fischer ABS pipes and fittings shall be black to RAL 9004 and white to shall be manufactured from acrylonitrile RAL 90¢0. The black jacket shall be UV butadiene styrene, ABS. The raw materi- resistant in accordance to DIN 8075. al used shall be a material for use with pressure bearing plastic pipe systems in 5 Solvent Cement Jointing and accordance to ISO 15493. For detailed Installation physical properties see Georg Fischer Should be in accordance with Georg literature reference Fi9030, pages 32–34. Fischer’s Guide to the Installation and Use of Plastic Pipelines.

¥ ‡ 27 28 ¥ ‡ Contents Page

Black and white: Product Range Pipe 30

Black and white: Product Range Fittings 30–34

Accessory Equipment 35–37

¥ ‡ 29

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¥ä ¥ ‡ 37QU Instructions for Solvent Cement Jointing of ABS

General

Solvent cement jointing calls for ade- quate technical knowledge, which can be acquired in the appropriate training courses. Your Georg Fischer representative will gladly provide you with information about training possibilities.

The dimensions of Georg Fischer pipes, fittings and valves conform generally to the various national standards as well as to ISO 727 concerning dimensions of Cutting the pipe to length sockets. Our fittings and valves can be used with any ABS pipes whose outside diameter tolerance conforms to ISO 15493.

According to ISO 727 the following mini- mal cement lengths are valid:

Pipe outside diameter Minimal cement – length Socket inside diameter d (mm) L (mm) 12 12.0 Chamfering the pipe 16 14.0 20 16.0 25 18.5 32 22.0 40 26.0 50 31.0 63 37.5 75 43.5 90 51.0 110 61.0 125 68.5 140 76.0 160 86.0 200 106.0 225 118.5 Tools and equipment

Pipe cutter d 10–63 790 109 001 Solvent cementing equipment Type KRA d 50–110 790 109 002 d 110–160 790 109 003 Preparations Plastic pipe cutter 230 V/50 Hz 790 201 001 Type KRT 250 120 V/60 Hz 790 201 002 The pipe must be cut off at right angles. 110 V/50 Hz 790 201 003 Remove the inside edges and chamfer Chamfering tool d 16–75 799 495 145 the outside ones as illustrated in the d 32–200 799 495 146 sketch. Only then is an optimal solvent Cleaner 799 298 010 (1 litre tin) cemented joint possible. Tangit ABS Solvent Cement 799 298 022 (0.65 kg tin) Brush sizes Pipe outside Brush Code-No. diameter in mm 16–110 Round brush ø 4 mm 799 299 001 12–132 Round brush ø 8 mm 799 299 002 40–163 Flat brush 25 x 3 mm 799 299 003 75–225 Flat brush 50 x 5 mm 799 299 004 Tin lid 799 298 028 White absorbent paper commercially available Solvent resistant commercially available protecting gloves

38 ¥ ‡ Pipe outside diameter b mm mm 6–16 mm 1–2 mm 20–50 mm 2–3 mm O 63 mm 3–6 mm

Important: Well-chamfered pipe ends prevent the layer of cement from being removed as the pipe is inserted into the fitting.

Wipe the outside of the pipe and the inside of the socket with a clean cloth to remove obvious dirt. Marking the jointing length on the pipe end makes it possible Checking the cement to check afterwards whether the pipe has been inserted to the full extent of the Cementing socket. For surfaces which are clean and free from grease, cleaning with absorbent paper and Tangit cleaner is not necessary for ABS. For surfaces not in perfect condition clean the outside of the pipe end and the inside of the socket thoroughly with ABS Cleaner and absorbent paper. Use a fresh piece of paper for each component. Remove any condensation which may have formed on the parts.

Marking the jointing length Cleaning the pipe and socket

Important: Pipe end and fitting socket Note: If the outside diameter of the pipe must be dry and free from grease and and the inside diameter of the socket are dirt and must not be touched after at opposite extremes of their tolerances, cleaning. then the pipe cannot be inserted dry into the fitting socket. This will only become ABS pipes should be cemented at tem- possible once the cement has been ap- peratures between –5 °C and +40 °C. plied. Take the following protective measures if the temperatures deviate from the The Tangit ABS Cement is supplied above: ready for use. Stir thoroughly before us- ing! Cement of the correct consistency At temperatures near freezing point con- will run evenly from a wooden spatula densation or ice water which may have held at a slant. Cement which no longer formed must be removed, e. g. with runs smoothly is unusable. The cement warm air. Cement and cleaner should must not be thinned. Cement and clean- be stored at room temperature. Com- er should be stored in a cool, dry place pleted joints must be left at 20–30 °C for (5–25 °C)! approximately 10 minutes to condition.

¥ ‡ 39 Avoid overheating when cementing at After the cement has been applied insert higher temperatures by protecting the the pipe to the full depth of the socket jointing area from direct sunlight. immediately without twisting and bring them into the correct alignment. Ensure The quick curing time of the cement ne- that the outlet of the fitting is in the cor- cessitates that the joint is made within rect position. Hold them briefly in this 1 minute after application of the cement position to allow the cement to set. Wait has started. The opening time of the ABS at least 10 minutes before the next joint, cement varies with the ambient tempera- extend the waiting time at temperatures ture and/or the thickness (1 mm) of the under 10 °C to 15 minutes. cement applied: Remove any surplus cement immediately, using absorbent paper.

A bead of excess solvent cement around the complete external circumference of the joint and a slightly smaller bead again around the complete internal cir- cumference show that the joint has been performed correctly.

After use clean the brush of excess ce- T Temperature [°C] ment with dry absorbent paper and then Y Open time [sec] clean thoroughly using TANGIT cleaner. Brushes must be dry before being re- Begin by applying a normal layer of used (shake out). cement to the fitting socket and then a thicker one to the pipe end with firm Replace the lid of the cement tin after brush pressure. Work in well. The brush use to prevent the solvent evaporating. strokes should always be in an axial di- Using the conical lid allows to leave the rection. brush in the cement tin during breaks.

To ensure that both jointing surfaces are completely covered with a smooth, even layer of cement, the brush should be generously loaded with cement.

The joints can be made single handed for pipes with diameters up to d 63 mm.

Applying the cement

Replace the lid of the cement tin during work breaks For d 75 mm and larger pipes, two peo- ple are needed to apply the cement to Both solvent cement and cleaner dis- the pipe end and fitting socket simultan- solve ABS. Pipes and fittings must not eously in order to avoid exceeding the therefore be laid on or allowed to come maximum opening time of the cement of into contact with spilled cement or paper 1 minute. containing cement residues.

40 ¥ ‡ The pipe trench is not a rubbish tip Adequate ventilation of the workplace

It is recommended to scavenge the pipe- Cement and cleaner are inflammable. line after finishing, and leave it filled with Extinguish open fires before commencing water if it is not directly used. Do not use work. Switch off unprotected electrical compressed air for scavenge. apparatus, electric heaters, etc. Do not smoke! Discontinue any welding opera- Drying period and pressure testing tions. Furthermore, observe all instructions The length of drying period before the issued by the solvent cement manu- joint may be subjected to testing or op- facturer (e. g. label of the tin and any erating pressure depends on the ambi- supplementary documentation). ent temperature and the tolerances. A longer waiting time should be applied when temperatures exceed ambient. Generally the waiting time after the last joint until the pressure test at a testing pressure of 15 bar (PN 10) must be at least 15 hours. If the pipe is only subject- ed to the operating pressure, e. g. after adaptation or repair works, the follow- ing rule of thumb for the drying period applies: 1 hour waiting time per bar operating pressure at temperatures of up to 25 °C. For waiting times at higher temperatures No naked flames when cementing please consult your local Georg Fischer No smoking Representative. Protect pipes and fittings from spilled Safety precautions solvent cement, cleaner and absorbent Tangit Cement and Tangit Cleaner con- paper which has been used to wipe off tain highly volatile solvents. This makes cement. Do not dispose of surplus solvent good ventilation or adequate fume ex- cement or cleaner in drainage systems. traction essential in closed spaces. Since the solvent fumes are heavier than air, The use of protective gloves is recom- extraction must occur at floor level, or at mended to avoid contact of the skin with least below the working level. Place pa- solvent cement and cleaner. If the cement per which has been used for cleaning or or the cleaner get in contact with eyes, for the removal of surplus cement into rinse immediately with water. closed containers to minimize the Consult a doctor! Immediately change amount of solvent fumes in the air. clothes that have solvent cement on them.

Always obey the safety regulations issued by the authorities responsible.

Do not close off cement pipelines during the drying process. This is particularly important at temperatures below +5 °C, when there is otherwise a danger of damaging the material.

¥ ‡ 41 ABS Tangit and Cleaner: Amounts required

ABS Tangit- ABS Tangit Tangit-Cleaner Tangit-Cleaner Socket Amount per Number of Joints Amount per Number of Joints d (ABS) Length ¢00 Joints per Tin ¢00 Joints per Tin mm mm* kg 0.650 kg litre (1 litre) 16 14 0,25 260 0,09 1111 20 16 0,35 186 0,18 556 25 18,5 0,40 163 0,3 333 32 22 0,45 144 0,5 200 40 26 0,60 108 0,7 143 50 31 0,90 72 0,9 111 63 37,5 1,10 59 1,1 91 75 43,5 1,25 52 1,3 77 90 51 1,70 38 1,45 69 110 61 2,50 26 1,7 59 140 76 5,00 13 2,1 48 160 86 6,47 10 2,5 40 200 106 9,96 7 3,5 29 225 118,5 12,53 5 4,5 22 250 131 15,39 4 5,5 18 280 146 19,21 3 6,5 15 315 163,5 24,20 3 7 14

d * The socket length can be calculated using the following simple formula: /2+6

42 ¥ ‡ Instructions for Solvent Cementing COOL-FIT ABS

The jointing technique for COOL-FIT ABS internal jointing follows the same tried and tested technique as that for stand- ard ABS using exactly the same tooling and Tangit cement.

Following is a summary of ABS solvent cement jointing for COOL-FIT ABS. Please refer to the standard ABS solvent cementing jointing instructions for exact curing times, handling instructions, health Mark the inside diameter of the pipe to and safety advice and commissioning the minimum socket depth required. procedure. Socket depth is always d/2 + 6 (mm), for example socket length for d90 = 5¢ mm (90/2 + 6).

Chamfer to 45° the internal diameter of the ABS pipe. Apply the ABS cement to the outside of the COOL-FIT nipple, axially, smoothly in one action, in an even layer, approxi- mately ¢ mm thick. Use a firm pressure on the brush when applying the cement to work the cement into the fitting.

Check the consistency of the ABS Tangit cement. The cement should run smoothly and before jointing check that all tools required are readily to hand.

Apply the ABS Cement to the inside surface of the COOL-FIT pipe. Apply the cement to the depth marked, using the same technique as with the fitting.

Insert the COOL-FIT ABS nipple axially into the pipe being careful not to rotate the parts. Remove all excess cement For surfaces not in perfect condition clean using absorbent paper. the outside surface of the cool-fit nipple The installer should take note of the and the inner surfaces of the cool-fit pipe, Tangit ABS opening time and safety using Tangit cleaner with clean absorbent precautions written on the Tangit tin and paper. in standard ABS jointing instructions.

¥ ‡ 43 Jointing technique: Pipe preparation (Calibration only required for d O 90)

1Cut pipe at right angles, 90°. 4 Insert the tool into the pipe to the depth indicated on the spindle. For For ABS dimensions ld90 calibration short lengths of pipe see instructions of the pipe is not required, please packed with the tool. follow cementing instructions.

2 For dimensions O d90 the internal 5Wind-out the jaws of the tool until the diameter of the pipe needs to be tool is firmly located. calibrated using the COOL-FIT calibration tool.

3 Assemble the COOL-FIT calibration 6Wind-in cutting head checking tool using the relevant parts for the that the cutting knife and the other required dimension. 2 locating heads are assembled in Detailed instructions are delivered with the correct location. the tool.

44 ¥ ‡ Jointing technique: Pipe preparation

7Please note that the tool calibrates ¢0 Wind-in the locating jaws until the the pipe and therefore may not tool is loose then carefully retract always remove material and may the tool taking care not to damage remove different amounts of material the pipe. as it cuts.

8 The cutting knife can be rotated to cut ¢¢ It is recommended that the installer with a fresh edge if the knife becomes checks the diameter of the calibrated blunt or if it is damaged. pipe at regular intervals, the internal diameters required are listed in the COOL-FIT catalogue and in the too- ling instructions.

9Wind-in the cutting head until it butts up to the end of the pipe.

¥ ‡ 45 Instructions for Insulating the Gap

Please take care that the «shrink sleeve, short» has been placed over the pipe before jointing.

If it is not possible to use the shrink Place the shrink sleeve over the middle sleeve or the sleeve is damaged Georg of the gap. Locate the sleeve by pressing Fischer has a «sealing wrap», effectively it onto the double sided sticky tape. a high-duty tape available on demand. It is also possible to use other heavy- duty insulating tapes instead of the shrink sleeve. For the life-span and sealing properties of these tapes please consult the individual manufacturers.

Wrap the «gap insulator» into the gap Using an open flame apply heat to the between the COOL-FIT ABS components sleeve, taking care to keep the flame taking care to ensure that the gap is moving to avoid the sleeve melting. completely filled. To avoid the sleeve distorting apply the heat to the middle of the sleeve, not from the side. The sleeve will now shrink to the outside diameter of the jacket pipe. Note: hot air can be used to shrink the sleeve but is not recommended due to the high amount of energy required to activate shrinking.

Apply the double sided sealing tape around the complete circumference of the outer pipe.

46 ¥ ‡ ABS Product Range

Background Information to the ABS Product Range from Georg Fischer

ABS from Georg Fischer is a pressure ABS metric can be used for mediums at bearing complete piping system that has temperatures between –40°C to +60°C been available from Georg Fischer since and has a nominal pressure rating of the mid 80’s. PN¢0 (¢0 bar water at 20°C). Georg Fischer offers 2 standard systems in ABS; firstly a BS Inch dimensioned Examples of application areas are: system and secondly a metric mm dimen- refrigeration secondary systems, for sioned system. See ISO¢5493 for details. instance in supermarkets or breweries, iced-water or ice slurry systems in ABS metric is available in dimensions pharamaceutical plants, water treatment from d¢6 to d3¢5 with a complete range plants, for drinking and cooling water on of fittings and transition fittings for metal ships. Many other application areas are to plastic connections as well as a com- possible. Please ask Georg Fischer for plete range of manually and actuated recommendations of suitability. valves. COOL-FIT ABS is only available using the metric ABS system. The ABS valves are completely corrosion resistant with no metal parts and can be actu- ated either pneumatically or electrically.

¥ ‡ 47 COOL-FIT

º Top Quality º Minimum On Site Time

pre-insulated plastic piping system

¥ ‡ Piping Systems

A Georg Fischer Rohrleitungssysteme GmbH, Sandgasse 16, 3130 Herzogenburg, Tel. +43(0)2782/856 43-0, Fax +43(0)2782/856 64, [email protected], www.georgfischer.at AUS George Fischer Pty Ltd, 186–190 Kingsgrove Road, Kingsgrove NSW 2008, Tel. +61(0)2/95 54 39 77, Fax +61(0)2/95 02 25 61 [email protected], www.georgefischer.com.au B/L Georg Fischer NV/SA, Digue du Canal 109-¢¢¢ — Vaartdijk 109-¢¢¢, 1070 Bruxelles/Brüssel, Tél. +32(0)2/556 40 20, Fax +32(0)2/524 34 26 [email protected], www.georgfischer.be BR George Fischer Ltda, Av. das Nações Unidas 21689, 04795-100 São Paulo, Brasil, Tel. +55(0)11/5687 1311, Fax +55(0)11/5687 6009 CH Georg Fischer Rohrleitungssysteme (Schweiz) AG, Amsler-Laffon-Strasse ¢, Postfach, 8201 Schaffhausen, Tel. +41(0)52 631 30 26, Fax +41(0)52 631 28 97 [email protected], www.piping.georgfischer.ch CHINA Georg Fischer Piping Systems Ltd Shanghai, No. 2Ý8 Kang Qiao Dong Rd., Shanghai 201319, Tel. +86(0)2¢/58 13 33 33, Fax +86(0)2¢/58 13 33 66 [email protected], www.cn.piping.georgfischer.com D Georg Fischer GmbH, Daimlerstraße 6, 73095 Albershausen, Tel. +49(0)7161/302-0, Fax +49(0)7161/30 2 111, [email protected], www.rls.georgfischer.de Georg Fischer DEKA GmbH, Kreuzstrasse 22, 35232 Dautphetal-Mornshausen, Tel. +49(0)6468/915-0, Fax +49(0)6468/915 221/222, [email protected], www.dekapipe.de DK/IS Georg Fischer A/S, Rugvænget 30, 2630 Taastrup, Tel. +45 70 22 19 75, Fax +45 70 22 19 76, [email protected], www.georgfischer.dk E Georg Fischer S.A., Alcalá, 85, 2a, 28009 Madrid, Tel. +34(0)9¢/781 98 90, Fax +34(0)9¢/426 08 23, [email protected], www.georgfischer.es F George Fischer S.A.S., 105–1¢3, rue Charles Michels, 93208 Saint-Denis Cedex 1, Tél. +33(0)1/492 2¢ 34 ¢, Fax +33(0)¢/492 2¢ 30 0, [email protected], www.georgefischer.fr GB George Fischer Sales Limited, Paradise Way, Coventry, CV2 2ST, Tel. +44(0)2476/535 535, Fax +44(0)2476/530 450, [email protected], www.georgefischer.co.uk GR Georg Fischer S.p.A., Athens Branch, 101, 3rd September Str., 10434 Athen, Tel. +30(0)1/882 0491, Fax +30(0)1/881 0291, [email protected] I Georg Fischer S.p.A., Via Sondrio 1, 20063 Cernusco S/N (MI), Tel. +3902/921 861, Fax +3902/921 407 85-6, [email protected], www.georgfischer.it ID George Fischer Representative Office, c/o Wisma Aria, 3rd Floor, Jl. H.O.S. Cokroaminoto 81, Jakarta 10310, Indonesia, Tel. +62(0)21/391 48 62, Fax +62(0)21/391 48 63 IND George Fischer Piping Systems Ltd, India Branch Office, Solitaire Corporate Park, 532, Building No. 5, 3rd Floor, Chakala, Ghatkopar Link Road, Andheri (E) 400 093 Mumbai, Tel. +91(0)22/820 2362, Fax +91(0)22/820 2462, [email protected] J Georg Fischer Ltd, 13–8, Nanbanaka 1-chome, Naniwa-ku, 556-0011 Osaka, Tel. +81(0)6/6635 2691, Fax +81(0)6/6635 2696, [email protected], www.georgfischer.jp N Georg Fischer AS, Rudsletta 97, ¢35¢ Rud, Tel. +47(0)67 18 29 00, Fax +47(0)67 13 92 92, [email protected], www.georgfischer.no NL Georg Fischer N.V., Postbus 35-8160, 8161 PA Epe, Tel. +31(0)578/678222, Fax +31(0)578/621768, [email protected], www.georgfischer.nl PL Georg Fischer Sp. z o.o., ul. Radiowa 1A, 01-485 Warszawa, Tel. +48(0)22/638 91 39, Fax +48(0)22/638 00 94, www.georgfischer.pl RO Georg Fischer Rohrleitungssysteme AG, Rep. Office Romania, 11 Barbu Delavrancea, 70000 Bucharest - Sector 1, Tel. +40(0)1/222 91 36, Fax +40(0)1/222 91 77 [email protected] S/FIN Georg Fischer AB, Box 113, 12523 Älvsjö-Stockholm, Tel. +46(0)8/506 77 500, Fax +46(0)8/749 23 70, [email protected], www.georgfischer.se SGP George Fischer Pte Ltd, ¢5 Kaki Bukit Road 2, KB Warehouse Complex, 4¢7 845 Singapore, Tel. +65(0)67 47 06 ¢¢, Fax +65(0)67 47 05 77, [email protected], www.georgefischer.com.sg USA George Fischer Inc., 2882 Dow Avenue, Tustin, CA 92780-7258, Tel. +1(714) 731 88 00, Toll Free 800/854 40 90, Fax +1(714) 73¢ 62 01 [email protected], www.us.piping.georgefischer.com Export Georg Fischer Rohrleitungssysteme AG, Ebnatstrasse ¢¢¢, Postfach, CH-820¢ Schaffhausen, Tel. +41(0)52 63¢ ¢¢ ¢¢, Fax +41(0)52 63¢ 28 93/631 28 58 [email protected], www.piping.georgfischer.com

Fi48 5720/4 (2.04) © Georg Fischer Rohrleitungssysteme AG, CH-820Ý Schaffhausen/Schweiz, 2004 Printed¥ in Switzerland ‡