BS EN 598 for sewerage applications

Transcription

1 BS EN 545 for water pipelines BS EN 598 for sewerage applications by SUNS PIPELINE COMPANY LIMITED Published in Apr 2016 (Rev 4)

2 Contents Introduction Page 2 Double Socket 90 Bend 28 Manufacturing Process - Double Socket 45 Bend 28 Ductile Iron Pipes 3 Double Socket 22.5 Bend 29 Ductile Iron Fittings 4 Double Socket Bend 29 Quality Checks & Assurance 5 All Socket Tee Ductile Iron Properties 6 Double Socket Level Invert Tee with Flanged 33 Branch Material Characteriestics & Chemical Double Socket Taper Composition Normative References 8 All Socket Crosses Technical Specification Data All Socket 45 Tee 38 Wall Thickness 9 Cast on Pipe/ Puddle Pipe (Double 38 Flanged/Flanged Spigot/Double Spigot) Allowable Pressures 9 Flanged Spigot 39 Operation Temperature 10 Flanged Socket 39 Straightness of Pipe 10 Mechanical Collar 40 Angular Deflection for Flexible Joints 10 Double Socket Collar 40 Permissible Straight Draw for Flexible Joints Blank Flange (Axial Movement) Coating & Lining 11 PN16/PN25 Flange to BS EN1092 / BS Jointing (Flexible Joints and Flanged Joints) 12 Pipe Blocks 43 Dimension of Pipes EPDM Gasket for Flanges to BS EN1092 / 44 BS4504 Dimension of Fittings P-Trap (Socket x Spigot) 45 Double Flanged 90 Bend 15 Long Radius Bend (Socket x Spigot) 45 Double Flanged 45 Bend 15 Installation Guide - Socket Joint 46 Double Flanged 22.5 Bend 16 Installation Guide - Flanged Joint 47 Double Flanged Bend 16 Repair 48 Double Flanged 90 Long Radius Bend 17 Recommendations for Handling, Packing & Storage Double Flanged 90 Duckfoot Bend 17 All Flanged Tee & Radial Tee Double Socket Tee with Flanged Branch Double Flanged Taper 24 All Flanged Crosses 25 All Flanged Level Invert Tee 26 All Flanged 45 Tee 27 Flanged Bellmouth 27 1

3 Introduction KEY brand Ductile Iron Pipes & Fittings are manufactured by SUNS PIPELINES COMPANY LIMITED while BUN KEE has been appointed as the sole distributor in Hong Kong and Macau region. Not only KEY by SUNS consistently delivers first & foremost the best quality products to clients, but also the most practical technical supports and honorable shipment against customer commitments with proven supplied track records. SUNS PIPELINES COMPANY LIMITED, which is under SUNS industry group, was founded in 2002 with the registered capital of 400 million. SUNS is a member of the drafting committee of ductile iron pipe s standard GB/T in China, and we also produce various international standards such as ISO2531, BS EN545, BS EN598 and ANSI/AWWAC 151 while a great variety of requirements from different end users are mostly fulfilled. SUNS is indeed a professional manufacturer of water-cooling ductile iron pipes and matched fittings. SUNS strictly perform ISO9001 international standard system on maintaining the product quality system. From raw material procurement to finished products, every little process is comprehensively controlled. SUNS has also been approved by many product system certification organization such as BV, WRAS, KSD and SGS. SUNS s products have been widely exported to more than 50 countries and regions aboard such as America, Spain, Belgium, England, Italy, Germany, Brazil, Saudi Arbia, Syria, Iraq, Ethiopia, Singapore, Vietnam and Hongkong.ect. SUNS succeed in winning the bid of products supplier towards 2008 Beijing Olympic Games, Nanjing Youth Olympic Games, Shanghai Expo Site, Wanjiazhai diversion project and many fire protection projects. In the past ten years, SUNS has already established long-term good cooperation relationship with more than 1000 water utility companies of Beijing, Tiajin, Taiyuan, Shanghai Pudong Veolia and so on. Our products as well as our services have been well acknowledged and accredited by the public. 2

4 Manufacturing Process Ductile Iron Pipes Spectral analysis Molten iron Adjusting the composition of molten Spheroidization Polishing Zinc coating Indentation test Heat annealing Centrifugal casting Hydrostatic test Chamfering Cement lining Curing of cement lining Polishing the cement lining Warehouse Packing Drying the bitumen Bitumen painting Heating the pipe 3

5 Ductile Iron Fittings EPS foaming Molding Splicing individual mold Dip coating of the mold Drying the coating Sand blasting Taking out the fitting shell Casting Spheroidization Molding in the sandbox Polishing Machining Zinc rich painting Hydrostatic test Cement lining Warehouse Bitumen painting Curing of cement 4

6 Quality Checks & Assurance Quality System Self-inspection, Inspection each other, Professional inspection of the QC department, Random inspection of stock. 87 inspection items for each pipe. Component analysis, Hydrostatic pressure test, Tensile / Elongation / Brinell hardness test, Wall & coating thickness test, Straightness test.etc The comprehensive and professional laboratory. Cerifications Advanced inspection equipments German spectal analyzer, American electic furnace, Utrasonic thicknesss tester. 5

7 Ductile Iron Properties Ductile iron, having various technical names while also known as ductile cast iron, nodular cast iron, spheroidal graphite cast iron (SG CI) and spherulitic graphite cast iron. Whilst most varieties of cast iron are brittle, ductile iron has higher ductility among which means having greater impact and fatigue resistance, due to its nodular graphite inclusions. Microstructure of Cast Iron (Grey Iron) Microstructure of Ductile Iron The key yardstick to clasify the grade between Ductile Iron to Grey Cast Iron is by comparing their Mechanical Property, namely to measure their tensile strength & elongation values. Advantage of Ductile Iron Pipes High Tensile strength, good elastic module and excellent ductility, making it suitable for high stress applications where pressure surge may be experienced. High corrosion resistance with external metallic zinc & finishing coatings. Excellent hydraulic flow. High working pressure comparing to other types of pipes. Ease of installation. Long lifetime. Can accommodate ground movement. Main applications of Ductile Iron Pipes Drinking and irrigation water networks. Sewerage networks. Fire fighting systems. Water-cooling systems including Sea-water cooling. 6

8 Material Characteriestics Mechanical Properties Ductile iron pipe Ductile iron pipe (Centrifugally cast) (Centrifugally cast) (BS EN 545) (BS EN 598) Grey cast iron pipe Steel pipe Tensile strength (N/ mm 2 ) Elongation (%) Hardness (HB) DN DN Neglect Approx. 140 DN K9 (Class 50 & above) 5.0 Hydrostatic Pressure test (MPa) DN K9 (Class 40 & above) 4.0 DN K12 (Class 50 & above) DN700 & above K9 & K12 (Class 50 & below) 5.0 (max.) Chemical Composition Chemical components Ductile iron pipe Grey cast iron pipe Steel pipe Carbon Silicon Manganese Phosphorus <=0.06 <= Sulfur <=0.02 <= Magnesium

9 Normative References BS EN 545 Ductile iron pipes, fittings, accessories and their joints for water pipelines. BS EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage applications. BS 6920 Suitability of non-metallic materials and products for use in contact with water intended for human consumption with regard to their effect on the quality of the water. BS EN Epoxy coating (heavy duty) of ductile iron fittings and accessories. BS EN Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications. BS EN ISO Metallic materials, Hardness testing, Brinell test, Part 1 : Test method. BS EN ISO 6708 Pipe works components - Definition and selection of DN (nominal size ). BS EN Circular flanges for pipes, valves, fitting and accessories, PN designated part 2: cast iron flanges. BS EN 196 & Cement Determination of strength, composition, specifications and conformity criteria for common cements BS 3416 Specification for bitumen-based coatings for cold application, suitable for use in contact with potable water. ISO 7268 Pipe components - Definition of nominal pressure. ISO Ductile iron pipes - External Zinc coating part 2 (Zinc rich paint with finishing layer) ISO 4633 Rubber seals joint rings for water supply, drainage and sewerage pipelines (specification for materials). 8

10 Technical Specification Data Wall Thickness According to BS EN 545:2002 & 2006, the nominal iron wall thickness of pipes and fittings are calculated as a function of the nominal size, DN, by the following formula, with a minimum of 5 mm for centrifugally cast pipe and 7 mm for pipes not centrifugally cast and fittings : e = K ( DN ) where e is the nominal wall thickness, in millimeters: DN is the nominal size: K is a coefficient used for thickness class designation. It is selected from a series of whole numbers: 7, 8, 9,10,11,12 Referring to the latest BSEN 545:2010, the minimm iron wall thickness of pipes is given as a functin of the nominal size, DN, and pressure class C, in table 16 and 17 of BSEN 545:2010 In general, all Ductile Iron Pipes & Fittings under KEY brand are fully in compliance with BSEN 545:2002, BSEN 545:2006, and BSEN 545:2010 respectively. Allowable Pressures - Socket & Spigot Joint pipe pressures : **Remarks** (Socket & Spigot Joint also named as Flexible Joint, Tyton Joint & Push-in Joint) The maximum values of PFA, PMA and PEA are calculated as follows: a) Allowable Operating Pressure (PFA) - Internal pressure, excluding surge, which the pipeline can safely withstand in permanent service. = 20 x e min (min. pipe wall thickness in mm) x 420 (min. tensile strength of DI) (DE - e min) x 3 (safety factor) b) Allowable Maximum Operating Pressure (PMA) - Maximum internal pressure including surge, which the pipeline can safely withstand in service. = 1.2 x PFA b) Allowable Test Pressure (PEA) - Maximum hydrostatic pressure applied on site to a newly installed pipeline, for a relatively short duration = PMA + 5 bar 9

11 - Flanged joint pipe and fittings pressures: Nominal Diameter (DN) PN16 PN25 PN40 PFA PMA PEA PFA PMA PEA PFA PMA PEA to to Operation Temperature Suitable for fluid temperatures between 0 to 50, excluding frost. Straightness of Pipe Pipes have a maximum deviation of 0.125% of their pipe length. Angular Deflection for Flexible Joints (Socket joint, Push-In joint) The allowable angular deflection on each flexible joint is listed below - 4 for DN80 to DN300 (per 6M Length) - 3 for DN350 to DN600 (per 6M Length) - 2 for DN700 & above (per 6M Length) Permissible Straight Draw for Flexible Joints (Axial Movement) Flexible joints for pipes and fittings are designed to accommodate sufficient axial movement where the allowable minimum withdrawal is 38mm when there is no angular deflection of the joint. 10

12 Coating & Lining options are provided as follows upon different applications and requirements : A) External Coating: [Standard Coating] *Metallic Zinc coating having a minimum mass of 130g/m² with finishing bituminous layer to BS3416 [Optional coating upon request] - *Thicker metallic zinc coating having a minimum mass of 200g/m² with finishing bituminous layer to BS3416 ; - Metallic zinc with a coat of etching primer and two tar epoxy top coat ; - Zinc-aluminum coating with finishing layer (Alloy of zinc and aluminum with or without other metals, having a minimum mass of 400g/m², with finishing layer) ; - External polythene coating in accordance with BS EN14628 ; - Polyurethane coating in accordance with BS EN15189 ; - **Fusion Bonded Epoxy / Epoxy Paint coating to BS EN14901 ; - **Fusion Bonded Epoxy coating to BS6920 ; - Optional sleeving: proprietary type Polyethylene sleeving as a supplement to the zinc coating with finishing layer B) Internal Linings: [Standard Lining] Sulphate-Resistant Cement mortar lining (SRC) ; [Standard Lining] High Alumina Cement mortar lining (HAC) ; [Optional lining upon request] - Sulphate-Resistant Cement mortar lining with dry film thickness 150 microns epoxy seal coat to BS6920 ; - Polyurethane lining in accordance with BS EN15655 ; - **Fusion Bonded Epoxy / Epoxy Paint coating to BS EN14901; - **Fusion Bonded Epoxy coating to BS6920 Remarks : * Metallic zinc spray is applied to pipes and zinc rich paint coating is applied to fittings ** Epoxy coating of ductile iron fittings and accessories comply with BS EN14901 epoxy coating (heavy duty) 11

13 Jointing - Flexible Joint (also named as Socket Joint, Tyton Joint, Push-In Joint or Push-On Joint) The most popular, quickest, and easiest-to-assemble joint for Ductile Iron pipe-lines while mainly adopted for underground water supply and gravity sewage applications. For accommodation of angular deflection, this joint consists of a single rubber gasket placed in a groove inside the socket end of the pipe. After lubricating the jointing areas in accordance with the manufacturer s instructions, the spigot end of the pipe is being pushed to insert while a pressure-tight and dependable seal is formed by means of the gasket. Proper anchorages shall be applied whilst flexible joint is non-restrained. - Flanged Joint Flanged joint is generally utlitized for above ground exposed pipeworks including water mains, rising mains, air, oil and/or other liquids where rigid, restrained joints are needed. It is widely used in industrial piping systems such as water treatment plants, sewerage treatment plants and other interior pipe-works. The flanges have a machined raised face and drilled holes. They can be attached by screw-on, cast-on or factory welded. 12

14 Dimension of Pipes Model No. P5-09 DN External Diameter DE (mm) Limit Nominal Deviations Class 25 Minimum wall thickness e (mm) Class Class Class Class Class K9 Approx.mass kg/m (K9) / / / / / / / / / / / / / / / / / / / / / / ,

15 Model No. P5-12 DN External Diameter DE (mm) Limit Nominal Deviations Class 30 Minimum wall thickness e (mm) Class Class Class Class K12 Approx.mass kg/m (K12) / / / / / / / / / / / / / / / / / / / / , / , Pipes are supplied in standard length of 6.0 metres and fully complied with BSEN 545:2002, BSEN 545:2006 & BSEN 545:2010 standards. Lengths of pipes other than those shown may be supplied by agreement between the purchaser and manufacturer. Limit deviation of standard pipe's length is +70 / -30 in mm. 14

16 Dimension of Fittings All flanged joint fittings are equipped with PN16 flange as standardize flange whereas PN10, PN25 and PN40 are also available on request. Limit deviations on lengths for socketed joints is ±20mm and for flanged joints is ±10mm. Double Flanged 90 Bend Double Flanged 45 Bend Δ # L (mm) L (mm) # # # # # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 15

17 Double Flanged 22.5 Bend Double Flanged Bend Δ # L (mm) L (mm) Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ # Δ # # # # # # # # # # # # # # # # # # # # # # # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser.

18 Double Flanged 90 Double Flanged 90 Long Radius Bend Duckfoot Bend L (mm) R (mm) L (mm) H (mm) # # # # # # # # # # # # # # # # # Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 17

19 All Flanged Tee L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 80 x # 350 x # 80 x x x # 350 x # 100 x x # 100 x # 400 x x x x # 400 x # 150 x x x # 400 x x # 400 x x x # 200 x x x # 450 x x x x # 450 x x # 450 x # 250 x # 450 x x x # 250 x # 500 x x x x # 500 x # 300 x x x # 500 x # 300 x # 500 x x # 500 x # 300 x x x # 500 x # 350 x x x # 600 x

20 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 600 x # 900 x # 600 x # 900 x x # 900 x # 600 x x # 600 x # 900 x # 600 x # 900 x x # 900 x # 600 x x # 600 x # 900 x x # 900 x # 700 x x # 700 x # 900 x # 700 x # 900 x x x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x x x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x x x # 800 x # 1000 x # 800 x # 1000 x # 800 x x x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x x x x # 800 x x # 800 x # 1200 x x # 1200 x # 800 x # 1200 x x # 1200 x

21 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 1200 x x # 1200 x # 1400 x # 1200 x x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x x x # 1200 x # 1500 x x x # 1200 x # 1600 x x # 1600 x # 1200 x # 1600 x # 1200 x x # 1400 x x # 1400 x x # 1400 x x # 1400 x # 1600 x # 1400 x # 1600 x # 1400 x x # 1400 x x # 1400 x x # 1400 x x # 1400 x x x x # 1400 x x All Flanged Radial Tee H L L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 100 x # 150 x

22 Double Socket Tee with Flanged Branch L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 80 x x x # 300 x Δ 80 x x # 100 x # 350 x x x Δ 100 x # 350 x x x Δ 100 x # 350 x # 150 x x x x x x Δ 150 x x x x Δ 150 x # 400 x x x x x Δ 200 x # 450 x x # 450 x Δ 200 x # 450 x x # 450 x Δ 200 x # 450 x x # 450 x x # 450 x x # 500 x x x x # 500 x Δ 250 x x x # 500 x x # 500 x x # 500 x

23 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch 500 x x # 500 x # 800 x x x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x x x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x x x # 600 x # 900 x # 600 x # 900 x x x # 700 x # 900 x # 700 x # 900 x # 700 x x x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x x x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x x x # 1000 x # 800 x # 1000 x # 800 x x # 800 x # 1000 x x # 1000 x # 800 x # 1000 x # 800 x x # 800 x # 1100 x x # 1100 x # 800 x # 1100 x # 800 x # 1100 x

24 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x x # 1100 x # 1400 x # 1200 x x # 1200 x # 1400 x # 1200 x x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x x # 1200 x # 1500 x # 1200 x x # 1200 x # 1600 x x # 1600 x # 1200 x # 1600 x x x # 1200 x x x x # 1200 x x # 1200 x # 1600 x # 1600 x Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 23

25 Double Flanged Taper L (mm) L (mm) L (mm) # 65 x x # 1000 x # 65 x Δ 400 x # 1000 x # 80 x x # 1000 x # 80 x # 450 x # 1000 x x # 450 x x Δ 80 x # 450 x # 1100 x # 100 x x # 1100 x # 100 x # 500 x # 1100 x # 100 x # 500 x x x # 500 x # 1200 x Δ 100 x x # 1200 x # 150 x # 500 x # 1200 x # 150 x # 600 x x # 150 x # 600 x # 1200 x # 150 x # 600 x # 1400 x # 200 x # 600 x # 1400 x # 200 x x # 1400 x x # 700 x # 1400 x Δ 200 x # 700 x x # 250 x # 700 x # 1500 x x x # 1500 x Δ 250 x # 800 x # 1500 x # 300 x # 800 x # 1500 x # 300 x # 800 x x x x # 1600 x Δ 300 x # 900 x # 1600 x # 350 x # 900 x # 1600 x x # 900 x x # 400 x # 900 x # 1600 x # 400 x x x x

26 All Flanged Crosses L (mm) H (mm) L (mm) H (mm) L H L H # 80 x # 400 x # 100 x # 400 x # 100 x # 400 x # 150 x # 450 x # 150 x # 450 x # 150 x # 450 x # 200 x # 450 x # 200 x # 450 x # 200 x # 450 x # 200 x # 450 x # 250 x # 450 x # 250 x # 500 x # 250 x # 500 x # 250 x # 500 x # 250 x # 500 x # 300 x # 500 x # 300 x # 500 x # 300 x # 500 x # 300 x # 500 x # 300 x # 500 x # 350 x # 600 x # 350 x # 600 x # 350 x # 600 x # 350 x # 600 x # 350 x # 600 x # 350 x # 600 x # 400 x # 600 x # 400 x # 600 x # 400 x # 600 x # 400 x # 600 x

27 All Flanged Level Invert Tee (mm) (mm) (mm) (mm) L H L H # 100 x # 450 x # 150 x # 450 x # 200 x # 450 x # 200 x # 450 x # 250 x # 500 x # 250 x # 500 x # 300 x # 500 x # 300 x # 500 x # 300 x # 600 x # 350 x # 600 x # 350 x # 600 x # 350 x # 600 x # 400 x # 700 x # 400 x # 700 x # 400 x # 800 x # 400 x # 800 x Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 26

28 All Flanged 45 Tee Flanged Bellmouth L (mm) K (mm) Body Banch # 80 x # 100 x # 150 x # 200 x # 250 x # 300 x # 350 x # 400 x # 450 x # 500 x # 600 x D L (mm) (mm) # # # # # # # # # # # # # # Δ # # # # # # # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 27

29 Double Socket 90 Bend Double Socket 45 Bend Δ # L (mm) L (mm) # # # # # # # # # # # # # # # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser * *

30 Double Socket 22.5 Bend Double Socket Bend L (mm) L (mm) Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 29

31 All Socket Tee L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch 80 x # 350 x x # 350 x x # 350 x x # 350 x x # 350 x x # 400 x Δ 150 x # 400 x x # 400 x x # 400 x x # 400 x x # 400 x Δ 200 x # 400 x x # 400 x x # 450 x Δ 250 x # 450 x x # 450 x x # 450 x Δ 250 x # 450 x x # 450 x x # 450 x Δ 300 x # 450 x x # 450 x x # 500 x Δ 300 x # 500 x x # 500 x x # 500 x # 350 x # 500 x # 350 x # 500 x # 350 x # 500 x

32 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 500 x # 800 x # 500 x # 800 x # 500 x # 800 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 600 x # 900 x # 700 x # 900 x # 700 x # 900 x # 700 x # 900 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 700 x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x # 1000 x # 800 x # 1100 x # 800 x # 1100 x # 800 x # 1100 x # 800 x # 1100 x

33 L (mm) H (mm) L (mm) H (mm) Body Banch Body Banch # 1100 x # 1200 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1100 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1400 x # 1200 x # 1500 x # 1200 x # 1500 x # 1200 x # 1500 x # 1200 x # 1600 x # 1200 x # 1600 x # 1200 x # 1600 x # 1200 x # 1600 x # 1200 x # 1600 x # 1200 x # 1600 x # 1600 x Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 32

34 Double Socket Level Invert Tee with Flanged Branch (mm) (mm) (mm) (mm) L H L H # 200 x # 500 x # 200 x # 600 x # 200 x # 600 x # 250 x # 600 x # 250 x # 600 x # 250 x # 600 x # 250 x # 600 x # 300 x # 600 x # 300 x # 700 x # 300 x # 700 x # 300 x # 700 x # 350 x # 700 x # 350 x # 800 x # 350 x # 800 x # 350 x # 800 x # 400 x # 800 x # 400 x # 800 x # 400 x # 900 x # 400 x # 900 x # 450 x # 900 x # 450 x # 900 x # 450 x # 1000 x # 450 x # 1000 x # 450 x # 1000 x # 500 x # 1000 x # 500 x # 1200 x # 500 x # 1200 x # 500 x # 1400 x # 500 x # 1400 x # 1400 x

35 Double Socket Taper L (mm) L (mm) L (mm) 100 x x # 700 x x x # 700 x x # 500 x # 700 x # 200 x # 500 x x x # 500 x x x # 500 x # 800 x x # 500 x # 800 x x # 500 x # 800 x x x # 800 x x x # 800 x x # 500 x # 800 x x # 600 x # 800 x x # 600 x # 800 x x # 600 x # 800 x # 400 x # 600 x x # 400 x # 600 x x # 400 x # 600 x # 900 x # 400 x # 600 x # 900 x x x # 900 x x # 600 x # 900 x x x # 900 x # 450 x # 700 x # 900 x # 450 x # 700 x # 900 x # 450 x # 700 x # 900 x # 450 x # 700 x # 900 x # 450 x # 700 x # 900 x # 450 x # 700 x # 900 x

36 L (mm) L (mm) L (mm) 900 x # 1100 x x x # 1100 x # 1200 x # 1000 x # 1100 x # 1400 x # 1000 x # 1100 x # 1400 x # 1000 x # 1100 x # 1400 x # 1000 x # 1100 x # 1400 x # 1000 x # 1100 x # 1400 x # 1000 x # 1100 x # 1400 x # 1000 x x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x x # 1200 x # 1400 x x # 1200 x # 1400 x # 1100 x # 1200 x # 1400 x # 1100 x # 1200 x # 1400 x # 1100 x # 1200 x x # 1100 x # 1200 x x # 1100 x # 1200 x x # 1100 x # 1200 x x # 1200 x x Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 35

37 All Socket Crosses (mm) (mm) (mm) (mm) (mm) (mm) L H L H L H # 80 x # 350 x # 500 x # 100 x # 400 x # 600 x # 100 x # 400 x # 600 x # 150 x # 400 x # 600 x # 150 x # 400 x # 600 x # 150 x # 400 x # 600 x # 200 x # 400 x # 600 x # 200 x # 400 x # 600 x # 200 x # 400 x # 600 x # 200 x # 450 x # 600 x # 250 x # 450 x # 600 x # 250 x # 450 x # 600 x # 250 x # 450 x # 700 x # 250 x # 450 x # 700 x # 250 x # 450 x # 700 x # 300 x # 450 x # 700 x # 300 x # 450 x # 700 x # 300 x # 450 x # 700 x # 300 x # 500 x # 700 x # 300 x # 500 x # 700 x # 300 x # 500 x # 700 x # 350 x # 500 x # 700 x # 350 x # 500 x # 700 x # 350 x # 500 x # 700 x # 350 x # 500 x # 800 x # 350 x # 500 x # 800 x # 350 x # 500 x # 800 x

38 (mm) (mm) (mm) (mm) (mm) (mm) L H L H L H # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1000 x # 1200 x # 800 x # 1100 x # 1200 x # 800 x # 1100 x # 1400 x # 800 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1100 x # 1400 x # 900 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1400 x # 1000 x # 1200 x # 1500 x # 1000 x # 1200 x # 1500 x # 1000 x # 1200 x # 1500 x # 1000 x # 1200 x # 1600 x # 1000 x # 1200 x # 1600 x # 1000 x # 1200 x # 1600 x Δ # # 1600 x Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 37

39 All Socket 45 Tee Puddle Pipe Double Flanged pipe with Puddle Flanged Spigot with Puddle Double Spigot with Puddle L (mm) K (mm) Body Banch Max. L (mm) # 80 x # # 100 x # # 150 x # # 200 x # # 250 x # # 300 x # # 350 x # # 400 x # # 450 x # # 500 x # # 600 x # Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 38

40 Flanged Spigot Flanged Socket L (mm) L (mm) Δ # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 39

41 Mechanical Collar Double Socket Collar Δ # L (mm) Lu (mm) # # # # # # # # # Δ # # Δ # # Δ # # Δ # # Manufacturer's design length British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser.

42 Blank Flange PN16 PN25 DN D a b c DN D a b c (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 41

43 Flange BS EN / BS4504 Both holes shall be arranged symmetrically about the horizontal centerline through the flange surface. In the case of tee, this horizontal cenerline is defined with the surface of the branch flange held pallet to the vertical plane. PN16 Flange to BS EN / BS4504 DN d1 D b f1 K L2 Bolt (mm) (mm) (mm) (mm) (mm) (mm) (mm) Size No M M M M M M M M M M M M M M M M M M M M52 44 Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 42

44 PN25 Flange to BS EN / BS4504 DN d1 D b f1 K L2 Bolt (mm) (mm) (mm) (mm) (mm) (mm) (mm) Size No M M M M M M M M M M M36 20 Pipe Blocks IBC Type FF Type (PN16) DN (mm) DN (mm) Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 43

45 EPDM Gasket for Flanges to BS EN1092 / BS4504 FF Type IBC Type DN Thickness Outside Diameter for PN16 Outside Diameter for PN25 (mm) Selection FF Type IBC Type FF Type IBC Type mm or mm or mm or mm Fittings with Access Door (For BS EN598) Size range: DN100 DN1200 Size Range: DN Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 44

46 P-Trap (Socket x Spigot) B A DN100 EN598 KEY C = Deep Seal DN (mm) A (mm) B (mm) C (mm) # # # Long Radius Bend (Socket x Spigot) R R DN (mm) R (mm) # # # # British Standard in Series A does not mention the length of this item. Unless there is an agreement between the seller and the buyer, the length for the items as shown in this catalogue will be supplied as standard Dimension of fittings as shown in this catalogue will be supplied subject to manufacturer s final option. Other lengths of fittings are also available by agreement between manufacturer and purchaser. 45

47 Installation Guide - Socket Joint A. Notes before installing 1) Clean the socket and spigot 2) Inspection the rubber gasket, and clean it. 3) Inspection the spigot outer chamfer B. Installation rubber gasket 1) As for pipes DN300, please install rubber gaskets as shows in Picture 1. 2) As for pipes > DN300, please install rubber gaskets as shows in Picture 2. C. Lubricant 1) Clean spigot and rubber rings 2) Make them smooth with lubricant, as shows in the following picture. D. Trench width When the pipes are laid in the trench, the width of trench should be 200mm - 300mm wider than the outside diameter of the pipe. E. Joint 1) As for pipes DN400, please see picture 1 2) As for pipes > DN400, please see picture 2 F. Checking Having been successfully inserted to the spigot, the joint should then be checked to see if the gasket is correctly seated, which can be done by inserting a metal ruler into the socket gap. 46

48 Installation Guide - Flanged Joint Installation for DI Flange Pipes 1) Check the gasket has to have the correct size. 2) Make sure that the flange surfaces are clean. 3) Make sure that the flanges are parallel and align, the vertical flange face position shall be two bolt holes parallel on top. 4) Insert the gasket carefully between the flanges. The gasket has to be centralized in the flange. 5) Bolts to be tightened in sequence (shown in the below) and to finger tighten. 6) Check alignment of flange joint and pipeline. 7) Tightened all bolts to the full torque. 8) Close the torque with one final pass in a clockwise sequence. Bolt Tightening Sequence Dismantling Procedure for DI Flange Pipes: 1) Bolts to be release in sequence (Same as tightening Sequence). 2) Total release all bolts and nuts from the flange joint. 47

49 Repair Area Preparation Lining repair must be carried out sheltered from frost. Rotate the pipe so that the area to be repaired is as close to the bottom as possible. Remove the damaged area and 1 or 2 cm of surrounding sound mortar with hammer and cold chisel. The edges of cleared zone must be vertical to the iron surface. Clean with a wire brush to remove non-adherent material. Moisten the repair area. A few minutes before making the repair, brush-apply the water emulsion mixture, wetting the original mortar over a width of about 20cm around the edges of the repair zone. Patching material preparation The emulsion must be the same as that used for the keying coat. Mix the two dry components, and then the two liquids, to give a pasty consistency mortar, adjust the amount of water if necessary. Mortar application Trowel the mortar on compacting it adequately to restore the thickness. Smooth the repaired surface with a palette knife (or sleeker). Check that there are no gaps between the fresh mortar and the original material. Apply a protective coat of water + emulsion not more than 30 minutes after final smoothing to prevent the patch from drying too quickly and to give it good strength (cover with a damp cloth until set). 48

50 Recommendations for Handling, Packing & Storage Handling The mechanical strength of ductile iron pipes and fittings, coupled with the robustness of their coatings, make them adequately suitable for site handling conditions. - Sufficient powerful lifting gear shall be used. - Guide the beginning and ending of the lift. - Manoeuver gently. - Avoid swinging, impacts or pipes rubbing against other pipes, the ground or trailer stanchions. These precautions are particularly important for epoxy sealed pipes, large diameter pipes, or those having special coatings. End lifting - Use appropriately shaped hooks, coated with a polyamide type protection. Please consult us. Barrel lifting - Use wide flat slings maintained sufficiently widely a part to prevent accidental slippage. - Prohibit wire ropes which may damage the coating. A single sling may be used on site. In this case, lift the pipe at its centre of gravity, with the sling gripping the pipe to prevent slippage. Bundle lifting DN80 to 300 bundles are unloaded with flat textile slings. Packing DN 300 : pipes bundles, fittings packed on pallets. Small diameter pipes are delivered from our works in bundles. The bundles are designed to facilitate and speed up pipe handing. DN > 300 : pipes and fittings unpacked. As for container shipping, we will pack in bulk. 49

51 Storage Storage of pipes and fittings on site must permit correct inventory control and facilitate any repair work. The storage area must be level. Avoid: - Marshy ground - Shitting soils. Deliveries must be inspected on arrival to the storage area and there is any damage (e.g. internal or external coating damage), it must be repaired before going into stock. Stack the pipes in homogeneous pipes (same diameter), in accordance with a rational storage plan. The same applies for fittings and accessories. Use sufficiently strong, good quality hard woods (timbers, wedges). It is always desirable to reduce the storage time as much as possible. Precautions need to be taken if the pipes have special coating. Please consult us. Stacking Bundle stacking The bundles supplies by SUNS can be stacked in a pile on 80x80x2600mm timber, with 3 or 4 bundles per row, not exceeding a stack height of 2.50m. Check the condition of the bundles periodically: in particular, the condition and tautness of the straps, as well as the general stack stability. Pyramid stack, socked to spigot Bottom layer : the bottom layer is laid on two timbers. Arranged in parallel, one being 1m from the socket end and the other 1m from the spigot end. The pipes are also parallel with one another. The sockets touch and are not in contact with the ground. The pipes at the two ends are secured at the sockets and spigots with large wooden wedges nailed to the timbers. The intermediate pipes are only secured at the spigot end using smaller wedges. Upper layer : the upper layers consist of pipes laid alternately socket to spigot, with all the sockets in one tier overhanging the spigot ends of the tier below, by the length of the socket plus 10cm (to prevent spigot deformation). The barrels of two consecutive tiers are in contact. Square stacks Bottom layer : laying and wedging after of the bottom layer is identical to the first method, but the pipes are sockets to spigots; their barrels are in contact. In addition, the sockets project beyond the spigots of adjacent pipes by the whole socket length, plus 5cm. For DN>150 pipes stacking is on three timbers(instead of 2). Upper layer : each tier consists of parallel pipes laid socket to spigot, as in the bottom layer. The pipes in one tier run at right angles to those in the tier below. The pipe ends are consequently wedged naturally by the alternating sockets in the tier below. This method keeps the packing material to a minimum, but involves individual lifting of pipes because of the stack formation. It is strongly recommended however that it should not be used for pipes with special coatings, in view of the type of support(point contacts). 50

52 BUN KEE (INT L) LIMITED 彬記 ( 國際 ) 有限公司 S i n c e Head Off ice 12/F., Phase 1, Austin Tower, 22-26A Austin Avenue, Tsim Sha Tsui, Kowloon, Hong Kong. Tel : (852) Fax : (852) Warehouse Sections M and N of Lot no in DD104, Yuen Long, New Territories. Tel : (852) Fax : (852) Retail Shop Mongkok G/F., No. 687 Shanghai Street, Mongkok, Kowloon. Tel : (852) Fax : (852) Wanchai G/F., No. 102 Thomson Road, Wanchai, Hong Kong (MTR EXIT A3, A4). Tel : (852) Fax : (852) Tsuen Wan G/F., No. 18 Tak Wah Street, Tak Fam Building, Tsuen Wan, New Territories, Hong Kong. Tel : (852) Fax : (852) Macau Rua Da Ribeira Do Patane No 13, Macau. Tel : (853) Fax : (852) Published in Apr 2016 (Rev 4) 51