GERMAN ATV-DVWK RULES AND STANDARDS
ADVISORY LEAFLET ATV-DVWK-M 275E Pipelines for the Field of the Technical Equipping of Wastewater Treatment Plants May 2001
GERMAN ATV-DVWK RULES AND STANDARDS
ADVISORY LEAFLET ATV-DVWK-M 275E Pipelines for the Field of the Technical Equipping of Wastewater Treatment Plants May 2001 ISBN 978-3-937758-73-2
Publisher/Marketing: Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.V. German Association for Water, Wastewater and Waste Theodor-Heuss-Allee 17 • 53773 Hennef • Germany Tel.: +49 2242 872-333 • Fax: +49 2242 872-100 E-Mail:
[email protected] • Internet: www.dwa.de
ATV-DVWK-M 275E
The German Association for Water, Wastewater and Waste, DWA (former ATV-DVWK), is the spokesman in Germany for all universal questions on water and is involved intensely with the development of reliable and sustainable water management. As politically and economically independent organisation it operates specifically in the areas of water management, wastewater, waste and soil protection. In Europe the DWA is the association in this field with the greatest number of members and, due to its specialist competence it holds a special position with regard to standardisation, professional training and information of the public. The ca. 14,000 members represent the experts and executive personnel from municipalities, universities, engineer offices, authorities and businesses. The emphasis of its activities is on the elaboration and updating of a common set of technical rules and standards and with collaboration with the creation of technical standard specifications at the national and international levels. To this belong not only the technical-scientific subjects but also economical and legal demands of environmental protection and protection of bodies of waters.
Imprint Publisher and marketing: DWA German Association for Water, Wastewater and Waste Theodor-Heuss-Allee 17 D-53773 Hennef, Germany +49 2242 872-333 Tel.: +49 2242 872-100 Fax:
[email protected] E-Mail: Internet: www.dwa.de
Translation: Richard Brown, Wachtberg Printing (English version): DWA ISBN-13: 978-3-937758-73-2 The translation was sponsored by the German Federal Environmental Foundation (DBU) Printed on 100 % Recycling paper.
© DWA Deutsche Vereinigung für Wasserwirtschaft, Abwasser und Abfall e.V., Hennef 2006 (DWA German Association of Water, Wastewater and Waste)
All rights, in particular those of translation into other languages, are reserved. No part of this Advisory Leaflet may be reproduced in any form – by photocopy, microfilm or any other process – or transferred into a language usable in machines, in particular data procssing machines, without the written approval of the publisher.
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ATV-DVWK-M 275E
Foreword Pipelines form a crucial point in the technical equipment of wastewater treatment plants. They serve for the conveyance of the media which is to be treated and utilised (liquids with and without solid matter component, gases). Pipelines are to be found in all areas of the technical equipment of wastewater treatment plants. Pipelines can be subjected to widely differing stresses (static and dynamic), corrosion (caused by the medium and/or the environment), abrasion, erosion, temperature (heat, cold) etc. The selection of the pipe material and the dimensioning of the pipelines with regard to diameter and wall thickness demand a high degree of specialist knowledge above all with regard to the type of stress, the material characteristic values, the possibilities for processing and not the least the comprehensive standard specifications and regulations associated with this field. With this Advisory Leaflet planners, those inviting tenders and those responsible for decisions are to be provided with assistance in achieving professional and economic solutions. In many cases proven solutions can be recommended, in other cases reference has to be made to technical documents and regulations in order to develop proper standards for invitation to tender and for the implementation in terotechnology.
Authors This Advisory Leaflet has been elaborated by the ATV-DVWK Working Group KA-11.2 “Mechanical engineering” within the ATV-DVWK Specialist Committee KA-11 “Technical equipping and construction of wastewater treatment plants”. Members of the Working Group are: Dipl.-Ing. John Becker, Worpswede Dipl.-Ing. Wolf-Dieter Blackert, Taunusstein Dr.-Ing. Rüdiger Hohmann, Essen (Chairman) Dipl.-Ing. Erwin Klauwer, Essen (Chairman up to 9/2000) Dr.-Ing. Hans-Herrmann Niehoff, Gladbeck Dipl.-Ing. Joachim Maßow, Rohrbach Dipl.-Ing. Christian Schnatmann, Essen
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ATV-DVWK-M 275E
Contents Foreword..................................................................................................................................................
3
Authors ..................................................................................................................................................
3
User Notes ...............................................................................................................................................
6
1
Area of Application ................................................................................................................
6
2
Abbreviations Used................................................................................................................
6
3
Stressing of the Pipelines by the Media ..............................................................................
7
4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.4.1 4.4.2
Selection of Material .............................................................................................................. Pipelines Made from Mild or Low Carbon Steel ....................................................................... General..................................................................................................................................... Processing of Pipelines Made from Mild or Low Carbon Steel ................................................ Pipelines Made from Stainless Steel........................................................................................ General..................................................................................................................................... Corrosion Resistance of Pipelines Made from Stainless Steel ................................................ Processing of Pipelines Made from Stainless Steel................................................................. Pipelines Made from Non-ferrous Metals................................................................................. Pipelines Made from Plastic ..................................................................................................... General..................................................................................................................................... Processing of Pipelines Made from Plastic ..............................................................................
8 8 8 8 9 9 9 10 10 11 11 12
5 5.1 5.2 5.3 5.3.1 5.3.2
Dimensioning of Pipelines .................................................................................................... Flow Rates and Minimum Nominal Diameters ......................................................................... Pressure Losses with the Transport of Viscous Liquids .......................................................... Selection of Pipelines ............................................................................................................... Pipelines Made from Steel and Stainless Steel ....................................................................... Pipelines Made from Plastic .....................................................................................................
12 13 13 14 14 14
6 6.1 6.2 6.2.1 6.2.1.1 6.2.1.2 6.2.2 6.2.2 6.2.3.1 6.2.3.2 6.2.3.3 6.2.3.4 6.2.3.5 6.3 6.4 6.5 6.6 6.7
Laying of Pipelines................................................................................................................. Expansion and Settling Compensation .................................................................................... Connection of Pipelines............................................................................................................ Permanent Connections of Pipelines made from Metallic Materials........................................ Welding and Brazing ................................................................................................................ Press Fittings............................................................................................................................ Permanent Connections Plastic ............................................................................................... Separable Connections ............................................................................................................ Flange Connections for Steel Pipelines ................................................................................... Flange Connections for Plastic Pipelines................................................................................. Pipe Couplings ......................................................................................................................... Bolts, Nuts, Washers................................................................................................................ Seals......................................................................................................................................... Fittings ...................................................................................................................................... Pipe Supports and Fixtures ...................................................................................................... Emptying, Ventilation and Cleaning ......................................................................................... Wall Leadthroughs ................................................................................................................... Lubrication Lines ......................................................................................................................
15 15 16 16 16 17 17 17 17 18 18 18 18 19 19 20 20 21
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ATV-DVWK M 275E 7 7.2 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.2 7.3 7.4 7.5
Other Matters........................................................................................................................... Insulation................................................................................................................................... Execution of Hot Protective Insulation ...................................................................................... Execution of Cold Protective Insulation .................................................................................... Insulation to Prevent Condensation Water ............................................................................... Frost Protective Insulation ........................................................................................................ Insulation for Pipes Made from Stainless Steel ........................................................................ Insulation Thicknesses.............................................................................................................. Insulation Cladding.................................................................................................................... Equipotential Bonding ............................................................................................................... Measurements .......................................................................................................................... Marking ..................................................................................................................................... Tests..........................................................................................................................................
21 21 21 22 22 22 22 22 22 22 23 23 24
Bibliography.............................................................................................................................................
25
Appendix .................................................................................................................................................. Appendix A: Tables ................................................................................................................................... Appendix B: Normative References ..........................................................................................................
26 26 35
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ATV-DVWK-M 275E
User Notes This Advisory Leaflet is the result of honorary, technical-scientific/economic collaboration which has been achieved in accordance with the principles applicable therefore (statutes, rules of procedure of the ATVDVWK and the Standard ATV-DVWK-A 400). For this, according to precedents, there exists an actual presumption that it is textually and technically correct. The application of this Advisory Leaflet is open to everyone. However, an obligation for application can arise from legal or administrative regulations, a contract or other legal reason. This Advisory Leaflet is an important, however, not the sole source of information for correct solutions. With its application no one avoids responsibility for his own action or for the correct application in specific cases; this applies in particular for the correct handling of the margins described in the Advisory leaflet.
1
Area of Application
In this Advisory Leaflet information is provided for the planning, execution and testing of pipelines for the area of technical equipment in wastewater treatment plants. With this, the special requirements of wastewater treatment plant-specific media on metal and plastic pipes are taken into account. This Advisory Leaflet can also be applied analogously for pipelines in wastewater treatment facilities and pumping stations outside wastewater treatment plants. There are numerous standard specifications and regulations on the dimensions, materials, requirements on testing, planning and execution of pipelines. With this Advisory Leaflet the handling of these comprehensive standard specifications and standards is to be made easier through limitation to the wastewater treatment plant-specific application case. Furthermore, experience is to be passed on as to which materials, designs etc. have proved themselves for the respective cases of application in wastewater treatment plants (e.g. medium, temperature, pressure).
• building services pipelines, • cable protection pipes. Below are given solutions as to how technical requirements can be met. They do not exclude other at least equally secure solutions such as, for example, are contained in the technical rules of other member states of the European Union or other partner states of the Agreement on the European Economic Area.
2
Abbreviations Used
[Translator’s note: with one exception all German abbreviations are used in the translation]
AFP
Asbestos-free fibrous material slabs
AGI
German Working Group for Industrial Construction
ATV-DVWK
German Association for Water, Wastewater and Waste
CE
EC Mark of Conformity
(designation)
CSM
Chlorosulphonated polyethylene
DampfkV
German Ordinance on Steam Boiler Installations
DIN The following are not dealt with in this Advisory Leaflet:
DIN-German Institute for Standardisation
EN
European Standard
• inlet and outlet sewers,
DruckbehV
German Ordinance on Pressure Vessels, Compressed Gas Tanks and Filling Facilities
DVGW
German Technical and Scientific Association for Gas and Water
• sewers within the wastewater treatment plant, • pipelines made from mineral construction materials (e.g. concrete, cement fibres, vitrified clay etc.),
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ATV-DVWK-M 275E DVS
German Welding Society
EG (Directive)
European Community
EPDM
Ethylene-propylene diene monomer (Ethylene-propylene-terpolymer)
ISO
International Standardisation Organisation
KRV
German Plastics Association
LAWA
German Federal State Working Group Water
NBR
Acrylnitrile-butadiene rubber
NPSH
Net positive suction head, a measure for the minimum suction head of a centrifugal pump (American source)
(-value)
PTFE
Polytetrafluoroethylene
RAL
German Institute for Quality Assurance and Marking
(-colour register)
TRB
Technical Rules for Pressure Vessels
TRR
Technical Rules for Pipelines
UVV
German Accident Prevention Regulation
VAwS
German Ordinance on Facilities for the Handling Water Hazardous and on Specialist Operations
VbF
German Ordinance on Combustible Liquids
VDE
Association of German Electrical Engineers
VdTÜV
German Federation of Technical Surveyance Associations
VOB
German Contract Procedures for Construction Works
WHG
German Water Resources Management Law
3
Stressing of the Pipelines by the Media
The media in the pipelines dealt with here are essentially wastewater and its sludge, process and drinking water, water in heating circuits, air, combustible gases as well as chemical additives for precipitation and flocculation. The temperatures of the surroundings or of the medium do not in general place any special requirements on metallic pipe materials. With the employment of plastics their permitted limiting temperature is, however, to be observed (e. g. with pipelines for pressure ventilation systems). The pipeline pressures – apart from a few exceptions, for example with water hammer, transport of sludge, explosion or detonation endangered pipeline sections – lie below 6 bar and place no increased demands on stability or wall thickness. The pressure level to be selected results from the maximum operating pressure which occur taking into account all particular operating conditions. With pipelines endangered by water hammer a pressure surge calculation is to be carried out in cases of doubt. Taking into account the service life the following are to be named as the most important selection criteria for the pipe materials, steel and plastic, most frequently employed in wastewater treatment plants: • the resistance to corrosion and • the resistance to wear against abrasive content substances. Table 1 (Appendix) gives an overview on media and pipe materials in wastewater treatment plants and the recommended proven combinations. (Note: in this Table pure oxygen is not listed as medium as, due to increased tendency to oxidation and possible fire hazard in connection with oils, greases, seal materials etc., the selection of materials should be assessed by specialist firms.)
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ATV-DVWK-M 275E
4
Selection of Material
With the selection of pipeline materials, from the point of view of operations, the media and the influences on the environment are decisive. According to economic aspects the costs for delivery, laying, operation, maintenance and for other operating factors (converted to annual costs) have a considerable influence.
4.1
Pipelines Made from Mild or Low Carbon Steel
4.1.1
General
For numerous cases of application mild steel is well-suited as pipe material due to its high stability, easy joining and laying techniques and due to its favourable price. For reasons of corrosion such pipes can be galvanised and/or coated with cement mortar or plastic (for this see ATV Advisory Leaflet M 263 (not yet available in English)) or be jacketed. Steel pipes are produced either without seams through rolling or mechanically from plates or strip welded with a longitudinal seam or, with larger diameters, welded in spiral form. The quality of welding seams of mechanically welded pipes is very high so that, as a rule, they satisfy the demands placed on them. The reduction of the material properties is laid down in the relevant delivery standard specifications (e.g. DIN 1626 and DIN 1628). Due to their significantly higher price seamless pipes only are used in exceptional cases only (see Table 2, Appendix). Spiral welded pies can be economic from DN 500 upwards.
Material quality L 235 (previously: St 37.0) is normal in accordance with EN 10027-1 for welded pipes. As today steel plates of the same continuous high quality are produced, the previous normal quality specification, for example for fully killed cast steel with verified suitability for welding, is unnecessary. Mild or low carbon steels with specially verified properties are necessary only for high strength requirements or for creep resistant pipelines. In the following Sections (4.2 ff) the selection criteria are given which make the employment of stainless steel qualities or plastics as pipe material appear as advisable or necessary.
4.1.2 Processing of Pipelines Made from Mild or Low Carbon Steel EN 25817 (previously DIN 8563-3) applies for the assessment of the welding seam quality. For slightly stressed pipelines, with which in cases of damage or leakage no hazards due to the medium occur, the lowest Assessment Group (D) can be sufficient as limit for irregularities in the welding seams. For higher requirements, for example with pipelines laid underground and with dynamic stresses as well as for the internal seam surface (towards the medium) at least Assessment Group C is to be called for. The required welding seam quality is to be laid down. For pipelines in the area of application of the DVGW as well as of the Pressure Vessel Ordinance the regulations applicable there are to be observed.
Due to the new European standardisation, in accordance with EN 10027-1 the abbreviations for steels are formed according to their employment and the mechanical or physical properties. For wastewater treatment plants inter alia the following main symbols are of interest: S = steels for general structural steel work P = steels for the construction of pressure vessels L = steels for the construction of pipelines E = engineering steels
For the technical welding processing only qualified welders may be used for manual and partly mechanical welding processes who can produce a valid welding test certificate in accordance with EN 287-1 for the required welding process. The firm carrying out the work should meet the technical welding quality requirements in accordance with EN 729-1 to EN 729-4.
These main symbols have appended the minimum yield strength in N/mm2.
• welding inspection,
The previously employed steel designations St 37.0 or RSt 37.2 are thus L 235 and S 235JRG2. Unfortunately this new classification system has not been taken over uniformly for all steels and in individual cases are, for example, to be ascertained from the manufacturers.
• testing of welding seams (test method, possible welding specialist, size of random samples, documentation of the tests etc.).
The following quality assurance measures are recommended and are to be laid down in the request for tenders:
• documentation of the welding tasks carried out by each welder,
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ATV-DVWK-M 275E 4.2
Pipelines Made from Stainless Steel
4.2.1 General Stainless steels are employed if particularly corrosive stresses are present for which other materials are longer equal to the situation or if there are special advantages according to other assessment criteria, for example if a pipeline made from stainless steel is more economic than one made from normal steel with corrosion protection. The corrosion resistance of stainless steels with their high alloy components of chromium and nickel is, however, only guaranteed if the selection of material to meet the application and the processing to match the material has been observed. Stainless steels are in particular to be recommended if • increased corrosion resistance against aggressive substances, in particular against the content substances of wastewater, • resistance with higher temperatures (no oxidation), • high resistance against corrosion erosion in flowing media, • low wear and through this low pollution of the medium (“product cleanliness”) is promoted. Typical areas of employment and cases of application are, for example: • digester gas pipes, • exhaust pipes, • air pipes in activated sludge and grit chamber facilities, particularly in the underwater area, • pipelines for chemicals. Further cases of application can be taken from Table 1 (Appendix). Straight bead welded circular pipes in accordance with DIN 17455 are sufficient as pipelines made from stainless steel – the weld factor 0.8 is, as a rule, sufficient – from hot or cold rolled strip, in each case non-heat-treated (D1/K1), matt pickled and rendered passive full bath, with tolerances D2/T3 for the external diameter and the wall thickness in accordance with DIN EN ISO 1127 as well as tolerances F2/S1 according to ISO 5252 (see Table 2 in the Appendix).
4.2.2 Corrosion Resistance of Pipelines Made from Stainless Steel The corrosion resistance of stainless steels depends on a thin, invisible surface layer which forms spontaneously through the reaction between the chromium in the alloy and the oxygen from the surroundings. This chromium oxide layer, the socalled passive layer, prevents corrosive attacks on the metal lying below. Mechanical damage or other impairment of the passive layer is only harmless if a spontaneous repassivation can form. Stainless steels are thus resistant against surface corrosion in oxygen-rich environments. Nevertheless stainless steels can also be impaired in their durability and resistance through corrosion. The following types of corrosion are frequently to be observed: • pitting corrosion (pitting), • crevice corrosion, • stress corrosion cracking, • corrosion fatigue, • stress and corrosion fatigue. Pitting and crevice corrosion are caused mainly by high chloride concentrations in the medium. The resistance against pitting and crevice corrosion grows with increasing alloying component. In addition to the chromium content, above all the molybdenum content and, with the higher alloyed steels, also the nitrogen content have an influence on the resistance. The effect of these alloying components is expressed simplified in the working sum = % Cr + 3.3 % Mo + 16 % N. The resistance to corrosion increases with increasing working sum. Under ideal conditions (inter alia no stagnant flow conditions) as well as with ambient temperatures, the following guidance values for the stability apply: stainless steels with the material number 1.4301 (X5 CrNi 18-10) and similar (Working sum 18) in (non-sensitised) delivery condition up to ca. 100 mg/l chloride, the material 1.4571 (X6 CrNiMoTi 17-12-2 with the working sum 25) and similar up to 800 mg/l chloride are seen as stable. With normal hot water temperatures (e.g. 60 °C – 80 °C) lower values are to be set. With higher chloride ion contents more corrosion resistant qualities such as, for example 1.4439 (X2 CrNiMoN 17-13-5 with the working sum 35) must be employed. In narrow gaps such as, for example, of flange gaskets or press fittings, due to a lack of flushing effect (stagnant flow conditions) there are concentrations of chloride ions, so that there pitting and crevice corrosion can occur to an increased degree.
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ATV-DVWK-M 275E Note: With a later heating up to temperatures between ca. 425 °C to 870 °C, for example wit welding in the area of the heat affected zone, a so-called sensitisation takes place through structural transformation, i.e. corrosion can already occur with lower chloride concentrations.
4.2.3 Processing of Pipelines Made from Stainless Steel For the technical welding processing of high alloy Cr-Ni steels only certified welders can be employed for manual and semi-mechanical welding processes, who can produce a valid welding test certificate in accordance with EN 287-1 for the required welding process, semi-finished products (plate or in this case for pipes), the type of seam, material group (here W11), welding position and seam design. Attention is drawn to 4.1.2 with regard to quality assurance measures. The highest resistance to corrosion is provided with a clean, smooth and metallically polished surface. Cracks, scratches and crevices are weak points and encourage the creation of crevice corrosion. Therefore, to maintain the resistance to corrosion, the annealing colours, scaling and slag residues must be removed as they, as imperfections in the passive layer, lead to corrosion damage at the welding seams. Equally metallic abrasion, in particular that of normal steel, has to be eliminated, which occurs on the surface of the material with the processing by tools. Resistance to corrosion is equally reduced through adhesive deposits of all types, for example from metallic oxides and metallic hydrated oxides (extraneous rust). In general, with the handling of stainless steels the following requirements apply: • with the storage and processing of stainless steels spatial separation from normal steel and unalloyed steels (otherwise formation of extraneous rust, initial easily removable rust). • avoidance of any contact with unalloyed or low alloy steels (bearing and tensioning elements, means for fastening, brushes etc.). In the case that these requirements cannot be met reliably, not only the welding seams but also the complete workpiece is to be pickled and, if required rendered passive after processing. As a rule only welding processes using protective gas, such as, for example, the wolfram-inert gas (“WIG” welding, Code No. 141 in accordance with EN 24063) or metal-active gas welding (“MAG” welding, Code No. 135), are employed.
The employment of electric arc manual welding (“E-Hand” welding, Code No. 111) is to be agreed in individual cases with the customer. The statements under Sect. 4.1.2. apply for the assessment of the quality of welding seams. With pipelines carrying digester gas the Assessment Group C should be specified. Ignition points next to welding seams and weld spatter are to be avoided and must be eliminated through grinding and polishing. Only those abrasives which are approved for high alloy Cr-Ni steels are to be employed. Through suitable forming processes (i.e. rinsing of the weld on the inside of the pipe using special inert gas mixtures, no forming pastes) and forming installations it must be ensured that, in particular in the area of the root no inadmissible annealing colours appear. (Note: on welding seams which are produced on site, even with the best possible welding seam preparation and using sufficient quantities of forming gases there are, nevertheless, straw yellow annealing colours; therefore welded joints should as far as possible be carried out under factory conditions). With the occurrence of inadmissible annealing colours (e.g. blue or even brown) it is necessary for the seams to be post-treated until free of annealing colours. Grinding using suitable abrasives, pickling or shot blasting with micro-glass beads is recommended. With pickling using pickling paste the rinsing water is to be disposed of correctly.
4.3
Pipelines Made from Non-ferrous Metals
For water pipelines, inter alia seamless copper pipes in accordance with EN 1057 are employed (material Cu-DHP in accordance with EN 12449, previously SF-Cu). For pipes according to the standard specifications there are internationally standardised pipe connections and fittings. These pipes can also be used for lubrication lines (see Sect. 6.7). Copper and copper alloys (e.g. brass or red brass) have only limited resistance against hydrogen sulphide and ammoniac, above all in wet media (e.g. digester gas). The resistance as a rule reduces further with increasing copper content. For example black copper sulphide is formed with the presence of hydrogen sulphide. With the presence of the triggering constraints, in addition to the corrosion stripping an uncontrolled failure of the components (e.g. fittings) is caused. Therefore, for digester gas, nonferrous metal designs are to be used.
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ATV-DVWK-M 275E For pipelines in technical ventilation facilities the aluminium alloy AlMg 3 is suitable (see also Table 1, Appendix).
4.4
Pipelines Made from Plastic
4.4.1
General
For numerous application cases there are available pipelines made from plastic due to the following advantage: • small weight, • very good resistance to chemicals, • low maintenance costs, • easy shaping and economic working properties. These advantages are opposed by disadvantages which are to be taken into account with the respective application case, for example: • as a rule low mechanical resistance, • low dimensional stability and resistance to the effects of heat, • susceptibility to ageing due to the effects of light (UV radiation) and heat,
The choice of materials and the pressure level of the pipeline components are of decisive significance for operating safety and achievement of a planned minimum service life. The following apply as relevant influencing factors: the operating pressure, the operating temperature, the medium to be transported and – different to metallic materials – also the duration of the loading. In particular to be observed is, due to the lower stability also the water hammer behaviour of plastic pipes, above all with regard to possible underpressure conditions. With the selection of plastics fundamentally the employment of secondary plastics should also be investigated. The suitable material dependent on pressure and temperature can be taken from Fig. 1. In this the influence of temperature on the material stability is clearly identifiable. Reductions in stability are already to be taken into account from 25 °C – 30 °C. For example, for the material PVC-U, in general designated as PVC, the limits of the employment capability are achieved already at 60° C and with PVC-C at 90 °C.
• to a high degree combustible (under certain circumstances toxic combustion products), • limited possibility of recovery, • tendency to shrink and creep, • danger of static electricity charging, • large thermal coefficient of elongation. Plastics are divided into thermoplastics, duroplastics and elastoplastics. Essentially plastic in accordance with Table 1 are employed as pipeline materials. Table 1:
Plastics for pipelines
Thermoplastic plastics: Polyvinyl chloride, unplasticised Polyvinyl chloride, chlorinated Polyethylene Polypropylene Polybutene Polyvinylidene fluoride Polyamide Duroplastic plastics: Unsaturated polyester resin, glass-fibre reinforced Phenacrylate resin, glass-fibre reinforced Epoxy resin, glass fibre reinforced
Abbreviation PVC-U PVC-C PE PP PB PVDF PA UP-GF PHA-GF EP-GF
Fig. 1:
Application limiting values for pipes made from thermoplastic materials [1] (25 years service life with safety factor included)
Included in all cases are the normal material safety factors. Deviating requirements due to shorter or longer service lives, deviating operating temperatures and special media conditions require an individual calculation. For pipes, fittings and accoutrements made from plastic the pressure levels for an operating temperature of 20 °C applies. In accordance with ISO 4065 the pipes are divided into series whereby pipes of the same serial number are approved for the same loading capability, which comparatively is the case with the designation according to the nominal pressure levels. The series is marked by
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ATV-DVWK-M 275E the letter S (see Table 4, Appendix). With plastic pipes the external diameter de1) is given. Particular attention is to be paid with the calculation of flow rates and pressure surges that, with larger wall thicknesses as a result of high stability requirements, significantly smaller internal diameters result. Large wall thicknesses also signify a jump in nominal diameter with the changeover to metallic pipelines if the internal diameter is to remain more or less the same (e.g. transition steel wall pipe to PE earth pipe).
4.4.2
Processing of Pipelines Made from Plastic
The Standard DVS 2210-1 is to be applied for the fabrication of pipelines made from thermoplastic plastics. The Standard DVS 2201-1 applies for the assessment of the quality of the welding seam connections made from thermoplastic plastics. Assessment Group I should be specified for underground pipelines as these pipelines can no longer be monitored at a later date. For surface pipelines Assessment Group II can be agreed as sufficient. Only for lightly loaded pipelines, with which in the case of damage or leakage, no hazards from the medium occur, Assessment Group III can also be agreed. The required quality of welding seams is to be laid down. Only qualified welders who can produce a valid welding certificate in accordance DVS 2212-1 for the required welding process may be employed for the technical welding processing for manual and semi-mechanical welding processes. A certificate of qualification in accordance with VdTÜV MB K 001 or in accordance with DVS 2221-1 is to be produced for the execution of adhesive joints. The KRV Standard A 9.8.4 is to be used for the fabrication of pipelines made from glass reinforced 2) plastics (GRP) . For pipelines within the area of application of the DVGW as well as the (German) Pressure Vessel Ordinance – if required in deviation to the above given statements – the there applicable regulations are to be observed.
The following quality assurance measures are recommended and are to be laid down in the request for tenders: • supervision of the laying tasks (e.g. supervision of welding), • documentation of the work of the respective performer (e.g. welding tasks, bonding tasks), • testing of welding seams, bonding etc. (test method, possible experts, size of random samples, documentation of the tests etc.).
5
Dimensioning of Pipelines
A first preliminary dimensioning of the pipeline can take place in accordance with the specified recommended values for normal rates and minimum nominal diameters. The selection of the desired flow rate is limited through technical flow limiting data (e.g. danger of blockage, deposits, vibrations, development of noise, erosion etc.). The first dimensioning – in particular with longer pressure lines – should follow a determination of the economical diameter including material variants. Here it applies that the annual costs (capital and operating costs are to be compared with each other and are to be optimised. The methods to be applied here as well as proposals for service lives to be applied are, for example, described in [2]. As one has to assume an ageing of the material with plastic pipelines the service life must be specified for the determination of the creep strength. With this, in addition to the pressure and temperature, the desired service life also has a certain, however, only small influence on the dimensioning and selection of material. The operating costs are essentially determined by the electrical work to be used for the transport. This results from the flow quantity, the delivery head hydraulic losses in the pipe plus the geodetic height difference, the pump efficiency, the annual operating hours and the price for electricity.
1) Translator`s note: de, the index used reflects the English translation of the German index da 2) Translator`s note: GRP is equivalent to GFK in the German version
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ATV-DVWK-M 275E 5.1
Flow Rates and Minimum Nominal Diameters
For the transport of water and wastewater with low solid matter contents the economical flow rates of Table 2 can serve as reference values [3]. Table 2:
Economic flow rates
DN
25
40
65
100 150 200 300
500
V [m/s]
1.4
1.6
1.8
2.0
2.2
2.9
Q [m3/h]
2.5
7
21
56
140 270 660
2.4
2.6
2050
In suction pipelines the flow rate is to be so selected, taking into account the pump characteristic (NPSH value), that cavitation can be avoided with certainty. With raw wastewater and in particular water-sand mixtures minimum flow rates ≥ 2 m/s are to be sought in vertical pressure pipelines, in order to avoid deposits and demixing. To avoid blockages the following minimum nominal diameters are laid down in accordance with Table 3 for the conveyance of certain media in wastewater treatment plants in accordance with DIN 19569 – 13) (for this compare also EN 12255-1): Table 3:
Minimum nominal diameters
Medium
Minimum nominal diameter
Water-sand mixture, suspended solids, activated sludge
DN 80
Raw sludge
DN 100 1)
Thickened digested sludge, thickened raw sludge
DN 100 1)
Thermally conditioned sludge
DN 65
1)
With upstream fine screens, comminution or screen facilities and with short delivery stretches smaller minimum nominal diameter can be selected.
The design velocity in air pipes for activated sludge plants and similar is to be limited with full blower performance to 15 m/s, with very short pipe lengths (e.g. directly after the compressor) to 25 m/s. Note: With the determination of the flow rates the values in compressed condition are to be applied.
5.2
Pressure Losses with the Transport of Viscous Liquids
The methods for the determination of pressure losses with the transportation of water are also to be applied for wastewater, sludge liquor and similar with solid matter contents up to ca 2 %. With higher shares of solid matter there are significant differences with regard to hydraulic conditions. The parameters for the description of the pressure losses are essentially dependent on the type of sludge and on the dry solids content. But also the share of organic substances of the solid mass and the treatment process can influence the transportation conditions. The fundamental difference therefore is due to the fact that sludge with a high share of solid matter does not follow Newton’s laws. With this the ratio of the so-called shear rate to the shear strain exercised is not constant as the dynamic viscosity is dependent on the shear forces operating on the sludge. The complex conditions demand that each individual case of a transportation of sludge over greater distances is examined carefully, in particular if thickened excess sludge is to be transported. To this belongs a viscometric determination of the flow curve of the original sludge (so far as it exists), which describes the relationship between shear rate and sear strain. The changes of the pressure losses dependent on dry solids content of a mechanically thickened sludge are shown as an example in Fig. 2. Additional literature is contained in [4, 5].
Conveyance of gases: In areas in which the pressure losses are covered from the system pressure, flow rates of 3.0 m/s to 5.0 m/s are to be recommended for digester gas. Ventilating ducts should have a maximum velocity of 8 m/s. 3) Author´s afternote: In the meantime DIN 19569 has been withdrawn and replaced by EN 12255-1
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ATV-DVWK-M 275E • Preferred Wall Thickness Series D according to ISO 4200 for steel pipes, • Preferred Wall Thickness Series A according to ISO 4200 for pipes made from stainless steel (see also DIN 19569-5 and DIN 19569-6)4). Depending on the individual case, in particular with larger pipeline cross-sections, larger wall thicknesses are recommended. For pipes with a diameter greater than DN 1000 wall thicknesses are to be laid down in the invitation to tender.
Fig. 2:
Pressure losses of sludge in pipelines [6]
5.3
Selection of Pipelines
The wall thicknesses of pipelines are to be sufficiently dimensioned taking into account corrosion and abrasion which occurs and with high pressures according to the maximum pressure of the medium. With the transportation of heavily abrasive substances (e.g. sand-water mixtures, primary sludge etc.) possibly larger wall thicknesses are to be selected as wear reserve. Due to the required resistance the employment of plastic is necessary as pipeline material with chemicals such as, for example, FeCl3 as precipitant. With unavoidable laying of underground pipelines for water-hazardous liquids double pipe systems are to be employed (see §19 WHG). With this the country-specific regulations are to be taken into account. To reduce pressure losses and to avoid deposits fittings are to be so selected that hydraulically favourable conditions result. The radius of curvature of pipe bends should not be less than 1.5 d.
5.3.1
Pipelines Made from Steel and Stainless Steel
With the selection of the diameter of steel pipelines as far as possible fall back on Series 1 in accordance with ISO 4200; this also corresponds with Series 1 in DIN 2458 for welded steel pipes as well as in EN ISO 1127 for welded pipes made from austenitic stainless steel. As wall thickness for these pipes the following suffice in the normal case (compare also Table 2, Appendix):
For smaller nominal diameters (e.g. up to DN 40) the employment of threaded pipes can be economical for water, hot water, air etc. In these cases threaded pipes according to DIN 2440 or to DIN 2441 are to be used.
5.3.2
Pipelines Made from Plastic
First the suitable pipe material is chosen according to the chemical resistance to the medium. Along with this the resistance to UV is also to be considered. (Therefore, with outside facilities and endangered areas PE should be used in preference to the more favourably priced PVC). Following this, via the employment conditions taking into account a medium-related safety factor, the so-called diameter/wall thickness ratio (SDR) and thus subsequently the wall thickness and the external diameter are laid down. For practical implementation, E DIN 8074:19975) can, for example, be called upon for pipes made from polyethylene (PE). First, depending on the temperature, years of operation and permitted operating pressure from Tables 5 - 13, the SDR values (or pipe series S) for various materials (PE 63, PE 80, PE 100) and safety factors are to be determined. For the determination of the pipe dimensions (external diameter de, wall thickness s) one can fall back on Table 2 of the same draft standard specification. As medium-related safety factors the following values are to be applied: (Clean) water 1.25 Chemicals 1.6 Gases and water-hazardous substances 2.0 With the determination of the wall thickness the following maximum pressure loading should be as4) Author`s afternote: In the meantime DIN 19569 has been withdrawn and replaced by EN 12255-1 5 ) Author`s afternote: In the meantime DIN 8047 has been published; Date of issue: August 1999
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ATV-DVWK-M 275E sumed, unless special operating conditions allow higher pressures to be expected, for example earth pressure with underground pipelines, increased pressure with pipeline scrapers, with water hammer, with the transport of thickened sludge, endangering through explosion/detonation:
Medium
Operating pressure
Process water Wastewater Sludge Digester gas Compressed air for the aeration
10 bar 3.2 bar 6 bar 6 bar (see DIN 19569-5)6) 2.5bar
Example: Transport of process water using a DN 100 pipeline Selected material Maximum temperature Years of operation Maximum overpressure
PE 80 20 °C 25 years 10 bar
Using the safety factor of 1.25 for water, there re7) sults from Table 8, E DIN 8074: 1997 for a permitted operating overpressure = 10 bar a SDR value of 13.6. According to Table 2 of this draft standard specification the required wall thickness of s = 8.1 mm can be determined (internal diameter = 93.8 mm) from this with an external diameter of = 110 mm. Under completely the same conditions a wall thickness of 12.3 mm (SDR = 9) results with the transportation of a water-hazardous liquid with a safety factor of 2.0, whereby the internal diameter would only be 85.4 mm.
6
Laying of Pipelines
With the laying of pipelines, extension compensating members, flanges, fittings, detachable fittings, supports, sampling-, flushing-, emptying connections etc. are necessary for the securing of correct assembly, function and maintenance depending on task and requirement. For the laying of pipelines underground attention is drawn to the relevant regulations, such as, for example, ATV-DVWK, DVGW, DIN, German Plastic Pipe Association. Basically the laying guidelines of the manufacturer are always to be observed.
6.1
Expansion and Settling Compensation
As every pipeline, depending on the loading and temperature changes, changes its length, a natural or artificial expansion compensation is to be provided. This is to be taken into account particularly with plastic pipelines as, for example, the longitudinal coefficient of expansion of PE is ca. 17 times greater than that of steel. A natural expansion compensation is, for example, achieved using compensating tube [lyre-shaped] bends. Their overhang from the axis of the pipe depends on the expansion to be expected (between two fixed points), on the diameter and on the material of the pipeline. An artificial expansion compensation is achieved, for example, with the help of compensators. Depending on the required expansion one differentiates between axial, angular and lateral compensators. Combinations of types of movement are also possible. For axial expansion compensation, stuffing box expansion compensators can also be employed. With the design of compensators degree and type of movement, nominal diameter, maximum pressure, temperature and the type of medium are to be taken into account with regard to abrasion and corrosion.
6) Author`s afternote: In the meantime DIN 19569 has been withdrawn and replaced by EN 12255-1 7) Author`s afternote: In the meantime DIN 8047 has been published; Date of issue: August 1999
With plastic pipes it is recommended as afar as possible to employ expansion bends and not compensators for linear compensation. At least it must be ensured that no deformation in the plastic pipe occurs through the restoring forces of the compensator. Thus, as a rule, no metal compensators are used here.
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ATV-DVWK-M 275E In particular with heating pipes and air pipes for activated sludge plants, the lateral change due to the high temperature of the medium is to be taken into account. With soft material compensators one differentiates between single-layer rubber compensators and multi-layer fabric compensators. The rubber compensators as a rule have the advantage of greater impermeability. The disadvantage is, however, their limited service life (observe manufacturer’s details). The material and, in particular, the seal face are dependent on the medium and other constraints such as, for example, compressive stress, operating temperature, resistance to UV or condensate produced and are therefore to be determined before construction. Below in Table 4 are the normal areas of employment of soft material compensators in wastewater treatment plants. The compensators should be realised with a flange connection. Support rings in soft material compensators are only required when, for example, an unacceptable under pressure for the compensators can occur in the suction line of pumps. Metal compensators, usually realised with an expansion bellows, made from several layers of metal bands, are employed with special demands on sealing and temperature. In pipelines for digester gas metal compensators are always to be installed.
Table 4:
Compensators are to be designed with lateral limiters, in case the exceeding of the permitted lateral change is possible. For settling compensation, for example between a structure threatened by settling and an underground pipeline, on many occasions compensators are not sufficient. For this articulated pipe joints or similar pipe fittings are to be employed.
6.2
Connection of Pipelines
With the connection of single pipes one differentiates between permanent and non-permanent connections.
6.2.1
Permanent Connections of Pipelines Made from Metallic Materials
6.2.1.1 Welding and Brazing Welding is the most frequent method of connecting pipes permanently (for this see Sects. 4.1.2 and 4.2.3). Due to this economic connection technology, the brazing of pipelines today is still used only with copper pipes in the area of heating.
Areas of application of materials for soft material compensators
Wastewater/process water:
EPDM
Ethylene-propylene diane monomer (terpolymer), not suitable for oils and media containing grease
CR:
Chloroprene rubber (Brand-name for example Neopren®) Application for process water and wastewater if laying of the pipeline takes place within the building (limited UV resistance)
Gas/mineral oil/digester gas:
NBR:
Acrylonitrile-butadiene rubber (Brand-name for example Perbunan-N®. With digester gas the resistance is dependent on the concentration of gas content substances, in particular of H2S
Chemicals:
CSM:
Chlorosulphonated polyethylene (Brand-name for example Hypalon®)
FPM:
Fluorinated rubber (Brand-name for example Viton®)
PTFE:
Polytetrafluoroethylene (Brand-name for example Teflon®)
IIR:
Butyl rubber
NR:
Natural rubber
EPDM:
Ethylene-propylene diane monomer (terpolymer), rubber mixture matched for application areas up to ca. +130 °C.
Drinking water: Hot water:
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ATV-DVWK-M 275E 6.2.1.2 Press Fittings Pipelines made from stainless steel up to a nominal diameter of DN 100 can be joined to each other permanently using pressed sleeves. This connection technique is very interesting economically due to the small amount of time with assembly. The slight undercutting of the preferred wall thickness Series A in accordance with ISO 4200 is, as a rule, justifiable. Attention is drawn to the manufacturer’s instructions with regard to application.
6.2.2
Permanent Connections of Pipelines Made from Plastic
Pipeline components made from plastic can be connected together permanently using gluing, welding or laminating. In particular with these work steps trained and qualified personnel with appropriate technical equipment are be employed (welding test and similar, see Sect. 4.4.2). Connections to PVC pipes are mainly glued. (PVC pipes normally to be found in building installations have bell joints). Pipe connections made from PE, PP and PVDF are welded (for this see also DVS 2207-1), whereby essentially the following welding methods are used: • heated tool – sleeve welding, • heated tool – butt welding, • (butt welding with heat reflectors), • heated spiral welding. Laminating is employed for connections of pipeli8) nes made from GRP with each other as well as with other materials.
6.2.2
Separable Connections
Separable connections for pipelines made from metallic materials and plastic can be provided using threaded joints, flanges, pipe couplings and clamping joints. For plastic pipelines clamp couplings and bell joints can be used. With smaller diameters threaded joints in place of flange couplings are normal.
6.2.3.1 Flange Connections for Steel Pipelines The flange is the most frequently employed connection technique for joining pipelines nonpermanently. Welding neck flanges (DIN 26309) to DIN 26339)), lapped or slip-on flanges (DIN 26419) and DIN 26429)) as well as plain face flanges for brazing or welding (DIN 25739) and DIN 25769)) are laid down in DIN Standard Specifications. Within the area of application of this Advisory Leaflet pressure level PN 10 as a rule is sufficient. With large nominal diameters (> DN 1000) as far as possible, PN 6 is used. Basic standard specification for flanges is DIN 2501-1, in which the connection dimensions are laid down. Requests for tender must contain the note “Flange connection dimensions in accordance with DIN 2501-1” together with the nominal pressure level (e.g. PN 10), in order to define the interfaces clearly. For nominal diameters up to DN 1000 and nominal pressures up to 10 bar flanges with connecting dimensions PN 10 are to be used for standardisation. Flanges for fittings are to be described analogously. The previously frequently used welding neck flanges are, particularly with stainless steel pipelines, being more and more being supplanted by lapped pipe ends or welding neck collar. The material of the lapped flanges is to be matched to the corrosive stress of the external medium. Coated lapped flanges should not be employed: • in underwater areas, • underground, • in corrosive atmospheres. The smooth flange represents a simple form of flange connection and can be seen as being of equal value to connections with welding neck flange connections. It, however, has the disadvantage that the welded seams cannot be xrayed. If the realisation of flange connections using smooth flanges is to be excluded then this is to be included in the request for tenders.
Attention is drawn to DVS 2210-1 for the design of separable connections for plastic pipelines and to KRV A 9.8.4 for thermoplastics and for GFP pipelines.
The flange leaf thicknesses given in the individual DIN Standard Specification are basically to be observed, a verification of the flange connection
8) Translator`s note: GRP is equivalent to GFK in the German version
9) Author`s afternote: In the meantime these standard specifications have been withdrawn and replaced by EN 1092-1
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ATV-DVWK-M 275E is then as a rule not required. If flanges with reduced leaf thickness are to be employed a verification of the connection in accordance with DIN V 250510) or EN 1591 is to be produced by the contractor.
6.2.3.2 Flange Connections for Plastic Pipelines Welding neck flanges and loose flanges are laid down in sets of rules and standards. Flange connections are to be realised in the pressure stage of the continuing pipeline or the subsequent fittings. The material of loose flanges is to be matched to the corrosive stress by the external medium. Coated loose flanges should not be employed: • in underwater areas, • underground, • in corrosive atmospheres.
6.2.3.3 Pipe Couplings Through the employment of pipe couplings the assembly time in comparison with flange connections can be shortened and repair work more simply carried out. Pipe couplings are suitable for the cospecific connection of thin- and thick-walled pipes made from metal or plastic as well as for the connection of pipes made from different materials. With transition from steel to plastic and with more or less the same internal diameters, a connection using pipe couplings is not possible due to the in general different external diameters (only ca. 1 mm divergence allowed!).The material 1.4301 is common for pipe couplings; special materials are available. The installation torques are given on the couplings. The realisation of the pipe coupling is to be matched to the required operating pressure. For the transfer of axial forces tensile resistant connections are, depending on manufacturer, available up to nominal diameter DN 600, flexible and thrust-free connections up to nominal diameter DN 2000. The selection of material for the base structure as well as for the fastening/locking device is dependent on the surrounding conditions only and not on the medium as these components do not come into contact with the medium.
If required, the necessary steel band inserts are to be matched to the medium. This applies also for the material of the sealing collars. As normal sealing materials the following are, for example, employed: for wastewater EPDM and for gases and hydrocarbons NBR. With digester gas with H2S-contents > 5 mg/m3 the guidance value for the gas properties in accordance with the approval by the DVGW is exceeded. (See Area of Application of the DVGW Standard 260 Part 1). Therefore, above this guidance value, due to the lack of stability of the sealing material NBR, currently the employment of pipe couplings is not to be recommended or is to be released in individual cases by the manufacturer.
6.2.3.4 Bolts, Nuts, Washers Materials for bolts, nuts and washers are to be planned according to the pipeline materials as well as the surrounding conditions. In the underwater area one selects them from stainless steels of the quality A2 or A4 in accordance with EN ISO 3506-1 to EN ISO 3506-3, in rooms with small corrosion stress from hot or electrogalvanised steel and in outside and wet room atmospheres from stainless steel (A2) or in hot galvanised qualities. Due to the tendency to seize, in particular with machine cut screw threads, and to counter rusting in, the application of thread lubricants is recommended. Vibrations can lead to the loosening of non-positively screwed connections. The tightening of the screwed connection using the correct preloading force is therefore important. The securing of screwed connections with suitable adhesive is effective.
6.2.3.5 Seals As seal material synthetic rubbers, for water and sludge EPDM and for gas NBR have proved themselves due to there previous, long-term employment under the same or similarly conditioned operating conditions. Furthermore, seals made from asbestos-free fibrous material slabs (AFP) are used which have replaced the seals known under the abbreviation “IT”. The selection of the sealing material is dependent on the medium and other constraints such as, for example, compression stresses, operating temperature or resistance to UV, and therefore is to be laid down before realisation. Below is listed a selection of sealing materials with abbreviations:
10) Author´s afternote: This DIN standard specification has been withdrawn and replaced by EN 1591-1
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ATV-DVWK-M 275E EPDM: NBR: AFP: PTFE: CSM:
Ethylene-propylene diene monomer (terpolymer) Acrylnitrile-butadiene rubber (brand name e.g. Perbunan-N®) “Asbestos-free fibrous material slabs (successor of the so-called “IT” seals) Polytetrafluoroethylene (brand name e.g. Teflon®) Chlorosulphonated polyethylene (brand name e.g. Hypalon®)
Seals made from metal are to be preferred for high compression stress; seals made from graphite for individual cases with requirements for fire protection. The thickness of seals made from AFP, due to the lower compressive creep stability, are determined with only 2/3 of the normal seal thickness of the “IT” seals. With seals made from PTFE the flow of this material is to be taken into account and therefore the seal thickness is to be selected as small as possible. Compared with EPDM, as a rule NBR has a higher gas imperviousness against hydrocarbons. The resistance to digester gas of the NBR mixtures to be used for sealing materials is, as a rule proven due to the available operating experience. The hydrogen sulphide normally contained in digester gas and the weak acids resulting from the solution of hydrogen sulphide in the condensate, dependent on the concentrations can, under certain circumstances lead to a decomposition of the seals. Seals made from AFP, for example using carbon fibres, are considered as resistant against methane and hydrogen sulphide. Sealing materials with low water absorption such as, for example, NBR are preferred for the employment of stainless steels. Normally with larger diameters or higher pressure seals with fabric or steel inserts or made from AFP are installed due to the high stiffness. With flange connections on PE pipes it is recommended that profile flange seals are used and that the bolts are tightened using a torque wrench in accordance with manufacturer’s details.
6.3
Fittings
Fittings take on important functions in process and operating technology, for example shutting, opening, regulating, aerating and ventilating etc. The following are differentiated: • valves with straight-lined movement of the sealing component parallel to the local direction of flow, • slide valves with straight-lined movement of the sealing component vertically to the flow direction, • stopcocks and butterfly valves with rotating or slewing movement of the sealing component. The type of fitting is to be determined depending on the application purpose (closure, regulation, type of medium, volume flow, pressure and temperature etc.). With the selection of the fittings the pressure ratings are to be chosen according to the respective application case. A summary for the selection of suitable fittings for the respective media is given by Table 8 in the Appendix. The connecting flange of the fitting is to be described analogous to Sect. 6.2.3.1. In addition, the required closure pressure, against which the fitting must close securely, is to be stated in the invitation to tender documents. The dead weight and the operating forces of the installed fittings may not load the pipelines unacceptably, this applies in particular for plastic pipelines. With the planning of the pipelines attention is to be paid to easy operation and dismantling of the fitting. Normally, all hand operated fittings above an operating height of 1.80 m are to be equipped with chain wheel and chain, spindle extension or similar.
6.4
Pipe Supports and Fixtures
Permitted spans L of filled and unfilled steel pipes in the range of diameters from DN 25 to DN 500 and a flowing medium with the density of water (1,000 kg/m3) can be extracted from Table 9.1 (Appendix). With plastic pipelines, due to the low strength values, the significantly differing modulus of elasticity and the effects of temperature which are not to be ignored, there are smaller separations between supports.
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ATV-DVWK-M 275E Permitted spans for thermoplastic plastic pipes filled with water can be taken from Table 9.2 (Appendix); those made from duroplastic plastics from Table 9.3 (Appendix).
• pipelines which, due to the medium to be pumped (e.g. thickened sludge), tend particularly to blockages, are to be fitted with flushing connections, cleaning ports, connections for cleaning brushes or similar.
In the main pipe clips in accordance with DIN 3567 and round steel stirrups in accordance with DIN 3567 are employed.
For pipeline systems in the field of gas the following are to be observed:
The supports are, for example, produced as welded construction, galvanized and in accordance with Table 10 (Appendix). They are to be divided into sliding and fixed bearings. Design and assembly must ensure an arrangement conforming in alignment and angle, free of deformation and tension. The freedom of movement of the pipeline must be ensured taking into account the variation of the media and ambient temperatures. The working surfaces of the sliding bearings are to be so designed that edge pressure is excluded. Fixed bearings are to be so developed that forces and moments can be taken up in three axes and be fed into the structure. Pipe racks are also used as standardised attachment system as an alternative to the normal welded structures. An advantage of these systems as a rule lies in the simplified verification of the static dimensioning and the significantly lower weight.
6.5
Emptying, Ventilation and Cleaning
• as far as possible no rise in the direction of flow as condensate is produced. In the case that this cannot be avoided an appropriate dimensioning must be carried out. • low points are to be provided with condensate interceptors for drainage.
6.6
Wall Leadthroughs
Often walls and ceilings have to be penetrated in the course of the laying of pipelines. The socalled wall leadthroughs are to be designed in accordance with the generally recognised rules of technology. The following criteria are, in particular, to be observed: • sealing against gas with neighbouring explosive areas, • fire protection, • corrosions protection (with aggressive atmospheres), • sealing against water under pressure, • time of implementation (during construction work or later).
The following information is to be taken into account with the planning and laying of pipelines for the emptying, ventilation and cleaning of pipelines:
Wall leadthroughs can be realised as chases for subsequent casting or as fairleads with subsequent sealing by means of annular seals.
• high points are to be avoided or fitted with ventilation devices (interruption of delivery through gas bubbles at the high points),
If annular seals are used in core bore holes particular value is to be placed on the execution of the boring. Scoring due to blunt tools can usually no longer be compensated by the seals. Borings must be carried out perpendicular in order that no unbalanced forces act on the seal, otherwise the sealing ability and service life of the annular seal is influenced negatively. The weight of the pipeline may not be taken up by the annular seal. An additional sheathing pipe is, as a rule, not required.
• low points are to be avoided and, with the danger of deposits, precautions are to be taken for the flushing of the system, • minimum nominal diameters of emptying facilities are to be observed (danger of blockages); the following have proved themselves: – DN 20 for condensate and other liquids without solid matter – DN 50 for viscous pumping media e.g. sludge, • drainage pipelines are to be laid to pump pits, floor drains etc.,
Annular seals are to be avoided if wall or ceiling penetrations are no longer accessible or accessible only with difficulty following assembly as a further tightening with leakages is no longer possible. With penetration of digesters one should, in general, avoid annular seals. The leadthrough is to be designed as installation pipe with wall
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ATV-DVWK-M 275E flange or as equivalent solution. The wall or ceiling leadthrough is to be considered structurally as fixed restraint and is to be dimensioned as fixed bearing. Axial or angular changes which occur are taken up by the pipelines leading outside or by pipe installation components such as, for example, compensators. If wall flanges are used with PE pipelines the flange should be reinforced with an additional steel ring in order to improve sealing. The provisions of DVGW Standard G 600 for wall and ceiling leadthroughs of pipelines carry gas are to be applied analogously. (It can be assumed that with reinforced concrete the dangers due to gas conducting layers as, for example, occur with brickwork, do not exist.) In accordance with DIN 1988-7 in general no corrosion protection is required with surface or buried laying. Before the plastering-in of galvanised steel pipes, protective bandages or protective foils are to be employed as corrosion protection. With stainless steel pipelines chloride-free mortar and, in case of need (e.g. with winter building measures), a building supervisory approved concrete additive (control of the chloride content) is to be employed. Provisions resulting from fire protection are to be observed. The constructor of the pipeline is therefore to be given which walls and ceilings, from the aspect of fire protection, are to be classified as firewalls and/or complex dividing wall. In accordance with the recommendations of the German Association of Property Insurers (VdS 2234) openings in firewalls are not permitted. If they are necessary for operating reasons they must be fire resistant protected. Pipelines may not produce any inadmissible forces on the wall. The following designs have, inter alia, proved themselves: • in firewall level movable pipelines with bushings made from non-combustible material, with which the remaining intermediate space is stuffed with non-combustible material of building material class A 1 with a melting point above 1000 °C, e. g. rock wool, • in firewall level fixed pipes, with which the intermediate space between pipeline and wall is to be completely filled using mortar or fire protection mortar, and a compensator is to be located before and after the firewall.
R 90 systems with general construction supervisory approval (e.g. R 90 bulkheads).
6.7
Lubrication Lines
Unalloyed steel or copper (see Chap. 4.3) is recommended for the production of lubrication lines in dry spaces, in the open and in wet spaces stainless steel with Material No. 1.4301 or 1.4571. Lubrication lines made from Polyamid, e.g. PA 12 in accordance with DIN 73378, are also possible. The pipelines are to be so laid that they cannot be mechanically damaged. All lubrication points should be easily accessible. Where this is not possible then they are to be brought together at easily accessible positions. The individual lubrication points and lines are to be marked.
7
Other Matters
7.1
Insulation
With pipe insulation one differentiates between insulation as heat and cold protection and insulation as corrosion protection or as sound proofing. Here only the area of heat and cold insulation is to be considered. Pipelines in which cold or warm media are transported are to be provided with pipe insulation for the reduction of the cold or heat losses, taking into account economic efficiency, operating safety and protective quality. For this, as insulation materials, there are available fibre or powder formed insulation matter, plastic foams and natural organic matter.
7.1.1
Execution of Hot Protective Insulation
As a rule, for heat protective insulation, mineral substances made from rock wool are employed as insulation material. This material can be employed in the form of • mineral fibre mats for the insulation of pipelines, containers and devices, • mineral fibre shells for the insulation of pipelines, • short floccy fibres for stuffing insulation.
Leading pipelines made from combustible material through firewalls is basically to be avoided. If this is not possible then they are to be compartmentalised using [German) Fire Resistance Class
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ATV-DVWK-M 275E 7.1.2
Execution of Cold Protective Insulation
As a rule, foam materials are employed for the rather seldom cold protective insulation in wastewater treatment plants.
7.1.3
Insulation to Prevent Condensation Water
Moisture precipitation on cold pipelines should be prevented though a sufficient insulation of the pipeline (surface temperature of the insulation greater than the temperature of the dew point of the surrounding atmosphere). Particularly suitable for such condensation water insulation are insulation materials which are resistant to the penetration of moisture (foamed materials), although also here the employment of mineral fibres is possible and normal. In addition to the demands on the mechanical properties an especially high demand is to be placed on the steam-tight design of the insulation.
7.1.4
Frost Protective Insulation
Water pipes in which, over long periods, the water does not flow can freeze up in winter. Cooling can be delayed through an insulation and thus the danger of a freezing up can be reduced. In order fundamentally to prevent freezing up, the pipelines must be provided with secondary heating and insulation. With the use of mineral fibre products normal here special value is also to be placed on the steam-tight closure of the insulation cladding.
7.1.5
Insulation for Pipes Made from Stainless Steel
Insulation materials for heat protective and cold insulation of stainless steel pipes may not have a percentage by mass of water soluble chloride ions which exceeds 0.05 % (insulation material with “AS” Quality in accordance with Standard AGI Q 135 are suitable).
7.1.6
Insulation Thicknesses
For the determination of sufficient insulation thickness there are tables available, both for heat and cold protective insulation as well as for condensation and frost protective insulation, which, depending on the nominal pipe diameters, the temperatures which occur and other relevant parameters give information on the required minimum insulation thickness.
If required, consideration of economic efficiency for insulation thickness (costs) in comparison to the heat energy saved (benefits) is also to be carried out. Insulation thicknesses of heat protective insulation on heating pipes are to be produced according to the details of the heating plant ordinance.
7.1.7
Insulation Cladding
All insulation is to be provided with cladding for protection against external stresses. With this galvanised thin sheet, aluminium sheet, stainless steel sheet and, in heating systems also PVC foil with a thickness of 0.5 mm – 1.0 mm can be employed. Flanges, valves, other fittings and pipe accessories must be clad for insulation using a cap made up from two or more parts and made in the form of the fitting to be clad. Removal and replacement of the insulation cap must be possible at all times with ease and rapidly.
7.2
Equipotential Bonding
All electrical conducting pipelines, independent of other electrical protective measures, are to be integrated into a equipotential bonding system. The equipotential bonding can be carried out on a central equipotential bonding rail or between each other. Suitable terminal lugs are to be planned on pipelines, flanges, containers etc. for connection to an equipotential bonding system. If non-conducting fittings or adapters are installed into the pipeline system these integrated items must be bridged using suitable lines. The electrically nonconducting properties of plastic pipes are to be noted in explosion endangered areas and with easily combustible pumping media. Here there is the possibility of employing special conducting raw materials (e.g. PE 80 el.). Equipotential bonding of pipeline systems is to be integrated into the overall system equipotential bonding. Depending on the structure of the protective measure and taking into account the valid VDE regulations for this, the foundation earth connection, null or earth conductor, earthling conducters for antenna and telephone systems as well as earth conducters or lightning protection must be integrated into the system. The linkages and connections to the equipotential bonding lines are to be correctly and permanently carried out by the installer of the electrical system in accordance with the valid provisions and regulations.
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ATV-DVWK-M 275E 7.3
Measurements
With invitations to tender (ITTs), which concern the VOB [German Conditions Concerning Contracts], in addition to DIN 18299: 199611), Section 5, DIN 18381: 19989), Section 5, also applies with regard to measurements and settlement. In this case, with measurements, mouldings and fittings and are “overmeasured”.
7.4
Marking
It is recommended to mark pipelines within systems in accordance with the medium which flows through them using coloured emphasis or through labelling. If, with the media, one is concerned with hazardous substances within the meaning of the [German] Chemical Law, there can be an obligation for marking in accordance with the [German] Hazardous Substance Ordinance. In accordance with § 23 (Packaging and Marking) there have to be markings at sufficient frequency on visibly laid pipelines and clearly visible close to “potentially hazardous points such as gate valves and connection points”. Attention is drawn to the Chemical Law and Hazardous Substance Ordinance with regard to the media – as examples are given digester gas, acids, caustic solutions – and details of marking. Where no regulations for marking exists, DIN 2403 should be applied. (Marking in accordance with DIN is laid down as generally applicable, special media of wastewater treatment are not given there.)
For the coloured marking of pipelines it is recommended that coloured rings or adhesive labels – if required with additional naming of the medium – are provided but not, however, to choose a continuous coat of paint as many pipe materials for the avoidance of corrosion must not be additionally coated. A proposal for the selection of colour for the marking of the media, based on DIN 2403 is contained in Table 5. It is proposed that: 1. fundamentally, marking is in accordance with the above given colour groups. 2. rings and/or adhesive labels or similar are to be selected in the basic colours and are to be provided additionally with written details and direction arrows. 3. all water (e.g. wastewater, process water, sludge liquor ≤ 2 % dry solid matter (DS)) are to be assigned to Group 1. Heating water is also to be listed under Group 1. Here, if necessary, DIN 2404 is to be observed. 4. all sludge > 2 % DS is to be assigned to Group 9. 5. all other substances (e.g. flocculation aids or flocculants, inert gases etc.) are to be assigned to obvious groups (e.g. FeCl3, FeCl2 ⇒ Group 6, milk of lime ⇒ Group 7, nitrogen ⇒ Group 5 etc.).
In accordance with DIN 2403 pipelines can be marked according to the substance which flows through them using signs, adhesive labels, coloured rings or through coloured cladding. Signs have the advantage that, in addition to the substance flowing through, they can also hold important details (e.g. direction of flow, markings corresponding to flow diagram, serial number for maintenance). Labelling, which is obtainable on the market as ready-made article, should be written simply, easily and permanently readable as well as being secure and simple to attach.
11)
Author´s afternote: DIN 18299, DIN 18381: New edition, date of issue: October 2006
May 2001
23
ATV-DVWK-M 275E Table 5:
Classification of colours to the flowing substances in accordance with DIN 2403
Substance flowing
Water Steam Air Combustible gases
Group
Colour name
1 2 3 4
Green Red Grey Yellow or yellow with additional colour red Yellow with additional colour black Orange Violet Brown or brown with additional colour red Brown with additional colour black Blue
Non-combustible gases
5
Acids Alkaline solutions Combustible liquids
6 7 8
Non-combustible liquids
9
Oxygen
0
7.5
Tests
Pipelines for an overpressure of more than 0.5 EG bar as a rule fall under the EC Directive “Pressure equipment”. In accordance with the basic concept of the EG Directive “Pressure equipment” the direct responsibility of the manufacturer is emphasised, i.e. the specialist no longer establishes the correctness of the pressure equipment, for example the pipeline, but rather the manufacturer. The manufacturer declares the conformity with the European Standards and, if required, affixing the CE marks Until common basic European standards are available, for example for pipelines, national standards and technical specifications, for example DruckbehV with [German] Technical Rules for Pressure Vessels (TRB) and [German] Technical Rules for Pipelines (TRR) are to be enlisted. Depending on the hazard potential (pressure, volume, dangerousness of the liquid) there are different categories for the assessment of conformity to be carried out by the manufacturer specified in the EG Directive “Pressure Equipment”.
Nearest colour sample in the RAL colour register RAL 840 HR RAL 6018 RAL 3000 RAL 7001 RAL 1021 RAL 3000 RAL 1021 RAL 9005 RAL 2003 RAL 4002 RAL 8001
RAL 3000 RAL 8001 RAL 9005 RAL 5015
For the lowest category of conformity evaluation, i.e. application cases which come under Article 3, Para. 3, equipment and pipelines must “be designed and produced in agreement with good engineering practice applicable in one of the Member Countries”. This means that the national standards and provisions in these cases can be used unlimited, but then, however, must without fail be specified in the invitation to tender. (Note: a large part of the pipelines in wastewater treatment plants fall under the category in accordance with Article 3, Para. 3.) Below the controlled region of 0.5 bar national regulations apply and acceptance and test criteria for the individual case are to be laid down, inter alia, in accordance with • the [German] Pressure Vessel Ordinance (DruckbehV), • the [German] Ordinance on Combustible liquids (VbF), • the [German] Ordinance on Facilities for the handling of Water Hazardous Substances (VAwS),
May 2001
24
ATV-DVWK-M 275E • the Standards of the German Technical and Scientific Association for Gas and Water (DVGW), • the applicable Accident Prevention Regulations ([German] UVV), • the [German] (DampfkV),
Steam
Boiler
Ordinance
• the respective building regulations etc. Pipelines which are operated within the framework of the public water and/or gas supply with an overpressure of at the most 16 bar, are to be allocated to the area of application of the DVGW. Under this fall the pipelines of the works network, fed from the public network of the supply company, with the connection up to and including the consumer facilities, e.g. the gas burners.
Bibliography [1] DVS 2210 Part 1: 1987 Deutscher Verband für Schweißtechnik und verwandte Verfahren e. V., Deutscher Verlag für Schweißtechnik GmbH, Düsseldorf [German Association for Welding Technology and Related Processes] [2] LAWA: Leitlinien zur Durchführung von Kostenvergleichsrechnungen Länderarbeitsgemeinschaft Wasser, 1998 [German Federal State Working Group Water (LAWA): [Guidelines for the carrying out of cost comparison calculations] [3] Wagner, W.: Rohrleitungstechnik Vogelverlag und Druck KG, Würzburg 1993 [Pipeline technology]
Furthermore, it is to be recommended, in the examination of the pipeline, to also include a check that the laying is correct with regards to planning and material. In the first instance this concerns the possibility of the unhindered absorbing changes is length, the functionally correct installation of device for changes of length as well as the arrangement of pipe mountings.
[4] Proff, E.; Lohmann, H. J.: Rheologische Charakterisierung flüssiger Klärschlämme Korrespondenz Abwasser (44), No. 9, 1997 [Rhealogical characterisation of liquid sewage sludge]
If fittings with actuators or also measurement, control and monitoring devices are installed the correct and planned function of the equipment is also to be examined.
[6] Klauwer, E. u. a.: Druckverluste bei Förderung von Klärschlämmen in Rohrleitungen. Untersuchungen des Ruhrverbandes, unveröffentlicht [Pressure losses with the conveyance of sewage sludge pipelines. Investigations of the Ruhr Association, unpublished]
[5] Proff, E.; Lohmann, H. J.: Schlammförderung Korrespondenz Abwasser (44), No. 10, 1997 [Conveyance of sludge]
May 2001
25
ATV-DVWK-M 275E
Appendix Appendix A: Tables A1 – Table 1:
Media and pipe materials in wastewater treatment plants
A2 – Table 2:
Dimensions of steel and stainless steel pipelines
A3 – Table 4:
Pipe wall thicknesses for plastic pipes
A4 – Table 8:
Media in wastewater treatment plants and fittings employable for these
A5 – Table 9.1:
Permitted supporting spans – steel pipes
A6 – Table 9.2:
Permitted supporting spans – thermoplastic plastic pipes
A7 – Table 9.3:
Permitted supporting spans – duraplastic plastic pipes
A8 – Table 10:
Design of supports and securing material
May 2001
26
ATV-DVWK-M 275E Media and pipe materials in wastewater treatment plants
17
May 2001
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Air
Steam Condensates Oil/greases
Dosing agents/ precipitants
Chemicals Other media
27
1) Maximum standard temperature in °C 2) Depends on the sludge composition and conditioning
3) Not within buildings 4) With high temperatures without condensation
x x x o o
x x X x
o o
X X X xL xL xL xL xL xL xL xL xL X x
x x4)
x x
x x
x x
x x
x x
x x
x x x x x x x x x
x x x x x x x x x x x x2)
x x x x x x x x x
x x x x x x x x x
x x x x x x x x x
x x
x x
x x
x x
x x
6)
x x
7)
x x x x7)
xL x x x x
x x x x x x x
x
x
x x
x x x x x
x x x x x
x x x
x
x
x x x
x
x
5) Note underwater zone 6) Other type of galvanisation
x x x x
x x x
x x x
x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x
x x x x x x x x
x x x
x x
x x
x x
x
x x
x
x
x x x x x x
x
x
x x
Polyamide (max 70°)1)
Aluminium alloys
Copper x
x 4)
x
x x x x x x x x x x x x x x x x
PVDF (max 120°)1)
Gases
x x
PB (max 90°)1)
Sludge
x x x x x o x o
EP-GF/UP-GF
Drinking water Process water (wells) Heating water Untreated wastewater Treated wastewater Sludge liquor Primary sludge Secondary sludge Sludge from chemical precipitation Faecal sludge Stabilised sludge Dewatered sludge Natural gas Propane (gaseous) Digester gas Flue gas / off gas from combustion of digester gas Off gas from digester gas combustion in gas engines Compressed for fine bubble aeration Compressed air for pneumatic systems Waste air from processes Air for aeration and ventilation Steam up to 10 bar / steam condensate Flue gas condensate Digester gas condensate Lubrication oil Old oil Heating oil / diesel oil Hydraulic oil Lubricating grease Aqueous polymer solution Aluminium chloride Aluminium sulphate Ferric chloride Ferric sulphate Milk of lime Caustic soda solution Hydrochloric acid Sand/water mixture Methanol (methylalchohol Ethanol (Ethyalchohol) Aceticacid / formic acid
PP (max 90°)1)
Water
HDPE (max 60°)1)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PVC (max 60°)1)
Medium
Steel, hot galvanised
Group
Plastics
ATV-DVWK-M 275E
No.
Wastewater
Creep resistant steels
Unalloyed steels
Re commendations x = applicable 0 = limited applicable L = danger of pitting corrosion
Nonferrous metals Austenite stainless steel ≥2% molybdenum, e.g. 1 4571
Steels
Material
Austenite stainless steel without molybdenum, e.g. 1.4301
A1 – Table 1:
o x x
x x x
x x x
x x x x
x
x
x
x
7) Only in non-corrosive atmospheres
May 2001
27
ATV-DVWK-M 275E A2 – Table 2: Dimensions of pipelines made from steel and stainless steel Steel pipes Nominal diameter DN 6 8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1,000
Threaded pipe medium gauge DIN 244012)
1/8” 1/4” 3/8” 1/2” 3/4”
10.2 x 2.00 13.5 x 2.35 17.2 x 2.35 21.3 x 2.65 26.9 x 2.65
1” 1 1/4” 1 1/2” 2” 2 1/2” 3”
33.7 x 3.25 42.4 x 3.25 48.3 x 3.25 60.3 x 3.65 76.1 x 3.65 88.9 x 4.05
4”
114.3 x 4.50
Stainless steel pipes
Steel pipe, welded
13.5 x 1.6 17.2 x 1.6 21.3 x 1.8 26.9 x 1.8 33.7 x 2.0 42.4 x 2.3 48.3 x 2.3 60.3 x 2.3 76.1 x 2.6 88.9 x 2.9 114.3 x 3.2 139.7 x 3.6 168.3 x 4.0 219.1 x 4.5 273.0 x 5.0 323.9 x 5.6 355.6 x 5.6 406.4 x 6.3 457.0 x 6.3 508.0 x 6.3 610.0 x 6.3 711.0 x 7.1 813.0 x 8.0 914.0 x 10 1,016.0 x 10
Welded or seamless 10.2 x 1.6 13.5 x 1.6 17.2 x 1.6 21.3 x 1.6 26.9 x 1.6 33.7 x 1.6 42.4 x 1.6 48.3 x 1.6 60.3 x 1.6 76.1 x 1.6 88.9 x 2.0 114.3 x 2.0 139.7 x 2.0 168.3 x 2.0 219.1 x 2.0 273.0 x 2.0 323.9 x 2.6 355.6 x 2.6 406.4 x 2.6 457.0 x 3.2 508.0 x 3.2 610.0 x 3.2 711.0 x 4.0 813.0 x 4.0 914.0 x 4.0 1,016.0 x 4.0
Notes: The external diameters are classified in accordance with ISO 4200 Series 1. With wall thicknesses for the steel pipes one is concerned with the Preferred Wall Thickness Series D from ISO 4200. With wall thicknesses for the stainless steel pipes one is concerned with Preferred Wall Thickness Series A from ISO 4200. Depending on the individual case, in particular with larger pipe cross-sections, greater wall thicknesses are to be recommended. With these measurements, commercially the wall thickness is 3.0 mm instead of the value in ISO 4200.
12) Author´s afternote: DIN 2440 has been withdrawn and replaced by EN 10255
May 2001
28
ATV-DVWK-M 275E
A3 – Table 4: Wall thicknesses for plastic pipes (extract for various materials and nominal pressures) Material PN1)
PE 80 (DIN 8074) 6
1)2)
10
1)2)
PE 100 (DIN 8074) 6
1)2)
10
1)2)
PP-H Type 1 (DIN 8078) 6
10
PVC-U (DIN 8062) 6
PVC-C (DIN 8079)
10
10
16
s
PA (DIN 16982)
PVDF (based on DIN 8062)
-
ABS (DIN 16891)*)
PB (DIN 16969)
10
16
6
16
UP-GF (DIN 19565-1) **)
3)4)
65)
105)
66)
106)
Row SDR
17.6
22
13.6
S
8.3
10.5
6.3
34.33
de
s
s
s
s
s
s
s
s
s
6
-
-
-
-
-
-
-
-
-
16.67 de
s
de
s
s
s
s
DN
de
Row
s
s
s
s
-
-
6
-
-
-
-
100
116
2
-
-
2.9
2.9
8
-
-
-
-
-
-
-
-
-
-
-
8
-
-
-
-
125
142
2
-
-
3.9
3.9
10
-
-
-
-
-
-
-
-
-
-
-
10
-
-
-
-
150
168
2
-
-
4.1
4.1
12
-
-
-
-
-
-
-
-
-
12
1.5
12
-
-
-
-
200
220.5
2
-
-
5.3
5.3
16
-
1.8
-
-
-
1.8
-
-
-
1.8
15
1.5
16
-
1.5
1.5
2.23)
250
272.1
2
-
-
6.4
6.4
20
-
1.9
-
1.8
1.8
1.9
-
-
-
2.3
18
2
20
-
-1.9
1.65
2.83)
300
324.5
2
5.2
5
6.4
6.3
25
-
2.3
-
1.9
1.8
2.3
-
1.5
-
2.8
22
2
25
-
1.9
1.95
2.33)
350
376.4
2
6.1
5.7
7.5
7.2
32
1.9
2.9
1.8
2.4
1.9
3-
-
1.8
-
2.4
35
2.5
32
-
2.4
2.15
3.03)
400
427.3
2
6.8
6.4
8.4
8.1
40
2.3
3.7
1.9
3
2.3
3.7
1.8
1.9
-
3
42
2.25
40
-
2.4
2.7
3.73)
450
478.2
2
7.5
7.1
9.3
9
50
2.9
4.6
2.3
3.7
2.9
4.6
1.8
2.4
-
3.7
-
-
50
-
2.9
3.3
4.63)
500
530.1
2
8.3
7.8
10.2
10.1
63
3.6
5.8
2.9
4.7
3.6
5.8
1.9
3
-
4.7
-
-
63
2.5
3
4.24
5.83)
600
617
1
9.6
9
11.7
11.5
75
4.3
6.8
3.5
5.6
4.3
6.9
2.2
3.6
3.6
5.6
-
-
75
2.5
3.6
4.9
6.84)
700
719
1
10.9
10.3
13.6
13.4
90
5.1
8.2
4.1
6.7
5.1
8.2
2.7
4.3
4.3
6.7
-
-
90
2.8
4.3
6
8.24)
800
821
1
12.4
11.7
15.4
15.2
110
6.3
10
5
8.1
6.3
10
3.2
5.3
5.3
8.2
116
7
110
3.5
5.3
7.2
10.04)
900
923
1
13.8
13.1
17.2
17
125
7.1
11.4
5.7
9.2
7.1
11.4
3.7
6
-
-
165
8
125
3.9
-
-
-
1000
1025
1
15.3
14.5
19
19
140
8
12.7
6.4
10.3
8
12.8
4.1
6.7
6.7
-
196
7
140
4.4
-
-
-
160
9.1
14.6
7.3
11.8
9.1
14.6
4.7
7.7
7.7
11.9
215
8
160
5
-
-
-
180
10.2
16.4
8.2
13.3
10.2
16.4
5.3
8.6
-
-
265
9
180
5.6
-
-
-
200
11.4
18.2
9.1
14.7
11.4
18.2
5.9
9.6
-
-
316
10
200
6.2
-
-
-
225
12.8
20.5
10.3
16.6
12.8
20.5
6.6
10.8
10.8
-
382
13
225
7.1
-
-
-
250
14.2
22.7
11.4
18.4
14.2
22.8
7.3
11.9
-
-
472
16
250
-
-
-
-
S:
Pipe series number, taken from ISO 4065
280
15.9
25.4
12.8
20.6
15.9
25.5
8.2
13.4
-
-
-
-
280
-
-
-
-
SN:
Nominal stiffness (N/m2), referred to the mean pipe diameter
17.9
28.6
14.4
23.2
17.9
28.7
9.2
15
-
-
-
-
315
-
-
-
-
355
20.1
32.2
16.2
26.1
20.1
32.3
10.4
16.9
-
-
-
-
355
-
-
-
-
400
22.7
36.3
18.2
29.4
22.7
36.4
11.7
19.1
-
-
-
-
400
-
-
-
-
SDR:
Standard Dimension Ratio: SDR = 2·S + 1 ≈ de/s
1)
PN as given at 20 °C
2)
SF = 1.6 safety factor
3)
PN 10 at 90 °C
May 2001
450
25.5
40.9
20.5
33.1
25.5
41
13.2
21.5
-
-
-
-
450
-
-
-
-
4)
PN 6 at 90 °C
500
28.3
45.4
22.8
36.8
28.3
-
14.6
23.9
-
-
-
-
500
-
-
-
-
5)
SN = 5000
560
31.7
50.8
25.5
41.2
31.7
-
16.4
26.7
-
-
-
-
560
-
-
-
-
6)
SN = 10000
630
35.7
57.2
28.7
46.3
35.7
-
18.4
30
-
-
-
-
630
-
-
-
-
710
40.2
64.5
32.3
52.2
40.2
-
20.7
-
-
-
-
-
710
-
-
-
-
800
45.3
-
36.4
58.8
45.3
-
23.3
-
-
-
-
-
800
-
-
-
-
900
51
-
41
66.1
51
-
26.3
-
-
-
-
-
900
-
-
-
-
1000
56.6
-
45.5
-
56.6
-
29.2
-
-
-
-
-
1000
-
-
-
-
*)
29
ATV-DVWK-M 275E
315
Explanatory notes:
Authort´s afternote: In the meantime DIN 16891 has been withdrawn
**) In the meantime DIN 19565-1 has been withdrawn and replaced by DIN EN 14364
May 2001
29
ATV-DVWK-M 275E
A4 – Table 8: Media on wastewater treatment plants and fittings employed for these
Iris diaphragm control valve
Diaphragm gate valve
Parallel slide gate valve
Sluice valves4), soft sealing
Sluice valves4), metallic sealing
Tapr plug valves
Non-return valves3)
Non-return valves 2)
Butterfly valves
Diaphragm valves
Ball check valves
Slide valves
Drinking water Process water (wells/ Heating water
xx xx xx
xx xx xx
xx xx xx
xx x kE
xx xx xx
xx xx xx
xx xx x
x x xx
xx xx kE
x x xx
x x xx
x x x
xx xx kE
kE x kE
x x kE
x x kE
4 5 6
Wastewater
Untreated wastewater Treated wastewater Sludge liquor
kE xx kE
kE xx kE
kE xx kE
kE x x
kE xx x
x xx x
xx xx xx
kE x kE
xx xx xx
kE x kE
kE x kE
kE x kE
x x xx
xx xx xx
x x x
kE X kE
7 8 9 10 11 12
Sludge
Primary sludge Secondary sludge Sludge from chemical precipitation Faecal sludge Stabilised sludge Dewatered sludge
kE kE kE kE kE kE
kE kE kE kE kE kE
kE kE kE kE kE kE
kE kE kE kE kE kE
kE x kE kE kE kE
kE kE kE kE kE kE
xx xx xx xx xx kE
kE kE kE kE kE kE
xx xx xx xx xx xx
kE kE kE kE kE kE
kE kE kE kE kE kE
kE kE kE kE kE kE
xx xx xx xx xx x
xx xx xx xx xx xx
x x x x x kE
kE kE kE kE kE kE
13 14 15 16 17
Gases
Natural gas Propane (gaseous) Digester gas Flue gas / off gas from combustion of digester gas Off gas from digester gas combustion in gas engines
xx xx xx kE kE
xx xx xx kE kE
xx xx xx kE kE
kE kE kE kE kE
xx xx xx xx xx
xx xx xx xx xx
kE kE kE kE kE
xx xx xx xx xx
xx xx xx kE kE
x x x kE kE
kE kE kE kE kE
xx xx xx kE kE
x x x kE kE
kE kE kE kE kE
kE kE kE kE kE
X X x kE kE
18 19 20 21
Air
Compressed for fine bubble aeration Compressed air for pneumatic systems Waste air from processes Air for aeration and ventilation
xx xx kE kE
kE xx kE kE
kE xx kE kE
x x kE kE
xx x xx xx
xx x xx xx
kE kE kE kE
xx x xx xx
xx xx x kE
x x x kE
x x x kE
kE kE kE kE
x kE x kE
x kE kE kE
X kE x kE
Xx5) kE kE kE
22
Steam
Steam up to 10 bar / steam condensate
xx
xx
xx
kE
kE
kE
kE
x
x
kE
kE
xx
kE
kE
kE
kE
23 24
Condensates
Flue gas condensate Digester gas condensate
xx xx
xx xx
xx xx
x x
x x
kE kE
xx xx
kE kE
xx xx
x x
xx xx
x x
kE kE
kE kE
kE kE
kE kE
25 26 27 28 29
Oil/greases
Lubrication oil Old oil Heating oil / diesel oil Hydraulic oil Lubricating grease
xx xx xx xx kE
xx xx xx xx kE
xx xx xx xx kE
kE kE kE kE kE
x x x x x
kE kE kE kE kE
kE kE kE kE kE
kE kE kE kE kE
xx xx xx xx xx
x x x x kE
x x x x kE
x x x x kE
x x x x kE
kE kE kE kE kE
x x x kE kE
kE kE kE kE kE
30 31 32 33 34 35
Dosing agents/ precipitants
Aqueous polymer solution Aluminium chloride Aluminium sulphate Ferric chloride Ferric sulphate Milk of lime
x x x x x kE
x x x x x kE
x x x x x kE
xx xx xx xx xx xx
x x x x x x
kE kE kE kE kE kE
xx x xx xx x x
x xx xx xx xx x
xx xx xx xx xx xx
kE kE kE kE kE kE
kE kE kE kE kE kE
kE kE kE kE kE kE
x x x x x kE
kE kE kE kE kE kE
xx xx xx xx xx xx
kE kE kE kE kE kE
36 37
Chemicals
Caustic soda solution Hydrochloric acid
xx xx
xx xx
xx xx
xx xx
x x
kE kE
xx xx
x x
xx xx
x x
x x
kE kE
kE kE
kE kE
xx xx
kE kE
38 39 40 41
Other media
Sand/water mixture Methanol (methylalchohol Ethanol (Ethyalchohol) Aceticacid / formic acid
kE xx xx xx
kE xx xx xx
kE xx xx xx
xx kE kE kE
x x x x
kE kE kE kE
xx kE kE kE
kE x x x
kE xx xx xx
kE x x x
kE x x x
kE kE kE kE
x kE kE kE
xx kE kE kE
kE x x x
kE kE kE kE
30
In corner and straight-way design Double clack valve with spindle , if required with lever and weight Shuttle valves or double check valves, swing check valves Designed as oval-body wedge gate valve or wedge-type flat wedge valve Annular piston valve also possible
Ball valves
Media
Water
Throttle valves
Group
1 2 3
Check valves
No.
ATV-DVWK-M 275E
May 2001 1) 2) 3) 4) 5)
Stop-cocks
Shut-off valves
preferred xx = employment normal x = employment possible kE = employment not normal
Double clack valves
Selector valves
Valves1)
Fitting
Note: Valves and cocks are used preferably up to a nominal diameter of DN 80 Double clack valves and slide valves are used preferably for nominal diameters > DN 80
May 2001
30
ATV-DVWK-M 275E A5 – Table 9.1: Permitted support separations – steel pipes Pipe dimensions
Empty pipe without insulation
Water-filled pipe, Without insulation
Water-filled pipe, insulation thickness DD40
Water-filled pipe, insulation thickness DD80
DN
de
s
q
L1
L6
q
L1
L6
q
L1
L6
q
L1
mm
mm
mm
kg/m
m
m
kg/m
m
m
kg/m
m
m
kg/m
m
L6 m
25
33.7
2.0
1.6
2.9
1.5
2.3
2.7
1.2
7.0
2.0
7.0
11.8
1.8
0.5
25
33.7
4.0
2.9
2.9
1.8
3.5
2.8
1.7
8.1
2.2
1.1
13.0
2.0
0.9
40
48.3
2.0
2.3
3.5
1.6
3.9
3.1
1.2
9.2
2.5
0.8
14.3
2.3
0.6
40
48.3
4.0
4.4
3.5
1.9
5.7
3.3
1.7
11.0
7.8
1.2
16.1
2.5
1.0
50
60.3
2.0
2.9
4.5
1.6
5.4
3.9
1.2
11.3
3.2
0.8
16.6
2.9
0.7
50
60.3
4.5
6.2
4.4
2.1
8.3
4.1
1.8
14.2
3.6
1.4
19.4
3.3
1.2
80
88.9
2.3
5.0
5.5
1.8
10.6
4.6
1.3
17.8
4.0
1.0
23.5
3.7
0.8
80
88.9
5.6
11.5
5.4
2.4
16.3
5.0
2.1
23.5
4.5
1.7
29.2
4.3
1.5
100
114.3
2.6
7.3
6.3
2.0
16.6
5.1
1.3
25.0
4.6
1.1
31.1
4.4
1.0
100
114.3
6.3
16.8
6.2
2.7
24.9
5.6
2.2
33.3
5.2
1.9
39.4
5.0
1.7
150
168.3
2.6
10.8
7.6
2.2
31.7
5.8
1.3
42.6
5.4
1. 1
49.5
5.2
1.0
150
168.3
7.1
28.2
7.5
3.0
46.9
6.6
2.3
57.8
6.3
2.1
64.7
6.1
2.0
200
219.1
2.0
15.7
8.7
2.3
51.4
6.5
1.3
64.7
6.1
1.1
72.3
5.9
1.1
200
219.9
7.1
37.1
8.7
3.1
70.1
7.4
2.3
83.4
7.1
2.1
91.0
6.9
2.0
250
273.0
2.9
19.6
9.7
2.4
75.6
6.9
1.2
91.5
6.6
1.1
99.9
6.5
1.1
250
273.0
7.1
46.6
9.7
3.3
99.2
8.0
2.2
115.0
7.7
2.1
123.4
7.6
2.0
300
323.9
2.9
23.3
10.6
2.5
102.7
7.3
1.2
120.9
7.0
1.1
130.1
6.9
1.1
300
323.9
8.0
62.3
10.6
3.5
136.8
8.7
2.4
155.0
8.4
2.2
164.2
8.3
2.2
350
355.6
3.2
28.2
11.1
2.6
123.9
7.7
1.3
143.6
7.4
1.2
153.3
7.3
1.1
350
355.6
8.8
75.3
11.1
3.7
165.0
9.1
2.5
184.7
8.8
2.3
194.3
8.7
2.3
400
406.4
3.2
32.2
11.9
2.7
157.9
8.0
1.2
179.9
7.7
1.1
190.4
7.6
1.1
400
406.4
10.0
97.8
11.8
3.9
215.0
9.7
2.6
237.0
9.5
2.5
247.5
9.4
2.5
500
508.0
4.0
50.4
13.3
3.0
246.7
8.9
1.4
273.4
8.7
1.3
285.4
8.6
1.3
500
508.0
11.0
134.8
13.2
4.7
320.3
10.7
2.7
347.1
10.5
2.6
359.1
10.4
2.6
Explanatory notes: The table is a summary of the table from TRR 100:1993 and amendments 1997. It contains only the two respectively listed load case-related minimum and maximum values. • General: Explanatory notes in detail can be looked up in TRR 100:1983 and amendments 1997. With the mass q related to the length the following data was taken into account: Medium: ρM Pipe material: ρR
= 1000 kg/m3 = 7900 kg/m3
Heat insulation: Metal jacket:
ρD = 120 kg/m3 ρB x sB = 10 kg/m2
sB = metal jacket thickness The spans between supports L1 were determined according to the criterion “limitation of deflection”. The limiting deflection f, with regard to the avoidance of possible “formation of puddles”, was here assumed as follows: for DN ≤ 50
f = 3 mm
for DN > 50
f = 5 mm.
With the determination of the cantilever lengths L6 a disturbed pipeline with a T-piece at the rigid support was assumed with I = 0.9/(2 s/dm). (See Appendix 2 of the TRR 100:1993 and amendments 1997). The selection of two limiting cases serves for the representation of the possible range of the span between supports.
May 2001
31
ATV-DVWK-M 275E A6 – Table 9.2: Permitted spans between supports –thermoplastic pipes (Water filled pipes, safety factor 1.25, without insulation) Pipe dimensions
PVC-U, PN10
DN
de
s2)
q
mm
mm
mm
kg/m
L1
PE-80, PN 10 L1
m
m
T1 = 20 °C
q
L1
kg/m
PP Type 1, PN 10 L1
m
m
T2 = 50 °C
T1 = 20 °C
q kg/m
L1
L1
m
m
T2 = 50 °C
T1 = 20 °C
PVDF, PN 10 q
L1
kg/m
L1
m
m
T2 = 50 °C
T1 = 20 °C
T2 = 50 °C
10
16
0.951)
0.751)
0.50
0.40
0.65
0.77
0.721)
0.571)
15
20
1.101)
0.901)
0.575
0.45
0.70
0.62
0.851)
0.701)
20
25
1.20
0.95
0.65
0.55
0.80
0.72
0.95
0.75
25
32
1.35
1.10
0.75
0.65
0.95
0.87
1.10
0.90
32
40
1.45
1.25
0.90
0.75
1.10
1.00
1.20
1.00
40
50
1.60
1.40
1.05
0.85
1.25
1.15
1.40
1.15
50
63
1.80
1.55
1.20
1.00
1.45
1.35
1.40
1.20
65
75
2.00
1.70
1.35
1.10
1.55
1.40
1.50
1.30
80
90
2.20
1.85
1.50
1.25
1.65
1.50
1.60
1.40
100 100
110
2.40
2.05
1.65
1.45
1.85
1.70
1.80
1.55
125
2.55
2.20
1.75
1.55
2.00
1.80
1.90
1.65
125
140
2.70
2.30
1.90
1.65
2.10
1.90
2.00
1.75
150 150
160
2.90
2.50
2.05
1.75
2.25
2.00
2.15
1.85
180
3.10
2.65
2.15
1.85
2.35
2.10
2.30
1.95
200 200
200
3.25
2.80
2.30
2.00
2.50
2.20
2.40
2.10
225
3.45
2.95
2.45
2.15
2.65
2.35
2.55
2.20
250 250
250
3.65
3.10
2.60
2.30
2.80
2.50
2.65
2.30
280
3.75
3.30
2.75
2.40
2.95
2.65
2.85
2.45
300
315
4.10
3.50
2.90
2.55
3.15
2.85
3.00
2.60
350
355
4.30
3.70
3.10
2.75
3.35
3.00
3.20
2.75
400
400
4.60
3.95
3.30
2.90
3.55
3.20
3.40
2.95
1) PN 16 Pipes, otherwise PN 10 2) Wall thicknesses s in accordance with Table 4 Explanatory notes: The table is a summary of the table from DVS 2210-1. It contains only the two respectively temperaturerelated minimum and maximum values. • General: Explanatory notes in detail can be looked up in TRR 100:1983 and amendments 1997. With the determination of L1 the following data are taken into account: Medium:
ρM
= 1000 kg/m3
Pipe material: ρR
= material dependent
The spans between supports L1 were determined according to the criterion “limitation of deflection” taking into account the permitted bending stress. L1/500 to L1/750 is assumed as guidance value for the permitted deflection. The selection of two limiting cases serves for the representation of the possible range of the span between supports. The value for t = 25 years is the basis for the modulus of creep EZL (German symbol EC).
May 2001
32
ATV-DVWK-M 275E A7 – Table 9.3:
Permitted support spans – pipes made from thermoplastics (Water filled pipes made from UP-GF, without insulation, calculation temperature 50 °C) Pipe Type B 1)
Pipe dimensions
Pipe Type D 1)
Pipe Type E 1)
de
s1)
L1
L1
L1
L1
L1
L1
L1
L1
L1
mm
mm
m
m
m
m
m
m
m
m
m
PN 6
PN 10
PN 16
PN 10
PN 16
PN 4
PN 6
PN 10
PN 16
See PN 10
See PN 16
2.1
See PN 16
2.0
See PN 16
See PN 16
See PN 16
2.3
25 32
2.3
2.2
2.4
40
2.4
2.3
50
2.6
2.5
65
2.7
2.7
3.0
3.0
80
2.9
2.8
3.2
3.4
100
3.0
3.0
3.4
3.7
125
3.1
3.2
3.7
3.8
4.1
3.3
3.4
3.9
4.1
4.5
150 200
3.4
3.5
2.6 2.8
3.6
3.9
3.6
3.8
4.3
4.7
5.2
250
3.8
3.9
4.4
4.0
4.4
4.5
4.8
5.3
5.8
300
4.0
4.4
4.9
4.3
4.8
4.8
5.2
5.8
6.4
350
4.2
4.7
5.2
4.7
5.2
5.1
5.6
6.2
6.9
400
4.4
5.0
5.6
5.0
5.6
5.5
6.0
6.6
7.3
500
5.1
5.6
6.2
5.6
6.3
6.1
6.6
7.4
8.2
1) Pipe types and wall thicknesses in accordance with DIN 16965-2, 16965-4, 16965-5
Explanatory notes The table is a summary of the tables from the [German] Directive “PuK – GFK” (Laying directive for pipelines made from textile glass fibre reinforced reaction moulding materials - Notes on planning and design* of the German Plastic Pipe Association (KRV)). It contains only the respectively listed pressure level-related values. • General: for explanatory notes in detail see Directive “PuK – GFK” of the KRV. With the determination of L1 the following data are taken into account: Medium:
ρM
= 1000 kg/m3
Pipe material
ρR
= material dependent
The spans between supports L1 were determined in accordance with the criterion “Limitation of deflection” taking into account the permitted bending stress. As limiting value for the deflection in the midspan a value of F 0 5 mm was assumed. The value for the employment time and the employment temperature are the basis for the modulus of creep EZL (German symbol EC).
May 2001
33
ATV-DVWK-M 275E
A8 – Table 10: Design of supports and mounting material
Environmental influences on the pipeline
Non-aggressive, in part moist atmosphere e.g. External facilities Pipe cellar Machine rooms
Non-aggressive, dry air
Consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient).
Consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient).
Consoles and mounting material (e.g. clips) made completely of galvanised steel. Pins, nuts and bolts made from electrogalvanised steel (galvanic separation not required).
Galvanised / black
Pipelines hot galvanised or black should not be employed here. If nevertheless used, consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient) with galvanic separation.
Consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient). Establish galvanic separation between mounting and pipeline.
Consoles and mounting material (e.g. clips) made completely of galvanised steel. Pins, nuts and bolts made from electrogalvanised steel.
Plastic / non-ferrous metals
Consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient). Establish galvanic separation with non-ferrous metals between mounting and pipeline.
Consoles and mounting material made completely of stainless steel (as a rule Material No.: 1.4301/1.4541 sufficient). Establish galvanic separation with non-ferrous metals between mounting and pipeline.
Consoles and mounting material (e.g. clips) made completely of galvanised steel. Pins, nuts and bolts made from electrogalvanised steel (galvanic separation not required).
Material of the pipeline
Stainless steel Material No.: 1.4301/1.4541/1.4571
May 2001
ATV-DVWK-M 275E
Aggressive, moist atmosphere e.g. Screen buildings Container halls Components lying immediately above water 8aeration pipelines etc.)
34 May 2001
34
ATV-DVWK-M 275E Appendix B: Normative References DIN 1626 (withdrawn)13): Welded circular unalloyed steel tubes not subject to special requirements; Technical delivery conditions DIN 1628 (withdrawn)14): Welded circular unalloyed steel tubes subject to special requirements; Technical delivery conditions DIN 1988-7: Drinking water supply systems; Prevention of corrosion (DVGW Code of Practice) DIN 2403: Identification of pipelines according to the fluid conveyed DIN 2404: Identification colour code for heating systems pipelines 15) DIN 2440 (withdrawn) : Steel tubes; Medium weight suitable for screwing
DIN 2441 (withdrawn)15): Steel tubes; Heavy weight suitable for screwing 16)
DIN 2458 (withdrawn) : Welded steel pipes and tubes; Dimensions, conventional masses per unit length DIN 2501-1: Flanges; Connecting dimensions 17)
DIN V 2505 (withdrawn) : Flanged joint calculation DIN 2573 (withdrawn)18): Plain face flanges for brazing or welding; Nominal pressure 6 DIN 2576 (withdrawn)18): Flanges, slip on type for brazing or welding; Nominal pressure 10 DIN 2614 (withdrawn)19): Cement mortar linings for ductile iron and steel pipes and fittings; Applications, requirements, testing Author´s afternote: 13) DIN 1626 has been withdrawn and replaced by DIN EN 10208-1, DIN EN 10217-1, DIN 1615, DIN EN 10224, DIN EN 10296-1 14) DIN 1628 has been withdrawn and replaced by DIN EN 102178-1 and DIN EN 10296-1 15) DIN 2440, DIN 2441 have been withdrawn and replaced by DIN EN 10255 16) DIN 2458 has been withdrawn and replaced by DIN EN 10220, 17) DIN V 2505 has been withdrawn and replaced by EN 1591-1 18) These DIN standard specifications have been withdrawn and replaced by EN 1092-1 19) DIN 2614 has been withdrawn and replaced by DIN 2880, DIN EN 545 and EN 10298
DIN 2630 (withdrawn)18): Welding neck flanges, nominal pressure 1 and 2.5 DIN 2631 (withdrawn)18): Welding neck flanges, nominal pressure 6 DIN 2632 (withdrawn)18): Welding neck flanges, nominal pressure 10 DIN 2633 (withdrawn)18): Welding neck flanges, nominal pressure 16 DIN 2641 (withdrawn)18): Lapped flanges, welding neck flanges, plain collars, nominal pressure 6 DIN 2642 (withdrawn)18): Slip-on flanges, upturned welding flanges, plain collars, nominal pressure 10 DIN 2880: Application of cement mortar for lining iron pipes, steel pipes and fittings DIN 3567: Pipe brackets for DN 20 to 500 DIN 3570: Steel straps for tubes of DN 20 to 500 DIN 8062: Unplasticised polyvinyl chloride (PVC-U, PVCHI); Dimensions DIN 8074: Polyethylene (PE); PE 63, PE 80, PE 100, PE-HD, HDPE; Dimensions DIN 8078: Types 1, 2 and 3 polypropylene (PP): General quality requirements and testing DIN 8079: Chlorinated polyvinyl chloride (PVC-C) pipes; – Dimensions DIN 16891 (withdrawn): Pipes of acrylnitrile-butadiene styrene (ABS) or crylnitrile-styrene acrylester (ASA); Dimensions DIN 16965-2: Wound glass fibre reinforced polyester resin (UP-GF) pipes, Type B pipes; Dimensions DIN 16965-4: Wound glass fibre reinforced polyester resin (UP-GF) pipes, Type D pipes; Dimensions DIN 16965-5: Wound glass fibre reinforced polyester resin (UP-GF) pipes, Type E pipes; Dimensions DIN 16969: Pipes made of polybutene (PB) PB 125; – Dimensions
May 2001
35
ATV-DVWK-M 275E DIN 16982: Polyamide tubes of circular cross-section (PA); Dimensions
DIN 30670: Polyethylene coatings of steel pipes and fittings; Requirements and testing
DIN 1745520): General purpose welded circular stainless steel tubes; Technical delivery conditions
DIN 3067123): Thermoset plastic coatings for buried steel pipes
DIN 18299:1996 (new edition: 2006) German construction contract procedures – Part C; General general technical specifications for building works DIN 18381:1998 (new edition: 2006) German construction contract procedures – Part C; General technical contract conditions for building services; Gas, water and sewage plumbing works inside buildings 21) DIN 19565-1 (withdrawn) : Centrifugally cast and filled polyester resin glass fibre reinforced (UP-GF) pipes and fittings for buried drains and sewers; Dimensions and technical delivery conditions
DIN 19569-122): Principles for the design of structures and technical equipment for sewage treatment plants; Part 1: General principles DIN 19569-5: Kläranlagen; Baugrundsätze für Bauwerke und technische Ausrüstungen; Teil 5: Besondere Baugrundsätze für Anlagen zur anaeroben Behandlung von Klärschlamm und Abwasser [Principles for the design of structures and technical equipment for sewage treatment plants; Part 5: Special principles for plants for the anaerobic treatment of sewage sludge and wastewater] 22)
DIN 19569-6 : Kläranlagen; Baugrundsätze für Bauwerke und technische Ausrüstungen; Teil 6: Besondere Baugrundsätze für Anlagen zur getrennten aeroben Klärschlammstabilisierung [Principles for the design of structures and technical equipment for sewage treatment plants; Part 6: Special principles for plants for the separate aerobic stabilisation of sewage sludge]
Author´s afternote: 20) DIN 17455 has been withdrawn and replaced by DIN EN 10296-2 “Welded circular steel tubes for mechanical and general engeneering purposes – Technichal delivery“ 21) DIN 19565-1 has been withdrawn and replaced by DIN EN 14364 “Plastics piping for drainage and sewage with or without pressure – Glass–reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifications for pipes, fittings and joints“ 22) In the meantime DIN 19569, Part 1 and 6 have been withdrawn and replaced by EN 12255-1
DIN 30678: Polypropylene coatings for steel pipes DIN 73378: Polyamide tubing for motor vehicles EN 287-1: Qualification test of welders – Fusion welding – Part 1: Steels (includes Amendment A1) 24) EN 729-1 : Quality requirements for welding – fusion welding of metallic materials Part 1: Guidelines for selection and use
EN 729-225): Quality requirements for welding – fusion welding of metallic materials Part 2: Comprehensive quality requirements EN 729-326): Quality requirements for welding – fusion welding of metallic materials Part 3: Standard quality requirements EN 729-427): Quality requirements for welding – fusion welding of metallic materials Part 4: Elementary quality requirements EN 1057: Copper and copper alloys – seamless round copper pipes for water and gas pipelines for sanitary installations and heating systems EN 1092-1 (2001): Flanges and their joints – Circular flangs for pipes, valves, fittings and accessories – Part 1: Steel, flanges, PN designated
23) DIN 30671 has been withdrawn and replaced by DIN EN 10289 “Steel tubes and fittings for onshore and offshore pipelines – External liquid applied epoxy and epoxy-modified coatings“ and DIN EN 10290 “Steel tubes and fittings for onshore and offshore pipelines – External liquid applied polyurethane and polyurethane-modified coatings.“ 24) DIN EN 729-1 has been withdrawn and replaced by DIN EN ISO 3834-1 “Quality requirements for fusion welding of metallic materials – Part 1: Criteria for the selection of the appropriate level of quality requirements“ 25) DIN EN 729-3 has been withdrawn and replaced by DIN EN ISO 3834-2 “Quality requirements for fusion welding of metallic materials – Part 2: Comprehensive quality requirements“ 26) DIN EN 729-3 has been withdrawn and replaced by DIN EN ISO 3834-3 “Quality requirements for fusion welding of metallic materials – Part 3: Standard quality requirements“ 27) DIN EN 729-4 has been withdrawn and replaced by DIN EN ISO 3834-4 “Quality requirements for fusion welding of metallic materials – Part 4: Elementary quality requirements“
May 2001
36
ATV-DVWK-M 275E EN 1591-1: Flanges and their connections – Design rules for gasketed circular flange connections – Part 1: Calculation method EN 10027-1: Designation systems for steels; Part 1: Steel names and principal symbols EN 10240: Internal and/or external protective coatings for steel tubes; Specifications for hot dip galvanised coatings applied in automatic plants EN 12255: Wastewater treatment plants EN 12449: Copper and copper alloys – seamless round tubes for general purposes 28) EN 24063 : Welding, brazing, soft soldering and braze welding; List of procedures and indenture numbers for graphic representation (ISO 4063)
EN 2581729): Arc-welded joints in steel; Guidance on quality levels for imperfections (ISO 5817:1992) EN ISO 1127: Stainless steel tubes – Dimensions, tolerances and conventional masses per unit length (ISO 1127:1992) EN ISO 3506-1: Mechanical properties of corrosion-resistant stainless steel fasteners – Part 1: Bolts, screws and studs (ISO 3501-1:1997) EN ISO 3506-2: Mechanical properties of corrosion-resistant stainless steel fasteners – Part 2: Nuts EN ISO 3506-3: Mechanical properties of corrosion-resistant stainless steel fasteners – Part 3: Set screws and similar fasteners not under tensile stress (ISO 3501-3:1997) ISO 4065: Thermoplastic pipes – Universal wall thickness table ISO 4200: Plain and steel tubes, welded and seamless; general tables of dimensions and masses per unit lenght 28) DIN EN 24063 has been withdrawn and replaced by DIN EN ISO 4063 „Welding and allied process – Nomenclature of processes and reference numbers“ 29) DIN EN 25817 has been withdrawn and replaced by DIN EN ISO 5817 „Welding-Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) – Quality levels for imperfections“
ISO 5252: Steel tubes; tolerance systems AGI Q 135: Dämmarbeiten – Wasserlösliche Chloride in Mineralwolledämmstoffen – Bestimmung, Grenzwerte, Kennzeichnung [Insulating work – water soluble chloride in mineral wool insulation – regulation, limiting values, marking Merkblatt [Advisory Leaflet] ATV-DVWK-M 263: Empfehlungen zum Korrosionsschutz von Stahlteilen in Abwasserbehandlungsanlagen durch Beschichtung und Überzüge [Recommendations on corrosion protection of steel components in wastewater treatment facilities using coating and protective layers] DVGW G 260: Teil 1: Gasbeschaffenheit [Part 1: Gas characteristics] DVGW G 600: Technische Regeln für Gas-Installationen – DVGW – TRGI (geändert durch DVGW G 600 Ergänzungen) [Technical Rules for Gas Installations (Amended by DVGW G 600 Supplement)] DVS 2201-1: Testing of semi-finished products made of thermoplstics, basics, indications DVS 2207-1, -11, -15: Schweißen von thermoplastischen Kunstoffen – Projektierung und Ausführung – Oberirdische Rohrsysteme [Welding of thermoplastics– project planning and implementation – surface pipe systems] DVS 2210-1: Industrierohrleitungen aus thermoplastischen Kunststoffen – Projektierung und Ausführung – Oberirdische Rohrsysteme [Industrial pipelines made of thermoplastics - project planning and implementation – surface pipe systems] DVS 2212-1: Prüfen von Kunststoffschweißern – Prüfgruppe I – Warmgas-Fächelschweißen (WF), WarmgasZiehschweißen (WZ), Heizelementstumpfschweißen (HS) [Examination of plastic welding –Group I] DVS 2221-1: Examination of plastics-bonders – Group I – Pipe-/socket-joints made of PVC-U, PVC-C and ABS with solvent adhesives EC Directive “Pressure equipment”:
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ATV-DVWK-M 275E Directive 97/23/EC of the European Parliament and of the Council dated 29 May 1997 on the alignment of the legal requirements of the Member Countries on pressure equipment (published in the Official Gazette of the European Community No. 97/L 181 dated 09 July 1997) KRV-Arbeitsblatt A 9.8.4: Verlegeanleitung, GFKIndustrierohre (Rohrleitungen aus GFK mit und ohne Auskleidung im Industriebereich) [KRV Standard A .8.4: Laying instructions, GRP industrial pipes (pipelines made of GRP with and without cladding in the industrial field)] TRR 100:1993 Bauvorschriften; Rohrleitungen aus metallischen Werkstoffen [Building regulations; pipelines made from metallic materials] TRR 100 Änderungen: 1997 Bauvorschriften; Rohrleitungen aus metallischen Werkstoffen [Amendments: 1997 Building regulations; pipelines made from metallic materials] VdS 2234: Brandwände und Komplextrennwände; Merkblatt für die Anordnung und Ausführung [Technical rule: Firewalls and complex divider walls; Advisory Leaflet for arrangement and implementation] VdTÜV MB K 001: Prüfung von Kunststoffklebern; Prüfgruppe I; Rohr/Muffen-Verbindungen aus PVC-U, PVC-C und ABS mit lösenden Klebstoffen [Testing of plastic adhesives; Group I; pipe/sleeve-joints made of PVC-U, PVC-C and ABS with soluble adhesives]
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