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Eurotubi Pressfitting System - Technical Guide

1. C Stainless steel Cupronickel Carbon steel Tab 10 Minimum distances between fixing points Tab 11 Approximate minimum spaces for pressing Tab 12 Minimum distances between fittings Tab 13 Stabilization times and duration of the load and seal tests in gas system System volume Stabilization time Duration of the test Tab 14 Requirements for disinfecting with solutions containing chlorine in stainless steel systems Factors Option 1 Option 2 Maximum concentration of liquid chlorine in water Maximum contact time Chlorine residue in drinking water after washing Tab 15 Insulation of the heat distribution networks in thermal systems Minimum thickness of insulating material based on the diameter of the pipe and the thermal conductivity of the insulating material Useful thermal conductivity of the insulating material at 40 C W m C External diameter of the pipe mm Tab 16 Stainless steel pipes for drinkable water roughness k 0 0015 mm Pressure drops R as a function of peak flow rate Vp and speed v at 10 C temperature Tab 17 Stainless steel pipes for gas roughness k 0 0015 mm Pressure drops R as a function of peak flow rate Vp and speed v at 10 C temperature Tab 18 Carbon steel pipes for heating roughness k 0 0015 mm Pressure drops R as a function of mass flow m and speed v at 80 C water temperature Tab 19 Cupronickel pipes for sea or soft water roughness k 0 0015 mm
2. Pressure drops R as a function of peak flow rate Vp and speed v at 10 C temperature Tab 20 Coefficients of single localized resistances Name Pressure drops Elbow or bend Angle adapter Preformed pipe bridge 45 elbow Reducer Coupling male adapter Combination pipe Tee Main flow from line into branch Tee Main flow from branch into line Tee Mainly through some line into branch Tee Mainly through some branch into line Tee Counterflow from line into branch Tee Counterflow from branch into line Tab 21 Stainless steel pipes for drinkable water Pressure drops Z as a function of speed v and addition of resistance values 2 at 10 C temperature Tab 22 Stainless steel pipes for gas Pressure drops Z as a function of speed v and addition of resistance values at 10 C temperature Tab 23 Carbon steel pipes for heating Pressure drops Z as a function of speed v and addition of resistance values at 80 C water temperature Tab 24 Cupronickel pipes for sea or soft water Pressure drops Z as a function of speed v and addition of resistance values at 10 C temperature
3. The same consideration also applies to the storage of the fittings The withdrawal of pipes must be done individually and not through dragging to avoid any scratching You must avoid launching the joints and heavy overlays which may cause damage to threads and deformations decreasing their seal capacity 9 2 Pipe cutting fig 21 Pipes must be measured and cut at right angles to their axis using a pipe cutter or fine tooth saw taking into account the depth of insertion into the fitting The blades must be suitable to the material of the pipes Avoid equipment that may cause mechanical deformations in general deformation from overheating such as the blowtorches or grinding wheels superficial scratches due to friction 9 3 Pipe end deburring fig 22 After cutting the pipes must be carefully deburred both inside and outside using a manual or electric deburring tool so as to avoid damaging the o ring seal when the pipe is inserted into the fitting causing possible leaks Any cutting residue swarf and deburring dust must be removed both internally and externally Note 90 of the damage regarding the leaks is due to not respecting these simple rules 9 4 Checking the presence and positioning of o rings fig 23 Before assembling the fittings the presence and correct positioning of the o rings in their seats must be checked and if necessary lubricated with water or talc to ease the insertion of the pipe O
4. 11 Vertical channels must be coated in elastic insulating materials The same type of coating must be applied to pipes passing through walls and ceilings 8 3 Expansion compensators Minimum pipe expansion can sometimes be compensated for by the degree of elasticity of the pipe system itself If this is not possible expansion compensators must be used There are several types axial expansion compensators U shaped expansion compensators Z shaped expansion compensators Fig 12 shows the configuration of flanged and threaded axial compensators connected to Eurotubi pressfittings Fig 13 shows the configuration of U shaped compensators while the diagram in fig 14 allows the compensation length to be calculated for the estimated expansion in stainless steel pipes Similarly fig 15 shows the configuration of a Z shaped compensator while the diagram in fig 17 allows the compensation length to be calculated for the estimated expansion in stainless steel pipes The latter diagram can also be used to calculate compensation in T shaped branches fig 16 8 4 Pipe fixing The pipe support collars serve two purposes keep the system in its correct position orienting expansion caused by temperature fluctuations There are two types of collars or fixing points fixed which lock pipes rigidly sliding which allow axial movement Positioning fixing points A pipe with no changes of direction or expansion comp
5. What is the difference between a dry and a wet sprinkler fire fighting system Wet sprinkler systems are more common and reliable The saying wet indicates that the pipes are filled with water under pressure When a sprinkler is exposed to a temperature higher than the intervention temperature for a long enough time the thermosensitive element breaks and lets the water flow immediately from the nozzles onto the area in flames The saying dry indicates that the pipes are filled with air under pressure rather than with water Dry sprinkler systems are installed in spaces where the temperature may be so low that it freezes the water of the wet system making it unusable Dry systems are often used in buildings without heating A special control valve called dry valve is positioned in a heated area to prevent the entry of water until a fire causes the activation of the sprinklers When the nozzles open air comes out and the pressure in the pipes decreases and causes the dry valve to open It is only at that time that water enters the pipes and is dispensed through the open sprinklers 10 When are carbon pipes that are zinc coated both internally and externally used And when are those zinc coated only externally used Carbon pipes that are zinc coated both internally and externally supplied by Eurotubi are certified VdS and used in sprinkler fire fighting systems as they are explicitly requested by Guideline VdS CEA 40
6. 2008 For safety reasons the test must be carried out by two testers and the maximum pressure applicable is 3 bar System with operating pressure up to 100 mbar The test includes two phases the load test and the subsequent seal test Load test Test pressure 7 bar Reading sensitivity of the test gauge 0 7 bar Duration of the test see Tab 13 The test starts after a time necessary for the pressure stabilization in accordance to the Tab 13 The outcome is successful if during the test time the pressure remained constant Ap 0 Main test Test pressure 750 mbar Reading sensitivity of the test gauge 0 7 mbar 1 mm H20 Duration of the test see Tab 13 The test starts after a time necessary for the pressure stabilization in accordance to the Tab 13 The outcome is successful if during the test time the pressure remained constant Ap 0 Note The Work Sheet DVGW G 600 TRGI 2008 provides the test finishes with an utilization capacity test through the connection of the system to the network gas in order to verify its suitability Systems with operating pressure gt 100 mbar and lt 1 bar The test includes a combinated load and seal test Combinated load and seal test Test pressure 3 bar Reading sensitivity of the test gauge 0 7 bar Duration of the test 720 minutes The test must start after about 3 hours from inserting the aeriform element in order to bring it to room temperature The outcome is
7. 76 1 88 9 108 mm it is advisable to secure the pipes with an assembly clamp In this way pipes and joints can not move and a perfect alignment is ensured 9 7 Pressing tool assembly fig 27 The pressing tools must be equipped with M profile terminals corresponding to the external diameter of the pipes and their joints The following types are required Clamp jaws for diameters from 12 to 35 mm Chain terminals with at least 3 sectors for the diameters from 42 to 108 mm Generally for these terminals it is necessary to use suitable adapters On these diameters Eurotubi does not accept jaw pressing even if commercially available Refer to the user manual for the particular tool for set up and operating instructions Note Pay attention to correctly grip the pressing tool to avoid any risk of injury 9 8 Pressing fig 28 For a good reliable pressing the internal channel of the jaws must form a perfect fit with the pre formed o ring seat around the entire circumference The joint is pressed by closing the jaws or the chain terminals The pressing cycle is considered effective if the terminals of the jaws or the segments of the chains touch each other Pressing must only be carried out once otherwise the seal could be damaged A small amount of swelling occurring in the area outside the o ring seat can be considered normal Pressing tool manufacturers do not advise performing empty pressing cycles or without pipe and j
8. External diameter by thickness Volume of water contained dm3 m Empty weight kg m Tensile strength Rm 2 270 N mm2 Yield resistance ReH 2 190 N mm2 Longitudinal lengthening A 2 8 Bending radius r 2 3 5 d Zinc thickness 2 7 5 um Tab 6 Carbon steel pipes for sprinkler fire fighting systems Technical characteristics Material External diameter by thickness Volume of water contained dm3 m Empty weight kg m Carbon steel E220 n 1 0215 according to UNI EN 10305 3 Tensile strength Rm 2 310 N mm2 Yield resistance ReH 2 220 N mm2 Longitudinal lengthening A 2 23 Bending radius r 2 3 5 d Zinc thickness 15 27 um Tab 7 Carbon steel Eurotubi Pressfitting System Different applications and characteristics Application Compressed air oil free and inert gas Compressed air with oil Solar without steam Material OR colour Max pressure Min max temperature Reccomendation Wet the o ring with water before inserting the tube into the fitting Tab 8 Cupronickel pipes for pipeline systems Technical characteristics Material External diameter by thickness Volume of water contained dm3 m Empty weight kg m Cupronickel copper nickel alloy n 2 1972 according to DIN 86019 Tensile strength Rm 300 400 N mm2 Yield resistance ReH 2 100 N mm2 Longitudinal lengthening A 2 30 Bending radius r 2 3 5 d Tab 9 Thermal expansion coefficient Material Coefficient of thermal expansion mm m
9. a distance This solution combined with the presence of the leak path o ring represents double safety for the installer fig 8 Note The press check sleeve was purposefully designed to remain torn on the fitting in a way to not deposit inside the pressing jaws In case film residues remain in the pressing jaws we recommend removing them prior to proceeding to a new joint operation 5 EUROTUBI STAINLESS STEEL PRESSFITTING SYSTEM 5 1 Pressfittings The pressfittings are made of austenitic stainless Cr Ni Mo steel n 1 4404 AISI 316L The diameter ranges from 15 to 108 mm Under development are the diameters 12 and 64 mm The types available are listed in the catalogue and the dimension they are identified with corresponds to the external diameter of the pipe on which they are pressed The special process used to make the pressfittings can be broken down into the following main stages cutting the pipe into sections and mechanical working bending or any other working cold forming of the o ring seat any welding of other parts of the fitting heat treatment in a controlled atmosphere at 1050 C to restore the material s original characteristics and increase the resistance to corrosion All the processes are controlled through the operating methods set by standard UNI EN ISO 9001 and are submitted to continuous audits by the authorities that have approved them for the various applications in compliance wit
10. in a permanent manner data providing details on the manufacturer and the production batch Note Please note that in the carbon pipe sector there are many many cheap and dimensionally correct productions commercially available but of unsuitable quality concerning finish tolerance and functional reliability 6 3 Application for heating Carbon steel Eurotubi Pressfitting System is used especially for closed circuit hot water heating systems The o ring seals made of black EPDM are available in the standard and leak path versions Pipes used in main systems are made of carbon steel E195 n 1 0034 E190 n 1 0031 or other degrees of equivalent functional validity and are protected externally through a galvanised or hot zinc plating process The technical characteristics are reported in Tab 5 Conditions of use Maximum operating pressure 16 bar Maximum temperature 120 C It is absolutely necessary that the circuits are closed or without air For anti freeze use it is necessary to request the approval of Eurotubi Technical Department 6 4 Sprinkler Fire fighting application The carbon steel Eurotubi Pressfitting System is approved for closed circuit wet sprinkler fire fighting systems for diameters from 22 to 108 mm It complies to standard UNI EN 12845 for the design of automatic sprinkler systems The o ring seals made of black EPDM are available in the standard and leak path versions The pipes
11. joint It is a visual system called press check sleeve a thin and eye catching coloured film applied externally to the joints conformed to the o ring housing This film does not compromise or interfere in any way with the assembly When the fitting is pressed the film tears and detaches from the metal assuming a fractured appearance and providing easy manual removal without using any tools fig 4 5 When checking the system the installer will quickly notice even from meters away if any coloured film has remained intact on the joints fig 6 If removing the film after pressing was forgotten during the visual check the installer will in any case notice a very different look from the original one Therefore it will not be necessary to get physically close to all the joints to examine each press joint and identify any slight drip If the pressing can not be seen but only touched in hidden or dark areas the condition of the film can be easily checked also just by touching it The colour of the film is associated to the different type of joints blue for joints of the stainless steel water range yellow for joints of the stainless steel gas range red for joints of the carbon steel range fig 7 The sleeve indicator is applicable to all the joints for diameters from 12 to 54 mm For the big sizes it is considered rather superfluous given that the dimension of the joints allows a quick visual check of the pressings also from
12. non ferrous joint between the two metals or it can be completely eliminated by using non ferrous spacers at least 50 mm in length It is absolutely forbidden to create systems with joints in carbon steel and stainless steel pipes or vice versa Resistance to external corrosion Corrosion can only occur on a stainless steel system in very particular situations such as prolonged contact with high concentrations of chloride or its compounds for example galvanic situations or covered swimming pools In these cases we recommend covering the pipes with a closed cell coating taking care to apply waterproof glue to the cutting and junction points Alternatively protective anti corrosion tape or paints can be used Felt sheathing or sheathing of similar materials must not be used as it may hold moisture for a long time and lead to corrosion In addition it is necessary to avoid laying pipes in direct contact with the ground cement and sea water 10 2 Stainless steel installations for gas fire fighting and other applications Stainless steel does not require additional anticorrosion protection in any of the other applications foreseen for its use 10 3 Carbon steel installations for heating Resistance to internal corrosion In water heating systems the closed circuit must be guaranteed so that the oxygen is not able to be introduced from external sources In these conditions carbon steel pipes are not subject to internal corrosion Any
13. of U shaped compensator in stainless steel Fig 15 Z shaped expansion compensators fixed point Fig 16 T shaped branch sliding point Fig 17 Length LB of Z shaped compensator in stainless steel Oscillating arm LB Expansion AL Fig 18 Pipe fixing straight pipe only one fixed point suitable Fig 19 Pipe fixing sliding point near to fitting wrong Fig 20 Pipe fixing fixed point on fitting wrong Fig 21 Pipe cutting Fig 22 Pipe end deburring Fig 23 Checking the presence and positioning of o rings Fig 24 Inserting pipes into fittings and marking the correct position Fig 25 insert mark template for diameters from 12 to 54 mm Fig 26 Use of assembly clamps for Big Sizes diameters Fig 27 Pressing tool assembly Fig 28 Pressing TABLES Tab 1 Pressing tools compatible with Eurotubi Pressfitting System Brand Usable range Diameters available All the machines adapters jaws and chains declared by the manufacturer to be suitable for profile M pressing For the mini model the use for stainless steel 35 is still being validated WARNING 1 The systems with diameters 42 gt 108 are compatible exclusively with chain terminals with a minimum of three sectors Jaw terminals for diameters 42 and 54 are not accepted as valid under penalty of the guarantee being voided 2 Dated models are considered valid if they guarantee the same performance as those currently commercially available 3 All models
14. small amount of oxygen that penetrates when filling during the heating of the water is freed and must be evacuated from the system through the vent valves Furthermore special additives must be used which stop oxygen from causing corrosion However such systems must always be kept filled even when not operating or should be emptied and kept dry to avoid both air and water being in contact with the metal a situation that can lead to corrosion On this point after the system has been emptied it is worth passing forced dry air through the interior to ensure complete drying Resistance to bimetallic corrosion Carbon steel components can also be used in mixed installations with non ferrous metals such as copper aluminum etc Importantly direct contact between carbon steel and stainless steel must be avoided as this situation may give rise to bimetallic corrosion This risk can be reduced by inserting a non ferrous joint between the two metals or it can be completely eliminated by using non ferrous spacers at least 50 mm in length It is absolutely forbidden to create systems with joints in stainless steel and carbon steel pipes or vice versa Resistance to external corrosion Carbon steel components present an external galvanised or hot zinc plated coating which however does not guarantee on its own a long lasting and effective protection from corrosion Protection from corrosive agents must be obtained through insulation painting o
15. successful if during the test time the pressure remained constant Ap 0 Note In Italy the test must be carried out in compliance with standard UNI TS 11147 11 2 Washing the pipes Before commissioning a drinking water system it is necessary to wash the pipes through the intermittent pumping of water and air under pressure in order to remove possible contaminants ensure the quality of the water prevent corrosion A quantity of water equal to at least twice the volume of the system is normally used Standard DIN 1988 part 2 and Practical Instructions ZVSK BHKS provide extensive indications on this subject However for stainless steel systems it is sufficient to simply wash with filtered drinking water since the corrosive phenomena favoured by the presence of extraneous materials are to be excluded 11 3 Disinfection A disinfection operation is carried out only for pressing reasons of hygiene for example in hospitals or following severe contamination from micro bacteria Stainless steel system may be disinfected with solutions containing chloride and respective the requirements of Tab 14 11 4 Noise insulation Pipes are a possible means of transmitting noise from other sources pumps valves etc and for this reason suitable actions must be taken to reduce noise transmission These essentially comprise the acoustic decoupling between the pipes and the structure of the building which is also useful to reduce v
16. systems and standard UNI 10779 and similar national ones concerning the feeding of hydrants and reels The o ring seals made of black EPDM are resistant to aging heat and chemical additives Both the profiles of the o rings in the standard and leak path versions are approved and available Conditions of use for reels and hydrants Maximum pressure 76 bar Conditions of use for sprinklers Maximum pressure for diameters up to 76 1 mm 16 bar Maximum pressure for diameters 88 9 and 108 mm 12 5 bar Certification For the sprinkler fire fighting application Eurotubi Pressfitting System was certified according to the German Guideline VdS CEA 4001 5 6 Other applications Other stainless steel Eurotubi Pressfitting applications are summarised in tab 4 6 EUROTUBI CARBON STEEL PRESSFITTING SYSTEM 6 1 Pressfittings The pressfittings are made of carbon steel E195 n 1 0034 or alternatively E235 n 1 0038 The diameters range from 12 to 108 mm The diameter 64 mm is being developed The types available are listed in the catalogue and the dimension they are identified with corresponds to the external diameter of the pipe on which they are pressed The special process used to make the pressfittings can be broken down into the following main stages cutting the pipe into sections and mechanical working bending or any other working cold forming of the o ring seat any welding of other parts
17. the test with compressed air or inert gas In this case it is mandatory to wet the seals before the assembly 11 1 1 Drinking water system The tests below comply to the requirements set out by the German body ZWSK Test with water The test with water must be carried out immediately before commissioning the system Otherwise the system must remain completely full until commissioning in any case guaranteeing the change of water at regular intervals not exceeding seven days and the total change of water just before commissioning the system see point 11 2 If this measure is impossible to implement the test must be carried out with compressed air or inert gas Note Emptying the system after testing is very dangerous The evaporation of residual water may lead to an increase in the local concentration of chloride and pose a high risk of corrosion see point 10 1 The test is normally carried out with filtered drinking water that does not contain particles gt 150 um The test starts after the temperature of the fluid has adjusted to the room temperature If the difference between the room temperature and that of the fluid is higher than 10 C you must wait at least 30 minutes The pressure test is arranged into two phases the preliminary test which is aimed at identifying possible connections without correct seal integrity for example due to failed pressing or a cut seal and then the main test Preliminary test Test pressure m
18. tool Tab 11 shows the minimum space to be allowed Distance between fittings Two pressfittings too close together can compromise the perfect seal of the joints Tab 12 shows the minimum distances to observe 8 5 Sprinkler fire fighting application The stainless and carbon pressfitting systems may be used for areas or buildings used for activities that according to standard VdS CEA 4001 are classified as at low risk e g schools offices hotels and at normal risk up to level 3 for example showrooms cinemas theatres industrial facilities of a specified type Furthermore they must only be used downstream of the alarm valve station It is necessary to ensure that no load falls on the pipes in normal conditions or in case of fire In each particular system mixing components of different materials is not permitted For the main or secondary distribution vertical lines carbon steel systems may not be used 9 INSTALLATION INSTRUCTIONS 9 1 Transport storage and withdrawal During the transport and storage of the pipes and joints it is necessary to take suitable precautions to avoid the danger of damage and contamination of dirt and humidity inside them During transport it is necessary to pay the due attention to temperature variations that may cause condensation to form and are particularly harmful to carbon steel Contact among stainless steel pipes and carbon steel pipes is to be avoided please see sect 10
19. 01 The use of these pipes for other applications requires careful assessment also based on legal provisions which vary from country to country Carbon connecting pipes that are zinc coated only externally are used for all the other applications Eurotubi provides pipes that are both galvanically and hot zinc coated externally The choice depends on the characteristics of resistance to corrosion required by the system higher for pipes that are hot zinc coated 11 Is the use of glycols admitted in Eurotubi Pressfitting Systems Eurotubi Pressfitting systems may have anti freeze products inside them ethylene glycol provided these are of good quality Due to the presence on the market of a large quantity of poor quality anti freeze products you are responsible to check the characteristics of the products before using them in order to avoid possible serious damage These anti freeze products may reach a maximum concentration of 50 It is not possible to use them with carbon steel pipes that are zinc coated internally as in sprinkler fire fighting systems because they cause the zinc to dissolve with the consequent possible clogging of the installation On the other hand carbon steel pipes that are zinc coated only externally may use glycols inside of them The fact that carbon steel joints are zinc coated internally is not a problem as their percentage weight in a system is negligible For special applications it is indispensable to conta
20. Eurotubi Pressfitting System Technical Guide STATE OF THE ART THERMAL SANITARY SYSTEMS International Accreditations The quality of used materials and the adoption of a rigorous quality control allowed Eurotubi Pressfitting system to obtain the conformity with the most severe European certifications Approval obtained directly by our distributor INDEX 1 INTRODUCTION 1 1 Materials 1 2 Benefits 2 SYSTEM DESCRIPTION 2 1 General information 2 2 Joining process 2 3 Pressing tools 3 O RING 3 1 Materials 3 2 Profiles 3 3 Flat seals 4 NO PRESSING VISUAL INDICATOR SLEEVE 5 EUROTUBI STAINLESS STEEL PRESSFITTING SYSTEM 5 1 Pressfittings 5 2 Pipe work 5 3 Application for drinking water 5 4 Application for gas 5 5 Fire fighting and sprinkler application 5 6 Altre applicazioni 6 EUROTUBI CARBON STEEL PRESSFITTING SYSTEM 6 1 Pressfittings 6 2 Pipe work 6 3 Application for heating 6 4 Sprinkler Fire fighting application 6 5 Other applications 7 EUROTUBI CUPRONICKEL PRESSFITTING SYSTEM FOR NAVAL APPLICATIONS 7 1 Pressfittings 7 2 Pipe work 7 3 Application in the naval sector 8 8 1 8 2 8 3 8 4 8 5 9 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 10 10 1 10 2 10 3 10 4 11 11 1 11 1 11 1 11 1 11 2 11 3 11 4 11 5 11 6 12 12 1 12 2 12 3 13 14 15 16 17 GENERAL USE TECHNIQUES Pipe laying and expansion Expansion room Expansion compensators Pipe fixing Sprinkl
21. Pressure bar must be 150 mbar Duration of the test minutes must be 2 120 minutes The ducts are watertight Ap 0 Main test Test pressure bar must be lt 3 bar for DN lt 50 and lt 1 bar for DN gt 50 Duration of the test minutes must be 2 30 minutes The ducts are watertight Ap 0 Place Date Signature of the customer or representative Signature of the first performer or representative Signature of the second performer or representative ANNEX 3 TEST REPORT WITH WATER FOR HEATING SYSTEMS SYSTEM CUSTOMER PERFORMER Following the test it is hereby declared that The entire system was visually checked to make sure that all the connections have been made in accordance with the best working standards The pipework has been completely aired out The operating pressure equals 10 bar e Water temperature C e Room temperature C e Temperature difference AT C must be lt 10 C Pressure test at room temperature Operating pressure bar Test Pressure bar Operating pressure x 1 3 Duration of the test minutes must be 2 30 minutes The ducts are watertight Ap 0 Pressure test in temperature to be carried out immediately afterwards Max operating temperature C must be 11 bar Test Pressure bar Operating pressure x 1 3 Duration of the test minutes must be 2 30 minutes The ducts are watertight Ap zal Place Date Signature of the customer or re
22. STOMER PERFORMER Following the test it is hereby declared that The entire system was visually checked to make sure that all the connections have been made in accordance with the best working standards The filling water is filtered and does not contain particles 150 um The pipework has been completely aired out The operating pressure equals 10 bar e Water temperature C e Room temperature C e Temperature difference AT C must be lt 10 C Preliminary test Test Pressure bar must be lt 6 bar Duration of the test minutes must be 2 15 minutes The ducts are watertight Ap 0 Main test Test pressure bar must be 11 bar Duration of the test minutes must be 2 30 minutes The ducts are watertight Ap 0 Place Date Signature of the customer or representative Signature of the performer or representative ANNEX 2 TEST REPORT WITH AIR OR INERT GAS FOR DRINKING WATER AND HEATING SYSTEMS SYSTEM CUSTOMER FIRST PERFORMER SECOND PERFORMER Following the test it is hereby declared that The entire system was visually checked to make sure that all the connections have been made in accordance with the best working standards The system was tested internally in n sections each test section must be lt 100 litres 0 1 m3 e Test fluid used air nitrogen Fluid temperature C e Room temperature C e Temperature difference AT C must be lt 10 C Preliminary test Test
23. Tab 8 7 3 Application in the naval sector The cupronickel Eurotubi Pressfitting System is the ideal solution to create systems to be used in sea water In addition the quality and reliability of its components make it suitable and potentially certifiable also for the distribution of other fluids such as drinking water for sanitary systems subject to approval and compressed air The o ring seals made of black EPDM are resistant to aging heat and all types of water including salt and treated water Conditions of use Maximum pressure 10 bar Minimum temperature 20 Maximum temperature 120 TC Certification For naval use the Eurotubi pressfittings have been certified as conforming to Standard R I N A Type Approval of Mechanical Joints for Pipes and IACS Unified Requirement n P2 8 GENERAL USE TECHNIQUES 8 1 Pipe laying and expansion The metal pipes change their length depending on the temperature and the material they are made of Therefore when installing pipework systems three rules must be followed to ensure good results leave sufficient room for expansion use expansion compensators position both fixed and sliding collars correctly The following formula is used to calculate longitudinal expansion AL a L AT 1 000 where AL is the expansion in mm a is the coefficient of expansion of the material expressed in mm m C L is the length of the pipe in m AT is the permitted tempe
24. alysis of the requirements needed for the type of installation Compressed air systems usually have oil therefore it is advisable depending on the purity requirements to have a dryer or oil separator available If the amount of residual oil is high 2 5 mg m3 we advise replacing the black EPDM o ring with the red FPM o ring better known as Viton which has a good resistance to oil and mineral grease oil and synthetic grease and to gas oil For these systems both the stainless steel and the carbon steel Eurotubi Pressfitting System can be used In any case it is worthwhile to remember that the operating temperature and pressure are two fundamental elements to know when choosing the type of material The maximum operating pressure is 16 bar In carbon steel systems the presence of moisture may generate corrosion Installing a dryer is essential Finally it is necessary to wet the o rings with water before assembling the joints 20 How long can a Eurotubi pressfitting system last A system made with Eurotubi pressfittings with approved connecting pipes with the correct pressing tools and by closely following the instructions in the Technical Guide is bound to last at least 20 years However this indication does not constitute a legal guarantee Our company and our products strictly follow the legal provisions concerning the guarantees provided by the seller ANNEX 1 TEST REPORT WITH WATER FOR DRINKING WATER SYSTEMS SYSTEM CU
25. aximum 6 bar Reading sensitivity of the test gauge 0 7 bar Duration of the test 75 minutes The outcome is successful if during the test time no leak was detected Main test Test pressure 77 bar Reading sensitivity of the test gauge 0 7 bar Duration of the test 30 minutes The outcome is successful if during the test time the pressure remained constant Ap 0 Test with air If the drinking water system is not promptly commissioned the test must be carried out with air or inert gas In this case it is mandatory to wet the seals before the assembly The air used must be oil free since the presence of oil may have a negative effect on hygiene and increase the risk of corrosion for materials such as copper or carbon steel and of damage for the EPDM seal The use of inert gas for example nitrogen etc is required in buildings for which high hygienic sanitary requirements are set such as hospitals out patient departments etc For safety reasons the tests must be carried out by two testers and the maximum pressure applicable is 3 bar as is the case for gas systems The test includes two phases the seal test and the subsequent load test Seal test Test pressure 750 mbar Reading sensitivity of the test gauge 7 mbar Test section 700 litres max 0 1 m3 Duration of the test 720 minutes For each 700 litres of additional volume the test time must be lengthened by 20 minutes The test starts after the temperature of t
26. ct the Eurotubi Technical Department 12 Is it possible to use different materials in the same system In so called mixed installations stainless steel and carbon steel can be used in contact with other non ferrous metals without any problem Direct contact between them on the other hand must be avoided to avoid bimetallic corrosion This topic is described in detail in points 10 1 and 10 3 13 Are stainless steel systems for drinking water subject to corrosion over time Stainless steel has an excellent resistance to corrosion thanks to the high performance of the material Local perforating corrosion may only occur in extremely aggressive environments that are absolutely outside the norm This topic is described in detail in point 10 1 14 Are stainless steel systems for other applications subject to corrosion over time Compared with systems for drinking water there are no additional requirements to be respected However in extreme cases such as the presence of large concentrations of chlorine salt marine environments or high temperatures normal stainless steel decay phenomena may occur This consideration is valid in general terms and is not linked to the type of pressfitting proposed 15 Can a superficial incision on stainless steel pipes or fittings cause corrosion Yes the extent of this phenomenon depends on the depth and width of the incision as well as on the material that caused it The worst case lies in a depos
27. e traditional o ring which guarantees that a pipe is hermetically sealed It is available in all the elastomer versions and used for all applications Leak path LBP fig 3 A patented innovatively designed o ring which is only available in the EPDM version and for diameters from 12 to 54 mm It has a polygonal shape including a succession of tubular sections with rectilinear axis and constant section arranged as a ring to generate a multitude of flows between the non deformed o ring and its seat If the fitting is inadvertently not pressed the profile of the o ring identifies the anomalous condition both during the seal test and visually through leaking of water in the form of dripping in compliance with the Work Sheet DVGW W 534 This characteristic is commonly known as Leak Before Press L B P Otherwise after the fitting has been pressed the o ring easily fills all the flows ensuring the hermetic seal as with the traditional type Various similar solutions are commercially available which focus on obtaining the same result described above In comparison to these the solution conceived by Eurotubi has the following benefits its shape is closer to the traditional o ring as it is the only seal with a constant circular section along its entire length you do not run the risk of leaks occurring after pressing as happens in other systems when due to the o ring s profile the rubber area with large deformations coincid
28. eference standard DVGW G 260 The o ring seals are made of yellow HNBR and as such are compatible with any of the gas varieties used and are resistant to aging Conditions of use Maximum pressure 5 bar Minimum temperature 20 CT Maximum temperature 70 Certification The Eurotubi pressfittings have been certified as conforming to the German Standard DVGW VP 614 for gas applications To conform to this standard each of the welded fitting complete with o ring seals undergoes a test The whole gas range has a yellow anti tampering label with initials DVGW GAS PN5 GT 5 to indicate their application for gas Note In this application it is absolutely forbidden to use o rings in black EPDM and ferritic stainless steel pipes unless DVGW 541 approved Note Every country is governed by specific regulations to be complied with For gas systems in ltaly it is necessary to comply to the following laws on the subject DM 12 04 1996 for systems with a total thermal flow greater than 35 KW UNI 7129 for gas systems for domestic use with single devices with a power lower than 35 KW UNI 11147 to ascertain the product characteristics of the pressfittings in gas applications 5 5 Fire fighting and sprinkler application Stainless steel Eurotubi Pressfitting System is also used for wet and dry fixed fire fighting systems for diameters from 22 to 108 mm It complies to standard UNI EN 12845 regarding the automatic sprinkler
29. ensators must have only one fixed anchoring point fig 18 In case of long pipes we recommend placing this collar towards the centre of the section so as to allow expansion in both directions This solution is also particularly suitable for vertical pipes that pass through many floors precisely because it allows for expansion in two directions also decreasing stress on the branches Without excluding the necessary expansion vents the fixed collars are also placed near components and terminals which are not subject to movements In addition the sliding collars must be positioned so as not to become dangerous fixed points fig 19 and fixed points must not be created on fittings fig 20 Note An incorrect application of the fixing points stopping the expansion vent may cause extremely dangerous tensions and damage the system Minimum distances Installing pipework correctly involves observing certain minimum distances which depend on several different factors Distance between fixing points Fixing points must be placed at an adequate distance from each other If the brackets are too close together they can prevent the absorption of expansion If they are too far apart they can increase vibration and amplify noise Tab 10 shows the distances recommended by Eurotubi Manoeuvring space for the pressing tool Adequate space for manoeuvre and to avoid obstacles must be allowed and this will vary according to the size of the pressing
30. ents stated in this Guide In Europe many regulations adopted by a country Germany for example are recognised as valid and sufficient also in other countries In any case it is the task of the designer and or the installer to ensure that the indications contained in this Guide are compatible with local legislation 5 Can connecting pipes be bent It is a good rule not to bend pipes choosing the right fittings for the variable route of the path However if necessary bends can be made provided that the rule that sets the minimum bending radius at 3 5 times the diameter of the pipe is respected for stainless steel this condition only applies if the material is annealed 6 How long do o rings last There are currently no direct duration tests for seals but only indirect tests The seals mounted in the Eurotubi joints have successfully passed the most stringent laboratory tests provided for by applicable regulations intentionally exaggerated to obtain maximum safety 7 Is it possible to use seals from other suppliers in Eurotubi Pressfitting joints Absolutely not this action voids any guarantee certification and accreditation for the entire system 8 What is the difference between an open circuit system and a closed circuit system The definition closed circuit refers to a system characterised by the total absence of air All the systems that do not belong to this type must be considered as open circuits 9
31. er fire fighting application INSTALLATION INSTRUCTIONS Transport storage and withdrawal Pipe cutting Pipe end deburring Checking the presence and positioning of o rings Inserting pipes in fittings and marking the correct position Use of assembly clamps for Big Size diameters Pressing tool assembly Pressing CORROSION RESISTANCE Stainless steel installations for drinking water Stainless steel installations for gas fire fighting and other applications Carbon steel installations for heating Carbon steel installations for sprinkler fire fighting and other applications SYSTEM COMMISSIONING Testing 1 Drinking water system 2 Heating system 3 Gas system Washing the pipes Disinfection Noise insulation Thermal insulation Protection against freezing PIPE CALCULATION Pressure drops Pressure drops of a straight pipe Pressure drops of single localized resistances COUPLING FITTINGS TABLE CHEMICAL COMPATIBILITY OF EUROTUBI PRESSFITTING SYSTEMS POSSIBLE CAUSES OF LEAKS GUARANTEE FAQ FREQUENTLY ASKED QUESTIONS ANNEXES 1 INTRODUCTION The Eurotubi Pressfitting System is an extremely fast and simple pressfitting assembly system producing reliable joints with high mechanical resistance for civil industrial naval and fire fighting pipework system installations The diameters currently available range from 12 to 108 mm depending on the material used The three greater diameters of 76 1 88 9 and 108 mm are co
32. es with the metallic area slightly deformed by the pressing thus not managing to hermetically seal all the potential flowpaths especially during thermal variations Note For diameters greater than 54 mm or the three big sizes the leak path function is guaranteed by the use of the standard o ring which was also approved in compliance with Work Sheet DVGW 534 3 3 Flat seals They are assembled in the orifices with swivel figures used when it is necessary to temporary split a section of the system Since repeating this operation may cause a deterioration of the seal the seal needs to be replaced during each intervention Also the flat seals are available in all the elastomer materials and are used for all applications according to the same criteria shown in Tab 2 for the o rings 4 NO PRESSING VISUAL INDICATOR SLEEVE In a new pressfitting system any leaks are attributable to just one reason the incorrect or failed pressing of the joints With a completed system during testing the check of all the joints may be rather difficult since the fitting installed but unpressed in any case offers a certain seal and the leak may be almost undetectable situation regarding the standard o ring In addition to using the leak path o ring described under point 3 2 of this Technical Guide Eurotubi provides installers with an additional solution that is useful to prevent or in any case easily identify any unpressed
33. f Z Zo Zp Z is the pressure drop of the single fitting expressed in mbar As well the following formula is used to calculate the pressure drop of the single fitting Z p v2 2 where E is the coefficient which depends on the fitting type p isthe fluid density expressed in Kg m3 v isthe fluid speed expressed in m s For a practical calculation of pressure drops it is possible to refer to the following tables 13 COUPLING FITTINGS TABLE e MINIMUM DISTANCE BETWEEN TWO PRESSINGS e DOUBLE TEE e SIDE MOUNTED TEES e ELBOW 45 FF WITH ELBOW 45 MF e 2 ELBOWS 45 F WITH PIPE e ELBOW 90 FF WITH ELBOW 90 MF e 2ELBOWS 90 FF WITH PIPE e ELBOW 90 FF AND ELBOW WITH PLAIN ENDS 90 long side e ELBOW 90 FF AND ELBOW WITH PLAIN ENDS 90 short side e ELBOW 45 MF WITH LATERAL TEE e ELBOW 45 MF WITH LATERAL TEE AND PIPE e ELBOW 45 MF AND LATERAL ELBOW 90 FF e ELBOW 90 MF WITH LATERAL TEE e ELBOW 90 MF WITH LATERAL TEE AND PIPE e LATERAL ELBOW 90 FF AND PIPE e TEE AND REDUCTION 14 CHEMICAL COMPATIBILITY OF EUROTUBI PRESSFITTING SYSTEMS Note The compatibility values stated are generic Liquids for food use other than water can not be included since pressfitting systems are not suitable for these elements as stagnation may form in correspondence with the joints For more information please contact the Eurotubi Technical Department Fluid Pipe and seals Acetic acid 20 Acetone 100 Acet
34. h the related technical specifications for drinking water DVGW W 534 gas DVGW VP 614 fire fighting VdS 2344 2100 26 marine RINA and various European accreditations SITAC CSTB etc All the pressfittings with a shaped press end are identified with a permanent marking which refers to the certifications obtained 5 2 Pipe work Pipes used in mains systems are made of austenitic stainless Cr Ni Mo steel n 1 4404 AISI 316L according to Standards UNI EN 10088 2 UNI EN 10217 7 and UNI EN 10312 Generally they are commercially available and sold in 6 metre lengths The pipes provided by Eurotubi Europa comply to the accreditations obtained and in particular to the technical specifications DVGW W 541 and VdS Therefore they are marked with the respective DVGW and VdS markings followed by approval numbers and may be used for all the applications If of the commercially available type the pipes must bear the DVGW marking followed by the approval number and may be used for all applications except for the sprinkler fire fighting application for which the use of pipes approved by Eurotubi is imperative The technical characteristics of the pipes are reported in Tab 3 5 3 Application for drinking water The stainless steel Eurotubi Pressfitting System is the ideal solution for the creation of systems used to distribute drinking water since stainless steel AISI 316L guarantees the utmost hygiene and significant resistance to corros
35. he fluid has adjusted to the room temperature If the difference between the room temperature and that of the fluid is higher than 10 you must wait at least 30 minutes The outcome is successful if during the test time the pressure remained constant Ap 0 Load test Test pressure 3 bar max for pipes with DN lt 50 1 bar max for pipes with DN gt 50 Reading sensitivity of the test gauge 0 7 bar Duration of the test 70 minutes The outcome is successful if during the test time the pressure remained constant Ap 0 The load test must be associated with a visual examination of all the pipes to make sure all the connections have been made in accordance with the best working standards 11 1 2 Heating system The test is usually carried out with water with the same criteria shown in point 11 1 1 above Concerning the main test the test pressure must be equal to 1 3 times the operating pressure Immediately after the test with cold water it is necessary to bring the system to the maximum temperature set by the project to check that also in this case there are no pressure drops Also in case of test with air or inert gas the test is carried out with the same criteria shown in point 11 1 1 above Please remember that it is mandatory to wet the seals before the assembly 11 1 3 Gas system The test is carried out with air or inert gas for example nitrogen etc and must be run in compliance with Work Sheet DVGW G 600 TRGI
36. hereas it is not recommended for systems with the presence of steam FPM red coinciding with FKM red commonly associated to INDUSTRIAL This material is used for some special applications with temperatures between 20 and 180 C and for pressures up to a maximum of 16 bar It is available in diameters from 12 to 108 mm and is used for industrial applications such as for example the transportation of different types of fluids such as lubricant and cutting oils gas oil etc and for compressed air systems with oil Whereas its use is not recommended for systems with the presence of steam Note Given that the green and red FPM materials basically have identical features in the near future Eurotubi intends to offer a single solution in blue FPM outperforming the current ones To fully understand the compatibility of the seals with the various types of fluids it is worth referring to section 14 below The characteristics and the applications of the different o rings are reported in Tab 2 Note In the presence of industrial applications and special systems it is necessary to consult the Eurotubi Technical Department providing indications on the temperature conditions and pressure and on the exact chemical composition of the convoyed component Note In no case will commercially available o rings assembled into Eurotubi joints be accepted 3 2 Profiles The o ring seals have a double configuration Standard fig 2 Th
37. ibrations There are essentially two solutions to insulate the pipes from the works using fixing bracers with insulating insert insulation of the pipes with elastic material A general design rule is not to assemble the pipes on thin walls but rather on heavy structured elements The greater the thickness the lower the transmission of sound vibrations It must be thus avoided to install the pipes in the middle of a thin wall while it is advisable to choose a thicker wall or position the pipes at the ends of thin walls 11 5 Thermal insulation Hot water pipes must be insulated in compliance with the codes of practice relating to energy conservation and heating systems The insulating material has the task of reducing the amount of energy needed to keep the pipes at the temperature level that best suits the operating conditions of the system The energy saving obtained is obviously directly proportional to the insulating power of the material given the same thickness of the insulating material used Presidential Decree 412 93 issued to implement art 4 par 4 of Law 10 91 provides for the pipes of the networks for the distribution of hot fluids in liquid phase or steam to thermal systems located outside buildings or in unheated places for example basements garages boiler rooms etc to be insulated with insulating material of a minimum thickness as set in Tab 15 For useful thermal conductivity values of the insulating material o
38. ils greases glues or other similar substances must on no account be used 9 5 Inserting pipes in fittings and marking the correct position fig 24 The pipe is inserted in the fitting in the axial direction with a slight rotating motion to overcome resistance from the o ring until it hits the stop To produce a perfectly secure joint the pipe must be marked with a felt tip pen where it meets the fitting so that any movement before or after pressing can be identified Alternatively the pipe may be previously marked with a marker using a suitable insert mark template limited to the diameters from 12 to 54 mm supplied by Eurotubi fig 25 If despite the application of the requirements described above slight rotation of the male side and lubrication of the seal to ease entry the pipe does not enter the joint it is necessary to avoid forcing and it is worth replacing the joint A angled entry of the pipe in the joint should be avoided since it may lead to damaging the o ring or cause its release from the natural seat The alignment of the pipes and the other components must take place prior to pressing If alignment is necessary after pressing you must avoid any stress on the seal points Instead it is possible to separately press the part of the system and then position it in the predetermined locations exercising due care 9 6 Use of assembly clamps for Big Size diameters fig 26 When pressing Big Size diameters
39. ion The o ring seals made of black EPDM are resistant to aging heat and chemical additives and are therefore particularly suitable for all types of treated water It is available in the standard and leak path versions In addition it also meets all the hygienic requirements in compliance with technical specification DVGW W 270 and Ministerial Decree 174 2004 Conditions of use Maximum pressure 16 bar Maximum related depression 0 8 bar absolute pressure 0 2 bar Maximum temperature 120 Certifications Eurotubi pressfittings have been certified for drinking water use by a great many national and international authorities Notably it far exceeds the demanding quality requirements of the German Standard DVGW W534 Note In this application it is absolutely forbidden to use o rings in HNBR and FPM as these are not approved for carrying drinking water Note The market has been recently offering the use of ferritic stainless steel pipe work in place of that made of austenitic steel Eurotubi provides pipes made of ferritic Cr Mo Ti without nickel stainless steel approved according to German technical specification DVGW W 541 5 4 Application for gas The Eurotubi Pressfitting System is approved in several European countries for use in gas distribution systems with external aboveground pipes running inside or outside buildings It can be used for all types of combustible gas both natural and liquid in the r
40. it of ferrous material on the incision 16 Are carbon steel systems for heating subject to corrosion over time This topic is described in detail in point 10 3 17 Which checks must be run before commissioning the systems It is necessary to carry out a visual control test of the system and the seal test as shown in point 11 1 or according to the regulations in force locally if more restrictive 18 What material must be used for solar systems For solar systems we recommend using the stainless steel pressfitting system due to its high resistance to corrosion and the higher quality of the material The use of the carbon steel pressfitting system is not excluded but is subject to a perfect thermal insulation to avoid the risk of corrosion and can only apply to a closed circuit system without the presence of air or steam Carbon steel connecting pipes must not be zinc coated internally As regards o rings two solutions may be considered black o ring in EPDM resistant to a maximum continuous temperature of 120 C and even higher for shorter periods it tolerates steam green o ring in FPM resistant to a maximum continuous temperature of 780 TC it does not tolerate steam Both seals are compatible with classic anti freeze and anti boiling products 19 What materials can be used for compressed air systems Compressed air systems include a wide range of applications As a general tip choose materials based on an in depth an
41. lared valid for both profiles is absolutely not tolerated for any diameter Note In practice pressing terminal sets and pressing tools from different manufacturers are often used The combination of possible couplings is so broad that it is not possible to provide any guarantee 3 O RING Made of synthetic rubber they guarantee that a joint is hermetically sealed The diameters currently available range from 12 to 108 mm depending on the material used 3 1 Materials Depending on the application o rings with the following materials are used EPDM black commonly associated to WATER The standard material available in diameters from 12 to 108 mm suitable for temperatures between 20 and 120 C and for pressures up to a maximum of 16 bar It has a host of applications and is used for drinking water heating cooling steam fire fighting compressed air oil free and inert gas systems HNBR yellow commonly associated to GAS This material is used in gas systems It is available in diameters from 15 to 108 mm and is suitable for temperatures between 20 and 70 C and for pressures up to a maximum of 5 bar FPM green coinciding with FKM green commonly associated to SOLAR This material is used for particularly testing conditions with temperatures between 20 and 180 C and for pressures up to a maximum of 16 bar It is available in diameters from 12 to 108 mm and is particularly suitable for solar systems W
42. loride Zinc sulfate 10 B Good Material slightly affected but suitable C Fair Some degree of reaction but suitable D Severe effect Not recommended X No useful data Application suitable only under the technical conditions seen in point 17 19 15 POSSIBLE CAUSES OF LEAKS OO IO Cle GOO Ne lt ot ot tl tC Cr O atrwWNM Oo 16 17 18 19 20 21 22 23 24 25 26 Tube inserted into the fitting creased or damaged Tube not pushed fully home in the fitting Non standard connection between tubes or non matched sizes Incorrect installation fixing Connection made to the fitting by the operator using incompatible products Installations subject to mechanical stress e g assemblings non properly lined up Other objects anchored to the structure housing the fitting Thermal expansion not compensated for by adequate fitting techniques or equipment Freezing of the installation Pressure or temperature specifications outside those indicated in the conditions of use Unforeseen external causes such as accidental impacts or sabotage Fittings welded by the operator rather than pressed Double pressing of the fitting Missing observance of the minimum distance between two fittings Poor storage and handling of the fittings with deterioration of the o ring caused by external agents such as light temperature dirt ozone etc Mechanical damage of the fitting cuts bending cru
43. mmonly called big size The design and commissioning of these distribution networks require a vast knowledge of technical notions and local regulations and legislation potentially varying from country to country This Technical Guide provides basic information to assess the fields of application with due skill design the systems according to the latest technological criteria perform the installations up to standard In any case it is the task of the designer and or the installer to ensure that the standards contained in this Guide are compatible with the local applicable laws Otherwise the local applicable laws prevail and therefore it is not possible to use Eurotubi Pressfitting System 1 1 Materials Depending on the application the following materials are used stainless steel carbon steel cupronickel 1 2 Benefits The main benefits of the Eurotubi Pressfitting System are alternative practice to traditional joining methods that require welding and or threading overall system cost saving fast and easy assembly clean and safe system with no risk for the installer reliable secure and long lasting seals minimal possibility of errors by operators no use of heat sources no fire risk during installation high corrosion resistance high thermal resistance weight significantly reduced compared to traditional metal systems high visual appeal ideal for visible installati
44. must be made of carbon steel E220 n 1 0215 and must be zinc coated internally and externally The technical characteristics are reported in Tab 6 Conditions of use Max operating pressure for diameters up to 76 1 mm 16 bar Max operating pressure for diameters 88 9 and 108 mm 12 5 bar Certification For sprinkler fire fighting applications Eurotubi Pressfitting is certified according to the German Guideline VdS CEA 4001 Note In this application where the pipes are zinc coated also internally it is forbidden to use anti freeze liquids such as for example glycol and other aggressive products since they cause the zinc to detach with consequent clogging of the valves or other parts of the system 6 5 Other applications The carbon steel Eurotubi Pressfitting System is ideal for the creation of various types of civil and industrial installations where the stainless steel pipework is not required Pipes used in main systems are made of carbon steel E195 n 1 0034 E190 n 1 0031 or other degrees of equivalent functional validity and are protected externally through a galvanised or hot zinc plating process The technical characteristics are reported in Tab 5 The conditions of use and the compatibility of the conveyed fluids are closely linked to the o ring seals housed in the pressfittings For these applications as an alternative to the externally zinc coated pipes it is possible to use the coated pipes which offer greate
45. must undergo periodic annual revision under penalty of any guarantee being voided Tab 2 O ring characteristics and applications Material Reference standard Min e max temperature Max pressure Applications Drinking water Heating and cooling Fire fighting Steam Compressed air oil free Inert gas Natural gas Methane Liquid gas Solar Oil Fuel Industrial applications Compressed air with oil Tab 3 Stainless steel pipes for pipeline systems Technical characteristics Material External diameter by thickness Volume of water contained dm3 m Empty weight kg m Austenitic stainless steel X2 CrNiMo 17 12 2 n 1 4404 AISI 316L according to UNI EN 10088 2 UNI EN 10217 7 and UNI EN 10312 Tensile strength Rm 490 690 N mm2 Yield resistance Rp0 2 2 190 N mm2 Longitudinal Lengthening A 2 40 Bending radius r 2 3 5 d for annealed pipes only Tab 4 Stainless steel Eurotubi Pressfitting System Characteristics for different applications Application Heating and cooling Steam Compressed air oil free and inert gas Compressed air with oil Solar without steam Material OR colour Max pressure Min max temperature Reccomendations Use the anti freeze at a maximum percentage of 50 Wet the o ring with water before inserting the tube into the fitting Tab 5 Carbon steel pipes for heating and other applications Technical characteristics Material
46. oduces two deformations The first radial deformation compresses the o ring in the shaped chamber and guarantees that the pipe is hermetically sealed The second geometric deformation of both fitting and pipe creates a mechanical joint resistant to slipping and rotation The resulting polygonal pressing profile varies according to the diameter being hexagonal or similar to a triangular shape but in any case creating a homogenous joint Fig 1 shows examples of the components in profile and section views before and after pressing Joints produced in this way are extremely strong but flexible enough to withstand the stresses resulting from initial installation and those such as vibrations and thermal expansion etc that occur in normal operating conditions This is provided that installation has been carried out according to the instructions in section 9 of this manual 2 3 Pressing tools The pressing process is achieved using pressing tools equipped with interchangeable press heads jaws or chains that vary according to the fitting and pipe diameters Various types of electromechanical and more frequently electrohydraulic pressing tools are commercially available in the different battery or mains powered 220V 110V 48V versions Usually they are divided into 3 classes depending on the maximum force applicable portable with low force up to 17KN able to press approximately up to a diameter of 28 mm medium force up
47. of the fitting annealing heat treatment zinc surface treatment All the processes are controlled through the operating methods set by standard UNI EN ISO 9001 and are submitted to continuous audits by the authorities that have approved them for the various applications in compliance with the related technical specifications for sprinkler fire fighting VdS 2344 2100 26 and various European accreditations SITAC CSTB etc 6 2 Pipe work Pipes used in main systems are made of carbon steel conforming to standard UNI EN 10305 3 E220 n 1 0215 for the sprinkler fire fighting application E195 n 1 0034 or E190 n 1 0031 or other degrees of equivalent functional validity for all the other applications The pipes provided by Eurotubi Europa are marked with the Eurotubi or EU marking unless in case of specific requests of the customers Generally they are commercially available and sold in 5 or 6 metre lengths For the sprinkler fire fighting application it is essential to use Eurotubi pipes approved and marked with the VdS marking followed by the approval number For all the other applications if you want to purchase commercially available pipes it is necessary to contact the Eurotubi Technical Department well in advance in order to perform an accurate analysis obviously including practical tests on samples and obtain the required authorization In the case of successful outcome the pipes must in any case state
48. oint since the great force in play may cause internal damage 10 CORROSION RESISTANCE 10 1 Stainless steel installations for drinking water Resistance to internal corrosion Stainless steel does not change the characteristics of drinking water nor does the water affect it in any way For this reason drinking water even when treated is absolutely compatible with the AISI 316L stainless steel used by Eurotubi Perfect hygiene is thus guaranteed Interstitial or drilling corrosion resistance In stainless steel interstitial or drilling corrosion may only take place in the presence of extremely aggressive environments In systems for drinking water these conditions may occur if the concentration of chloride is significantly higher than the value of 250 mg l set as the limit tolerated by current laws Very special reasons however may lead to similar conditions with the danger of local corrosion The potential situations of risk and the precautions to be adopted to limit their effects are listed below The system is emptied and in some open sections to the environment puddles of water form The slow evaporation of residual water may raise the local concentration of chloride above the permitted values favouring the formation of corrosive phenomena In these cases after emptying the system it is necessary to circulate dry air to ensure the pipe system is completely dried In threaded connections sealant materials containing chloride
49. on request and the dimension with which they are identified corresponds to the external diameter of the pipe on which they are pressed Due to the special nature of these products Eurotubi does not keep stocks and only accepts orders of a considerable numeric quantity The special process used to make the pressfittings can be broken down into the following main stages cutting the pipe into sections and mechanical working forming of the o ring seat any welding of other parts of the fitting All the processes are controlled through the operating methods pursuant to standard UNI EN ISO 9001 2008 and are subject to the audits set by the Authority RINA which approved them for the naval sector 7 2 Pipe work Pipes used in main systems are made of cupronickel copper nickel alloy n 2 1972 according to standard DIN 86019 Generally they are sold in 6 metre lengths and in consideration of the special characteristics of the material they are handled in boxes or with special attention The pipes provided directly by Eurotubi are marked with the Eurotubi or EU marking unless in case of the customer s specific request If of the commercially available type subject to consultation with Eurotubi Technical Department the pipes must respect the required characteristics and report in a permanent manner data providing details on the manufacturer and the production batch The technical characteristics of the pipes are reported in
50. ons exceptional fluid flowing properties the end quality depends on the equipment rather than on the skill of the operator who does not need to be highly qualified 2 SYSTEM DESCRIPTION 2 1 General information The following components make up the Eurotubi Pressfitting System Pressfittings The basic system component At each end arranged for the pressing there is a shaped seat which holds a synthetic rubber o ring seal They are available in various types and figures including some of various materials which can be used for flanged and threaded connections or welded joints Pipe work The second system component Supplied by Eurotubi Europa Commercially available pipes may also be used provided they comply to the technical specifications set out in sections 5 6 and 7 of this manual detailing the various applications Pressing tools Used to join the two components these also are supplied by Eurotubi Europa Commercially available tools may also be used provided they comply to the requirements set out at point 2 3 of this manual 2 2 Joining process Pressfitted pipe joints are fast easy and risk free The result of the operation is definitive since it is no longer possible to separate the components and return to the original condition The pipe is inserted into the fitting up to the stop then the jaw attachments of the pressing tool press the shaped end of the fitting onto the pipe Pressing pr
51. ons of temperature below 0 C 12 PIPE CALCULATION 12 1 Pressure drops Water or gas which flow in the pipes gradually lose their own pressure because of the different resistances they meet on the course These resistances are due both to straight pipe resistance or to single casual conditions as direction changes section reductions etc Therefore the whole of pressure drops for a pipe system is calculated according to the following formula Ap Ap1 Ap2 where Ap is the total pressure drop Ap1 is the pressure drop due to straight lengths Ap2 is the pressure drop due to single localized resistances 12 2 Pressure drops of a straight pipe The following formula is used to calculate pressure drops due to straights lengths Api 2R where 2R is the result of R1 h Roe lo Rael R is the unitary pressure drop expressed in mbar o in Pa m is the straight pipe length in m As well the following formula is used to calculate the unitary pressure drop R A p v 2 d where A is the pipe friction coefficient is the fluid density expressed in kg m3 v is the fluid speed expressed in m s is the internal pipe diameter in mm For a practical calculation of pressure drops it is possible to refer to the following tables 12 3 Pressure drops of single localized resistances The following formula is used to calculate pressure drops due to single localized resistances where XZ is the result o
52. presentative Signature of the performer or representative ANNEX 4 TEST REPORT WITH AIR OR INERT GAS FOR GAS SYSTEMS SYSTEM CUSTOMER FIRST PERFORMER SECOND PERFORMER Following the test it is hereby declared that The entire system was visually checked to make sure that all the connections have been made in accordance with the best working standards e Test fluid used air nitrogen e Volume dell impianto liters Operating pressure bar System with operating pressure up to 100 mbar Load test Test pressure bar must be 1 bar Stabilization time minutes Duration of the test minutes The ducts are watertight Ap 0 The system has been connected to the network gas Seal test Test pressure bar must be 150 mbar Stabilization time minutes Duration of the test minutes The ducts are watertight Ap 0 The system has been connected to the network gas System with operating pressure gt 100 mbar and lt 1 bar Combinated load and seal test Test pressure bar must be 3 bar Stabilization time minutes must be 180 minutes Duration of the test minutes must be 120 minutes The ducts are watertight Ap 0 Place Date Signature of the customer or representative Signature of the first performer or representative Signature of the second performer or representative SOME REFERENCES Some buildings where Eurotubi Pressfittings were used 1 Grenoble Hospital F
53. r plastic coating on the pipes In the absence of protection a prolonged exposure to moisture particularly for chased installations may cause internal corrosion It is therefore necessary to cover the pipes with a closed cell coating or with anti corrosion tape making sure that no part remains uncovered or detachment areas form between the insulating material and the pipe where condensation may generate Felt sheathing must not be used as it holds moisture and encourages corrosion 10 4 Carbon steel installations for sprinkler fire fighting and other applications Carbon steel does not require additional anticorrosion protection in any of the other applications foreseen for its use Note Please bear in mind that Eurotubi advises against using carbon steel for cooling system due to the considerable risks of corrosion induced by condensation on the cold pipes 11 SYSTEM COMMISSIONING 11 1 Testing After installation and before covering insulation or painting the system must undergo testing to ensure its suitable carrying capacity and seal integrity The test method and result must be necessarily documented in a report see annexes 1 4 of this guide The choice of the test method depends on the type of installation the fluid selected as testing with and the progress over time of the building works as well as the requirements related to hygiene and corrosion If the system must be emptied after the pressure test we advise carrying out
54. r resistance against corrosion These are available in diameters ranging from 12 to 54 mm and are protected externally by a film of anti corrosion paint and an adhesive layer of polypropylene plastic The external surface is smooth but may be subsequently painted according to customers requirements The applications with the related characteristics are reported in Tab 7 We strongly advise not using carbon steel Eurotubi Pressfitting System for cooling systems since it is not possible to guarantee a completely reliable insulation Should you not follow this recommendation you must be responsible for obtaining perfect insulation to avoid external corrosion Note The resistance to corrosion represents a fundamental aspect to be held in consideration On this point please refer to points 9 3 and 9 4 of this Guide Note Concerning the Italian standard UNI 11147 on gas applications which allows the use of pressfittings conforming to product standard UNI 11179 which also includes carbon steel Eurotubi has decided for ethical and safety reasons that its carbon steel system can absolutely not be used for gas applications 7 EUROTUBI CUPRONICKEL PRESSFITTING SYSTEM FOR NAVAL APPLICATIONS 7 1 Pressfittings The pressfitting joints are made of cupronickel copper nickel alloy n 2 1972 which conforms to Standard DIN 86019 The diameters range from 15 to 108 mm The types that may be ordered are listed in the special catalogue provided
55. rance 2 Grand Hotel Ermitage Evian France 3 Borgholms Castle Sweden 4 Armani Hotel Milan Italy 5 Berlin Eastgate Germany 6 Halmstad Hospital Sweden 7 New Castle Stuttgart Germany 8 IFP Oil French Institute Lyon France 9 Hines Cesar Pelli A Tower Milan Italy 10 Decin municipal library Czech Republic 11 Synchrotron Soleil Paris France 12 KMD Odense Denmark 13 ESAB production complex Vamberk Czech Republic 14 Mercedes Help Center Moscow Russia 15 Aeroplaza St Petersburg Russia CAPTIONS Fig 1 Joining of pressfitting on pipe Profil view Section view Before pressing After Pressing Fig 2 Standard o ring Fig 3 Leak path o ring Fig 4 Tearing and manual removal of the sleeve after pressing Fig 5 Fitting with sleeve before and after pressing Fig 6 The presence of the sleeve is easily detectable with a visual check even at a distance Fig 7 Colour of the sleeve according to the material Fig 8 Leak path o ring Sleeve Double reliability Fig 9 Thermal expansion in stainless steel and cupronickel as a function of the length and the temperature variation Expansion Pipe length m Temperature variation C Fig 10 Chased pipe elastic bearing Fig 11 Pipe under floating floor floating floor slob massive floor isolation layer Fig 12 Axial expansion compensators Fig 13 U shaped expansion compensatorsa a through preformed pipe b with pressfittings Fig 14 Length LU
56. rature difference Tab 9 shows the coefficients of expansion for the various pipe materials For a practical calculation of the thermal expansion according to the pipe length and the temperature variation see the graph in fig 9 which applies to stainless steel and cupronickel and is also applicable to carbon steel but allowing for the fact that the thermal expansion of carbon steel is reduced by 1 3 33 Example The thermal expansion of a 20 metre stainless steel pipe subjected to a temperature variation of 70 C e g from 20 to 50 C is the following AL 16 5 20 70 1000 23 1 mm The same result can also be obtained from the graph in fig 9 If the pipe is carbon steel the expansion is AL 11 20 70 1000 15 4 mm The same result can also be obtained from the graph in fig 9 but reducing the expansion for stainless steel by 1 3 7 7 mm 8 2 Expansion room When laying pipework distinctions should be made between visible pipes chased pipes pipes under floating floors Expansion in visible pipes is absorbed by the elasticity of the run itself provided that the pipes are correctly fixed Chased pipes must not be in direct contact with the plaster but wrapped in a pad of elastic material such as glass wool or plastic foam fig 10 Thus fitted soundproofing requirements are also satisfied Under a floating floor pipes are laid below the isolation layer and can expand freely fig
57. s are used at times which may cause a localised increase of the chlorides in the water and consequently a risk of oxidation Among these please remember the existence of a particular type of Teflon which contains chlorine though very rarely available Thus only Teflon tapes with no chlorine hemp with chloride free sealant paste or sealing tapes also with no chlorides are used External elements for example electric heating cables cause an increase in the temperature of water through the pipe wall with possible formation of deposits with a high concentration of chlorides In case of using these elements we recommend checking that the temperature does not permanently exceed 60 with temporary peaks of 70 C as during thermal disinfestation operations In case of accidental heating stainless steel may alter the structure sometimes assuming a tempering colour This alteration in the metal creates the conditions for intercrystalline corrosion Please remember that it is absolutely forbidden to bend and cut the stainless steel pipes when hot using flexible pipes or oxyacetylene torch Resistance to bimetallic corrosion mixed installations Stainless steel is resistant to corrosion even in systems where it is in contact with non ferrous metals bronze copper and brass regardless of the direction of the water If however it is in direct contact with carbon steel bimetallic corrosion can occur This risk can be reduced by inserting a
58. shing Replacement of seals or spare parts not supplied by Eurotubi Tearing of the o ring for example caused by pipes not properly deburred Incorrect tube insertion causing the o ring to become dislodged from its position Use of unsuitable o ring lubricants it is possible to use only talc and water Internal or external liquids not compatible with the o ring material composition Pressing carried out with worn pressing jaws Use of a pressing machine no longer capable of exerting sufficient force the result of wear and tear poorly performed or lack of maintenance Pressing jaws not correctly positioned in relation to the fitting when pressed Pressing jaws not fully closed Use of non standard pressing jaws or jaws certified for other profile types 16 GUARANTEE The use of original Eurotubi Pressfittings with the correct pipes and approved pressing tools coupled with strict adherence to the technical instructions given for both the design and installation of the system will guarantee the longevity of the system Damage arising from material or manufacturing defects in the fittings is fully covered by insurance 17 FAQ FREQUENTLY ASKED QUESTIONS 1 What does Pressfitting System mean Pressfitting system means the permanent joining of pipes and fittings through a mechanical pressing operation A pressfitting system comprises the pipes the fittings the o ring seals and in the assembly phase the pressing tools
59. ther than those stated the minimum thickness of the insulating material is obtained by linear interpolation The thickness of the insulation may be reduced by 50 for the vertical risers of the pipes located inside the thermal insulation of the building casing by 70 for the pipes running inside structures not facing the outside or unheated rooms In addition to preventing thermal dispersion the insulation of the pipe may prevent the occurrence of external corrosion and noise transmission Finally insulation also acts as a safety precaution against accidental knocks For stainless steel installations the insulating material has to be without chlorine or its compounds 11 6 Protection against freezing Where there is a danger of water freezing in pipes they must be protected with insulating material of sufficient thickness and with the use of antifreeze up to max 50 to avoid damage to the installation The freezing of water based liquids causes an increase in volume that the pipes on a thin wall can not withstand thus incurring permanent geometrical deformation Note A freezing episode has irreversible effects on the system In this case the joints need to be re checked both visually and through the seal test Maximum attention must be devoted to this problem in particular when systems are created in the winter period since the conditions at worksites are always precarious and some systems may be negligently left full of water in conditi
60. to 40 KN they are the most common and versatile and are able to press up to a diameter of 54 mm high force more than 40 KN suitable to press big size diameters starting from a diameter of 76 1 mm They are of significant size and weight The Eurotubi Pressfitting System can be used with a wide variety of pressing tools provided that these are equipped with M profile terminals Tab 1 below lists the three main manufacturers commercially available that Eurotubi constantly tests with its products as well as the related ranges compatible with Eurotubi Pressfitting System There are other manufacturers some reliable especially with the latest models Since it is not possible to guarantee beforehand the compatibility with all the tools commercially available users are invited to contact the Eurotubi Technical Department to have instructions on this point We recommend following the use and maintenance methods set by the manufacturer closely regularly checking the working surfaces of the jaws frequently cleaning the jaws with a degreaser keeping it correctly lubricated when the tools have worn out dispose of all the components especially the batteries according to the requirements indicated by the related regulations No claim will be accepted unless the compliance with the maintenance revision programme specified by the manufacturers is documented The use of jaws and chain with a V profile or dec
61. used to produce the joints 2 What does an Approved Pressfitting System offer A Pressfitting system is considered approved when it has successfully passed the tests carried out by a Product Certifying Body for a certain application Eurotubi Pressfitting System has obtained the most important European certifications see page 2 referred to in sections 5 6 and 7 The system is deemed reliable when the requirements of this technical guide are respected and in particular the operating conditions set in the accreditation the general use techniques illustrated in section 8 the installation instructions illustrated in section 9 3 Which systems can be created with Eurotubi Pressfitting System Eurotubi Pressfitting System can be used for different applications depending on the material stainless steel is mainly used for systems for the distribution of drinking water and gas carbon steel is mainly used for closed circuit hot water heating systems cupronickel is mainly used in the naval sector for carrying salt water The growing diffusion of this joining system has led the Eurotubi Pressfitting System to be used in a much wider range of industrial applications as mentioned in sections 5 6 and 7 4 Which requirements must be respected to use the pressfitting systems The design and installation of the system must respect local regulations the guidelines developed by industry best practice and the requirem
62. ylene Ammonia dry Ammonium chloride 1 Ammonium nitrate 10 50 Ammonium phosphate 10 Ammonium sulfate 10 Aniline Aqua regia aqua fortis Battery acid Benzene Boric acid 5 Butane Butanol Calcium Hydroxide lt 10 C Calcium Hypochlorite Carbon dioxide Caustic soda lt 50 Chlorine dry Citric acid 5 Compressed air Copper chloride Copper nitrate Copper sulfate 10 Photo developer fixing bath Engine oil Ethane Ethylene glycol Ethylene Oxide Ferric chloride watery Ferric sulfate Formaldehyde Formic acid Gas oil Gasoline Gear oil Hexane Hydrochloric acid 100 Hydrogen fluoride Hydrogen peroxide 10 Kerosene A Excellent Material not affected Linseed oil Lubricating oils Machine oil Magnesium chloride lt 20 Magnesium hydroxide 100 C Magnesium sulfate lt 40 Methane Methanol Mineral oil Naphtha Naphthalene Nickel chloride 10 30 Nickel sulfate Nitric acid lt 20 Paraffin Phosphoric acid Potassium chloride Potassium hydroxide lt 50 C Potassium sulfate 10 Propane liquefied Prussic acid Sea water Sodium bicarbonate Sodium chloride 5 Sodium nitrate lt 40 Sodium phosphate Sodium sulfate 10 Sulfuric acid 10 60 C Sulfuric acid smoking Sulfuric acid 100 moist Sulphur dioxide dry Tannin Tanning agents for leather Tartaric Acid 10 100 C Toluol 20 C Trichloroethylene Turpentine Water lt 100 C Water deionised Water distilled Zinc ch

Eurotubi Pressfitting System - Technical Guide

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