Ppr Techincal Data Sheet

2010

almonaplast.com

PPR TechnicalData Sheet

Req. No. 44 100 100485

2 3

01 Chapter 01

/CERTIFICATES

01 Chapter 01

/INDEX

Chapter 01

Guide to Almona System 01Contents

Chapter 01 GENERAL FEATURES OF Almona SYSTEM

Introduction

The Raw Material

Fields of application

Page 04

Chapter 06 Technical Guidelines

Operating conditions

Loss of pressure

Expansion and stirrups

Page 13

Chapter 02 Main Characteristic Of The System Page 06

Chapter 03 Almona + Aluminium Foil System Page 08

Chapter 04 Norms And Directives Page 10

Chapter 05 Dimensional Characteristics Page 11

Chapter 07 Processing Page 29

Chapter 08 Resistance To Chemicals Page 36

Chapter 09 Precautions Page 40

Chapter 10 Testing The Installation Page 44

Chapter 11 Almona Product Range Page 47

4 5

GENERAL FEATURES OF Almona SYSTEM01 Chapter 01

About US

Introduction

The Raw Material

Established in 2008, Almona is a leading pipe manufacturing company in Saudi Arabia. Certified to ISO 9001:2008 Quality Management Systems.

Almona is the first choice for customers across Saudi Arabia, with a product range from 20mm to 125mm pipes and its accessories. The pipes comply with the Saudi (SASO) and German (DIN) Standard.

Almona success is the result of the company’s persistent commitment to continuous innovation and technology, with a relentless pursuit to provide quality products and services.

Almona is a system of pipes and fittings made from Polypropylene Ran-dom Copolymer (PPR-C), specially developed for the use and construction of heating and water supply systems of the most widely varying forms, with outstanding reliability over time.

One special feature of Almona system is the assembly technique, in which the parts to be connected are welded by melting. After welding, the pipe and fitting from a single, continuous body, with none of the problems which may derive from potential leakage points.

The assembly method, the wide range of sizes and the fittings available, the versatility of the system and its excellent chemical and physical properties make Almona a product of exceptional quality.

Almona system is made from PPR-C, a Random Copolymer Polypropylene approved for the production of pipes according to DIN 8078 standards (Polypropylene Pipes. General Quality Requirements - Tests).

The raw material is supplied in granules.

Before processing, the granule is submittet to specific tests in our labora-tories to verify its suitability for use (ISO/R 1133 procedure 18. Melt index MFI 190/5).

(PPR-C) is a thermoplastic resin which is transformed into the finished prod-uct by a rise in temperature, which plasticizes the material, allowing the pipe to be produced by means of extrusion, and the fittings by moulding.

These processes are carried out inside our factory, under the control of skilled, qualified staff. The dimensions of the pipes and fittings, with the rel-ative processing tolerances, are established in accordan-ce with DIN 8077 (Pipes in polypropylene, PP, dimensions).

Chapter 01

GENERAL FEATURES OF Almona SYSTEM 01Chapter 01

Characteristics ofPPR-C Type 3

Characteristics ofPPR-C Type 3

Almona system is suitable for transporting hot and cold fluids under pressure for long periods of time.

This capability makes it ideal for the construction of water supply, heating and air-conditioning systems, in residential and industrial buildings.

It is also suitable for transporting fluids for human consumption and industrial fluids (see table on page 39).

See chapter 6 of this Guide for a more complete discussion of the operating conditions the system is able to withstand.

Property TestMethod

Unit ofMeasurment

TestValue

Viscosity J ISO 1628 T3 cm3/g 430

Density at 23°C ISO 1183 g/cm3 0.898

Melting zone DIN 53736 B2 °C 150-154

Modulus of elasticity ISO 527 N/mm2 700

Impact test (Charpy) DIN 8078 - no breakage

Thermal conductivity at 20°C (λ) DIN 52612 W/m K 0.24

Dielectric constant DIN 53483 - 2.3

Volume resistivity DIN 53482 ohm cm >1 x 1016

Dielectric strenght DIN 53481 kV/mm ≥ 20

Specific heat at 20°C Adiabatic calorimeter kJ/kg K 2.0

Loss factor DIN 53483 - < 5 x 10-4

Coefficient of thermal VDE 0304 K-1 1.5 x 10-4

linear expansion Section 1 § 4

Ultimate strength ISO 527 N/mm2 40Ultimate elongation speed 50 mm/min % > 5 Test piece 1 B

Melting index MFI 190/5 ISO 1133 procedure 18 g/10 min 0.5 MFI 230/2.16 ISO 1133 procedure 12 g/10 min 0.3 MFI 230/5 - g/10 min 1.5

6 7

Main Characteristic Of The System02 Chapter 02

Low ThermalConductivity

Resistance ToElectrochemical

Corrosion

Introduction

The material’s high level of thermal insulation guarantees low heat loss on the part of the fluid transported. This means minimal drop in temperature between the hot water production and delivery points, with consequent energy saving.

The low thermal conductivity value also causes a drastic reduction in the formation of condensation on the outside of the pipe, a frequent problem on metal pipes in some temperature and humidity conditions.

Finally, it takes longer for the water to freeze when the outdoor tempera-ture is particularly low.

Almona is chemically inert and highly resistant to a wide range of acids and bases. This makes it suitable for contact with the materials normally used in the construction sector, such as lime or cement, with no need for specific protection.

For transport of/or contact with special substances, please refer to check the chemical resistance of the polypropylene, consulting the table provid-ed on page 39.

Almona has many characteristics which make it an ideal system for con-structing modern plants at the technological state of the art.

Volume resistivity (at 20°C) of Almona and the metals normally used inthe heating and water supply sector

Almona (determined according toDIN 53482) > 1 • 1016 Ω cmSteel = 0.1÷ 0.25 • 10-4 Ω cmPure iron = 0.0978 • 10-4 Ω cmPipe grade industrial copper = 0.017241 • 10-4 Ω cm

Thermal conductivity (at 20°C) of almona and the metals normallyused in heating and water supply systems.

Almona (deter. according to DIN 52612) λ = 0.24 W/mKSteel λ = 45 ÷ 60 W/mKIron λ = 45 ÷ 60 W/mKCopper λ = 300 ÷ 400 W/mK

Chapter 01

Main Characteristic Of The System 02Chapter 02

LOW NOISE

HYGIENIC ANDNON-TOXIC

RESISTANCE TOSTRAY ELECTRIC

CURRENTS

LOW LOSSOF PRESSURE

EASYWORKABILITY

Due to the material’s high sound insulation value, the noise level of systems is considerably reduced both with particularly high water flow speeds and when water hammers are present.

(PPR-C Type 3), the raw material used for production of Almona system, is com-pletely non-toxic and complies with current standards at international level.

Thanks to its high electrical insulating properties, Almona is unaffected by stray currents, which may create dangerous punctures in metal pipes. This phenom-enon occurs above all in installations in zones with a high concentration of in-dustrial facilities, close to railway lines and in other zones with a high concen-tration of electrostatic currents.

Thanks to the particularly homogeneous, compact structure of the material, achieved using a state of the art production technology, the inside surfaces of Almona pipes and fittings are non porous and free from cracks or crazing. This means the surfaces are extremely smooth, and loss of pressure are very low (see graphs on page 17).

There is also no risk of pipe blockages caused by scale deposits.

Due to the density of just 0.898 g/cm3, pipes and fittings are very light. Com-bined with the wide range of fittings available, this enables complete installa-tions to be made easily and safely, with considerable time savings compared to conventional products.

8 9

Almona + Aluminium Foil System03 Chapter 03

Introduction

PROPERTIES

Alongside Almona normal PPR Pipes has also developed another system in random copolymer polypropylene, under the trade mark of Almona STABI Pipe.

This product is made from the same raw material as the basic line, which is used to produce pipes bonded on the outside during extrusion with a sheet of aluminium. This part is then given a further coating of a PP-R layer by a co-extrusion process.This surface layer protects the aluminium sheet from any degradation pro-cesses which might affect it when in service.

As well as the characteristics already mentioned for the conventional sys-tem, the composite pipe thus obtained offers a series of additional proper-ties listed hereafter.

Chapter 01

Almona + Aluminium Foil System 03Chapter 03

LOW THERMALEXPANSION

EXCELLENTWORKABILITY

SHEARSTRENGTH

The sheet of aluminium helps to keep the pipe’s thermal expansion coefficient low:

α = 0.06 mm/m°C

facilitating installations of the material outside walls or floors.

The composite pipe is very easily bent into shape, aiding installation with runs with frequent changes in direction. Once bent as required, the pipe retains this shape with no further changes.

The aluminium sheet and outer PP-R coating give Almona STABI pipe greater shear strength, providing greater protection for the underlying pipe.

10 11

Norms And Directives04 Chapter 04

NORMS ANDDIRECTIVES

DIN 1988Drinking water pipes in the floorPart 1. Technical standards for drink-ing water installations.

DIN 4109, sheet 5Soundproofing in the construction sector (complementary regulations).Soundproofing in water piping.

DIN 16774Thermoplastic mass: polypropylene PP.

DIN 53735Tests of plastic materials; determina-tion of melt index of thermoplastics.

KTW RECOMMENDATIONSCommunication of the Germany Min-istry of Health concerning the admis-sibility of plastic materials and other non-metal materials in the context of the law on food products and the drinking water sector.Recommendations concerning plastic materials and drinking water (KTW) of the German Ministry of Health.

DIN 16962Polypropylene (PP) pipes and fittings.Sheet 5: general quality requirements - tests.Sheet 6: moulded elbows for welding with couplings, dimensions.Sheet 7: moulded union tees forwelding with couplings, dimensions.Sheet 8: moulded caps and couplings for welding with couplings,dimensions.Sheet 9: moulded pipe fittings and re-ductions for welding with couplings, dimensions.Sheet 10: collars, flanges andseals for welding with couplings,dimensions.

DIN 2000Directives concerning the require-ments for drinking water.Design, development and operationof installations.

DIN 8076Pressurized thermoplastic pipelines.Compression type metal fittings.

DIN 8077Polypropylene PP pipes, dimensions.

DIN 8078Polypropylene pipes. General qualityrequirements - tests.

DIN 16960Welding of thermoplastic materials,principles.

DVS 2203Tests of thermoplastic pipe fittingsfor welding.

DVS 2207, part 11Welding of thermoplastic materials,PP type 1 and type 2, pipes andaccessories.

DVS 2208, part 1Machinery and equipment for weld-ing thermoplastics, welding withhot elements.

W 328Realization of drinking water installa-tions inside buildings.

SpecificationsRegulations on the general condi-tions for water pipe, from 20.06.1980.

VOB part C DIN 18381Installation of gas, water and wastepipes inside houses.

Chapter 01

Dimensional Characteristics 05Chapter 05

TABLE OF DIMEN-SIONS OF ALMONA

SYSTEM, PN20


SYSTEM, PN16


STABI SYSTEM, PN25

Tollerancemm

(+)0.3(+)0.3(+)0.3(+)0.4(+)0.5(+)0.6(+)0.7(+)0.9(+)1

(+)1.2

Tollerancemm

(+)0.3(+)0.3(+)0.3(+)0.4(+)0.5(+)0.6(+)0.7(+)0.9(+)1

(+)1.2

Tollerancemm

(+)0.5(+)0.6(+)0.7(+)0.8(+)1.0(+)1.2(+)1.4(+)1.6(+)2.1(+)2.3

Tollerancemm

(+)0.5(+)0.6(+)0.7(+)0.8(+)0.9(+)1.1(+)1.3(+)1.5(+)1.8(+)2.0

Outsidediameter

mm

2025324050637590

110125

Outsidediameter

mm

2025324050637590

110125

Thinkness,mm

3.44.25.86.78.4

10.5

Thinkness,mm

0.50.50.50.50.50.5

Outerdiameter

mm

202532405063

Inner pipe

Thinkness,micron

200200200200200200

Aluminum

Outerdiameter

mm

21.826.833.841.851.864.8

Outer coat

Thicknessmm

3.44.25.86.78.4

10.512.515

18.420.9

Thicknessmm

2.83.54.55.66.98.7

10.412.515.217.3

Insidediameter

mm

13.216.621.226.633.2425060

73.283.2

Insidediameter

mm

14.41823

28.836.245.654.265

79.290.4

AverageweightKg / m

0.1720.2660.4340.6711.051.652.343.365.046.49

AverageweightKg / m

0.1480.23

0.3760.5830.8961.422.022.914.325.58

12 13

Fiting in PP-R for welding

PP-R fiting with metal insert

Dimensional Characteristics05 Chapter 05

FITTINGS Almona system comprises a wide range of fittings, which can be subdivid-ed into two groups, depending on their intended use:

a) PP-R fittings for welding;b) PP-R fittings with metal insert.

In the first case, the joint between the pipe and the fitting (and in some cases between fitting and fitting) is made by melting the parts, while in the second case one end of the fitting has a threaded metal insert sunk into the PP-R body. Parts of this kind are used in the ends of the system, allowing connection to equipment installed previously, or any other threaded metal elements.

For diagrams and availability of fittings in the various sizes, see pages52-53-54-55 of this guide.

a

b

Chapter 01

Technical Guidelines 06Chapter 06

OPERATINGCONDITIONS

REGRESSIONCURVES FORPPR-C Type 3

The main parameters affecting the behaviour of plastics are:

- mechanical stress = PRESSURE- thermal stress = TEMPERATURE- duration of stress = TIME

These parameters are linked together by means of the REGRESSION CURVES of the material, shown in graph form below. Almona system pipes and fittings must be used and installed in accordance with THESE parameters, i.e. without exceeding the limit conditions for operation. It must be remembered that Al-mona belongs to the PN20 operating class. For this class, the OPERATING CON-DITIONS, obtained from the regression curves applying a safety coefficient of 1.5, are the following:

PRESSURE = 10 barTEMPERATURE = 60°CTIME = 50 years

Equi

vale

nt s

tres

ses

(N/m

m2 )

DurationYears

Hours

10 15

20

10

0.5

0.7

1.0

2

3

4

5

7

10

20

30

10 10 10 1010 10 10

14 15

Technical Guidelines06 Chapter 06

LOSS OFPRESSURE

The continuousloss of pressure

Calculation of the loss of pressure is a fundamental step in the design of heating and water supply systems. This parameter is closely linked to the delivery rate of the system, meaning the amount of water which reaches the individual users in the unit of time. Loss of pressure may be continuous or localized. The sum of these two components provides the total loss of pressure of the system.

Continuous loss of pressure are generated by the continuous resistanceswhich a fluid encounters as it travels along a pipe. These consist of the in-ternal frictions of the fluid itself, due to viscosity, and those generated by contact with the inside surface of the pipe.

Continuous headlosses are measured in pressure units (pascal, bar, metres or millimetres of water column); in general, the measurement refers to a unit length of pipe.

In the specific case of Almona and Almona STABI system pipes, the continu-ous loss of pressure are determined by means of the graphs given on the facing page (measured for water at 20°C).

FLOW RESISTANCE DIAGRAM

Example:

To use the monogram, at least two quantities will have to be established, one of which is the size of the pipe and the second generally the flow rate or speed.

Pipe PN20: Ø 32 x 5,4

Ø int. = 21,2 mm (point A)speed 1 m/s (point B)

By joining points A and B with a straight line, points C and D are found which indicate a flow resistanceJ = 0,075 m/m and a flow rate Q = 0,35 l/s

Chapter 01


B

C

A

D

SPEED(m/s)

FLOW RESISTANCE(m/m)

INTERNALD IAMETER(mm)

FLOW RATE(l/s)

WATER AT 20 ° C

16 17


SPEED(m/s)

FLOW RESISTANCE(m/m)

INTERNALD IAMETER(mm)

FLOW RATE(l/s)

WATER AT 60 ° C

Chapter 01


Examples ofdimensions of a

cold water supplynetwork

Connected appliancesand relative delivery rates

(UNI 9182-87)

1 Washbasin1 WC with cistern1 Bidet1 Bath1 Sink1 Dishwasher1 Washing machine

7 Appliances

0.1 l/s0.1 l/s0.1 l/s0.2 l/s0.2 l/s0.2 l/s0.1 l/s

0.1 l/s

Ø 25

Ø 25

Ø 32

Ø 40

Ø 50

Ø 50

Ø 25

Ø 25

Ø 25

7 appliances

7 appliances

7 appliances

7 appliances

28 a

pplia

nces

21 a

pplia

nces

14 a

pplia

nces

N°appliances

7142128

Totaldeliveryrate l/s

1.02.03.04.0

Simult.factor

%

55.038.033.028.0

Simult.deliveryrate l/s

0.550.760.991.12

Almonadiameter

mm

25324050

Almonadeliveryrate l/s

0.60.81.01.2

Loss ofpresssuremmc.a./m

52527013564

Waterspeed

m/s

2.82.31.81.4

Note: the simultaneous delivery rates take into account the probabilitythat the taps will be turned on simultaneously.

18 19


Localizedloss of pressure

Localized resistancecoefficients “r”

for Almona pipes& fittings

Localized loss of pressure are generated by the irregularities which a fluid encounters as it flows along the pipeline (bends, valves, reductions, etc.).

There are various ways of expressing localized loss of pressure; in our dis-cussion, we consider those which refer to the measurement of the so-called “localized resistance coefficient” associated to Almona range of pipe fit-tings.

N° Figure Graphic symbol Resistancecoefficient

1 Coupling

2 Reduction till 2 dim.2a Reduction ≥ 3 dim.

3 Elbow 90°

4 Elbow 45°

5 Union Tee5a Reduced union Tee




9 Threaded Tee

10 Male threaded joint

11 Red.male threaded joint

12 Male threaded elbow

13 Red.male threaded elbow

0.25

0.550.85

2.0

0.6

1.83.6

1.32.6

4.29.0

2.25.0

0.8

0.4

0.85

2.2

3.5

Chapter 01


Loss of pressure zin relation to r=1

with water at 10°Cfor various

speeds v

Total loss ofpressure

Once the coefficients “r” are known, the system’s localized loss of pressure are calculated using the following formula:

z = Σ r • v2 • γ / 2g = 5 • Σ r • v2 (mbar)

where:γ = 999.7 kg/m3 specific weight of waterg = 9.81 m/s2 gravity accelerationv = speed of water in m/sΣ summation

As already mentioned, the total system headloss is obtained by adding to-gether the continuous and localized loss of pressure:

ΔP = l • R + z • 10where:ΔP = total loss of pressure (mm c.a.)l = pipeline lenght (m)R = continuous loss of pressure (mm c.a./m)z = localized loss of pressure (mbar)

Flowingspeed v

(m/s)

Flowingspeed v

(m/s)

Loss of pressure zfor r = 1(mbar)

Loss of pressure zfor r = 1(mbar)

0.10.20.30.40.50.60.70.80.91.01.11.21.31.41.51.61.71.81.92.02.12.22.32.42.5

0.10.20.50.81.31.82.53.24.15.06.17.28.59.8

11.312.814.516.218.120.022.124.226.528.831.3

2.62.72.82.93.03.13.23.33.43.53.63.73.83.94.04.14.24.34.44.54.64.74.84.95.0

33.836.539.242.1454851555861656872768084889297

101106110115120125

~

20 21


EXPANSION ANDSTIRRUPS

Expansioncontraction in

Almona andAlmona STABI system pipes

Each material which undergoes a variation in temperature over time reacts by modifying its size to varying degrees.This phenomenon is called thermal expansion; the body will increase in volume when the temperature rises, or contract when it decreases.

Thermal expansion may be linear, superficial or cubic, depending on whether it mainly affects one, two or all three of the body’s dimensions.

In the case of pipelines, the expansion is mainly linear, since their length far exceeds their other dimensions.

The parameter which provides guidance on a pipe’s tendency to expand or contract in case of a temperature variation is its linear expansion coef-ficient.

Therefore, when designing and constructing installations it is essential to know the value of this coefficient, in order to calculate the amount of ex-pansion/contraction and adopt the necessary measures to ensure that this will not damage the piping.

Naturally, Almona and Almona STABI system pipes are not immune from thermal expansion, and so this must be carefully evaluated during design and installation.

First, it is important to distinguish between the two alternative installationmodes:

- installation under concrete- installation externally (visible)

In the first case, the effect of the expansion is negligible, since the material is able to absorb it itself and no special measures are required.

On the other hand, when pipes are installed outside the walls and exposed to considerable variations in temperature, it is essential to allow for the thermal expansion by proceeding as described hereafter.

Chapter 01


Calculating theexpansion

EXAMPLE 1:Expansion

EXAMPLE 2:Contraction

The variation in length ΔL of a Almona pipe further to a temperature varia-tion can be calculated using the following formula:

ΔL = α • L • ΔTwhere:ΔL = variation in pipe length (mm)α = linear expansion coefficient of the material, which for Almona is 0.15 mm/m°C, while for Almona STABI pipe it is 0.06 mm/m°CL = length of the pipe section free to expand (m)ΔT = difference in temperature between the time of installation and the operating temperature (°C).

L = 6 m;Tm = 20°C (installation temperature);Tmax = 75°C (maximum operating temperature);

from which we obtain

ΔL = α • L • ΔT = 0.15 • 6 • 55 = 49.5 mm (Almona pipe)ΔL = α’ • L • ΔT = 0.06 • 6 • 55 = 19.8 mm (Almona STBAI)

L = 6 m;Tm = 30°C (installation temperature);Tmin = 5°C (minimum operating temperature, e.g. air-con ditioning);

from which we obtain

ΔL = α • L • ΔT = 0.15 • 6 • (-25) = -22.5 mm (Almona pipe)ΔL = α’ • L • ΔT = 0.06 • 6 • (-25) = -9.0 mm ( Almona STABI)

In this case, the pipe expands, increasing its initial length.

In this case, the pipe expands, increasing its initial length.

22 23


Calculating of ΔL inrelation to ΔT, per

metre of pipe

The parameter ΔL can also be calculated using the graph shown below.

EXAMPLE 2:Relating to the graph

ΔT = 50°C with Tm = 20° C on installation Tmax = 70° C max.operating temp.

ΔL = a) 7.5 mm for Almona pipe b) 3 mm for Almona STABI pipe

these values are multiplied by the total length of the pipe to obtain the total expansion value.

______ = Almona pipe α = 0.15 mm/m °C- - - - - - = Almona STABI pipe α’ = 0.06 mm/m °C

ΔT (°

C)

ΔL (mm/m)

Chapter 01


INSTALLATIONTECHNIQUE WHEN

THERMALEXPANSION IS

PRESENT

Fixed and slidingpoints

Fixed points

Example ofa fixed point

Once the variation in length of the piping has been calculated, the neces-sary measures must be taken to ensure that its effects do not cause prob-lems for the piping itself. The following procedures may be used:

- provision of fixed and sliding points;- compensation with expansion arms.

These are the fixtures which secure the piping to the masonry structureof the building, totally or partially preventing the movements generated by thermal expansion.

Fixed points prevent pipes from moving, and so must provide a rigid con-nection between the installation on the one hand and the masonry on the other.

They are constructed using rigid collars, consisting of a gripping element,generally metallic, lined with rubber on the pipe side, and a component for fixing to the wall on the other side. Naturally the part in rubber (or in another similar material) is intended to prevent dangerous cutting of the surface of the pipe.

Fixed points must normally be positioned where the system changes direc-tion (branches, elbows, etc.) to ensure that the expansion forces are not dis-charged in these points. In al cases, a fixed supporting point should always be provided next to any joint in the pipe created using a coupling or any other welded fitting.

Obviously, the fixed points limit the length of the sections of pipe free to expand, and thus reduce the relative ΔL value.

fitting

connection to the wall

fixedpoint

fixed point

Almonapipe

24 25


Sliding points allow the pipe to move axially in both directions. They therefore have to be positioned well away from joints made using pipe fittings, on a free length of the pipe’s surface. The collar which forms the sliding support point must be absolutely free from parts which might damage the outside surface of the pipe.

Sliding points also provide support and ensure (provided enough of them are installed) that the pipe remains straight in spite of thermal stresses.

See “stirrup distances”.

Sliding Points

Example ofsliding point

The stirrupdistances

To allow correct installation of Almona and Almona STABI system pipes on the outside of walls, the following is the graph used to calculate the stirrup distances between points. These distances remain the same regardless of whether the pipes are horizontal or vertical.

When Almona STABI pipes are used, the reduced expansion of these pipes allows the distances between points to be increased.

connection to wall permitted axial travel

slidingpoint

Almonapipe

STIR

RU

P D

ISTA

NC

ES in

cm

PIPE EXTERNAL DIAMETER in mm

Chapter 01


Compensatingusing expansion

arms

With this technique, the pipe run is designed to allow any expansion to be ab-sorbed. To ensure this, expansion arms, where the pipe is able to expand in case of thermal stresses, are installed at points where the direction changes (elbows, tees, etc.).

The specifications of these expansion arms are calculated using the following formula:

LS = F • √ d • ΔLwhere:LS = expansion arm lenght (mm)F = constant of the material (for PP = 30)d = pipe outside diameter (mm)ΔL = pipe length variation (mm)

EXAMPLE 1:

Nota: when Almona STABI pipe is used in the same conditions and with the same F value, the expansion arm will be shorter than for Almona. This is because of the lower thermal expansion coefficient, which means that the increase in pipe length is reduced.

To calculate the expansion arm length for a section of Almona pipe

where:d = 40 mm (outside diamter);L = 6 m;ΔT = 55°C

Previous calculations have given a ΔL = 49.5 mmTherefore:

LS = F • √ d • ΔL = 30 • √ (40 • 49.5) = 1335 mm

L

LS

FP

FP LP

ΔLExample of

expansion arm

26 27


Tem

per

atu

re d

iffer

ence

in °C

Length variation ΔL in mm

Min

imu

m e

xpan

sio

n a

rm le

ng

th in

mm

Calculatingexpansion arm

length using graphs(Almona System)


DIAGRAMEXAMPLES

The following are some examples of correct installation of Almona system on the outside of walls, with the various techniques adopted to allow for the ther-mal expansion of the material.

L

FP FP

FP

LP

L

FP

FP

LS LS

LS

L�L

�L

�L

28 29

Fixed point at baseof vertical pipe section

Length absorption with compensation loopin a straight section of pipe

Fixed point in the middleof the vertical section

Technical Guidelines06 Chapter 06 Processing 07Chapter 07

EQUIPMENT

MAKING WELDS

Welding using thewelding machine

The following specific equipment is required for the construction ofinstallations using Almona system components:

Almona system elements can be welded together using the welding machine or an electric welder and suitable electric couplings.

Welds are made by first heating the outside surface of the pipe and the inside surface of the fitting simultaneously, on the welding machine die. The pipe is then inserted in the fitting, to create a socket joint.

3 size welding machine pipe cutter

PRISMA bench welder

30 31

Processing07 Chapter 07

1) Preparing the welding machineFit the welding machine with the dies of the diameters to be processed and connect the plug to the 220 V power supply socket. Wait until the green light on the machine goes out, indicating that the welding machine has reached the working temperature.

2) Preparing the elements for weldingCut the pipe using the cutting tool provided and check that the parts to be connected are clean. Otherwise, clean the surfaces to be mated during welding with a clean cloth.

3) Making the weldAfter checking that the welding machine is ready, fit the pipe and the fit-ting simultaneously into the dies of the corresponding size, following the working conditions stated in the table in page 32. After heating, remove the elements from the dies and make the joint.

Sequence of operations:

Processing 07Chapter 07

Processing timetable

Diameter Dmm

1416182025324050637590

Heatingtime

seconds

555578

1218253030

Workingtime

seconds

444446668

1010

Coolingtime

minutes

22223444688

N.B.:The heating time is calculated from the moment when the pipe and fitting make contact on the dies.

PROCESSINGAlomna STABI

Making a joint with thewelding machine

Almona STABI can be processed in the same way as Almona, but the outer layer of PP-R and the underlying aluminium sheet must be removed. As an alterna-tive, the special self-adapting unions can be used.

Sequence of operations

1) Preparing the welding machine and cutting the pipe These operations take place as described previously for the Almona system.

2) Scraping the pipeThis operation, carried out on the end of the pipe to be welded, is performed using a special scraping tool by hand, or mechanically with the aid of a drill.

To ensure that the scraper blade only removes the aluminium and outer PP-R cladding, it is very important to adjust the blade using the screw provided, with the aid of the setting template.

32 33


When scraping, it is also essential to take care not to reduce the thickness of the PP-R pipe.

3) Making the weldThe weld is then made following the procedures described previously.

Adjusting the blade

Scraping by hand Scraping mechanically

USING THE HOLEREPAIRING DIE

If a hole is accidentally made in the pipe (with a drill bit, for example) and if the hole is in only one side of the pipe, it can be repaired using the hole repairing die, bearing in mind that the pipe size must be compatible with the die diameter.

The repair procedure is as follows:

- Clean and dry the part to be repaired.- Fit the male part of the hole repairing die into the hole; it must melt the surface to be welded. The die has a metal bush which can be adjusted by the operator to suit the pipe thickness, to ensure that the die cannot be in-serted too far and melt the other side of the pipe. To make this adjustment, undo the screw which fixes the bush and then move it along the die.

- At the same time as the male part of the die melts the area around the hole, the female part melts the repair bar usually supplied with the die.


- Once the heating time has passed (5 sec.) the repair bar must be inserted in the hole. When this operation is complete, wait for everything to cool and then cut off the excess part of the repair bar. If the diameter of the hole to be repaired is greater than that of the die, or both sides of the pipe are punctured, the piece of pipe must be cut out and the repair made using normal pipe fit-tings, or more easily using the electric couplings.

Hole in pipe

Welding operation

Simultaneous heating of the hole area and repair bar

Cutting off theexcess repair bar

34 35

INSTRUCTIONSFOR using Almona

Saddle

1) Preparing the pipe surface.

2) Procedure for borning the pipe.

3) Dies for polyfuse welding and fusion procedure.

The use of a saddle fitting enables derivations to be applied to previouslyinstalled tracts of piping whose diameter is larger than the requirements of the new fitting tracts to be made.

To carry out the required welding, it is imperative that the appropriate dies for the polyfuse welding are used. These dies, thanks to their particular ge-ometry allow for the fusion of concave or convex surfaces to be welded increasing the surface area to be fused.

The section to be affected by the deviation must be cleaned of all tracesof dirt. The surface to be welded must be scraped, using an appropriate scraper.The scraping process is essential for removing the external film of the pipe, that over time, has oxidized and which will prevent a good weld from being achieved.

Boring the pipe can be done using a standard drill tip.The size of this tip must always be 1 mm smaller than the size of the deriva-tion to be made (see table below).

Make the hole whilst working, taking care not to damage the wallopposite.

With normal polyfuse welding the dies must be mounted bearing the fol-lowing in mind:The concave element acts on the external surface of the pipe on which the derivations are to be executed and on the hole made.The convex element acts on the fitting made for the derivation.


3) Welding operation.

3) Cooling.

3) Estimated times and tip diameters

After verifying that the polyfuse welding device has reached working con-ditions, indicated by the green indicator light going off, at the same time exert a light pressure until the surfaces of the dies fit perfectly together with those of the pipe and fitting. The time required for this operations is shown in the table, bearing in mind that the heating time indicated must be calculated from the moment the surfaces come into contact with each other. Once the set period of time has elapsed, the seams of the fused material will appear.

Once the heating time has elapsed, the dies must be removed from the ele-ments to be joined and, exerting an even pressure, bring the pipe-fitting elements together within the time indicated in the table, keeping them pressed for at least an additional 30 seconds.

At the end of the welding operation, avoid either mechanical or heat stress to the joint for the time of cooling which must take place at ambient tem-perature.


Derivationdiameter

mm

202532

Heatingtime sec

578

Workingtime sec

446

Coolingtime sec

120180240

Drill tipmm

192431

36 37

Resistance To Chemicals08 Chapter 08

TABLE OF CHEMICALAGENTS RESISTANCE OF POLYPROPYLENE

PPR-C Type 3

PPR-C, Type 3 polypropylene has high resistance to a large number of ag-gressive substances, and is therefore particularly suitable for special appli-cations.

The table below provides the resistance of PPR-C, Type 3 to various chemi-cals. The table refers to the raw material only, not subjected to outside mechanical stresses and at atmospheric pressure. For transport of com-bustible fluids, comply with any legal regulations in force.

Take care when the installation is to carry water with chlorine content over the limits permitted by law and/or contains elements which induce oxida-tion in general.

SYMBOLS

+ = highly resistantΟ = resistantΟ = fairly resistantΘ = scarcely resistant- = non resistant

sol.sat. = saturated solutiont = all %s = it loses colour

+

Examined substances Concentration Temperature (°C) % 20 60 100

Acetone 100 + ΟAcid(see acid name) -Acetic, acid 100 + +Acetic, anhydride 100 +Alum sol.sat. + +Aluminium, salt t + + +Amber, acid sol.sat. + +Ammonia, gas 100 + +Ammonia, liquid conc. + +Ammonium, acetate t + + +Ammonium, nitrate t + + +Ammonium, phosphate t + + +Ammonium, sulphate t + + +Ammonium, carbonate t + + +Aniline 100 + ΟAntifreeze - + +Apple juice - + +

+

Examined substances Concentration Temperature (°C)%

20 60 100

Asphalt - + ΟAspirin® - +

Barium, chloride t + + +Battery, acid - + +Beer - +Benzaldheyde 100 +Benzaldheyde, liquid sol.sat. (0.3) +Benzoid, acid 100 + +Benzol 100 Θ -Benzoyl chloride 100 Θ -Borax sol.sat. + +Boric, acid 100 + +Bromine, liquid 100 -Bromine, dry steam high conc. - -Bromine, dry steam low conc. Ο -Butane, liquid 100 +Butane gas 100 + +Butanol 100 +Butter 100 + +Butyl, alcohol - + +Butyl, gas 100 ⊕

Calcium, chloride sol.sat. + + +Calcium, nitrate sol.sat. + +Carbon, tetracheoride 100 Θ -Chlorine, liquid 100 -Chlorine, dry gas 100 - - -Chlorine, wet gas 100 Ο - -Chloroform 10 Θ -Chlorosulfonic, acid 100 - - -Chromic, acid - + ΟChromium, salt sol.sat. + +Chromium plating bath - + +Chromium trioxide sol.sat. + -Coca Cola® - +Cacao - + + ⊕Coffee - + + +Copper, salt sol.sat. + + +Copper, nitrate 30% + + +Cream - +Cresol 100 + ΟCyclohexan 100 +Cyclohexanol 100 + +

Diesel oil - + ΟDiethyl ether 100 ΟDimenthyl formamide 100 +Diossano 100 + Ο -Dixan liquid - + + +


20 60 100

Ethyl, acetate 100 Ο ΟEthyl, alcohol 100 +Ethyl, benzol 100 Ο -Ethyl, chloride 100 -Ethyl, hexanol 100 +

Flour - +Formaldehyde 40 + +Formic, acid - +Fruit juice - + +

Gelatine - + + ⊕Gin 40 +Glycerine 100 + +Glycerine, liquid low conc. + + +Glycolic, acid 100 + +Glucose - + + +

Heptane 100 ⊕ ΟHexane 100 + ΟHydrocloric, acid high conc. + +Hydrocloric, acid low conc. + +Hydrocloric, ammonium t + + +Hydrogen peroxide 3 + + +Hydrogen peroxide 10 + +

Iodine, tincture - +s

Iron, salt sol.sat. + + +Iso octane 100 + ΟIso propylic alcohol 100 + +

Jam - + + ⊕

Lactic, acid - + +Lanolin - + ΟLemonades - +Lemon juice - + +Limestone - + + +Liquors t +

Magnesium, salt sol.sat. + + +Margarine - + +Mayonnaise - +Menthol - +Mercury 100 + +Methanol 100 + +

Resistance To Chemicals 08Chapter 08

38 39

Resistance To Chemicals08 Chapter 08


20 60 100

Methyl chloride 100 ΟMethyl-ethyl-ketone 100 + ΟMilch - + + ⊕Muriatic, acid 10 + +Mustard - + +Naphta 100 +Naphtalene, decahydro 100 Θ - -Naphtalene 100 +Naphtalene, trachloride 100 Ο -Nitric, acid 10 ⊕ - -Nickel, salt sol.sat. + +Nitrobenzene 100 ⊕ Ο

Octane - + ΟOil:Oil ether 100 + ΟOil of turpenthine - Ο -Oleic, acid 100 +Oleum t - - -Orange, juice - + +Ozone <0.5 ppm. ⊕ ΘAlmond oil - + +Animal oil - + ⊕ ΘCamphor oil - + +Coconut oil - + ⊕Cod oil - +Cloves oil - +Combustible oil - + ΟLinseed oil - + +Mais oil - + ΟMotor oil - + ΟOlive oil - + +Oxalic oil - + + +Paraffin oil - + Ο -Peanut oil - + ⊕ ΘPeppermint oil - + +Rosin oil - + ⊕Silicone oil - + ⊕

Paraffin 100 + +Petroleum 100 +Pepper - + +Sodium perborate sol.sat.(1.4) + +Perfume - +Phenol sol.sat. + +Phosphurus, acid sol.sat. + +Phosphurus, oxichloride 100 Ο -Photographic acid - + +


20 60 100

Potassium carbonate sol.sat. + +Potassium chlorate sol.sat. (7.3) + +Potassium chlorite sol.sat. + + +Potassium chromate sol.sat. (12) + + +Potassium iodide sal.sat. + +Potassium nitrate sol.sat. + +Potassium permangan. sol.sat. (6.4) + ⊕Potassium persulfate sol.sat. (0.5) +Potassium sulfate sol.sat. + + +Propane gas 100 + +Propane, liquid 100 +Pyridine 100 + Ο

Quinine - +

Salt dry - + +Silver, salt sol.sat. + +Soap liquid 10 + + +Soda caustic 100 + +Sodium bicarbonate sol.sat. + + + Sodium carbonate sol.sat. + +Sodium chlorate 25 + +Sodium chloride sol.sat. + + +Sodium chlorite 5 +Sodium hypochlorite 5 + +Sodium nitrate sol.sat. + +Sodium phosphate sol.sat. + + +Sodium sulphate sol.sat. + + +Sodium sulphite sol.sat. + +Sodium thiosulphate sol.sat. + +Starch t + +Sulphure, carbon - Ο

Tea - + + ⊕Tetra-chlorine-ethylen 100 Ο -Tetraidrophurano 100 Ο -Thiophene 100 Ο -Tin II chloride sol.sat. + +Toothpaste - + +Trichlorethylene 100 Ο ΘTricresylphosphate - +Turpentine 100 -

Urea sol.sat. + +

Vanilla - + +Vaseline - + ΟVinegar - + +

Resistance To Chemicals 08Chapter 08

Examined substances Concentration Temperature (°C) % 20 60 100

Water:Boric water sol.sat. (4.9) + +Brackish water - + + +Bleach 12.5% chlorine Ο ΟDistilled water 100 + + +Drinking water - + + +Lake water - + + +Soda water - +Chloric water sol.sat. Ο -Wax - + Ο

Xylene 100 Ο -

40 41

Precautions09 Chapter 09

Foreword

OPERATINGCONDITIONS

ULTRAVIOLETRAYS

Use of a system of plastic pipes and fittings offers a series of advantages from various points of view, as fully described in “Main features of Almona system”, Chapter 2 (page 7). However, in order to enjoy all the benefits of these properties, the user must be well aware of every aspect relating to the product to be used. To assist Almona system user, we have prepared a number of important rec-ommendations, set out below.

The use of Almona and Almona STABI in the stated operating conditions creates absolutely no problems for the material.However, exceeding the limit conditions for use may impair the product’sresistance.All precautions must therefore be taken to ensure that this does not occur; this not only protects the system itself, but frequently also its user.

Almona pipe must never be installed or stored where it is subject to direct ultraviolet rays (sunlight or neon lights). Ultraviolet ray causes ageing in the material, leading to loss of its initial chemicalphysical char-acteristics.

Almona STABI pipes can be installed on the outside of walls, but on the inside of the building, while installations with direct exposure to U.V. ra-diation are not recommended, since its effects gradually break down first the external PP-R film, then the aluminium sheet and finally the pipe below.

Precautions 09Chapter 09

HANDLING PIPES

FORMATIONOF ICE

During handling, storage and use on site, bundles of pipes or individual lengths must be protected against excessive external stresses, such as shaking, knocks, hammer blows, etc. This is even more important as the ambient temperature falls, since at low temperatures the material is more rigid and has a less elastic response to outside stresses.

When water passes from the liquid to the solid state (ice), its volume increases to an extent which may generate stresses inside the installation which the ma-terial is unable to withstand. The appropriate measures must be taken to ensure that this does not occur, draining the system completely after testing if there is the risk of freezing.

42 43

Precautions09 Chapter 09

CONTACT WITHSHARP EDGED

BODIES

BENDING

Any contact with sharp edged bodies (such as brick shards) causes cuts on the outside of the pipe which might lead to breakages later. Care must be taken to ensure that this does not occur during storage and installation, and any scratched or scored pipes must not be used.

To bend Almona system pipes, proceed as follows:

- for very wide radius curves, the pipe may be bent cold

- for radii close to, but not below, 8 times the diameter of the pipeconcerned, the pipe should be heated with hot air.

- flames must not be used.

Rmin ≥ 8 D

Precautions 09Chapter 09

FITTINGS WITHMETAL INSERT

CUTTING PIPES

WELDING

When using Almona system fittings with threaded female metal insert, do not apply excessive tightening torques when connecting to male fittings. Also, take care not to place too much hemp between the parts to be assembled. Teflon is to be preferred in all cases. In addition, check that the male part is long enough for a proper connection; generally, at least one turn of thread should be left free.

If installation requirements mean that a Almona system fitting must be con-nected to an iron pipe or union, the connection should be made using Almona fittings with male thread.

Use tools capable of making a burr-free cut, perpendicular to the pipe’s axis.

The parts for welding must always be thoroughly clean and the welding ma-chine’s thermostat must indicate that it has reached the operating temperature. No twisting forces must be applied to the connected parts, either during or after welding. See page 30, “Welding with the welding machine”.

44 45

Testing The Installation10 Chapter 10

PROCEDURE Testing plays a fundamental role in ensuring that the installation operatescorrectly. Testing allows the installation technician to check that the system is not leaking at any point, for any reason.

The operations required are:

- Visual check on the pipes and fittingsThis ensures that the pipes and fittings have been installed correctly and that no parts have been accidentally damaged by sharp-edged bodies.

- Tightness test This is carried out with the system still directly accessible; it is filled with water at ambient temperature, taking care to vent the air present.

After filling, after sealing the system, it is put under pressure for 24 h with the following pressure value:

TESTING PRESSURE = PN (pipe nominal pressure)

For the Almona system, PN = 20 bar.After the specified time, a visual inspection allows the installation techni-cian to check whether there are any leakage points.

Prototype Water System

46

Prototype System: Mounting Columns

ALMONA PP-R PIPES AND FITTINGS

Product Range

48 49

Almona Product Range

CODE

10 30210 30410 30610 30810 31010 31210 31410 31610 318

SIZE

20 x 3,425 x 4,232 x 5,440 x 6,750 x 8,4

63 x 10,575 x 12,590 x 15,0

110 x 18,4

UNIT PRICE,

PIPE PN 20أنبوب ضغط 20 بار

CODE SIZE UNIT PRICE,

STABI PIPE PN 25أنبوب عازل 25 بار

10 33210 33410 33610 33810 34010 342

202532405063


SOCKETجلبة

2025324050637590

10 40210 40410 40610 40810 41010 41210 41410 41610 418 110


REDUCTIONنقاص

10 504 25-2010 506 32-2010 508 32-2510 512 40-2510 514 40-3210 520 50-3210 522 50-4010 528 63-4010 530 63-5010 532 75-5010 534 75-6310 536 90-6310 538 90-7510 539 110-7510 540 110-90


END CAPسدة لحام

10 802 2010 804 2510 806 3210 808 4010 810 5010 812 6310 814 7510 816 9010 818 110


CROSSOVERكوع جمل

202532

10 90210 90410 90610 909 40

15years warranty

سنـــــــــــة ضمان

Almona Product Range

15years warrantyسنـــــــــــة ضمان


END PIECEسدة بسن

10 100 2010 102 25


CLAMP PPRقاعدة تركيب مفرده

12 212 2012 213 2212 214 2512 215 2712 217 40


DOUBLE CLAMP PPRقاعدة تركيب مزدوجه

12 228 2012 230 2512 232 32


ELBOW 90°كوع

10 60210 60410 60610 60810 61010 61210 61410 61610 618

2025324050637590

110


ELBOW 45°كوع فتح

10 624 2010 626 2510 628 3210 630 4010 632 5010 634 63


T-PIECEقسام

10 702 2010 704 2510 706 3210 708 4010 710 5010 712 6310 714 7510 716 9010 718 110

11 Chapter 11 11Chapter 11

50 51

15years warranty



REDUCTION-Tقسام نقاص

10 734 20-25-2010 736 25-20-2010 738 25-20-2510 740 25-25-2010 748 32-20-2010 749 32-20-2510 750 32-20-3210 752 32-25-2510 754 32-25-2010 756 32-25-3210 758 40-20-4010 761 40-25-4010 762 40-32-4010 763 50-25-5010 764 50-32-50


NIPPLE ROUND FEMALEجلبة سن داخلي

11 202 20 1/2"11 204 20 3/4"11 206 25 3/4"11 208 25 1/2"11 209 32 3/4"11 210 32 1"


NIPPLE HEXAGON FEMALEجلبة سن داخلي سداسية

11 211 32 1"11 212 40 1 1/4"11 214 50 1 1/2"11 216 63 2"11 218 75 2 1/2"11 220 90 3"11 222 110 4"


NIPPLE ROUND MALEجلبة سن خارجي

11 402 20 1/2"11 404 20 3/4"11 406 25 3/4"11 408 25 1/2"11 409 32 3/4"11 410 32 1"


NIPPLE HEXAGON MALEجلبة سن خارجي سداسية

11 412 40 1 1/4"11 414 50 1 1/2"11 416 63 2"11 418 75 2 1/2"11 420 90 3"11 422 110 4"


FLUSH WALL DISKكوع سن داخلي مع مثبت

11 102 20 1/2"11 103 25 1/2"11 105 25 3/4"


ADAPTOR MALEشد وصل سن خارجي

11 502 20 1/2"11 504 25 3/4"11 508 32 1"11 516 40 1 1/4"11 518 50 1 1/2"11 520 63 2"11 522 75 2 1/2"

15years warrantyسنـــــــــــة ضمان


ADAPTOR FEMALEشد وصل سن داخلي

11 302 20 1/2"11 304 25 3/4"11 306 32 1"11 314 40 1 1/4"11 316 50 1 1/2"11 318 63 2"11 320 75 2 1/2"


ELBOW 90° FEMALEكوع سن داخلي

11 602 20 1/2"11 604 20 3/4"11 606 25 1/2"11 608 25 3/4"11 610 32 3/4"11 612 32 1"


ELBOW 90° MALEكوع سن خارجي

11 616 20 1/2"11 618 20 3/4"11 620 25 1/2"11 622 25 3/4"11 624 32 3/4"11 626 32 1"


T-PIECE FEMALEقسام سن داخلي

11 702 20 1/2"11 704 20 3/4"11 706 25 1/2"11 708 25 3/4"11 710 32 3/4"11 712 32 1"


T-PIECE MALEقسام سن خارجي

11 716 20 1/2"11 717 20 3/4"11 718 25 1/2"11 720 25 3/4"11 721 32 3/4"11 722 32 1"

Almona Product Range Almona Product Range11 Chapter 11 11Chapter 11

52

15years warranty



SINGLE WELDING MACHINEطقم ماكينة لحام

12 410


BUTTERFLY VALVEمحبس سداسي

11 800 2011 802 2511 803 32


CHROME COATED VALVEwith long triangular leverمحبس كروم

11 805 2011 807 2511 809 32


SPHERICAL VALVEمحبس سكين

11 826 2011 828 2511 830 3211 832 4011 834 5011 836 63

15سنة ضمان15 Years Warranty

جودة عاليةHigh Quality

صناعة سعوديةMade in Saudi Arabia

Almona Product Range11 Chapter 11

54 55

notes notes

...QUALITY IS OUR FIRST PRIORITY

Almona Plastic Products

Tel: (966) 1 4102327 - (966) 1 4102326Fax: (966) 1 4871236

P.O.Box: 270736 Riyadh: 11352Kingdom of Saudi Arabia

[email protected]

Almona is the first choice for customers across Saudi Arabia,with a product range from 20mm to 125mm pipes and its accesso-ries. The pipes comply with the Saudi (SASO) and German (DIN) Standard.

Butterfly valveMADE INSAUDI ARABIA

Documents

Ppr Techincal Data Sheet