Design-Flow IPS Industrial HDPE

PE family

Design-Flow IPS Industrial HDPE ushers in a new generation piping system designed specifically for broad-based applications. The dynamic combination of specifiable pipe, fittings, valves, and advanced fusion technologies integrates well into the industrial process industry.

Due to its robust mechanical strength, high impact resistance (including very low temperatures) and excellent chemical resistance, Design-Flow IPS Industrial HDPE is the best all-around product for your industrial process application. In addition to quality 4710/PE100 materials Georg Fischer Piping Systems offers state of the art Contact Butt fusion machines with controlled parameters and fast fusion times as well as proven Electrofusion technology all combining repeatable weld joints and confidence in weld quality.


Product Overview

Technical Data:

Size Range:

  • 2" - 36" IPS

Pressure Rating:

  • SDR 9 (250 PSI) @ 73°F
  • SDR 11 (200 PSI) @ 73°F
  • SDR 17 (130 PSI) @ 73°F

Operating Temperature:

-50°C to 60°C (-58°F to 140°F)

Joining Technology:

  • IR Plus Fusion
  • Butt Fusion
  • Electrofusion

Standard Ratings:

  • ASTM D638
  • ASTM D2837
  • ASTM D3035
  • NSF 61

Material:

  • Polyethylene (PE)

Fields of Application:

  • Chilled Water
  • Process Cooling Water
  • Industrial Water Treatment
  • Bulk Water Distribution
  • Pharmaceutical Manufacturing
  • Pulp and Paper Manufacturing
  • HVAC
  • Power Generation
  • Semiconductor

Advantages:

  • Robust mechanical strength
  • High impact resistance at very low temperatures
  • Good abrasion resistance
  • High chemical resistance
  • Ease of installation
  • Low weight
  • Excellent cost to performance ratio
  • Safely and securely joined by heat fusion
  • Corrosion-resistant

Specification

1.0 Scope

This specification covers the requirements for the GF Piping Systems (PE) IPS/DIPS Piping Systems intended for a wide range of industrial applications including water, wastewater and effluent treatment as well as a wide range of chemical applications. The components of the ecoFIT IPS (PE) piping system are in accordance with the following standards.

2.0 Basic System Data

2.1 Material Specification for Design Flow (PE) IPS/DIPS Pipe & Fittings

  1. All Design Flow (PE) IPS/DIPS pipe shall be manufactured from a PE100/4710 high density copolymer resin meeting the requirements of ASTM D3350 and D3035. Pipe shall be manufactured to SDR 11 or SDR 17 dimensions with a pressure rating of 200 psi or 130 psi respectively when measured at 68°F. The material shall achieve a minimum tensile strength of 3600 psi when tested at 73°F according to ASTM D 638. The material shall also comply with guidelines approved by the U.S. Food and Drug Administration (FDA) as specified in the Code of Federal Regulations (CFR), Title 21, Section 177.160 for basic polyethylene and Section 178.3297 “colorants for polymers” for pigments suitable for contact with foodstuff, pharmaceutical use and potable water. Piping materials shall conform to the requirements of ASTM D2837 for hydrostatic design basis. Industrial grade pipe shall be supplied capped off at the extruder and supplied in 20ft lengths.

  2. All Design Flow (PE) IPS/DIPS fittings shall be manufactured from a PE100/4710 high density copolymer resin meeting the requirements of ASTM D3350. Fittings in sizes through 42” shall be butt fusion type, suitable for heat fusion joining. All fittings through 42” shall be compatible with manual and contact butt fusion machines. Fittings shall be manufactured to SDR 11 or SDR 17 dimensions with a pressure rating of 200 psi or 130 psi respectively when measured at 68°F.

  3. All components of the pipe and fitting system shall conform to the following applicable ASTM Standards, D3035, D638, D2837, shall conform to NSF Standard 61 for potable water applications and shall conform to FDA CFR 21 177.160 and 178.3297. All pipes shall be marked with manufacturers name, pipe size, SDR rating, type, quality control mark and pressure rating information. Fittings shall be embossed with a permanent identification during the production process to ensure traceability. All flanged connections shall utilize flange rings with bolt patterns to accommodate ANSI bolt circles. All threaded connections shall have pipe threads designed in accordance with the requirements of ASTM D2464, which references ANSI B1.20.1 (formerly B2.1) for tapered pipe threads (NPT).

  4. Pipe, valves, fittings and joining equipment shall be supplied by a single source provider to insure compatibility of system components and to assure proper joint integrity.

  5. Acceptable material shall be GF Design Flow Industrial Polyethylene as manufactured by Georg Fischer Central Plastics.

  6. Pipe and fittings shall be manufactured by an FM approved and listed facility.

 

3.0 Material Specification for Valves

3.1 Butterfly Valves

3.1.1 Plastic Butterfly Valves

  1. Butterfly valves suitable for the Design Flow (PE) System of GF Piping Systems are made from PP-H, ABS, or PVC material.

  2. All butterfly valves, sizes 2”–12”, shall be GF Piping Systems Type 567/578 wafer/lug type with a double eccentric disc design manufactured by GF Piping Systems in accordance with EN ISO 16136. Seals shall be available in EPDM, FPM and PTFE/FPM. The lever handle shall be lockable in increments of 5 degrees. There shall always be six teeth engaged between the ratchet and the index plate to ensure accurate and safe positioning of the lever. There shall be the option of fine adjustment by use of a specific hand lever, allowing the disc to be exposed at any angle between 0° and 90°. As an option, the hand lever shall be lockable. The hand lever shall be manufactured of high strength PPGF (polypropylene glass fiber reinforced). The option of an integrated electric position indicator shall be available. As an option the valves can be actuated by gear box with hand wheel. The electric position indicator shall be integrated into the mounting flange. Butterfly valves shall have low actuation torque to enable easy operation. All butterfly valves Type 567/578 manufactured by GF Piping Systems are designed for a nominal pressure rate of 10 bar. All butterfly valves Type 563 are designed for a nominal pressure rate of 4 bar.

3.1.1.1 Electrically Actuated Butterfly Valves

  1. Electric actuators shall be GF Piping Systems Types EA31 or EA42 dependent on valve size. They shall be manufactured by GF Piping Systems in accordance with EN 61010-1, as per the above specifications. Actuator housing shall be made of PPGF (polypropylene glass fiber reinforced), flame retardant and feature external stainless steel screws. All electric actuators shall have an integrated emergency manual override and integrated optical position indication.

  2. All electric actuator types shall have the following accessories available:
    • Fail-safe unit
    • Heating element
    • Cycle extension, monitoring, and counting
    • Motor current monitoring
    • Position signalization
    • Positioner Type PE25
    • Limit switch kits Ag-Ni, Au, NPN, PNP
    • Manual override
    • AS-Interface Plug Module

3.1.1.2 Pneumatically Actuated Butterfly Valves

  1. Pneumatic actuators shall be GF Piping Systems Types PA 35 (sizes 2” and 2½), PA40 (size 3” only), PA45 (size 4”), PA55 (size 6”), PA60, PA65. They shall be supplied by GF Piping Systems. Pneumatic actuators shall be available as fail safe close, fail safe open and double acting and have an integrated optical position indication. Actuator housing shall be made of hardened anodized aluminum. Actuators shall contain integrated Namur interfaces for the easy mounting of positioners, limit switches and accessories. All pneumatically actuated butterfly valves shall have the following accessories available:

    • Solenoid pilot valve remote or direct mounted in voltages 24VDC/AC, 110VAC, 230VAC
    • Positioner Type DSR 500-3
    • Feedback with following limit switches Ag-Ni, Au, NPN, PNP, NAMUR
    • Stroke limiter & emergency manual override
    • ASI-controller

4.0 Material Specification for Design Flow (PE) IPS Ball Valves

Ball valves consist of a valve body out of PP-H, ABS, or PVC combined with connection parts in PE.

4.1.1 Manual Operated Ball Valves – Municipal

  1. All manual ball valves shall be manufactured by Georg Fischer Central Plastics’ from a high density polyethylene (PE100) material according to ASTM D3350 with a smooth, full bore design available in SDR 11 IPS sizes 1 ¼" through 6” as standard. The fused valve body and ends shall be constructed of bi-modal PE3408/PE4710 resin which also carries an MRS rating of 10 (PE100). The valve shall be suitable for operation in systems using a .63 design factor at pressures up to 200 psig and also meeting the requirements of ASTM D2513. The sealing element is an elastomer that is captured on the valve seat. The valve operation is 1/4 turn (clockwise open) using a 2” square drive and can be supplied with gear reduction actuation. The valve is compatible for heat fusion with like or similar PE materials including PE2406/PE2708. It is suitable for installation by butt fusion, electrofusion, mechanical jointing, and other methods. It can be supplied in various end configurations, such as flanged or pupped as needed.


4.1.2 Manual Operated Ball Valves – Industrial

  1. All Design Flow (PE) ball valves with inch sizes 2” IPS to 4” IPS, shall be Polypropylene valve body and PE100 ends Type 546 and/or 543 with true double union design manufactured by GF Piping Systems in accordance with EN ISO 16135. Incorporated into its design shall be a safety stem with a predetermined breaking point above the bottom O-ring, preventing any media leaking in the event of damage. The valve nut threads shall be buttress type to allow fast and safe radial mounting and dismounting of the valve during installation or maintenance work. Seats shall be PTFE with backing rings creating selfadjusting seals and constant operating torque. Backing rings and seals shall be EPDM or FPM. The handle shall include in its design an integrated tool for removal of the union bush. Union bushes shall have left-hand threads to prevent possible unscrewing when threaded end connectors are removed from pipe.

4.1.3 Ball Valve Accessories – Industrial

  1. A Multi-Functional Model (MFM) in PPGF equipped with internal limit switches for reliable electrical position feedback, is mounted directly between the valve body and the valve handle. This MFM is also the necessary interface for later mounting of actuators.

  2. Mounting plate in PPGF with integrated inserts for mounting on any support

  3. Lockable multi-functional handle

4.2 Material Specification for Design Flow (PE) IPS Diaphragm Valves

  1. Diaphragm valves consist of a valve body out of PP-H, ABS, or PVC.
    • Type 514 (2” true double union design with PE ends)
    • Type 517 (3” and 4” flange design)
  2. Diaphragm valves shall have EPDM or PTFE/EPDM backed diaphragm type seal configurations and EPDM backing or FPM O-ring seals.
  3. Valves shall be Type 514 Diaphragm Valves as manufactured by GF Piping Systems.
  4. Diaphragm valves and shall be rated for 150 psi when measured at 68°F. Top works must include integral lock out device on handle. Pneumatic valve actuators, if required shall be supplied by GF Piping Systems to ensure proper system operation.

5.0 Welding and Assembly

  1. All electrofusion fittings shall be manufactured under strict quality requirements as stated by the manufacturer such as ISO9001 or equivalent. All electrofusion fittings must be packaged to ensure cleanliness and protection from contamination.

  2. All butt fusion fittings and valves shall also be manufactured with laying lengths designed for use with electrofusion capabilities with and for butt fusion machines according to DVS 2207-11 including CNC control parameters from GF Piping Systems or conventional butt as per AWWA or ASTM.

  3. Optional IR Plus fusion machines, IR63 Plus, IR225 Plus use non-contact radiant heating. The cooling time for is calculated 36 Industrial PE Technical Handbook 2016 on the basis of ambient temperature and the bead surface temperature. To increase the cooling capacity, an additional cooling fan is included in the IR-225 Plus.

  4. Only authorized and certified welders by GF Piping Systems are allowed to perform fusion on GF approved equipment.

  5. The welding and the installation should be in accordance with GF Piping Systems guidelines.

6.0 Quality

6.1 Production Conditions

Pipes, fittings, valves and accessories shall be manufactured in an environment equivalent to, or meeting the requirements of a

Quality Assurance System such as ISO 9001.

6.2 Uniformity

Pipes, fittings, valves and welding machines shall be supplied from one manufacturer, GF Piping Systems to ensure correct and

proper jointing between components and uniform chemical and physical properties of the piping system.

6.3 Handling of Material

  1. Material shall be stored in original packaging and protected from environmental damage until installation.

  2. Pipe shall be supported sufficiently to prevent sagging. Care shall be taken not to gouge or otherwise notch the pipe in excess of 10% of the wall thickness.

6.4 Training, Certification and Installation

  1. Site personnel, permissible for PE piping installation, shall undergo training and certification according to manufacturer’s published guidelines prior to performing any jointing operations on site.

6.5 Testing

  1. The system shall be tested in accordance with the manufacturers’ recommendations.

  2. Following is a general test procedure for GF Piping Systems. It applies to most applications. Certain applications may require additional consideration. For further questions regarding your application, please contact your local GF representative.

    1. All pressure tests should be conducted in accordance with the appropriate building, plumbing, mechanical and safety codes for the area where the piping is being installed.

    2. When testing plastic piping systems, all tests should be conducted hydrostatically and should not exceed the pressure rating of the lowest rated component in the piping system (often a valve). Test the system at 150% of the designed operational pressure. (i.e.: If the system is designed to operate at 80PSI, then the test will be conducted at 120PSI.)

    3. When hydrostatic pressure is introduced to the system, it should be done gradually through a low point in the piping system with care taken to eliminate any entrapped air by bleeding at high points within the system. This should be done in four stages, waiting ten minutes at each stage (adding ¼ the total desired pressure at each stage).

    4. Allow one hour for system to stabilize after reaching desired pressure. After the hour, in case of pressure drop, increase pressure back to desired amount and hold for 30 minutes. If pressure drops by more than 6%, check system for leaks.

    Note: If ambient temperature changes by more than 10

    °

    F during the test, a retest may be necessary.

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