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POLSAFE

Gas Distribution System


PIPELIFE INTERNATIONAL

Pipelife International GmbH is one of the world's leading suppliers of plastic piping systems. Plastic pipes and fittings are produced in 34 Pipelife manufacturing plants in 24 countries in Europe, Asia and North America. Pipelife's head office is located in Vienna-Austria. Pipelife international is a joint venture between Solvay SA Belgium and Wienerberger AG Austria. Pipelife Nederland BV manufactures a wide range of products for all major pipe and fitting markets. The Dutch head office and main production plant are located in Enkhuizen-Holland. An important product line produced by Pipelife Nederland is the Polsafe Gas Distribution System. Pipelife in Europe

Pipelife’s core business: Water ● Water ● hot and cold ● drinking water Waste and sewage soil and waste ● sewage ●

Energy gas distribution ● electrical ● flue gas ● district heating/cooling ●

Pipelife in Asia

Power and information cable protection

Industry ● oil and gas exploitation ● petrochemical industry Agriculture ● irrigation ● land drainage

Pipelife in North America


CONTENTS Polsafe system description Polsafe technical information

4 5-6-7

Ductile PVC Rubber seals Ductile PVC pipe installation Polsafe service line installation Polsafe balloon positioning Polsafe economics

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Installation costs Maintenance costs Polsafe product range

9-10-11-12-13-14

Ductile PVC pipes Ductile PVC fittings Polsafe fittings Service line pipes and couplers Accessories

Standards

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POLSAFE

POLSAFE SYSTEM DESCRIPTION

The Polsafe Gas Distribution System is a complete range of pipes and fittings for gas distribution. Polsafe pipes and fittings are made of Ductile PVC. The Polsafe Gas Distribution System has been approved for system pressures up to 200 mBar, however higher system pressures are possible. The Polsafe Gas Distribution System is well known for its patented self-sealing gas valve and the possibility of making house connections and repairs on live distribution mains. The Polsafe Gas Distribution System consists of a complete assortment of Ductile PVC pipe, rubber ring socket couplers, other rubber ring socket fittings and spigot fittings for distribution mains, with diameters from 50 up to 315mm. For service lines a complete range of PE80 pipe and Ductile PVC tensile tight couplers is available in diameters 25 up to 40mm. A service line connection on a main Polsafe distribution line can be realised by means of a Polsafe saddle and a Polsafe saddle tee. A balloon entry on a Polsafe distribution main can be made with a Polsafe saddle and a Polsafe saddle adapter. A by-pass can be realised easily with Polsafe components. All Polsafe Gas Distribution System components are executed in yellow, RAL1024. For Polsafe Gas Distribution Systems professional saddle tapping tools and balloon positioning equipment is available. Polsafe Gas Distribution System components are Gastec QA approved. Gastec is the Dutch Centre for Gas Technology.

Polsafe stands for: ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

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high tech simplicity simple pipe installation with pipe lengths and socket couplers gas free assembly on live mains simple saddle mounting self-clamping lower saddle simple mounting of saddle tees and saddle adapters simple saddle tapping procedure removable cutter simple service line installation tensile tight connector on saddle tees tensile tight service line couplers simple balloon positioning Ductile PVC components Nitrile Butadiene Rubber (NBR) seals Gastec QA approved products

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POLSAFE TECHNICAL INFORMATION

POLSAFE

DUCTILE PVC Polsafe pipes and fittings are made of Ductile PVC. Ductile PVC is a mixture of PVC and modified PE. The modified PE gives the material a high ductility. Ductile PVC's strength and stiffness are still at a high level, sufficient to guarantee a good performance of the rubber ring socket fittings and sufficient to resist ground loads adequately. Stiffness for Ductile PVC pipe SDR41 is 3,5 kN/mm and for Ductile PVC pipe SDR33 6,0 kN/mm. Recent studies have shown that under standard installation conditions these Ductile PVC pipes will show less than 5% deflection in the long run. Due to its high ductility Ductile PVC has a higher impact resistance and is resistant to crazing and cracking initiated by aggressive constituents in the gas. Ductile PVC is insensitive to notches due to its high fracture toughness . Therefore premature catastrophic failures are very unlikely to occur. Recent studies at Gastec, the Dutch Centre for Gas Technology, have shown that Ductile PVC will not show propagating failures up to a gas pressure of more than 4 Bar.

RUBBER SEALS For the rubber ring socket fittings a special multi-lipped rubber ring has been developed, suitable to compensate long term pipe deformation. This rubber ring sealing concept has been used from the early 60's and has proved to be very successful. Rubber rings in Polsafe socket fittings and also other rubber seals in Polsafe saddles and other components are made of Nitrile Butadiene Rubber (NBR). This rubber type is very suitable for use with natural gas and gas condensate and is covered by various standards, e.g. EN682 type G.

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POLSAFE

POLSAFE TECHNICAL INFORMATION

DUCTILE PVC PIPE INSTALLATION A Polsafe Ductile PVC pipeline can be installed with just one push rod and some lubricant. The system with pipe lengths and rubber ring socket fittings is very easy to install.

POLSAFE SERVICE LINE INSTALLATION In order to make a house connection to a Ductile PVC main pipeline a Polsafe gas saddle must be mounted on the main. The lower saddle part must be positioned on the pipe first. Because of the special design it will stay on the pipe without holding it. This allows the worker to use two hands for further assembly. The upper saddle part can be clamped to the lower one with the two saddle clamps. Afterwards a Polsafe saddle tee can be screwed into the Polsafe saddle and the saddle can be tapped. The removable cutter is designed in such a way that no bore chips can get into the main or into the service line. The self-sealing valve in the Polsafe saddle tee will prevent loss of gas during boring a live main. A PE service line pipe can be connected to the Polsafe saddle tee with the tensile tight connector on the saddle tee.

self-sealing gas valve

saddle tee with tensile tight connector

upper saddle fits on lower saddle in both directions

saddle clamps main pipe

self-clamping lower saddle

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POLSAFE TECHNICAL INFORMATION

POLSAFE

POLSAFE BALLOON POSITIONING In order to position a balloon in a Ductile PVC main pipeline a Polsafe gas saddle must be mounted on the main first. After mounting the saddle a Polsafe saddle adapter can be screwed into the Polsafe saddle and the main can be tapped. After tapping the balloon can be positioned with Polsafe positioning equipment and the balloon can be inflated. The self-sealing valve in the Polsafe saddle adapter will prevent escape of gas during boring and balloon positioning.

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POLSAFE

POLSAFE ECONOMICS

INSTALLATION COSTS Installation costs for a Polsafe Gas Distribution System are relatively low, due to quick and easy installation. Depending the actual situation cost reductions up to 30% compared to PE system costs can be obtained.

MAINTENANCE COSTS Thorough investigations have shown that repair frequency for a Polsafe Gas Distribution System is much lower than repair frequencies for other gas distribution systems. This is shown in the following table:

System material Repairs per 100km per year

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Steel

Cast iron

Asbestos cement

PE

Ductile PVC (Polsafe)

6,9

45

21

7,1

2,4

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POLSAFE PRODUCT RANGE

POLSAFE

DUCTILE PVC PIPES DUCTILE PVC PIPE SDR 41, Gastec QA approved Size Code 50 63 75 90 110 160 200 250 315

x x x x x x x x x

2,0 2,0 2,0 2,2 2,7 3,9 4,9 6,1 7,7

309733 307202 307206 307210 307214 307222 307226 307230 307234

DUCTILE PVC PIPE SDR 33, Gastec QA approved Size Code 110 160 200 250 315

x x x x x

3,4 4,9 6,2 7,7 9,7

306791 306799 306803 306807 306811

Meters per bundle 1170 780 500 630 430 220 140 70 50

Meters per bundle 430 220 140 70 50

DUCTILE PVC FITTINGS DUCTILE PVC COUPLER Size 50 63 75 90 110 160 200 250 315

DUCTILE PVC REPAIR COUPLER Size 50 63 75 90 110 160 200 250 315

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Code

Packing

318985 301144 301146 301147 301149 301152 301153 301154 301155

45 40 24 16 12 6 1 1 1

Code

Packing

318986 301177 301178 301179 301180 301159 301160 301161 301162

45 40 24 16 12 6 1 1 1

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POLSAFE

POLSAFE PRODUCT RANGE

DUCTILE PVC REDUCER Size 63 75 75 90 90 110 110 110 160 200 250 315

x x x x x x x x x x x x

Code

50 50 63 63 75 63 75 90 110 160 200 250

302148 301872 301279 301280 301281 301282 301283 301284 301286 301288 301289 301290

DUCTILE PVC TEE Size

Code

63 75 90 110 110 110 110 160 160 200 200 200

318535 318536 318537 318538 318539 318540 318541 318542 318543 315847 315848 315849

x x x x x x x x x x x x

63 75 90 63 75 90 110 110 160 110 160 200

DUCTILE PVC END CAP Size 63 75 90 110 160 200

DUCTILE PVC END CAP Size 250 315

1 0

2 0 0 0

1 1 1 1 1 1 1 1 1 1 1 1

Packing 4 6 4 5 5 3 4 1 1 1 1 1

Code

Packing

312337 312338 312339 312340 312341 312342

70 30 30 30 12 1

Code

Packing

301540 302068

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Packing

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POLSAFE PRODUCT RANGE

DUCTILE PVC FORMED BEND 11° Size 63 75 90 110 160 200 250 315

DUCTILE PVC FORMED BEND 221/2° Size 63 75 90 110 160 200 250 315

DUCTILE PVC FORMED BEND 30° Size 63 75 90 110 160 200 250 315

DUCTILE PVC FORMED BEND 45° Size 50 63 75 90 110 160 200 250 315

DUCTILE PVC FORMED BEND 90° Size 50 63 75 90 110 160 200 250 315

Code

POLSAFE

Packing

301054 301064 301070 301076 301090 301095 301102 301110

Code

Packing

301056 301066 301071 301078 301091 301097 301104 301111

Code

Packing

301057 301067 301072 301079 301092 301098 301105 301112

Code

Packing

315703 301059 301068 301073 301081 301093 301099 301107 301113

Code

Packing

315840 301062 301069 301075 301084 301094 301101 301109 301114

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POLSAFE

POLSAFE PRODUCT RANGE

POLSAFE GAS SADDLE Size 63 75 90 110 160 160 200 200 250 250 250 *315 *315 *315

x x x x x x x x x x x x x x

1 1 1 1 1 1 1 2 1 2

/2” /2” 1 /2” 1 /2” 1 /2” 2” 1 /2” 2” 1 /2” 2” 1 /2” 1 /2” 2” 1 /2” 1 1

Code

Packing

320309 320310 320311 320312 320331 320334 320332 320335 320333 320336 320112 320316 320337 320111

20 20 20 14 8 8 5 5 4 4 4 2 2 2

*) type M POLSAFE SADDLE TEE, tensile tight Size SDR 25 32 32 40

x x x x

1 1 1 1

⁄2” ⁄2” 1 ⁄2” 1 ⁄2” 1 1

SDR17,6/11 SDR17,6 SDR11 SDR17,6

POLSAFE SADDLE ADAPTER Size 1 /2” 2” 2 1/2” 1

Code

Packing

320300 320301 320303 320302

10 10 10 10

Code

Packing

320319 320320 320325

10 8 5

1 1/2” saddle adaptors are suitable for balloons 63 up to 110mm 2” saddle adaptors are suitable for balloons 160 up to 315mm 2 1/2” saddle adaptors are suitable for balloons 250 and 315mm

POLSAFE SADDLE PLUG Size 1 1/2” 2”

Code

Packing

320321 320322

40 50

POLSAFE CUT-OFF PLUG, for temporary service cut-off Size Code 11⁄2 “ 2“

1 2

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320317 308606

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Packing 20


POLSAFE PRODUCT RANGE

POLSAFE TESTING PLUG, for service line testing Size Code

Packing

320341

20

POLSAFE TESTING CAP, for Polsafe saddle tee Size Code

Packing

320318

50

POLSAFE TESTING CAP, for Polsafe saddle adapter Size Code 1 1/2” 2”

POLSAFE

Packing

320342 320343

50 50

SERVICE LINE PIPES AND COUPLERS POLVALENE PE80 PIPE YELLOW SDR17,6, Gastec QA approved Size Code 50m coils 25 32 40

x x x

2,0 2,0 2,3

320652 320653 320654

308337 308338 308670

POLVALENE PE80 PIPE YELLOW SDR11, Gastec QA approved Size Code 50m coils 25 32 40

x x x

2,3 3,0 3,7

-

Code 100m coils 309592 309593 311191

DUCTILE PVC COUPLER PE-PE, tensile tight Size Code 50m coils 25 32 40

Code 100m coils

SDR17,6/11 SDR17,6 SDR17,6

Code 100m coils 318556 318557 318555

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POLSAFE

POLSAFE PRODUCT RANGE

DUCTILE PVC TRANSITION COUPLER PE-COATED STEEL, tensile tight Size SDR 25 32 32 32 40 40

x x x x x x

⁄4 ⁄4 1 1 1 1 1⁄4

“ “ “ “ “ “

3 3

SDR17,6/11 SDR17,6 SDR17,6 SDR11 SDR17,6 SDR17,6

DUCTILE PVC TRANSITION COUPLER PE-COATED COPPER, tensile tight Size SDR 25 32 32 40 40 40 40

x x x x x x x

15 22 22 28 28 35 35

x x x x x x x

25 32 32 40 40 40 40

SDR17,6/11 SDR17,6 SDR11 SDR17,6 SDR11 SDR11 SDR11

Code 306925 318559 306927 306928 306929 318562

Code 320368 320369 320371 320370 320372 320374 320373

Ductile PVC transition couplers PE-coated copper must be mounted with a brass thrust ring Thrust Thrust Thrust Thrust

ring15mm ring22mm ring28mm ring35mm

304374 304375 304376 304377

ACCESSORIES TYPICAL POLSAFE TAPPING SET

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TYPICAL POLSAFE BALLOON POSITIONING SET

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Packing 20 10 10 10 10 10

Packing 30 30 10 10 10 10 10


STANDARDS

POLSAFE

NEN7230

Plastic piping systems for gas supply - High impact PVC pipes - Requirements and testing methods

NEN7231

Plastic piping systems for gas supply - High impact PVC fittings - Requirements and testing methods

NEN7232

Plastic piping systems for gas supply - High impact PVC saddles with clamp connection Requirements and testing methods

NEN7240

Plastic piping systems for gas supply - High impact PVC tensile tight couplers Requirements and testing methods

NEN7212

Rubber seals in distribution systems for natural gas

PREN1555

Plastic piping systems for gaseous fuel supply - Polyethylene (PE)

BRL2051

Lubricant for rubber ring seals

ISO6993

High impact PVC pipes for gaseous fuel supply

The above mentioned standards can be obtained from: Nederlands Normalisatie Instituut PO Box 5059 2600 GB DELFT Holland

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o c t oo bc et o r b 2e 0r 0 02 0 0 0

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Pipelife Nederland B.V. P.O. Box 380, 1600 AJ Enkhuizen, Holland Flevolaan 7, 1601 MA Enkhuizen, Holland Tel.: ++31.228.355555 Fax: ++31.228.355666 info@pipelife.nl http://www.pipelife.nl


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