hypro™ pvc-o pipes installation guide -...

Molecor (SEA) Sdn Bhd © August 2014

HYPRO™ PVC-O Pipes

Installation Guide

Molecor (SEA) Sdn Bhd

A member of the FITTERS Group

T : +603-62767155 | F : +603-62751378

Wisma FITTERS, No. 1, Jalan Tembaga SD 5/2,

Bandar Sri Damansara, 52200 Kuala Lumpur,

Malaysia

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1. Introduction

1.1 The revolutionary HYPRO™ PVC-O pipes developed by

Molecor offers the benefits of the most advanced and eco-

friendly technology for water transport, and are the best

choice for high pressured fluid transport. HYPRO™ PVC-O

pipes comply with international standard ISO 16422:2006

and are certified by SIRIM QAS International.

1.2 This guide provides general recommendations with

regards to the installation of HYPRO™ PVC-O pipes.

Extraordinary conditions not included in this guide should be referred to the Engineer or

field inspectors to provide on-site solutions. Nevertheless, technical advice from Molecor

would always be available. The objective here is to encourage the use of preferred and

recommended methods that lead to proper and professional installation, which

consequently ensures the maximum efficiency and service life of the pipes.

1.3 Ultimately, the Engineer who designs the pipeline will determine how it is to be

installed. It is not our intention that this guide should assume that responsibility unless the

Engineer so directs.

1.4 This guide is based on Molecor’s experience and on an array of published reports from

other industry resources. Users may also find additional helpful advice in technical

guidelines published by the governing water authorities in each respective jurisdiction.

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2. Handling and Storage

2.1 While HYPRO™ PVC-O pipes are light-weight and easy to handle, careful handling of the

pipes should be practiced to avoid causing unnecessary damage to them.

2.2 Pipes are delivered to the installation site in

standard pallet size units. Unload the pipes in the units

as shipped and use equipment such as fork lifts or front

end loaders with forks. Avoid sliding the forks against

the underside of the pipes in the pallet which may cause

unnecessary abrasions to the pipes. Unloaded pipes

should be situated on level ground.

2.3 HYPRO™ PVC-O pipes are manufactured with integrated sockets. To avoid uneven

stacks, these pipes should be stacked in layers with sockets placed at alternative ends. Avoid

applying loads on the sockets.

2.4 HYPRO™ PVC-O has unbeatable impact resistance; however, unsightly surface scratches

may be caused by coming into contact with sharp objects or sharp edges. Storage areas

should be clear of surface irregularities such as stones, branches or other sharp projections.

2.5 Pipes at the installation site which are positioned along the trench should be located as

close as possible to the line of the trench where they can be lowered with the least amount

of additional handling.

3. Trench Preparation

3.1 Safety first. The contractor or installer bears the responsibility of ensuring that all

regulations have been complied with, and that safety procedures for the protection of

workers and the public have been adhered to.

3.2 The width of the top of the trench is determined by parameters set by the governing

water authority of the installation site and also best practice adhered to by the installer.

Take note that the trench width at the pipe zone should be kept to a practical minimum.

3.3 Although other types of applications are possible, HYPRO™ PVC-O pipes are particularly

recommended for underground installation. The minimum width of the trench can be

calculated using the following tables:

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4. Assembly of Hypro™ PVC-O pipes

4.1 HYPRO™ PVC-O pipes are manufactured with integrated sockets including the rubber

rings of each socket. This eliminates the rubber ring insertion procedure at the installation

site.

4.2 Lay the pipes with sockets forward, assembly will consist of concentrically pushing the

spigot of one pipe into the socket of another.

4.3 Steps for assembly:

4.3.1 In preparation for assembly, ensure that the socket and spigot end of each pipe is

cleaned. Avoid further contamination after cleaning.

4.3.2 Apply lubricant on the chamfer of the spigot end and in the

rubber ring joint.

4.3.3 Align the pipe and place the spigot end inside the socket.

4.3.4 Firmly push the free end into the other pipe. Introduce until the end

mark on the spigot end is no longer visible.

4.4 Other methods for assembly of HYPRO™ PVC-O include:

4.4.1 Trench Excavator method: After preparing trench using excavator, the excavator could

be utilized for pushing the pipe spigot into the socket. This is most commonly used for large

diameter pipes. Use timber at the edge of the pipe so that the excavator bucket is not in

direct contact with the pipe.

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4.4.2 Crowbar method: Entry of spigot into the socket by pushing with crowbar.

4.4.3 Fork Tool method: For is placed over and behind the socket of the last pipe that was

laid. Join the pipes by wrapping a wire rope sling around the spigot.

5. Assembling Pipes to Fittings

5.1 Fittings are connected directly with the pipe to allow deviations or reductions. It is very

important to fix the fitting to the ground in order to guaranty the net structural resistance.

5.2 HYPRO™ PVC-O pipes allow connecting the spigot ends to all kinds of fittings with

connection to a flange.

5.3 HYPRO™ PVC-O pipes are compatible to fittings used in the water industry. Our technical

service will provide you advice in case you need it.

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6. Cutting and Chamfering

6.1 Cutting methods and techniques include band saw cutting, cold sawing, laser cutting and

lathe cutting. The most common method in cutting, is band saw cutting.

6.2 Pipes can be cut to length on-site by using hand saw or power cutting tool. Select a flat

ground and roll the pipe across the ground while scribing a cutting line on the pipe wall with

a felt pen. This line should be placed carefully to ensure accurate cutting.

6.3 Chamfering the pipe involves filing, scraping or grinding on the end of the pipe by

removing 25% of the wall thickness at an angle of 10 to 15 degrees. Ensure that there are no

sharp edges at the spigot end. Such sharp edges will damage the rubber rings when the

spigot is pushed into the socket.

6.4 A new witness mark should be made on the pipe spigot to match the socket depth.

7. Tapping and Service Connections.

7.1 A new connection to existing piping without

interruption of emptying that section of pipe is

possible by using “hot tapping” method. Typical

connections consist of tapping fitting, isolation valve,

and hot tapping machine. Fine tooth ‘shell cutters’ or

hole saws are most recommended to avoid any risk

of spalling of the internal pipe surface.

7.2 The hole saw is used to make an opening in the pipe so that a line plugging head can be

inserted.

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8. Repair and Cut-ins

8.1. Mechanical joints or couplings can be used where a section of pipe has to be removed

to insert another fitting or where the section of pipe is damaged. Care should be taken to

avoid excessive bolt torques which may result in distortion of the pipe wall.

8.2 Steps for repairs and cut-ins:

8.2.1 Determine the length of the replacement section, cut the pipe to the proper length.

8.2.2 Bevel the length of the replacement section; locate the reference marks on all ends.

8.2.3 Mount the couplings.

8.2.4 Insert the replacement section into pipeline and slide the couplings into position.

9. Contact Information

9.1 For further technical advice or to arrange for a technical presentation or seminar, please

contact our business headquarters in Kuala Lumpur, Malaysia:

Molecor (SEA) Sdn Bhd

A member of the FITTERS Group

Wisma FITTERS, No. 1, Jalan Tembaga SD 5/2, Bandar Sri Damansara,

52200 Kuala Lumpur, Malaysia

Tel: +603-62767155

Fax: +603-62751378

Email: [email protected]

hypro™ pvc-o pipes installation guide -...

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