1 PRODUCT STANDARD AND RANGE OF APPLICATION

Transcript

1 1 PRODUCT STANDARD AND RANGE OF APPLICATION EO malleable iron fitting meet all the requirements of the EN 10242:1994 standard, design symbol A. This standard specifies the requirements of the design and performance of the threaded pipe fittings in malleable cast iron. This standard is in effect in all the countries members of the CEN (European Committee for Standardisation): Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom. As specified in this standard, the fittings are fit for the transmission of fluids and gases up to the following limits of pressure and temperatures, (see fig. 1): a) Normal application a1) Minimum service: temperature -20º C Pressure to the minimum service temperature: 25 bar a2) Maximum permissible working pressure for temperature between 20º C and 120º C: 25 bar a3) Maximum permissible working pressure for temperatures between 120º C and 300º C: 20 to 25 bar* * Interpolated values b) Special applications For special applications to temperatures less than 20 º C or any other different from the normal applications, it has to be asked to ATUSA. Pressure bar Temperature ºC Fig. 1: Pressure Temperature rating Note : 1 bar = 10 5 N/m 2 = 100 kpa EO malleable iron fittings can be used in all types of installations for the transport of fluids: liquids, air, water, natural gas, fuel gas, etc...

2 2 TECHNICAL SPECIFICATIONS 2.1. MATERIAL EO fittings are produced in white heart malleable cast iron in accordance with the specifications of the design symbol A of the EN 10242:1994 standard. This quality grade is known as EN-GJMW , (the previous names were GTW in DIN 1692 standard and W in BS 6681 standard). This means that a test bar with a diameter of 12 mm. presents the following mechanical properties: - Tensile strength min.:. 400 N/mm 2 (40 kg./mm 2 ) - Yield strength min. 0.2% 220 N/mm 2 (22 kg./mm 2 ) - Min. elongation after fracture.. 5 % - Max. BRINELL hardness HB The malleability of EO fittings allows that the cylindrical zones of fittings up to 2 can withstand without the appearance of cracks a distortion of 10 % of their outside diameter, and fittings of more than 2 a distortion of 5% respectively. In order to guarantee that the material is free from internal defects that might cause problems of leakage, the EO fittings are individually checked in a pressure test according to EN 10242: GALVANIZATION EO malleable iron fittings are hot dip galvanized according to EN 10242:1994. The zinc coating has the following properties: The covering is over 500 gr./m 2, which implies an average thickness of more than 70 µn. The purity of the zinc coating is 98.05% and the impurities do not exceed the admissible values according to EN 10242:1994. The process of hot dip galvanisation provides our EO fittings with a zinc coating that is joined metallurgically to the base material by a number of Fe-Zn alloys, as shown in figure 2 This metallurgical joint provides a strong adhesion between the zinc and the base material. The thickness of the zinc coating and the adhesion between the zinc and the base material give to our EO white heart malleable iron fittings an optimal and permanent corrosion protection. Due to the purity of the zinc layer, EO fittings are specially recommended for the use in drinking water installations. Figure 2 1st LAYER = (ETA) PURE ZINC 2nd LAYER = (ZETA) ZINC IRON ALLOY (5,8 % to 6,8 % of Fe.) 3rd LAYER = (DELTA) ZINC IRON ALLOY (7 % to 12 % of Fe.) 4th LAYER = (GAMMA) ZINC IRON ALLOY (of molec. Thickness, 21 % to 28 % of Fe.)

3 2.3. WASHING AND VARNISHING PROCESSES In order to remove residues of chips, cutting compound or any contamination caused during the threading process our EO fittings are thoroughly washed and finally protected with an anticorrosion varnish THREADED JOINTS TYPE OF THREAD Jointing threads The EO white heart malleable cast iron pipe fittings are mechanised in accordance to the specifications of the A design symbol with external taper threads (R) and parallel internal threads (Rp) and comply with the ISO 7/1 standard, which is equivalent to DIN 2999 and BS Compression threads The EO white heart malleable cast iron pipe fittings (design symbol A) are threaded with internal and external parallel threads (G) according to ISO 228/ NOMINAL DIAMETER AND CONNECTING MEASURES mm /8 ¼ 3/8 1/2 3/ /4 1 1/ / ALIGNMENT OF THE THREADS The process of mechanisation used for EO fittings guarantees an alignment of the threads with a deviation of less than 0.5º (30 ) as required by the product standard

4 TIGHTNESS OF THREAD JOINTS The design of this taper-parallel threaded joint by itself provides a reliable tightness of the joint. This safety is achieved by the fact that the sealing is done by the compression metal on metal which exists between the flanks of the taper external and the parallel internal thread when the joint is properly tightened with the correct tool. Consequently the only function of the sealing material is to compensate deviations from the theoretical thread profile which cannot be avoided in the manufacturing process. From the mechanical point of view, all tensile compressive and bending stresses on the threaded joints are absorbed by the above mentioned contact metal on metal. For this reason the taper external threads are designed as shown in fig. 3 a : The required thread length in order to put into contact the taper external thread with the first turn of the parallel internal thread. This contact is made manually. b : The part of the thread where the above mentioned seal of metal is made. c : The thread end with fully formed crests and unformed roots. The usable thread length is the sum of a and b SCREWED IN BY HAND (BEGIN OF THE CONTACT METAL-METAL) TOOL TIGHTENED Fig. 3 When the pipes are threaded during the installation, the following facts have to kept in mind: 1.: The diameters indicated in table 1 have to be measured from the distance a from the pipe end. 2.: The length of the pipe thread has to be equal to the usable thread length (of the fittings) as stated in table 1. Keeping in mind the tolerance of the thread diameters, the length b is never inferior to 11/2 times the pitch of the thread. This implies a minimum tightening by tool of 11/2 times the pitch. TABLE 1 External Threads Diameter Length a Length b Usable Pitch Ext. Med. Int. (Hand screwed) (tool tightened) Thread Size (crest - mm.) Length 1/4 1,337 13,157 12,301 11,445 6,0 2 3/4 3,7 9,7 3/8 1,337 16,662 15,806 14,950 6,4 2 3/4 3,7 10,1 1/2 1,814 20,955 19,793 18,631 8,2 2 3/4 5,0 13,2 3/4 1,814 26,441 25,279 24,117 9,5 2 3/4 5,0 14,5 1" 2,309 33,249 31,770 30,291 10,4 2 3/4 6,4 16,8 1" 1/4 2,309 41,910 40,431 38,952 12,7 2 3/4 6,4 19,1 1" 1/2 2,309 47,803 46,324 44,845 12,7 2 3/4 6,4 19,1 2" 2,309 59,614 58,135 56,656 15,9 3 1/4 7,5 23,4 2" 1/2 2,309 75,184 73,705 72,226 17,5 4 9,2 26,7 3" 2,309 87,884 86,405 84,962 20,6 4 9,2 29,8 4" 2, , , ,072 25,4 4 1/2 10,4 35,8

5 2.5. DI MENSION Z In general terms, the dimension Z is defined as the distance between the `pipe end (end of the thread of the fitting) and the axis or the centre of the fitting. (fig. 4) Fig. 4 The dimension is of special importance, for it allows the calculation in advance of the length of the pipes to be used in an installation, i.e. based on the installation plans the dimension Z of the fittings indicated in the corresponding tables allows to preassemble the pipes already in the plumber s workshop and thus reduces the work on the building site to the mere joining of the components. In order to join A of pipe 1 with point B of pipe 2 and if L1 and L2 are known, using the dimension Z the pipe lengths l1, l2 and l3 are calculated as follows: Point B Pipe 2 Pipe 1 Point A Fig.5

6 5 RECOMMENDATIONS FOR THE INSTALLATION 5.1. TO GUARANTEE THE TIGHTNESS 1. Use the appropriate sealing material. In table 2 the adequate sealing materials for each type of installation are indicated. Table 2 Sealing paste PTFE Teflon Hemp Special Non hardening Sealing strip with minium Hemp Sealing paste Potable water * (1) * (2) * Hot water (3) * (1) * Natural Gas and GLPS (3) * (1) * (2) Compressed air * (1) * (2) Chemical fluids up to 160 ºC * (1) Usable with or without hemp. (2) The thickness of the sealing strips has to be above 0,1 mm. (3) The EN 751-1, EN y EN standards, establish the sealing materials, its classification, characteristics and working conditions with metallic jointing threads in contact with gas 1 st, 2 nd and 3 rd family and hot water. 2. The internal parallel threads of the fittings have to be joined to the taper external threads. (See section ). 3. Pipe components which do not permit a minimum tightening by tool as indicated in section when being threaded must not be used. 4. The surfaces of the threads have to be cleaned before being threaded. 5. The sealing material has to be applied homogeneously and thoroughly on the external thread, using only sealing material suitable for the application. (See table 2). 6. A fine film of lubricant should be applied on the surfaces to be threaded in order to prevent the sealing material from getting stuck and thus avoid irregularities in the sealing effect. 7. Check if all axes of the different threaded joint components are aligned according to the tolerances as indicated in EN 10242:1994 standard. (See section 2.4.3) PREVENTING CORROSION EXTERIOR OF THE INSTALLATION Experience has shown that most cases of premature failure of installations were due to avoidable external attack. For this reason the following instructions should be followed : When the installation is fixed into the wall : - Do not use gypsum or scagliola or mixtures with these materials. - Cover the installations with lagging material or water-repellent strip. - Wall in the installation with a layer of rich concrete (min. 300 kg./m 3 ). - Avoid proximity of water or humidity to the exterior surfaces of the installation. If possible, install the pipe above ground or in sewage systems that are well ventilated and accessible. Do not use the installation as ground connection for electrical appliances INTERIOR OF THE INSTALLATION In installations where galvanized pipes or fittings are used, check if all components are completely galvanized. Do not use copper pipes, because they could produce galvanic effects.

7 6 DESIGNACION OF THE FITTINGS 6.1. FITTINGS TYPES AND SYMBOLS In the index table of dimensions you will find the numbering used by ATUSA for the designation of the fittings, the EN symbol and the table of this catalogue where all dimensions of all fittings are indicated. The dimensions of the EO fittings do not exceed the tolerances required by the product standard EN 10242:1994. (See table 3). Table 3 DIMENSIONS TOLERANCE from to 30 1, , , , , , ,0 These models are produced in steel, in galvanised finish are electrolitically plated and are not recommended for potable water installations DESIGNATION OF THE FITTINGS The designation consists of the number of the fitting type (Fig. 6), size and the symbol G for galvanized or N for black fittings. The fitting size is indicated by the nominal diameter of its thread in inches. If a fitting has more than two threads and all have different sizes, then the designation is made according to the following scheme (See fig. 6) Fig.6 Examples: - Elbow female 2 inches, galvanized: Fig G - Reducing socket 2 inches to 1 inch, black: Fig x 1 N - Reducing tee with outlets of 1, 1/2 and 3/4 inches: Fig x 1/2 x 3/4 N

8 Tipo EN Tabla Pág. Tipo EN Tabla Pág. 1 G A D A G R A A D A G UA G 4/45º UA G 1/45º UA

9 Type EN Table Pag. Type EN Table Pag. 98 UA E A 1/45º A 4/45º C B R C R B R B Z a E Z a 2

10 Type EN Table Pag. Type EN Table Pag. 240 M N 8 R-L N T N T M a T M T M2 R-L P N P

11 Type EN Table Pag. Type EN Table Pag M a M U U U U P T

12 TABLE 1 2 (G1) 1 (G4) 3 (G8) a b z 1/4 1/ /8 3/8 3/ /2 1/2 1/ /4 3/4 3/ /4 1 1/4 1 1/ /2 1 1/2 1 1/ /2 2 1/2 2 1/ TABLE 2 2A (D1) 1A (D4) a z 1/ / / /

13 TABLE 3 41 (G1/45º) 40 (G4/45º) a b z 3/8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/ TABLE 4 85 D l z 3/8 3/ /2 1/ /4 3/ TABLE 5 90 (A1) 92 (A4) a b z 1/4 1/ /8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/

14 TABLE 6 90 (A1) a b z1 z2 1/2 x 3/ /4 x 3/ /4 x 1/ x 1/ x 3/ /4 x 1/ /4 x 3/ /4 x 1/ /2 x 3/ /2 x /2 x 1 1/ x 1 1/ x 1 1/ TABLE 7 95 (UA 1) 96 (UA 11) a b z1 z2 S máx. 3/8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/

15 TABLE 8 97 (UA 2) 98 (UA 21) a b z1 S máx. 3/8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/ TABLE (A 1/45º) 121 (A 4/45º) a b z 1/2 1/ /4 3/

16 TABLE (B1) 180 (C1) a z 1/ /8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/ TABLE 11

17 TABLE (B1) a b c z1 z2 z3 3/8" x 1/4" x 3/8" /8" x 1/2" x 3/8" /8" x 3/4" x 3/8" /2" x 1/4" x 1/2" /2" x 3/8" x 3/8" /2" x 3/8" x 1/2" /2" x 1/2" x 3/8" /2" x 3/4" x 3/8" /2" x 3/4" x 1/2" /2" x 1" x 1/2" /4" x 1/4" x 3/4" /4" x 3/8" x 3/8" /4" x 3/8" x 1/2" /4" x 3/8" x 3/4" /4" x 1/2" x 3/8" /4" x 1/2" x 1/2" /4" x 1/2" x 3/4" /4" x 3/4" x 3/8" /4" x 3/4" x 1/2" /4" x 1" x 1/2" /4" x 1" x 3/4" /4" x 11/4" x 3/4" " x 1/4" x 1" " x 3/8" x 3/4" " x 3/8" x 1" " x 1/2" x 3/8" " x 1/2" x 1/2" " x 1/2" x 3/4" " x 1/2" x 1" " x 3/4" x 3/8" " x 3/4" x 1/2" " x 3/4" x 3/4" " x 3/4" x 1" " x 1" x 3/8" " x 1" x 1/2" " x 1" x 3/4" " x 11/4" x 1/2" " x 11/4" x 3/4" " x 11/4" x 1"

18 TABLE (B1) a b c z1 z2 z3 11/4" x 3/8" x 1" /4" x 3/8" x 11/4" /4" x 1/2" x 1/2" /4" x 1/2" x 1" /4" x 1/2" x 11/4" /4" x 3/4" x 1/2" /4" x 3/4" x 3/4" /4" x 3/4" x 1" /4" x 3/4" x 11/4" /4" x 1" x 3/8" /4" x 1" x 1/2" /4" x 1" x 3/4" /4" x 1" x 1" /4" x 1" x 11/4" /4" x 11/4" x 3/8" /4" x 11/4" x 1/2" /4" x 11/4" x 3/4" /4" x 11/4" x 1" /4" x 11/2" x 1" /4" x 11/2" x 11/4" /4" x 2" x 11/4" /2" x 3/8" x 11/2" /2" x 1/2" x 11/4" /2" x 1/2" x 11/2" /2" x 3/4" x 11/4" /2" x 3/4" x 11/2" /2" x 1" x 1" /2" x 1" x 11/4" /2" x 1" x 11/2" /2" x 11/4" x 1" /2" x 11/4" x 11/4" /2" x 11/4" x 11/2" /2" x 11/2" x 1/2" /2" x 11/2" x 3/4" /2" x 11/2" x 1" /2" x 11/2" x 11/4" /2" x 2" x 11/2" " x 3/8" x 11/2"

19 TABLE (B1) a b c z1 z2 z3 2" x 3/8" x 2" " x 1/2" x 11/2" " x 1/2" x 2" " x 3/4" x 11/2" " x 3/4" x 2" " x 1" x 11/2" " x 1" x 2" " x 11/4" x 1" " x 11/4" x 11/4" " x 11/4" x 11/2" " x 11/4" x 2" " x 11/2" x 1" " x 11/2" x 11/4" " x 11/2" x 11/2" " x 11/2" x 2" " x 2" x 1/2" " x 2" x 3/4" " x 2" x 1" " x 2" x 11/4" " x 2" x 11/2" " x 21/2" x 2" " x 3" x 2" /2" x 1/2" x 21/2" /2" x 3/4" x 21/2" /2" x 1" x 21/2" /2" x 11/4" x 21/2" /2" x 11/2" x 2" /2" x 11/2" x 21/2" /2" x 2" x 2" /2" x 2" x 21/2" /2" x 21/2" x 11/2" /2" x 21/2" x 2" " x 3/4" x 3" " x 1" x 3" " x 11/4" x 3" " x 11/2" x 3" " x 2" x 3" " x 21/2" x 3" " x 4" x 3"

20 TABLE (B1) a b c z1 z2 z3 4" x 1/2" x 4" " x 3/4" x 4" " x 1" x 4" " x 11/4" x 4" " x 11/2" x 4" " x 2" x 4" " x 21/2" x 4" " x 3" x 4" TABLE (E1) a c z1 z2 1/ / / / TABLE (E2) a z / / /

21 TABLE (M2) a z 1/4" x 1/8" /8" x 1/8" /8" x 1/4" /2" x 1/4" /2" x 3/8" /4" x 1/4" /4" x 3/8" /4" x 1/2" " x 3/8" " x 1/2" " x 3/4" /4" x 3/8" /4" x 1/2" /4" x 3/4" /4" x 1" /2" x 1/2" /2" x 3/4" /2" x 1" /2" x 11/4" " x 1/2" " x 3/4" " x 1" " x 11/4" " x 11/2" /2" x 3/4" /2" x 1" /2" x 11/4" /2" x 11/2" /2" x 2" " x 3/4" " x 1" " x 11/4" " x 11/2" " x 2" " x 21/2" " x 1" " x 11/4" " x 11/2" " x 2" " x 21/2" " x 3" 94 28

22 TABLE (N4) Fg. a b z S. Máx. 1/4" x 1/8" I /8" x 1/8" I /8" x 1/4" I /2" x 1/4" II /2" x 3/8" I /4" x 1/4" II /4" x 3/8" II /4" x 1/2" I " x 1/4" II " x 3/8" II " x 1/2" II " x 3/4" I /4" X 3/8" II /4" x 1/2" II /4" x 3/4" II /4" x 1" I /2" x 3/8" II /2" x 1/2" II /2" x 3/4" II /2" x 1" II /2" x 11/4" I " x 3/8" III " x 1/2" III " x 3/4" III " x 1" II " x 11/4" II " x 11/2" II /2" x 1/2" III /2" x 3/4" III /2" x 1" III /2" x 11/4" III /2" x 11/2" II /2" x 2" II " x 3/4" III " x 1" III " x 11/4" III

23 TABLE (N4) Fg. a b z S. Máx. 3" x 11/2" III " x 2" II " x 21/2" II " x 1" III " x 11/4" III " x 11/2" II " x 2" III " x 21/2" III " x 3" II TABLE (N8) a S. Máx. 1/4" x 1/8" /8" x 1/8" /8" x 1/4" /2" x 1/4" /2" x 3/8" /4" x 3/8" /4" x 1/2" " x 1/2" " x 3/4" /4" x 1/2" /4" x 3/4" /4" x 1" /2" x 3/4" /2" x 1" /2" x 11/4" " x 1" " x 11/4" " x 11/2" /2" x 2" " x 21/2" 83 95

24 TABLE (M4) a z 1/4" x 1/8" /8" x 1/4" /2" x 1/4" /2" x 3/8" /4" x 3/8" /4" x 1/2" " x 1/2" " x 3/4" /4" x 1/2" /4" x 3/4" /4" x 1" /2" x 3/4" /2" x 1" /2" x 11/4" " x 1" " x 11/4" " x 11/2" (M4) a z 3/8 x /8 x /2 x /2 x /4 x /4 x /4 x a (M4) a z 3/ / /

25 TABLE (M2) 271 (M2 R-L) a z 1/ / /8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/ TABLE 23 a S. máx. 280 (N8) 281 (N( R-L) (N8) 280 (N8) (N8R-L) (N8R-L) 1/ / /8 3/ /2 1/ /4 3/ /4 1 1/ /2 1 1/ /2 2 1/

26 TABLE (T1) 291 (T8) 291a (T8) 290 (T9) mín. a b c 300 (T1) S. Máx. 291 (T8) 291 A (T8) 290 (T9) 1/8 1/8-1/ /4 1/4-1/ /8 3/8-3/ /2 1/2 1/2 1/ /4 3/4 3/4 3/ /4 1 1/4 1 1/4 1 1/ /2 1 1/2 1 1/2 1 1/ /2 2 1/2-2 1/ TABLE (P4) d e m mín. S. Máx 1/2 1/2 36, /4 3/4 41, , /4 1 1/4 63, /2 1 1/2 69, ,

27 TABLE (P4) d e m mín. S. Máx 1/4 1/4 35, /8 3/8 31, /2 1/2 36, /4 3/4 41, , /4 1 1/4 63, /2 1 1/2 69, , /2 2 1/2 110, , , TABLE d A B b K H m f 3/8 3/ ,5 1/2 1/ ,5 3/4 3/ , ,5 1 1/4 1 1/ /2 1 1/ /2 2 1/

28 TABLE d A B b K H m f 3/8 3/ ,5 1/2 1/ ,5 3/4 3/ , ,5 1 1/4 1 1/ /2 1 1/ /2 2 1/ TABLE (U1) 340(U11) G a z S. Máx. 1/4 1/4 5/ /8 3/8 7/ /2 1/2 1 1/ /4 3/4 1 1/ / /4 1 1/ /2 1 1/2 2 1/ / /2 2 1/2 3 1/ / (U2) 341 (U21) G a z S. Máx. 1/4 1/4 5/ /8 3/8 7/ /2 1/2 1 1/ /4 3/4 1 1/ / /4 1 1/ /2 1 1/2 2 1/ / /2 2 1/2 3 1/ /

29 TABLE G L Z S. Máx 1/2 1 1/ /4 1 1/ / / /2 2 1/ / TABLE D h d S. Máx 1/ /4 38, , , , / , / , , TABLE D L Z d 1/ ,5 7,5 30 3/4 38, ,5 1 44,5 26,5 9,5 41,5 1 1/ ,5 1 1/ ,5 12,5 58,5 2 77,

30 TABLE (P1) G d2 l m n S. Máx. 1/4 5/8 18, /8 7/ /2 1 1/8 27, /4 1 1/ /2 41, / /2 2 1/ / /2 3 1/2 92, / TABLE l 1/8 19 1/4 17 3/8 24 1/2 25 3/ / / / TABLE (T11) a S. Máx. 1/ / / / / , /