plumbers handbook 2006
TRANSCRIPT
THE PLUMBERSHANDBOOK
SEVENTH EDITION (mod 2006)
KEMBLA AUSTRALIA
The information in this publication has been assembled for
guidance only. Care has been taken to ensure accuracy,
but no liability can be accepted for any consequences
which may arise as a result of its application.
It may not be reproduced in whole or part without the written
consent of MM Kembla.
All plumbing work should be performed by competent,
accredited tradespersons in accordance with current relevant
Standards and specifications required by the authority
within whose jurisdiction the work is to be performed.
To ensure an installed system will provide satisfactory
performance and the expected life, Industry practitioners
must give careful consideration to all aspects of:
design
operating condition
the internal and external environments
use of approved materials
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THE PLUMBERS HANDBOOK
SEVENTH EDITION (mod. 2006)
www.kembla.com.au
MM Kembla is proud to issue the seventh edition of the KemblaPlumbers Handbook which is published as an industry aid at a time whenmarked changes are taking place with respect to installation practice andmaterial specification. This revision reflects some of those changes.
Although historically a manufacturer of KEMBLA copper and brass tubes, MM Kembla as a result of the combined efforts of the PortKembla, Brisbane and New Zealand manufacturing plants and personnel,has developed a flexible copper system for domestic, residential, commercialand industrial piping applications. Through its national network of distributors,MMKembla offers a total system of reliable quality tubes, fittings,breeches and assemblies which are manufactured and marked in accordancewith relevant StandardsMark and WaterMark Licences.
The inherent flexibility and reliability of copper offers specifiers, designers,building owners, installers and occupiers significant benefits for an array ofpiping services which include plumbing, drainage, gas, refrigeration, airconditioning, fire services, air, steam and medical installations. Copper pipingproducts are readily available with no embargo on intermixing of pipe andfitting brands. Small outside diameters offer space savings whilst lightweight and ductility assists installers. The impermeability of copper preventsthe ingress of external substances which could have adverse impact onhealth and copper’s potential for 100% recycling contributes to a cleanenvironment. In addition to these attributes, copper systems are cost effective.
This Kembla Plumbers Handbook is issued with the expectation that recipientswill use the information to complement design and installation skills developedby an industry responsible for copper piping systems which play essentialroles in Australia’s development, and the health of its people.
FOREWORD
1
Kembla’s 90 Year Guarantee
Kembla’s 90 years of experience in manufacturing tubing productsguarantees you:
The tradition of highest quality- to meet all internationally
established standards
Proven reliability- through many decades of
experience with plumbing,refrigeration & air conditioning.
Superior service- through support from Australia’s
largest independent distributionnetworks.
Company commitment
2
Proven since 1916
Copper tubes for water, gas, sanitation, fire services, air and steam-diameter range DN 3 to DN 250.Plastic coated “Kemlag” and “Kemline” copper tube for potable water,recycled water and gas services.Copper and brass round, square and rectangular tubes for generalengineering purposes.Copper and copper alloy tubes for heat exchangers.Copper tubes for refrigeration and air conditioning.High conductivity copper tubes for electrical purposes.Kemchrome chrome plated annealed copper service tube.
Copper fittings, capillary, compression and large diameter, for plumbingapplications (Australian, New Zealand, British, European and USAstandards).Davis brand compression fittings for plumbing, gas and general purposes.Victaulic fittings for plumbing, fire and mechanical services in DN 50to DN 150.Copper refrigeration fittings.Specialty copper U bends and air conditioning fittings.Traps, junctions, bends for plumbing.Stainless steel fittings for medical, chemical, food and industrial processing.Copper fire sprinkler droppers.
Plumbing items:combinations, spouts, shower sets, laundry arms, shower arms, pipeclips, flush pipes, shower rails, breeches and pre-fabricated assemblies,exposed bath and/or shower assemblies, laboratory fittings, assembliestapped for water saving devices, water meter assemblies.General items:grabrails and handles.
T U B E P R O D U C T S
F I T T I N G S
A C C E S S O R I E S
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KEMBLA Product Range
ForewordCompany CommitmentProduct Range
Tube Specifications and Size RangesCopper Tube PropertiesStandard Plumbing Tube DetailsCopper Tube IdentificationCopper Tubes for Plumbing, Gas Fitting and Drainage Applications to AS1432Bendable Temper TubingLarge Diameter Copper TubesKemlag Pre-insulated Copper TubeKemline PVC Covered Copper TubeCopper Tube for RefrigerationSteam LinesAir LinesSafe Working Pressure Calculations for Copper TubesBrass Tube for Sanitary PlumbingTube Mass Calculation FormulaAS1432 Mass Per LengthFittings Specifications and Size RangesFittings Product RangePressure & Non-pressureCompressionScrewed BrasswareVictaulic Mechanical Jointing SystemAccessoriesCorrosion Protection Systems for Pipe & FittingsWater Supply Piping DesignWater CompositionWater Mains
CONTENTS
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PAGE
123
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9
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11
141415
1718
21
21
2223
2324
25
26
26
26
2627
29
30
31
31
32
Dead LegsPipe SizingFlow Rates at Fixtures or AppliancesRecommended Water VelocitiesPressure Loss and Flow Data for CopperCalculation FormulaeCalculation Factors for Water Flow RatesFitting Loss FactorsPressure Loss Tables for AS1432 Type B TubesWater HammerPipe SpacingCopper Tube Exposed to Freezing ConditionsInstallation PracticeSafety PrecautionsElectrical EarthingRoof and Trench WorkProximity of Water Pipes to Other ServicesPlumbing PrecautionsInstallation and DesignCleaningSupply TanksEarth RodsProtection of Potable Water SuppliesJointing MethodsCompression JointsSoft Soldered Capillary FittingsSilver Brazed JointsColour identification of Silver Brazing AlloysExpanded JointsBranch FormingRoll-Grooved JointsPush-Fit Joints
5
CONTENTS PAGE
3233
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3435
363738
43
44
44
46
46464646474747474747484849495050515252
Concealment of Copper Water ServicesInstallation of Hot Water LinesCopper and Brass Tubes for Sanitary PlumbingMaterial LimitationsPipe SupportExpansion JointsFreedom from restraintPenetration SealantsPipe Grade ConversionsCopper Tube for Fire ServicesFire Hydrant SystemsFire Sprinkler SystemsCopper for Gas PipingTest PressuresProtection During Building ConstructionBending Kembla Copper TubesGeneral ConsiderationsAnnealing (Softening) for BendingStress Relief After BendingCold BendingHot BendingTube Bending CalculationsTemperatures by ColourCorrosion Rating for Copper and 70/30 DR BrassUseful Conversion FactorsEmergency Cardiopulmonary Resuscitation
CONTENTS PAGE
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72
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TUBE SPECIFICATIONS AND SIZE RANGES
MaterialsWithin this publication, the following materials are commonly referred to as“Copper” and “70/30 DR Brass”.
Copper Phosphorus Deoxidised Copper, High Residual Phosphorus, Alloy C12200
70/30 DR Brass 70/30 Arsenical Brass, Alloy C26130This alloy is dezincification resistant (DR) and meets the requirements for a DR brass material.
Note: Both materials are suitable for the conveyance of a drinking water as they comply with Australian Standard AS3855.
Size RangeOutside Diameter (mm)
Copper 3.18mm up to and incl. 254.0mm70/30 DR Brass 15.88mm up to and incl. 152.4mm
Thickness (mm)Copper 0.31mm up to and incl. 3.25mm70/30 DR Brass 0.71mm up to and incl. 3.25mm
Standard LengthsStraights Diameters up to and incl. 152.40mm...........6 metres
Diameters above 152.40 up to and incl. 203.20mm.........................................4-6 metresDiameters above 203.20mm.....................3-6 metres
Coils Diameters up to and incl. 7.94mm.............30 metres(copper only) Diameters over 7.94mm up to 31.75mm....18 metres
Standards Applicable to Copper and Copper Alloy TubesAS 1432 Copper Tubes for Plumbing, Gasfitting and Drainage
ApplicationsAS 1572 Copper and Copper Alloys - Seamless Tubes for
Engineering PurposesAS/NZS 1571 Copper - Seamless Tubes for Air Conditioning and
RefrigerationAS 1569 Copper and Copper Alloys - Seamless Tubes for
Heat ExchangersAS 3795 Copper Alloy Tubes for Plumbing and Drainage
Applications
Other Relevant Standards
AS/NZS 3500 National plumbing and drainage
AS 2419.1 Fire hydrant installations - Systems design, installation
and commissioning
AS 2441 Installation of fire hose reels
AS 2118 Automatic fire sprinkler systems
AS 2118.1 Standard
AS 2118.2 Wallwetting sprinklers (Drenchers)
AS 2118.3 Deluge
AS 2118.4 Residential
AS 2118.5 Domestic
AS 2118.6 Combined sprinkler and hydrant
AS 2118.9 Piping support and installation
AS 2118.10 Approval documentation
AS 4118 Fire sprinkler systems
AS 4118.2.1 Piping - General
AG 601 Gas Installation Code
AS 2896 Medical gas systems - Installation and testing of
non-flammable medical gas pipeline systems.
AS/NZS 1667 Part 2 Refrigerating Systems - Safety requirements,
fixed applications.
AS 4041 Pressure Piping
*For more details on Fire Services, refer to the Kembla Fire Systems Handbook
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COPPER TUBE PROPERTIESPHOSPHORUS DEOXIDISED COPPER HIGHRESIDUAL PHOSPHORUS ALLOY C12200
NOMINAL COMPOSITION (%)
Copper 99.90 minimumPhosphorus 0.015-0.040
TUBE SPECIFICATIONS
Recommended AS 1432Related AS/NZS 1569, 1571, 1572EN1057ASTM B75, 88JISH3300NZS3501
PHYSICAL PROPERTIESMelting Point 1083˚CDensity 8.94 x 103 kg/m3 at 20˚CThermal Expansion Coefficient 17.7 x 10-6 per ˚KThermal Conductivity 305-355 W/(m.K)Specific Heat Capacity 0.385 kJ (kg.K)Electrical Conductivity (annealed) 75-90% I.A.C.S.Electrical Resistivity (annealed) 0.0192-0.0230 microhm m at 20˚CModulus of Elasticity 17 GPaModulus of Rigidity 44 GPa
JOINTING PROPERTIESSoldering ExcellentBrazing ExcellentWelding
oxy-acetylene Goodcarbon arc Good using alloy filler rodsgas shield arc Goodcoated metal arc Good using alloy filler rodsresistance spot Not recommendedresistance butt Not recommended
SUITABILITY FOR SURFACE FINISHING BYPolishing ExcellentPlating ExcellentMachining Machinability rating (20)
TYPICAL MECHANICAL PROPERTIESTube Temper Annealed Bendable Hard drawnHardness (HV/5) 70max 80-100 100minYield 0.2% proof (MPa) 70 220 350Ultimate tensile (MPa) 220 280 380Elongation (% on 50mm) 55 20 5
FABRICATION PROPERTIESCold Work ExcellentHot Work ExcellentHot Work Temp 750˚C-875˚CAnnealing Range 450˚C-600˚C
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STANDARD COPPER PLUMBING TUBE DETAILS
In recognition of our meeting the stringent quality assurance requirementsof Standards Australia, Kembla Tube & Fittings holds a licence for tube manufactured to comply with AS 1432.
Kembla Tube & Fittings is proud to display the Australian StandardsMark onKEMBLA copper plumbing tubes which are all made in Australia.
COPPER TUBE IDENTIFICATIONKEMBLA copper tubes, manufactured to meet the requirements of AS 1432,are incised at 0.5m intervals along the tube with our manufacturer’strademark, the StandardsMark, the Australian Standard number, nominalsize, thickness type, and the letters “BQ” where tubes are “Bendable”temper, e.g.
KEMBLA AS 1432 LIC.945 DN 15B BQ
In addition, “Hard drawn” and “Bendable” copper tubes to AS 1432 arecolour coded, with either a legend in the designated colour for the particularthickness Type or, the legend in black and a separate distinguishing colourmark along the length.The legend includes our manufacturer’s trademark,“Australia” the country of origin, the StandardsMark, the Australian StandardNumber, Standards Australia licence number, nominal size, thickness typeand “BQ” to identify Bendable temper tubes e.g.
KEMBLA AS 1432 LIC.945 DN 15B BQ
Four colours are used to represent the tube specification types:Type A - Green Type B - BlueType C - Red Type D - Black
Tables listing the nominal sizes for the 4 types of tube in AS 1432 are shownon pages 11 to 13 inclusive.
It is noted that copper tubes are made from the one alloy and are of similarquality. The word “TYPES” refers to the 4 thickness categories with Type “A”being the thickest and Type “D” being the thinnest tube permitted for use bywater authorities.
COPPER TUBES FOR PLUMBING, GASFITTING AND DRAINAGE APPLICATIONS TO AUSTRALIAN STANDARD 1432 - 2004
DN6DN8
DN10
DN15DN18DN20
DN25DN32DN40
DN50DN65
DN80DN90
DN100
DN125DN150DN200
6.35 x 0.91 7.94 x 0.919.52 x 1.02
12.70 x 1.0215.88 x 1.2219.05 x 1.42
25.40 x 1.6331.75 x 1.6338.10 x 1.63
50.80 x 1.6363.50 x 1.63
76.20 x 2.0388.90 x 2.03
101.60 x 2.03
127.00 x 2.03152.40 x 2.64203.20 x 2.64
1/4” x 20g5/16” x 20g3/8” x 19g
1/2” x 19g5/8” x 18g3/4” x 17g
1” x 16g11/4” x 16g11/2” x 16g
2” x 16g21/2” x 16g
3” x 14g31/2” x 14g
4” x 14g
5” x 14g6” x 12g8” x 12g
11,3208,8108,350
6,1005,7505,560
4,7503,7503,100
2,3101,840
1,9001,6301,500
1,2001,300
910
*Applicable up to 50oC. For safe working pressures at other temperatures refer Page 22.
TYPE A
11
Nom.Size
ActualTube Size
Metric (mm)
ActualTube SizeImperial
*SafeWorking
Pressure (kPa)
DN6DN8
DN10
DN15DN18DN20
DN25DN32DN40
DN50DN65
DN80DN90
DN100
DN125DN150DN200
6.35 x 0.717.94 x 0.719.52 x 0.91
12.70 x 0.9115.88 x 1.0219.05 x 1.02
25.40 x 1.2231.75 x 1.2238.10 x 1.22
50.80 x 1.2263.50 x 1.22
76.20 x 1.6388.90 x 1.63
101.60 x 1.63
127.00 x 1.63152.40 x 2.03203.20 x 2.03
1/4” x 22g5/16” x 22g3/8” x 20g
1/2” x 20g5/8” x 19g3/4” x 19g
1” x 18g11/4” x 18g11/2” x 18g
2” x 18g21/2” x 18g
3” x 16g31/2” x 16g
4” x 16g
5” x 16g6” x 14g8” x 14g
8,5606,7007,220
5,2904,8103,970
3,5002,7802,300
1,7101,370
1,7101,3001,200
9601,000
720
COPPER TUBES FOR PLUMBING, GASFITTING AND DRAINAGE APPLICATIONS TO AUSTRALIAN STANDARD 1432 - 2004
*Applicable up to 50oC. For safe working pressures at other temperatures refer Page 22.
12
TYPE B
Nom.Size
ActualTube Size
Metric (mm)
ActualTube SizeImperial
*SafeWorking
Pressure (kPa)
DN10DN15DN18
DN20DN25
9.52 x 0.7112.70 x 0.7115.88 x 0.91
19.05 x 0.9125.40 x 0.91
3/8” x 22g1/2” x 22g5/8” x 20g
3/4” x 20g1” x 20g
5,5204,0704,180
3,4502,560
13
DN32DN40DN50
DN65DN80DN90
DN100DN125DN150
31.75 x 0.9138.10 x 0.9150.80 x 0.91
63.50 x 0.9176.20 x 1.2288.90 x 1.22
101.60 x 1.22127.00 x 1.42152.40 x 1.63
11/4” x 20g11/2’’ x 20g
2” x 20g
21/2” x 20g3” x 18g
31/2” x 18g
4” x 18g5” x 17g6” x 16g
2,0401,6901,260
1,0101,130 970
890830800
COPPER TUBES FOR PLUMBING, GASFITTING AND DRAINAGEAPPLICATIONS TO AUSTRALIAN STANDARD 1432 - 2004
*Applicable up to 50oC. For safe working pressures at other temperatures refer Page 22.
TYPE C
TYPE D
Nom.Size
ActualTube Size
Metric (mm)
ActualTube SizeImperial
*SafeWorking
Pressure (kPa)
Nom.Size
ActualTube Size
Metric (mm)
ActualTube SizeImperial
*SafeWorking
Pressure (kPa)
Available Sizes:DN 15A 12.70 x 1.02mmDN 15B 12.70 x 0.91mmDN 15C 12.70 x 0.71mm
DN 18B 15.88 x 1.02mmDN 18C 15.88 x 0.91mmDN 20B 19.05 x 1.02mmDN 20C 19.05 x 0.91mm
LARGE DIAMETER COPPER TUBESOccasionally large diameter tubes, which are not included in the AS1432range, are specified for special applications. The following sizes are projectionsof the AS1432 tables. Safe working pressures have been included for temperatures up to 50˚C.
TYPE
Nom.Size
DN200DN225DN250
Nom. W.T mm
3.253.25
SWPkPa
1005 905
SWPkPa
810730
SWPkPa
595645580
Nom. W.T mm
2.642.64
Nom. W.T mm
1.632.032.03
DBA
14
BENDABLE TEMPER TUBINGIn certain circumstances it may be desirable to use a straight tube whichhas improved bending characteristics compared to normal hard drawn tempertube. To fill this need, a selected size range of 6m straight length coppertubes is available in bendable temper.
These particular tubes are capable of being bent, without local annealing,to minimum centreline radii of 45mm, 60mm and 85mm for nominal sizesDN15, DN18 and DN20 respectively.
Bendable temper tubes are coded with the letters “BQ” to distinguish themfrom normal hard drawn tubes.
eg. KEMBLA AUSTRALIA AS 1432 Lic. 945 DN 15B BQ
KEMLAG PRE-INSULATED COPPER TUBEA comprehensive range of pre-insulated tubes is available with a PVC sheathingfor use in a variety of end use applications e.g. short run domestic hot waterlines, burying in corrosive soils, laying under floors and concrete slabs(where approved), chasing into walls and masonry, pipework exposed toaggressive environments.
The moisture resistant and chemically inert green insulation is clearlymarked with KEMLAG, AUSTRALIA (the country of manufacture), the cop-per tube size in mm, the Australian Standard, the Australian Standardlicence number, the tube nominal size and thickness type e.g KEMLAG AUS-TRALIA COPPER TUBE IS 12.7 x 1.02mm AS 1432 Lic 945 DN 15A.
All DN15, DN18 and DN20 KEMLAG copper tubes are covered with a microcellular grooved insulation to minimise heat loss. Straight lengths in thissize range are Bendable Temper.
The PVC insulation will soften at elevated temperatures and the productshould not be used for installations operating continuously at temperaturesabove 75˚C.
When KEMLAG lines are to be exposed to aggressive and moist environmentsor buried, all joints must be wrapped or otherwise protected to ensure thatthe entire pipeline covering is water tight. Each end must also be madewater tight.
Where KEMLAG tubes are to be used in sizes above DN20 for the conveyanceof hot water, it may be necessary to provide additional thickness of insulationto achieve acceptable heat losses - see page 45. Purpose designed insulationshould be used where heat loss is critical.
In localities subject to freezing conditions, additional insulation may berequired to prevent water freezing in exposed pipelines - see page 45.KEMLAG alone will not prevent water freezing.
The PVC insulation on KEMLAG is resistant to ultraviolet radiation and theproduct can be installed in situations where the pipes are in direct sunlight.No piping must be placed in direct contact with metal roofs.
®
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KEMLAG TUBE SIZESKemlag tube is available as either 18m coils or 6m straights. The range ofstock sizes is shown below. Other sizes from DN15 to DN100 may be availableon application.
STANDARD SIZE RANGE
6m Straights (mm) Nominal Size 18m Coils (mm)
It is to be noted that lagging consisting of hair felt or other fibrous materialshould be used only in dry, well-ventilated places. The use of such lagging indamp or confined, poorly ventilated environments is not recommended.
®
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12.70 x 1.02
12.70 x 0.91
15.88 x 1.02
15.88 x 0.91
19.05 x 1.02
19.05 x 0.91
25.40 x 1.22
25.40 x 0.91
31.75 x 1.22
38.10 x 1.22
50.80 x 1.22
101.60 x 1.63
DN15A
DN15B
DN18B
DN18C
DN20B
DN20C
DN25B
DN25C
DN32B
DN40B
DN50B
DN100B
12.70 x 1.02
12.70 x 0.91
15.88 x 1.02
19.05 x 1.02
19.05 x 0.91
KEMLINE PVC COVERED COPPER TUBE
A range of copper tubes with a tough outer PVC sheathing is available foruse where corrosion or mechanical protection is required. KEMLINE®
copper tubes may be used for pneumatic or hydraulic control lines, gasreticulation and underground pipelines. The PVC covering is thinner thanKEMLAG and the product is available in a biscuit colour. It is also availablewith a LILAC coloured coating for recycled water services.
STANDARD SIZE RANGE (mm)
BISCUIT LILAC
6.35 x 0.91 12.70 x 0.91 31.75 x 1.22 63.50 x 1.227.94 x 0.91 19.05 x 1.02 38.10 x 1.22 76.20 x 1.639.52 x 0.91 25.40 x 1.22 50.80 x 1.22 101.60 x 1.63
Consideration will be given to requests for additionalsizes for both KEMLAG® and KEMLINE®.
LP GAS PIPELINES FOR VEHICLE ENGINESRigid copper fuel supply piping that is subject to container pressure shall bein accordance with AS 1432 or AS 1572.
A minimum nominal thickness of 0.91mm applies to DN10 copper tube orsmaller, whilst for larger sizes the minimum nominal thickness is to be noless than 1.02mm.
KEMLINE pre-insulated tube is used for this application to satisfy the requirementsof Australian Standard AS 1425: “LP gas fuel systems for vehicle engines”which specifies that piping is to be protected throughout its exposed length.
It is recommended that reference be made to AS 1425 to identify specificinstallation practice requirements.
®
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COPPER TUBE FOR REFRIGERATIONAn extensive range of copper tube is manufactured specifically to cater forthe special requirements of refrigeration gas lines. These tubes comply withthe required internal cleanness limits specified in AS/NZS1571: Copper-seam-less tubes for air-conditioning and refrigeration.Tubes are factory cleaned and supplied sealed to maintain the cleanness ofthe bore under normal conditions of handling and storage.
Standard stock sizes of AS/NZS 1571 tube are incised at approx. 0.5m intervalswith our manufacturing trademark, the Australian Standard number and thicknessof tube e.g. KEMBLA AS/NZS 1571 0.91. Non-stock sizes may be availableon request.
The Joint Australian/New Zealand Standard AS/NZS 1677 addresses safety,design, construction, installation, testing, inspection, operation and maintenanceof refrigeration systems. Important considerations are:
■ The refrigerant must be compatible with copper.Ammonia is not compatible with copper.
■ Tubes must be able to withstand the maximum working pressure of the system, based on the maximum operating temperature.
■ Precautions should be taken, at the design stage, to accommodate movement due to thermal cycles.
■ Liquid hammer may produce pressures in excess of those anticipated at the design stage. The undesirable pressures could cause failure of piping, hence they should be avoided.
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KEMBLA AS/NZS 1571 tube for air conditioning, refrigeration and mechanical services.
Actual Tube SizeCopper Tube Safe
Working Pressures (kPa)
Service Temperature Range (˚C)Imperial (inch) Metric (mm)Outside
DiameterOutside
DiameterWall
ThicknessWall
ThicknessUp to 50
Over 50up to 65
0.032
0.032
0.032
0.032
0.032
0.040
0.035
0.040
0.045
0.036
0.048
0.055
0.036
0.048
0.064
0.036
0.048
0.064
0.072
0.036
0.048
0.080
1/4
5/16
3/8
1/2
5/8
5/8
3/4
3/4
3/4
7/8
7/8
7/8
1
1
1
1 1/8
1 1/8
1 1/8
1 1/8
1 1/4
1 1/4
1 1/4
6.35
7.94
9.52
12.70
15.88
15.88
19.05
19.05
19.05
22.22
22.22
22.22
25.40
25.40
25.40
28.58
28.58
28.58
28.58
31.75
31.75
31.75
0.81
0.81
0.81
0.81
0.91
1.02
0.89
1.02
1.14
0.91
1.22
1.40
0.91
1.22
1.63
0.91
1.22
1.63
1.83
0.91
1.22
2.03
10635
8290
6800
4995
3945
5030
3600
4150
4670
3140
4265
4930
2730
3705
5025
2420
3275
4435
5015
2170
2935
5005
9545
7440
6105
4480
3540
4515
3230
3725
4190
2815
3825
4425
2450
3325
4510
2175
2940
3980
4500
1950
2635
4495
Notes: Safe working pressures have been based on tube minimum thickness and the annealed temper design tensilestress values specified in Australian Standard AS 4041 - “Pressure Piping”. The calculations allow for softeningwhen tubes are brazed or heated. The test pressure for copper piping installations shall not exceed 1.5 times thesafe working pressure of the copper tube. Tubes with increased wall thickness have been included in the table toaddress high working pressures associated with new generation refrigerants with different pressure requirements.Operating pressures for specific refrigerants should be obtained from refrigerant suppliers. When designing andinstalling refrigerant piping, reference should be made to current local regulations and the joint Australian/NewZealand Standard AS/NZS 1677 “Refrigerating Systems”. Pink = suitable for all refrigerants, including R410A.
COPPER REFRIGERATION TUBE
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Actual Tube SizeCopper Tube Safe
Working Pressures (kPa)
Service Temperature Range (˚C)Imperial (inch) Metric (mm)Outside
DiameterOutside
DiameterWall
ThicknessWall
ThicknessUp to 50
Over 50up to 65
0.036
0.048
0.080
0.048
0.090
0.036
0.048
0.064
0.094
0.048
0.036
0.048
0.064
0.048
0.064
0.064
0.064
0.110
1 3/8
1 3/8
1 3/8
1 1/2
1 1/2
1 5/8
1 5/8
1 5/8
1 5/8
2
2 1/8
2 1/8
2 1/8
2 5/8
2 5/8
3
4
4 1/8
34.92
34.92
34.92
38.10
38.10
41.28
41.28
41.28
41.28
50.80
53.98
53.98
53.98
66.68
66.68
76.20
101.60
104.78
0.91
1.22
2.03
1.22
2.29
0.91
1.22
1.63
2.41
1.22
0.91
1.22
1.63
1.22
1.63
1.63
1.63
2.79
1970
2660
4525
2435
4690
1660
2240
3020
4550
1810
1265
1700
2290
1375
1845
1610
1200
2015
1770
2390
4065
2185
4210
1490
2010
2710
4080
1625
1135
1530
2055
1230
1655
1445
1080
1805
KEMBLA AS/NZS1571 tube for air conditioning, refrigeration and mechanical services.
COPPER REFRIGERATION TUBE
20
STEAM LINESLightweight, ductility, ease of installation and corrosion resistance are someof the attributes which make copper worthy of consideration for steam lines.When designing steam lines it is necessary to:■ Refer to the requirements of AS 4041■ Select tubes which will withstand the maximum operating pressures and
temperatures of the system. Safe working pressures and temperatures for tubes are addressed on page 22.
■ Avoid steam hammer which could produce undesirable pressure surges.■ Ensure provision is made to accommodate thermal expansion.■ Take precautions to eliminate vibration from the piping.■ Tubes should be no thinner than those specified in AS 1432 for Type B
sizes.■ Copper tube may not be suitable when steam is contaminated with
chemicals and where high velocities could be involved.
kPa
1020304050607080
kPa
90100200300400500600700
˚C
45.860.169.175.981.385.990.093.5
kPa
800900
100011001200130014001500
˚C
96.799.6120.2133.6143.6151.9158.8165.0
˚C
170.4175.4179.9184.1188.0191.6195.1198.3
AIR LINES
Corrosion resistance and ease of installation make copper an attractivealternative to steel piping for air lines. In comparison to plastics, copperresists damage, will not burn or evolve toxic gases and offers maximum scopefor modification with minimum interruption to the service.
At both the design and installation stages, attention should be given toselecting the appropriate tube for the maximum operating pressures andtemperatures. Accommodation should be made for expansion, avoidanceof vibration and hammer which might result from the operation of fast-actingsolenoids.
21
Saturated Steam Pressures (Absolute)
SAFE WORKING PRESSURE CALCULATIONS FOR COPPER TUBES
The safe working pressures for copper tubes at temperatures up to 50˚Care shown on pages 11 to 13. Values for elevated temperatures may be cal-culated by multiplying Psw figures at 50˚C by the appropriate temperature fac-tor, T. For sizes outside AS 1432, values for other tubes may be calculated bythe following formula. Calculations are based on annealed tube to allow forsoftening at brazed joints.
2000 x S x tmin
D - tmin
PSWD=
Where:PSW
S
T
D
tmin
D
= minimum wall thickness (mm)
= outside diameter (mm)
= maximum allowable design tensile stress for annealed tube (see below)
= temperature factor
= safe working pressure (kPa)
Values for SD for various temperature ranges were taken from AS 4041,Pressure Piping Code.Design strengths at intermediate temperatures may be obtained by linearinterpolation.
Temperature Range ˚C
up to 50over 50-75over 75-125over 125-150over 150-175over 175-200
MAXIMUM ALLOWABLEDESIGN TENSILE STRESS ( )
(MPa)
413433322821
SD T
1.000.830.800.780.680.51
The testing pressures for copper plumbing installationsshould not exceed 1.5 times the safe working pressure.
Note: 1 kPa = 0.145 p.s.i100 kPa = 1 bar
22
BRASS TUBE FOR SANITARY PLUMBING
A range of 70/30 DR brass tubing is available for use in sanitary plumbingwork. The tubes are specially produced for this application and meet therequirements of Australian Standard AS 3795. Each tube is clearly identifiedat intervals along the length with an ink mark e.g.
KEMBLA AUSTRALIA AS 3795 LIC 1043 DR BRASS DN50D
KEMBLA DR BRASS tubes are manufactured from an inhibited brass alloywhich is virtually immune from dezincification. Individual tubes are marked“DR BRASS” to highlight that the material is dezincification resistant. Tubesare supplied in a special 1/2 hard temper to ensure they are free from residualstress. For restrictions on the use of brass tubes refer to page 60.
Standard 70/30 DR BRASS Tube Sizes
Nominal Size
DN40BDN40DDN50BDN50DDN65BDN80BDN80DDN100BDN100D
Actual Size (mm) Nominal Mass (kg/m)
1.210.911.621.222.043.562.454.373.28
Nominal Capacity (L/m)
1.001.031.841.882.934.184.277.597.72
Tube Mass Calculation Formula
M = (OD - T) x T x Y
Where:M = Tube mass per metre (kg/metre)OD = Outside diameter (mm)T = Thickness (mm)Y = Constant
MATERIAL
Copper70/30 Brass
CONSTANT - Y
0.02810.0268
23
38.10 x 1.2238.10 x 0.9150.80 x 1.2250.80 x 0.9163.50 x 1.2276.20 x 1.6376.20 x 1.22
101.60 x 1.63101.60 x 1.22
Based on maximum mean outside diameter and standard thickness30 metre length coilProjected AS 1432 large sizes (kg/metre) - see page 14.
AS1432 COPPER TUBESAPPROXIMATE MASS PER LENGTH (kg)
NomSize Straights
6mCoils18m
DN6DN8DN10
DN15DN18DN20
DN25DN32DN40
DN50DN65
DN80DN90DN100
DN125DN150DN200
DN225DN250
TYPE A TYPE B TYPE C TYPE DCoils18m
Coils18m
Straights6m
Straights6m
Straights6m
4.175.394.39
6.039.0512.66
19.6024.8330.07
--
---
---
--
0.831.081.46
2.013.024.22
6.538.28
10.02
13.5117.00
25.3929.7334.08
42.7766.6689.27
20.5822.90
3.384.333.96
5.437.679.30
14.9218.8422.76
--
---
---
--
0.680.871.32
1.812.563.10
4.976.287.59
10.2012.81
20.4923.9827.47
34.4551.4768.85
16.7618.65
--
3.16
4.316.898.35
11.27--
--
---
---
--
--
1.05
1.442.302.78
3.76--
--
---
---
--
---
---
-4.735.71
7.659.60
15.4218.0420.65
30.0741.439.23
12.9214.37
✱
✱ ✱
✱
▲
◆
◆
◆
◆ ◆
◆◆
✱
◆
▲
24
FITTINGS SPECIFICATIONS AND SIZE RANGESKembla Tube & Fittings offers a full range of Kembla brand copper and copperalloy fittings for use in both pressure and non-pressure applications.Copper capillary pressure fittings, which are marked AS 3688, complementthe safe working pressures of AS 1432Type B copper tubes of similar nominaldiameter.Compression fittings have been added to the Kembla range to provideplumbers an even wider choice for making copper piping joints. These precisionmade brass fittings are dezincification resistant, as are non-pressure copperalloy fittings. The range of Kembla fittings complies with and is marked inaccordance with the relevant StandardsMark and WaterMark requirementsof SAA MP 52.
Copper
Size Ranges
Capillary fittings
High pressure bends, tees
3D long radius bends
Reducers
Victaulic fittings
Compression fittings
SWV fittings
Expansion joints
Traps, gullies & fittings
Pan collars
AS 3688
AS 3688
AS 3688
AS 3688
AS 3688
AS 3688
AS 3517
AS 3517
AS 1589
AS 1589
DN 15-250
DN 32-250
DN 15-250
DN 15 x 10
250 x 200
DN50-DN150
-
DN 32-250
DN 32-150
DN 32-100
DN 100 &
100 x 80
-
-
-
DN 40 x 32
100 x 80
-
DN10-20
DN 32-100
DN 32-100
DN 32-100
DN 100 &
100 x 80
Type Specification Brass
AS 1589 Copper and copper alloy waste fittingsAS 3517 Capillary fittings of copper and copper alloy for non pressure
sanitary plumbing applicationsAS 3688 Water Supply - Copper and copper alloy body compression
and capillary fittings and threaded end connectorsSAAMP52 Manual of authorization procedures for plumbing and
drainage products
Standards Applicable to Copper and Copper Alloy Fittings
25
FITTINGS PRODUCT RANGE1. Pressure and Non-PressureCapillary ElbowsCapillary JoinersCapillary TeesCopper Cap and LiningsCopper ConnectorsCopper CTS Bend with IOCopper CTS Bends PlainCopper CTS Junction BendsCopper CTS Junction Bends InvertedCopper CTS Sweep Junction AdaptorsCopper JunctionsCopper Pressure BendsCopper Pressure TeesCopper Reducers - ConcentricCopper Reducers - EccentricEnd CapsExpansion JointsInspection PiecesPan Collars
P TrapsPalazzi Traps Cast Brass Tubular OutletS TrapsTrap Adaptors (Ruffs)Trap ComponentsTrapscrew Rings (Brass)Trapscrew (Cleaning Eyes)Tube Bushes DR Brass FemaleTube Bushes DR Brass Male70/30 DR Brass Bends Plain70/30 DR Brass Bends with IO70/30 DR Brass Tubular Gully Traps70/30 DR Brass Cap and Linings70/30 DR Brass Connectors70/30 DR Brass Junction Bends70/30 DR Brass JunctionsLanding Valve Adaptors70/30 DR Brass Reducers - Concentric70/30 DR Brass Reducers - Eccentric
2. Compression Fittings
✱ EZY-SEAL: UNF thread and nylon olive✱ OZTITE: BSP thread with copper or nylon olive✱ OZFLARE: 60˚ flare compressionRange:Unions, elbows, wall elbows, tees, nuts, olives, cones, stop ends and nuts.
3. Screwed Brassware
Elbows, tees, backnuts, caps, sockets, adaptors, bushes, nipples and all thread and plugs.
26
The Copper Victaulic system is anew concept for joining largediameter copper tubing. In usesince 1925 for steel (and otherIPS pipe), cast and ductile iron,the grooved piping concept is nowavailable to join copper tubing(CTS) in DN50 to DN150 sizes.The system uses a proven pressure-responsive synthetic rubber gasketto seal on the outside diameter ofthe tubing. This means no heat isrequired and no lead is used. Thecoupling housing surrounds thegasket gripping into groovesrolled into the tubing. The housingis isolated from the fluid but providesthe gripping strength for pressureratings up to 355 PSI (2460kPa),depending on the type of coppertubing and size.A Stub Flange Adaptor is availablewith Tables D and E, ASA Class150, or DIN flanges to permit theeasy adaption of flanged products.
mechanical jointing system
Compatible copper fittings in 90˚,45˚ elbow, tee and reducing configurations are supplied groovedready for installation.Standard Victaulic Vic-Easy® rollgrooving tools (VE-226AC andVE-26AC) can be used to field orshop roll groove all types ofAustralian copper tubing.Tools must be equipped only withVictaulic rolls designed specificallyfor grooving Australian coppertube (colour coded copper). DONOT use rolls intended for steelpipe or joint failure may occur.All Copper Victaulic Fittings aremanufactured in accordance withAustralian Standards AS 3688 foruse in conjunction with HardDrawn Copper Pipe to AustralianStandards AS 1432 Types A, Band D.
27
PRODUCT RANGE
Couplings & Valves
Copper Elbows 90˚, 45˚
Copper Tees - Equal, Reducing
Copper Reducers
Tapping Bands
Copper Flange Adaptors
Flanges
Caps/End Plugs
Roll Grooving Machines
Gasket Lubricant
A whole new way to join DN50 to DN150 copper tubingwith dimensions to Australian Standard AS 1432.
28
ACCESSORIESKembla Plumbing Fittings produce a range of plumbing assemblies and accessories , at a factory located in Brisbane.Facilities are available for forging, bending, brazing, pipe fabrication, polishing and chrome plating.
PRODUCT RANGE
29
Recess Tees.Shower Arms.Spouts.Water Meter Assemblies.Assemblies tapped for water savingdevices.Washing Machine Combinations &Adaptors.Fire Sprinkler Droppers.
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Combinations & Breeching Pieces.Prefabricated Assemblies.Annealed & Chrome Plated CopperTube.Bathroom Accessories.Exposed Combinations.Laundry Arms.Pipe Clips & Saddles.Recess Combinations.
PRODUCT NUMBERSSHOWN AREINDICATIVE ONLY. LOCALVARIATIONSAPPLY.
08530Shower Assembly
08635Extended HoseCock Outlet
08527Shower Assembly Top Inlet/Tails Up
08512Reverse Bath & Shower Assembly
086160862008621Twin ScrewedOutlet
08627Single
Screwed Outlet
Under most normal operating conditions, Kembla copper and brass tubeswill resist serious corrosion. However, special precautions need to be takento protect pipelines which will be buried in aggressive soils and thoseexposed to corrosive atmospheres. Part of the complete Kembla plumbingsystem is a range of petrolatum coatings for the protection of:
■ Either bare piping or bends and joints in Kemlag lines■ Complete unprotected pipelines
Petrolatum tape is a non woven bonded synthetic fabric, fully impregnatedand coated with neutral petrolatum based compounds and inert fillers.Petrolatum tape is chemically inert and does not polymerise or oxidise andtherefore retains its water resistance and dielectric properties over an indefinite period.
Prior to the application of the tape, the surface should be cleaned and coatedwith petrolatum priming paste. This primer is used to displace surface moistureto passivate surface oxides and to fill small irregularities.
A petrolatum mastic compound is available to improve the contour offlanges, bolts, valves and other irregular shapes prior to applying tape. Whileapplying petrolatum tape, smooth the tape surface by hand to eliminate airbubbles and to ensure intimate contact and lap seals.
PIPEDIAMETER
DN20DN25DN32DN40DN50DN80DN100DN150DN200
RECOMMENDEDTAPE WIDTH (mm)
5050757575100100150150
PETROLATUM TAPE(ROLLS) ✱
4050424759658483107
PETROLATUMPRIMING PASTE (kg)
1.72.12.73.03.85.67.210.613.8
Note: An overlap of 55% is generally recommended,however a minimum 20mm overlap may be used onpipes DN150 and larger.
✱ Allowance for 55% overlap.
CORROSION PROTECTION SYSTEMS FOR PIPE & FITTINGS
30
COVERAGE ESTIMATES / 100m
WATER SUPPLY PIPING DESIGNCopper tube is renowned for its satisfactory performance in plumbing systems. However, when occasional problems have occurred, subsequentinvestigations revealed that, in general, failures were either associated withsystem design or an aggressive operating environment. At the design stage,all aspects of the internal and external service conditions must be consid-ered if failures are to be avoided.
WATER COMPOSITION
Long term performance of copper water pipes is dependant on theestablishment of a natural, protective, internal surface film. The quality ofsome waters may preclude the development of protective films. Untreatedwaters which do not have buffering capacity and transient conditions areboth potential contributors to the non-development or degradation of desirablefilms in copper pipes.
Low pH of water, less than 7, can contribute to the internal deterioration ofwater mains and service pipes. Linings on cement-lined mains may beattacked and calcium carbonate deposit on copper piping and initiatecorrosion cells. The potential for cuprosolvency increases as water pHdecreases below 7. In acidic water, there is likelihood of small traces ofcopper going into solution.
Elevated pH water is now also suspected of being a contributor tocuprosolvency. In the 1996 Australian Drinking Water guidelines, it is statedthat, “New concrete tanks and cement-mortar lined pipes can significantlyincrease pH...”. The effectiveness of some chlorination treatments may bediminished in high pH waters and result in deterioration of the waters microbiological quality.
The composition of untreated supplies and bore waters should be examined to ensure compatibility with copper prior to installation of piping.Untreated tank water may not be compatible with copper due to the waterslack of stability and potential microbiological variability.
31
WATER MAINS
It is important to examine the layout and condition of the water mains whichwill service the building. Properties with extensive distribution systemsshould not be connected to the end of a large water main as accumulatedsedimentary matter may settle on pipes and develop into corrosion cells.Ring mains are essential. In situations where there is a low draw off ratefrom the mains a flushing facility may be necessary.
DEAD LEGS
Copper pipe systems must be free from sections in which potable watermay remain stagnant for long periods. Particular attention must be given topipeline design in laboratories, the location of drinking fountains, domesticbar sink taps, ensuites, ice making machines etc. Where possible, suchfixtures should be connected with short length to a main flow line or if such isimpractical, connected close to a downstream regularly used water service.
32
PIPE SIZINGPipe sizing is critical. Pipes must not be oversized as low velocities, lessthan 0.5m/sec, may allow undesirable suspended solids in the water todeposit on pipes. Excessive velocities will cause turbulence and maydestroy protective films.
All piping should be accurately sized to ensure acceptable flow rates tofixtures and appliances without exceeding maximum velocity limits.Information required for sizing calculations include:1. Minimum and maximum pressure available at the main;2. Minimum and maximum pressure requirements for outlets to fixtures
and appliances.AS/NZS 3500.1.2 specifies a minimum pressure of 50kPa at the most disadvantaged fixture and a maximum static pressure of 500kPa atany outlet.
3. Head losses through tubes and fittings;4. Static head losses.
Accurate pipe sizing may require full hydraulic calculations.
More information on this subject is contained in the following publications:1. AS/NZS 3500 - Australian National Plumbing and Drainage
Part 1.2 - Water Supply: available from Standards Australia2. Selection and Sizing of Copper Tubes for Water Piping Systems:
available from the Institute of Plumbing Australia.
FLOW RATES AT FIXTURES OR APPLIANCESThe flow rates from taps, valves and to cisterns should not be less thanthe values given below.
Water ClosetBathBasin
Spray TapShower
Sink (standard tap)Sink (aerated tap)
Laundry TubWashing MachineHot Water SystemHose Tap (DN20)Hose Tap (DN15)
Fixture/Appliance Flow Rate (L/s)
0.100.300.100.030.100.200.100.200.200.200.300.20
33
RECOMMENDED WATER VELOCITIES
(i) Pipelines at mains pressure
(ii) Pipelines from storage tanksserving -the next two floorsbelow the next two floors
(iii) Pipelines (pumped supply) -suction pipelinesdelivery pipelines
Section of Water ServiceInstallation
Acceptable Velocity(m/s)
1.0 to 3.0
0.1 to 0.51.0 to 1.5
1.2 to 2.01.5 to 3.0
Exclusive of fire services, the recommended maximum water velocityin piping shall be 3 m/s.
These velocities are related to acceptable sound levels of moving watercontaining entrained air and to minimise the effects of erosion. Erosion inwater tubing results from the impingement of rapidly moving water, sometimes containing air bubbles or suspended solids, and can result incomplete penetration of the tube wall. The problem of impingement is morenoticeable at sharp changes in direction (bends, tees) where localisedturbulence can lead to high water velocities.
Irregularities in the bore caused by dents, misalignment, distortion at bends,solder globules, etc, can lead to erosion damage downstream.
34
CAPACITYHow many litres of water in 65 metresof DN80A tube.
CAPACITY (C) = L x N
L = tube length in metresN = calculation factor for DN80A
C = L x N= 65 x 4.087= 265.7 litres
To determine the overall mass of apipe filled with water, add the appropri-ate value from the Table on page 24.
VELOCITYDetermine the velocity of water in a DN20B tube with 0.25 litres/sec flow rate.
VELOCITY (V) =
Q = flow rate in litres/secN = calculation factor for DN20B
V = =
= 1.10 metres/sec
FLOW RATECalculate the flow rate in a DN15Btube with 1.5 metres/sec water flowing.
FLOW RATE (Q) = V x N
V = velocity in metres/secN = calculation factor for DN15B
Q = V x N= 1.5 x 0.093= 0.14 litres/sec
Q 0.25N 0.227
QN
FRICTION LOSSFind the friction loss in DN100B tubewith water at 15˚C flowing at 18 litres/sec.
FRICTION LOSS (H) = F x Q
F = calculation factor for DN100B at 15˚C
Q = flow rate in litre/sec
H = F x Q
= 0.0266 x 18= 4.83 metres/100metres
Note: 1kPa = 0.102 metres head
... Pressure loss =
= 47.4 kPa/100 metres
ALLOWANCE FOR FITTINGSFind the pressure loss in a DN100 lineflow tee fitting at 10 litres/sec flow rate.
HEAD LOSS (H) = A x
A = fitting loss factor (see table)Q = flow rate in litres/secN =calculation factor for DN100B
H = A x
=0.046 x
= 0.08 metres
Pressure loss =
= 0.78 kPa
PRESSURE LOSS AND FLOW DATA FOR COPPER PIPESAND FITTINGS CALCULATION FORMULAE
The following formulae may be used in conjunction with the tables on page 36and 37.
151.8
151.8
1.8
15
QN
2( )
4.83
0.102
QN
2( )10
7.595
2( )
0.08
0.102
35
CALCULATION FACTORS FOR WATER FLOW RATES IN AS 1432COPPER TUBE
68
1015182025324050658090
100125150200
68
1015182025324050658090
100125150200
1015182025324050658090
100125150
0.0160.0290.0440.0890.1420.2060.3850.6370.9531.7752.8504.0875.6537.472
11.87116.99930.766
0.0190.0330.0470.0930.1500.2270.4140.6750.9991.8372.9284.1795.7607.595
12.02617.28331.146
0.0520.1000.1550.2330.4370.7041.0341.8842.9884.2735.8717.723
12.10717.469
7397017460
66601215
400162.7
36.4310.864.1340.92990.29850.12560.057680.029530.0097230.0041070.000989
4928012880
57971103
347.4129.1
30.69.483.70.8570.280.1190.0551 0.02840.009420.003950.00096
4546927322121
26.98.573.400.8060.268 0.1130.05270.02730.009270.00385
TYPE
6939016380
62501140
375152.634.1810.19
3.8780.87230.28000.11780.054110.027700.0091210.0038530.000928
4623012085
54381035
325.9121.128.7
8.893.470.8040.2620.1120.0517 0.02680.008840.00370.0009
426487030211425.3
8.043.190.7560.25 0.1060.04940.02560.00870.00361
5823013740
5245958315128.1
28.688.5493.2540.73210.23500.098900.045410.023250.0076540.0032330.000778
3879510140
4563868273.5101.6
24.17.462.910.6740.220.09380.0434 0.02240.007420.003110.00076
3579730254
95.621.2
6.752.680.6340.211 0.08890.04150.02150.00730.00303
5500012980
4955905297121
27.098.0743.0740.69140.22190.093410.042890.021960.0072290.0030540.000736
3664095754310
820258.3
95.9922.77.052.750.6370.2080.08880.041 0.02110.007010.002930.000714
3380690240
90.320.06.372.530.5990.1980.0840.03920.02030.00690.00286
NOMINALSIZEDN
N(CAPACITY)
L/m
CALCULATION FACTORSCONSTANTS FOR FRICTION LOSS BASED ON
WATER TEMPERATUREF at 4˚C F at 15˚C F at 60˚C F at 82˚C
WATER FLOW RATES
36
Type A
Type B
Type C
Type D
FITTING LOSS FACTORS ‘A’
DN150DN100DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80Diameter
FITTING ‘A’ VALUE
ELBOW
Branch
Flow
TEES
BEND 90˚Long Radius
Reducers
Outlets
Stop Taps
Gate Valves
Globe ValvesLift Check
Valves
Swing CheckValves
Angle Valves
0.112
0.061
0.122
0.046
0.051
0.026
0.714
0.018
0.714
0.280
0.459
0.087
0.048
0.107
0.046
0.051
0.026
0.51
0.014
0.51
0.189
0.332
0.076
0.041
0.097
0.046
0.051
0.026
0.434
0.012
0.434
0.153
0.255
0.071
0.033
0.092
0.046
0.051
0.026
0.408
0.011
0.408
0.138
0.204
0.061
0.027
0.082
0.046
0.051
0.026
0.367
0.009
0.51
0.102
0.138
0.051
0.021
0.076
0.046
0.051
0.026
0.357
0.0087
0.434
0.102
0.122
0.046
0.018
0.071
0.046
0.051
0.026
0.332
0.0082
0.382
0.102
0.112
0.041
0.015
0.061
0.046
0.051
0.026
0.306
0.0071
0.357
0.102
0.107
0.036
0.012
0.056
0.046
0.051
0.026
0.255
0.0066
0.321
0.102
0.102
0.031
0.010
0.051
0.046
0.051
0.026
0.204
0.006
0.276
0.102
0.098
37
TUBE SIZE DN10B TUBE SIZE DN15B TUBE SIZE DN18B
HEAD LOSS HEAD LOSS HEAD LOSS
15˚ckPa/m
15˚ckPa/m
15˚ckPa/m
60˚ckPa/m
60˚ckPa/m
60˚ckPa/m
Velocitym/s
Velocitym/s
Velocitym/s
FlowRateL/s
0.050.060.070.080.090.100.120.140.160.180.200.220.240.260.280.300.320.340.360.380.400.420.440.46
PRESSURE LOSS ESTIMATES FOR TYPE B COPPER TUBES
1.061.281.491.701.912.132.552.98
2.433.374.455.656.998.4511.7315.48
2.042.833.734.745.877.099.84
12.99
0.540.650.750.860.971.081.291.511.721.942.152.372.582.803.01
0.460.640.851.081.331.612.232.953.754.635.606.657.788.89
10.26
0.390.540.710.901.121.351.872.473.143.894.705.586.527.538.61
0.330.400.470.530.600.670.800.931.071.201.331.471.601.731.872.002.132.272.402.532.672.802.933.07
0.150.200.270.340.420.510.700.931.181.461.762.092.452.833.233.664.114.585.085.606.146.707.297.90
0.120.170.220.280.350.420.590.780.991.221.481.762.052.372.713.073.453.854.264.705.155.636.126.63
38
TUBE SIZE DN20 TUBE SIZE DN25 TUBE SIZE DN32
HEAD LOSS HEAD LOSS HEAD LOSS
15˚ckPa/m
15˚ckPa/m
15˚ckPa/m
60˚ckPa/m
60˚ckPa/m
60˚ckPa/m
Velocitym/s
Velocitym/s
Velocitym/s
FlowRateL/s
0.100.150.200.250.300.350.400.450.500.550.600.650.700.750.800.850.900.951.001.201.401.601.802.00
PRESSURE LOSS ESTIMATES FOR TYPE B COPPER TUBES
0.440.660.881.101.321.541.761.982.202.422.642.863.08
0.190.390.660.981.361.792.282.823.414.054.735.476.25
0.160.330.550.821.141.511.912.372.863.403.974.595.24
0.240.360.480.600.720.850.971.091.211.331.451.571.691.811.932.052.172.292.422.90
0.040.090.160.230.320.430.540.670.810.961.121.301.481.681.882.102.332.572.813.91
0.040.080.130.190.270.360.450.560.670.790.931.071.241.411.561.761.952.152.363.28
0.220.300.370.440.520.590.670.740.810.890.961.041.111.191.261.331.411.481.782.072.372.672.96
0.030.050.070.100.130.170.210.250.300.350.400.460.520.580.650.720.790.871.211.602.032.513.04
0.020.040.060.080.110.140.170.210.250.290.340.380.440.490.550.610.670.731.021.341.702.112.55
39
TUBE SIZE DN40 TUBE SIZE DN50 TUBE SIZE DN65
HEAD LOSS HEAD LOSS HEAD LOSS
15˚ckPa/m
15˚ckPa/m
15˚ckPa/m
60˚ckPa/m
60˚ckPa/m
60˚ckPa/m
Velocitym/s
Velocitym/s
Velocitym/s
FlowRateL/s
0.20.40.60.81.01.21.41.61.82.02.22.42.62.83.03.54.04.55.05.56.06.57.07.58.08.5
PRESSURE LOSS ESTIMATES FOR TYPE B COPPER TUBES
0.200.400.600.801.001.201.401.601.802.002.202.402.602.803.00
0.060.070.140.230.340.470.620.790.981.181.411.641.902.172.46
0.020.050.110.190.290.400.520.660.820.991.181.381.591.822.06
0.330.440.540.650.760.870.981.091.201.311.421.521.631.912.182.452.722.99
0.030.050.080.110.140.180.230.270.330.380.440.500.560.750.961.181.431.70
0.030.040.070.090.120.150.180.230.270.320.370.420.480.630.800.991.201.42
0.340.410.480.550.610.680.750.820.890.961.021.201.371.541.711.882.052.222.392.562.732.90
0.030.040.050.060.070.090.110.120.140.160.190.240.310.390.470.550.650.750.850.971.091.21
0.020.030.040.050.060.080.090.100.120.140.160.210.260.320.390.460.540.630.720.810.911.02
40
TUBE SIZE DN80 TUBE SIZE DN90 TUBE SIZE DN100
HEAD LOSS HEAD LOSS HEAD LOSS
15˚ckPa/m
15˚ckPa/m
15˚ckPa/m
60˚ckPa/m
60˚ckPa/m
60˚ckPa/m
Velocitym/s
Velocitym/s
Velocitym/s
FlowRateL/s
1.02.03.04.05.06.07.08.09.0
10.0011.0012.0013.0014.0015.0016.0017.0018.0019.0020.0020.5021.0021.5022.0022.5023.00
PRESSURE LOSS ESTIMATES FOR TYPE B COPPER TUBES
0.240.480.720.961.201.441.681.912.152.392.632.873.11
0.010.040.080.130.200.280.360.460.570.690.820.961.21
0.010.030.070.110.170.230.310.390.480.580.690.810.93
0.350.520.690.891.041.221.391.561.741.912.082.262.432.602.782.95
0.020.040.060.090.130.170.210.260.320.380.440.510.590.660.750.83
0.010.030.050.080.110.140.180.220.270.320.370.430.490.560.620.70
0.390.530.660.790.921.051.181.321.451.581.711.841.972.112.342.372.502.632.702.762.832.902.963.03
0.020.030.050.070.090.110.140.170.200.230.270.300.340.390.430.480.530.580.600.630.660.690.710.74
0.020.030.040.050.070.090.110.140.160.190.220.250.290.320.360.340.440.480.500.530.560.570.600.62
41
TUBE SIZE DN125 TUBE SIZE DN150 TUBE SIZE DN200
HEAD LOSS HEAD LOSS HEAD LOSS
15˚ckPa/m
15˚ckPa/m
15˚ckPa/m
60˚ckPa/m
60˚ckPa/m
60˚ckPa/m
Velocitym/s
Velocitym/s
Velocitym/s
FlowRateL/s
5.07.5
10.012.515.017.520.022.525.027.530.032.535.037.540.042.545.047.550.055.060.065.070.075.080.0
PRESSURE LOSS ESTIMATES FOR TYPE B COPPER TUBES
0.420.620.831.041.251.461.661.872.082.292.492.702.913.12
0.020.030.050.080.110.150.190.240.280.340.400.460.520.59
0.010.030.050.070.100.130.160.200.240.280.330.380.440.50
0.580.720.871.011.161.301.451.591.741.882.032.172.312.462.602.752.893.18
0.020.030.050.060.080.100.120.140.170.190.220.250.280.310.340.380.420.49
0.020.030.040.050.070.080.100.120.140.160.180.210.230.260.290.320.350.41
0.480.560.640.720.800.880.961.041.121.201.281.361.441.531.611.771.932.092.252.412.57
0.010.020.020.020.030.030.040.050.050.060.070.080.080.090.100.120.140.160.180.210.23
0.010.010.020.020.020.030.030.040.040.050.060.060.070.080.090.100.120.140.160.180.20
42
WATER HAMMERHydraulic shock in pipelines is commonly referred to as water hammer.However, water hammer is only one result of the harmful effects created byhydraulic shock. Hydraulic shock occurs when fluid flowing through a pipeis subjected to a sudden, rapid change in velocity. The pressure wave generated travels back and forth within the piping until the energy is dissipated.
When the tubes are not adequately secured or supported, or the tube runsare particularly long, these rebounding pressure waves cause the tubes tovibrate and hit against the supporting structure causing the noise referredto as water hammer. The noise is objectionable but not, in itself, inherentlydangerous. Noise may not be as noticeable in plastic pipes but damagingshock stresses are still imposed on pipes and fittings. Hydraulic shock cancause damage to joints, taps, valves, meters and even to the pipeline itself.Water hammer effects can be generated by foot action taps, solenoid valvesin clothes and dishwashing machines, quick acting quarter-turn taps andpumps. Tube should be fixed in position securely at the spacings shown inthe table on page 44 to minimise noise associated with hydraulic shock.Water hammer effects may be minimised by reducing the velocity of thewater flow in the tubes, reducing the inlet pressure of the water in the sys-tem, closing manually operated taps slowly and by fitting slow acting sole-noid valves.
In certain cases it may be necessary to fit a water hammer arrestor as closeas possible to the source of the problem. These devices are available fromplumbing merchants.
Additional information on this subject is outlined in the “Water HammerBooklet” produced and supplied by the Copper Development CentreAustralia: phone - 02 9380 2000 and fax - 02 9380 2666. A Copper Industrytoll free Help Line 1800 426637 is available if assistance is required toresolve persistent existing water hammer problems.
43
Large diameter riser Quick closure valve
Quick Closure
Enlarged Pipe
Shock Flow
Branch
Pressure Wave Enlarges Pipe
COPPER TUBES EXPOSED TO FREEZING CONDITIONSFreezing of water within the tube can result in bursting and precautionsshould be taken to prevent direct exposure of piping to these conditions.When the ambient air temperature regularly falls below freezing, all pipinglocated outside buildings should be buried to a minimum depth of 400mm. Anyexposed sections should be covered with a continuous waterproof insulation.In very cold climates, it will be necessary to provide additional insulation overthe normal pre-insulated tubes. Piping within the building may also freezeup if it is located in positions which are difficult to keep warm. These areaswould include on the outside of roof or wall insulation batts, unheated roofspaces, unheated cellars, locations near windows, ventilators or externaldoors where cold drafts occur, and any location in direct contact with cold sur-faces such as metal roofs, metal framework or external metal cladding. Tubesinstalled in any of these locations should be insulated to minimise the pos-sibility of water freezing.
Where it is unavoidable to install copper tubes on metal roofs, special caremust be taken to insulate the pipeline to prevent bi-metallic corrosion. It isrecommended brackets be used to lift the tube off the roof and the entirepipeline be covered with a waterproof insulation which will withstand theanticipated environmental conditions. Factory pre-insulated tubes will not pro-vide adequate protection to prevent water freezing in exposed pipes.
The suggested minimum thickness of the insulation required to minimise freez-ing problems is given on page 45. It should be noted that the presence ofinsulation will not prevent water freezing if the conditions are particularlysevere over an extended period of time. In situations where the building isnot in use over the winter months, and no heating of the inside area is main-tained, it may be necessary to completely drain the pipes to prevent damageby water freezing.
44
NOMINALSIZE
DN15DN18DN20DN25DN32DN40DN50
MAXIMUMFIXING (m)
1.51.51.52.02.52.53.0
NOMINALSIZE
DN65DN80DN90
DN100DN125DN150
MAXIMUMFIXING (m)
3.04.04.04.04.04.0
PIPE SPACINGThe following MAXIMUM FIXING distances apply to horizontal and verticalruns of copper piping for water supply:
MINIMUM THICKNESS FOR THERMAL INSULATION
Thermal conductivity of insulating material (W/m.K)
PipeSize
Minimum thickness required (mm)
0.03 0.05 0.06 0.07
DN15DN18DN20DN25DN32
0.04
96432
149643
2012854
29151065
40201286
These insulation thicknesses were calculated, using the formulaegiven in BS 5422, to just prevent freezing of water initially at 15˚C ifexposed to an ambient temperature of -5˚C for a period of 8 hours. Iftemperatures fall below -5˚C or freezing conditions extend for periodsof longer than 8 hours, additional thickness of insulation may benecessary.
It is important to note that water will freeze first in small diameterpipelines.
THERMAL CONDUCTIVITY OF INSULATING MATERIALS
Thermal conductivity(W/m.K)Example of material
Rockwool or fibreglass sectional pipeinsulation (prefabricated sections)
Rockwool or fibreglass loose fill orblanket material.
Foamed nitrile rubber
Loose vermiculite (exfoliated)
Flexible foamed plastic (Kemlag)
0.032
0.032-0.045
0.040
0.06-0.07
0.070-0.075
45
INSTALLATION PRACTICESAFETY PRECAUTIONS
ELECTRICAL EARTHING
Do not break, cut or remove sections of metallic water tubing used as anearth electrode for an electrical installation or remove a water meter beforesuitable precautions have been taken to ensure that it is safe to do so andminimise the risk of electric shock.
The main switch or switches on the premises shall be switched off and a tagreading ‘DANGER DO NOT SWITCH ON’ attached over the switch.
A bridging conductor, fitted with suitable clamps and having a current ratingof not less than 70A, shall be connected across the intended gap.
The pipe shall be cleaned to bare metal where the clamps are to be connected.
The electrical bridge shall not be broken or removed until all work on the waterservice is completed and continuity of the metallic service pipe is restored.
Where any existing metallic service pipe is to be replaced in part or in itsentirety by plastics pipe or other non-metallic fittings or couplings, the workshall not commence until the earthing requirements have been checked byan electrical contractor and modified, if necessary.
ROOF AND TRENCH WORK
Special care must be taken by a plumber engaged in roof or trench work.Before commencing such work, it is imperative that the job be plannedcarefully with specific attention given to worker safety. All trench and roofwork must be performed in accordance with safe practice and requirementsspecified by the regulatory authority.
PROXIMITY OF WATER PIPES TO OTHER SERVICES
Above and below ground water services shall be installed so that no potentialsafety hazard is created when in close proximity to other services. Accessshould be provided for maintenance and modifications to piping. Detailedinformation is outlined in AS/NZS3500.1.2.
46
PLUMBING PRECAUTIONS INSTALLATION AND DESIGN
If the life expectancy of a copper system is to be maximised, it must bedesigned correctly and installed by professional, trained personnel usingestablished practices.
Care is to be taken to ensure piping is free from damage and distortion. Bendsare to be of uniform radius and joints made without internal obtrusions. Also:● Fluxes must be flushed from pipes and fittings. It is unnecessary to use
flux for copper to copper joints if silver-copper-phosphorus filler rods are used.
● Overheating is to be avoided.● Pipes are to be clamped securely within specified spacing limits.● Potential sources of vibration are to be eliminated to avoid noise and
possible premature failure due to fatigue. Water hammer is an area of concern [see page 43].
● Forces due to expansion and contraction must be calculated andaccommodated in the design.
CLEANING
Piping must be flushed regularly with clean compatible water during installationand prior to commissioning of the building. If water is allowed to stagnate,deposits may interfere with the formation of protective films on copper.
SUPPLY TANKS
Tanks should be flushed on a routine basis to prevent sludge build-up andsubsequent pollution of water services.Protective coatings on lined tanks must be inspected regularly for deterioration.
EARTH RODS
Electrical earths must be installed properly if associated corrosion problemsare to be avoided. Pipe and earth rod connection clamps must be clean,secure and positioned correctly.
The use of electrical isolation fittings at water main tappings have reducedcurrents flowing from mains into properties and vice versa.
PROTECTION OF POTABLE WATER SUPPLIES
All water supply systems shall be designed, installed and maintained so asto prevent contaminants from being introduced into the potable water system. Only potable water shall be supplied to plumbing fixtures for drinking, bathing, culinary use or the processing of food, medical or pharmaceutical products. Backflow prevention devices are used to preventcontamination of potable water supply.Special references to hazard ratings and the requirements for use ofbackflow prevention devices are outlined in AS/NZS3500.1.2.
47
JOINTING METHODS
Copper tubes can be easily joined using compression fittings, capillary fittings and either soft solders or silver brazing alloys, or by ‘fittingless’ plumbingtechniques using silver brazing alloys.
When joining the ends of pipes of different diameters, a reduction fittingshall be used. It is unacceptable to crimp the larger tube and fill the cavity.
In order to ensure high quality, leakproof joints are made, the following precautions should be taken:
(a) COMPRESSION JOINTS
Compression fittings are available in various forms, ie olive, flared and croxedtypes. It is important:
● tube ends should be square and de-burred.● flaring, swaging and croxing tools should be well maintained and free
from scores or damage.● care must be taken to avoid twisting or distortion of tube by not over-
tightening.● tube shall not be crimped or grooved.
The EZY-SEAL fittings distributed by Kembla offer significant installationadvantages including:
● no need to dis-assemble the fitting.● fine thread for ease of application.● custom designed as a nylon olive fitting.● use DN10 for both 3/8” and metric tube mixer tails.● re-usable joint.● suitable for 95˚C maximum temperature and 2MPa pressure.
To install EZY-SEAL fittings:
i. Loosen the nut of the fitting approximately 1/2 turn.ii. Insert the tube fully to the tube stop.iii. Hand tighten the nut onto the body.iv. Securely tighten the nut using two wrenches, one on the nut and one on
the fitting body. Continue to tighten the assembly until a firm feeling is encountered [approximately 40 ft/lb torque].
v. Check for leaks.
48
(b) SOFT SOLDERED CAPILLARY FITTINGS
● Soft soldered fittings are to be of the long engagement type complying with AS3688.
● Tube ends must be square, de-burred and thoroughly cleaned.● Flux should be applied uniformly around the tube surface and residues
removed immediately the joint has cooled.● Fluxes containing ammonium compounds, amines or its derivatives
must not be used.● Uniform heating should be applied to joints and overheating avoided.● The joint should be made in such a way that globules of solder are not
retained on the inside or outside surfaces of the tube.● A solder containing not more than 0.1% lead must be used. Compositions
of some suitable ‘lead-free’ soft solders are given below:
● Soft solders are not to be used with annealed coiled copper tube.● The chemical composition of water in some areas may preclude the use
of soft soldered joints.
(c) SILVER BRAZED JOINTS
● Tube ends are to be square, de-burred and thoroughly clean.● Fully engage the tube and fitting or expanded end of mating tube.● Tube and joint are to be well supported.● Apply heat in a uniform manner to the tube and joint area until brightred.● Brush the filler metal rod into the shoulder of the fitting. It should melt
on contact and flow by capillary action around the joint.● Maintain a cherry red colour until joint penetration is complete.● Avoid overheating and the formation of filler metal globules inside and
outside the joint.● When the joint is complete, either allow to cool in air or, if necessary,
quench in water or with a damp cloth.● The silver brazing filler metal must contain a minimum of 1.8% silver and
maximum 0.05% cadmium.● Flux is not necessary for copper-to-copper joints when a silver-phosphorus-
copper filler metal is used but must be used for brass fittings and pipes.● When flux is used, it should be applied uniformly and sparingly.
49
% Tin
96.59599
96.5
%Antimony
-5--
%Copper
--14
%Silver
3.5--
0.5
● Flux should be non-aggressive and water soluble. It must not contain ammonium compounds, amines or its derivatives.
● In fabricated fittings, branches are not to penetrate main lines where flow conditions apply.
● During the brazing process, surrounding combustible structures must beprotected from heat by using a heat shield.
● Filler rod ends should be disposed of thoughtfully.
(d) COLOUR IDENTIFICATION OF SILVER BRAZING ALLOYS IN ACCORDANCE WITH AS1167
ColourIdentification
AlloyClassification
Melting Range˚C
Silver Content %
Silver-Copper-Phosphorus Alloys for Flux-Free Brazing of Copper
Silver-Copper-Zinc Alloys [Cadmium-free] for intermediate temperaturebrazing
Canary [Yellow]SilverTan [Brown]
B2B3B4
645-704645-740645-700
25
15
PinkGold
A3A8
688-744660-780
5040 + 2%Ni
50
(e) EXPANDED JOINTS
Tubes of the same diameter may be joined end-to-end by expanding theend of one length with a purpose-built expansion tool to form a socket intowhich the mating tube is inserted, prior to brazing as in Section (C).
When making expanded joints:
● Tube ends must be cut square and internal burrs removed.● Prior to expansion, the tube ends should be softened [annealed] uniformly
to a dull red colour using a heating torch, then cooled.● Use only purpose-built expansion tools that have been maintained in
good working order.
(f) BRANCH FORMING
This practice reduces the need for fittings and the number of brazed joints.It is ideal for pre-fabrication, retrofit projects and where piping modificationsare required during construction.
Hand and electric forming tools are available for rapid production of branchesup to DN50. When using tools, follow the manufacturer’s instructions.Tools may be available to make branches larger than DN50 or alternativelylarge branches for pressure piping and angled junctions in sanitary plumbingpipes may be manually formed by:
● Cutting an undersized oval hole in the main tube.● For tee connections at 90˚, the dimension of the larger diameter of the
oval hole should be equal to the diameter of the branch tube lessallowance for an overlap which will form a collar not less than 4 times the main tube thickness once the socket has been formed.
● With entries at 45˚ or greater, the diameter measurement is taken from the angular cut branch tube, making similar allowances for socket overlap.
● Heat the surface around the hole to a dull red colour and cool with a wet cloth.● Insert a dressing pin into the oval hole then carefully and evenly form the
socket to accept the branch tube. The pin can be manipulated by either hand or use of a mallet.
● If required, heat can be applied to soften metal around the hole during dressingout. Copper must not be over-heated past dull red, whereas brass is not to be worked in the 250˚-550˚C range to avoid embrittlement.
● The inserted branch must not penetrate or obstruct the main pipe bore.● Branch formed joints must be silver brazed.
51
(g) ROLL-GROOVED JOINTS
Roll-grooved joints have been in use since 1925. A roll-grooved systemhas recently been developed for Australian Standard DN50-DN150copper tube diameters. Special copper tools are available to producejoints as are pre-grooved tees, elbows and reducing fittings.
When installing roll-grooved tube, refer to the special systeminstallation instructions. Some precautions are:
● Cut the pipe square. It must be free from distortion and de-burred.● Groove the pipe with the appropriate Australian copper grooving tool.
Steel grooving roll sets must never be used.● Ensure the gasket landing is smooth and clean.● Measure the accuracy of the groove against the specification.
Check pipe is not out of round.● Apply lubricant to inside and outside of gasket.● Slide gasket onto the end of one pipe.● Bring pipe ends together and slide gasket into place between
grooves.● Undo one bolt on the coupling and place coupling over gasket.● Make sure that the coupling sits squarely in the grooves.● Tighten bolts.● Only Australian size couplings are to be used.● Never dis-assemble joints unless they have been depressurised.
(h) PUSH-FIT JOINTS
Various types of push-on fittings are approved for copper piping.It is important when using such fittings that:
● Tube ends are cut square and de-burred.● The fitting manufacturer’s installation instructions are followed.● Attention must be given to whether such fittings will break electrical
earth continuity.
52
CONCEALMENT OF COPPER WATER SERVICES
In order to provide accessibility for maintenance, it is recommended that allhot and cold lines be concealed, wherever possible, within areas such ascornices, pelmets, cupboards, skirtings or ducts.As a matter of principle, it is not recommended that service lines becast into or buried under reinforced concrete slabs.Reference should be made to the specific regulations and codes of practicelaid down by the local responsible authority when any tubes are to be concealed.Particular attention should be given to requirements specified in theNational Plumbing and Drainage Code.
The following general information is provided for guidance when tubes areto be concealed in relatively inaccessible locations.
(i) TUBES IN WALLS
Copper water services located in walls shall not be less than Type C. In timberframework, holes are to be accurately sized to firmly locate fully laggedpipe. Alternatively, neutral cure silicon sealant is to be used to completely fillthe annular space and secure unlagged pipes.
Holes drilled in metal frames are to be accurately sized to accommodatelagged pipes, suitable grummets or sleeves compatible with copper. Thereshould be no direct contact between pipes and framework or restriction ofmovement.
(ii) TUBES IN CHASES, DUCTS OR CONDUITS
All tubes should be lagged with an approved flexible foamed plastic material.Pipelines should be clipped and held in place in chases with easily removablemortar. Ducts must have removable covers. Proper provision should bemade for expansion of hot water lines. Care should be taken to preventdamage to the tube.
(iii) TUBES UNDER CONCRETE
Pipelines laid under concrete should be no thinner than Type B. Jointsshould be kept to a minimum and made using approved silver brazing alloy.Tubes are to be either Kemlag or placed in a water-tight conduit. The endsof the conduit and Kemlag should be sealed to prevent ingress of water. Wheretube penetrates a slab it is to be lagged with a minimum thickness of 6mmflexible water-tight lagging. Soft soldered joints are not permitted. All jointsare to be kept to a minimum but it is preferable to have no joints beneathconcrete slabs.
53
(iv) TUBES IN CONCRETE
When there is no suitable alternative to embedding tubes in concrete wallsor floors, they should be located in chases or ducts with removable covers.All tubing should be no thinner than Type B and covered over its completelength with an approved foamed plastic material. Tubes should not extendthrough any expansion joint in the concrete. Proper provision should bemade for expansion of the concealed tubes and the connecting tubesoutside the concrete structure.
Note: Kemlag pre-insulated tube is an approved flexible foamed plastic material for use in concealed piping.
(v) TUBING BELOW GROUND
Water supply tubes laid below ground shall have a minimum cover as follows:
In PUBLIC AREAS 450mm covering is required for unpaved, paved or roadsurfaces whilst 300mm depth is required for solid rock.
In PRIVATE PROPERTY a 300mm cover applies to areas subject to vehiculartraffic, 75mm under houses or concrete slabs and 225mm for all other locations.
Copper and copper alloy tubes and fittings should not be used unless suitablyprotected against external corrosion where they might be in contact withsuch materials as:
ash, sodium chloride [salt], magnesite, ammonia and its compounds or derivatives, nitrates, nitrites, mercury salts, foundry sands, animal excreta,urine or any other identified or potential aggressive environment.
In such cases tube and joints should be continuously protected by a toughwaterproof covering. Kemlag pre-insulated tube is ideally suited to theseadverse environments provided joints are adequately protected and endssealed. Unprotected tubes should not be laid in or allowed to cross rubbledrains or similar waste disposal systems.
54
PROTECTION FOR JOINTS
Loose fitting Kemlag sheaths are available in one metre lengths which canbe cut and slipped over breaks in DN15 and DN20 nominal size Kemlagtubes.
Dimensions of these sheaths are such that they may be slipped overKemlag and fittings as shown below:
Heat shrink sleeving could be used to protect straight joints in largerdiameter Kemlag installations. Petrolatum products are recommendedwhen covering tees, bends and other bulky fittings.
INSTALLATION OF HOT WATER LINESThe operating conditions for hot water lines differ in many respects fromthose for cold water, and consideration of the important differences will helpavoid failures from incorrect pipeline design or unsatisfactory installationtechniques.
Two important factors which must be considered are:
1. Movement of the tubes due to expansion and contraction.2. Corrosion rates increase with increasing temperature.
On occasions, due to incorrect design, longitudinal expansion and contractionresults in a repeated alternating stress concentrating in the tube andultimate failure by corrosion fatigue.
55
Copper Tube Copper TubeFitting
KemlagInsulationKemlag Sheath or petrolatum tape products
Overlaps to be taped
During planning, special attention should be given to location of fittings,bends, ends of runs, branch joints, and to those areas where heat from brazingor soldering has softened the tube causing a localised loss in strength. Thestressing produced from expansion effects usually concentrates in theseregions and these are the most likely sites for corrosion fatigue failures.
To minimise the effect of localised stressing, it is necessary to make sufficient allowance for the free movement of the tube. This implies not onlya loose fit between the tube and its surroundings, but also that adequateallowance is made for the increase in length resulting from thermal expansion.
The amount of longitudinal movement depends on the length of the run andthe expected temperature change. Minimum practical values can beobtained from Table 1.
Table 1
ALLOWANCE FOR LENGTH INCREASE [mm]
Temperature Increase ˚C
Up to 3Over 3 to 5Over 5 to 9Over 9 to 12Over 12 to 15Over 15 to 20Over 20 to 25
100
69
1622273645
90
58
1520243240
80
58
1317222936
70
47
1215192531
60
46
1013162227
40
3479
111518
50
358
11141823
Tube Length[metres]
Table based on the formula:
Expansion [mm] = tube length (m) x temperature rise (˚C) x 0.0177
A useful “rule of thumb” for normal hot water lines is to allow for 1mm expan-sion for every 1 metre of straight run.
The effects of expansion and contraction may be minimised by installingtubes in ducts or clear space and this should be done wherever possible.
56
Expansion loops, bellows or bends may also be used for larger installationswhich have relatively long runs and for tubes of large diameters or in situationswhere significantly large temperature differences occur repeatedly.
The following diagrams show standard dimensional loops and offsets withsuitable radii being given in Table 2.
Expansion loops and offsets must be placed horizontally to avoid formingair locks at the top of the loops and to ensure proper circulation of the water.It is preferable to locate the bend or loop as close to the mid point of thestraight run as possible.
U-Bend
Coiled Loop
Offset Bend
'Lyre' Bend
RR
R
R
R
R
R
RR
3.41R
2.83 R
45˚
4R
4R
57
DN125DN100DN15 DN20 DN25 DN40 DN50 DN65 DN80 DN90
RADII FOR EXPANSION LOOPS AND BENDS ‘R’ (mm)Expansion
(mm) NOMINAL TUBE SIZE
Table 2
1015202530405060708090100
180220250300320340400450460510610680
210270300350370430480530560610640760
250290380400430490550630660710740840
320370430500530620680760790860920990
350410510550610720780880910990
10201120
4004405606306607708809601020112011501190
430500620680740870100010601130122012501340
470540670730780920105011601220132013501420
5106007108108401000115012601320141014301470
5606507909109501130130013501450153015501570
Table 3
* For pipe sizes DN18 and DN32 the next larger pipe is used.
Provision for expansion must be considered when designing tuberuns and fixing points by allowing freedom of movement at bends,branches and offsets.
Allowance for expansion should incorporate:i. A clear space to permit movement - refer Table 3 [B]ii. Sufficient free length of tubing around the bend or along thebranch to prevent over-stressing the tube - refer table 3 [A].
L(run length)
m
Up to 4.5Over 4.5 to 9Over 9 to 18
A(free length)
Min.mm
6009001200
B(for 60˚C temp rise)
Min.mm
51020
58
Fatigue cracks have sometimes occurred at bends in hot water lines wherethe tube passes from one structure to another, eg from a concrete floor upinto a wall.
To reduce stressing of the tube in this region, the bend radius should be aslarge as possible. These cracks usually occur on the sides of the bendwhere the tube is oval and result from flexing of the wall of the tube at thesepoints.
Additional precautions should be taken to ensure that hot water lines arenot damaged by flattening or twisting as these faults can act as stress concentrators and lead to failure by fatigue.
59
COPPER AND BRASS TUBES FOR SANITARY PLUMBINGIt is well known that copper and brass tubes offer significant advantages todesigners of sanitary plumbing systems. Some attributes are the material’slight weight, ease of installation, flexibility, space saving capacity, corrosionresistance and ability to be prefabricated.
Nevertheless, careful attention must be given to material selection andinstallation practice if a system is to perform satisfactorily. The completeinternal and external operating environment is to be considered whenselecting pipeline materials. Corrosive discharge liquids or aggressive surrounds could reduce the life of a system.
MATERIAL LIMITATIONS:COPPER PIPES AND FITTINGS
● Pipes and fittings shall not be used for urinal discharges only, but may be permitted where the flow is diluted by discharges from regularly used upstream fixtures. They shall not be used in conjunction with grease arrestors.
● Type B pipes shall not be field bent beyond a 10 degree offset angle.● Type D pipes shall be used in straight lengths only and shall not be offset
by bending.● Type D pipes shall not be used for sanitary drainage below ground.● Bends and junctions at the base of stacks up to 9m in height shall be
formed from no thinner than Type B pipe.● For stacks greater than 9m in height, bends and junctions at the base are
to be cast or hot pressed copper alloy.
BRASS PIPES AND FITTINGS
● Pipes shall only be used in the as-supplied 1/2 hard temper.● Pipes shall not be bent, offset or misaligned.● Pipes shall not be used with compression fittings.● No fitting other than a junction shall be fabricated in the field.● Local annealing is only permitted where necessary for making joints.
It is important to note that some cleaning chemicals have contributed to thecorrosion of metal pipes. Both copper and brass may be affected by someundiluted discharges from commercial dishwashers, glass washers and barsinks.
60
PIPE SUPPORT
Vertical and graded pipes are to be supported at maximum intervals of 3metres. Pipes are not to be supported or spaced by means of brazing orwelding short sections of material to the surface of each pipe.All brackets are to be lined with an inert, non-abrasive material where theycontact pipes. Other than at expansion joints, the brackets shall, when fullytightened, permit tube to move longitudinally. Brackets are to clamp expansionjoints securely and prevent their movement.
EXPANSION JOINTSSTACKS
Where a stack passes through more than 2 floors, whether above its baseor above any offset bend, expansion joints are to be fixed:● At the base of the stack or in the vertical pipe above an offset bend.● At alternate floor levels where the stack is unrestrained or at each floor level
except the top floor when the stack is restrained or is subject to hot discharges.● The expansion joint at any intermediate floor is to be placed immediately
above the junction of the highest discharge pipe connected to the floor concerned.
GRADED DISCHARGE PIPES
An expansion joint is to be installed as close as practicable to the stack inany restrained, graded discharge pipe exceeding 6 metres in length.
BED PAN SANITIZER AND WASHER
An expansion joint is to be installed at each floor in any soil stack, soil ventand steam relief vent pipe connected to a bed pan sanitizer and washersupplied with steam.
FREEDOM FROM RESTRAINT
A pipe is considered to be unrestrained provided that:● No restraint on longitudinal movement occurs where it passes through walls
or floors. A 6mm annular space is to be provided and the space may be filled with an approved flexible sealant [page 62].
● No restraint on movement shall occur on any branch discharge pipe for a distance of 450mm from its junction with a stack.
Where the discharge pipe penetrates any floor or wall within such distance, a 6mm annular space is to be provided. The space may be filled with anapproved flexible sealant.
61
Hot discharge Cold discharge
Expansion joint notrequired at top floorunless restrained atpoint of roofpenetration.
Clear space6 min.
5th
Expansion joints
4th
Expansion joint aboveoffset bend
3rd
Expansion joints
2ndExpansion
joint
1st
Expansion joint at baseof stack
Ground floorGround level
(a) Location of expansion joints
Flexiblesealant
Clear space6 min.
Clear space6 min.
Flexiblesealant
Free of restraint
450 min.(b) Freedom from restraint
DIMENSIONS IN MILLIMETRESNote: Vents omitted for clarity
Expansion Joints in Copper and DR Brass StacksCopied from AS/NZS3500.2.2
62
PENETRATION SEALANTS
The installation of pipes through fire rated members is critical. Particularattention is needed where pipes penetrate various adjoining fire ratedcompartments. In the event of a fire, flames must be restricted from passingfrom one compartment to another at points where pipes penetrate.
Special installation techniques have been developed, tested and certifiedto satisfy BCA requirements for copper and brass pipes. Specific caulkingcompounds are available to close off pipe penetrations and provide a firerated seal.
A Passive Fire Protection Manual - Service Penetrations and Control Jointsoutlines some certified techniques and materials. The manual is availablefrom FPA [telephone 03 9890 1544].
Sealant suppliers will assist in the identification of product suitable for spe-cific fire rating requirements.
PIPE GRADE CONVERSIONS
Percentage %
20.006.655.003.352.502.001.651.451.25
Ratio (gradient)
1 in 51 in 151 in 201 in 301 in 401 in 501 in 601 in 701 in 80
Percentage %
1.101.000.850.700.650.600.500.400.35
Ratio (gradient)
1 in 901 in 1001 in 1201 in 1401 in 1501 in 1601 in 2001 in 2501 in 300
63
COPPER TUBE FOR FIRE SERVICESCopper tube is permitted to be used in fire hydrant, hose reel and automaticsprinkler systems. However, limitations apply. When considering piping forthese applications, it is important that:
● Design and installation is performed by competent, accredited personnel.● Reference is made to current relevant Standards, some of which are listed
on page 8.● The local regulatory authority approves of the work to be performed and
materials to be used.
FIRE HYDRANT SYSTEMS
In accordance with AS2419.1, copper pipes used above or below ground inhydrant systems are required to comply with AS1432 Types A or B orAS1572 where thicker tube is necessary. Select tube which will meet a testpressure of 1700kPa or 1.5 times the highest working pressure, whichever isthe greater.
Soft soldered joints are not permitted.
Copper is prohibited to be used in above ground situations in non-firesprinklered buildings unless protected using materials which will provide aFRL of not less than -/60/60 or be located in a floor or ceiling system thatachieves a resistance to the incipient spread of fire of not less than 60 minutes.
FIRE SPRINKLER SYSTEMS
Copper is permitted to be used in wet fire sprinkler systems only as definedin AS2118.1 for hazard classifications up to OH3 Special, AS2118.4[Residential] and AS2118.5 [Domestic].
● Tube shall be to AS1432 and minimum Type B. Thickness will depend on applicable test pressures as outlined on page 67.
● Capillary and compression fittings to AS3688 are permitted to be used.● Joints may be brazed with minimum 1.8% silver-copper-phosphorus filler
metal.● Soft soldered joints are permitted for residential and domestic systems
as well as light and ordinary hazard 1 occupancies when piping is concealed in ceilings or void spaces.
● Copper may be bent to a minimum radius of 6 diameters for sizes DN50 or smaller and 5 diameters for larger sizes.
64
More detailed information on copper’s use for fire applications may be foundin the KEMBLA FIRE SYSTEMS HANDBOOK which is available, free ofcharge, from the various Kembla State Sales Offices. The Handbook is not asubstitute for relevant Standards or local authority regulations.
COPPER FOR GAS PIPING
Copper is approved for fuel gas piping in AG601 - Gas Installation Code. Itis suitable for conveyance of Town Gas, Natural Gas, Liquefied PetroleumGas in the vapour phase, Tempered Liquefied Petroleum Gas andSimulated Natural Gas:
● AS1432 Type A or B tube is required for pressures up to and including 200kPa.
● Copper is not permitted in the ground beneath a building at pressures above 7kPa unless protected with either a plastic coat [Kemlag] or aproprietary wrapping acceptable to the authority. Where pipe is coated, theentire length is to be protected and made water-tight, including ends.
● Permissible joints are: flared copper alloy compression, capillary, expanded sockets and formed branches [in hard tube only].
● Soft soldered joints and olive type fittings are not permitted.● When copper alloy [brass] fittings are to be buried in the ground, they
must be DR or effectively protected against corrosion.
65
TEST PRESSURES
Australian Standards for various systems specify that the piping is tobe tested to the following pressures. It is strongly recommended thatinstalled piping be tested prior to burial or concealment. Adherence tothis procedure will facilitate the location and repair of any leak exposedby the pressure test.
SYSTEM
Cold Water
Hot Water[excluding stor-age container orhot water heater]
SanitaryPlumbing
Gas Piping* specific practice is outlined inAG601* only applies fortest pressuresnot exceeding400kPa
Fire Hydrant
AUSTRALIANSTANDARD
AS/NZS3500.1.2
AS/NZS3500.4.2
AS/NZS3500.2.2
AG601
AS2419.1
PRESSURE
1500kPa for 30 minutes minimum
1500kPa for 30 minutes minimum
Hydrostatic test to flood level or airpressure test at 30kPa for 3 minutes minimum
a. New piping before appliancesare connected or repaired/alteredsystem with appliances isolated:* pressurise to 7kPa or twice operating pressure, whichever isgreater.* no loss of pressure during anisolation period of 5 minutes afterstabilisation plus an additional 5minutes for every 30 litres [0.03m3]of pipe volume.b. New piping or repaired/alteredsystems with appliances connected:* pressurise to operating pressure.* test period as for ‘a’.
Not less than 1700kPa for a periodof 2 hours or 1.5 times the highestworking pressure whichever is thegreater.
66
SYSTEM
Fire Hose Reel
Fire Sprinkler
* Domestic
* Residential
* AS2118
* Wall-wetting[drencher]
AUSTRALIANSTANDARD
AS/NZS3500.1.2
AS2118.5
AS2118.4
AS2118
AS2118.2
PRESSURE
1500kPa for not less than30 minutes.
Not less than 1500kPa.
Not less than 1500kPa.
1.4MPa for a period of 2 hours or400kPa in excess of the maximumstatic working pressure, whicheveris the greater.
1.4MPa for a period of 2 hours of400kPa in excess of the maximumstatic working pressure, whicheveris the greater.
PROTECTION DURING BUILDING CONSTRUCTIONCare is to be taken to ensure that water service pipes are not damaged duringnormal building activities. Concealed piping is to be maintained under normalwater pressure while subsequent building operations are being carried outwhich could cause damage to the pipes. The service must be flushed withclean water at regular intervals until the building is occupied.
BENDING KEMBLA COPPER TUBESa. GENERAL CONSIDERATIONS
The making of good bends in copper tube requires care and skill. Oneessential requirement is that the material must have sufficient ductility for itto deform into the shape of the bend without seriously weakening the tubewall or giving rise to undesirable distortion or fractures.
Distortion and fractures are usually caused by bending tool wear, excessivetube hardness or lack of proper bending techniques.
Good bends are produced with a smooth action of the bender without jerksor relative movement between bender and tube.
67
Annealed temper tube is desirable for hand bending since it can be workedwith the least amount of strain, and is more suited to the small radiusedbends used in plumbing installations.
When using hand bending tools, the presence of oil or grease in the grooveor on the tube, can lead to excessive wrinkling on the inside of the bend. Asimilar fault can result if the groove has been excessively worn. Kinking canoccur if the wiper shoe is not positioned correctly at the start of bending.
b. ANNEALING [SOFTENING] FOR BENDING
Heating for too long, or at too high a temperature, causes excessive graingrowth with little or no additional softening. It results in coarsening of thegrains and can cause an undesirable “orange peel” surface to develop duringbending. In the worst case, it can lead to rupture of the metal.
The typical range for annealing Copper and 70/30 DR Brass is 450˚-600˚C.This temperature range is distinguished by the heated metal changing to a“dull red” colour.
68
ANNEALING PROCEDURESThese can vary from large-scale furnace annealing, to the use of a gas torchwhere only localised annealing is required. Where torches are used, caremust be taken to avoid concentrating the heat on one spot or heating for anexcessive time. The annealing of thin-wall tube should be approached withextreme care as incorrect procedures can result in burning of the metal orloss of thickness due to oxidation. If undesirable grain growth is to be avoided,an accurate estimation of temperature is important. Furnace annealingnormally utilises pyrometers for this purpose, but with torch annealing theuse of temperature-sensitive crayons is recommended.
THE EFFECT OF TIME ON ANNEALINGThe time at temperature can vary from just a few minutes to 1/4 hour ormore. To achieve a fine grain size, it is best to anneal at lower temperaturesand correspondingly increase the “soak” time. Optimum properties can bestbe obtained by experimentation.
COOLING AFTER ANNEALINGCopper and 70/30 DR Brass tubes may be cooled by either quenching inwater or allowing to cool naturally in air.
SURFACE CLEANING [PICKLING]Any scale or other oxide products which develop on the surface of copper andbrass tubes when heating in air may be removed by immersion in appropriateacid solutions.
c. STRESS RELIEF AFTER BENDING
When tubes are bent cold, the metal is usually left in a state of internalstress. These residual stresses may cause some metals to crack when theyare exposed to certain agents such as ammonia, mercury, or liquid solder.The stresses can also cause a loss of shape which may be important if, forexample, the bent tube has to be brazed to form part of a fabricated assembly.If the tube is required to operate under onerous conditions, or if there is anydoubt about the need for such treatment, then it is always advisable to stressrelieve.
Stress relief is not normally required with copper, but is essential for 70/30 DRBrass. Treatment consists of heating in the temperature range 300˚-360˚C,and holding for a time sufficient to reduce the internal stresses to a safe level.10-15 minutes should be an adequate soak time for all tubes. An undueincrease in temperature or soak time is liable to produce a slight softening ofthe metal. There is no need for stress relief if the tubes have been bent hotand cooled naturally, or if the tubes are to be annealed soon after bending.
If there is any doubt about the adequacy of stress relieving treatment, or aneed to test for susceptibility to stress corrosion cracking, then this can bedone by means of the mercurous nitrate test. Details of this test are given inAustralian Standard 2136 and British Standard 2871: Part 3.
69
d. COLD BENDING
Provided correct tempers and tube thickness are chosen, copper and 70/30DR Brass can be bent cold.
The single, most important requirement in cold bending is that the materialshould be sufficiently ductile.Typical elongation values for copper and 70/30DR Brass are given on page 71.
Due to elastic recovery of the metal, some small allowance may be necessaryfor springback when accurate alignments are required.
There is always a tendency for the outside wall to flatten, and if this becomesobjectionable, it may be overcome by the use of internal support in the formof a mandrel, suitable filler material or by the use of bending springs.
e. HOT BENDING
Most metals can be bent hot providing there is adequate internal support bymandrels or suitable fillers to prevent distortion.
Large diameter tubes, principally those with thick walls, require mechanicalmeans for bending and are therefore commonly bent hot as this reduces theload required to effect the bend.
Hot cracking from embrittling agents or unsuitable fillers may occur andexamples of these are some low melting point alloys containing bismuthand cadmium, and sodium hyposulphite (hypo) filler.
Ordinary phosphorus deoxidised copper tubing (C12200) as used forplumbing, may be bent hot, but very high temperatures and prolonged heatingshould be avoided as excessive oxidation and grain growth can occur. Inextreme cases this can lead to a loss of grain boundary cohesion causingthe metal to crack during bending.
Copper tube may be bent hot in the range 700˚-800˚C, but excessive heatingtimes should be avoided. 70/30 DR brass tube may be hot bent in the range725˚-825˚C, but temperatures of 250˚-550˚C should be avoided as thematerial is susceptible to hot-short cracking in this temperature range.
f. TUBE BENDING CALCULATIONS
The minimum bend radius to which a tube can be bent depends on theamount of ‘stretch’ the outside wall of the bend will withstand without causingundue distortion or fracturing. Good ductility is thus an essential requirement.Other significant factors are tube material, diameter, wall thickness, and thetype of bending equipment employed.
There is relatively little difference in the bending characteristics of copperand brass although power requirements necessary to form bends willincrease as alloy strengths increase.
70
It is general practice when designating minimum bend radii, to refer to thedimension of the centreline of the bend in the case of round tubes and tothe inside of the bend in the case of square or rectangular tubes.
O.D.
r
R
The following formula which takes into account the tube’s ductility may beused as a rough guide for determining minimum bend radii:
R (Centre Line Radius) = r + 1/2 ODr is the inside bend radius.
Min. bend radius (R) = 50.8 x 5055
= 46.18mm=
Where R = minimum centre line radius and E = % elongation in 50mm.
Typical Elongation Values (E)
COPPER Soft - 55 Hard - 1070/30 DR BRASS Soft - 65 Hard - 15
Example: determine the minimum bend radius of a 50.8mm outsidediameter soft copper tube.
R = tube diameter (O.D. in mm) x 50
E
No minimum radii are available for hot bending, but buckling can be reducedby peening the inside of the bend. The more difficult bends are done slow-ly. Hot bending can result in some metals cracking and details of this havebeen given in the section on hot bending.
For making a given bend there is no precise demarcation as to whethertools are necessary, but guidance on their use may be obtained from the fol-lowing chart.
254055
71
BENDING WITHOUT TOOLS
TEMPERATURES BY COLOUR
APPEARANCE
Lowest red heat visible in the darkRed hot in the darkFaint redDark redBrilliant redCherry redBright cherry red
APPROX. TEMP ˚C
335400-500
516650-700
800900
1000
72
60
50
40
30
20
10
01 2 3 4 5 6 7 8 9 10 11 12 13 14
TUBES CAN BE HANDBENT WITHOUT USE OF
SPECIAL TOOLS SUCH ASMANDREL OR WIPER DIES
SPECIAL TOOLSREQUIRED
RATIO OFCENTRE LINE RADIUS (C.L.R.)
OUTSIDE DIAMETER (O.D.)
RA
TIO
OF
OU
TS
IDE
DIA
ME
TE
R (
O.D
.)W
ALL
TH
ICK
NE
SS
(w
t) APPROXIMATE LINEOF DEMARCATION
FOR ANNEALED TUBE
wtC.L.R. O.D.
CORROSION RATINGS OF COPPER AND 70/30 DR BRASS
ENVIRONMENT
AcetoneAcids............. Chromic
CitricHydrochloricNitricPhosphoricSulphuricTanicTartaric
AlcoholsAniline dyesAnimal/excreta and
decomposed undiluted urineAshesAsphaltAtmosphere....Industrial
MarineRural
BeerBenzene, BenzolBleaching PowderBrinesCarbon tetrachloride (m)Fruit juicesFuel oilGases........... Acetylene
Ammonia (m)Bromine (m)ButaneCarbon Dioxide (m)Carbon MonoxideChlorine (m)FreonHydrogenHydrogen Sulphide (m)MethaneNatural GasNitrogenOxygenPropaneSteamSulphur Dioxide (m)
COPPER
ADACDBCAAAC
DDAAAAAABBBBADDCABACAADABAAAAB
70/30 DR BRASS
ADCDDDDBCAC
CDABBBBADDDDBDDDACADAACAAAAACD
73
CORROSION RATINGS OF COPPER AND 70/30 DR BRASS (contuined)
ENVIRONMENT
GasolineKeroseneLacquersMagnesiteMercury and saltsSilver saltsSodium ChlorideSodium HypochloriteSugar solutionTrichlorethylene [dry]Trichlorethylene [m]Varnish - solventsWater..............Carbonated
PotableSea waterMine waterSoapySewage
COPPER
AAADDDBCAABABABCAA
70/30 DR BRASS
AAADDDDDBACACBCDBC
RATINGS
A - EXCELLENT under most conditions.B - GOOD. May be considered in place of ‘A’ when some other
property governs use.C - FAIR. May only have limited life.D - POOR. Not recommended.
Note:
● [m] moist● both materials unsuitable for use with ammonia, ammonium
compounds and amines.● tinning may be required if used in contact with food products.● some cleaning chemicals have contributed to the corrosion of
metal pipes. Both copper and brass may be affected by someundiluted discharges from commercial dishwashers, glass washersand bar sinks.
74
1
1728
6.1024x10-2
61024
61.024
277.4
16.387
28317
1
106
103
4546.1
5.787x10-4
1
3.5315x10-5
35.315
3.5315x10-2
0.16054
1.6387x10-5
2.8317x10-2
10-6
1
10-3
4.5461x10-3
1.6387x10-2
28.317
10-3
103
1
4.546
3.6046x10-3
6.229
2.1997x10-4
219.97
0.21997
1
1
104
1010
6.452
929
108
4.0469x107
2.59x1010
10-4
1
106
6.4516x10-4
9.2903x10-2
104
4046.9
2.59x106
10-10
10-6
1
6.4516x10-10
9.290x10-8
10-2
4.0469x10-3
2.59
10-8
10-4
102
6.4516x10-8
9.2903x10-6
1
0.40469
259
2.471x10-8
2.471x10-4
247.1
1.5942x10-7
2.2957x10-5
2.471
1
640
3.861x10-11
3.861x10-7
0.3861
2.491x10-10
3.587x10-8
3.861x10-3
1.5625x10-3
1
1.0764x10-3
10.764
1.0764x107
6.9444x10-3
1
1.0764x105
4.356x104
2.7878x107
0.155
1.55x103
1.55x109
1
144
1.55x107
6.2726x106
4.0145x109
1
102
105
2.54
30.48
91.44
1.6093x105
10-2
1
103
2.54x10-2
0.3048
0.9144
1609
10-5
10-3
1
2.54x10-7
3.048x10-4
9.144x10-4
1.609
0.3937
39.37
3.937x104
1
12
36
6.336x104
3.2808x10-2
3.2808
3280.8
8.3333x10-2
1
3
5280
1.0936x10-2
1.0936
1093.6
2.7778x10-2
0.33333
1
1760
6.2137x10-6
6.2137x10-4
0.62137
1.5783x10-5
1.8939x10-4
5.6818x10-4
1
1
103
2.83x10-2
0.45359
6.35
14.594
50.802
1016
10-3
1
2.83x10-5
4.5359x10-4
6.35x10-3
1.4594x10-2
5.0802x10-2
1.016
35.274
35274
1
16
224
514.8
1792
3.584x104
2.205
2.205x103
6.25x10-2
1
14
32.174
112
2240
1.9684x10-2
19.684
5.58x10-4
8.928x10-3
0.125
0.28727
1
20
9.8421x10-4
0.98421
2.79x10-5
4.464x10-4
6.25x10-3
1.436x10-2
5x10-2
1
6.8522x10-2
68.522
1.9425x10-3
3.1081x10-2
0.4351
1
3.481
69.62
0.15747
1.5747x102
4.464x10-3
7.142x10-2
1
2.298
8
1.6x102
VOLUME
USEFUL CONVERSION FACTORS
tonne oz lb stone toncwtslugkgMASS
m km in ft mileydcmLENGTH
acrehacm2AREA
m2 km2 in2 ft2 mile2
in3 ft3 cm3 m3 Imp. gal.litre
75
1
0.10197
1.4098x10-2
0.45359
1016
70.932
7.233
1
32.174
7.207x104
2.205
0.22481
3.1081x10-2
1
2.24x103
9.807
1
0.13826
4.448
9964
9.842x10-4
1.004x10-4
1.3875x10-5
4.4643x10-4
1
1
9.807
1.356
3.671x106
2.6478x106
2.6845x106
4186.8
1055.1
0.10197
1
0.13826
3.671x105
2.7x105
2.7374x105
4.269x102
1.076x102
0.73756
7.233
1
2.6552x106
1.9529x106
1.98x106
3.0878x103
7.782x102
10-6
9.807x10-6
1.356x10-6
3.671
2.6478
2.6845
4.1868x10-3
1.0551x10-3
2.7778x10-7
2.7241x10-6
3.7662x10-7
1
0.7355
0.7457
1.1629x10-3
2.9307x10-4
3.77x10-7
3.703x10-6
5.12x10-7
1.36
1
1.014
1.5811x10-3
3.9846x10-4
3.7251x10-7
3.653x10-6
5.0505x10-7
1.341
0.98632
1
1.5595x10-3
3.9301x10-4
9.4782x10-4
9.2949x10-3
1.2851x10-3
3412.1
2509.6
2544.4
3.968
1
1
12
0.20
39.37
1.0936x10-2
10.936
17.6
8.3333x10-2
1
1.6667x10-2
3.281
9.1134x10-4
0.91134
1.467
2.54x10-2
0.3048
5.08x10-3
1
2.7778x10-4
0.27778
0.44704
5
60
1
1.968x102
5.4681x10-2
54.681
88
91.44
1097.3
18.288
36x102
1
103
1609.3
9.144x10-2
1.097
1.8288x10-2
3.6
10-3
1
1.609
5.6818x10-2
0.68182
1.1364x10-2
2.237
6.2137x10-4
0.62137
1
1
3.937x10-2
13.595
0.53524
406.8
27.682
0.40146
4.0146
25.4
1
345.3
13.595
10332
703.1
10.197
101.97
1.868
7.3556x10-2
25.4
1
760
51.715
0.75006
7.5006
2.4909
9.8067x10-2
33.864
1.3332
1013.2
68.948
1
10
0.24909
9.8067x10-3
3.3864
0.13332
101.32
6.8948
0.1
1
7.3556x10-2
2.8959x10-3
1
3.937x10-2
29.921
2.036
2.953x10-2
0.2953
2.4577x10-3
9.6759x10-5
3.3421x10-2
1.3158x10-3
1
6.8046x10-2
9.8692x10-4
9.8692x10-3
3.6118x10-2
1.422x10-3
0.49115
1.9337x10-2
14.696
1
1.4504x10-2
0.14504
PRESSURE
in Hg atm kPambpsiin H2O
ft/s ft/min m/s m/h mphkm/hin/s
VELOCITY
hp.hrMetrichp.hrMJ
ENERGY
Joule kgf.m ft.lbf kW.hr Btu
FORCE
kgf N(kgm/s2) pdl lbf tonf
mm H2O torr (mmHg)
76
USEFUL CONVERSION FACTORS (cont.)
Emergency Cardiopulmonary Resuscitation
Stay with casualty - call for help and start resuscitation
Airway
● clear the airway● quickly turn the casualty on side● remove foreign material from mouth● place neck and jaw in correct positions.
● check breathing● listen to breath● watch for chest movement● if breathing, leave patient on side
- keep airway clear
Breathing
If not breathing:● quickly turn casualty on back● start expired air resuscitation, mouth to
mouth or mouth to nose● open airway● 5 full ventilations in 10 sec.
● check carotid pulse.If pulse present
● resuscitation at a rate of 15 per min[one every 4 sec]
● check the circulation after 1 min and then every 2 min.
Circulation
● check the carotid pulse.If absent:
● begin external cardiac compression● place the heel of one hand on the lower
half of the sternum● lock the other hand to the first by grasping
wrist or interlocking fingers● keep fingers off the chest
One operator:2 ventilations and
15 compressions every 15 seconds.Two operators:* one compression per second* one ventilation after every 5
compressions
Check progress
If effective:● carotid pulse felt with each compression● skin will become pinker
If breathing returns:● place the patient on side● keep the airway clear
Get Help
In metropolitan areas dial 000 and ask forambulance service. In country areas, contactyour local ambulance service.
77
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