Installation for ALMATHERM piping system is not different from any other conventional piping systems, except for the superior leak proof fusion joining system.

However, there are some finer points and guidelines that need special attention when installing ALMATHERM products.

 

Support Intervals

 

For visible pipe works that need aesthetics, proper support intervals are necessary. This will prevent unsightly but common ‘snaking’ or ‘sagging’ found in plastic pipe systems.

 

Pipe Support Intervals (mm) for ALMATHERM Classic Pipes PN10, PN16 & PN20;

 

Pipe Support Intervals (mm) for ALMATHERM STABI and FASER Pipes of PN16 & PN20;

 

 

 

Exposed Installations

 

Cold Water Risers

There is no need for expansion joint as there will be no linear expansion for ALMATHERM cold water pipes. Vertical support is necessary like all other piping systems.

 

Ceiling Walls

During the planning and laying of visible pipes for hot water on ceilings or walls, besides taking into account the support intervals, special attention must be given to the linear expansion due to temperature differences. This will also help to prevent ‘sagging’ and ‘snaking’ of pipelines. No consideration is necessary for STABI and FASER pipes. Hence, to prevent unsightly installations, the following appropriate procedure must be observed: 

 Linear Expansion

 

For transportation of hot water, like all metal or plastic pipes, we have to deal with its linear expansion. This applies only to the Classic PN20 pipes for hot water applications. No consideration is necessary for PN20 STABI and FASER pipes as the coefficient of linear expansion is 3.0 x 10 ¯5 (K ¯1).

The coefficient of linear expansion for the ALMATHERM Classic PN20 pipes is 15.0 x 10 ¯5 (K ¯1).

 

Step1. Determine the Linear Expansion using the calculation formula:

Δl = ϑ x L x Δt

 

Where:

Δl = linear expansion in mm

ϑ  = coeff. of linear expansion, constant for ALMATHERM PIPES 0,15mm/mk

Δt = temperature difference between normal water temperature and desired operating hot water temperature.

 

Example:

Pipe diameter of 25mm, length of 1,5m, normal cold water temperature is 25°C and hot water from water heater is set at 60°C.

Δl = ϑ x L x Δt

    = 0,15 x 1,5 x 35

Linear expansion is 7,88 ~ 8,00mm. Values for PN20  pipes can be found in following table.

 

Step2. once the Linear Expansion is established, compensation for this expansion can be made by either an Expansion Elbow or Expansion Loop.

 

Expansion Elbow

 

With FS= Fixed Support, SS= Sliding Support, EA= Elbow Arm

 

Formula to determine the length of Elbow Arm EA;

 

EA = k x (d x Δl)1/2

 

Where:

k = constant, 15

Δl = linear expansion

d = pipe diameter

 

Note: in an elbow expansion joint the FS must be located at the EA section and the EA perpendicular to the direction of expansion.

 

Example:

Pipe of diameter 25mm, length of 1,5m, normal cold water temperature is 25°C and hot water from water heater is set at 60°C

EA = k x (d x Δl)1/2

      = 15 x (25x8) 1/2

      = 212,13 ~ 212mm

 

Expansion Loop

 With FS= Fixed Support, SS= Sliding Support, EA= Elbow Arm

 

Formula to determine the Loop Width LW;

 

LW = (2x Δl) + SW

 

Where:

SW = Safety Width assigned as 150mm

Δl = Linear Expansion

 

Note: in an expansion lope, the FS is located at the pipe section of LW. All other pipe supports must be SS. Calculation of EA is the same as above expansion elbow example.

 

Example:

Pipe of diameter 25mm, length of 1,5m, normal cold water temperature is 25°C and hot water from water heater is set at 60°C

LW = (2x Δl) + SW

      = (2x8) + 150

The loop width is 166mm 

 

 

Concealed Installation

 

In concealed installation, for both cold and hot water pipe lines, it is not necessary to take into account linear expansion. Pipes can be encased or embedded in walls, concrete and plaster as with other metal pipes.

 

The expansion of pipe due to temperature with not damage the wall plastering as the linear expansion is prevented by the compressive strain and tensile stress of concrete and plaster, it will be absorbed through the material itself.

 

Insulation Hot Water System

 

Normally for hot water systems, it may not be necessary to insulate ALMATHERM pipes in tropical countries for interior or concealed installation. This is due to the low thermal conductivity property of ALMATHERM (0,24 W/mK). Heat loss will be minimum. However, for application where central boiler is used for distribution of hot water and the circulation of hot water being continuous, it is necessary to insulated distribution lines to prevent excessive loss heat and energy wastage. Because of the low thermal conductivity of ALMATHERM pipes, insulation thickness is greatly reduced. Following is the recommended insulation thickness.

 

Insulation thickness for exposed hot water pipes.

Chilled Water System

 

For chilled water of temperature less than 10°C, due to condensation that might take place, insulation is necessary but reduced considerably in thickness as compared to metal pipes. Heat loss for hot water pipe is reduced to a minimum.

 

Above table shows the insulation thickness for ALMATHERM pipes in cold countries and chilled water systems so as prevent condensation.

 

 

S   = Insulation Thickness, mm (0,038 W/mK Conductivity)

Te = Outside surrounding temperature, °C

Ti = Internal water temperature °C

 

 

Pressure Test

 

After installing ALMATHERM piping system, it is necessary to go through a pressure test. Unlike metal pipes, ALMATHERM like all other plastic pipe systems, had to follow different pressure test procedure owing to their mechanical properties of expansion when subject to pressure, temperature difference and coefficient of expantion.

A change in temperature of 10 K corresponds to a pressure change of 0,5 to 1,0 bar. Thus, the test medium shall as far as possible, be kept at a constant temperature throughout the test.

 

Test Procedure (According to DIN 1988 Part 2 or BS 6700: 1977)

 

Preparation for Filling Testing the System

 

For pressure testing, pressure gauges that allow reading of changes in pressure of 0,1 bar shall be used, fitted at the lowest possible point in the system.

 

Pressure testing for leakages must be conducted white pipe works are still accessible and before concealing or plastering.

 

Finished pipe work must be completely fitted with filtered water and vented.

 

Procedure

 

After pipe work is filled with water and completely vented to release air locks in the system, testing can begin:

  1. Test Pressure = (permissible working pressure + 5 bars) shall be produced 2 times within 30 minutes at 10 minutes intervals.

Note: Restore by hand pump to required test pressure after the 10 minute interval if the pressure drops. If leakage is detected, rectify the leakage are and repeat procedure.

 

  1. If no leakage is detected, for the next 30 minutes, check if the pressure has dropped by more than 0,6 bars and if there is any visible signs of leakage.

Note: if leakage is detected, rectify the leakage are and repeat procedure. If pressure drops by more than 0,6 bar within this period, leakage must have occurred. Detect and rectify.

 

  1. If pressure drop is within 0,6 bars and no leakage detected, continue the test without restoring the required pressure for the next 60 minutes. During this time, it shall be checked if the pressure drop is more than 0,2 bars and no leakage is detected.

Note: if leakage is detected, rectify the leakage are and repeat procedure. If pressure drops by more than 0,6 bar within this period, leakage must have occurred. Detect and rectify and repeat procedure.

  1. Pressure test is successful when all the above are met and the readings should be recorded.

 

Graphical Representation of Pressure Test Procedure.

 

 

 

Test Record

  

 

 Precautionary Measures during Installation

 

  1. To reduce from a large diameter pipe to a smaller diameter pipe, a socked must be used in conjunction with a reducer. For example, to reduce from pipe diameter of 50mm to 25mm, a socket of 50mm must first be attached to the 50mm pipe followed by a reducer 50/25mm and followed by the 25mm pipe.

 

  1. When using ALMATHERM fittings with metal threaded parts, white Teflon sealing tapes must be applied adequately to prevent prevent leakage from threads.

 

  1. Over tightening of fixtures to ALMATHERM fittings with metal parts may cause damages and leakage problems. Care must be taken to prevent over tightening.

 

  1. During Fusion Welding:

 

    1. Fusion parts must be free from sand and particles.
    2. Welding time and depths must be observed.
    3. Do not twist and turn pipes and fitting while inserting and detaching from welding machine.

 

  1. Metal plugs must be used during pressure tests.

 

  1. Pressure test must be conducted BEFORE concealing pipe works.

 

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