Gulf Construction Online - Pipes in the groove with sustainability

Environment Protection

Grooved piping ... have a union at every joint for easy re-routing during system expansion.

Pipes in the groove with sustainability

01 December 2009

GROOVED joining technology has been providing a more efficient, cleaner and safer system compared with other pipe joining methods, such as welding, long before the evolution of green building, claims the US-based Victaulic, a leading producer of mechanical pipe joining systems.

“Sustainable design involves more than just site orientation and energy-saving construction techniques. What goes into a building in the way of infrastructure is equally important,” says a company official. “Well-planned heating, ventilation and air-conditioning (HVAC), plumbing and other mechanical engineering systems are essential to making a building sustainable throughout its life cycle.”

Among such systems is mechanical grooved piping, which is rooted in sustainability. The inherent qualities of grooved joining technology make it environment-friendly.

Mechanical piping systems are increasingly being used in HVAC and industrial applications due to the time and labour-saving features associated with installation. They are also used extensively for plumbing, fire protection, water and wastewater treatment, oilfield operations, mining, power plants, military and marine systems, and other demanding fluid-handling applications.

The economics of the grooved method derive from simplified assembly that involves three basic concepts:
• A pressure-responsive gasket that creates a leak-tight seal;
• Couplings that hold the pipe together; and
• Fasteners that secure the couplings.

Mechanical piping systems offer an alternative to welding, threading and flanging for water distribution, equipment and pump connections, water softeners and filters as well as drain, waste and vent piping, the official says.

Elaborating on the system, he says: “Grooved systems use a roll grooving process to join pipes, valves and other components. A groove is rolled into the end of the pipe to engage the coupling housings and the gasket seals on the outside diameter of the pipe. The gasket sealing action is enhanced as the coupling housings are tightened and by line-operating pressure or vacuum.

“Using a two-housing coupling design, pipe fitters can make rugged, secure joints quickly and easily, using only basic hand tools. And with a union at every joint, contractors have maximum field flexibility for on-site decision making. All joints are sealed with a pressure-responsive gasket for optimum integrity, designed to withstand years of sustained high compressive and cyclical loads.”

Turning to the benefits of the system, he says that reducing the need for welding means better air quality, less particulate matter released into the atmosphere and decreased fire risk. “There also is less material waste, reducing site impact,” he adds.

Victaulic products are made from a combination of natural and recycled resources using lean and responsible manufacturing processes. In fact, 90 per cent of the steel used is recycled, and the products are manufactured using natural elements of fire, sand, water and air, the spokesman points out.

And at Victaulic, products are painted using a dip coating application which, unlike spray painting, does not atomise so is not a source of regulated pollutant emissions. In addition, dip coating eliminates the need for volatile solvents that are used to thin paints in the spray painting process.

Victaulic products offer environmental benefits during installation. He explains: “Mechanical grooved piping systems significantly reduce or eliminate waste altogether, cut emissions and noise pollution on the job site providing a safer and healthier environment, he says.

“The reduced need for welding lowers emissions on the job site. By-products of solder fumes can contain lead oxide, carbon monoxide, VOC (volatile organic compounds) and hydrochloric acid, in addition to many other harmful particles and gases.

“In 2007 alone, the use of Victaulic grooved mechanical pipe couplings in lieu of welding on HVAC piping systems reduced airborne weld emissions by 145 tonnes of particulate matter – which is equivalent to eliminating the airborne pollution of 1 million cars on the road for a month,” the official states.

“A grooved mechanical pipe joint does not require the use of electricity during installation, reducing the draw on burdened power resources. Pipes that are joined by welding or soldering require the use of vast amounts of electricity for prolonged periods of time, consuming up to 4,000 watts of energy per hour on a 200-mm joint,” he points out.

The installation of a grooved mechanical joint is also cleaner than welded joints, and so reduces on-site job waste. Unlike soldering and brazing methods, grooved mechanical joints do not require flux to seal the joint, which must be flushed and cleaned from the system prior to operation, he adds.

The advantages of the grooved piping system extend into the maintenance phase of the building, facilitating the process and also reducing energy consumption, according the spokesman.

“Energy costs typically represent 30 per cent of a building’s annual budget and are the single largest operating cost (Energy Star). The Energy Systems Lab at Texas A&M University indicated that energy use in buildings could be reduced from 10 to 40 per cent by improving operational strategies in buildings, including maintenance strategies. In an HVAC system, booster pumps and strainers need routine maintenance to operate efficiently.

“With welded piping systems, accessing valves, strainers, pumps and water softeners is often a time-consuming and inconvenient process due to system shutdown and drainage. The more difficult the process the more likely the maintenance will be deferred,” he elaborates. “Mechanical pipe joining systems provide an optimal way to effectively maintain piping systems in structures, thereby reducing the deferral of maintenance and promoting operating efficiency and saving money. Their ease of installation and ability to disassemble and reinstall the same components make them a simple solution for the frequent performance of both routine and unscheduled maintenance. For access to a grooved piping system, a maintenance person simply loosens the two coupling bolts.

“With a union at every joint and easier access there is less deferred maintenance, and peak energy efficiency of buildings is easier to obtain. This means reduced overall costs. Grooved piping systems can also be installed wet or dry to speed the maintenance process.

“Additionally, mechanical pipe joining systems are a safe alternative for maintaining piping systems in specialised facilities. From gas and petroleum installations to hotels and casinos, sites where open flames could potentially create a hazardous environment no longer need to close down during maintenance.”

Organisations that have implemented comprehensive maintenance programmes find that their total costs can be as much as 50 per cent lower than the costs for those that continue to defer routine maintenance. Facilities in which proper HVAC maintenance is completed will use at least 15 to 20 per cent less energy than those where systems are allowed to deteriorate1.

“Given busy agendas and budget constraints in today’s industry, it is easy to see why mechanical pipe joining systems can have a huge impact on both immediate and future economic and sustainability returns,” he concludes.
Founded in 1925, Victaulic is the world’s leading producer of mechanical pipe joining systems and develops products for a full range of industrial, commercial and institutional piping system applications.

Reference:
1 Piper, James PE, “HVAC Maintenance and Energy Savings”, Building Operating Management (March 2009).