AS 3688 - 2016 Water supply and gas systems—Metallic fittings and end connectors

1.1 SCOPE This Standard specifies requirements for metallic body pipe fittings and connectors for use with copper tube, stainless steel pipe, stainless steel tube and adaptor fittings for connection to other pipe materials in water supply and gas systems where the continuous working temperature— (a) does not exceed 95ºC, and where the maximum operating pressure does not exceed 1 400 kPa; or (b) is the ambient supply temperature, where the maximum operating pressure does not exceed 2 100 kPa. Products designed for a temperature in excess of 95°C are included where tested to the appropriate temperature criteria

SCOPE

This Standard specifies requirements for metallic body pipe fittings and connectors for use with copper tube, stainless steel pipe, stainless steel tube and adaptor fittings for connection to other pipe materials in water supply and gas systems where the continuous working temperature—

(a) does not exceed 95ºC, and where the maximum operating pressure does not exceed

(b) is the ambient supply temperature, where the maximum operating pressure does not exceed 2 100 kPa Products designed for a temperature in excess of 95°C are included where tested to the appropriate temperature criteria.

APPLICATION

(a) Capillary fittings—copper and copper alloy Section 5 (b) Compression fittings Section 6 (c) Threaded-end connectors Section 7 (d) Union end connectors and couplings Section 8 (e) Roll-grooved jointing end connectors and coupling body Section 9 (f) Mechanical jointing push-on and press-fit end connectors Section 10 (g) Other copper alloy fittings Section 11

Fittings such as end connectors intended to join alternative pipe systems made from other materials (e.g plastics) shall also comply with the relevant dimensional and performance requirements of the appropriate Australian, New Zealand or Joint Australian/New Zealand Standard for the alternative pipe system

For limitations on use of fittings in gas applications, refer to the AS/NZS 5601 series and AS/NZS 4645.1

Metallic systems, fittings, end connectors and couplings joined to alternative systems may be certified to this Standard (AS 3688)

Means for demonstrating compliance with this Standard are given in Appendix A

Fittings used for gas applications have modified performance requirements relevant to the AS/NZS 5601 series Fittings used exclusively for gas do not need to comply with the requirements of AS/NZS 4020.

DEFINITIONS

For the purpose of this Standard, the definitions given in AS/NZS 3500.0 and those below apply

A joint or fitting that includes a brazed or welded section

A pipe thread with geometry suitable for screw fastening as detailed in AS 1722.2 or ISO 228.1

NOTE: Where these threads are used on pipes or fittings for conveying fluids, pressure-tight joints are not made on the threads; a pressure-tight seal is effected by means other than thread interference (e.g union couplings, compression connections and other sealing mechanisms)

1.4.3 Gas systems Gas systems as defined in the AS/NZS 5601 series

A plumbing fitting end which incorporates an elastomeric sealing element and to which a pressing tool and jaw are applied to make a mechanical and leaktight joint

A mechanical device which, by closing jaws, causes radial compression of the plumbing fitting end onto the connecting tube

A plumbing fitting end which incorporates an elastomeric sealing element and a grab ring which makes a mechanical and leaktight connection when it is pushed onto a tube

A pipe thread with geometry suitable for sealing by interference on the thread, utilizing a thread taper, intended for connecting pipes and fittings with a pressure-tight joint used for conveying fluids as detailed in AS ISO 7.1

A connecting end on a pipe or fitting that is threaded either on an internal surface or external surface so that it can be used to make a threaded joint

A connector end for a pipe or fitting that allows a union joint to be made

The operating temperature of pipe work system which is influenced by either the temperature of the water being transported or the environmental conditions in gas installations.

DESIGNATION OF SIZE

The size by which a fitting is designated shall be the nominal size of the pipes or tubes with which it is to be jointed

The method of specifying the sizes of fittings shall be in accordance with Appendix C

NOTE: Designated sizes do not necessarily indicate exact dimensions as these details are given in the relevant tables herein

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MARKING

Where required, provision shall be made on every fitting for the inclusion of the certification mark The area shall be of sufficient size to accommodate the mark Continuously threaded products shall be exempt from this requirement Indented marks shall be applied in such a way as not to deform or otherwise damage the fitting

NOTE: Manufacturers may agree with the certifying body regarding whether or not the mark will be applied to individual components in a fitting that passes the required tests

Component parts of a fitting that may be sold separately shall bear the manufacturer’s identification mark as a minimum requirement The only exception is that in the event the component is too small to be marked effectively with the manufacturer’s identification mark and the other marking as defined in this Standard, then the item being offered for sale shall be suitably packaged and the packaging marked in accordance with the marking requirements nominated

1.6.3 Marking requirements All fittings shall be legibly marked with the following:

(a) Manufacturer’s name, brand or trademark

(b) For plumbing products used in Australia, the WaterMark Where used for other applications, the mark of the certifying body

(d) Maximum service temperature of water fittings (where designated less than 95°C)

(e) DR brass fittings shall be marked as per the requirements of AS 2345

(f) Press fittings used for gas applications shall be colour identified as specified in Clause 10.5

NOTE: Compliance with WaterMark is achieved in accordance with the rules of the WaterMark Certification Scheme.

PRODUCT DOCUMENTATION

Product documentation shall be available that identifies critical product characteristics such as—

(d) pressure/temperature or other limitations; and (e) UV degradation due to weathering

MATERIALS 2.1 SCOPE OF SECTION

MATERIALS IN CONTACT WITH DRINKING WATER

Materials in contact with drinking water shall comply with AS/NZS 4020 with a scaling factor of 0.01

Metallic components made from a single material may be pre-qualified by use of simulated samples for certification in accordance with Appendix L.

METALLIC MATERIALS

For the purpose of this Standard, the following materials are deemed to be corrosion-resistant:

(a) Copper, as specified in Clause 2.3.2

(b) Copper alloy, as specified in Clauses 2.3.3 and 2.3.4

(c) Stainless steel, as specified in Clause 2.3.5

(d) Material for springs, as specified in Clause 2.5(b)

(e) Other materials, as specified in Clause 2.5

2.3.2 Copper Copper shall comply with the following:

(a) Tubular components—Copper shall be alloy designation C 10200 or C 12200 of

2.3.3 Copper alloy Copper alloy shall comply with EN 13388 or the following:

(a) Castings—AS 1565 or ASTM B584 and a lead content of less than 4.5%

(c) Rod for machined parts—AS/NZS 1567

(d) Tubular components—Copper alloy tubes complying with AS 1572 alloy designation

C 26130 Where bent or stamped in the fabrication process, the pipe shall be sufficiently stress-relieved, so that it is capable of passing the stress corrosion test specified in ISO 6957 Clause 8, using a test solution of pH 9.5 without prior pickling, after all fabrication processes are completed

NOTE: ISO 6957 requires that the entire component is tested before any coating or plating operation

Pressed end fittings manufactured from copper-zinc alloys containing more than 10% zinc shall be capable of passing the stress corrosion test specified in ISO 6957 Clause 8, using a test solution of pH 9.5 without prior pickling, after all pressing processes are completed

2.3.4 Dezincification-resistant (DR) copper alloy

Copper/zinc alloy components designed for use in contact with water or soils shall comply with AS 2345

Stainless steel in contact with water or gas shall comply with ASTM A276 for wrought components or ASTM A269 for tubular components, Grades 316, 316L, 316Ti, UNS S31803 (2205) or equivalent

Stainless steel not in contact with water or gas shall comply with ASTM A276 for wrought components or ASTM A269 for tubular components, Grades 304, 304L, 304LN, 316, 316L, 316Ti, UNS S31803 (2205) or equivalent.

PLASTIC COMPONENT MATERIALS

Plastic materials used for components in fittings and connectors shall be of a type recommended by the polymer manufacturer as suitable and appropriate for use Characteristics to be taken into account shall include, but not be restricted to, aging, compatibility and resistance to variations in water quality and elevated temperatures

Acetal plastics used for structural components that are in contact with the water supply shall be copolymer.

OTHER COMPONENT MATERIALS

(a) Filler metals Filler metal shall be one of the following:

(i) Silver brazing alloy containing not more than 0.05% cadmium, complying with

(ii) Copper-phosphorous brazing alloys complying with AS 1167.1 with a minimum of 1.8% silver

(iii) Solder complying with the requirements of AS 1834.1 and having a maximum of 0.1% lead

(b) Materials for springs shall comply with one of the following:

(ii) Phosphor bronze to AS 2738, C51000 and C51800

NOTE: Other materials may be used, provided that they meet the performance criteria of this Standard and of the relevant materials Standard

(c) Washers and sealing rings Sealing materials shall be appropriate for the application, as follows:

(i) Elastomeric seals for water systems shall comply with AS 1646

(ii) Elastomeric seals for gas press fit shall be yellow HNBR material and comply with EN 549

(d) Lubricants Lubricants shall be as follows:

(i) Drinking water systems shall comply with Clause 2.2

(ii) Gas systems shall be suitable for use with all gases

DESIGN AND DIMENSIONS 3.1 SCOPE OF SECTION

TUBE STOPS

Unless specified otherwise in this Standard, each socket shall be provided with an internal shoulder or stop to register the limits of the tube engagement

The height of the shoulder or stop shall be not less than the value given in Table 3.2 and shall extend for not less than 25% of the internal circumference of the socket The minimum stop height for any press fit fittings is not less than 0.5 mm

The thickness of the shoulder or stop, measured axially, shall be not less than 1.5 mm

MINIMUM MEAN DIAMETER OF WATERWAY AND HEIGHT OF SHOULDER OR STOP FOR COPPER AND COPPER ALLOY FITTINGS

Minimum overall height of shoulder or stop

SLIP FITTINGS

Fittings supplied without an internal tube stop shall comply in all other respects with this Standard The bore of the fitting shall be sized to allow the fitting to slide over the appropriate nominal size of specified tube.

SPIGOTS

Where ends are provided as plain spigots for copper and copper alloy fittings, the outside diameter of the spigot shall comply with the outside diameter of the specified tube of hard-drawn copper tubes complying with AS 1432 and for capillary fittings the length shall comply with Column 3 of Table 5.2.1

FIXING DEVICE

To assist with installation, fittings may be provided with lugs or similar fixing devices.

WATERWAYS

For double-ended fittings, the minimum mean waterway diameter shall be based on the requirement for the nominal size of the smaller end of the fitting

For branch fittings, the waterway in each portion of the fitting shall be based on the nominal size of the end connector on each portion of the fitting

Dedicated fittings for specific applications may have a reduced waterway subject to negotiations between the manufacturer and the user

The minimum mean diameter of the waterway through a fitting shall be as specified in Table 3.2 The diameter may be established by measurement or by means of a sphere of diameter specified in Table 3.2

The maximum deformation of a circular section waterway shall not exceed 2% of the minimum mean waterway diameter, excluding any roll-grooved section

The minimum mean diameter of the waterway through a fitting shall be as specified in Table 3.6.4

MINIMUM MEAN DIAMETER OF WATERWAY FOR STAINLESS STEEL PRESS FIT FITTINGS

Minimum mean waterway diameter mm

THICKNESS OF METAL PARTS OF FITTINGS SPECIFIED BY DIMENSION

Unless otherwise specified in this Standard, the minimum thickness at any point of a fitting shall be not less than that specified in this Clause The measured thickness shall exclude the depth of any screw thread and the thickness of any coating or plating material

3.7.2 Minimum thickness of unspecified metal parts

Unless specified elsewhere in this Standard, the minimum wall thickness at any point shall be as given in Table 3.7.2(A) or 3.7.2(B), as appropriate

COPPER AND COPPER ALLOY FITTINGS

Sections subject to hydrostatic pressure

Sections not subject to hydrostatic pressure

STAINLESS STEEL FITTINGS SPECIFIED BY DIMENSION

Formed from pipe 10S mm 40S mm

PIPE THREADS

All pipe threads shall comply with the relevant requirements of Clauses 3.8.2 and 3.8.3, after manufacture is completed, including any plating operation All threads shall be chamfered at the face to an included angle of not less than 60° and not greater than 90° for not less than half the thread pitch or more than one thread pitch

NOTE: For normal plumbing applications, threads are right-hand In certain applications, left-hand threads may be specified, e.g gas and recycled water

Connections intended to be pipe threads where pressure-tight joints are made on the threads, shall comply with the relevant requirements of AS ISO 7.1

Threads shall comply with the following:

(a) External threads Series R (b) Internal threads Series Rp or Rc 3.8.3 Fastening pipe threads

Connections intended to be pipe threads where pressure-tight joints are not made on the threads to effect the connection, shall comply with the relevant requirements of AS 1722.2 or ISO 228.1

Threads shall comply with the following:

(a) External threads Series GB (b) Internal threads Series G 3.8.4 Fastening thread engagement—Assembled joints

Threaded joints that will be disassembled for any purpose or assembled in a permanent manner shall have the minimum number of full threads engaged as specified in Table 3.8.4 The number of full threads shall be counted when the threaded joint is assembled with washers or seals

TABLE 3.8.4 NUMBER OF THREADS ENGAGED

Minimum number of full threads engaged

3.8.5 Other thread forms Other thread forms shall comply with a recognized Standard.

FABRICATED FITTINGS

Fittings with fabricated joints shall be capable of complying with Clause 4.3 The minimum wall thickness, not including the thread depth, of each part of a joint shall comply with Clause 3.7 The joint shall be mechanically locked after fabrication by methods such as, but not restricted to, burred or peened over, welding, soldering/brazing or use of jointing compounds

GEOMETRY OF FITTINGS

(a) Machined parts, when assembled, shall be coaxial, parallel and cylindrical within the limits required for the particular material and design

(b) End connectors shall be in line with the appropriate axis of the fitting

(c) Angles of fittings shall be ±1° of the manufacturer’s nominated designation.

PLATING AND OTHER SURFACE FINISHES

(a) Metal finishes may be applied to surfaces If applied, threaded-ends of fittings shall comply with Clause 3.8

(b) Other finishes may be applied to surfaces but not to threaded-end connections and mating parts of union ends.

FINISH AND WORKMANSHIP

(a) sound and free from folds, laps, blisters, laminations, blowholes, and other defects that affect the performance or function of the fitting in service;

(b) supplied free of sand, grit, and swarf; and

(c) free of burrs, fins, irregularities and sharp edges that would affect the performance or function of the fittings in service

Castings may be plugged, stopped, or patched but only by a vacuum impregnation process with a material complying with Clause 2.2, and hydrostatically tested in accordance with Clause 4.2

PERFORMANCE REQUIREMENTS 4.1 SCOPE OF SECTION

LEAKTIGHTNESS UNDER INTERNAL PRESSURE TEST

When tested in accordance with Appendix D, fittings shall show no signs of weeping, cracks, leakage or other failure For the purpose of type testing, machined cast fittings shall be subjected to both the hydrostatic pressure test and pneumatic pressure test Other fittings shall be subjected to the hydrostatic pressure test only.

STRENGTH OF FABRICATED JOINT (TORQUE TEST)

When tested in accordance with Appendix E, the fabricated joint shall show no signs of cracking, splitting, thread damage or other failure

NOTE: This test is for a fabricated joint, and the twisting of copper tube tails (away from the joint) does not constitute a failure of the test.

STRENGTH OF JOINT ASSEMBLY (PRESSURE CYCLING TEST)

When tested in accordance with AS/NZS 3707 and Appendix F at 95°C or the manufacturer’s nominated maximum service temperature, a joint assembly shall withstand not less than 50 000 pressure cycle pulsations

At the completion of cyclic testing, the joint assembly shall be depressurized and removed from the immersion bath and permitted to stabilize at ambient temperature for not less than

4 h, after which it shall be subjected to a hydrostatic pressure test of not less than 2 000 kPa for 60 +15, −0 min

The joint assembly shall show no signs of cracks, leakage or other failure at any stage of testing procedures.

RESISTANCE TO PULL-OUT OF ASSEMBLED JOINTS

When tested in accordance with Appendix G at 95°C or the manufacturer’s nominated maximum service temperature, a pipe shall not pull out of the assembled fitting.

STRENGTH OF NUT AND ASSEMBLY (TORQUE TEST)

When tested in accordance with Appendix H, the nut and assembly shall show no signs of splitting, cracking or thread damage.

LEAKTIGHTNESS UNDER INTERNAL PRESSURE WHILST SUBJECTED TO

When tested in accordance with Appendix I, the fitting under test shall show no visible signs of leakage or damage Water fittings shall be tested under hydrostatic pressure and gas fittings under pneumatic pressure

METHOD FOR DETERMINING COMPATIBILITY OF WATER FITTINGS WITH

When tested in accordance with Appendix J:

(a) Push-on fittings shall withstand internal pressures in the pipe of 1 400 kPa at a temperature of 95 ±2°C for 1 000 +50, −0 h, and 2 000 kPa at a temperature of

(b) Press-fit fittings shall withstand internal pressures in the pipe of 1 400 kPa at a temperature of 95 ±2°C for 48 hours, followed by a pressure of 2 000 kPa for one hour at 20 ±5°C.

ROLL-GROOVED ASSEMBLY (JOINT PRESSURE RESISTANCE TEST)

When assembled in accordance with the manufacturer’s instructions and tested in accordance with Appendix K at 2 000 kPa or 1.5 times the specified maximum operating pressure, the joint assembly shall not leak.

VACUUM TEST FOR LEAKTIGHTNESS OF JOINTS WITH TUBE UNDER

When assembled with tube and tested in accordance with Appendix M at a test pressure of

−80 ±5 kPa for one hour, the change in pressure shall not be greater than 5 kPa.

LEAKTIGHTNESS UNDER INTERNAL PNEUMATIC PRESSURE

When tested in accordance with Appendix N, at pneumatic pressure of 2.2 kPa for

10 minutes, followed by a second test at 11 kPa for 10 minutes and a third test at 1.1 × maximum operating pressure (500 kPa) for 10 minutes, the fitting under test shall show no visible signs of leakage.

RESISTANCE OF GAS PRESS FITTINGS TO TEMPERATURE CYCLING

When tested in accordance with Appendix O to a hot temperature of 100 ±2 C and a cold temperature of −20 ±2 C and subsequently tested for leaktightness under internal pneumatic pressure in accordance with Appendix N, the fittings shall not show any visible signs of leakage.

RESISTANCE OF PRESS FITTING JOINTS AND TUBES TO VIBRATION

When tested in accordance with Appendix P at 1 500 ±50 kPa, ±1 mm deflection,

1 000 000 cycles, at a frequency of 20 Hz, the fittings shall not show any visible signs of leaking at the end of the testing

Four test samples for each size shall be subject to each assessment

When tested in accordance with Appendix P at atmospheric pressure, ±1 mm deflection

1 000 000 cycles, at a frequency of 20 Hz and subsequently tested for leaktightness under internal pneumatic pressure in accordance with Appendix N, the fittings shall not show any visible signs of leakage throughout the complete testing period

Four test samples for each size shall be subject to each assessment.

RESISTANCE OF GAS PRESS FITTINGS TO HIGH TEMPERATURE

When tested in accordance with Appendix Q at 650 ±10ºC and 100 ±10 kPa for 30 minute test duration, the leakage rate of nitrogen shall not exceed 150 dm³/h

SCOPE OF SECTION

This Section specifies the dimensions, tolerances and performance requirements for capillary fittings designed with short engagement sockets intended for use with brazing alloys.

DESIGN AND DIMENSIONS

Capillary fittings shall conform to the dimensions specified in Figure 5.2.1 and Table 5.2.1 5.2.2 Internal diameter of socket

The internal diameter at any point of the socket over the length that is designed to make close contact with the tube shall be within the limits given in Column 2 of Table 5.2.1, as appropriate to the size of the fitting

Where fittings manufactured from the tube are slightly oval, they shall be considered satisfactory provided they can accept a GO gauge of diameter equal to the appropriate minimum diameter specified in Column 2 of Table 5.2.1 when reasonable hand pressure is exerted This GO gauge may be profiled at the nose end for a length not exceeding 0.5 mm 5.2.3 Length of socket

For that surface of the socket that is designed to make close contact with the tube, the minimum length shall be the dimension given in Column 3 of Table 5.2.1, as appropriate to the size of fitting For plain sockets, the length shall be the distance from the face of the fitting to that point on the shoulder of the socket against which the inserted tube abuts

The minimum wall thickness of the fittings at any point (dimension X) shall be not less than the values given in Column 4 or 5 of Table 5.2.1, as appropriate

NOTE: The minimum wall thickness of the fitting depends on the type of material used

5.2.5 Branches of different nominal size

Where a fitting has branches of different nominal sizes then the thickness in any branch shall be as specified for the nominal size of that branch

5.2.6 Waterway diameter The waterway diameter shall comply with Clause 3.6

NOTE: The top half of the section indicates a typical machined socket and the bottom half indicates a typical formed socket

FIGURE 5.2.1 DIMENSIONS OF CAPILLARY SOCKETS FOR USE WITH

DIMENSIONS OF CAPILLARY SOCKETS FOR USE WITH BRAZING ALLOY

Internal diameter of socket (dimension A) mm

Length of socket surface in contact with tube (dimension B) mm

Forged and other sections† mm

Min Max Min Minimum at any point

* For materials complying with Clauses 2.3.2 (a), 2.3.3 (d) and 2.3.5

† For forged and other material complying with Clauses 2.3.3 (a), (b), (c) and 2.3.5.

PERFORMANCE REQUIREMENTS

Fittings complying with this Section shall comply with Clause 4.2 and, where applicable, Clause 4.3

Where the capillary fittings are made out of copper tube, in compliance with AS 1432 sizes greater than DN 80, the test pressure shall be the safe working pressure as specified in

COMPRESSION FITTINGS 6.1 SCOPE OF SECTION

DESIGN

Copper alloy compression fittings manufactured to the dimensional requirements of this Standard shall conform to the dimensions given in Figures 6.2.1(A) and 6.2.1(B) Where a dimension is not given, it shall comply with the design requirements of Section 3

6.2.2 Compression fittings complying with performance requirements

Fittings of similar designs or other designs are permitted subject to compliance with Section 3 and Clause 6.3 of this Standard For copper alloy fittings, the minimum wall thickness of the extreme end of a cone shall be not less than that specified in Clause 6.2.1.

Compression fittings complying with Clause 6.2.1 shall be capable of complying with Clauses 4.2, 4.3 and 4.5

6.3.2 Compression fittings complying with Clause 6.2.2

Fittings complying with Clause 6.2.2 shall comply with Clauses 4.2, 4.4, 4.5 and 4.6, and where applicable, Clause 4.3

(Thread size designation) (see Note 3)

* Fastening pipe thread to AS 1722.2 or ISO 228.1, Series G or GB

1 For size of tube stop and location, see Clause 3.2 Slip fitting to be provided without shoulder.

2 Minimum wall thickness at all unthreaded sections as specified in Tables 3.7.2(A) and 3.7.2(B).

3 Wall thickness at threaded section as specified in Figures 7.2(A) and 7.2(B).

Rubber olive (croxed fittings only)

(Thread size designation) (see Note 3)

* Fastening pipe thread to AS 1722.2 or ISO 228.1, Series G or GB

1 Angle of olive not to exceed angle in body or nut

2 Size of tube stop and location (see Clause 3.2) Slip fitting to be provided without shoulder

3 Minimum wall thickness at all unthreaded sections as specified in Tables 3.7.2(A) and 3.7.2(B)

4 Wall thickness at threaded section as specified in Figures 7.2(A) and 7.2(B)

5 Dimension X in (b) to be sized from the maximum mean outside diameter of the tube

FIGURE 6.2.1(B) COMPRESSION ENDS—OLIVE AND CROXED

THREADED-END CONNECTORS 7.1 SCOPE OF SECTION

DIMENSIONS

End connectors with fastening threads shall conform to the dimensions shown in Figure 7.2(A), Table 7.2(A), Figure 7.2(B) and Table 7.2(B)

End connectors with sealing threads shall conform to the dimensions shown in Figure 7.2(C), Table 7.2(C), Figure 7.2(D) and Table 7.2(D).

DESIGN

Internal fastening threads shall be provided with a stop at the end of the thread for at least 25% of the circumference of the thread The stop shall be one of the following:

(a) Plain end A thread runout with at least 1.5 mm of unremoved material after the thread finishes (see Figure 7.2(A) for typical details)

(b) Shoulder A shoulder at least 1.5 mm thick (see Figure 7.2(A) for typical details)

7.3.2 Wrenching flats For wrenching flats the following applies:

(a) Fittings with externally threaded ends shall be provided with 2, 4, 6 or 8 wrenching flats or be of a design that allows tightening to the torques specified in Appendix H without the use of special tools If hexagonal or octagonal, the wrenching flats shall comply with dimensions F of Table 7.2(B) and E of Table 7.2(D) Where wrenching flats are chamfered, the minimum length at corners shall be at least 75% of dimension E of Table 7.2(B) or D of Table 7.2(D)

(b) Fittings with two or more internally or externally threaded connections may have only one set of wrenching flats and, where fittings are provided with a fixing device in accordance with Clause 3.5 or are of such a physical shape that tightening can be achieved with readily available tools, no wrenching flats need be provided

7.3.3 Thickness of threaded-end connectors with fastening threads

The minimum wall thickness, including depth of thread, shall be as specified in dimension C of Table 7.2(A) Where a fitting has branches of different nominal sizes, then the thickness in any branch shall be as specified for the nominal size of that branch

Male tapered threaded-ends of fittings shall be in accordance with Figure 7.2(D) and Table 7.2(D)

Female threaded ends of fittings shall be in accordance with Figure 7.2(C) and Table 7.2(C).

Fittings complying with this Section shall be capable of complying with Clauses 4.2 and 4.3

(i) Internally threaded end—Plain (ii) Internally threaded end with shoulder stop and hexagonal or octagonal wrenching flats

FIGURE 7.2(A) INTERNAL PARALLEL FASTENING THREADS—AS 1722.2/ISO 228.1

Minimum thread length including run out

Minimum wall thickness including thread mm mm

1 Minimum mean diameter of waterway shall comply with Clause 3.6

2 Minimum wall thickness shall comply with Clause 3.7

3 Chamfer at thread start shall comply with Clause 3.8

(i) Externally threaded end—Plain (ii) Externally threaded end with shoulder stop and hexagonal or octagonal wrenching flats

FIGURE 7.2(B) EXTERNAL PARALLEL FASTENING THREADS—AS 1722.2/ISO 228.1

TABLE 7.2(B) EXTERNAL PARALLEL FASTENING THREADS AS 1722.2/ISO 228.1

Minimum thread length including run out

Run out or undercut (mm)

Minimum wall thickness including thread

Minimum axial length of wrenching flat

Minimum dimension across wrenching flats

(mm) Min Max (mm) (mm) (mm)

3 Chamfer at thread start shall comply with Clause 3.8

FIGURE 7.2(C) INTERNAL PARALLEL SEALING THREADS—AS ISO 7.1

TABLE 7.2(C) INTERNAL PARALLEL SEALING THREADS—AS ISO 7.1

Minimum outside wall on Rp thread

Minimum thread length with free runout mm mm mm mm

3 Chamfer at thread start shall comply with Clause 3.8.

FIGURE 7.2(D) EXTERNAL TAPERED SEALING THREADS—AS ISO 7.1

TABLE 7.2(D) EXTERNAL TAPERED SEALING THREADS—AS ISO 7.1

Minimum axial length of wrenching flats

Min Max mm mm mm mm

3 Chamfer at thread start shall comply with Clause 3.8.

UNION END CONNECTORS AND COUPLINGS 8.1 SCOPE OF SECTION

DESIGN

The minimum wall thickness of union end connectors and couplings tails shall comply with Clause 3.7

The minimum wall thickness of union end connectors and coupling nuts shall comply with Figure 7.2(A) and Table 7.2(A)

8.2.2 Screw threads Threads of union end connectors and union couplings shall comply with Clause 3.8.3

Loose nuts may be provided with wrenching flats or other means for tightening such as knurls and wings The integrity of the design shall enable the assembled joint to comply with the performance requirements of this Standard

ROLL-GROOVED JOINTING END CONNECTORS AND COUPLING BODY 9.1 SCOPE OF SECTION

MATERIALS

(a) Housing The body of the coupling shall be manufactured from either—

(i) ductile cast iron complying with ASTM A395 Grade 65-45-15 and ASTM A536 Grade 65-45-12 (equivalent to AS 1831, minimum Grade 450-10) and coated with a suitable anti-corrosive finish; or

(ii) stainless steel complying with ASTM A351, A743 and A744 Grade CF-8M

(b) Elastomeric gasket The gasket material utilized as the seal in the coupling shall comply with Clause 2.5(c)

(c) Fasteners Fasteners utilized to assemble the coupling shall be heat-treated carbon steel conforming to the physical properties of ASTM A183 or ASTM A449 with a minimum tensile strength of 758 000 kPa and be protected from corrosion by electro-zinc plating.

DESIGN

(a) Copper and copper alloy The general design and dimensions shall comply with the requirements of this Standard (i.e AS 3688)

(b) Stainless steel The general design and dimensions shall comply with the relevant requirements of ASTM A403

9.3.1.2 Roll-grooved connection ends Roll-grooved connection ends shall comply with the dimensional requirements given in—

(a) Figure 9.3.1.2(A) for copper ends; or (b) Figure 9.3.1.2(B) for stainless steel ends

End connectors for connection to either copper or copper alloy tubes or fittings shall comply with this Standard (i.e AS 3688)

Other connection ends shall comply with the requirements of the Australian Standard that is relevant to the connection

End connections with fabricated joints shall be capable of complying with the performance requirements of Clause 9.4

For copper tube applications, the design of the coupling shall include an angled pad so as to allow general adjustment for minor inconsistencies of the rolled grooved profile and always maintain pad-to-pad contact

Allowable flare diameter mm mm mm mm mm mm ± 0.8 +0.8/ − 0.0 +0/–0.5 Ref only Max

FIGURE 9.3.1.2(A) DIMENSIONS OF ROLL-GROOVED JOINTING END CONNECTORS

AND COUPLING BODY—COPPER TUBES TO AS 1432

Allowable flare diameter mm mm mm mm mm mm ± 0.76 ± 0.76 +0 Ref only Max

FIGURE 9.3.1.2(B) DIMENSIONS FOR ROLL-GROOVED JOINTING END CONNECTORS AND COUPLING BODY—STAINLESS STEEL PIPES USING

PERFORMANCE REQUIREMENTS AND TEST METHODS

Roll-grooved fittings and assembled joints shall comply with Clauses 4.2, 4.3, 4.4, 4.5, 4.7 and 4.9.

INSTALLATION INSTRUCTIONS

(a) be in accordance with AS/NZS 3500.1 and AS/NZS 3500.4;

(b) detail the procedures for assembling rolled grooved joints;

(c) detail the methods of forming a roll-grooved end on a pipe on site; and (d) include recommendations for the tools and equipment to be used for forming the roll-grooved end

MECHANICAL JOINTING PUSH-ON AND PRESS-FIT END CONNECTORS 10.1 SCOPE OF SECTION

DESIGN

10.2.2 Joint assembly—Push-on-end connectors

The design of the end connector assembly shall incorporate an O-ring or component to provide sealing and a grab ring to prevent longitudinal movement of the tube

10.2.3 Joint assembly—Press-fit end connectors

The design of the assembly shall incorporate an O-ring or component to provide sealing and is crimped with press tool and jaw to prevent longitudinal movement of the tube.

PERFORMANCE

Mechanical jointing end connectors for water supply shall comply with Clauses 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.10 and 4.13 Clauses 4.10 and 4.13 are not applicable to push-on fittings

Press fit end connectors for gas applications shall comply with Clauses 4.3, 4.5, 4.6, 4.7, 4.10, 4.11, 4.12, 4.13 and 4.14

Where the design principle changes, performance testing shall be carried out to verify each design, e.g press fitting with additional gripping device.

INSTALLATION INSTRUCTIONS

(a) be in accordance with AS/NZS 3500.1, 3500.4 and 3500.5, the AS/NZS 5601 series and AS/NZS 4645.1;

(b) detail procedures for assembling the fitting; and (c) include recommendations for tools and equipment

MARKING FOR GAS PRESS-FIT FITTINGS

In addition to the marking requirements in Clause 1.6, gas press fittings shall be durably and legibly marked on both sides with two yellow coloured rectangles containing the word

‘GAS’ Seals shall be colour-coded yellow

OTHER COPPER ALLOY FITTINGS 11.1 SCOPE OF SECTION

THREADED SOCKETS

The internal thread in sockets may be continued through the fitting without a thread stop or runout in the centre

11.2.2 The design of sockets with sealing pipe threads

The design shall comply with Figure 7.2(C) and Table 7.2(C) and the length of the threaded socket shall be a minimum of the two times the dimension given in Table 7.2(C), Column B

11.2.3 The design of sockets with fastening pipe threads

The design shall comply with Figure 7.2(A) and Table 7.2(A) and the length of the threaded socket shall be a minimum of two times the dimension given in Table 7.2(B), Column B.

REDUCING BUSHES WITH OVERLAPPING INTERNAL AND EXTERNAL

Reducing bushes with overlapping internal and external threads and other designs for reducing bushes shall be permitted in any combination of nominal sizes, provided that the minimum wall thickness complies with the requirements of Clause 3.7

11.3.2 Reducing bushes with sealing pipe threads

Reducing bushes with sealing pipe threads shall comply with Figures 7.2(C) and 7.2(D) and Tables 7.2(C) and 7.2(D)

11.3.3 Reducing bushes with fastening pipe threads

Reducing bushes with fastening pipe threads shall comply with Figures 7.2(A) and 7.2(B) and Tables 7.2(A) and 7.2(B).

CONTINUOUSLY THREADED FITTINGS

Fittings may be supplied with continuous threads, which do not require wrenching provisions Threads shall comply with Clause 3.8.3(a) The internal bore shall comply with Clause 3.6 and the minimum wall thickness including thread shall comply with Table 7.2(B), Column D.

APPENDIX A MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD

This Appendix sets out the means by which compliance with this Standard shall be demonstrated by a manufacturer under the WaterMark product certification scheme

The long-term performance of plumbing systems is critical to the durability of building infrastructure, protection of public health and safety, and protection of the environment

The purpose of product certification is to provide independent assurance of the claim by the manufacturer that products comply with this Standard

The certification scheme serves to indicate that the products consistently conform to the requirements of this Standard

The sampling and testing plan, as detailed in Paragraph A5 and Table A5.1, shall be used by the conformity assessment body Where a batch release testing program is required, it shall be carried out as detailed in Paragraph A7 and Table A5.2, by the manufacturer

A test performed by the manufacturer on a batch of components, which has to be satisfactorily completed before the batch can be released

Clearly identifiable collection of units, manufactured consecutively or continuously under the same conditions, using material or compound to the same specification

One or more units of product drawn from a batch, selected at random without regard to quality

NOTE: The number of units of product in the sample is the sample size

A specific plan that indicates the number of units of components or assemblies to be inspected

Schedule of units of the same type, identical dimensional characteristics, all the same nominal diameter and wall thickness, from the same compound The batch is defined by the manufacturer

Testing performed to demonstrate that the material, component, joint or assembly is capable of conforming to the requirements given in this Standard

A5 TESTING A5.1 Type testing Table A5.1 sets out the requirements for type testing and frequency of re-verification

Table A5.2 sets out the minimum sampling and testing frequency plan for a manufacturer to demonstrate compliance of product(s) to this Standard on an ongoing basis However, where the manufacturer can demonstrate adequate process control to the conformity assessment body, the frequency of the sampling and testing nominated by the manufacturer’s quality plan and/or documented procedures shall take precedence for the purposes of WaterMark product certification

In the event of a test failure, the products within the batch shall be tested at an appropriate acceptable quality level (AQL) and only those batches found to comply may be claimed and/or marked as complying with this Standard

The following tests are to be undertaken on product at a laboratory recognised by the conformity assessment body Other design requirements shall be verified by the submission of documentation that confirms compliance, e.g drawings

TABLE A5.1 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN

Characteristic Clause Requirement Test Method Frequency

Materials 2.2 Materials in contact with drinking water AS/NZS 4020‡ Change in material

2.3 Metallic materials As per relevant

2.5 Other materials As per relevant

Leaktightness under internal pressure test Appendix D

Strength of fabricated joint (Torque test) Appendix E

Characteristic Clause Requirement Test Method Frequency Compression fittings

Resistance to pull-out of assembled joints

Strength of joint assembly (Pressure cycling)

Resistance to pull-out of assembled joints

Strength of nut and assembly (Torque test)

Design and dimensions 7.2 Dimensions Direct measurement

Strength of fabricated joint (Torque test) Appendix E Union end connectors and couplings

Characteristic Clause Requirement Test Method Frequency Roll-grooved jointing system

Design and dimensions 9.2 Materials As appropriate Change in design

Strength of joint assembly (Pressure cycling)

Resistance to pull-out of assembled joints Appendix G

Leaktightness under internal hydrostatic pressure whilst subjected to bending

Roll-grooved assembly (Joint pressure resistance)

Design and dimensions 10.2 Design DV* Change in design

Performance requirements 10.3 Leaktightness under internal pressure Appendix D

Strength of joint assembly (pressure cycling test)

Leaktightness under internal pressure whilst subjected to bending

Method of determining compatibility of fittings with pipe

Vacuum test for leaktightness of joints with tube under vacuum

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Resistance of press fitting joints and tubes to vibration

Design and dimensions 10.2 Design DV* Change in design

Leaktightness under internal pressure whilst subjected to bending

Vacuum test for leaktightness of joints with tube under vacuum

Leaktightness under internal pneumatic pressure

Resistance of gas press fittings to temperature cycling

Resistance of press fitting joints and tubes to vibration

Resistance of gas press fittings to high temperature

Design 11.2 Threaded sockets DV* Change in design

Reducing bushes with overlapping internal and external threads

Leaktightness under internal pressure Appendix D

‡ or every five years whichever occurs first

* DV (direct verification) review and check against the design

The following tests are to be undertaken on product at a laboratory recognised by the conformity assessment body or by the manufacturer/supplier using their own calibrated testing equipment

2.3 Metallic materials As per relevant Standard

2.4 Plastic and elastomeric materials As per relevant Standard 2.5 Other materials As per relevant Standard

Capillary fittings Design 5.2 Dimensions Direct measurement Once per batch

Performance requirements 5.3 Leaktightness under internal pressure test Appendix D Once per batch Compression fittings

Design 6.2.1 Dimensions Direct measurement Once per batch

Performance requirements 6.3 Leaktightness under internal pressure test Appendix D

100% cast/once per batch other than cast Threaded-end connectors

Once per batch 7.3 Design Direct measurement/

Union-end connectors and couplings

8.2.3 Provision for tightening Roll grooved jointing system

Once per batch 9.3 Design Direct measurement/

Design and dimensions 10.2 Design DV* Once per batch

Reducing bushes with overlapping internal and external threads

* DV (direct verification) review and check against the design

APPENDIX B LIST OF REFERENCED DOCUMENTS

(Normative) The following are the normative documents referenced in this Standard:

1167 Welding and brazing—Filler metals 1167.1 Part 1: Filler metal for brazing and braze welding

1349 Bourdon tube pressure and vacuum gauges

1432 Copper tubes for plumbing, gas fitting and drainage applications

1565 Copper and copper alloys—Ingots and castings

1572 Copper and copper alloys—Seamless tubes for engineering purposes

1646 Elastomeric seals for waterworks purposes

1722 Pipe threads of Whitworth form 1722.2 Part 2: Fastening pipe threads

1834 Material for soldering 1834.1 Part 1: Solder alloys

2345 Dezincification resistance of copper alloys

2738 Copper and copper alloys—Compositions and designations of refinery products, wrought products, ingots and castings

3707 Method for testing pressure cycling resistance of pipes and fittings

5200 Plumbing and drainage products 5200.053 Part 053: Stainless steel pipes and tubes for pressure applications

1567 Copper and copper alloys—Wrought rods, bars and sections

1568 Copper and copper alloys—Forging stock and forgings

3500 Plumbing and drainage 3500.0 Part 0: Glossary of terms 3500.1 Part 1: Water services 3500.4 Part 4: Heated water services 3500.5 Part 5: Housing installations

4020 Testing of products for use in contact with drinking water

4645 Gas distribution network management 4645.1 Part 1: Gas distribution networks

5601 Gas installations 5601.1 Part 1: General installations 5601.2 Part 2: LP Gas installations in caravans and boats for non-propulsive purposes

7 Pipe threads where pressure-tight joints are made on the threads 7.1 Part 1: Dimensions, tolerances and designation

228 Pipe threads where pressure-tight joints are not made on the threads 228-1 Part 1: Dimensions, tolerances and designation

6957 Copper alloys—Ammonia test for stress corrosion resistance

ASTM A183 Standard Specification for Carbon Steel Track Bolts and Nuts

Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

A276 Standard Specification for Stainless Steel Bars and Shapes A313 Standard Specification for Stainless Steel Spring Wire

A351 Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts

A395 Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures A403 Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

A449 Standard Specification for Hex Cap Screws, Bolts and Studs, Steel, Heat

Treated, 120/105/90 ksi Minimum Tensile Strength, General Use A536 Standard Specification for Ductile Iron Castings

A743 Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel,

Corrosion Resistant, for General Application

A744 Standard Specification for Castings, Iron-Chromium-Nickel, Corrosion

B584 Standard Specification for Copper Alloy Sand Castings for General

Copper And Copper Alloys—Compendium Of Compositions And Products

EN 549 Rubber Materials For Seals and Diaphragms For Gas Appliances And Gas

EN 10312 Welded Stainless Steel Tubes For The Conveyance Of Water And Other

Aqueous Liquids—Technical Delivery Conditions

APPENDIX C SIZES AND TYPES OF FITTINGS

C1 FITTING SIZES The sizes of fittings shall be specified as follows:

(a) Straight through fittings For fittings with two unequal ends, the larger end shall be given first (see Figures C1(A) to C1(F) for typical fittings)

(b) Fittings having three ends Fittings having three ends shall be specified first by the ends on the ‘run’, i.e the two ends (the larger being specified first) in the same straight line, and then by the remaining end (see Figures C1(G) to C1(J) for typical fittings)

(c) Fittings having four ends Fittings having four ends shall be specified first by the larger end on the ‘run’ and then by the second end on the run, followed by the remaining ends, the larger of the two remaining ends being specified first (see Figures C1(K) for typical fitting)

C2 END CONNECTIONS End connectors shall be specified as follows:

(i) External threads shall be either Series R, e.g R3/8, R1/2, R4

(ii) Internal threads shall be either Series Rp or Rc, e.g Rp3/8, Rp1/2, Rp4

(i) External threads shall be Series GB, e.g G3/8B, G1/2B

(ii) Internal threads shall be Series G, e.g G3/8, G1/2

(c) Capillary fittings The nominal size shall be followed by letters as follows:

Capillary sockets CS (d) Compression fittings

The nominal size shall be followed by the letters Cn, e.g 15Cn, 20Cn, 32Cn

Tiêu đề	Metallic fittings and end connectors
Trường học	Standards Australia
Chuyên ngành	Water supply and gas systems
Thể loại	Australian Standard
Năm xuất bản	2016
Thành phố	Sydney

Định dạng
Số trang	81
Dung lượng	1,76 MB