Technical Info

Gas sizing, pressure testing, warranty terms and compliance standards for Lightning systems.

Gas Sizing & Pressure Drop

Lightning gas systems use approved Lightning PEX-AL-PEX (Sleeve) and Lightning Crimp Gas pipe to safely distribute Natural Gas (NG) and Liquefied Petroleum Gas (LPG). Pipe sizing must always be performed using the correct gas type and allowable pressure drop.

Pipe Sizing Method

1Add the MJ rating of all appliances on the line.
2Determine the length of the longest run.
3Using the NG table, find the required pipe size.
4For each branch run, add fitting allowances, calculate effective length, select the next highest table length.

Example: sizing run A→B→C→D — longest run = 31m + 2.4m fitting allowance = 33.4m → use 35m column

Natural Gas (NG) Reference Conditions

—Pressure: 1023.15 mbar
—Gas temperature: 15°C
—Heating value (gross): 38.7 MJ/m³

Sizing tables available for pressure drops: 0.075, 0.12, 0.25, 0.75, 1.5 kPa

LPG Reference Conditions

—Pressure: 1023.15 mbar
—Temperature: 15°C
—Heating value (gross): 95.4 MJ/m³
—Typical allowable pressure drop: ~0.25 kPa

Pressure Drop Reference Tables

SLEEVE — 0.075 kPa

Supply pressure: ~1.1 kPa

Pipe Size (mm)	2m	4m	6m	8m	10m	12m	14m	16m	18m	20m	25m	30m	35m	40m	45m	50m	55m	60m	65m	70m	75m	80m	85m	90m	95m	100m
16	80	55	45	38	34	30	26	22	20	18	14	12	11	8	7	6	6	5	5	4	4	4	4	3	3	3
20	140	96	77	66	58	53	49	45	43	40	35	29	25	21	19	17	16	14	13	12	11	11	10	9	9	9
25	251	172	139	119	105	95	88	81	77	73	64	58	53	47	45	41	38	35	32	30	28	26	25	23	21	20
32	490	336	270	232	204	186	171	159	149	141	124	114	104	92	86	81	77	74	71	68	66	64	62	60	57	56

Values in MJ/h — Natural Gas (NG). Pressure: 1023.15 mbar, Gas temp: 15°C, Heating value: 38.7 MJ/m³

Pressure Testing & Purging — Drinking Water Systems

All Lightning drinking water systems must be flushed, pressure tested and documented in line with AS/NZS 3500 and the Lightning Technical Manual.

Crimp Systems

✓Visually inspect joints to confirm pipe pushed fully to stopper
✓Check inspection holes to ensure pipe is correctly inserted
✓Use a test gauge on each joint — gauge must not touch the copper ring
✓Flush system before and after pressure testing
✓During initial pressurisation, vent air from furthest point
✓Record results on the Lightning pressure test form

Test in accordance with AS/NZS 3500 at 1500 kPa for not less than 30 minutes, prior to burial or concealment.

Sleeve Systems

✓Visually confirm all sleeve joints pulled all the way to stopper
✓Flush installation prior to and after pressure testing
✓Follow AS/NZS 3500 for test procedure and venting
✓Testing must be completed before pipework is concealed or buried
✓Completed Lightning pressure test form required for warranty

Water services must show no leakage when subjected to a hydrostatic pressure of 1500 kPa for a period of not less than 30 minutes.

Expansion Systems

✓Visually inspect all expansion rings pushed fully to stopper
✓Allow minimum 30 minutes after last expanded ring fitting before testing
✓Flush system before and after pressure testing
✓Testing should be completed before pipework is buried or concealed
✓Completed pressure test form required for warranty

Carry out testing in accordance with AS/NZS 3500, testing water services at 1500 kPa for at least 30 minutes.

Press Systems — Copper & Stainless Testing

Lightning Copper Press and Lightning 316 Stainless Steel Press systems must be tested in accordance with the relevant standards and any additional local regulations.

✓Gas installations: test in accordance with AS/NZS 5601 – Appendix E
✓Water installations: test in accordance with AS/NZS 3500
✓Ensure all joints are visually inspected during testing

The Lightning press systems incorporate a Leak Path Design O-ring, which assists in identifying unpressed joints during pressure testing when installed and tested correctly.

Approvals & Certifications

Standards and licence numbers for Lightning products, as stated in the Lightning technical documents. Download the Technical Guide for Architects or the Press System brochures for the full approvals.

Lightning product standards and certification licence numbers
Product	Standard	Approval	Notes
PE-X pipe	AS/NZS 2492:2007	Watermark licence WM 75207	Crosslinked polyethylene (PE-X) pipe for pressure applications.
Brass and stainless steel fittings (PEX systems)	AS/NZS 2537.2:2011	Watermark licence WM74832	Mechanical jointing fittings for PE-X pressure applications, and plastic piping systems for hot and cold water installations.
PEX-AL-PEX gas pipe	AS 4176.8:2010	ISO Type 5, licence AMI 7457	Multi-layer pipe systems for consumer gas installations, maximum operating pressure up to and including 500 kPa. Install to AS/NZS 5601.1:2022.
Copper Press water fittings (DN15–DN50)	AS 3688	Watermark licence WMK27087	DZR lead-free CW511L brass with EPDM sealing element. Install to AS/NZS 3500.
Copper Press gas fittings (DN15–DN50)	AS 3688, tested to AS 3688 and BS 8537	Licence SMK41743	Copper and DZR lead-free CW511L brass with HNBR sealing element. Install to AS/NZS 5601, consumer piping pressure up to 200 kPa.
Stainless Steel Press tube (DN15–DN168)	AS 5200.053, ASTM A269	Watermark approval WM75213	Outside diameters 15 mm to 168 mm.
Stainless Steel Press fittings	AS 3688	Watermark approval WM75213, AMI GAS approval AMI75213	316L stainless steel (EN 1.4404).

Technical Info

Gas Sizing & Pressure Drop

Pipe Sizing Method

Natural Gas (NG) Reference Conditions

LPG Reference Conditions

Pressure Drop Reference Tables

Pressure Testing & Purging — Drinking Water Systems

Crimp Systems

Sleeve Systems

Expansion Systems

Press Systems — Copper & Stainless Testing

Approvals & Certifications

Resources & Downloads

Warranty Information

Lightning Pressure Test Form

Technical Guide for Architects

Copper Press Brochure

Stainless-Steel Press Brochure

Explore the Full Product Range

Pipe Size (mm)	2m	4m	6m	8m	10m	12m	14m	16m	18m	20m	25m	30m	35m	40m	45m	50m	55m	60m	65m	70m	75m	80m	85m	90m	95m	100m
16	80	55	45	38	34	30	26	22	20	18	14	12	11	8	7	6	6	5	5	4	4	4	4	3	3	3
20	140	96	77	66	58	53	49	45	43	40	35	29	25	21	19	17	16	14	13	12	11	11	10	9	9	9
25	251	172	139	119	105	95	88	81	77	73	64	58	53	47	45	41	38	35	32	30	28	26	25	23	21	20
32	490	336	270	232	204	186	171	159	149	141	124	114	104	92	86	81	77	74	71	68	66	64	62	60	57	56

Pipe Size (mm)	2m	4m	6m	8m	10m	12m	14m	16m	18m	20m	25m	30m	35m	40m	45m	50m	55m	60m	65m	70m	75m	80m	85m	90m	95m	100m
16	80	55	45	38	34	30	26	22	20	18	14	12	11	8	7	6	6	5	5	4	4	4	4	3	3	3
20	140	96	77	66	58	53	49	45	43	40	35	29	25	21	19	17	16	14	13	12	11	11	10	9	9	9
25	251	172	139	119	105	95	88	81	77	73	64	58	53	47	45	41	38	35	32	30	28	26	25	23	21	20
32	490	336	270	232	204	186	171	159	149	141	124	114	104	92	86	81	77	74	71	68	66	64	62	60	57	56

Pipe Size (mm)	2m	4m	6m	8m	10m	12m	14m	16m	18m	20m	25m	30m	35m	40m	45m	50m	55m	60m	65m	70m	75m	80m	85m	90m	95m	100m
16	80	55	45	38	34	30	26	22	20	18	14	12	11	8	7	6	6	5	5	4	4	4	4	3	3	3
20	140	96	77	66	58	53	49	45	43	40	35	29	25	21	19	17	16	14	13	12	11	11	10	9	9	9
25	251	172	139	119	105	95	88	81	77	73	64	58	53	47	45	41	38	35	32	30	28	26	25	23	21	20
32	490	336	270	232	204	186	171	159	149	141	124	114	104	92	86	81	77	74	71	68	66	64	62	60	57	56