Pipes Full Data V11006 06Jul09

TECHNICAL INFORMATION SHEETS

Pre-Insulated Pipes

PIPE2000 Ltd

3 Kelvin Road Manor Trading Estate

Benfleet, Essex SS7 4QB

Tel No 01268 759567 Fax No 01268 569932 email: [email protected] www.pipe2000.co.uk

TECHNICAL INFORMATION SHEETS PRE-INSULATED PIPES

CALPEX® - The Professional Solution for Engineers

PIPE2000 Ltd




15.04.2009

CALPEX® district heating pipe CPX

Subject to technical changes

Table of Contents

1.0 Table of Contents

1.1 System description 1.100 System description (general)1.105 System description (data)1.110 Long-term behaviour/lifetime calculation1.115 CALPEX® UNO/DUO range, heating 6 bar – structure, dimensions, materials, weights and delivery lengths1.120 CALPEX® UNO/DUO range, sanitary 10 bar – structure, dimensions, materials, weights and delivery lengths1.125 CALPEX® QUADRIGA range, heating 6 bar, sanitary 10 bar – structure, dimensions, materials,

weights and delivery lengths

1.2 Planning, design engineering1.200 Pressure loss chart, heating, 6 bar1.205 Pressure loss chart, sanitary, 10 bar1.210 Heat loss, heating, 6 bar 1.215 Heat loss, sanitary, 10 bar1.220 Heat loss, heating 6 bar, sanitary 10 bar, QUADRIGA1.225 Planning and connection technology, heating strip, sanitary, 10 bar

1.3 Components1.300 House entry bend 90°, heating 6 bar, UNO and DUO1.305 House entry bend 90°, sanitary 10 bar, UNO and DUO1.310 House entry bend 90°, heating 6 bar, sanitary 10 bar,

QUADRIGA1.315 CALPEX® L-shell, DN 20 - DN 501.316 CALPEX® Big L-shell, DN 20 - DN 501.320 Joint (PE-HD shrink sleeve), DN 20 - DN 1001.325 CALPEX® I-shell, DN 20 - DN 501.326 CALPEX® Big I-shell, DN 65 - DN 1251.330 CALPEX® T-shell, DN 20 - DN 50 1.335 CALPEX® Big T-shell, DN 65 - DN 100 1.340 T-joint, dimension DN 150 1.345 Y-pipe, heating, 6 bar1.350 Distribution chamber, dimensions DN 20 - DN 1001.355 Distribution chamber, installation for dimensions DN 20 - DN 1001.360 Concrete protective plate for distribution shaft1.365 Insulation material, PE foam (DN 20 - DN 100), PUR foam containers (DN 20 - DN 150)1.370 Screwed connectors, outer thread, weld end1.375 Screwed connectors, coupling: equal, reduced1.380 Screwed connectors, T-piece

1.0

1.385 Compression connectors, thread, weld end with sliding sleeve1.390 Compression connectors, coupling, angle 90° with sliding sleeve1.395 Compression T-piece, with sliding sleeve 1.400 Electro-fusion joint, dimensions DN 65 - DN 1501.405 End cap, standard, shrinkable1.410 Wall sealing ring, for wall openings1.415 Building entry, wall opening/core bore1.420 Wall seal, core bores/cement pipe liners1.425 Building entry, core bores/cement pipe liners1.430 Pipe warning tape

1.5 Underground construction, installation1.500 Pipe routing1.505 Trench dimensions1.510 Connection (rigid/fl exible), CALPEX® plastic casing pipe1.515 House entry, screwed connector, shaft entry, fi xed point forces1.520 House connection, compression joint, shaft entry, fi xed point forces1.525 Installation of house connection1.515 House connection, screwed connector 1.520 House connection, joint with sliding sleeves1.525 Installation of house entry1.530 Installation tool, general and for screwed connector1.535 Installation tool, for joint with sliding sleeves1.540 Heating strip, sanitary, 10 bar, drawing in, sensor, joint

johnknight

Text Box

UK DISTRIBUTOR PIPE2000 Ltd T: 01268 759567 F: 01268 569932 e: [email protected] www.pipe2000.co.uk

15.04.2009



System description

1. General

CALPEX® district heating pipe is the registered trade name for a fl exible pipe system from Brugg Pipe Systems, specifi cally designed for the low temperature use. It is ideal for use in small and midsize district and local heating networks, in industrial and agricultural applications, for drink-ing water supplies, sewage systems, cooling systems and swimming pool installations.

CALPEX® district heating pipe has a carrier pipe made of cross-linked polyethylene, PEXa. This material was selected because of its excellent thermal and mechanical properties. It is a corrosion-proof and chemically resistant material. The product is free of harmful substances, making it exceptionally environment-friendly.

The PEXa pipe in the heating series is equipped with an oxygen diffusion barrier (EVOH).

The thermal insulation is CFC-free fl exible rigid polyurethane foam with excellent insulation values.

The bending capability of CALPEX® district heating pipe means that it is generally possible to pass over or under existing supply pipes and obstacles can be easily bypassed.

With CALPEX® district heating pipe, users can choose the shortest pipe route without the restrictions required by the classical method of pipe construction.

The fl exible CALPEX® district heating pipe is delivered to the site continuously in coils or on a cable drum. Long delivery lengths enable pipes to be laid in the ground largely without joints. This means that the pipe trench can be considerably narrower. This in turn allows considerable savings on underground work, especially as regards DUO pipes.

Taking account of the very short time required for installation, CALPEX® district heating pipe is not only the technically ideal solution but also the key to saving time and expense when setting up district heating networks; less co-ordination is required on site and the pipes are laid simply and quickly.

The physical properties of the PEXa pipe combined with the composite insulation mean that thermal expansion can be ignored when using this product.

Installing the connecting pieces is very simple. The joints are fi tted quickly and reliably with conventional screwed connectors, compression joints or electro-fusion joints. The wide range of accessories ensures that solutions can be chosen for every possible situation.

2. Range of applications

Heating, pipe series 5 (SDR 11): Max. temp. for continuous operation TBmax: 80 °CMax. permitted operating temp. Tmax: 95 °C (fl uctuating)Max. permitted operating pressure p: 6 bar

see sheet CPX 1.110

Sanitary, pipe series 3.2 (SDR 7.4):Max. temp. for continuous operation TBmax: 80 °CMax. permitted operating temp. Tmax: 95 °C (fl uctuating)Max. permitted operating pressure p: 10 bar

see sheet CPX 1.110

1.100

johnknight

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15.04.2009



PEXa carrier pipe Reference temperature °C Value Test standard

Density - 938 – 940 kg/m3 DIN 53479

Thermal conductivity - 0.38 W/mK DIN 52612

Tensil strength 20 26 – 30 N/mm2 DIN 53455

Tensil strength 80 18 – 20 N/mm2 DIN 53455

Modulus of elasticity 20 600 – 900 N/mm2 DIN 53457

Modulus of elasticity 80 300 – 400 N/mm2 DIN 53457

Linear expansion coeffi cient 20 1.4 · 10 E-4 1/K -

Linear expansion coeffi cient 100 2.0 · 10 E-4 1/K -

Crystallite melting range - 130 – 136 °C -

Chem. resistance 20 / 40 / 60 - DIN 8075 B.1

System description

1. Carrier pipe

Materials Basic material: High-density polyethylene (PE-HD), peroxide cross-linked (PEXa), colour: naturalBonding agent PE-modifi ed, heat-stabilized, colour: red (heating), white (sanitary)Oxygen barrier layer Ethylene / vinyl alcohol (EVOH), heat-stabilized, colour: naturalRequirements As per DIN 16892 / DIN 16893 and E DIN EN 12318-2, pipes in series 3.2

as per DVGW worksheet W 544Impermeability to oxygen As per DIN 4729 at 40 °C, oxygen permeability based on the interior pipe volume as per DIN 4726 from ≤ 0.10 g / (m3 x d)Pipe series DIN 16893 Series 5 (SDR 11): for heating (with EVOH barrier)

Series 3.2 (SDR 7.4): for sanitary (without EVOH barrier)Long-term behaviour See catalog sheet CPX 1.110Properties Unaffected by aggressive water; low pressure losses; very good chemical and mechanical resistance

1.105

2. Thermal insulation

Materials: CALPEX® heating CFC-free, cyclopentane-blown polyurethane foam (PUR) with �50 value of 0.0237 W/mK. CALPEX® sanitary CFC-free, 100% CO2-blown polyurethane foam (PUR) with �50 value of 0.032 W/mK.

PUR insulation Reference temperature °C CALPEX® heating CALPEX® sanitary Test standard

Density - > 60 kg/m3 > 60 kg/m3 ISO 845

Thermal conductivity 50 ≤ 0.0237 W/mK ≤ 0.032 W/mK EN 253 and

ISO 8497

Percentage of closed cells - ≥ 90 % ≥ 90 % -

Water absorption after 24 hours - ≤ 10 % ≥ 10 % EN 253

3. Protective casing

Materials: linear polyethylene, low density (LLD-PE), seamlessly extrudedPurpose: mechanical protection and moisture resistance

LLD-PE protective casing Reference temperature °C Value Test standard

Density - 918-922 kg/m3 ISO 1183

Thermal conductivity - 0.33 W/mK DIN 52612

Crystallite melting range - 122 °C ISO 11357-3

johnknight

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15.04.2009



1.110

Long-term behaviourLifetime calculation

Long-term behaviour (Table)

The values have a safety factor of 1.25 and are based on a series of measurements covering an average of 32,000 hours. They can be compared with Table 5 as per DIN 16893. All values have been tested and confi rmed by the competent organizations in various countries. A typical fl uctuating temperature distribution for the fl ow in a district heating system gives an average temperature/year of approx. 66 °C.

Lifetime calculation using Miner's Rule

If the PEXa pipe system is operated with alternating temperatures T1 … Tn, the operating period D can be calculated using the following formula:

1 D = (f1/D1 + f2/D2 + f3/D3 + … + fn/Dn)

D = lifetime in years for operation with alternating temperatures between T1 … Tn

D1 … Dn = Maximum lifetime in years for operation with constant temperatures T1 … Tn and pressure

f1 … fn = Proportionate operating periods at constant temperatures T1 … Tn

Example of lifetime calculation

The basis is a typical temperature collective over one year, with fl uctu-ating operation.

1 year = 365 days = 8760 hours.

Temperature

Flow

T1 65°C

T2 70°C

T3 75°C

T4 80°C

T5 85°C

T6 90°C

T7 95°C

Operating hours

f1 1090 hours

f2 1360 hours

f3 1600 hours

f4 1210 hours

f5 1850 hours

f6 1050 hours

f7 600 hours

Pressure

bar

6.0

6.0

6.0

6.0

6.0

6.0

6.0

Dn*

Years

100 years

80 years

75 years

55 years

45 years

25 years

16 years*Values from table interpolated

Calculated lifetime:

1D =

1090/8760 1360/8760 1600/8760 1210/8760 + + +

100 80 75 55

1 = 47.10 1850/8760 1050/8760 600/8760 + +

45 25 16

The calculated lifetime for the operating parameters mentioned in the table is 47 years. A safety factor of 1.25 is incorporated in this calcula-tion.

Operating temperature: Heating, (pipe series 5 SDR 11) Sanitary (pipe series 3.2 SDR 7.4)

°C Operating pressure (bar) Operating pressure (bar)

1 year 10 years 25 years 50 years 1 years 10 years 25 years 50 years

10 17.9 17.4 17.2 17.1 28.3 27.6 27.3 27.1

20 15.8 15.4 15.2 15.1 25.1 24.4 24.2 24.0

30 14.0 13.7 13.5 13.4 22.3 21.7 21.4 21.3

40 12.5 12.1 12.0 11.9 19.8 19.3 19.1 18.9

50 11.1 10.8 10.7 10.6 17.7 17.2 17.0 16.8

60 9.9 9.7 9.5 9.5 15.8 15.3 15.2 15.0

70 8.9 8.6 8.5 8.5 14.1 13.7 13.6 13.4

80 8.0 7.7 7.6 7.0 12.7 12.3 12.1 10.8

90 7.2 6.9 6.0 5.4 11.4 11.0 10.6 10.2

95 6.8 6.5 5.8 5.3 10.8 10.3 10.0 9.6

1 MPA = 10 bar Values extrapolated Values extrapolated

+

johnknight

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15.04.2009



1.115

CALPEX® UNO/DUO rangeHeating, 6 bar

CALPEX® in coils:Dimensions:DN 20 - DN 125

CALPEX® in straight lengths:Dimensions:DN 150

Type DN Inches PEX carrier pipe Outer casing Minimum Volume Weight Maximum delivery lengths

d x s D x s1 bending radius carrier pipe Jumbo coil Maxi coil

“ mm mm m l/m kg/m m m

25/ 76 20 ¾“ 25 x 2.3 78 x 2.0 0.7 0.32 0.90 520 807

32/ 76 25 1“ 32 x 2.9 78 x 2.0 0.7 0.53 1.00 520 807

40/ 91 32 1¼“ 40 x 3.7 93 x 2.2 0.8 0.83 1.39 377 590

50/111 40 1½“ 50 x 4.6 113 x 2.4 0.9 1.30 1.97 271 429

63/126 50 2“ 63 x 5.8 128 x 2.7 1.0 2.07 2.60 192 305

75/142 65 2½“ 75 x 6.8 143 x 3.0 1.1 2.96 3.39 143 229

90/162 80 3“ 90 x 8.2 163 x 3.2 1.2 4.25 4.56 92 149

110/162 100 4“ 110 x 10.0 163 x 3.2 1.2 6.36 5.10 92 149

110/182 100 4“ 110 x 10.0 183 x 3.3 1.4 6.36 5.68 52 86

125/182 125 5“ 125 x 11.4 183 x 3.3 1.4 8.20 6.37 52 86

160/250 150 6” 160 x 14.6 250 x 3.9 – 13.4 3 11.31 12 12




25 + 25/ 91 20 + 20 2 x ¾“ 2 x 25 x 2.3 93 x 2.2 0.8 2 x 0.32 1.34 377 590

32 + 32/111 25 + 25 2 x 1“ 2 x 32 x 2.9 113 x 2.4 0.9 2 x 0.53 1.87 271 429

40 + 40/126 32 + 32 2 x 1¼“ 2 x 40 x 3.7 128 x 2.7 1.0 2 x 0.83 2.48 192 305

50 + 50/162 40 + 40 2 x 1½“ 2 x 50 x 4.6 163 x 3.2 1.2 2 x 1.30 3.96 92 149

63 + 63/182 50 + 50 2 x 2“ 2 x 63 x 5.8 183 x 3.3 1.4 2 x 2.07 5.28 52 86

- We will produce different dimensions or special items on request (> 500 m).- Larger or smaller delivery lengths can be supplied on drums if requested.- Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width)

UNO DUOPEXa carrier pipe

PUR foam PE foil LLD-PE casing

s1d

s

DDd

s

PEXa carrier pipe

PE-HD casing pipe

CALPEX® heating, 6 bar, UNO

CALPEX® heating, 6 bar, DUO

johnknight

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15.04.2009



1.120

CALPEX® UNO/DUO rangeSanitary, 10 bar

CALPEX® sanitary, 10 bar, UNO




22/ 76 16 5⁄8“ 22 x 3.0 78 x 2.0 0.7 0.201 0.96 520 807

28/ 76 20 ¾“ 28 x 4.0 78 x 2.0 0.7 0.314 1.06 520 807

32/ 76 25 1“ 32 x 4.4 78 x 2.0 0.7 0.423 1.12 520 807

40/ 91 32 1¼“ 40 x 5.5 93 x 2.2 0.8 0.660 1.56 377 590

50/111 40 1½“ 50 x 6.9 113 x 2.4 0.9 1.029 2.25 271 429

63/126 50 2“ 63 x 8.7 128 x 2.7 1.0 1.633 3.06 192 305

32/111 HBK 25 1“ 32 x 4.4 113 x 2.4 0.9 0.423 1.83 271 429

40/126 HBK 32 1¼“ 40 x 5.5 128 x 2.7 1.0 0.660 2.49 192 305

50/126 HBK 40 1½“ 50 x 6.9 128 x 2.7 1.0 1.029 2.76 192 305

CALPEX® sanitary, 10 bar, DUO




28 + 22/ 91 20 + 16 ¾“ + 5⁄8“ 28 x 4.0 + 22 x 3.0 93 x 2.2 0.8 0.314 + 0.201 1.47 377 590

32 + 22/111 25 + 16 1“ + 5⁄8“ 32 x 4.4 + 22 x 3.0 113 x 2.4 0.9 0.423 + 0.201 1.95 271 429

40 + 28/126 32 + 20 1¼“ + ¾“ 40 x 5.5 + 28 x 4.0 128 x 2.7 1.0 0.660 + 0.314 2.60 192 305

50 + 32/126 40 + 25 1½“ + 1“ 50 x 6.9 + 32 x 4.4 128 x 2.7 1.0 1.029 + 0.423 2.96 192 305


UNO DUO PEXa carrier pipePUR foam PE foil LLD-PE casing

s1d

s

D

18∞

Heating strip channel (HBK)

(see sheets CPX 1.225, 1.540)

johnknight

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15.04.2009



1.125

CALPEX® QUADRIGA rangeHeating 6 bar, sanitary 10 bar

Type

H25 + 25/S28 + 22/142

H32 + 32/S28 + 22/142

H32 + 32/S32 + 22/142

H40 + 40/S40 + 28/162

DN

20

20

20

16

25

25

20

16

25

25

25

16

32

32

32

20

Inches

“

¾“

¾“

¾“5⁄8

1“

1“

¾“5⁄8“

1“

1“

1“5⁄8“

1¼“

1¼“

1¼“

¾“

Carrier pipe

d x s

mm

25 x 2.3

25 x 2.3

28 x 4.0

22 x 3.0

32 x 2.9

32 x 2.9

28 x 4.0

22 x 3.0

32 x 2.9

32 x 2.9

32 x 4.4

22 x 3.0

40 x 3.7

40 x 3.7

40 x 5.5

28 x 4.0

Outer casing

D x s1

mm

143 x 3.0

143 x 3.0

143 x 3.0

163 x 3.2

Minimum

bending radius

m

1.1

1.1

1.1

1.2

Volume

carrier pipe

l/m

0.327

0.327

0.314

0.201

0.539

0.539

0.314

0.201

0.539

0.539

0.423

0.201

0.835

0.835

0.660

0.314

Weight

kg/m

3.25

3.39

3.41

4.15

Jumbo coil

m

110

110

110

65

Maxi coil

m

169

169

169

101

Maximum delivery length


PEXa carrier pipe

PUR foam

PE foil

LLD-PE casing

s1d

s

D

CALPEX® , heating 6 bar, sanitary 10 bar, QUADRIGA

johnknight

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15.04.2009



1.200

Pressure loss chartHeating, 6 bar

Water temperature 80 °CSurface roughness ε = 0.007 mm (PEXa)(1 mmWS = 9.81 Pa)

Pressure loss ∆p [Pa/m]

25/20.4 mm

(DN 20, ¾”)

32/26.2 mm

(DN 25, 1”)

40/32.6 mm

(DN 32, 1¼”)

50/40.8 mm

(DN 40, 1½”)

75/61.4 mm

(DN 65, 2½”)

63/51.4 mm

(DN 50, 2”)

3.0 m/s

2.0 m/s

1.5 m/s

1.0 m/s0.75 m

/s

0.5 m/s0.4 m

/s0.3 m/s

Water velocity

Mas

s fl o

w ra

te m

[kg

/h]

Q [kW]

1000

500

300

200

100

5030

20

1020

3050

100

200

300

500

4000

030

000

2000

010

000

5000

3000

2000

1000

500

300

20 30 40 50 80

100

200

300

400

500

800

1000

200012

0

140

160

180

1200

1400

1600

1800

20 °

C

∆T

30 °

C

7000

010

0000

2000

00

1000

2000

3000

150

7540

15

7515

020

0030

0050

00

90/73.6 mm

(DN 80, 3”)

110/90.0 mm

(DN 100, 4”)

125/102.2 mm

(DN 125, 5”)

160/130.8 mm

(DN 150, 6”)

4.0 m/s

6000

040

00 Q·860m ≈ ∆T

m = Flow rate in kg/hQ = Power requirement in kW∆T = Temperature difference VL (fl ow)/RL (return) in °C

johnknight

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15.04.2009



1.205

Pressure loss chartSanitary, 10 bar

Water temperature 60 °CSurface roughness ε = 0.007 mm (PEXa)(1 mmWS = 9.81 Pa)

Q·860m ≈ ∆T

m = Flow rate in kg/hQ = Power requirement in kW∆T = Temperature difference VL (fl ow)/RL (return) in °C

Pressure loss ∆p [Pa/m]

22/16.0 mm

(DN 16, 5⁄8“)

28/20.0 mm

(DN 20, ¾“)

32/23.2 mm

(DN 25, 1“)

40/29.0 mm

(DN 32, 1¼“)

50/36.2 mm

(DN 40, 1½“)

63/45.6 mm

(DN 50, 2“)

3.0 m/s

2.0 m/s

1.5 m/s

1.0 m/s0.75 m

/s

0.5 m/s0.4 m

/s

0.3 m/s

Water velocity

Q [kW]

1000

500

300

200

100

5030

20

1020

3050

100

200

300

500

4000

030

000

2000

010

000

5000

3000

2000

1000

500

300

20 30 40 50 80

100

200

300

400

500

800

1000

200012

0

140

160

180

1200

1400

1600

1800

20 °

C

∆T

30 °

C

4000

Mas

s fl o

w ra

te m

[kg

/h]

johnknight

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15.04.2009



1.210

Heat lossHeating, 6 bar

CALPEX® UNO

Heat losses q [W/m] for one UNO pipe

CALPEX® UNO U-value Average operating temperature TB [°C]

[W/mK] 40° 50° 60° 70° 80° 90°

25/ 76 0.127 3.8 5.1 6.4 7.6 8.9 10.2

32/ 76 0.161 4.8 6.4 8.1 9.7 11.3 12.9

40/ 91 0.167 5.0 6.7 8.4 10.0 11.7 13.4

50/111 0.173 5.2 6.9 8.7 10.4 12.1 13.8

63/126 0.196 5.9 7.8 9.8 11.8 13.7 15.7

75/142 0.212 6.4 8.5 10.6 12.7 14.8 17.0

90/162 0.229 6.9 9.2 11.5 13.7 16.0 18.3

110/162 0.328 9.8 13.1 16.4 19.7 23.0 26.2

110/182 PLUS 0.262 7.9 10.5 13.1 15.7 18.3 21.0

125/182 0.337 10.1 13.5 16.9 20.2 23.6 27.0

160/250 0.318 9.6 12.8 15.9 19.1 22.3 25.5

Heat losses q [W/m] for one DUO pipe

CALPEX® DUO U-value Average operating temperature TB [°C]

[W/mK] 40° 50° 60° 70° 80° 90°

25 + 25/ 91 0.195 5.9 7.8 9.8 11.7 13.7 15.6

32 + 32/111 0.200 6.0 8.0 10.0 12.0 14.0 16.0

40 + 40/126 0.228 6.8 9.1 11.4 13.7 16.0 18.2

50 + 50/162 0.213 6.4 8.5 10.7 12.8 14.9 17.0

63 + 63/182 0.254 7.6 10.2 12.7 15.2 17.8 20.3

CALPEX® DUO (fl ow and return in one pipe)

Type of installation, CPX UNO:Type of installation, CPX DUO:Pipe distance:Cover above pipe:Ground temperature:Soil conductivity:Conductivity of PUR foam:Conductivity of PEX pipe: Conductivity of PE pipe:

2-pipe, laid in the ground1-pipe, laid in the ground a = 0.10 mH = 0.60 mTE = 10 °C�E = 1.2 W/mK�PU = 0.0237 W/mK�PEXa = 0.38 W/mK�PE = 0.33 W/mK

Heat loss during operation: q = U (TB -TE) [W/m]U = Heat transfer coeffi cient [W/mK]TB = Average operating temperature [°C]TE = Average ground temperature [°C]VL = FlowRL = Return

a = 0.1 m

H =

0.6

m

TE �E

H =

0.6

mTE

�E

RL (return)

VL (fl ow)

johnknight

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15.04.2009



1.215

Heat lossSanitary, 10 bar

CALPEX® UNO

Heat losses q [W/m] for one UNO pipe

CALPEX® UNO U-value Average operating temperature TB [°C]

[W/mK] 40° 50° 60° 70°

22/ 76 0.153 4.6 6.1 7.7 9.2

28/ 76 0.187 5.6 7.5 9.4 11.2

32/ 76 0.213 6.4 8.5 10.7 12.8

40/ 91 0.230 6.9 9.2 11.5 13.8

50/111 0.234 7.0 9.4 11.7 14.0

63/126 0.266 8.0 10.6 13.3 16.0

32/111 HBK 0.154 4.6 6.2 7.7 9.2

40/126 HBK 0.166 5.0 6.6 8.3 10.0

50/126 HBK 0.204 6.1 8.2 10.2 12.2

CALPEX® DUO

Heat losses q [W/m] for one DUO pipe

CALPEX® DUO U-value Average operating temperature TB [°C]

[W/mK] 40° 50° 60° 70°

28 + 22/ 91 0.284 8.5 11.4 14.2 17.0

32 + 22/111 0.236 7.1 9.4 11.8 14.2

40 + 28/126 0.261 7.8 10.4 13.1 15.7

50 + 32/126 0.347 10.4 13.9 17.4 20.8

Type of installation, CPX UNO: Type of installation, CPX DUO: Cover above pipe:Ground temperature:Soil conductivity:Conductivity of PUR foam:Conductivity of PEX pipe: Conductivity of PE pipe:

1-pipe, laid in the ground 1-pipe, laid in the groundH = 0.60 mTE = 10 °C�E = 1.2 W/mK�PU = 0.032 W/mK�PEXa = 0.38 W/mK�PE = 0.33 W/mK

Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coeffi cient [W/mK]TB = Average operating temperature [°C]TE = Average ground temperature [°C]

H =

0.6

m

TE �E

H =

0.6

mTE

�E

johnknight

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15.04.2009



1.220

Heat lossHeating 6 bar, sanitary 10 bar, QUADRIGA

CALPEX® QUADRIGA

Heat losses q [W/m] for one QUADRIGA pipe

CALPEX® QUADRIGA U-value Average operating temperature TB [°C]

[W/mK] 50° 55° 60° 65°

H 25 + 25/S 28 + 22/142 0.246 9.8 11.1 12.3 13.5

H 32 + 32/S 28 + 22/142 0.288 11.5 13.0 14.4 15.8

H 32 + 32/S 32 + 22/142 0.302 12.1 13.6 15.1 16.6

H 40 + 40/S 40 + 28/162 0.335 13.4 15.1 16.7 18.4

Type of installation for QUADRIGA: Cover above pipe:Ground temperature:Soil conductivity:Conductivity of PUR foam:Conductivity of PEXa pipe: Conductivity of PE pipe:

1-pipe, laid in the ground H = 0.60 mTE = 10 °C�E = 1.2 W/mK�PU = 0.032 W/mK�PEX = 0.38 W/mK�PE = 0.33 W/mK

CALPEX® QUADRIGA - heat loss during operation

Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coeffi cient [W/mK]TB = Average operating temperature [°C]TE = Average ground temperature [°C]

Example of calculation for average operating temperature TB [°C]Flow - heating: 70 °CReturn - heating: 40 °CFlow - sanitary: 60 °CReturn - sanitary: 50 °C

70° + 40° + 60° + 50°

TB = = 55 °C

4

H =

0.6

m

TE

�E

johnknight

Text Box


15.04.2009



1.225

Heating strip, sanitary, 10 bar

Planning and connection technology

1. Requirements for heating strip

1.1 Minimum power

Type CALPEX® UNO

32/111

40/126

50/126

40 °C

5.8 W/m

6.3 W/m

7.3 W/m

50 °C

7.8 W/m

8.3 W/m

10.3 W/m

60 °C

9.6 W/m

10.4 W/m

12.8 W/m

In relation to a maintained temperature of:

1.2 Recommendations for heating strip

Hot water: Frost protection:HWAT-R from Raychem meets the FS-B-2X from Raychem requiresrequirement for Ø 50/126, 60 °C thermostat with temperature sensor, UTR15 Automatic power adjustment with HWAT-ECO

Heating strip type

HWAT-R

FS-B-2X

Fuse

13 A

16 A

20 A

10 A

16 A

Length Lmax

60 m

80 m

100 m

65 m

105 m

Max. heating circuit length in relation to a cut-in temperature of 12 °C (HWAT) or 0 °C (FS-B-2X)

Fuse protection using automatic cutouts with characteristic C

2. Joint

3. T-branch

For the T-branch, note that the sum of two connected pipes must not be > Lmax*. T-switches cannot be supplied.* Lmax = max. permitted length for heating strip

L ≤ Lmax*

Through connection

Supply Through connection

L ≤ Lmax*

Separation of heating strip

Supply Supply

End closure

Supply End closure

Through connection

L ≤ Lmax*

Supply

End closure

Through connection

L ≤ Lmax*

The heating strip and the accessories are installed by the electrician!

johnknight

Text Box


15.04.2009



1.300

House entry bend, 90°Heating 6 bar, UNO and DUO

Type DN Inches PEX carrier pipe Outer casing Volume Weight

d x s D x s1 carrier pipe

“ mm mm l/m kg/unit

25/ 76 20 ¾“ 25 x 2.3 75 x 2.9 0.32 2.30

32/ 76 25 1“ 32 x 2.9 75 x 2.9 0.53 2.50

40/ 91 32 1¼“ 40 x 3.7 90 x 3.5 0.83 3.47

50/111 40 1½“ 50 x 4.6 110 x 4.3 1.30 4.92

63/126 50 2“ 63 x 5.8 125 x 4.9 2.07 6.50

75/142 65 2½“ 75 x 6.8 140 x 4.4 2.96 8.47

90/162 80 3“ 90 x 8.2 160 x 5.0 4.25 11.40

110/162 100 4“ 110 x 10.0 160 x 5.0 6.36 14.23

110/182 100 4“ 110 x 10.0 180 x 5.6 6.36 16.19

125/182 125 5“ 125 x 11.4 180 x 5.6 8.20 17.20

160/250 150 6“ 160 x 14.6 250 x 6.2 13.43 13.96

CALPEX® UNO

Bend, 90° DN 150 (St 37.0)With welded-on compression coupling

1114

1114

Figures in mm




25 + 25/ 91 20 + 20 2 x ¾“ 2 x 25 x 2.3 90 x 3.5 2 x 0.32 4.32

32 + 32/111 25 + 25 2 x 1“ 2 x 32 x 2.9 110 x 4.3 2 x 0.53 4.67

40 + 40/126 32 + 32 2 x 1¼“ 2 x 40 x 3.7 125 x 4.9 2 x 0.83 7.42

50 + 50/162 40 + 40 2 x 1½“ 2 x 50 x 4.6 160 x 5.0 2 x 1.30 9.90

63 + 63/182 50 + 50 2 x 2“ 2 x 63 x 5.8 180 x 5.6 2 x 2.07 13.96

CALPEX® DUO

Bend, 90° DN 20 - DN 125 (PEXa)

UNO DUO

A

1100

1600

250

250

johnknight

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15.04.2009



1.305

House entry bend, 90°Sanitary, 10 bar, UNO and DUO




22/ 76 16 5⁄8“ 22 x 3.0 75 x 2.9 0.20 2.40

28/ 76 20 ¾“ 28 x 4.0 75 x 2.9 0.31 2.65

32/ 76 25 1“ 32 x 4.4 75 x 2.9 0.42 2.80

40/ 91 32 1¼“ 40 x 5.5 90 x 3.5 0.66 3.90

50/111 40 1½“ 50 x 6.9 110 x 4.3 1.02 5.62

63/126 50 2“ 63 x 8.7 125 x 4.9 1.63 7.65

CALPEX® UNO

Bend, 90° DN 16 - DN 50 (PEXa)

UNO DUO

A

1100

1600

250

250




28 + 22/ 91 20 + 16 ¾“ + 5⁄8“ 28.0 x 4.0 + 22.0 x 3.0 90 x 3.5 0.31 + 0.20 3.67

32 + 22/111 25 + 16 1“ + 5⁄8“ 32.0 x 4.4 + 22.0 x 3.0 110 x 4.3 0.42 + 0.20 4.87

40 + 28/126 32 + 20 1¼“ + ¾“ 40.0 x 5.5 + 28.0 x 4.0 125 x 4.9 0.66 + 0.31 6.50

50 + 32/126 40 + 25 1½“ + 1“ 50.0 x 6.9 + 32.0 x 4.4 125 x 4.9 1.02 + 0.42 7.30

CALPEX® DUO

Figures in mm

johnknight

Text Box


15.04.2009

CPX


1.310

House entry bend, 90°Heating 6 bar, sanitary 10 bar, QUADRIGA

CALPEX® QUADRIGA

Figures in mm




H25+25/S28+22/142 20 ¾“ 25 x 2.3 140 x 4.4 0.327 8.12

20 ¾“ 25 x 2.3 0.327

20 ¾“ 28 x 4.0 0.314

16 5⁄8“ 22 x 3.0 0.201

H32+32/S28+22/142 25 1“ 32 x 2.9 140 x 4.4 0.539 8.47

25 1“ 32 x 2.9 0.539

20 ¾“ 28 x 4.0 0.314

16 5⁄8“ 22 x 3.0 0.201

H32+32/S32+22/142 25 1“ 32 x 2.9 140 x 4.4 0.539 8.52

25 1“ 32 x 2.9 0.539

25 1“ 32 x 4.4 0.423

16 5⁄8“ 22 x 3.0 0.201

H40+40/S40+28/162 32 1¼“ 40 x 3.7 160 x 5.0 0.835 10.37

32 1¼“ 40 x 3.7 0.835

32 1¼“ 40 x 5.5 0.660

20 ¾“ 28 x 4.0 0.314

CALPEX® district heating pipe

1100

250

1600

250

Bend, 90° DN 16 - DN 50 (PEXa)

johnknight

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15.04.2009



1.315

CALPEX® L-shellDimensions DN 20 - DN 50 (Ø 76 - 126 mm)

CALPEX® L-shell, UNO/DUO

Outer casing Ø d2

Ø d1 76 91 111 126

76 x

91 x

111 x

126 x

Structure of the half-shell

1 ABS half-shells2 PEX angle coupling; see CPX 1.390 3 Sealing clamps (14 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

d1

1

4

3

5

2

6

d2

376

376

Figures in mm

CALPEX

CALP

EX

CALPEX® shells are freely reducable from Ø 126 mm to Ø 76 mmCALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.350).

johnknight

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15.04.2009



1.316

CALPEX® Big L-shellDimensions DN 20 - DN 50 (Ø 76 - 126 mm)

CALPEX® Big L-shell, UNO/DUO

Outer casing Ø d2

Ø d1 76 91 111 126 142 162 182

76 x

91 x

111 x

126 x

142 x

162 x

182 x x


1 ABS half-shells2 PEX angle coupling; see CPX 1.390 3 Sealing clamps (22 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

d1

1

4

3

5

2

6

d2

508

508

Figures in mm

CALPEX

CALP

EX

CALPEX® Big-shells are freely reducable from Ø 182 mm to Ø 76 mmCALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.350).

johnknight

Text Box


15.04.2009



1.320

Joint using PE-HD shrink sleeve

1 PEX coupling; see sheet 1.3902 Insulation material, PUR or PE; see sheet 1.3653 Shrink sleeve pipe4 Shrink hose

Ø d2 76 91 111 126 142 162 182 250

76 x x x

91 x x x

111 x x x

Ø d1 126 x x x

142 x x x

162 x x x

182 x x

250 x x

Ø d2 90 110 125 140 160 180 200 225 250 280 315

76 x x x

91 x x x x x

111 x x x x x

Ø d1 126 x x x x

142 x x x x

162 x x x x x x

182 x x x x x x

250 x x x x x x x

CALPEX®-CALPEX® CALPEX® to insulated steel pipe

1 2 3 4CALPEX® joint

CALPEX® reduction joint

CALPEX® – Insulated steel pipe 1 2

d1d1

d1

d2d2

d2Weld on

Install

Dimensions DN 20 - DN 150

Installation note:

CALPEX

CALPEX

CALPEX CALPEX

CALPEX

Insulated steel pipe

CALPEX Insulated steel pipe

1

2

johnknight

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15.04.2009



1.325

CALPEX® I-shellDimensions DN 20 - DN 50 (Ø 76 - 126 mm)

1 4 3 2 5 6

d2

578

CALPEX® I-shell, UNO/DUO

Outer casing Ø d2

Ø d1 76 91 111 126

76 x

91 x x

111 x x x

126 x x x x


1 ABS half-shells2 PEX coupling; see CPX 1.390 3 Sealing clamps (12 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.350).

Figures in mm

d1

CALPEXCALPEX

johnknight

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15.04.2009



1.326

CALPEX® Big I-shellDimensions DN 65 - DN 125 (Ø 142 - 182 mm)

1 4 3 2 5 6

d2

752

CALPEX® BIG I-shell, UNO/DUO Structure of the half-shell

1 ABS half-shells2 PEX coupling; see CPX 1.390 3 Sealing clamps (22 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

Figures in mm

d1

CALPEXCALPEX

Outer casing Ø d2

Ø d1 76 91 111 126 142 162 182

76 x

91 x x

111 x x x

126 x x x x

142 x x x x

162 x x

182 x x x x

CALPEX® Big-shells are freely reducable from Ø 182 mm to Ø 76 mmCALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.350).

johnknight

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15.04.2009



1.330

CALPEX® T-shellDimensions DN 20 - DN 50 (Ø 76 - 126 mm)

CALPEX® T-shell, UNO/DUO

Outer casing Branch, Ø d2

Ø d1 - Ø d3 76 91 111 126

76 - 76 x x x x

91 - 91 x x x x

91 - 76 x x x x

111 - 111 x x x x

111 - 91 x x x x

111 - 76 x x x x

126 - 126 x x x x

126 - 111 x x x x

126 - 91 x x x x

126 - 76 x x x x


1 ABS half-shells2 PEX T-piece; see CPX 1.395 3 Sealing clamps (16 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

d2

1

2 5

4

3

6

d3d1

578

373

CALPEXCALPEX

CALP

EX


Figures in mm

johnknight

Text Box


15.04.2009



1.335

CALPEX® Big T-shellDimensions DN 65 - DN 125 (Ø 142 - 182 mm)

CALPEX® Big T-shell, UNO/DUO Outer casing Branch, Ø d2

Ø d1 - Ø d3 76 91 111 126 142 162 182

142 - 142 x x x x x x x

142 - 126 x x x x x x x

142 - 111 x x x x x x x

142 - 91 x x x x x x x

142 - 76 x x x x x x x

162 - 162 x x x x x x x

162 - 142 x x x x x x x

162 - 126 x x x x x x x

162 - 111 x x x x x x x

162 - 91 x x x x x x x

162 - 76 x x x x x x x

182 - 182 x x x x x x x

182 - 162 x x x x x x x

182 - 142 x x x x x x x

182 - 126 x x x x x x x

182 - 111 x x x x x x x

182 - 91 x x x x x x x

182 - 76 x x x x x x x


1 ABS half-shells2 PEX T-piece; see CPX 1.395 3 Sealing clamps (27 pcs.)4 Insulation material; see CPX 1.3655 Glued surface6 Reduction ring or sealing ring

d1 d3

752

d2

508

1

6

3

45


Figures in mm

CALPEXCALPEX

CALP

EX2

johnknight

Text Box


15.04.2009



1.340

T-jointDimension DN 150 (Ø 250 mm)

View A

Outer casing Branch, Ø d2

Ø d1 Ø d3 25/76 32/76 40/91 50/111 63/126 75/142 90/162 110/162 110/182 125/182 160/250

160/250 - 160/250 x x x x x x x x x x x

We can supply T-pieces with different branches on request

CALPEX CALPEX

Structure of T-joint

1 T-piece, insulated steel pipe (St 37.0)2 Shrink-on hoop3 Shrink sleeve pipe4 In-situ PUR foam5 CALPEX connector6 CALPEX pipe

CALP

EX

A

1

2

3

4

5

6

45° CALPEX

Insula

ted st

eel p

ipe

CALPEX® T-joint, DN 150

johnknight

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15.04.2009



UNO pipes DN Ø D DUO steel pipe DUO CPX pipe Ø C

mm mm mm mm mm

26.9 - 110 20 110 26.9 + 26.9/110 25 + 25/ 91 110

33.7 - 110 25 110 33.7 + 33.7/110 32 + 32/111 110

42.4 - 125 32 125 42.4 + 42.4/125 40 + 40/126 125

48.3 - 125 40 125 48.3 + 48.3/160 50 + 50/162 160

60.3 - 140 50 140 60.3 + 60.3/180 63 + 63/182 180

1.345

Y-pipeHeating, 6 bar

CALPEX® DUO / 2 x CALPEX® UNO

CALPEX® DUO / 2 x pre-insulated steel pipe (St 37.0)

UNO pipes DN Ø D DUO CPX pipe Ø C

mm mm mm mm

2 x 25/ 76 20 75 25 + 25/ 91 90

2 x 32/ 76 25 75 32 + 32/111 110

2 x 40/ 91 32 90 40 + 40/126 125

2 x 50/ 111 40 110 50 + 50/162 160

2 x 63/ 126 50 125 63 + 63/182 180

CPX UNO

steel pipe

CPX UNO

steel pipe

RL (return)

RL (return)

VL (fl ow) (right)

VL (fl ow) (right)

VL (fl ow) (bottom)

VL (fl ow) (bottom)

RL (return)

RL (return)

250

250

300

300

400

400

250

250

2020

2020

300

300

11 0/+1

11 0/+1

View: A - A

Note: With UNO pipe, in the direction of

fl ow, the forward fl ow (VL) is always on

the right and with DUO pipe, it is always

at the bottom.

View: A - A

Note: With UNO pipe, in the direction of

fl ow, the forward fl ow (VL) is always on

the right and with DUO pipe, it is always

at the bottom.

VL (fl ow) (right)

VL (fl ow) (right)

� D

� D

� C

� C

CPX DUO

Figures in mm

Figures in mm

CPX DUO

A

A

johnknight

Text Box


15.04.2009



Distribution chamberDimensions DN 20 - DN 125

Distribution chamber for all joints (DN 20 - DN 125)The distribution chamber is used to cover and protect completed BRUGG pipe joints, shut-off valves or junction branches. The distribution chamber is a watertight structure made of polyethylene; its multi-functional design makes it possible to use one chamber type for all pipe dimensions (DN 20 - DN 125).

Wall thickness approx. 8 mm

1.350

Ø Chamber exit Pipe dimensions (outer diameter)

Ø outer, 206 x 8 mm Leadthrough for outer Ø Ø 182, 162*

Ø outer, 166 x 8 mm Leadthrough for outer Ø Ø 142, 126*

Ø outer, 136 x 8 mm Leadthrough for outer Ø Ø 111, 91*, 76*

* with additional centering ring

145

270

130

200

8

120120

120360

� 80

0

� 20

6

� 16

6

� 1

36�

1040

475

Figures in mm

johnknight

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15.04.2009



Distribution chamberInstallation for dimensions DN 20 - DN 125

1.355

1 2

3 4

5 6

7 8

Two-part reduction ring

See CPX installation instructions

Flat seal

29 x 12

M10 x 35

� 1

36

� 1

66

� 2

06

� 1

66

� 2

06

▲

CALPEX®

johnknight

Text Box


15.04.2009



Protective concrete platefor distribution chamber

1.360

Schematic diagram showing installation of cover plate LoadThe cover plate has to be used wherever there might be public traffi c and for low-depth installations. The maximum load per unit of area must not exceed q = 153 kN/m² (SLW 60 to DIN 1055).

Installation method Correct installation of the sand must be ensured so that the plate can perform its function as a load shield for the inspection chamber. A Proctor density of dpr = 96 % should be the target for compaction. For subsequent work on the inspection chamber, the cover plate has lifting eyes. After completing the work and refi lling the pit, make sure that the infi ll between the inspection chamber and concrete slabs is restored correctly.

Filling/insulation materialSome suggestions for fi lling and insulation materials that can be used are listed below:- Bulk polystyrene material- Armafl ex or Tubolit- Foam using BRAG PUR foam canister

NoteThere is no need to use fi lling material in the distribution shaft. Likewise, it is not essential to insulate the pipes! The decision is up to the customer.

NoteThe plate must be located so that it completely covers the chamber below (see illustration).

Cover

plate

o 120

Inspection chamber

20

Sand, compacted

Figures in cm

GOK

Sand, compacted

Inspection chamber

80

5020 94

133

16 152121

12

21

21.57.5

2 Q 131 top

1 Q 221 bottom

4 3 x � 12

3 17

x �

10/

20

� 110� 120

3 � 10/202 Q131 top

1 Q221 bottom

5 ME.1 � 10

5 3.8 continuous

meters � 10

1 Q 221 bottom

2 Q 131 bottom

3 17 x � 10/20 mm (L = 0.5 m)

Total length 8.5 m

4 3 x � 12 mm (L = 0.85 m)

Total length 2.55 m

6

Figures in cm

Armouring

johnknight

Text Box


15.04.2009



Insulation materialPE foam (DN 20 - DN 125), PUR foam container(s) (DN 20 - DN 150)

1.365

Insulation material for shrink joints

Polyethylene foam tube, (DN 20 - DN 125)Extruded pipe insulation made of closed-cell polyethylene, excellent for insulating CALPEX® shrink joints (not for CALPEX® shells). Various thicknesses of insulation are available for the most common pipe diameters.

The insulation material (thickness and length) is supplied for the relevant joint types. The insulation must be fi tted precisely into the joints on site.

PUR foam for shrink joints and CALPEX® shells CFC-free, cyclopentane-blown PUR foam in plastic bottles

The required quantity of CFC-free polyurethane foam is delivered in suitable container sizes for the various joints and T-pieces. The components are supplied separately in two bottles and are only mixed together when needed. Please note the safety regulations in the installation instruc-tions supplied with the product.

Safety regulations

Protective goggles and gloves must be wornwhen using this product.

Synthetic gloves

Protective goggles

PE

johnknight

Text Box


15.04.2009



Screwed connectorsOuter thread, weld end

1.370

Connection with external thread Heating, 6 bar Sanitary, 10 bar

Material: brass Material: brass

PEX pipe Screwed connector L PEX pipe Screwed connector L

mm mm mm mm mm mm

25 x 2.3 25 x 2.3-¾“ 53 22 x 3.0 22 x 3.0-¾“ 51

32 x 2.9 32 x 2.9-1“ 63 28 x 4.0 28 x 4.0-¾“ 58

40 x 3.7 40 x 3.7-1¼“ 67 32 x 4.4 32 x 4.4-1“ 63

50 x 4.6 50 x 4.6-1½“ 71 40 x 5.5 40 x 5.5-1¼“ 67

63 x 5.8 63 x 5.7-2“ 80 50 x 6.9 50 x 6.9-1½“ 71

75 x 6.8 75 x 6.8-2½“ 92 63 x 8.7 63 x 8.7-2“ 80

90 x 8.2 90 x 8.2-3“ 92

110 x 10.0 110 x 10.0-4“ 102

Heating, 6 bar

Material: brass / St 37.0

PEX pipe Weld end L

mm mm mm

22 x 3.0 26.9 x 2.65 180

25 x 2.3 26.9 x 2.65 180

28 x 4.0 26.9 x 2.65 180

32 x 2.9 33.7 x 2.3 180

40 x 3.7 42.4 x 2.6 185

50 x 4.6 48.3 x 2.6 190

63 x 5.8 60.3 x 2.9 195

75 x 6.8 76.1 x 3.2 200

90 x 8.2 88.9 x 3.2 240

110 x 10.0 114.3 x 3.6 280

Connection with weld end

PEX 22-75

PEX 90-110

PEX 22-75

PEX 90-110

L

L

L

L

St 37.0

St 37.0

johnknight

Text Box


15.04.2009



Screwed connectorCoupling: equal, coupling: reduced

1.375

Coupling, equal Heating, 6 bar Sanitary, 10 bar


PEX pipe Coupling L PEX pipe Coupling L

mm mm mm mm mm mm

25 x 2.3 25 x 2.3 60 22 x 3.0 22 x 3.0 58

32 x 2.9 32 x 2.9 67 28 x 4.0 28 x 4.0 65

40 x 3.7 40 x 3.7 71 32 x 4.4 32 x 4.4 67

50 x 4.6 50 x 4.6 75 40 x 5.5 40 x 5.5 71

63 x 5.8 63 x 5.7 81 50 x 6.9 50 x 6.9 75

75 x 6.8 75 x 6.8 89 63 x 8.7 63 x 8.7 81

90 x 8.2 90 x 8.2 130

110 x 10.0 110 x 10.0 130

Heating, 6 bar Sanitary, 10 bar


PEX pipe Coupling PEX pipe Coupling L

mm mm mm mm mm

32 x 2.9 / 25 x 2.3 32-1“ / 25-¾“ 32 x 4.4/28 x 4.0 32-1“ / 28-¾“ 58

40 x 3.7 / 32 x 2.9 40-1¼“/32-1“ 40 x 5.5/32 x 4.4 40-1¼“/ 32-1“ 87

50 x 4.6 / 40 x 3.7 50-1½“/40-1¼“ 50 x 6.9/40 x 5.5 50-1½“/ 40-1¼“ 96

63 x 5.8 / 50 x 4.6 63-2“ / 50-1½“ 63 x 8.7/50 x 6.9 63-2“ / 50-1½“ 110

75 x 6.8 / 63 x 5.8 75-2½“/ 63-2“ 140

90 x 8.2 / 75 x 6.8 90-3“ / 75-2 ½“ 175

110 x 10.0 / 90 x 8.2 110-4“ / 90-3“ 315

Coupling, reduced

PEX 22-75

PEX 90-110

PEX 22-75

PEX 90-110

L

L

L

L

johnknight

Text Box


15.04.2009



Screwed connectorsT-piece

1.380

Heating, 6 barMaterial: brass

Ø d1 Ø d3 Branch, Ø d2

mm mm

22 x 3.0 25 x 2.3 28 x 4.0 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0

22 x 3.0 - 22 x 3.0 x

25 x 2.3 - 25 x 2.3 x

28 x 4.0 - 28 x 4.0 x

32 x 2.9 - 32 x 2.9 x x x x

32 x 2.9 - 28 x 4.0 x

32 x 2.9 - 25 x 2.3 x

40 x 3.7 - 40 x 3.7 x x x x x

40 x 3.7 - 32 x 2.9 x x x x

50 x 4.6 - 50 x 4.6 x x x x x x

50 x 4.6 - 40 x 3.7 x x x x x

63 x 5.8 - 63 x 5.8 x x x x x x x

63 x 5.8 - 50 x 4.6 x x x x x x

75 x 6.8 - 75 x 6.8 x x x x x x x x

75 x 6.8 - 63 x 5.8 x x x x x x x

90 x 8.2 - 90 x 8.2 x x x x x x x x x

90 x 8.2 - 75 x 6.8 x x x x x x x x

110 x 10.0 - 110 x 10.0 x x x x x x x x x x

110 x 10.0 - 90 x 8.2 x x x x x x x x x

Other T-pieces can be supplied on request.

PEX � 22-75 PEX � 90-110

d2d2

d1 d1d3 d3

johnknight

Text Box


15.04.2009



Compression connectorsOuter thread, weld end

1.385

Connector with external thread Heating, 6 bar Sanitary, 10 bar


PEX pipe Screwed connector L PEX pipe Screwed connector L

mm mm mm mm mm mm

25 x 2.3 25 x 2.3-¾“ 62 22 x 3.0 22 x 3.0-¾“ 58

32 x 2.9 32 x 2.9-1“ 72 28 x 4.0 28 x 4.0-¾“ 62

40 x 3.7 40 x 3.7-1¼“ 82 32 x 4.4 32 x 4.4-1“ 72

50 x 4.6 50 x 4.6-1½“ 89 40 x 5.5 40 x 5.5-1¼“ 82

63 x 5.8 63 x 5.7-2“ 109 50 x 6.9 50 x 6.9-1½“ 89

75 x 6.8 75 x 6.8-2½“ 110 63 x 8.7 63 x 8.7-2“ 109

90 x 8.2 90 x 8.2-3“ 115

110 x 10.0 110 x 10.0-4“ 120

125 x 11.4 125 x 11.4-5” 125

160 x 14.6 160 x 14.6-6” 130

Connector with weld end Heating, 6 bar

Material: Steel

PEX pipe Weld end L1 L2

mm mm mm mm

22 x 3.0 26.9 x 2.65 50 20

25 x 2.3 26.9 x 2.65 50 20

28 x 4.0 26.9 x 2.65 50 24

32 x 2.9 33.7 x 2.3 60 24

40 x 3.7 42.4 x 2.6 70 29

50 x 4.6 48.3 x 2.6 85 37

63 x 5.8 60.3 x 2.9 90 32

75 x 6.8 76.1 x 3.2 95 35

90 x 8.2 88.9 x 3.2 95 35

110 x 10.0 114.3 x 3.6 90 30

125 x 11.4 139.7 x 3.6 108 48

160 x 14.6 168.3 x 4.1 114 50

L

L1

L2

St 37

johnknight

Text Box


15.04.2009



Compression connectorsCoupling: equal, coupling: reduced, angle piece: 90°

1.390

Heating, 6 bar Sanitary, 10 bar


PEX pipe Coupling L PEX pipe Coupling L

mm mm mm mm mm mm

25 x 2.3 25 x 2.3 69 22 x 3.0 22 x 3.0 58

32 x 2.9 32 x 2.9 82 28 x 4.0 28 x 4.0 70

40 x 3.7 40 x 3.7 90 32 x 4.4 32 x 4.4 82

50 x 4.6 50 x 4.6 104 40 x 5.5 40 x 5.5 90

63 x 5.8 63 x 5.7 122 50 x 6.9 50 x 6.9 104

75 x 6.8 75 x 6.8 127 63 x 8.7 63 x 8.7 122

90 x 8.2 90 x 8.2 127

110 x 10.0 110 x 10.0 127

125 x 11.4 125 x 11.4 133

160 x 14.6 160 x 14.6 143

Coupling

Coupling, reduced Heating, 6 bar Sanitary, 10 bar

Material: Brass/steel* Material: brass

PEX pipe Coupling PEX pipe Coupling L

mm mm mm mm mm

32 x 2.9/ 25 x 2.3 32-1“ / 25-¾“ 32 x 4.4/28 x 4.0 32-1“ / 28-¾“ 76

40 x 3.7/ 32 x 2.9 40-1¼“/ 32-1“ 40 x 5.5/32 x 4.4 40-1¼“/ 32-1“ 86

50 x 4.6/ 40 x 3.7 50-1½“/ 40-1¼“ 50 x 6.9/40 x 5.5 50-1½ / 40-1¼“ 97

63 x 5.8/ 50 x 4.6 63-2“ / 50-1½“ 63 x 8.7/50 x 6.9 63-2“ / 50-1½“ 113

75 x 6.8/ 63 x 5.8 75-2½“/ 63-2“ 124

90 x 8.2/ 75 x 6.8 90-3“ / 75-2½“ 127

110 x 10.0/ 90 x 8.2 110-4“ / 90-3“ 127

125 x 11.4/110 x 10.1* 125-5“ / 110-4“ 228

160 x 14.6/125 x 11.4* 160-6“ / 125-5“ 262

L

L

Angle piece, 90°

z

Heating, 6 bar

Material: brass

PEX pipe PEX pipe a z

mm mm mm mm

25 x 2.3 25 x 2.3 54 32

32 x 2.9 32 x 2.9 64 37

40 x 3.7 40 x 3.7 74 42

50 x 4.6 50 x 4.6 87 48

63 x 5.8 63 x 5.8 106 60

75 x 6.8 75 x 6.8 117 67

90 x 8.2 90 x 8.2 127 76

110 x 10.0 110 x 10.0 137 87

Sanitary, 10 bar

Material: brass

PEX pipe PEX pipe a z

mm mm mm mm

22 x 3.0 22 x 3.0 – –

28 x 4.0 28 x 4.0 – –

32 x 4.4 32 x 4.4 66 39

40 x 5.5 40 x 5.5 74 42

50 x 6.9 50 x 6.9 87 39

63 x 8.6 63 x 8.6 106 60

z

a

a

johnknight

Text Box


15.04.2009



Compression connectorsT-piece

1.395

¹ Soldered fi ttings- T-pieces made of steel can be supplied on request- Other T-pieces can be supplied on request. - Dimension DN 150 is supplied in prefabricated and pre-insulated form (see sheet CPX 1.340).

Heating, 6 barØ d1 Ø d3 Branch, Ø d2

mm mm

25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4

25 x 2.3 - 25 x 2.3 o/x

32 x 2.9 - 32 x 2.9 o/x o/x

32 x 2.9 - 25 x 2.3 o/x

40 x 3.7 - 40 x 3.7 o/x o/x o/x

40 x 3.7 - 32 x 2.9 o/x¹ o/x¹

50 x 4.6 - 50 x 4.6 o/x o/x o/x o/x

50 x 4.6 - 40 x 3.7 o/x o/x o/x¹

63 x 5.8 - 63 x 5.8 o/x o/x o/x o/x o/x

63 x 5.8 - 50 x 4.6 o/+ o/x o/x o/x

75 x 6.8 - 75 x 6.8 o/x o/x o/x o/x o/x o/x

75 x 6.8 - 63 x 5.8 o/+ o/x o/+ o/x o/x

90 x 8.2 - 90 x 8.2 o/+ o/x o/x o/+ o/x o/+ o/x

90 x 8.2 - 75 x 6.8 o/+ o/+ o/+ o/+ o/+ o/+

110 x 10.0 - 110 x 10.0 o/+ o/x o/+ o/x o/x o/+ o/+ o/x

110 x 10.0 - 90 x 8.2 o/+ o/+ o/+ o/+ o/+ o/+ o/+

125 x 11.4 - 125 x 11.4 o o o o o o o o o

Material:x = Brass CuZn39Pb3 (DN 20 - DN 50), Gunmetal Rg7 (DN 65 - DN 100)o = St 37.0, welded+ = CrNi 1.4404, 1.4432, 1.4435 (316L)

d2

d1 d3

d2

d1 d3

Brass/CrNi St. 37.0

Sanitary, 10 barØ d1 Ø d3 Branch, Ø d2

mm mm

22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7

22 x 3.0 - 22 x 3.0 x x

28 x 4.0 - 28 x 4.0 x x x x

28 x 4.0 - 28 x 3.0 x

32 x 4.4 - 32 x 4.4 x x x x

32 x 4.4 - 28 x 4.0 x x x x

40 x 5.5 - 40 x 5.5 x x x x x

40 x 5.5 - 32 x 3.0 x x x x

40 x 5.5 - 28 x 4.0 x x x

50 x 6.9 - 50 x 6.9 x x x x x

50 x 6.9 - 40 x 5.5 x x x x x

50 x 6.9 - 32 x 4.4 x x x x x

50 x 6.9 - 28 x 4.0 x x x

63 x 8.7 - 63 x 8.7 x x x x x x

63 x 8.7 - 50 x 6.9 x x x x

63 x 8.7 - 40 x 5.5 x x x x

johnknight

Text Box


15.04.2009



Heating, 6 bar

Material: cross-linked polyethylene

PEX pipe PEX pipe

mm mm

75 x 6.8 75 x 6.8

90 x 8.2 90 x 8.2

110 x 10.0 110 x 10.0

125 x 11.4 125 x 11.4

160 x 14.6 160 x 14.6

Coupling

Electro-fusion jointsDimensions DN 65 - DN 150

1.400

Can be supplied on requestTransition sleeve/joint with thread (AG)

Can be supplied on requestTransition sleeve/joint, with fl ange

Angle piece, 90°

Only trained personnel, using suitable fusion equipment, may install the electro-fusion joints for PEXa connections.

Heating, 6 bar

Material: cross-linked polyethylene

PEX pipe PEX pipe

mm mm

75 x 6.8 75 x 6.8

90 x 8.2 90 x 8.2

110 x 10.0 110 x 10.0

125 x 11.4 125 x 11.4

160 x 14.6 160 x 14.6

johnknight

Text Box


15.04.2009



End capStandard, shrinkable

1.405

Shrink-on end cap, UNO End cap, UNO (LD-PE)

Shrink-on end cap, DUO End cap, DUO (LD-PE)

CALPEX® UNO

Type

22/ 76

25/ 76

28/ 76

32/ 76

32/111 HBK

40/ 91

40/126 HBK

50/111

50/126 HBK

63/126

75/142

90/162

110/162

110/182 PLUS

125/182

160/250

CALPEX® DUO

Type

25 + 25/ 91

28 + 22/ 91

32 + 22/111

32 + 32/111

40 + 28/126

40 + 40/126

50 + 32/126

50 + 50/162 PLUS

63 + 63/182 PLUS

QUADRIGA

Type

25 + 25/28 + 22/142

32 + 32/28 + 22/142

32 + 32/32 + 22/142

40 + 40/40 + 28/162

LD-PE end caps are fi tted on; suitable for dry rooms

A A

View A View A

Shrink-on end cap, QUADRIGA End cap, QUADRIGA (LD-PE)

johnknight

Text Box


15.04.2009



Wall sealing ringfor wall openings

1.410

for pipes up to O/D 182 mm for pipes over O/D 250 mm

CALPEX® UNO, DUO, QUADRIGA

Outer casing diameter Neoprene wall sealing ring

Ø Di, inner Ø Da, outer

mm mm mm

76 74 118

91 88 133

111 107 153

126 122 168

142 137 183

162 155 203

182 175 223

250 243 290

Building entry (see sheet CPX 1.415)

Ø Da

Ø Di

Ø Da

Ø Di

50 50 Figures in mm

johnknight

Text Box


15.04.2009



Building entryWall opening

1.415

Wall leadthrough

Wall opening Outer casing L min H min

Ø D

mm mm mm

78 450 250

93 500 250

113 500 300

128 550 300

143 600 350

163 650 350

183 670 380

250 810 450

PEX connection piece:

see sheet 1.370

or sheet 1.390

End cap:

see sheet 1.405Wall seal: see sheet 1.410

CALPEX pipe;

see sheets 1.115, 1.120

D

approx. 80 mm

80 mm

80 80100D D

L

H

Figures in mm

CALPEX®

johnknight

Text Box


15.04.2009



Wall sealCore bores/cement liner pipes

1.420

Standard With additional centering ring

Core bores

Perfect bores are required for installation. As hairline cracks may be present in the concrete or result from drilling, it is advisable to seal the entire length of the borehole with suitable sealant (such as AQUAGARD).

Tightness can only be guaranteed if this recommendation is fol-lowed.

1 CALPEX® district heating pipe2 Seal set, single-seal 1 x 40 mm, Shore hardness D 353 Seal set, double-seal* 2 x 40 mm, Shore hardness D 354 Liner pipe: made of fi bre cement or coated core bore

* Suitable for pressure from water up to 0.5 bar

Outer pipe Liner pipe, core bore Seal set Seal set

Ø R Ø D Ø R1 inner Ø D1 outer

mm mm mm mm

76 150 78 150

91 150 93 150

111 200 113 200

126 200 128 200

142 200 143 200

162 250 163 250

182 250 183 250

250 350 251 350

Building entry (see sheet CPX 1.425)

Oute

r sid

e of

base

men

t

3

4

1

R D

Oute

r sid

e of

base

men

t

2 3

4

1

R D

Inne

r sid

e of

base

men

t

Inne

r sid

e of

base

men

t

johnknight

Text Box


15.04.2009



Building entryCore bores/cement pipe liners

1.425

Wall leadthrough

Core bores Outer casing D1 A

Ø D

mm mm mm

78 150 180

93 150 180

113 200 230

128 200 230

143 200 280

163 250 280

183 250 330

250 350 380

min. 30

A

D1

Figures in mm

PEX connection piece:

see sheet CPX 1.370

or CPX 1.390

End cap:

see sheet CPX 1.405

CALPEX® pipe:

see sheets CPX 1.115, 1.120

Wall seal:

see sheet CPX 1.420

D

CALPEX®

80 mm

johnknight

Text Box


15.04.2009



Pipe warning tape

1.430

CALPEX® pipe warning tape

Pipe warning tape to be laid in the ground.Roll length: 250 m

CALPEX® trench structure

1 Pipe warning tape2 Excavated material3 Washed sand

Installation depth; see sheet CPX 1.505

1 2 3

60 3010

D10

T

johnknight

Text Box


15.04.2009



1.500

Pipe routing

CALPEX® – Connection to insulated steel pipe

CALPEX®

CALPEX®

CALPEX®

A

C

B

Insu

late

d st

eel p

ipe

Loop-in method CALPEX® – CALPEX® connection

A

B

C

D

E

A

B

C

D

CALPEX®

CALPEX®

johnknight

Text Box


15.04.2009



Trench dimensions1.505

Trench profi le, 2 CALPEX® pipes

UNO DUO, QUADRIGA

Casing pipe Width Depth Minimum

Ø D B T bending radius

mm cm cm m

78 45 80 0.7

93 50 80 0.8

113 55 85 0.9

128 55 85 1.0

143 60 85 1.1

163 65 90 1.2

183 70 95 1.4

250 80 100 -

Casing pipe Width Depth Minimum

Ø D B T bending radius

mm cm cm m

93 30 80 0.8

113 30 85 0.9

128 35 85 1.0

143 35 85 1.1

163 35 90 1.2

183 38 95 1.4

Trench profi le, 4 CALPEX® pipes

1 Pipe warning tape; see sheet CPX 1.4302 Excavated material3 Sand, washed, max. grain size 8 mm

SLW 30 300 kN total load as per DIN 1072; if subject to higher traffi c loads (e.g. SLW 60), a load-distributing superstructure as per RStO75 is required.

With no traffi c load, the minimum trench depth T can be reduced by 20 cm.

Installation depth:Max. installation depth: 2.6 mOur approval is required for installation at greater depths.

1 2 3

1010

3060

D

T

10 10 10D DB

1010

3060

D

T

D10 10B

1 2 3

10 10 10 10 10D D D D

B (4 x D + 5 x 10)

1010

30D

60

T

1 2 3

10 10 10D D

105

1030

DD

60

T

B

1 2 3

Figures in cm

Figures in cm

johnknight

Text Box


15.04.2009



Connection (rigid/fl exible)CALPEX® to insulated steel pipes

1.510

Installation instructions for transition from CALPEX® to insulated steel pipe (KMR)

1. Junction with T-piece 2. Transition with fi xed point

The transverse expansion ∆l must not exceed the expansion that can be accommodated by junction pipe DS and the CALPEX® pipe.

The thermal movement Δl of the insulated steel pipe cannot be com-pensated by the CALPEX® pipes. A fi xed point must be installed.

3. Transition with Z-bend 4. Transition with expansion bend

Static design of the Z-bend according to expansion variable ∆l.

DS = Expansion limb ∆l = Thermal movement FP = Fixed point (plastic casing pipe) DK = Expansion pad

If pipe length L or ∆l is more than permitted for DS, a fi xed anchor point must be installed.

- Design of expansion components- Positioning of expansion pads as per the section on PREMANT®

CALPEX®

CALPEX®

CALP

EX®

CALP

EX®

Joint/sleeveJoint/sleeve Insulated steel pipe

Insulatedsteel pipe

Insulated steel pipe

DK

≤ 2.0DS ≤ 2.0min 1.0

Rmin

Rmin

2.0 m∆

I∆

I

CPX T-shell

∆I

1.0 DS ≤ 2.5 1.0 DS ≤ 2.5

DK DK

CALPEX® CALPEX®

FP

FP

Joint/sleeve Joint/sleeve

∆I

∆I

L

Figures in m

Figures in m

Insulatedsteel pipe

Insulatedsteel pipe

johnknight

Text Box


15.04.2009



House entry, screwed connectorShaft entry, fi xed point forces

1.515

Connection with external thread Heating, 6 bar

PEX pipe A

mm mm

25 x 2.3 210

32 x 2.9 220

40 x 3.7 220

50 x 4.6 220

63 x 5.8 230

75 x 6.8 235

90 x 8.2 260

110 x 10.0 270

Sanitary, 10 bar

22 x 3.0 210

28 x 4.0 210

32 x 4.4 220

40 x 5.5 220

50 x 6.9 220

63 x 8.7 230

Connection with weld end Heating, 6 bar

PEX pipe B

mm mm

25 x 2.3 340

32 x 2.9 340

40 x 3.7 340

50 x 4.6 360

63 x 5.8 340

75 x 6.8 340

90 x 8.2 410

110 x 10.0 450

* Dimensions can be reduced by max. 60 mm if end cap is walled in.

Fixed point forces occurringCALPEX® heating, 6 bar CALPEX® sanitary, 10 bar

Maximum fi xed point forces occurring per pipe for:

TB = 90 °C, pB = 6 bar TB = 60 °C, pB = 6 bar

Type DN Fmax [N] Type DN Fmax [N]

25/ 76 20 925 25/ 76 20 755

32/ 76 25 1495 32/ 76 25 1225

40/ 91 32 2365 40/ 91 32 1940

50/111 40 3685 50/111 40 3015

63/126 50 5785 63/126 50 4740

75/142 65 8205 75/142 65 6720

90/162 80 11860 90/162 80 9720

110/182 100 17675 110/182 100 14480


TB = 60 °C, pB = 10 bar

Type DN Fmax [N]

22/ 76 16 820

28/ 76 20 1350

32/ 76 25 1730

40/ 91 32 2700

50/111 40 4230

63/126 50 6715

Fixed point

PEX connecting piece

with external thread:

see sheet 1.370End cap:

see sheet 1.405

Wall sealing ring:

see sheet 1.410

CALPEX® pipe

see sheets

1.115 and1.120

*A

*80

approx. 80

max

. 100

Weld on

Install


with weld end: see

sheet 1.370

Fixed pointEnd cap:

see sheet 1.405

approx. 80

*80

*B

1

2

Figures in mm

Figures in mm

johnknight

Text Box


15.04.2009



House entry, compression jointShaft entry, fi xed point forces

1.520

Connection with external thread Heating, 6 bar

PEX pipe A

mm mm

25 x 2.3 260

32 x 2.9 260

40 x 3.7 270

50 x 4.6 270

63 x 5.8 320

75 x 6.8 320

90 x 8.2 330

110 x 10.0 340

125 x 11.4 340

160 x 14.6 340

Sanitary, 10 bar

22 x 3.0 260

28 x 4.0 260

32 x 4.4 260

40 x 5.5 270

50 x 6.9 270

63 x 8.7 320Connection with weld end

Heating, 6 bar

PEX pipe B

mm mm

25 x 2.3 250

32 x 2.9 250

40 x 3.7 260

50 x 4.6 270

63 x 5.8 310

75 x 6.8 310

90 x 8.2 310

110 x 10.0 310

125 x 11.4 310

160 x 14.6 310

* Dimensions can be reduced by max. 60 mm if end cap is walled in.

Fixed point forces occurringCALPEX® heating, 6 bar CALPEX® sanitary, 10 bar


TB = 90 °C, pB = 6 bar TB = 60 °C, pB = 6 bar

Type DN Fmax [N] Type DN Fmax [N]

25/ 76 20 925 25/ 76 20 755

32/ 76 25 1495 32/ 76 25 1225

40/ 91 32 2365 40/ 91 32 1940

50/111 40 3685 50/111 40 3015

63/126 50 5785 63/126 50 4740

75/142 65 8205 75/142 65 6720

90/162 80 11860 90/162 80 9720

110/182 100 17675 110/182 100 14480

125/182 110 22878 125/182 110 18745

160/250 125 37510 160/250 125 30730


TB = 60 °C, pB = 10 bar

Type DN Fmax [N]

22/ 76 16 820

28/ 76 20 1350

32/ 76 25 1730

40/ 91 32 2700

50/111 40 4230

63/126 50 6715

Fixed point


with external thread:

see sheet 1.385End cap:

see sheet 1.405

Wall sealing ring:

see sheet 1.410CALPEX® pipe:

see sheets

1.115 and 1.120

approx. 80

*80

*A

max

. 100


with weld end:

see sheet 1.370

Fixed pointEnd cap:

see sheet 1.405

*B

*80

approx. 80

Weld on

Install

1

2

Figures in mm

Figures in mm

johnknight

Text Box


15.04.2009



Installation of house entry

1.525

1 Align pipe and cut to length at right-angles.

2 Using pipe cutter or saw, cut through casing at distance X (UNO) or Z (DUO).

UNO screwed connectorHouse connection:DN 16 - 65: X = 90 mmDN 80 - 100: X = 140 mmJoint/sleeve:DN 16 - 65: X = 70 mmDN 80 - 100: X = 140 mm

DUO screwed connectorHouse connection:DN 16 -40: Y = 80 mmDN 16 - 40: Z = 180 mmJoint/sleeve:DN 16 - 40: Y = 60 mmDN 16 - 40: Z = 160 mm

UNO compression jointHouse connection:DN 16 - 40: X = 140 mmDN 50 - 125: X = 180 mmJoint/sleeve:DN 16 - 40: X = 110 mmDN 50 - 100: X = 140 mmDN 125 - 150: X = 150 mm

DUO compression jointHouse connection:DN 16 - 40: Y,Z = 140 mmDN 50 Y,Z = 160 mmJoint/sleeve:DN 16 - 40: Y,Z = 110 mmDN 50 Y,Z = 140 mm

5 Using a knife blade to a maximum depth of 5 mm, split the casing.

6 Peel off the casing. 7 Cut back/remove the insulation along length X, (Z) Important: Do not scrape or score the outer surface of the carrier pipe!

8 Fit the wall sealing ring. Tighten the clamps (if present).

9 Carefully shrink on the pipe end closure according to the Raychem DHEC installation instructions which are enclosed in the package.

10 Install the fi tting as per the enclosed installation instructions for BEULCO (screwed connector) or REHAU (compression joint).

3 4UNO DUO y

zx

CALPEX® CALPEX®

johnknight

Text Box


15.04.2009



Installation toolsgeneral and for screwed connector

1.530

Cut to length and strip insulation Shrink procedure

It is recommended that gloves are worn for shrinking work. Hammer as auxiliary tool

Fit of connection piece

Pipe cutter for PEX pipe

Spanner wrench 25 mm fl at bit for cutting fi ller hole

Cleaning products and cleaning cloths

Knife to split casing and remove insulation

The saw is used to cut the casing pipe and the insulation

The gas burner is used to shrink hoses and joints

25 m

m

johnknight

Text Box


15.04.2009



Expander head Ø 50 - 110 mm

Press yoke Ø 50, 63 mm

Reducer Ø 75/90 mmfor yoke, Ø 110 mm

Case with expander headsand press yoke

Installation toolsfor press fi t joints

1.535

Manual tool for PEX Ø 22 - 40 mm (packed in one case)

Expander tool, up to Ø 32 mm(basic tool)

Press tool, up to Ø 40 mmExpander tool for Ø 40 mm(basic tool)

Expander head, up to Ø 32 mm Expander head, over Ø 40 mm Press yoke, Ø 22 - 40 mm

Hydraulic tool for PEX Ø 50 - 110 mm (packed in two cases)

Electro-hydraulic tool for PEX Ø 125 - 160 mm (packed in two cases)

Hydraulic press and expander tool Ø 50 - 110 mm including foot pump (basic tool)

Hydraulic press and expander tool Ø 125 - 160 mm including foot pump (basic tool)

Expander head Ø 125 - 160 mm

Press yoke Ø 160 mm

Reducer Ø 125 mmfor yoke, Ø 160 mm

Case with basic toolincluding head and yoke

Case with basic tool(without heads and yoke)

Case with expander headsand press yoke

Case with basic tool(without heads and yoke)

johnknight

Text Box


15.04.2009



Heating strip, sanitary, 10 barDrawing in, sensor, joint

1.540

1. Pulling through the heating strip1. Unroll the pipe so that it is straight, next to the trench (without bends). See also CPX 1.120. Shorten the casing and cut back the channel. From one end, push the glass fi bre wire (ø 6.5 mm) through the channel. The heating strip can be pushed in for straight lengths of up to 30 m.

2. Connect the heating strip or pull cord to the wire (drill a hole in the strip) and pull through the heating strip.

4. Joint

Through connection L ≤ Lmax* Feed in from one end

Separate of heating strips L > Lmax*Feed in from both end (each strip ≤ Lmax)

Protect the heating strip against moisture* Lmax = max. permitted length for heating strip

The heating strip and the accessories are supplied and installed by the electrician!

2. Installation of the temperature sensor for frost protectionThe temperature sensor has to be installed on the carrier pipe, opposite the heating strip. It must be installed at the coldest point of the pipe (outside the building). For this purpose, cut open an area of the casing measuring 10 x 7 cm and peel it off, cut open 10 x 7 cm of foam, fi x the temperature sensor onto the carrier pipe with adhesive tape, fi ll the hole with the insulation material supplied, apply fi lling adhesive S1113 below and above the temperature sensor cable (see Detail B), and seal with the sealing set.

Glass fi bre wire

Heating strip

CALPEX®

Temperature sensor cable

Shrink hose Filling adhesive, S 1113, 60 mm long Shrink hose Temperature sensor

approx. 10 cm

approx. 120 mm

appr

ox. 7

cm

250 mm 300 mm

Heating strip

(HWAT-R; FS-B-2X)

Heating strip joint

(S-06 for HWAT-R and FS-B-2X)

Heating strip

(HWAT-R; FS-B-2X)

End closure

(E-03 for HWAT-R and FS-B-2X)

Shorten the casing by 120 mm and cut off the exposed channel.

CALPEX®

CALPEX®

CALPEX®

CALPEX®

CALPEX® CALPEX® CALPEX® CALPEX®

Detail A

Detail B Detail C

3. Remove the insulation

Detail D

Detail E Detail F

johnknight

Text Box



CASAFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS

PIPE2000 Ltd




CASAFLEX - District heating pipe

03.6.05

CFL–

Subj

ect

to t

echn

ical

cha

nge

–

5.0Contents

5.0 Contents 5.1 System description

5.100 System description5.105 Quality certificate 5.110 CASAFLEX (CFL) - District heating pipe UNO Construction, Dimensions, Material, Weight and Delivery length5.111 CASAFLEX (CFL) - District heating pipe DUO Construction, Dimensions, Material, Weight and Delivery length 5.2 Engineering

5.200 Method of laying5.210 Pressure loss diagram5.215 Heat loss CASAFLEX - UNO5.216 Heat loss CASAFLEX - DUO5.220 Combination CASAFLEX - plastic sheath pipe5.225 Transit T-Piece KMR5.240 Pit constructions, building entry

5.3 Components

5.300 Connecting piece CASAFLEX - UNO5.300.1 Connecting piece CASAFLEX - UNO Typ 255.300.5 Connecting piece CASAFLEX - UNO DN 1005.301.2 Connecting piece CASAFLEX - DUO5.301.3 Y-pipe CASAFLEX - DUO5.305 Connecting socket5.315 Wall sealing ring5.316 Wall duct5.320 Accessory equipment Connecting piece - Insulating material, Trench warning tape

5.5 Data for excavation, Installation

5.500 Trench dimensions5.505 Building entry, Wall breakthrough5.505.1 Building entry, anchor forces5.505.2 Construction work5.505.5 Over ground laying5.515 Installation of house connection

PIPE2000 Ltd UK Distributor

Tel: 01268 759567 Fax: 01268 569932email: [email protected]

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5.100System description

1. General Remarks

CASAFLEX district heating pipe system is the name given to a flexible domestic connection system made by BRUGG Rohrsysteme. It is designed for use in small and medium-sized district and local heating networks, in industry and agriculture, in solar collec-tor systems and swimming pools.

The CASAFLEX district heating pipe system hasa corrugated carrier pipe made of stainless steel(X5 CrNi 18/9). The corrugated pipe has been desig-ned on fluid dynamic lines.

The heat insulation consists of a chlorofluoro-carbon-free and flexible polyurethane foam with outstan-ding heat insulating properties. Under the sheath pipe of PE-LD is a safety foil which prevents the diffusion of the gases.

The flexibility of the CASAFLEX district heating pipe allows it to follow the conditions of almost any rou-te. Existing service pipes and other obstacles can be crossed over, below or bypassed easily.

The pipes can be laid across existing pipework, either from above or below and routed easily around any obstacles.

Regardless of the conventional structure of pipe-work, it is possible with the CASAFLEX district hea-ting pipe system to select the shortest route.

The CASAFLEX district heating pipe can be supplied to the site in the desired length, either in a single

piece or in coils or on drums. It can be laid in earth largely without connection points, which means the trenches can be considerably narrower than usual. As a consequence, considerable time can be saved on excavation work.

If you consider the short laying time, the CASAF-LEX district heating pipe is not only the technically perfect solution, but because of the reduction in co-ordinating work and the fast and easy way it is laid, it is also the key to saving time and money when laying district heating pipe systems.

The physical properties of the corrugated carrierpipe make it possible to lay it without having totake thermal expansion into account.

Assembly of the connections is extremely user-friendly with simple screw connection enabling the joints to be assembled quickly and in complete safety.

2. Range of Application

• Operating temperature up to 160 °C Highest temperature up to 180 °C• Operating pressure PN 16 up to PN 25




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5.105Quality certificateISO 9001



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D

6d

1 2 3 4 5

5.110District heating pipeCASAFLEX - UNO

Type DN Inch Carrier Casing min. Capacity Weight max. delivery length CASAFLEX pipe pipe bending carrier Drum1) Coil2)

d D radius pipe ["] [mm] [mm] [m] [l/m] [kg/m] [m] [m]

1) Dimension of drums Ø 3000 x 1600 (large), type EX202) Dimension of coils Ø 2800 x 800 (large)* on request

Pos Material

1 Corrugated stainless steel carrier pipe of nickel-chromium steel acc. to EN 10088 1.4301 / AISI 304 or 1.4571 / AISI 316Ti, or 1.4404 / AISI 316L

2 Only DN 20 - DN 80 Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam), up to 160 °C operating temperature (180 °C peak), thermal conductivity λ = 0,025 W/mK at 50 °C average temperature Only DN 100 Flexibel insulation of CFC-free polyurethane foam, usable up to 130 °C, thermal conductivity λ = 0,0255 W/mK at 50 °C average temperature

3 Expanded metal (only DN 20 to DN 80)

4 Multi-layer barrier foil

5 Casing pipe from low density polyethylene, PE-LD black (VDE 0209) seamless extruded. Protection against mechanical influence and moisture.

6 Detection monitoring wires: (a) 1 x NiCr, (b) 1 x Cu insulated; (c) 1 x Cu

Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System

22/91 20 3/4" 22 91 0.8 0.44 1.30 570 245/370*

30/91 25 1" 30 91 0.8 0.80 1.48 570 245/370*

39/111 32 1 1/4" 39 111 1.0 1.35 2.15 370 200/260*

48/111 40 1 1/2" 48 111 1.0 2.04 2.46 370 200/260*

60/126 50 2" 60 126 1.2 3.12 3.02 230 160/190*

75/142 65 2 1/2" 75 142 1.5 5.12 4.10 210 110/140*

98/162 80 3" 98 162 1.8 8.43 5.70 180 90/125*

127/182 100 4" 127 184 2.0 14.3 7.40 - 86




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5.111District heating systemCASAFLEX - DUO

1) Dimension of drums Ø 3000 x 1600 (large), type EX202) Dimension of coils Ø 2800 x 800 (large)* on request

Type DN Inch Carrier Casing min. Capacity Weight max. delivery length CASAFLEX pipe pipe bending carrier Drum1) Coil2)

d D radius pipe ["] [mm] [mm] [m] [l/m] [kg/m] [m] [m]

Pos Material

1 Corrugated stainless steel carrier pipe of nickel-chromium steel acc. to EN 10088 1.4301 / AISI 304 or 1.4571 / AISI 316Ti, or 1.4404 / AISI 316L

2 Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam), up to 160 °C operating temperature (180 °C floating), thermal conductivity λ = 0,025 W/mK at 50 °C average temperature

3 Expanded metal

4 Multi-layer barrier foil

5 Casing pipe from low density polyethylene, PE-LD black (VDE 0209) seamless extruded. Protection against mechanical influence and moisture.

6 Detection monitoring wires: (a) 1 x NiCr, (b) 1 x Cu insulated; (c) 1 x Cu

Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System

22 + 22/111 20 3/4 22 111 1.1 0.44 2.5 370 200/260*

30 + 30/126 25 1 30 126 1.4 0.80 3.1 230 160/190*

39 + 39/142 32 1 1/4 39 142 1.5 1.35 3.7 210 110/140*

48 + 48/162 40 1 1/2 48 162 1.8 2.04 4.2 180 90/125*

6 1 2 3 4 5d

D



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5.200Method of laying

Connection CASAFLEX - plastic sheath pipe

Looping-in method

Laying from building to building

CASAFLEX

CASAFLEX

CASAFLEX

CASAFLEX

pla

stic

sh

eath

pip

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The shape of the corrugations and the diameter of the CASAFLEX internal pipes have been designed in line with the principles of fluid dynamics so that the specific pressure losses correspond approximately to those of the nominal connection sizes. The sizing ranges of this specification should be respected. In accordance with the rules of sound engineering practice, the flow velocity should not exceed 2 m/s when connecting via a heat exchanger or 1 m/s in the case of a direct connection.

5.210Pressure loss(diagram)

Water, average temperature = 80 °C

[mmWS/m]

Pressure loss

Flo

w q

uan

tity

[kg

/h]

CFL 60/126

CFL 39/111

CFL 30/91

CFL 48/111

1.0 m/s

0.9 m/s

0.8 m/s

0.7 m/s

0.6 m/s

0.5 m/s

0.4 m/s

0.3 m/s0.2 m

/s

0.1 m/s

CFL 22/91

CFL 75/142

CFL 98/162CFL 127/182



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5.215Heat lossCASAFLEX - UNO

CASAFLEX, parallel laying of 2 single lines

a = 0.1 m

E = 10 °C

E = 1.2 W/mK

Tλ

H =

0.6

m

= 0.43 W/mKλ

Heat loss during operation:q = K · (TB - TE) [W/m]

K = Specific heat losses [W/mK]TB = Average operating temperature [°C]TE = Average earth temperature [°C]

Heat loss q [W/m] for single line pipe, parallel laying

TypeCASAFLEX

K-value[W/mK]

average operating temperature TB [°C]

40° 50° 60° 70° 80° 90° 100° 110° 120° 130°

DN

PIR = 0.025 W/mKλPUR = 0.0255 W/mKλ

22/91 20 0.113 3.4 4.5 5.7 6.8 7.9 9.0 10.2 11.3 12.4 13.5

30/91 25 0.143 4.3 5.7 7.1 8.6 10.0 11.4 12.6 14.3 15.7 17.2

39/111 32 0.153 4.6 6.1 7.6 9.2 10.7 12.2 13.8 15.3 16.8 18.4

48/111 40 0.197 5.9 7.9 9.8 11.8 13.8 15.8 17.7 19.7 21.7 23.6

60/126 50 0.217 6.5 8.7 10.8 13.0 15.2 17.4 19.5 21.7 23.9 26.0

75/142 65 0.266 8.0 10.6 13.3 15.9 18.6 21.3 23.9 26.6 29.2 31.9

98/162 80 0.335 10.1 13.4 16.8 20.1 23.5 26.8 30.2 33.5 36.9 40.2

127/182 100 0.591 17.7 23.6 29.5 35.4 41.3 47.2 53.2 59.1 65.0 70.9




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5.216Heat lossCASAFLEX - DUO

Heat loss during operation:q = K · (TB - TE) [W/m]

K = Specific heat losses [W/mK]TB = Average operating temperature [°C]TE = Average earth temperature [°C]

Heat loss q [W/m] for single pipe

TypeCASAFLEX

DN K-value[W/mK]


40° 50° 60° 70° 80° 90° 100° 110° 120° 130°

E = 10 °C

E = 1.2 W/mK

T

λ

H =

0.6

m

= 0.43 W/mKλ

CASAFLEX DUO pipe

22 + 22/111 20 0.156 4.7 6.2 7.8 9.4 10.9 12.5 14.0 15.6 17.2 18.7

30 + 30/126 25 0.181 5.4 7.2 9.0 10.9 12.7 14.5 16.3 18.1 19.9 21.7

39 + 39/142 32 0.224 6.7 8.9 11.2 13.4 15.7 17.9 20.2 22.4 24.6 26.9

48 + 48/162 40 0.251 7.5 10.0 12.5 15.0 17.6 20.1 22.6 25.1 27.6 30.1

PIR = 0.025 W/mKλ



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5.220Connecting instructionCASAFLEX - plastic sheath pipe

Laying instructions for combination CASAFLEX (CFL) on plastic sheath pip (KMR)

1 Transition from T-piece KMR

CASAFLEX

CASAFLEX

CA

SAFL

EXC

ASA

FLEX

min. 1.0 DS ≤ 2.0

≥ 2.0

Rmin. DP KMR

KMRDP Pipe joint

Flex-T-piece

Δl

Δl

1 Transition with fixed point

CASAFLEX≤ 2.0

KMR

FP

Pipe joint

Δl

1 Transition with Z elbow

CASAFLEX

1.0 DS ≤ 2.5

KMR

DP Pipe joint

Δl

1 Transition with expansion elbow

CASAFLEX

1.0 DS ≤ 2.5

KMR

DPPipe joint

Δl L

FP

all dimensions in m

The lateral expansion Δl must only be sufficient for the expansion to be absorbed by the T-branch DS and by CASAFLEX district heating pipes.

The expansion Δl, owing to increase of temperature, does not need to be compensated by the CASAF-LEX

If pipe length L resp. Δl is > than permissible, a fixed point should be included to allow exact checking of the expansion.

Laying of Z elbow according to the expansion Δl, which must be compensated by section DS.

DS = Expansion leg Δl = Expansion FP = Plastic sheath pipe - fixed point DP = Expansion pads

• Design of expansion elements• Location of expansion pads according to the Chapter Plastic Sheath Pipe from the main catalogue.

Rmin.




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1 T-Piece KMR2 Shrink-on seal3 PE-Pipe joint4 Polyurethane hard foam5 Monitor leads6 CASAFLEX Connecting piece7 CASAFLEX District heating pipe

5.225Transition T-Piece KMR

Construction of T-piece KMR

KMR = Plastic sheath pipe

View A

KMR

A

KMR

CFL

1

2

3

4

5

6

7

KMR

CASAFLEX45°



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5.240Pit constructionBuilding entries

Planing and engineering of pit constructions

Pit constructions in district and local heating net-works are normally very work-and time-intensive to build and maintain.

They must be constructed so as to be watertight, and any surface water which may get in must be removed as soon as possible in order to prevent da-mage to the pits and the heat insulation of the pipes feeding into them.

The pipe entries, depending on the local conditions, must be furnished with a watertight seal. In the case of surface water which exerts no pressure, a simple labyrinth seal will be sufficient; where there is pres-sure from the ground water an adjustable packing seal is almost always needed.

The pipe endings are mostly only equipped with a splash water guard. It is also possible to deliver them with protection against surface water, however, but any protracted flooding, especially at operating tem-peratures, should be avoided even then.

Due to these requirements, the use of pit construc-tions has today largely been discontinued.

In their place pre-insulated T-pieces and, where necessary, pre-insulated shut-off and evacuation/ven-tilation valves are fitted. In this way it is possible to save costs for the construction and maintenance of pits, frequently quite considerable, while at the same time increasing operating safety.




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building dry See design on the drawing

T-Piece / Pipe joint Pos. 7, Protection cap is not necessary

Shaft see CFL 5.240 + 5.300.1

5.300Connecting pieceCASAFLEX - UNO - Type 16

The CASAFLEX connecting piece is especially desig-ned for the connection of CASAFLEX district hea-ting pipes. It is designed for all installation of house connections and for connections in the dry shafts, as

well as transition with expansion elbow and as tran-sition from T-pieces. The CASAFLEX connecting piece is intended for use with hot water pipes (PN 16).

1 Support ring2 Sealing ring3 Connection piece4 Pressure ring5 Allen screws6 Detection conductors7 Protection caps, two pieces8 CASAFLEX heating pipe9 Stretching tape

61253 4 7 8

sd

9

Type Execution

Execution Data Table

Type DN Inches Steel carrier pipe d x s ["] mm

22/9130/91 39/11148/11160/126

2025324050

3/4"1"11/4" 11/2"2"

26.9 x 2.633.7 x 3.242.4 x 3.248.3 x 3.260.3 x 3.6



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Type DN Inches pipe CASAFLEX connection dxs ["] [mm]

In the connection Type 25 the rib mesh is integrated via a metal cap or clamping ring; this increases the mechanical stability of the assembly,

1 back-up ring 2 graphite sealing ring 3 connection piece 4 pressure ring 5 hexagonal socket head screw 6 monitor leads 7 protective cap and monitor lead exit 8 CASAFLEX cable 9 clamping ring (DN 65 - 100)10 rib mesh11 shrink sleeve

22/91 20 3/4” 26.9x2.6

30/91 25 1” 33.7x3.2

39/111 32 1 1/4” 42.4x3.2

48/126 40 1 1/2” 48.3x3.2

60/126 50 2” 60.3x3.6

75/142* 65 2 1/2” 76.1 x 3.6

98/162* 80 3” 88.9 x 4.0

5.300.1ConnectionCASAFLEX - UNO - Type 25

* PN 16 without clamping ring for the rib mesh

which is necessary when operating pressures exceed 16 bar. The connections are intended for use with hot water pipes.

3 5 1 2 4 6 9 8 10




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5.300.5Connection UnitDN 100 - Type 16

The CFL connection unit is a connection element specially designed for CASAFLEX district heating pipes. It is used to establish all connections to pipe

11 10

1 internal backing sleeve2 graphite packing3 connection piece4 thrust collar5 cylindrical screw6 O-ring7 screw8 protective cap9 shrink sleeve10 detection conductors11 connector for monitoring wires12 CASAFLEX pipe

3 5 2 4 1 7 6 8 12 9

Type DN Inches pipe CASAFLEX connection dxs ["] [mm]

127/182 100 4” 114.3 x 4.5

installations in buildings and shafts as well asfor transition and T-connections. The connection units are intended for use with hot water pipes upto PN 16.



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5.301.2ConnectionCASAFLEX - DUO - Type 16

The CFL connection unit is a connection element specially designed for CASAFLEX district heating pipes. It is used to establish all connections to pipe installations in buildings and shafts as well as for transition and T-connections.

The connection units are intended for use with hot water pipes.

1 core piece2 graphite packing3 connecting end4 pressure ring5 press plate A

6 cone plate B7 allen bolts8 end cap (2 pieces)9,10 clamps

Type DN Inches pipe connection CASAFLEX d x s A L D2 ["] [mm] [mm] [mm] [mm]

22 + 22/111 20 3/4” 26,9 x 2,6 45,9 ∼ 138 131

30 + 30/126 25 1” 33,7 x 3,2 52,7 ∼ 141 145

39 + 39/142 32 1 1/4” 42,4 x 3,2 61,4 ∼ 208 164

48 + 48/162* 40 1 1/2” 48,3 x 3,2 * * *

* on request

3 52 1 4 86

7

9 10

A D2

L

d x

s




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5.301.3Y PipeCASAFLEX - DUO

Typ DN Inches Pipe connection Ø C A 2 x single Ø D CASAFLEX d x s KMR steel pipe ["] [mm] [mm] [mm] [mm] [mm]

22 + 22/111 20 3/4" 26.9 x 2.6 140 65 26.9 x 2.6 90 30 + 30/126 25 1" 33.7 x 3.2 160 75 33.7 x 3.2 90 39 + 39/142 32 1 1/4" 42.4 x 3.2 180 80 42.4 x 3.2 110 48 + 48/162 40 1 1/2" 48.3 x 3.2 200 93 48.3 x 3.2 110

150 170

2150

300

250300

RL

VL

ø C

RLVL

A View A

ø D

90

ACFL - alarm wires

ø C



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91 X

111 X

126 X

d1

142 X

162 X

182 RMBD 4

5.305Connecting socket

1 Coupling (2 Connecting pieces ME welded by installer)2 Connecting piece, see page CFL 5.300, position 33 Insulation material (PUR-foam hose), see page CFL 5.3204 Shrinking socket5 Shrink sleeve

CASAFLEX connecting socket

CASAFLEX - plastic sheath pipe (KMR)

CASAFLEX

1

CASAFLEX

3 4 5

d2

Ø carrier pipe equal

CASAFLEX

2

KMR

3

d2d1

d2 91 111 126 142 162 182

91 X X X

111 X X X

126 X X

d1

142 X X

162 X

182 RMBD 4 RMBD 4

d2 91 111 126 142 162 182 200

CASAFLEX - CASAFLEX CASAFLEX - KMR




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22/91 93 133 30/91 93 133 39/111 113 153 48/111 113 153 60/126 128 168 75/142 144 183 98/162 164 203 127/182 183 218

5.315Wall sealing ring

Ø D

a

Ø D

50 mm

Type Protective sheath CASAFLEX Ø D Ø Da mm mm

Data table



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Pipeline diameter Pipe liner casing tube sealing set A/B PE core drill hole Ø mm Ø mm DN Ø D internal mm Ø D external mm

91 150 150 93 150 111 200 200 113 200 126 200 200 128 200 142 250 250 144 250 162 250 250 163 250 182 300 300 183 300

5.316Wall duct

Sealing set B, double sealinglarge 2 x 40 mm, hardness 35

Sealing set A, (centering)large 1 x 20 mm

Pipe liner made of fibre cementor coated core drill hole

Ø D internal Ø D external

For each pipe duct one sealing set C40 and one sealing set A is needed!

Core drill holes

A prerequisite for installation are perfect drill holes. Since hairline cracks can exist in concrete or can arise as a result of the work, we recommend sealing the drill hole walls over the entire lengths with a sealant (e. g. AQUAGARD). We cannot guarantee a good seal if these recommendations are not observed.

After the installation of the sealing set the axial alignment of the pipe may not be changed.

When ordering the sealing sets, please state the diamaters D internal and D external.




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5.320Insulation material

T-piece sets and sockets

PUR - foam package

The required volume of polyurethane foam is sup-plied in the appropriate foam package for the va-

rious sockets and T-pieces. The two components will be mixed together by removing the separating clip.

Base: CO2-blown, CFC-free PUR-Foam

plastic gloves

eye protection

Safety precautions for the foam insulationPUR - foam package

Trench warning tape for laying under ground

Standard length 100 m

Laying depth; see work sheet CFL 5.500

Componend A

Separating clip

Componend B

Note:

PUR-Foam is suitable for constant operatings temperature up to 120°C.Applications with higher operatings temperature (max. 160°C) only on request.



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SLW 30 = 50 kN wheel load, resp. 300 kN total load according to DIN 1072. For bigger loads (i.e. SLW 60) a load distribution superstructure according to RStO75 is required. Without traffic load the mini-mum covering hight may be reduced by 20 cm.

1 Trench warning tape; see work sheet CFL 5.3202 Excavated material3 Sand washed, grain size 0-3/4 mm4 CASAFLEX District heating pipe5 Connecting piece; see work sheet CFL 5.300

Trench section by house connectionTrench section

Trench section by the connection of T-piece

Covering depthmaximum covering depth: 2.6 mHigher covering only after consultation with us.

22/9130/9139/11148/11160/12675/14298/162127/182

9393

113113128144163184

5050555555606565

8080858585859090

1.01.01.01.01.21.51.82.0

10 10 10D D

D10

103060

1 2 3

1.0

m

4 4

5

All dimensionin cm

B

4

max. 2 m max. 1 m

2.5 m Rmin

1.5

x B

Type Casing Width Depth min. bending pipe B T radius ØD mm cm cm m

5.500Trench dimensions




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5.505Building entryWall breakthrough

Connection with weld-on end

Wall breakthrough

Breakthrough bored

Monitoring socket on the wallMonitor leads

Monitoring socket on the pipe

Fixed point;see text

Wiring tothe socket

Wall sealing ring;see work sheet CFL 5.315

Connecting piece;see work sheet CFL 5.300

CASAFLEX districtheating pipe; see work

sheet CFL 5.110

End-cap

ca. 80

160min

. 250

Fixed point

all dimensions in mm

The connection and the CASAFLEX pipe are not sui-table for absorbing the expansion of the continued pipe. For this reason a fixing point clamp must be mounted.(see work sheet CFL 5.505.1)

30

D1

min

.

A

H

L min.

8080 100D D

93 500 300 113 500 300 128 550 300 144 600 350 163 650 350 182 700 400

Casing pipe L min. H Ø D mm mm mm

93 200 230 113 220 250 128 240 270 144 260 290 163 280 310 182 300 330

Casing pipe D1 min. A Ø D mm mm mm



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5.505.1Building workAnchor forces

CASAFLEX district heating pipe is a selfcompen-sating, statically neutral system – i.e. the system takes up longitudinal heat expansion internally. Loads and deformation due to external influences can however only be taken up by the system to a limited extent.

Connection to conventional systems should involve as little loading as possible. Depending on the self-compensation and pressure inside the pipe, thefollowing anchor forces per pipe should be observed.

Typ F F F F F (6 bar) (10 bar) (16 bar) (21 bar) (25 bar) (KN) (KN) (KN) (KN) (KN)

DN 20 0.3 0.5 0.8 1.0 1.2 DN 25 0.5 0.8 1.4 1.8 2.1 DN 32 0.8 1.4 2.2 2.9 3.5 DN 40 1.3 2.1 3.4 4.5 5.4 DN 50 1.9 3.2 5.1 6.7 8.0 DN 65 3.1 5.2 8.3 10.9 12.9 DN 80 5.1 8.5 13.7 17.9 21.3 DN 100 8.6 14.4 23.0 30.2 36.0

Anchor forces per pipe




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When carrying out building work on CASAFLEX dis-trict heating pipework, the alignment and position of the pipe must be secured. The following open trench lengths should not be exceeded.

If greater lengths need to be laid bare, sand saddles can be placed at the prescibed intervals.

Type Length Length Length Length Length A (for 6 bar) (for 10 bar) (for 16 bar) (for 21 bar) (for 25 bar) (m) (m) (m) (m) (m) (m)

DN 20 6 4 3 2 2 0.5 DN 25 6 4 3 2 2 0.5 DN 32 6 4 3 2 2 0.5 DN 40 5 4 3 2 2 0.5 DN 50 5 4 3 2 2 0.5 DN 65 5 4 3 2 2 0.6 DN 80 5 4 3 2 2 0.6 DN 100 5 4 3 2 2 0.6

5.505.2Building work

Open trenchlength L

Open trenchlength L

Sand saddle

A

Dimensions of the saddlesH

S ≈ 2 x D

A, B

S ≈ 7 x D

A, L

S ≈ 4 x D

A

T-pieces must be secured by additional sand saddles.

If trenches are excavated parallel to the CASAFLEX routing, the following separation distance must be observed:

LS

B S



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CFL

5.505.5Laying in the open

Type Angled steel section Intervals Min. (galv.) between clamps bending radius

CFL 22/91 60 x 60 x 6 2 m 0.8 m CFL 30/91 60 x 60 x 6 2 m 1.0 m CFL 39/111 70 x 70 x 7 2 m 1.0 m CFL 48/111 70 x 70 x 7 2 m 1.0 m CFL 60/126 80 x 80 x 8 2 m 1.2 m CFL 75/142 90 x 90 x 9 2 m 1.5 m CFL 98/162 90 x 90 x 9 2 m 1.8 m CFL 127/182 90 x 90 x 9 2 m 2.0 m

When CASAFLEX piping is to be laid in the open, the following precautions must be taken:

1. Lay a continuous mounting rail (very economic: angled profile steel, galvanized)

2. Changes of direction should also be supported (wherever possible on a pre-bent angled profile)

3. Reinforced at prescribed intervals with clamp rings and pressure distribution plates, 3 clamps in a 90° curve.

4. Limit PN 105. Secure the ends with anchor points.6. Make use of BRUGG's help when making project

plans and laying the cable

Support during planning and laying by BRUGG




03.6.05

CFL–

Subj

ect

to t

echn

ical

cha

nge

–

5.515Installation house connection PN 16CFL 22/91 - CFL 60/126



Technische Änderungen vorbehalten/Subject to technical changes

Ausgabe: 05/1-01 DE

MontageanleitungInstallation instructions

Art.-Nr : 66356

DE

CASAFLEX

CH:D:A:B:I:PL:SK:SF:

Ausgabe: 05 / 1-01 DE, Freigabe: 16.01.2001 RD

BRUGG Rohrsysteme Ges. mbH, Reischlgasse 5, A-4950 Altheim, Tel. 07723 / 439 620, Fax 07723 / 439 623BRUGG Pipesystems N. V., Kampenhoutsebaan 16, B-1982 Elewijt (Zemst), Tel. 015/ 621 050, Fax 015/ 621 167BRUGG Pipesystem srl, Via L. Bertolini 27, I-29100 Piacenza, Tel. 0523 / 590 431, Fax 0523 / 594 369BRUGG Systemy Rurowe, Sp. z o. o. ,Ul. Lipowa 1, PL-05-860 Plochocin, Tel. 022/ 722 56 26, Fax 022/ 722 51 97BRUGG Rohrsysteme, Beniakova 6, SK-84105 Bratislava, Tel. 07/ 716 443, Fax 07/ 716 443BRUGG PEMA OY, P. O. Box 707, SF-60101 Seinäjoki, Tel. 00358 400 560 719 , 00358 641 77 000

BRUGG Rohrsystem AG, Industriestrasse 39, CH-5314 Kleindöttingen, Tel. 056/ 268 78 78, Fax 056/ 268 78 79BRUGG Rohrsysteme GmbH, Adolf-Oesterheld-Str. 31, D-31515 Wunstorf, Tel. 05031/170-0, Fax 05031/170 170

PIPE2000 LtdUK Distributor

Tel No 01268 759567Fax No 01268 569932

email: [email protected]: www.pipe2000.co.uk

Für Schäden und Betriebsstörungen, die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder dieNichtbeachtung der Montageanleitung ergeben, wird keine Haftung übernommen. Es gelten die allgemeinen Verkaufsbedingungen.

Kopieren verboten.

1. Inhaltsverzeichnis / Content

D: • Allgemeine Hinweise Seite 1 Art.-Nr. 66356E: • General instructions Seite 2 Art.-Nr. 66356• Dimensionen Seite 3• Transport, Empfang und Verlegung der Rohre Seite 3• Montage bei tiefen Temperaturen Seite 4• Verarbeiten des Rohres für Verbindungen (Bild 1 - 12) Seite 5,6• Erstellung der Verbindung im Haus (Bild 13 - 17) Seite 7

2. Allgemeines

Diese neu überarbeitete Montageanleitung für das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch,französisch, italienisch sowie englisch vor. Sie ersetzt alle früheren Ausgaben und ist Bestandteil jederMateriallieferung. Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgänge fürVerlegung und Montage. Sie sind das Ergebnis umfangreicher Entwicklungsarbeiten und der praktischenErfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. Bevor Sie mit der Arbeit beginnen,sollten Sie sorgfältig jede Phase dieser Montageanleitung durchlesen. Danach führen Sie Schritt für Schrittaus. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. Tragen Sie Handschuhe und Schutzbrille. Fürweitere Informationen wenden Sie sich bitte an Ihren örtlichen Verkaufsberater.

3. Rohrkonstruktion CASAFLEX

• Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr. 1.4301, DIN 17 441 • Dämmung aus FCKW-freiem, 100 % CO2-geblasenem PUR-Schaum • Schutzmantel aus Polyäthylen LDPE

4. Anwendungsbereich

CASAFLEX-Fernwärmeleitung ist der Name für eine biegbare Hausanschlussleitung der Brugg Rohrsysteme.Sie ist für den Einsatz in kleinen und mittleren Fern- und Nahwärmenetzen, sowie in Industrie undLandwirtschaft, in Sonnenkollektoranlagen, und in der Schwimmbadtechnik gedacht.

Das Rohrsystem CASAFLEX eignet sich für den unter- und oberirdischen Transport von Heizungswasser bismax. 130 °C und max. 16 bar Dauerdruck.Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht.

MontageanleitungCASAFLEX

Art.-Nr. 66356

Seite: 1 von 7

Ausgabe: 05 / 1-01 DEdeutsch/english



1. Content / Inhaltsverzeichnis

D: • Allgemeine Hinweise page 1 art.-no. 66356E: • General instructions page 2 art.-no. 66356• Dimensions page 3• Transport, reception and laying of pipes page 3• Installation at low temperatures page 4• Convert pipe for connections (picture 1 - 12) page 5,6• Installation of a house connection (picture 13 - 17) page 7

2. General

This completely revised installation instruction for the pipe-system CASAFLEX is held in english, german,french and italian. It replaces all earlier versions and is included in any material delivery. The followingchapters describe all steps of laying and installing. They are a result of comprehensive development andpractical experience of the producer Brugg Pipe Systems and its suppliers. Please study this installationinstruction carefully before starting. Then follow it step-by-step. Adhere to the local security regulations forinstallation work. Carry gloves and safetyglasses. For further information please contact your local salesengineer.

3. Pipe construction CASAFLEX

• Service-pipe of nickel-chromium steel X5 CrNi 18/9, Wno. 1.4301, DIN 17 441. • Insulation of CFC-free, 100 % CO2-blown polyurethane-foam • Jacket-pipe of polyethylene LDPE

4. Application

CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems.CASAFLEX is for the use of small and middle district heating systems as well as for industrial use, agriculture,solar energy and swimming pool technology.

The pipe system CASAFLEX is designed for under- and above ground transport of heating water up to max.130 °C and up to max. 16 bar permanent pressure.The pipe-type and range of application is printed on the jacket.

For damages and operating troubles, resulting from application of system components which are not recommended by ourcompany or in case of not following the installation instruction, we do not undertake any liability. Our general terms and

conditions are applicable. Copies are prohibited.

Installation instructionCASAFLEX

art.-no: 66356

page: 2 from 7

issue: 05 / 1-01 DEenglish/deutsch

Subject to technical changes/Technische Änderungen vorbehalten


D: Transport, Empfang und Verlegung der Rohre Alle Masse in mmE: Transport, reception and laying of pipes Dimensions in mm

Dimensionen/Dimensions

BaureiheRange

MediumrohrService-pipe

MantelJacket

InhaltVolume

GewichtWeight

BiegeradiusBending radius

DN d x s mm

ømm Liter/m kg/m

R min m

202525323240405050

22.0 x 0.330.4 x 0.330.4 x 0.339.4 x 0.439.4 x 0.448.2 x 0.548.2 x 0.560.4 x 0.560.4 x 0.5

7893

113113128113128128143

0.440.800.801.351.352.042.043.123.12

1.101.161.931.682.602.462.923.023.54

0.80.81.01.01.21.01.21.21.3


Art.-Nr. 66356

Seite: 3 von 7

Ausgabe: 05 / 1-01 DEdeutsch/english


Kopieren verboten.

Sandschicht, Korngrösse 0-4 mmSand, grain size 0-4 mm

22/7630/9130/111 PLUS39/11139/126 PLUS48/11148/126 PLUS60/12660/142 PLUS

60

0

mm

Rmin

Rmin

600

m

m

60

0

mm

80

80

10

0D D

8 08

0D

A

D1

30

Mantelrohr

Ø D mm

7893

113128143

D1 Aminmm mm

180200220240260

210230250270290

ca. 60 °C

2

1



Spannbänderfixing ribbons

Verlegung und Montage von CASAFLEX-Rohren


Kopieren verboten.

MontageanleitungAssembly Instructions

CASAFLEX

Art.-Nr. 66356

Seite: 4 von 7

Ausgabe: 05 / 1-01 DEdeutsch


ca. 60 °C

3. Verlegung und Montage bei tiefen Aussentemperaturen (< 5°C)Ring wenn möglich in einer geheizten Halle lagern oder mit Heizstrahlern Aussenmantel wärmen und dann sofort verlegen. Rohrende wie oben beschrieben richten.

2. Rohrende richten (Skizze)Aussenmantel auf ca. 60°C wärmen (Oberfläche glänzt) und im eingespannten Zustand abkühlen. Richtschiene vom Rohr lösen.

1. Verlegung (Skizze)Spannbänder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen.

Laying and installation of CASAFLEX pipes

1. Laying (sketch)Cut fixing ribbons one after the other from outside to inside whileunwinding the coil in the trench or adjacent.

2. Direct pipe-end (sketch)Heat up outer jacket to approx. 60°C (surface shines) and cool it down in a fixed situation.Disassemble directional tool.

3. Laying and installation with low outer temparature (<5°C)Store coil, if possible, indoor or warm up the outer jacket with a heating appliance and lay immediately.Direct pipe-end as described above.

english



Kopieren verboten.

D: Verarbeiten des Rohres für Verbindungen. E: Convert pipes for connections.


deutsch / english

1 2

Einzelteile der Verbindung1 Druckring2 Stützring3 Graphit - Dichtring4 Anschlussstück5 Innensechskantschrauben

D:

E:

D:

Art.-Nr. 66356

Seite: 5 von 7

Ausgabe: 05 / 1-01 DE

1234

5

5

Components of the connection1 pressure ring2 support ring3 sealing ring4 connection piece5 allen screws

200 mm

max. 5 mm

D:

E:

Mantel vom Rohrende mit Säge durchtrennen und längs aufschneiden. Säge max. 5 mm tief einstecken.

Separate with saw the jacket from the pipe end and open it longitudinally. The saw deeps into foam max. 5 mm.

3

D:

E:

4

D:

E:

Mantel entfernen.

Remove coat.

5

D:

E:

Innenrohr auf Länge rechtwinklig absägen.

Cut the service pipe square to its axis.

6

Meldedern am Rohrende freilegen und herausziehen.

Lay open the detector wires andpull them out.

Benötigte WerkzeugeHandsäge, Markierungsstift, Zoll-stock, Messer, Edelstahlbürste, Feile (H2), Zange, Innensechs-kantschlüssel*, Ratsche, Brenner

*SW 6 DN 20 + 25*SW 8 DN 32 + 40*SW 10 DN 50

Requested tool Saw, marking pen, folding role, knife, high grade steel brush, file (H2), pliers, allen spanner*, spanner, gas burner.

E:

30-100 mm


4.1

4.2

Ø22-39: 50-60 mmØ48-60: 60-70 mm



Kopieren verboten.

D: Verarbeiten des Rohres für Verbindungen.E: Convert pipes for connections.


deutsch / english

7 8 9

10 11 12

D:

E:

D:

E:

Rohrende mit Drahtbürste metallisch blank säubern + entstauben. Achtung: Rohroberfläche ist die Dichtfläche.

Clean pipe end to the flare surface with steel brush and make it free of dust. Attention: pipe surface = seal surface.

Innenrohr mit Hilfe des Druckrings rechtwinklig auf Länge absägen.

Cut the service pipe with help of the pressure ring square to its axis.

Art.-Nr. 66356

Seite: 6 von 7


0.5 mm

D:

E:

Druckring (1) ganz nach hinten schrauben.Stützring (2) einschrauben. Gewinde-Ansatz muss mit Rohrende abschliessen.

Screw pressure ring (1) backwards. Screw on supporting ring (2).Attachement thread must close together with the pipe end.

D:

E:

Anschlussstück (4) ohne Dichtring auf den Stützring aufschieben und gegendrücken. Druckring (1) bis 0.5 mm gegen Anschlussstück vor-schrauben.

Move connection piece (4) without sealing ring onto the support ring and push together. Screw pressure ring (1) up to 0.5 mm against connection piece.

D:

E:

Dichtring (3) auf den Stützring aufschieben, Druckring nicht mehr drehen.Move sealing ring (3) onto the supporting ring, do not turn the pressure ring.

D:

E:

Schrauben ölen! Anschlussstück aufschieben, Schrauben anziehen bis Anschlussstück am Druckring anliegt. Gegen Verdrehen festhalten.

Lubricate the screws! Tighten up the screws to the pressure ring. Hold it to avoid distort.

Ø 22–39: 35 mmØ 48–60: 45 mm

0 mmÖl


controlling1-2 mm

11.1

11.2

1

2

3

4

1



Kopieren verboten.

D: Erstellung der Verbindung im HausE: Installation of a house connection


deutsch / english

13

17

D:

E:

Mauerdichtring montieren.

Mount the wall sealing ring.

Art.-Nr. 66356

Seite: 7 von 7


16

D:

E:

Schrumpfschläuche über die 2 Adern ziehen; mit weicher Flamme schrumpfen (max. 5-10 s).

Push shrink sleeves above 2 detector wires; shrink with small flame (max. 5-10 s).

Überwachungsdose an WandMonitoring socket on the wall

D: Überwachungsdose am RohrE: Monitoring socket on the pipe

160

ca. 80m

in. 2

50

Festpunkt; siehe Text Fixing point; see text

Die Anschlussverbindung resp. die CASAFLEX-Leitung ist nicht geeignet um Dehnungen der weitergehenden Leitung aufzunehmen. Aus diesem Grunde ist eine Festpunktschelle zu montieren.

D:

The connection resp. the CASAFLEX pipe is not suitable for absorbing the expansion of the continued pipe. That‘s why a fixing point clamp must be mounted.

E:

15

D: Überflüssige Meldeader zurück schneiden.WIREM/BRANDES: rot + grün; Nordisches System: Cu-weiss + grün.

D: Schutzkappe montieren,Meldeadern herausziehen.

Mount the protection caps,the detector wires push out.

E:

14

Cut the remain detection conductorWIREM/BRANDES: red + greenNorth System: Cu-white + green

E:



- Tec

hnis

che

Änd

erun

gen

vorb

ehal

ten

-- S

ubje

ct to

tech

nica

l cha

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-

flexible solutions

Für Schäden und Betriebsstörungen, die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben, wird keine Haftung übernommen. Es gelten die allgemeinen Verkaufsbedingungen.

Kopieren verboten.

Art.-Nr. 66356

Seite: 1 von 7


MontageanleitungCASAFLEX®

75/142 + 98/162 PN 16

1. Inhaltsverzeichnis / Content D:• Allgemeine Hinweise Seite 1 Art.-Nr. 66356E:• General instructions Seite 2 Art.-Nr. 66356• Dimensionen Seite 3• Transport, Empfang und Verlegung der Rohre Seite 3• Montage bei tiefen Temperaturen Seite 4• Verarbeiten des Rohres für Verbindungen (Bild 1 - 12) Seite 5,6• Erstellung der Verbindung im Haus (Bild 13 - 17) Seite 7

2. Allgemeines

Diese neu überarbeitete Montageanleitung für das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch, französisch, italienisch sowie englisch vor. Sie ersetzt alle früheren Ausgaben und ist Bestandteil jeder Materiallieferung. Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgänge für Verlegung und Montage. Sie sind das Ergebnis umfangrei-cher Entwicklungsarbeiten und der praktischen Erfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. Bevor Sie mit der Arbeit beginnen, sollten Sie sorgfältig jede Phase dieser Montageanleitung durchlesen. Danach führen Sie Schritt für Schritt aus. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. Tragen Sie Handschuhe und Schutzbrille. Für weitere Infor-mationen wenden Sie sich bitte an Ihren örtlichen Verkaufsberater.

3. Rohrkonstruktion CASAFLEX

• Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr. 1.4301, DIN 17441• Dämmung aus FCKW-freiem, 100 % CO2-geblasenem PUR-Schaum • Schutzmantel aus Polyäthylen LDPE

4. Anwendungsbereich

CASAFLEX-Fernwärmeleitung ist der Name für eine biegbare Hausanschlussleitung der Brugg Rohrsysteme. Sie ist für den Einsatz in kleinen und mittleren Fern- und Nahwärmenetzen, sowie in Industrie und Landwirtschaft, in Sonnenkollektoranlagen, und in der Schwimmbadtechnik gedacht.

Das Rohrsystem CASAFLEX eignet sich für den unter- und oberirdischen Transport von Heizungs-wasser bis max. 130 °C und max. 16 bar Dauerdruck. Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht.

flexible solutions


- Tec

hnis

che

Änd

erun

gen

vorb

ehal

ten

-- S

ubje

ct to

tech

nica

l cha

nge

-

flexible solutions


Kopieren verboten.

Art.-Nr. 66356

Seite: 2 von 7



75/142 + 98/162 PN 16

1. Inhaltsverzeichnis / Content D:• Allgemeine Hinweise Seite 1 Art.-Nr. 66356E:• General instructions Seite 2 Art.-Nr. 66356• Dimensionen Seite 3• Transport, Empfang und Verlegung der Rohre Seite 3• Montage bei tiefen Temperaturen Seite 4• Verarbeiten des Rohres für Verbindungen (Bild 1 - 12) Seite 5,6• Erstellung der Verbindung im Haus (Bild 13 - 17) Seite 7

2. General

This completely revised installation instruction for the pipe-system CASAFLEX is held in english, german, french and italian. It replaces all earlier versions and is included in any material delivery. The following chapters describe all steps of laying and installing. They are a result of comprehensive development and practical experience of the producer Brugg Pipe Systems and its suppliers. Please study this installation instruction carefully before starting. Then follow it step-by-step. Adhere to the local security regulations for installation work. Carry gloves and safetyglasses. For further information please contact your local sales engineer.

3. Pipe construction CASAFLEX

• Service-pipe of nickel-chromium steel X5 CrNi 18/9, Wno. 1.4301, DIN 17 441• Insulation of CFC-free, 100 % CO2-blown polyurethane-foam • Jacket-pipe of polyethylene LDPE

4. Application

CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems. CASAFLEX is for the use of small and middle district heating systems as well as for industrial use, agriculture, solar energy and swimming pool technology.

The pipe system CASAFLEX is designed for under- and above ground transport of heating water up to max. 130 °C and up to max. 16 bar permanent pressure. The pipe-type and range of application is printed on the jacket.

flexible solutions


- Tec

hnis

che

Änd

erun

gen

vorb

ehal

ten

-- S

ubje

ct to

tech

nica

l cha

nge

-

flexible solutions

Art.-Nr. 66356

Seite: 3 von 7



75/142 + 98/162 PN 16

Dimensionen/Dimensions

600

mm

Rmin

Rmin

600

mm

600

mm

80 80100

D D

8080

D

A

D1

30

Manteau

Ø D mm

D1 Aminmm mm

78

93

113

128

143

163

183

180

200

220

240

260

280

300

210

230

250

270

290

310

330

D: Transport, Empfang und Verlegung der Rohre Alle Masse in mmE: Transport, reception and laying of pipes Dimensions in mm

BaureiheRange

DN

ZollInches

(")

RohranschlussPipe connector

dxsmm

AussenrohrOuter pipe

mm

InhaltVolume

Liter/m

GewichtWeight

kg/m

BiegeradiusBending radius

R minm

75/14298/162

6580

2½3

76.1 x 3.688.9 x 4.0

142162

5.128.43

4.105.70

1.501.80

flexible solutions


- Tec

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Änd

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flexible solutions


Kopieren verboten.

Art.-Nr. 66356

Seite: 4 von 7



75/142 + 98/162 PN 16

Verlegung und Montage von CASAFLEX-Rohren

1. Verlegung (Skizze)Spannbänder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen.

2. Rohrende richten (Skizze)Aussenmantel auf ca. 60°C wärmen (Oberfläche glänzt) und im eingespann-ten Zustand abkühlen. Richtschiene vom Rohr lösen.

3. Verlegung und Montage bei tiefen Aussentemperaturen (< 5°C)Ring wenn möglich in einer geheiz-ten Halle lagern oder mit Heizstrahlern Aussenmantel wärmen und dann sofort verlegen. Rohrende wie oben beschrie-ben richten.

Laying and installation of CASAFLEX pipes

1. Laying (sketch)Cut fixing ribbons one after the other from outside to inside while unwinding the coil in the trench or adjacent.

2. Direct pipe-end (sketch)Heat up outer jacket to approx. 60°C (surface shines) and cool it down in a fixed situation.Disassemble directional tool.

3. Laying and installation with low outer temparature (<5°C)Store coil, if possible, indoor or warm up the outer jacket with a heating appli-ance and lay immediately.Direct pipe-end as described above.

Spannbänderfixing ribbons

ca. 60 °C

flexible solutions


- Tec

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che

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Kopieren verboten.

Art.-Nr. 66356

Seite: 5 von 7



75/142 + 98/162 PN 16


1 2

D: Benötigte Werkzeuge Handsäge, Markierungsstift,

Zoll-stock, Messer, Edelstahlbürste, Feile (H2), Zange, Innensechs-kantschlüs-sel*, Ratsche, Brenner

E: Requested tool Saw, marking pen, folding role,

knife, high grade steel brush, file (H2), pliers, allen spanner*, spanner, gas burner.

4

4.1

4.2

D: Mantel entfernen.

E: Remove coat.

D: Einzelteile der Verbindung 1 Druckring 2 Stützring 3 Graphit - Dichtring 4 Anschlussstück 5 Innensechskantschrauben

E: Components of the connection

1 pressure ring 2 support ring 3 sealing ring 4 connection piece 5 allen screws

5 6

D: Meldedern am Rohrende freilegen und herausziehen.

E: Lay open the detector wires and pull them out.

3

200 mm

max. 5 mm

D: Mantel vom Rohrende mit Säge durchtrennen und längs aufschneiden. Säge max. 5 mm tief einstecken.

E: Separate with saw the jacket from the pipe end and open it longitudinally. The saw deeps into foam max. 5 mm.

D: Innenrohr auf Länge rechtwinklig absägen.

E: Cut the service pipe square to its axis.

Ø75-98: 100 mm

2 134

5

5

flexible solutions


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Kopieren verboten.

Art.-Nr. 66356

Seite: 6 von 7



75/142 + 98/162 PN 16


1

4

0.5 mm

3

controllingø75: 3 mmø98: 8 mm

Öl

0 mm

7 8

D: Rohrende mit Drahtbürste metallisch blank säubern + entstauben.

Achtung: Rohroberfläche ist die Dichtfläche.

E: Clean pipe end to the flare surface with steel brush and make it free of dust. Attention: pipe surface = seal surface.

10

D: Innenrohr mit Hilfe des Druckrings rechtwinklig auf Länge absägen.

E: Cut the service pipe with help of the pressure ring square to its axis.

11 12

D: Dichtring (3) auf den Stützring aufschieben, Druckring nicht mehr drehen.

E: Move sealing ring (3) onto the supporting ring, do not turn the pressure ring.

D: Anschlussstück (4) ohne Dichtring auf den Stützring aufschieben und gegendrü-cken. Druckring (1) bis 0.5 mm gegen Anschlussstück vor-schrauben.

E: Move connection piece (4) without sealing ring onto the support ring and push together. Screw pressure ring (1) up to 0.5 mm against connection piece.

9

1

2

D: Druckring (1) ganz nach hinten schrauben.

Stützring (2) einschrauben. Gewinde-Ansatz muss mit Rohrende abschliessen.

E: Screw pressure ring (1) backwards. Screw on supporting ring (2).

Attachement thread must close together with the pipe end.

D: Schrauben ölen! Anschlussstück aufschie-ben, Schrauben anziehen bis Anschlussstück am Druckring anliegt. Gegen Verdrehen fest-halten.

E: LUBRICATE THE SCREWS! Tighten up the screws to the

pressure ring. Hold it to avoid distort.

Ø 75: 70 mmØ 98: 80 mm

11.1

11.2

flexible solutions


Art.-Nr. 66356

Seite: 7 von 7



75/142 + 98/162 PN 16

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flexible solutions


Kopieren verboten.

Art.-Nr. 66356

Seite: 7 von 7



75/142 + 98/162 PN 16

D: Erstellung der Verbindung im HausE: Installation of a house connection

13 14

D: Mauerdichtring montieren.

E: Mount the wall sealing ring.

16

D: Überflüssige Meldeader zurück schneiden.

WIREM/BRANDES: rot + grün; Nordisches System: Cu-weiss + grün.

E: Cut the remain detection con-ductor

WIREM/BRANDES: red + green North System: Cu-white +

green

160

ca. 80

min

. 250

Festpunkt; siehe Text

D: Überwachungsdose am RohrE: Monitoring socket on the pipe

D: Überwachungsdose an WandE: Monitoring socket on the wall

Fixing point; see text

D: Die Anschlussverbindung resp. die CASAFLEX-Leitung ist nicht geeignet um Dehnungen der weitergehenden Leitung aufzunehmen. Aus diesem Grunde ist eine Festpunktschelle zu montieren.

E: The connection resp. the CASAFLEX pipe is not suitable for absor-bing the expansion of the continued pipe. That‘s why a fixing point clamp must be mounted.

D: Schutzkappe montieren,Meldeadern herausziehen.

E: Mount the protection caps,the detector wires push out.

15

D: Schrumpfschläuche über die 2 Adern ziehen; mit weicher Flamme schrumpfen (max. 5-10s).

E: Push shirnk sleeves above 2 detector wires; shrink with small flame (max. 5-10s).

17

flexible solutions


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CASAFLEX® - Fernwärmeleitung

Montageanleitung DN65 - DN80CFL - Anschlussverbindung PN 25

1 Stützring2 Graphitdichtring3 Anschlussstück4 Druckring5 Innen-Sechskantschraube6 Meldeadern7 Schutzkappe und Aderherausführung8 CASAFLEX-Leitung9 Klammersegmente10 Streckgitter11 Schrumpfmanschette

Bei der Anschlussverbindung Typ PN 25 wird das Streckgitter über eine Blechkappe mit ein-bezogen; dies erhöht die mechanische Stabili-tät, was bei Betriebsdrücken oberhalb von 16 bar notwendig ist.

Die Anschlussverbindungen sind für Heizwas-serleitungen bestimmt.

1 back-up ring2 graphite sealing ring3 connection piece4 pressure ring5 hexagonal socket head screw6 monitor leads7 protective cap and monitor lead exit8 CASAFLEX pipe9 clamping ring10 rib mesh11 shrink sleeve

In the connection type PN 25 the rib mesh is integrated via a metal cap or clamping ring; this increases the mechanical stability of the assembly, which is necessary when operating pressures exceed 16 bar.

The connections are intended for use with hot water pipes.

29944 10

7

5

3

6

1 8

Montageanleitung / Installation instructionCASAFLEX - Anschlussverbindung Typ PN25

DN 65 + DN 80

1

11


CASAFLEX® - Fernwärmeleitung CFL

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2

HandsägeHandsaw

DruckringPressure ring

SchelleClip collar

AnschlussverbindungThe connector assemply

BlechkappeMetal cap

SchraubenScrews

StützringBack-up ring

KlammersegmenteClamp segments

Graphit - DichtringGraphite sealing ring

AnschlussstückConnector

Montage - WerkzeugTools for installation

1

2

RatscheRatchet

InnensechskantschlüsselHexagonal socket head screwdriver

ZangePliers

Halbrund - Feile (Hieb 2)Half-round fi le (No. 2)

Edelstahl - DrahtbürsteStainless steel wire brush

Messer / KnifeZollstock / Ruler

MarkierungsstiftMarker

Persönliche Schutzausrüstung: Schutz-handschuheAchtung: Unfallverhütungsvorschriften beachten!

Personal protective clothing: protective glovesAttention! Be careful to observe all safety regulations


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3

3 4

5 6

Achtung: Blechkappe über das Rohr ziehen.Absetzmaß auf PE-Mantel am Umfang mar-kieren. A=100mmAttention: Pull the metal protective on the pipe.Mark the length to be stripped off on the cir-cumference of the PE jacket. A=100mm

PE-Mantel mit Messer in Umfangsrichtungund in Längsrichtung aufschneiden.

Cut open the jacket using the knife around the circumference and lengthwise.

PE-Mantel abschälen.Achtung: Blechkappe

Peel off the PE jacket.

Streckgitter mit Handsäge am Umfangdurchsägen.

B = 80mm

Saw through the rib mesh on the circumfe-rence with the handsaw.

B = 80mm

A

BB



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4

Innenrohr am Sägering entlang absägen.

Saw off the inner pipe along the line of the saw collar.

Streckgitter mit Blechschere 4 mal am Umfang in Achsrichtung einschneiden, nach hinten weg-klappen. Schaum vom Innenrohr entfernen, das freigelegte Innenrohr mit Drahtbürste metallisch blank bürsten!

Cut into the rib mesh in 4 places on the circumfe-rence along the axis using the metal shears, and bend it back. Remove the foam from the primary inner pipe and brush the inner pipe clean with the wire brush until the metal is free of all debris!

Druckring bis gegen den Schaum aufschrau-ben, Sägering gegen den Druckring schrau-ben.

Screw the pressure ring up against the foam, Screw the saw collar up against the pressure ring.

Streckgitter mit Drahtbürste freilegen.Achtung: Streckgitter ist scharfkantig!

Uncover the rib mesh using the wire brush till it lays bare. Attention: The rib mesh has sharp edges!

7 8

9 10


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11 12

13 14

5

Anschlussstück aufsetzen.

Place the connector over the assembly.

Sägering entfernen; Sägeschnitt mit Feile entgraten.

Remove the saw collar; smooth off any ridges in the saw cut with the fi le.

Stützring in das Innenrohr einschrauben. Gewindeende muß mit dem Wellrohrende abschließen.

Screw the back-up ring into the inner pipe. The end of the screw thread must form a clo-se fi t with the end of the corrugated pipe.

Graphit-Dichtring auf den Stützring aufschie-ben.

Push the graphite sealing ring over the back-up ring.



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15 16

17 18

6

Schrauben einsetzen und schrittweise im Uhrzeigersinn festziehen. Druckring und An-schlussstück müssen auf Block liegen.

Put in the screws and tighten them gradually clockwise. The pressure ring and the connec-tor must be in alignment.

Streckgitter um den Druckring umformen.

Mould the rib mesh around the pressure ring.

Blechhaube vorziehen, dabei Überwachungs-adern durch die Gewindehülse herausführen.

Pull the metal protective sheath forwards, taking care to lead out the monitor leads th-rough the thread socket.

Mit Klammersegmenten die Blechhaube ge-gen den Druckring fi xieren.

Secure the metal sheath with the clamp seg-ments against the pressure ring.


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7

Schelle aufsetzen und festschrauben.

Slip the clip collar over the assembly and screw it tight.

Überwachungsadern mit Siliconkabel verbin-den.

Connect the monitor leads with the silicon cable.

19 20



Installation instructionsDN 100 25.02.03

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CFL5.311.6

page 1

11 10

3 5 2 4 1 7 6 8 12 9

114,

3 x

4,5

1 in te rn a l b a c k in g s le e v e2 g ra p h ite p a c k in g3 c o n n e c t io n p ie c e4 th ru s t c o lla r5 c y lin d r ic a l s c re w , M 1 2 x 5 06 O - r in g7 s c re w8 p ro te c t iv e c a p9 s h r in k s le e v e1 0 d e te c t io n c o n d u c to rs1 1 c o n n e c to r fo r m o n ito r in g w ire s1 2 C A S A F L E X p ip e1 3 p re in s ta l la t io n s c re w , M 1 2 x 7 0

1.0 Introduktion

Fig. 1

Fig. 2

8

3

4

2

6

1

5 1311

Do not begin work until you have read theinstallation instruktions carefully.




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CFL5.311.6

page 2

2.0 Preparing the pipe end

2.2 Aligning the pipe endsStraighten out a length of approx. 1 m ofthe pipe, using a bending device ifnecessary.Fix the piping securely in place before fittingthe connector assembly (e.g. on anassembly stand).

Always use pipe clamping jaws when fixing the pipe in the vice.

2.2 Stripping off the PE jacket

2.1 tools

1

2

3

4 5 6 7 8 9 10 11

1. gloves2. clamp3. wrench4. hexagonal tool5. ratchet6. stainless steel brush7. file8. knife9. saw10. marker11. yardstick

Fig. 3

Fig. 4Make a mark at a length of 120 mm on the casingpipe.

Fig. 5

Make a mark around the casing pipe using theprotection cap as a guide.

110 x 30




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CFL5.311.6

page 3

Cut radially using the saw.Warning: take care of the monitoring wires!

Fig. 7

Fig. 8

Cut the casing pipe longitudinally using the knife.

Fig. 9

Remove the casing pipe.

Fig. 10

Bend the monitoring wires backwards.

Remove the foam using the knife.

Fig. 6




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CFL5.311.6

page 4

Fig. 11

Fig. 12

Make a mark on the corrugated pipe 90mm farfrom the end of casing pipe.

Fig. 13

Fit the clamp at that mark and check the distance3 times around the pipe.

Saw through the corrugated pipe using the face ofthe clamp as a guide.

Fig. 14 and 15

Insert a cloth and remove ridges from the pipe endinside and outside.




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CFL5.311.6

page 5

Fig. 16

Fig. 17

Clean the outer surface using a stainless steelbrush:

Remove the cloth and all shavings.

Fig. 18

3.0 Fitting the connector

Screw the internal backing sleeve (1) up to 2/3 ofits length into the corrugated pipe.

Fig. 19

Screw the thrust collar (4) against the end of thecorrugated pipe.




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CFL5.311.6

page 6

Fig. 20

Push the connecting piece (4) right up against theinternal backing sleeve. The distance between theconnecting piece (4) and the thrust collar must be1,5-2mm. You can screw the internal backingsleeve in or out until you reach this setting.

Fig. 21

1,5-2mm Fig. 22

Pull out the connection piece (3) and push thegraphite packing (2) in its whole length insidethe gap between the internal backing sleeve andthe thrust collar.

Push the connection piece (3) right up against thethrust collar using the preinstallation screws (13).

Fig. 23Tighten the preinstallation screws (13) until thecylindrical screws can be used. Replace allpreinstallation screws (13) with cylindrical screws.Tighten all cylindrcal screws clockwise. Theconnecting piece (4) and the thrust collar (1) mustbe screwed together face to face until seatedsnugly against each other.Use oil to grease all screws!

oil




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CFL5.311.6

page 7

Fig. 24If required: fit the O-ring (6) .

Fig. 25Push the connecting cable through its bore andconnect it with the monitoring wires.Note seperate installation instruction

Fig. 26

Grease the O-ring (6) . Fit the protective cap witha strong push til the beveled edge of the thrustcollar.

Fix the protective cap with its screws (7) .

Screw the connector for monitoring wires (11).

If required: fit shrinking sleeve half to half oncasing pipe and protective cap.Note seperate installation instruction.

Fig. 27

0 mm



Wall sealing ring26.02.03

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CFL

5.315

Wall sealing ring

Da D

50 mm

CASAFLEXType Protective sheath

¬ D mm ¬ Da mm 22/76 22/91 PLUS

7893

118133

30/91 30/111 PLUS

93113

133153

39/111 39/126 PLUS

113128

153168

48/111 48/111 PLUS

113128

153168

60/126 60/142 PLUS

128144

168183

75/142 75/162 PLUS

144164

183203

98/162 164 203127/182 183 218

Data table


CFL5.560.1

CASAFLEX - Fernwärmeleitung

DUO Anschlußverbindung

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Montageanleitung Art.Nr.69727

1. Bauteile: 1-Druckplatte (Markierung "A"), 2-Druckring ,3-Stützring, 4-Anschlußstück, 5-Grapitdichtring,6-Konusplatte (Markierung "B"), 7-Innensechskant-schraubenZusätzlich: Endkappe, Überwachungsader-Set

Parts: 1-pressure plate (marking "A"), 2-pressure ring ,3-core piece, 4-connection end, 5-graphite packing ring,6-cone plate (marking "B") , 7-allen boltsIn addition: end cap, connection set for monitoring wires

2. Markierung am Mantelrohrende = 50mm

Marking at casing pipe end = 50mm

3. Mantel entlang der Markierung einsägen.Sägetiefe = Sägeblatthöhe.ACHTUNG: Innenrohre und Überwachungsadernnicht beschädigen!

Saw casingpipe along marking.depth=depth of saw blade.Attention: do not damage service-pipes ormonitoring wires!

4. Mantelrohr mit Messer axial einschneiden.

Cut casingpipe axial with knife.

3

1

24

6

7

5

50mm


CFL5.560.2



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Montageanleitung

5. Mantel und Streckgitter abschälen Achtung: Streckgitter ist scharfkantig! Innenrohre mit Messer freilegen Überwachungsadern mit Messer freilegen

Seperate casing and expanded metal Attention: sharp-edged expanded-metal Lay open service pipes with knife

Lay open monitoring wires with knife

6. Innenrohre mit Edelstahldrahtbürste sorgfältig metallischblank bürsten

Achtung: Rohroberfläche ist Dichtfläche!

Clean the outer surface of the servicepipes using a stainless steel brush Attention: pipe surface =seal surface

7. Innenrohre auf der einander zugewandten Seite mit ver-drilltem Schleifleinen sorgfältig metallisch blank reinigen

Clean the outer surface of the servicepipes between the pipes using a drilled abrasive paper

8. Sägeschnitt mit Feile entgraten

Remove burrs from pipe end inside and outside using ahalfround file


CFL5.560.3



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Montageanleitung

9. die Druckplatte(1) über die Innenrohre schieben, dabeidie Rohre mit dem Holzkeil spreizenDie Aussparungen müssen zum Rohrende weisen.

Pull pressure plate(1) over the servicepipes using thewooden wedge as a spread.The wards have to point to the pipe end.

10. Druckringe(2) auf die Innenrohre aufschrauben;der größere Durchmesser zeigt zur Druckplatte

Screw the pressure rings(2) up to the service pipes; the greater diameter points towards the pressure plate

11. die Stützringe(3) in die Innenrohre einschrauben. Derzylindrische Ansatz muß mit dem Wellrohrende abschlie-ßen.

Screw the core piece(3) into the servicepipe up to theend of the thread. The thread must end flush with theinner pipe.

12. Anschlußstücke(4) über die Stützringe schieben; dieDruckringe werden soweit verdreht, daß zwischen An-schlußstück und Druckring ein Spalt von 0,5 mm ver-bleibt.

Push the connecting end(4) right up against the core piece. The distance between the connecting end and the pressure ring must be approx. 0,5mm. Screw the pressure ring in or out until you reach this setting.

0,5mm


CFL5.560.4



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Montageanleitung

13. Anschlußstücke wieder abnehmen.Die Druckringe in die Aussparungen der Preßplatte drük-ken.Druckringe und Stützringe hierbei nicht mehr verdrehen.

Remove connecting ends and push the pressure ringsinto the wards of the pressure plate.The core piece and the pressure ring must not berotated doing this.

14. Grapitringe(5) auf die Rohrenden aufschieben

Place the graphite packing ring(5) onto the pipe end

15. Anschlußstücke wieder aufsetzen

Refit the connecting ends

16. Konusplatte(6) über die Anschlußstücke schieben; der größere Durchmesser zeigt dabei zum Rohr.

Push the cone plate(6) over the connecting ends; the greater diameter has to point towards the pipe


CFL5.560.5



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Montageanleitung

17.Schrauben(7) einsetzen und schrittweise umlaufend fest-ziehen. Druckplatte und Konusplatte müssen auf Blockliegen.Schrauben mit säurefreiem Öl schmieren!

Fit the allen head bolts(7) and tighten them gradually ina clockwise pattern.Insert the bolts with a non acid based grease!

18. Falls erforderlich:Überwachungsadern verbindenEndkappe aufsetzen und mit Schlauchschellen befesti-gen

If required:Connect monitoring wiresFit end cap and fix it with clamps

19. Fertig!

Ready!

20. Werkzeug: Handsäge, Markierungsstift, Zollstock, Mes-ser, Edelstahldrahtbürste, Halbrundfeile (Hieb 2), Zange,Innensechskantschlüssel, RatscheSonderwerkzeug: Holzkeil, Schleifleinen K 180 ( im Lie-ferumfang)Persönliche Schutzausrüstung: Schutzhandschuhe

Tools: saw, marker, yardstick, knife, stainless steel brush,half round file, pliers, allen key, ratchetSpecial tools: wooden wedge, abrasive paper K 180(delivered)For safety: gloves

0,5mm

0mm

OIL


WIREM

10.0

15.10.2003

Table of contents

CH

10.0 Table of contents

10.1 General system description

10.100 System description10.110 Functional description10.120 Measuring description

10.2 Design and reference charts

10.200 Design and reference charts10.210 Welding plans

10.3 Control unit U89A

10.300 Unit description, technical data10.310 Unit description, page 210.320 Fault handling procedure10.330 Electrical circuit, wiring diagram10.340 Option: Remote control transmission

District Heating ControlPIPE2000 Ltd-For Information

Tel: 01268 759567 Fax:01268 569932email: [email protected]

WIREM

10.100

15.10.2003

CH

The piping for district heating laid outunderground, is nowadays mostly equippedwith control equipment, to monitor itsoperation. The advantage of this lies in theearly detection and quick location ofdamages. Feeler wires melted into thethermal insulation in the factory perform,together with the monitoring equipment, agreat number of functions. The safety of theinstallation is improved and the costs ofrepairs reduced.

The systems FLEXWELL -cable, FERWAG -pipe and CASAFLEX -district heating pipe ofBRUGG Pipe Systems are equipped ex-workswith the Reference Resistance Measure-ment system (WIREM ). Other monitoringsystems can be supplied if specified. TheBRUGG STEEL PROTECTION PIPE is availableas an option.

WIREM and BRANDES are compatiblesystems.

The WIREM technology with its feeler wiresand control equipment makes manyfunctions possible:

• Check of the humidity in the thermal insulation starting at the production stage. Supply of data on the state of the insulation.

• Detection and identification of the feeler conductor making contact with the inner pipe, a breakage or damages anywhere in the circuit can be detected and identified.

General system description

District Heating Control

• An entry of humidity through e.g. a faulty welding seam, loose sleeve or external damage can be detected, monitored located and reported during operation.

• A display reports a failure or interference basing on early detection and self diagnostics.

• Feeler gauges connected to the control system and situated in wells, can produce an alarm in case of entry of water.

• Alarms, measurands, state of contacts and other data can be registered and transmitted to other systems.

The network of monitoring, measuring andlocating units can be built up at willdepending on conditions of volume of datarequired and network size.

The range of units extends from the manualinstruments to measure the condition of theinsulating material and manual fault location(unit U 89A) to fully automatic monitoringand fault location, testing over dialog andstoring of results, as well as data transmissionto other computers and printers.

®

®

®

®

®

®

PIPE2000 Ltd-For Information


WIREM

10.110

15.10.2003

1 2 3

2 1

Structure of the feeler conductor1. Gaps in insulation at regular intervals for wet contact detection2. PTFE-Insulation, coloured red3. NiCr conductor

1. Copper core2. FEP-Insulation, coloured green

The physical principle for monitoring, as well as forfault location, is the resistance reference method(WIREM ), which is that of the unloaded resistancebridge principle.

A defined voltage is applied between the feeler wire,embedded in the thermal insulation, and the pipe (seefigure). Should the isolation resistance diminish, as willhappen when a wet spot occurs, a voltage rise will beregistered in the monitoring instrument and an alarmwill be released.

Principle of monitoring

Monitoring unit

Feeler wire (red)

Return wire (green)

I

S


The reference resistance determines the tolerancethreshold and is adjustable.

Monitoring of the thermal insulation is performed bya special feeler wire (see figure). The wire itself isprotected against direct contacts to metal, by athermally stable PTFE sleeving. A contact between thenaked NiCr wire and wet spots occurs in perforationsalong the PTFE sleeve. This permits monitoring overthe entire length of the feeler wire.

The perforations allow an accurate evaluation of thewet spots regarding their intensity in the wholemonitored spectrum, from „dry“ with over 50M to„wet“ with under 10K insulation resistance.

For the monitoring itself, an FEP isolated, copper returnwire is laid out parallel to the feeler wire.

Both wires form a feeler loop (see figures), which canattain 1000 m in length and therefore is able to monitor1000 m of piping. Branches of piping are also followedby branches in feeler wires, i.e. feeler wire out, returnwire back (see figure).

Pipe center line

Layout of the feeler loop

Feeler loop with branch-off

Large pipe networks of several kilometers in length aredivided into monitoring sections of under 1000 meters.A monitoring unit is installed at each section.

Loop

Insulation

CH

Functional aspects

Position of the feeler cablesThe monitoring cables (feeler wire and return wire)are embendded in the insulating material betweenthe inner and outer pipes. In the FERWAG - andCASAFLEX - pipe they run parallel, on eiter side of the

inner pipe and about half way through the insulation,while in the flexible system FLEXWELL -cable, they arewound around the inner pipe and run close to eachother.


Feeler wire (red)

Return wire (green)

Structure of the return wire

®

®

®

®



WIREM

10.120

15.10.2003

Determining thefault location

To locate the wet spot or contact fault, a voltage U isapplied across the loop.

At the end of the feeler loop, a part voltage U1caused by the wet spot, is measured between theinner pipe and the feeler cable.

The result is expressed not in Volt but in % of theapplied voltage.

5.7 /m and the return wire near zero , thefollowing relationship results:

Determining the fault location

A breakage in the feeler loop will be immediatelydetected in automatic installations, but the locationof the break has to be performed manually by othermeans.The usual method used in such cases is the timedelay measurement.A capacitance measurement can also be used.

To avoid subsequent faults and gaps in the feelerloop, strict quality control and measurement checks

. They target,

Locating a break in the feeler loop or in themonitoring circuit

U1

U= = =

R1

R 100%

x% L1

L

UU1RR1x %LL1

The gravity of the insulation fault (insulation resistance)has no influence on the precision of location, as it isbalanced out in the measurement concept.

CH

U1U

x%Fault location unit

Wet spot

100 %

= Applied voltage= Measured voltage= Total loop resistance= Part loop resistance= Part result= Total pipe length= Distance to fault


Feeler wire (red)

Return wire (green)


Since the feeler wire has a relatively high resistance of

during production are applied in generalamong others, the solidity of all wire connections.



WIREM

10.200

15.10.2003

Heating Plant

Block 1

U89A

21 2 3

U89A

11 2 3

Feeler Return

Wiring between the terminalsBrugg in the building, done by

an electrician

Monitoring terminals

CrNi wire (red)Cu wire (green)

Resistance / length (DR)R = 5.7 /m

Forward2219

Return2220

Insulation resistance (IR)Grade BS-MH-2

Forward0 = >50 M

Return0 = >50 M

The monitoring system BRANDES

Control units

Block 2

Block 3

T-pieces(downward)

Results of measurements

Design

The design of the control circuit isdone parallel to the design of thepiping. The whole installation is thendivided into separate loops with amaximal length of 1000 to 1200 mper unit. All units can be placedcentrally in one building. For futureexpansion of the network, it is goodpractice to insert some spare cablesbeside the pipes.

Reference drawings (Wiring diagrams)

CH

TT 1,5 mm2, or U 72 0,8 mmLength 9m : armoured wire

Wiring by an electrician

Design and ReferenceDrawings

Block 4


T-pieces(downward)



WIREM

10.210Reference DrawingsWelding plans

Heating Plant

Block 1

Block 2

Block 3

Pipe

Materials

To find the exact location of thefault above earth, it is veryimportant to have access toreference drawings. The moreprecise these are, the easier andquicker the spot can be found.Welding plans have proved to bethe best reference.

CH

FER 60.3-140FER 76.1-160FER 88.9-180

Stand. L Elbow [m]

6 m6 m

12 m

0.5x0.50.65x0.650.65x0.65

FER 60.3-140FER 76.1-160

FER 88.9-180

6.74

12.0

12.0

12.0

12.0

12.0

Bg 90 , 0.65x0.65

6.52

12.0

12.0

12.0

12.0

12.0

12.0Bg 90 , 1.56x0.92

7.9

7.9 1.0

1.0

12.0

12.0

1.826.57

Bg 86 , 0.65x0.65

Bg 61 , 0.65x0.65

Venting

Bg 90

12.01.56

0.92

12.0

12.0

8.0

8.45

12.0

12.0

12.0

5.23 6.0

5.84

5.84

6.04.65

6.0

6.06.0 4.3

6.0

6.0

6.0

4.92

6.0

1.9

6.0

4.6

3.75

6.0

5.81

6.0 5.0

6.0

1.77

5.0

6.06.0

Bg 85 , 0.65x0.65

1.01.0

5.85.8

5.6

4.6

6.0

6.0

6.0

6.0Bg 90 , 0.50x0.50

Bg 90 , 0.65x0.65

Bg 61 , 0.65x0.65

Bg 860.65x0.65

1.0

Bg 90 , 0.65x0.65

Bg 85 , 0.65x0.65Block 4

A

View A

Elbow 900.95x1.05

0.95

1.05

0.95

Bg 90 , 0.50x0.50

1.0

1.0

1.0

Draining, DN 320.55

1.0

1.0

Bg 90 , 0.50x0.50

Bg 90 , 0.50x0.50

Bg 76.5 , 0.65x0.65

12.0

15.10.2003


Reference DrawingWelding plan

Reference Drawings

T-pieces(downward)

Bg = Elbow



WIREM

10.300

15.10.2003

The instrument monitors theelectrical insulation resistancebetween the detector leadand pipe (earth). A break inthe detector lead or earthleakage (<5 kOhm) is signalledsimultaneously. The earthleakage signalling can also beused as a shaft monitor. Byconnecting a level switch (e.g.EHS-JOLA 6M, Otto FischerAG) between the direct leadreturn and pipe.

The unit is suitable for fittingin a switch cabinet and forsurface mounting.

Function

Unit description

Button and 2 signal lamps are mounted on the instrument.

Lamps

green : operatingred : fault

Surface mounting

For operation, an additional button and 2 signal lamps must be fitted in the cabinet door.

Fitting in switch cabinet

If the electrical insulation resistance is exceeded (moist insulation), if there is a failure or earth leakage (shaft monitoring), a horn, lamp or central alarm system is triggered. At the same time the fault signal lamp lights up on the instrument or cabinet door as follows:

Fault

Insulation moist

Failure in monitoring loop

Earth leakage, shaft monitoring with float switch

Brugg Rohrsystem AG 5200 Brugg

CH

Unit description U89Atechnical data



WIREM

10.310

15.10.2003

75

150

107

A

View A

Unit descriptionU89A

CH


Alarm output for external fault displayThe instrument has an alarm output to supply a horn, a lamp or a central alarm system.

AcknowledgementBy pressing the double function button (instrument test + acknowledgment button), the alarm output isswitched off. The fault lamp remains alight until the fault has been remedied.

Instrument testThe instrument is maintenance-free. However, we recommend that you implement a monthly operatingcheck. By pressing the button a fault is simulated. As a result, a check is made of all the electronics.During this, the fault lamp must be alight. During the test, the alarm output can be blocked orconnected through by means of the switch fitted on the printed circuit board. The switch should be setto the required position during installation.

Technical data• Supply voltage • Voltage tolerance • Power consumption • Output • Breaking capacity • Cable inlet • Connection type • Protection system • Ambient temperature • Max. loop length

220 V 50 Hz 10 %1.5 VAHigh-tension current contactmax. 250 V AC 5 A (alternating current)max. 30 V DC 5 A (direct current)6 paracril cable sleeves mounted on sides2 break-through apertures in casing bottomConnection screws with terminal plates, max. 2 x 1.5 mm2IP 40-10 to +50 C0 to 10 kOhm (0 - 1200 m)

Casing dimensions

Break through for wall fastening ø 4.2 mm.

Break through for wall fastening ø 4.2 mmBreak through for clamp fastening to 35 mm standard bar DIN 46277.Clamp in instrument.



WIREM

10.320

15.10.2003

CH


Fault handling procedure

Possible fault causes

Procedure in the event of a fault CautionBefore opening the instrument,switch off the main switch

Fault

1. Green lamp not alight

2. Fault lamp (red) alight

a) continuously

b) flashes

c) flashes intermittently

Possible cause

• no mains voltage• 50 mA fuse on pc board defective

• Insulation in pipe moist

• Break in monitoring loop (in the pipe or in the sockets)

• Earth leakage in shaft monitoring with level switch (water in shaft)• Detector lead (loop) short circuit to earth (< 5k )

Equipment test without pipe system

Procedure

1. Loop. Remove terminal 1 + 2

2. Connect terminal 1 + 2

3. Press button (instrument test)

4. Connect terminals 1, 2 + 5

Fault lamp display

must flash

must go out

must be alight

must flash intermittently

If all 4 states are OK, then the cause should be sought in the pipe system (sockets, connecting lines).



WIREM

10.330

15.10.2003

CH

Electrical circuit,wiring diagram


Terminal 3potential freeWith direct connectionterminals A - Bno connectionterminal 3

4

5

6

7

8

9

10

11

12

13

14

15

16

PC b

oard

con

nect

ors

•

Mains 220 V 1.5 VA

Be sure to connect earth, in special cases connect to pipe.

50 mA

Terminals

Contact load 250 V AC / 5 ANot applicable for surface mounting

Shaft monitoringwith float switch

•

Connection pipe

term

inal

Cor

1

Ala

rm o

utpu

t fo

r "F

ault

exte

rnal

"in

inst

rum

ent

test

on p

c bo

ard

free

b

lock

ed

N

P

Supply for fault external

horn, lamp, collective alarm

red

greenoperating

fault

Supply for display

1

2

3

Cu (green or blue)

A

B

Assembly limit BRUGG

C

DH - Line

Cr Ni (red or brown)

DH - Line

insulation moist break loop short circuit shaft

1

2

3

Cu (green or blue)

TT 1,5 mm , or U 72 0,8 mm

A

B


FW - Leitung


2

DH - Line

DH - Line

DH - Line

DH - Line

FW -

Lei

tung

DH - Line

BRU

GG

Wiring for branched network, example only Wiring principle: Always probe loop

Term

inal

s

Wiring between the sockets by an electrician (by the owner)

Cab

inet

Faul

tex

tern

al

*

* e.g. level regulatorEHS - JOLA 6 MOtto Fischer AG

Acknowledge instrument test

CC

C

Switc

h

TT 1,5 mm , or U 72 0,8 mm2

Caution: Before opening the instrument, switch off main switch.

Weak currentmax. 12 V

Weak current

Brea

king

cap

acity

max

imum

250

V A

C 5

A, 3

0 V

DC

5A

Monitoring socket

Monitoring socket

Cu (green or blue)


Cu (green or blue)


Cab

inet

Assembly limitBRUGG

Assembly limitBRUGG

Wiring by electricianLength 9 m: armoured wire

Length 9 m: armoured wireWiring by electrician



WIREM

10.340

15.10.2003

Option:Remote control transmission

13

12

11

10

9

R1

R2

R1 R2

0

II

0

01

0

I

CH


Version for remote control transmission e.g. "Ridat Rittmeyer"

The U 89 instrument is also suitable for computer controlled remote transmission. In this case, there is no need for wiring the cabinet door. These outputs are wired as followed by a change on the PC board.

The functions of the network and fault lamp on the instrument, and also "Fault external" (terminals 6 to 8) remain unchanged.The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission.

Terminals 9 to 13 Logical states

Everything OK

Insulation moist

Earth leakage in shaft monitoringwith level switchDetector lead has short circuit to earth

Break in loop



PIPE2000 Ltd





COPPERFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS

PIPE2000 Ltd




CCO9.0

4.7.2000


9.1 System description

9.100 System description part 19.105 System description, part 29.115 Copper heating piping for local networks

Structure, dimensions, materials, weights and supplied lengths

9.2 Planning, design engineering

9.200 Pipe routing9.201 Pipelaying instructions, part 19.202 Pipelaying instructions, part 29.203 Pipelaying instructions, part 39.210 Pressure losses9.220 Heat losses

9.3 Components

9.320 Joint sleeve / Fitting the T-piece9.340 Insulating material9.345 Soldered fittings / soldering instructions9.355 Connection of copper heating pipe to KMR9.365 End cap9.370 Wall sealing ring / Pipe warning tape

9.5 Underground construction work, assembly

9.500 Trench dimensions9.505 Pipe entry into buildings

Table of contents

Copper Heating PipingPIPE2000 Ltd UK Distributor


CCOCopper Heating Piping
1. General

CCO Copper Heating Piping for LocalNetworks is a flexible pipe system suitable fortemperatures of up to 120 °C. This piping isintended for use in small and medium-sizedlocal heating networks.

CCO Copper Heating Piping for LocalNetworks has a medium pipe made of copper.Manual processing of this piping is very easy.

The heat insulation consists of a flexible CFC-free hard polyurethane foam with outstandingheat insulation characteristics.

The flexibility of the CCO Heating Piping forLocal Networks means that it can be adaptedto virtually any pipe conditions with noproblems. Pipes can cross above or belowexisting supply lines, and obstacles can beeasily bypassed.

CCO Heating Piping for Local Networks makesit possible to choose the shortest pipe route,without taking classical pipe constructionmethods into consideration.

CCO Heating Piping for Local Networks issupplied to the site as one piece in the desiredlength, in rings. By and large, the pipe can belaid in the ground without any connectionpoints so that the pipe trenches can beconsiderably narrower, making substantialsavings possible on the undergroundconstruction work. This is particularly true ofDUO lines.

Another feature: only a very short time isrequired to lay the pipe. All of these benefitsmean that CCO Heating Piping for LocalNetworks is not only a technically perfectsolution, but also that it offers the key tosaving time and costs when constructing localheating networks - thanks to the reducedoutlay on coordination at the site, and the fastand simple installation procedure.

2. Range of application

Heating: max. 120 °C and max 16 bar operating pressure

CCO Heating Piping for Local Networks can be supplied with one or two inner pipes.

9.100

4.7.2000

System DescriptionPart 1Tel: 01268 759567 Fax: 01268 569932

email: [email protected]

Cu medium pipe ValueExamination

norm

8.93

max. 140

220 to 270

40 to 70

125‘000

16.6 · 10 E-6

kg/dm

N/mm

N/mm

N/mm

1/K

-

DIN 17671

DIN 17671

DIN 17671

-

-

4. Heat insulation

Material:

Density

Heat conductivity

Closed cells

Water absorption after 24 hours

–

50

–

–

> 60

≤ 0.032

≥ 90

< 10

kg/m

W/mK

%

%

DIN 53420

DIN 52612

–

EN 253


Density

Heat conductivity

Crystallite melting range

–

–

–

928-938

0.43

105-110

kg/m

W/mK

°C

DIN 53479

DIN 52612

–

Material: Purpose:

CFC-free, 100% CO2-driven polyurethane foam (PUR)

Polyethylene of low density, PE-LD, extruded seamless Protection against mechanical effects and moisture

CCO

9.105

4.7.2000

3

22

3

3

2

Referencetemperature °C

-

-

-

-

-

3. Medium pipe

Material: Soft copper, R220 to EN1057Oxygen-free copper, deoxidised with phosphorusSF-Cu F22 to DIN17671

Characteristics: Meets the requirements specified by EN 1057(mechanical values in the delivered state)

System DescriptionPart 2

Copper Heating Piping

ValueExamination

normReference

temperature °C

ValueExamination

normReference

temperature °C

PUR insulation

PE-LD protective casing

Density

Elongation limit

Ultimate tensile strength

Hardness

Modulus of elasticity

Linear expansion coefficient



UNO DUO

CCO

9.115

4.7.2000

CCO, UNO

CCO, DUO

Outer casing in black PE-LD polyethylene (VDE 0209), extruded seamless.Protection against mechanical effects and moisture.

Medium pipe in soft copper, R220, to EN1057, SF-Cu F22 to DIN 1787/17671/1754 1

Material

2 Flexible, CFC-free polyurethane foam, resistant up to 130 °CThermal conduction coefficient λ = 0.032 W/mK at 50 °C average temperature

PE-LD film3

4

Pos

Type DNProtective

sheathD x s1min, mm

Min. Bendingradius

m

Weight

kg/m

max. Delivery lengthRing without connections

m

1 2 3 4

15/6315/7518/6318/7522/6322/7528/7535/90

1010151520202532

Carrier pipe Cud x smm

15 x 1.015 x 1.018 x 1.018 x 1.022 x 1.022 x 1.028 x 1.235 x 1.5

Capacitycarrier pipe

l/m

0.130.130.200.200.310.310.510.83

DNm kg/m m

15+15/9018+18/9022+15/90

22+22/9028+15/90

28+22/90

101520102025102520

15 x 1.018 x 1.022 x 1.015 x 1.022 x 1.028 x 1.215 x 1.228 x 1.222 x 1.0

2 x 0.132 x 0.201 x 0.311 x 0.132 x 0.311 x 0.511 x 0.131 x 0.511 x 0.31

63 x 1.875 x 2.063 x 1.875 x 2.063 x 1.875 x 2.075 x 2.090 x 2.2

90 x 2.290 x 2.290 x 2.2 –90 x 2.290 x 2.2 –90 x 2.2 –

0.70.70.70.70.70.70.70.8

0.80.80.8 –0.80.8 –0.8 –

Ring dimensions: Ø 2800 x 800 mm (width) / pipe length without interrelated fittings

0.931.091.011.171.121.271.572.27

1.351.501.51

1.721.92

2.03

280280300300200200130

On request

280300200

200130

130

Heating, 120 °C, 16 bar, UNO and DUO

Local heating andhouse connection piping


max. Delivery length

Ring without connectionsWeightCapacity

carrier pipel/m

Min. Bendingradius

Protectivesheath

D x s1min, mm

Carrier pipe Cud x smm

Type



CCO

9.200

4.7.2000

B

C

A

A

B

C

D

E

A

B

C

D


Examples of pipe routing

Connection: copper local heating pipe - plastic casing pipe

Copper local heating pipe


Copper local heating pipe Note expansion pad as shown on catalogue pages CCO 9.201, 9.202 and 9.203

Note expansion pad as shown on catalogue pages CCO 9.201, 9.202 and 9.203

Note expansion pad as shown on catalogue pages CCO 9.201, 9.202 and 9.203

Copper-copper connectionLooping-in method



CCO

9.201

4.7.2000

2 m

< 5 m

Special solder must be used to solder the pipes together(this must be resistant to galvanic or electrochemicalcorrosion). The soldering instructions / manufacturer'sinstructions for the soldered connections must befollowed without fail.

The shape of the copper piping should not be bentmore than three times. This also includes rolling apartand rolling together.

If the lengths of pipe to be laid exceed 5 m, the copperjunction pipes must first be bent into a sinusoidalshape (curve length: L = 2 m, amplitude: 10 x outerdiameter of copper local heating pipe).

B

Bild 3

> 10 m

B

Bild 3

≤ 10 m

B

Bild 3

> 10 m

B

Bild 3

5 - 10 m

Pipelaying instructions

Pipelaying instructionsPart 1

Expansion pad

10 x Ø outer casing

Expansion pad for sinusoidal curves




Expansion padfor sinusoidal curves





Examples of pipe routes

Copper Heating PipingPIPE2000 Ltd UK Distributor


CCO

9.202

4.7.2000

The copper local heating pipe can onlyaccommodate forces and deformations fromconnected external pipes to a limited extent.

Expansion padding has to be applied to copperlocal heating junction pipes. The number ofexpansion pads required depends on themovement of the main pipe. The 3 illustrationsshown below provide the basic rules:

CCO or KMR

Thickness of expansion pads: 40 mm

The expansion pads must be applied as far asthe casing of the main pipe (i.e. they arepositioned on top).

The first layer of expansion pad is positionedaround the local copper heating pipe whichbranches off (the junction pipe).The second and third layers of expansion pad areonly applied at the sides (i.e. they are placedadjacently). The foregoing illustrations assumethat junction sleeves are used.

1 m

Illustration 1

Illustration 3

Illustration 2

Expansion pad∆ l ≤ 20 mm

2 m

CCO oder KMR

Expansion pad20 ≤ ∆ l ≤ 40 mm

3 mExpansion pad40 ≤ ∆ l ≤ 60 mm



Pipe junctions from copper or steel Main pipes on copperLocal heating pipes

CCO or PLASTIC CASING PIPE



CCO

9.203

4.7.2000

Straight transitions from plastic casing pipes to the copper local heating pipe

For transitions from plastic casing pipes to the copperlocal heating pipe, it should be noted that the copperlocal heating pipe can only absorb the heat expansionto a limited extent. The following examples show howthis can be guaranteed:

KMRCCO

KMR CCO

max. 20 m

The maximum length of the plastic casing pipe is 10 m.Expansion padding is required.

The maximum length of the plastic casing pipe is 20 m.Expansion padding is required.

KMR

CCO

The length of the plastic casing pipe may exceed 20 m.Expansion padding is required.

Instructions for reducing the medium pipe

The following rules must be followed for a reduction ofthe medium pipes:

1. If gunmetal reductions are used, no particular instructions need to be followed.2. The following instructions refer to reductions with normal copper soldered sleeves

ReductionCCO CCO

CCO, reduced

max. 5 m

The heat expansion is absorbed by the sinusoidal curve(see page CCO 9.210) upstream of the T-junction.Expansion padding is required.

KMRCCO

The maximum length of the plastic casing pipe is 5 m.Expansion padding is required. No sinusoidal curve isrequired on the copper pipe.

max. 10 m

max. 5 m



more than 20 m

.



CCO

9.210

4.7.2000

Pressure loss, ∆p

m ≈ Q · 860

∆T

Roughness ε = 0.0015 mm (copper)(1 mm water column = 9.81 Pa)

kg/h

Pressure loss


Water, average temperature 80 °C

m = flow in kg/hQ = power required in kW∆T = temperature difference forward and return flow in °C

10 100 500 200 300 20 30 40 50 3 4 5 7 700 2000 30001000

Pa/m1mbar/m

10mbar/m



TE

Eλ

.

..

..

..

..

....

...

. ..

70° 80° 90° 110° 120°100°

TypeCCO UNO

TypeCCO DUO

CCO

9.220

4.7.2000Heating, 120°C, 16 bar, UNO and DUO

15/63

15/75

18/63

18/75

22/63

22/75

28/75

35/90

70° 80° 90° 110° 120°100°

15+15/90

18+18/90

22+15/90

22+22/90

28+15/90

28+22/90

0.13

0.12

0.15

0.13

0.18

0.15

0.19

0.20

7.8

7.2

9.0

7.8

10.8

9.0

11.4

12.0

9.1

8.4

10.5

9.1

12.6

10.5

13.3

14.0

10.4

9.6

12.0

10.4

14.4

12.0

15.2

16.0

11.7

10.8

13.5

11.7

16.2

13.5

17.1

18.0

13.0

12.0

15.0

13.0

18.0

15.0

19.0

20.0

14.3

13.2

16.5

14.3

19.8

16.5

20.9

22.0

0.16

0.18

0.19

0.22

0.29

0.26

9.6

10.8

11.4

13.2

17.4

15.6

11.2

12.6

13.3

15.4

20.3

18.2

12.8

14.5

15.2

17.6

23.2

20.8

14.4

16.2

17.1

19.8

26.1

23.4

16.0

18.0

19.0

22.0

29.0

26.0

17.6

19.8

19.8

24.2

31.9

28.6

a=0.1m

E Eλ

. .

..

...

.. .. ...

. .

.

. .

Heat loss

Copper heating pipe

Heat loss q [W/m] for single-line pipe UNO

(Forward and return flow in the same protective sheath)

Heating loss q [W/m] for twin-line pipe DUO

K-Value[W/mK]


K-Value[W/mK]

Heat loss during operation: q = K (TB -TE) [W/m] K = Specific heat losses [W/mK]TB = Average operating temperature [°C]TE = Average earth temperature [°C]

2 separate UNO pipesundergroundH = 0.60 mTE = 10 °C E = 1.2 W/mK PU = 0.032 W/mK PEX = 0.38 W/mK PE = 0.43 W/mK

Method of laying: Covering height:Earth-temperature:Conductivity of ground:Conductivity of PUR-foam:Conductivity of PEX-pipe: Conductivity of PE-casing: λ

λλλ



Copper heating pipe



Connecting socketTee Branch insulation kit

CCO

9.320

4.7.2000

63 - 63 63 - 7563 - 9075 - 6375 - 75 75 - 9090 - 6390 - 7590 - 90

75 90 d1 d3

Junction, d2

xxxxxxxxx

xxxxxxxxx

63

xxxxxxxxx

Ø external

CCO

4

5

2

1 3

d2

CCOCCO

Connecting socket


d2 75 9063

637590

d1x

xx

1 2 3 4

Tee Branch insulation kit


1 CCO joint, see sheet CCO 9.3452 Insulation material, see sheet CCO 9.3403 Shrinking socket4 Shrinking hose

1 Copper T-piece, see sheet COO 9.3452 GFK half-shells3 Insulating material, see sheet COO 9.3404 Reducer ring5 Special sealing compound

GFK fibreglass-shell tested byFernwärme-Forschungsinstitut (FFI)

of Hannover

Dimensions of GFK shell



CCO9.340

4.7.2000

PUR - foam bottle

Security requirement forthe foam insulationCO2 -blown,

CFC-free PUR-foam

PUR - foam bottle

plastic gloves

Component B

Component A

Separating rail eye protection

The required volume of polyurethane is supplied in the appropriate container size for the various sleeves or T-pieces. For fitting, the mixing rod supplied with the container is pushed through the container and the components are mixed together with a hand drill.

Base:

Insulation material



PUR-foam pack, PE-foam hose

plastic gloves

eye protection



Connection with external thread

Joint, equal

CCO

9.345

4.7.2000

T-connection piece, equal, reduced

Joint, reduced

Article number 7270 +GF+




Caution!Solder sleeves with notches are available in the trade; under no circumstances must these be used!

Soldered fittings Soldering instructionsThe special BRUGG solder must be used to solder the fittings.

Solder with high silver content

Type

Euro standardisation

ISO 3677

CompositionGuideline analysis (%)

Application

Flux

Technical information

Heat sources

Brugg Pipe Systems recommends fittings from the Georg Fischer company (+GF+).All joints and T-pieces, etc. can be obtained in all dimensions from 18 to 35 mm.

BRL 8.50.34

pr EN 1044

B Cu Ag Zn Sn 630-730

Ag Zn Sn Si Cu34 27 3 0.1-02 36

Capillary brazing joints soldering for steels, copper and copper alloys, nickel and nickel alloys. For solder points with operating temperatures up to 200 °C. Suitable for Cu pipe installation to DVGW working sheet GW 2.

Rods thinly covered with flux

Working temperatureMelting rangeTensile strength

Specific gravityElongationElectrical conductivity

Acetylene/oxygen mixtureThe oxy-fuel gas flame must be set to neutral.

710 °C630-730 °C360 N/mm2480 N/mm29,0 g/cm3> 12 %14 Sm/mm2

St 37St 50


Soldering instructionsSoldered fittings



Copper Heating Piping CCO

9.355Connection of copperheating pipe to KMR

3.7.2000

45°

70

The branche line of the Copper Heating pipe toKMR (plastic sheath pipe) would be connectedusing prefactored St-Cu-fitting. The fittingwould be welded on his steel end and would beconnected with soldered fitting on his copperend.

St-Cu-Fitting

Connecting jointOuter ø in mm

St x Cu

17.2 x 1526.9 x 1826.9 x 2233.7 x 2842.4 x 35

215215215215225

185185185185145

L 2mm

Flex-T-Socket

160 - 200 mm 225 - 250 mm 280 - 315 mmBranche line Outer ø mm

637590

XXX

90 mm 110 - 140 mmKMR-Pipe

Outer ø

XXX

XXX

XXX

XXX

Cu

St-Cu-Fitting

L 1mm

The branche line would be insulated by the shrinking socket, double internal and external sealed



End cap

The cap is shrunk onto the pipe end with a gas flame or hairdryer. Suitable for moist rooms and introduction into shafts.

CCO

9.365

4.7.2000

Data table

Type CCO

15/6315/7518/6318/7522/6322/7528/7535/90

15+15/9018+18/9022+15/9022+22/9028+15/9028+22/90

DHEC 2000DHEC 2000

DHEC 2000DHEC 2000

DHEC 2000DHEC 2000

DHEC 2000DHEC 2100

DHEC 3200DHEC 3200

DHEC 3250DHEC 3250 P604

DHEC 3250DHEC 3250 P604


Shrinkdown end cap

Copper heating pipe

Shrinkdown end cap



CCO

9.370

4.7.2000

50

Datentabelle

Type CCO

15/6315/7518/6318/7522/6322/7528/7535/90

15+15/9018+18/9022+15/9022+22/9028+15/9028+22/90

Da

6578657865787893939393939393

102118102118102118118133133133133133133133


Wall sealing ringPipe warning tape

To be laid in the ground

Standard roll length: 250 m

Laying depth: see sheet CCO 9.500

Wall sealing ringall dimensions in mm

Copper heating pipe

Wall sealing ringOuter pipe casing D

Pipe warning tape



.

. .. .

..

. ..

..

.. . .

.

..

..

...

. .

.

.

..

. ..

.

.

.

...

. .. . .

.

.

.

(4xD + 2x10)B

10 D 10

21 3

.. .

...

. ..

..

..

.. .

.

.

.. .

.

. ..

..

..

.

..

.. .. .

.

.

B10 D D 10

21 3

DD D

.

..

..

.

..

... .

.

.

.

.

...

.

.

.

.

.. ..

...

.

.

.

.

. ..

.

..

.

1010 D DB

21 3 21 3

. ..

.

.

.

.

.. . .

.

.

.. .

.

..

.

.

.

...

.

..

10 D

B

10

. . ..

.

6.37.59.0

Width

cmT

cm

434548

777879

0.70.70.8

BDepth Minimum

radius ofcurvature, m

9.0

cmT

cm

80 0.8

B

DUO

CCO

9.500

4.7.2000

30

10

... ..

.

.

..

.. ..

.

.

.

....

..

.

...

......

... ... ..

.... .. .

When digging the pipe trench, make sure that the pipes lie in a sand bed (grain size: 0-8 mm) of at least 10 cm, and that there is coverage of the same thickness above.


Trench dimensions

Trench profile, 2 copper local heating pipes

UNONormal trench cross-section in road area

all dimensions in cm

Pipe casingØ D cm

Pipe casingØ D cm

Width Depth Minimumradius of

curvature, m

Trench profile, 4 copper local heating pipes (loop-in method) all dimensions in cm

1 Pipe warning tape2 Excavated material3 Washed sand, grain size 0-3/4 mm

Laying depth: maximum laying depth: 2.6 mOur approval is required before laying at greater depths.

SLW 30 = 300 kN total load to DIN 1072; for exposureto higher operating loads (such as SLW 60), a load-distributing superstructure to RStO75 is required.

With no traffic load, the minimum trench depth T canbe reduced by 20 cm.



CCO

9.505

4.7.2000

80 mm

CCO

ca 80 mm

60 mm

A

80 80100D D

L

637893

D1 Aminmm mm

160180200

190210230

30

Outer casingØ D mm

637590

L Hminmm mm

400450500

250250250

Outer casingØ D mm


Entry into buildings

Entry into buildings

Wall openings

Pipe; see sheet CCO 9.115

Wall sealing ring; see sheet CCO 9.370

Copper connection piece;see sheet CCO 9.345

End cap; see sheet CCO 9.365

Wall opening

Dimensions in mm

Dimensions in mm

Breakthrough bored



PIPE2000 Ltd





EIGERFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS

PIPE2000 Ltd




EIGERFLEX CPE

4.0

15.10.2003



4.100 System description DN 20–100, Ø Carrier pipe 25 110 mm4.110 EIGERFLEX® pipe DN 20–40, Ø Carrier pipe 25 50 mm4.115 EIGERFLEX® pipe DN 50–100, Ø Carrier pipe 63 110 mm

Structure, dimensions, weights and supplied lengths

4.2 Planning, design engineering

4.200 Pressure loss4.205 Heat losses4.210 Connection to end of frost protection strip4.215 Sleeve joint - frost protection strip4.220 T-piece - frost protection strip

4.3 Components

4.300 Joint sleeve Fitting the T-piece

4.310 Insulating material4.320 Screwed PE joint

PE T-piece4.330 End cap4.340 Wall sealing ring

Pipe warning tape4.345 Wall sealing ring (DOYMA)

4.5 Underground construction work, assembly

4.500 Trench dimensions Pipe entry into buildingsOpenings in walls

®

Table of contents

–––



PE medium pipe

DensityHeat conductivityUltimate tensile strength (tearing resistance)Modulus of elasticityLinear expansion coefficientCrystallite melting range

Value Test standard

––

202020–

9500.43

32600-900

1.8 · 10 E-4127 - 131

kg/mW/mKN/mmN/mm1/K° C

DIN 53479DIN 52612DIN 53455DIN 53457DIN 52328 –

3

2

2

1. Medium pipeMaterial: Life expectancy: Characteristics:

Polyethylene class PE with high density, to DIN EN ISO 1216250 years at 20° C and 10 bar continuous load (30 ° C and 6.3 bar) Suitable for cold water and sewage/waste water pipes operating at up to 20 ° C/10 bar and 30 ° C/6.3 bar respectively

CPE

4.100System description

15.10.2003

3. Heat insulationMaterial:

CFC-free, 100% CO -driven polyurethane foam (PUR)2


PE-LD - protective casing

DensityHeat conductivity Crystallite melting range

–––

928-9380.43

105-110

kg/mW/mK° C

DIN 53479DIN 52612 –

Material: Purpose:

Polyethylene of low density, PE-LD, extruded seamless Protection against mechanical effects and moisture

3

2. Frost protection strip

DimensionsMinimum bending radiusOperating voltageMax. permissible ambient temperature

Maximum heating circuit length Power delivery (W/m at 5 ° C)

Material:

Copper conductorConductive heating element

InsulationScreened protective braiding

Outer casing

Width 7.9 mm, Thickness 5.6 mm20 mm230 V ACContinuous operation 65 ° C, short periods 85 ° C, to -30° C128 m / 16 A, (118 m / 13 A)11 W/m

Ref. temperature ° C

EIGERFLEX

Flexible pipe system with frost protection strip

To protect people and equipment, we basically specify a 30 mA residual current-operated device(FI).

PUR-insulation

DensityHeat conductivityClosed cellular structureWater absorption after 24 hrs.

Value

–50––

> 60 0.032

90 10

kg/mW/mK%%

DIN 53420DIN 52612 –EN 253

3

Ref. temperature ° C Test standard

Value Ref. temperature ° C Test standard

25 - 50 mm 63 - 110 mmPower delivery 11 W/m

Frost protection strip,self regulating

Width 7.9 mm, Thickness 5.6 mm20 mm230 V ACContinuous operation 65 ° C, short periods 85 ° C, to -30° C102 m / 16 A, (84 m / 13 A)17 W/m

Power delivery 17 W/m

®PIPE2000 Ltd UK Distributor


PE-Foil

PE-LD casing, corrugated

PUR-Foam

PE Medium pipe

CPE

4.110

Aluminium foil,50 mm wide

EIGERFLEX - pipe25 - 50 mm

with frost protection strip

EIGERFLEX pipe

Frost protectionstrip Freezstop

11FSM2-CT

s1s

d D

EIGERFLEX

15.10.2003

®

EIGERFLEX®

EIGERFLEX

Frost protection strip:Power delivery 11 W/m

Further insulation thickness classes on request• Dimension on request


Ring dimensions: Jumbo Coil Outer diameter 2800 mm x 800 mm (width)Maxi Coil Outer diameter 2800 mm x 1200 mm (width)

Larger lengths can be supplied on request. Delivery is on drums.On request, shorter lengths will be supplied on drums.

3/4"1"11/4"11/2"

25 x 2.332 x 2.940 x 3.750 x 4.6

78 x 2.078 x 2.093 x 2.293 x 2.2

0.70.70.80.8

0.3270.5390.8351.307

0.901.001.391.54

20253240

760760560560

• 520520377377

25/7632/7640/9150/91

Type DN Inches

["]

Medium pipe PEd x smm

Outher casingD x s1mm

Min. bendingradius

m

Mediumpipe

volume

Weight

kg/m

max. delivery length

Jumbo-Coil Maxi-Coilm m

®

®

®



CPE

4.115EIGERFLEX - pipe63 - 110 mm

with frost protection strip 15.10.2003

®

EIGERFLEX

Ring dimensions Jumbo Coil Outer diameter 2800 mm x 800 mm (width)Maxi Coil Outer diameter 2800 mm x 1200 mm (width)

Larger lengths can be supplied on request. Delivery is on drums.On request, shorter lengths will be supplied on drums.

EIGERFLEX pipe

2"21/2"3"4"

63 x 5.875 x 6.890 x 8.2

110 x 10.0

128 x 2.7128 x 2.7163 x 3.2163 x 3.2

1.01.01.21.2

2.0912.9614.2546.362

2.602.754.565.69

506580

100

63/12675/12690/162110/162

280280144144

1921929292

s1s

d D

EIGERFLEX

Frostprotection strip

channel

EIGERFLEX

Frost protection strip:Power delivery 17 W/m

Frost protection strip channel8

18

PE-Foil

PE-LD casing, corrugated

PUR-Foam

PE Medium pipe


Frost protectionstrip Freezstop

17FSM2-CT


Type DN Inches

["]

Medium pipe PEd x smm

Outher casingD x s1mm

Min. bendingradius

m

Mediumpipe

volume

Weight

kg/m

max. delivery length

Jumbo-Coil Maxi-Coilm m

®

®

®

®



Pressure lossPE-Pipe

Water, average temperature 20 ° CRoughness = 0.01 mm (PE)(1 mmWS = 9.81 Pa)

Pressure loss p [Pa/m]

Water speed

Flo

w in

m [

kg/h

]

1000

010

0030

050

020

0030

0050

0020

000

3000

0

10020 20050

1000

200050

0

32/26.2

(DN 25)

40/32.6

(DN 32)

50/40.8

(DN 40)

63/51.4

(DN 50)

75/61.4

(DN 65)

30 40 300

4000

0

1600

1200

1800

1400

4000

2.0 m/s1.5 m

/s1.0 m/s

0.4 m/s

0.75 m/s0.5 m

/s

3.0 m/s

120

180

140

160

80 800

0.3 m/s

90/73.6

(DN 80)110/90

(DN 100)

400

CPE

4.200

15.10.2003

EIGERFLEX®

25/20.4

(DN 20)



Heat losses at different external temperatures or surface temperatures of the casing pipe.

Medium temperature: 2 ° C

The frost protection strip can no longer compensate for a heat loss of more than 10 W/m, and there is a danger of freezing.

CPE

4.205Heat losses

15.10.2003

EIGERFLEX®

surface temperatureof the

outher casing[ ° °°° C]

-

EIGERFLEX Pipe-dimensions

32/76 40/91 50/91 63/126 75/126 90/162 110/162

q W/m Medium temperature: 2° C

If the pipes are laid underground (covered height H = 0.6 m), the heat losses are reduced by at least 20%.

Tmed = 2 ° C

surface temperatures

25/76

-1-2-3-4-5-6-7-8-9

-10

-11-12-13-14-15-16-17-18-19-20

-21-22-23-24-25-26-27-28-29-30

-31-32-33-34-35-36-37-38-39-40

0.71.01.21.41.71.92.22.42.62.9

3.13.43.63.84.14.34.64.85.05.3

5.55.86.06.26.56.77.07.27.47.7

7.98.28.48.68.99.19.49.69.8

10.1

0.81.01.31.61.82.12.32.62.93.1

3.43.63.94.24.44.74.95.25.55.7

6.06.26.56.87.07.37.57.88.18.3

8.68.89.19.49.69.9

10.110.410.710.9

1.11.41.82.22.52.93.23.64.04.3

4.75.05.45.86.16.56.87.27.67.9

8.38.69.09.49.7

10.110.410.811.211.5

11.912.212.613.013.313.714.014.414.815.1

0.91.21.61.92.22.52.83.13.43.7

4.04.34.75.05.35.65.96.26.56.8

7.17.47.88.18.48.79.09.39.69.9

10.210.510.911.211.511.812.112.412.713.0

1.21.62.02.52.93.33.74.14.54.9

5.35.76.16.67.07.47.88.28.69.0

9.49.8

10.210.711.111.511.912.312.713.1

13.513.914.314.815.215.616.016.416.817.2

1.11.41.82.22.52.93.23.64.04.3

4.75.05.45.86.16.56.87.27.67.9

8.38.69.09.49.7

10.110.410.811.211.5

11.912.212.613.013.313.714.014.414.815.1

1.72.22.83.43.94.55.05.66.26.7

7.37.88.49.09.5

10.110.611.211.812.3

12.913.414.014.615.115.716.216.817.417.9

18.519.019.620.220.721.321.822.423.023.5

0.60.81.01.11.31.51.71.92.12.3

2.52.72.93.03.23.43.63.84.04.2

4.44.64.84.95.15.35.55.75.96.1

6.36.56.76.87.07.27.47.67.88.0

®



15.10.2003Frost protection strip

The temperature sensor has to be installed on the medium pipe opposite the heating strip. It must befitted at the coldest point on the pipe (outside the building). For this purpose, cut open a 10x7 cm area ofthe outer casing and peel back, cut out 10x7cm foam, and fix the temperature sensor on the inner pipewith adhesive tape. Fill the hole with the insulating material that is provided: apply filling adhesive S1113below and above the temperature sensor cable (see sketch), seal with shrinkdown tube.

230 V

Thermostat UTR 15with temperature sensor

End closure EA-H

Frost protection strip

approx. 10 cm

appr

ox. 7

cm

Temperature sensorShrinkdown tube

EIGERFLEX®

Temperature sensor cable

Shrinkdown tube Filling adhesive S 1113, 60 mm long

CPE

4.210Connection and end

Temperature sensor on pipe

35-40 cm

Shorten as described in fittinginstructions

EIGERFLEX

1. Technical data

2. Preparation

Remove 35-40 cm of insulation at the ends and carefully expose the strip. Then shorten the inner pipe to length according to the fitting instructions.

3. Installation procedure

4. Installing the temperature sensor on the pipe

Heating strip type Max. heating circuit length based on switch-on temperature of 5 ° C:

self regulating

16 A max. 100 m(13 A max. 80 m)

Regulation: Thermostat UTR 15• adjustment range: –5° C to 15 ° C• pipe contact thermostat or ambient thermostat

EIGERFLEX®

• Electrical installation according to local regulations• Only to be connected by an authorised electrical installer• 30 mA residual current-operated device (FI) - required by regulations!• Automatic fuse, C-characteristic

Sensor cable length 3 m; can beextended to a maximum of 100 m,with screened cable, 1.5 mm

Temperature sensor in open air

Connection box (provided by customer)

Connection heating strip / cold lead A-H/Kmax. 100 m

Protect the heating strip against moisture

2

®



15.10.2003Frost protection strip

CPE

4.215Sleeve joint

40 cm

Shorten as shown inillustration 2

EIGERFLEX

1. Technical data

3. Preparation

Remove 40 cm of insulation at the ends and carefully expose the strip. Then shorten the inner pipe to length as shown in illustration 2.

Heating strip type: Max. heating circuit length at switch on temperature of 5° C:

self-regulating

max. *100 m/16 A (max. 80 m/13 A)

EIGERFLEX®

2. Planning

Supply

Connection Frost protection strip/frost protection strip V-H/H

L 100 mContinuous joint

End closure EA-H

L > 100 mSeparation

max. 100 m max. 100 m

End closureEA-H

15 cm

Protect heating strip against moisture

Seal with sleeve setCatalogue page 4 300 + 4.310

4. Sleeve joint

30 cm

40 cm

30 cm

Continuous jointL 100 m

SeparationL > 100 m

max. 100 m

Illustration 2Illustration 1

Screwed joint or welded sleeve

Supply

30 cm

Supply

* for larger lengths see catalogue sheet CPE 4.100

Connection Frost protection strip/frost protection strip V-H/H

End closure EA-H

®

15 cm



15.10.2003

CPE

4.220T-pieceFrost protection strip

50 cm

EIGERFLEX

1. Technical data Frost protection strip

3. Preparation

Remove 50 cm of insulation at the ends and carefully expose the strip. Then shorten the inner pipe to length according to the fitting instructions.

Heating strip type: Max. heating circuit length at switch on temperature of 5° C:

self-regulating

max. *100 m /16 A (max. 80 m /13 A)

EIGERFLEX®

2. Planning

Protect heating strip against moisture

4. Fitting T-piece with T-junction

End closureEA-H

T-piece Micro Uni Clip MUC

L 100 m

At the T-junction, make sure that the sum of the connected pipes is not 100 m.

Connection V-H/H

L 100 m

SupplyA-H/K

End closure EA-H

Example 2: total length 100 mExample 1: total lenght 100 m

Example 3: total length 100 mEnd closureEA-H

End closureEA-H

Connection V-H/H

End closure EA-H

* for larger lenghts see catalogue sheet CPE 4.100

T-Piece Micro Uni Clip MUC

Screwed T-piece or electro welded T

®

Supply (usingconnectionA-H/K)

Supply (usingconnectionA-H/K)



Joint sleeveFitting the T-piece

Joint sleeve

all Ø dimensions in mm

d2 91 126 16276

7691

126162

d1

xx

xx

1 PE joint, see sheet CPE 4.3202 Insulation material, see sheet CPE 4.3103 Shrinkdown sleeve pipe4 Shrinkdown tube

CPE

4.300

15.10.2003

EIGERFLEX®

Fitting the T-piece

25/76 - 25/7632/76 - 32/7640/91 - 40/9140/91 - 32/7650/91 - 50/9150/91 - 40/9163/126 - 63/12663/126 - 50/9175/126 - 75/12675/126 - 63/12690/162 - 90/16290/162 - 75/126110/162-110/162110/162- 90/162

32/76 40/91Ø d1 Ø d3

Junction, Ø d2

90/16250/91 63/126 75/126

xxxxxxxxxxxxx

110/162

x

xxxxxxxxxx

x

xxxxxxxx

x

xxxxxx

x

xxxx

x

xx

x

1 PE T-piece, see sheet CPE 4.3202 GFK half-shells3 Insulating material, see sheet CPE 4.3104 Reducer ring5 Special sealing compound

25/76

xxxxxxxxxxxxxx

d1 d2

1 2 3 4

EIGERFLEX

3 2 4 51

d1 d3

d2

645 mm

max

. 490

mm

®



CPE

4.310

15.10.2003

EIGERFLEX®

PE

Sockets

Polyethylene foam hose Pipe-extruded insulation of closed cell, high-quality polyethylene, ideally suited for insulating

sockets. Various insulation coating thicknesses for the most common pipe diameters.

The insulating material (thickness and length) is supplied for the relevant socket types. The hoses should be adapted exactly to the sockets on the building site.

PUR - foam bottle


The required volume of polyurethane foam is supplied in the appropriate foam bottle packing sizes for the various sockets and T-pieces. The delivered stick has to be pushed through the foam bottle. The two components are mixed together by an electrical mixer.

PUR - foam bottleBase:CO2-blown, CFC-free PUR-Foam

Component A

Component B

Separating rail

Security requirement forthe foam insulation

plastic gloves

eye protection

Insulation materialPE-foam hose, PUR-foam pack

®CALPEX



Screwed PE jointScrewed PE T-piece

CPE

4.320

15.10.2003

EIGERFLEX®

Connection all dimensions in mm

25 x 2.332 x 2.940 x 3.750 x 4.663 x 5.875 x 6.890 x 8.2

110 x 10.0

PE-Pipe Type

53636771809292

102

L

25 x 2.3 - 3/4“32 x 2.9 - 1“

40 x 3.7 - 11/4“50 x 4.6 - 11/2“

63 x 5.7 - 2“75 x 6.8 - 21/2“

90 x 8.2 - 3“110 x 10.0 - 4“

Ø 75

Ø 90

Type L

coupling

Ø 75

Ø 90

25 x 2.332 x 2.940 x 3.750 x 4.663 x 5.875 x 6.890 x 8.2

110 x 10.0

606771758189

130130

d1

d2

d3

Screwed PE T-piece

25 x 2.3 - 25 x 2.3

32 x 2.9 - 32 x 2.9

40 x 3.7 - 40 x 3.7

40 x 3.7 - 32 x 2.9

50 x 4.6 - 50 x 4.6

50 x 4.6 - 40 x 3.7

63 x 5.8 - 63 x 5.8

63 x 5.8 - 50 x 4.6

75 x 6.8 - 75 x 6.8

75 x 6.8 - 63 x 5.8

90 x 8.2 - 90 x 8.2

90 x 8.2 - 75 x 6.8

110x10.0 -110x10.0

110 x10.0 - 90 x 8.2

32 x

2.9

40 x

3.7

50 x

4.6

63 x

5.8

75 x

6.8

Ø d1 Ø d3

Junction, Ø d2

90 x

8.2

x

x

x

x

x

x

x

x

x

x

x

x

x

110

x 10

Ø 75

Ø 90

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Alternative types of joint

Alternative types of joint(not in stock)

• Electro-welded PE sleeve• Electro-welded T, PET-T with welded sleeve• Pipe coupling Straub or Norma

Electro-welded PE sleeve

PE pipe coupling

d1

d2

d3L

LL

L



End cap

CPE

4.330

15.10.2003

Heat shrinkable end cap

EIGERFLEX®

Data table

EIGERFLEX

25/7632/7640/9150/9163/12675/12690/162110/162

6103161031610318630086326863266099963340

Type CPE Shrink end cap

Frost protection strip

The end cap is shrunk on by applying a gas flame or hot airjet to the end of the pipe.Within dry rooms its application is not absolutely necessary.

®



Wall sealing ringPipe warning tape

CPE

4.340

15.10.2003D

a D

50

EIGERFLEX®

Data tableall dimensions in mm

EIGERFLEX

32/76, 25/7640/9150/9163/12675/12690/162110/162

789393

128128163163

Wall sealing ringOuther casing pipe D Da

118133133168168203203

Typ CPE

Wall sealing ring

Pipe warning tape

ACHTUNG !

FERNWÄRMELEITUNG

Tape for underground

laying

Standard length:250 m

Laying depth; see page CPE 4.500

®



CPE

4.345

15.10.2003

Prerequisites for installation are perfect drill holes. Since hairline cracks can exist in concrete or can arise as a result of the work, we recommend sealing the drill hole walls over the entire lengths with a sealant (e. g. AQUAGARD).

We cannot guarantee a good seal if these recommendations are not observed.

Core drill holes

Wall ductDOYMA

Core drilling

ROuter diameter

EIGERFLEXPE Ø mm

DPipe liner

Core drill holeØ mm

150150200200250250300

7691

111126142162182

Ø D internal, mm

7893

113128143163183

150150200200250250300

Doyma Type C40Doyma Type A40

Ø D external, mm

1 EIGERFLEX ®- cold water pipe

2 DOY MA Type A40, large 1 x 40 mm

3 DOYMA Type C40, double sealing, large 2 x 40 mm, Hardness 35

4 Pipe liner made of fibre cement or coated core drill hole

* Suitability against pressurised water

3

R

1

D

4

D

1

R

2

4

3

StandardDOYMA C40

DOYMA C40 with additional centering ring DOYMA A40

Exte

rnal

Cel

lar/

shaf

t(I

nte

rnal

)

Exte

rnal

Cel

lar/

shaf

t(I

nte

rnal

)

EIGERFLEX ®

®



Trench dimensionsBuilding entry

Trench section, 1 CPE Leitung

all dimensions in cm 21 3

. ..

.

.

.

.

.. . .

.

.

.. .

.

..

.

.

.

...

.

..

D10

10 D

min

60

10

B

30

10

. . ..

.

T

CPE

4.500

15.10.2003

Outhercasing

Ø D mm

7693

113128143163

Large

cmT

cm m

808085858590

0.70.80.91.01.11.2

BDepth min. bending

radius

253030353535

1 Pipe warning tape; see page CPE 4.3402 Excavated material3 Sand washed, grain size 0-3/4 mm

EIGERFLEX®

Wall entry

End cap; see page CPE 4.330

80 mm

EIGEFLEX® -Pipe, see page CPE 4.110

Wall sealing ring, see page CPE 4.340

D

PE-connecting piece, see page CPE 4.320

EIGERFLEX

ca 80 mm

60 mm

Building entry

Breakthrough bored

Dimensions in mm

80 80D

A

A

7893

113128

163

Amm

240250

270290

320

Wall breakthrough Outhercasing

Ø D mm

7893

113128

163

Dmm

180200

220240

280

D

Outhercasing

Ø D mm

Dimensions in mm

SLW 30 = 50 kN wheel load, resp. 300 kN totalload according to DIN 1072. For bigger loads(i.e. SLW 60) a load distribution superstructureaccording RStO75 is required.Without traffic load the minimum covering hightmay be reduced by 20 cm.

Covering hightmaximum covering hight: 2.6 mThe higher covering needs our according.

®



PIPE2000 Ltd





FLEXWELL® THE PROFESSIONAL SOLUTION FOR ENGINEERS

PIPE2000 Ltd




FHK

28.02.98

– Su

bjec

t to

tec

hnic

al c

hang

e –

FLEXWELL heating cable

3.0Contents

3.0 Contents

3.1 System description3.110 Technical specifications

Design, dimensions, materials,weights and delivery lengths

3.2 Planning, design3.201 Pressure loss diagram3.203 Heat loss diagram3.210 Loop-in method

Laying methodHouse connections (spacing and axial dimensions)

3.211 ConnectorsNominal widths, pipe-connection dimensions,axial and wall-spacing dimensions

3.212 Laying through protective pipes3.213 Horizontal jet drilling method

3.3 Components3.301 Connectors3.303 Straight through connection3.304 T-connections3.305 Wall ducts

StandardDoyma ductPipe lining connection

3.306 House connection bend

3.4 Technic of application3.414 Trenchless laying

3.5 Excavation works, installation3.501 Instructions for excavation works

Technical codes, standards,guidelines for constructionTrench dimensionswall openingCore drill holes

3.502 Instructions for excavation worksStraight through connection

3.503 Instructions for excavation worksT-piece connections

3.504 Instruction for excavation worksHouse connection bends

3.506 Distances to other supply lines

3.6 Master texts for tenders3.600 Supply and laying of

FLEXWELL heating cable3.602 Supply of steel shafts

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3.1System Description

The flexibility of the FLEXWELL heating cableenables unproblematic adaptation to virtually allroute conditions. Obstacles like existing supplylines present no problem because the pipe cansimply be passed over, under or around them.Without regard to classical pipe construction, theshortest route can be selected with theFLEXWELL heating cable.

The FLEXWELL heating cable is a safe solutionespecially in earth subsidence zones and in verywet ground (high groundwater level). It can belaid in water (under water) without problem.

The pipe trenches for the FLEXWELL heatingcable can be dimensioned considerably narrowerthan for rigid pipe systems. This makes significantsavings in underground construction projectspossible.

Due to its flexibility, the FLEXWELL heating cableis especially well suited for the horizontal jetdrilling method. This method is used wherevervaluable surfaces have to be protected or difficultcrossings made.

If one also considers the very short laying time,the FLEXWELL heating cable is not only atechnically perfect, but also very economicalsolution for the transport of district heating withleast-possible nuisance to the district heatingcustomer and general public during theconstruction period.

FLEXWELL heating cable is the protected namefor a flexible pipe system from BRUGG Rohrsyste-me to transport district heating and warm tapwater. This pipe, which is laid underground, hasproven itself in practical applications underextreme and very different conditions for manyyears.

FLEXWELL heating cable is equiped with acorrugated carrier pipe of special steel. Thismaterial is extremely corrosion resistant andtherefore best suited to transport various medialike heating water, warm tap water, drinkingwater, condensation and others.

The corrugations of the carrier pipe not only givethe district heating pipe its flexibility, but alsocompensate the temperature related lengthchanges of the pipe. Elements to absorb theelongation (U-bends, L-limbs, fixed points) asrequired in rigid pipe systems are not necessary.

With its corrugated steel sheath pipe theFLEXWELL heating cable belongs to the family ofsteel casing pipes as far as its expected lifetime isconcerned. The continuous, outer multilayercorrosion protection provides incomparable safetyin the ground during operation.

The heat insulation of the FLEXWELL heatingcable consists of flexible polyurethane hard foam(CFHC-free), which with operating temperaturesof up to 150 oC withstands higher temperaturesthan conventional PUR-insulated pipes.

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3.110Design, Dimensions, Materials,Weights and Delivery Lengths

s1

s2

1 6 2 3 4 5

D3d1

1 Corrugated carrier pipe of nickel-chromium steel X5 CrNi 18-10 (1.4301, EN 10088), (AISI 304) orX6 CrNiMoTi 17-12-2 (1.4571, EN 10088), (AISI 316Ti) or X2 CrNiMo 17-12-2 (1.4404, EN 10088),(AISI 316L)

2 Corrugated sheath pipe of steel Ast 4 LG, DIN 16243 Heat insulation of flexible polyurethane hard foam (CFHC-free), resistant up to 150 oC, thermal

conductivity at 50 oC: 0.032 W/mk4 Two layers of rubber/bitumen polyment separated by a plastic film5 Protective sheath of polyethylene 2YM1 (PE) according to VDE 02096 Electronic detection conductors: (a) 1 x NiCr, (b) 1 x Cu insulated, (c) 1 x Cu

Wire pair: a + b (red + green) = WIREM/BRANDES Systemb + c (green + Cu-white) = Nordic System

*) according to maximum possible drum capacity and normal manufacturing length

Table 1 FLEXWELL heating cable - Dimensions, weights, delivery lengths

Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/22 147/22 200/31

Comparable nominal width [DN] 25 32 50 65 80 100 125 150

Special steel carrier pipe d1 [mm] 30 30 38.9 38.9 60 75.8 98 98 127 147 197.5

s1 [mm] 0.3 0.3 0.4 0.4 0.5 0.6 0.8 0.8 0.9 1.0 1.2

Steel sheath pipe S2 [mm] 0.6 0.6 0.6 0.6 0.7 0.8 0.8 0.9 0.9 0.9 1.3

External diameter D 3max [mm] 94 121 121 156 156 178 178 233 233 233 313

Carrier pipe volume [dm3/m] 0.81 0.81 1.35 1.35 3.12 5.12 8.43 8.43 14.3 17.3 23.2

Weight [kg/m] 3.9 5.4 5.7 8.6 9.1 12.2 12.8 19.3 19.8 20.3 33.2

Max. delivery length*) [m] 1.000 640 640 590 590 480 480 270 270 250 150

Minimum bending radius [m] 1 1.2 1.2 1.5 1.5 2 2 4 4 4 6

Trench width [m] 0.5 0.55 0.55 0.6 0.6 0.65 0.65 0.75 0.75 0.75 1



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3.201Pressure Loss Diagram

[kg

/h]

Average water temperature = 80°C

Example:Flow rate 7000 kg/h;FLEXWELL heating cable type 75/171→ pressure loss 90 Pa/m

Flo

w r

ate

Pressure loss

FHK 75/171

1 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 10 100 1000 [Pa/m]

0.1 0.5 1.0 5 10 50 100 [mmWS/m]

300.000

200.000

100.000987

5

6

4

3

2

2

987

6

5

4

3

10.000

987

6

5

4

3

2

1.000

100

1.0 m/s

0.9 m/s

0.8 m/s

0.7 m/s

0.6 m/s

0.5 m/s0.4 m

/s0.3 m/s

0.2 m/s

FHK 200/310

FHK 147/220

FHK 127/220

FHK 98/171 FHK 98/220

FHK 60/148

FHK 39/116 FHK 39/148

FHK 30/91 FHK 30/116

0.1 m/s

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3.203Heat Loss Diagram

0.6

m

60

50

40

30

20

10

0

70

60

50

40

30

20

10

0

tE = 10 °C λE = 1.2 W/mK

FHK 75/171

FHK 60/148FHK 98/220

FHK 98/171FH

K 20

0/31

0 u. F

HK 14

7/22

0

FHK 127/220

FHK 30/116 u. FHK 39/148FHK 30/91 u. FHK 39/116

0 10 20 30 40 50 60 70 80 90 100 110 120 130

Hea

t lo

ss [

W/m

K]

Hea

t lo

ss [

kcal

/mh

]

Carrier pipe temperature [°C]

Example:Carrier pipe temperature 110° CFLEXWELL heating cable type 127/220→ heat loss 40 W/m or 34 kcal/mh

Conductivity of ground λE = 1.2 W/mKEarth temperature tE = 10° C



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3.210.1Loop-in MethodLaying Method

Due to its flexible construction, the FLEXWELLâ heating cable is suitable for laying by the „loop-in method“from cable technology.

The advantages are:- no underground branches or connections- reduction in risks- increase in safety- reduction in costs- possibility for inexpensive installation of fittings inside the building

Fig. 1 Conventional method of laying, connections and branches underground

Fig. 2 Loop-in method, connections in the building



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3.210.2Loop-in MethodHouse Connections

incoming pipes

4

1

3

min. 350

min. 350 2

Field-run pipes

Flow

Return

Return

Flow

1 FLEXWELL heating cable2 Connector3 Wall duct4 Wall opening (watertight sealing on site)

Depending on the altitude (high, low), a drain or vent possibility must be provided on construction side.For the size and arrangement of the wall openings see worksheets FHK 3.501.3 and FHK 3.501.4.

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3.211.1Axial and Wall-Spacing DimensionsConnection Unions

Type 30/91 to 75/171

Connector with graphite sealing ringtype GR

1 FLEXWELL heating cable2 Wall duct3 Connector type GR4 Wall opening (watertight sealing on site)

(for size and position of the wall openings see worksheetsFHK 3.501.3 and FHK 3.501.4)

4

3

min. 350

L1

l1

1

2

min. 350e1

Type FHK 30/91 30/116 39/116 39/148 60/148 75/171Comparable nominal DN 25 DN 32 DN 50 DN 65

widthsD x s 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9

e1 165 200 200 240 240 270L1 120 130 130 135 145 145I1 220 230 240 245 280 300

Nominal widths, pipe-connection, wall and axial-spacing dimensions Dimensions in mm

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3.211.2Axial and Wall-Spacing DimensionsConnectors

Type 98/171 to 147/220

Connector type A Connector type BBend position optional

Axial and wall-spacing dimensionsConnector type DE

6

1

2

L1

l13

D

min. 350 min. 350

4

Dl2

L1

r

e1

min. 350l3

L1

min. 350

5

Type FHK 98/171 98/220 127/220 147/220Comparable nominal DN 80 DN 100 DN 125

widthsD x s 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0

e1 270 310 310 310L1 235 280 280 280r 122 150 180l1 385 430 430l2 385 455 490l3 400 445 445

1 FLEXWELL heating cable2 Wall duct3 Connector type A4 Connector type B5 Connector type DE

6 Wall opening watertight sealing on site(for size and position of the wall openingssee worksheets FHK 3.501.3 andFHK 3.501.4)

Nominal widths, pipe-connection, wall and axial-spacing dimensions Dimensions in mm

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3.211.3

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Centre distances and wall clearancesfor welded connection

Typ 30/91 to 200/310

Fig. 2: Wall clearances and centre distances

Fig.1: Connection variant G, welded

min. 350 (550)1) e1

min. 350 (550)1)

1

4

2

L1

l1

3

D

Nennweiten, Rohranschluss-, Wand- und Achsabstandsmasse Masse in [mm]

FHK-Typ 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

vergleichbareNennweite

DN 25 DN 32 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150

D x s 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0 168.3 x 4.5

e1 165 200 200 240 240 270 270 310 310 310 410

L1 215 215 215 230 230 235 235 280 280 280 210 (310)1)

l1 377 373 383 388 385 426 426 300 (400)1)

1) Dimensions in brackets apply when connection is installed on site, those without brackets forpipework assembled at our works.

1 FLEXWELL district heating cable2 wall through-connection3 connection4 wall entry with watertight seal made on

site (size and alignment of wall entrysee worksheets FHK 3.501.3 andFHK 3.501.4)

Nominal bores, pipe connection, wall and centre distances dimensions in mm

comparablenominal bore

FHK type



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3.212.1Laying through Protective Pipes

The following instructions must be followed whenlaying FLEXWELL heating cables (FHK) throughprotective pipes:

1. A protective pipe is basically needed for everyFHK to guarantee sound guidance whenpulling the FHK through the protective pipe.The protective pipe must run straight withoutany bends. There may also not be any offsetsat the joints between protective pipes thatseverely impede pulling in of the FHK or rendersame impossible or could cause damage to theprotective PE sheath.

2. In the case of through-pressing it is not alwayspossible to introduce two small protectivepipes into the ground next to each other. Alarge protective pipe is then pressed in instead.In such cases it is necessary to contact usbeforehand to arrange a constructive solution.

3. There must be enough work space at groundlevel in front of and behind the protective pipefor the traction engine with cable trailer to beable to manoeuvre without difficulty and pullthe FHK into the protective pipe withoutdeviating from the route axis.

4. Bends in the route directly in front of andbehind the protective pipes are to be avoided.If this cannot be guaranteed, the routing mustbe arranged with us beforehand.

5. In the case of protective pipes made of PVC,PE or asbestos cement the FHK is pulledthrough the protective pipe without runnersand with runners in the case of protectivepipes of steel and concrete. The internal dia-meter of the protective pipes must be at least20 mm larger than the external diameter ofthe FHK or runners (FHK 3.212.2, fig. 1 and 2).




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3.212.2Laying through Protective Pipes

1) Deviations only after consultation with BRUGG Rohrsysteme2) Min. covering for SLW 60 = 0.80 m, for SLW 30 or under a road pavement 0.60 m3) Min. covering = 0.60 m4) Joints without root seam

Type FHK 30/91 30/116 39/148 75/171 98/220 200/310

39/116 60/148 98/171 127/220

147/220

Max. FHK casing pipe Ø [mm] 95 121 156 178 233 313

Runner spacing L [m] 2.00 2.00 2.50 3.00 3.00 4.00

without runners

PVC sewer pipe acc. to DIN 19 534 2) [mm] 125 x 3 160 x 3.6 200 x 4.5 250 x 6.1 315 x 7.7 400 x 9.8

Clearance between FHK and PVC pipe [mm] 24 32 35 60 67 67

AZ sewer pipe acc. to DIN 19 850 2) [mm] 141 x 8 168 x 9 220 x 10 274 x 12 328 x 14 436 x 18

Internal pipe Ø [mm] 125 150 200 250 300 400

Clearance between FHK and AZ pipe [mm] 30 29 44 72 67 87

with runners

Steel pipe acc. to DIN 2458 3) 4) [mm] 168.3 x 4 219.1 x 4.5 219.1 x 4.5 273 x 5 323.9 x 5.6 406.4 x 6.3

Internal pipe Ø [mm] 160 210 210 263 313 394

Runner (made by Frankenplastik) 3 S19 4 S19 4 T19 2 F + 1 G25 3 F + 1 G25 4 F + 1 G25

Clearance between FHK and pipe [mm] 27 51 20 35 30 31

Fig. 1: Laying of district heating pipe through straight, well-aligned protective pipes without runners.Max. protective pipe length = 30 m1)

FHK

Clearance min. 20 mm

PVC/PE/AZ sewer pipePlug joint for PVC sewer pipePE sewer pipeAZ sewer pipe

Plastic runner

FHK

Clearance min. 20 mm

Protective pipe of steel4) or concrete

Fig. 2: Laying of district heating pipe through straight, well-aligned protective pipes with runners.Max. protective pipe length = 30 m1)

max. 1.0 mmrunner distanceL from end

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3.213Horizontal Jet DrillingMethod

Due to its flexibility, the FLEXWELL heating cable is especially well suited for the horizontal jet drillingmethod described below. This method can be applied to the complete dimensional series from FHK 30/91to FHK 200/310.

The horizontal jet drilling method was developed for trenchless laying of supply lines. It is used wherevervaluable surfaces (parks, nature reserves, pedestrian zones, paved paths, front gardens, etc.) have to beprotected or where difficult crossings (water, canals, busy roads, railway lines, dams, buildings, etc.) haveto be made.

Short description of the methodThe drill consists of a single screwed hollow drill rod and a drill head equipped with nozzles.

A water-bentonite mixture injected under high pressure and in small quantities cuts and loosens the groundand stabilises and lubricates the bore hole.

The special shape of the drill head enables a controlled change in direction and exact control of drilling.

At the end of the pilot hole the drill head is replaced with an expansion head equipped with nozzles andthe FLEXWELL heating cable is coupled to it.

At the same time as the drill rod is retracted the FLEXWELL heating cable is pulled into the bore holeexpanded and supported by the water-bentonite suspension.

Advantages of the system• No trenches, earthworks only for assembly trenches• Little damage to the surface• No consequential damage, e.g. through subsidence of the ground or road surface• Little obstruction/danger to stationary and moving traffic• Protection of trees and plants• Largely independent of the weather• High working speed

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3.301.1Connectors PN 25Type 30/91 to 75/171

Version GR

The district heating pipe connectors with graphitesealing ring type GR (fig.1) is a connectionelement specially designed for FLEXWELL heatingcables for heating and tap water pipes up to asize of DN 65. It is used to establish allconnections to pipe installations in buildings and

Nordic wire white insulation

15 14 13 10

12

4 3 7 1 12 11 10 9 6

Copper wire green insulation

Detector wire NiCr red insulation

85

2

Detail X

X

Fig. 1: Connector with graphite sealing ring type GR

Version for tap waterpipes

Type FHK 30/91 39/116 60/148 75/17130/116 39/148

Comparable nominal width [DN] 25 32 50 65

Pipe union dimensions heating water pipe [mm] 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9

Pipe thread tap water pipe R 1 R 1 1/4 R 2 R 2 1/2

Nominal widths, pipe union dimensions

shafts as well as for transition and T-connections.The electronic detection conductors are passedout of the connectors watertight. This connectorcan withstand a maximum temperature of 150 OCup to nominal pressure stage PN 161).

1 Header ring2 Back-up ring3 Graphite sealing ring4 Connection piece5 Fillister head screw6 Screw cap7 O-ring8 Washer9 Clamp

10 Electronic detectionconductors

11 Electronic detectionconductor screw fitting

12 Silicon cable13 Insulation14 Compression joint15 Heat-shrink sleeve

1) In pressure tests in partially filled trenches or with unfixed connectors max. permissible pressure = 0.5 bar

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3.301.2Connectors PN 16Type 98/171 to 147/220Versions A, B and DE

The heating cable connector (fig.1) is aconnection element specially designed forFLEXWELL heating cable. It is used to establish allconnections to pipe installations in buildings andshafts as well as for straight through andT-connections (FHK 3.303 and FHK 3.304).

The connector comes in three variants (fig. 2). Ondelivery the pipe ends are protected by plasticcaps to protect the carrier pipe from dirt. Theconnectors type A and B (fig. 2) are intended forheating water pipes. The connector type DE also

comes in a special version for tap water pipes. Itcomes with an PTFE-surrounded IT seal. This PTFEsleeve may not be removed or damaged.

The electronic detection conductors are passedout of the connector watertight.

These connectors can withstand a maximumtemperature of 150 OC up to nominal pressurestage PN 161).

1) In pressure tests in partially filled trenches or with unfixed connectors max. permissible pressure = 0.5 bar

Figure 1: Connection union (type A)

24 7 10 8 6 2 5 3 17 18 19 4 14 1 13 15 16

9 11 12

X

23 22 21 20

17

Detector wire NiCr red insulationNordic wire white insulationCopper wire green insulation

Detail X

1 Front ring2 Supporting socket

(alternatively type A, B, DE)3 Lead sealing ring4 Inner wire ring5 Outer wire ring6 Flange ring7 Stud bolt8 Washer9 Hex nut

10 Hex nutCross hole

11 Seal wire12 Lead seal13 Creased packing14 Strain washer15 Permanently plastic synthetic

band16 PE corrosion protection band17 Silicon cable18 Cable bushing19 Copper sealing ring20 Electronic detection

conductors21 Insulation22 Compression joint23 Heat-shrink sleeve24 Protective cap

Type FHK 98/171 127/220 147/22098/220

Comparable nominal width [DN] 80 100 125

Pipe union dimensions [mm] 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0


Type A Heating Type B Heating Type DE Sanitary + HeatingFlange connection dimensions

according to PN 16

Figure 2: Connector versions

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3.301.3Connectors PN 25Type 30/91 to 200/310

Version G, welded

14

1 12 9 8 3 2 4 7 5 13 10 11

WIG seam

1 9 8 6 7 3 2 11 10 4 5

1315

13 12 14 10Detail X TIG seam

X

7 16 6 17 5

Detail Y

4

Y

FLEXWELL heating cableType FHK 30/91 - 147/220

1 Connection piece withwelding socket piece

2 Protective cap3 Threaded piece R 1/2"4 Permanently plastic

jointing compound5 Heat-shrink sleeve6 Electronic detection

conductor bushing R 1/2"7 Sealing ring8 Heat-shrink sleeve9 Silicon cable

10 Electronic detectionconductors

11 Heat-shrink sleeve12 Compression joint13 Heat-shrink sleeve14 Insulation

1 Connection piece withwelding socket piece

2 Protective cap3 Reducing nipple4 Silicon cable5 Electronic detection

conductors6 Compression joint7 Glass fabric sleeve8 Sealing ring9 Screwed cable gland

10 Permanently plastic seal11 Shrink collar12 Weld seam

(protective cap/connection)13 Weld seam

(protective cap/connection)14 Weld seam

(“black“ / “white“)15 Weld seam

(“white“ / “white“)16 Heat-shrink sleeve17 Insulation

Detector wire NiCr red insulationNordic wire white insulationCopper wire green insulation

Nordic wire white insulationCopper wire green insulation

Detector wire NiCr red insulation

FLEXWELL® heating cableType FHK 200/310

Note: In pressure tests in partially filled trenches or with unfixed connectors max. permissible pressure = 0.5 bar.

Type FHK 30/91 39/116 60/148 75/171 98/171 127/220 147/220 200/31030/116 39/148 98/220

Comparable nomina width [DN] 15 32 50 65 80 100 125 150

Pipe union dimensions [mm] 33.7x2.6 42.4x2.6 60.3x2.9 76.1x2.9 88.9x3.2 114.3x3.6 139.7x4.9 168.3x4.5


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3.303.1Straight through Connections PN 16Type 30/91 to 147/220

∅ Dmax

L

7 4 3 6 2 4 5 1

Construction of the Straight through connection PN 16

1 FLEXWELL heating cable with connectors2 Electronic detection conductors3 Joint pipe with supporting sockets4 HP PE reducing socket type RMA5 Shrink collar6 Shrink collar7 PUR hard foam

Type FHK L ∅ Dmax Shrink collar 5 Shrink collar 6[mm] [mm] WTD CLW WTD CLW

30/91 800 215 150x430 lg 145 lg 150x780 lg 145 lg

30/116 800 235 150x520 lg 145 lg 150x840 lg 145 lg39/116 800 235 150x520 lg 145 lg 150x840 lg 145 lg39/148 800 265 150x630 lg 145 lg 150x940 lg 145 lg60/148 800 265 150x630 lg 145 lg 150x940 lg 145 lg75/171 850 290 150x700 lg 145 lg 225x1020 lg 220 lg98/171 850 320 150x700 lg 145 lg 225x1110 lg 220 lg98/220 850 355 150x890 lg 145 lg 225x1220 lg 220 lg

127/220-147/220 850 355 150x890 lg 145 lg 225x1220 lg 220 lg

Dimensions of the straight through connection




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3.303.2Straight through Connections PN 25Type 30/91 to 200/310, Welded

1 3 4 5 6 2 7 1

∅ Dmax

L

∅ Dmax

FLEXWELL heating cableType FHK 30/91 - 147/220

6 4 3 2 7 5 1

L

1 FLEXWELL heating cable with connector2 Orbital weld (construction-side)3 Joint pipe with welding lip4 HP PE shrink joint5 Shrink collar6 PUR hard foam7 Electronic detection conductors

Type FHK L [mm] ∅ Dmax (mm)

30/91 800 215

30/116 - 39/116 800 23539/148 - 60/148 800 265

75/171 850 29098/171 850 320

98/220 - 127/220 - 147/220 850 355200/310 900 320

Dimensionof the straight through connection

1 FLEXWELL heating cable2 Shrink collar3 Metal collar4 Plug5 Welding ring6 PUR hard foam7 Jointing compound

FLEXWELL heating cableType FHK 200/310



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3.304T-Connection

500

1000

~1400

A 3 6 2 7 4 5 1

Construction of the T-connection

100

H

D2

50

1000

~1350

45°

D1

H D D2 50 1 2= ++

View A (all dimensions in mm)

1 FLEXWELL heating cable with connector2 Electronic detection conductors3 T-piece4 HP PE shrink joint5 Shrink collar6 Shrink collar7 PUR hard foam

Depending on the pressure stage, the T-pieces are supplied with the standard or welded connector.



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3.305.1Wall ductWatertight ≤≤≤≤≤ 0.3 bar

3

6

A

4

For

dim

ensi

ons

see

wor

kshe

ets

3.50

1.3

and

3.50

1.4

Type FHK A B Number of sealing rings

30/91 160 40 1

30/116 186 40 139/116 186 40 139/148 221 40 160/148 221 40 175/171 243 40 198/171 243 40 198/220 298 40 1

127/220 298 40 1147/220 298 40 1200/310 378 75 2

1 Fastening ring2 Hexagon screw M6 x 203 Washer4 Cast ring5 Sealing ring6 FLEXWELL heating cable

All dimensions in mm




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3.305.2Doyma Wall Duct with Core Drill Holeor Asbestos Cement Pipe Lining

Presswater-tight >>>>> 0.3 bar

ØDexternalØDinternal

Doyma sealing set type A1 piece per duct

Doyma sealing set type C401 piece per duct

Core drill hole or asbestoscement pipe lining type 3000construction-side

The internal diameter of the core drill hole or asbestos cement pipe lining (= ØDexternal) must bespecified when ordering the Doyma sealing set.

The pipe may not be moved axially after mounting the Doyma sealing set.

FHK Ø Core drill hole or pipe lining Doyma sealing set

DN Type 3000 D internal D external

25 30/91 150 94 15025 30/116 200 121 20032 39/116 200 121 20032 39/148 250 156 25050 60/148 250 156 25065 75/171 250 178 25080 98/171 250 178 25080 98/220 350 233 350100 127/220 350 233 350125 147/220 350 233 350150 200/310 400 313 400



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3.305.3Doyma Wall duct withSteel pipe lining

Presswater-tight ≤≤≤≤≤ 0.3 bar

The internal diameter of the steel pipe lining (= ØDexternal) must be specified when ordering theDoyma sealing set.

The pipe may not be moved axially after mounting the Doyma sealing set.

ØDexternal ØDHØDinternal

Doyma sealing set type C401 piece per duct

Doyma sealing set type A1 piece per duct

Steel pipe lining construction-side(with corrosion protection)

FHKSteel pipe lining Doyma sealing set

DN Type D internal D external

25 30/91 168.3x4.5 94 159

25 30/116 219.1x6.3 121 20632 39/116 219.1x6.3 121 20632 39/148 244.5x6.3 156 23150 60/148 244.5x6.3 156 23165 75/171 273.0x6.3 178 26080 98/171 273.0x6.3 178 26080 98/220 323.9x7.1 233 309100 127/220 323.9x7.1 233 309125 147/220 323.9x7.1 233 309150 200/310 406.4x6.3 313 393




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3.305.4Pipe Lining ConnectionPresswater-tight > 0.3 bar

Ø Da

Shrink collar

pipelining

min. 250 mm

l2l1

D1 x s1D2 x s2

Minimum axialaxial spacing a

of the pipe liningsHP PE reducing cap


30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

External Ø FHK over PE [mm] 94 121 156 178 233 310

Pipe lining of steel with DN 150 DN 150 DN 200 DN 250 DN 300 DN 400

corrosion protection Ø Da x s [mm] (168.3x4.5) (168.3x4.5) (219.1x5.9) (273.0x6.3) (323.9x7.1) (406.4x6.3)

Minimum axial spacing a [mm] 360 360 410 460 500 560

FP runner type 1 F + 1 G25 2 C 15 2 F + 1 G25 2 M36 2 M + 1 N36 2 M + 2 N36

HP PE reducing cap Ø D1 x s1 [mm] 110x3.0 137x2.8 175x3.8 196x4.0 250x4.9 339x4.5

HP PE reducing cap Ø D2 x s2 [mm] 196x4.0 196x4.0 245x4.5 303x5.5 340x6.0 422x6.0

l1 and l2 [mm] 150 150 150 150 150 150

Shrink collar

Connection FHK/reducing joint WTD 150 x 450 lg 150 x 530 lg 150 x 650 lg 150 x 720 lg 150 x 890 lg 225 x 1170 lg

Connection pipe lining/reducing joint WTD 150 x 720 lg 150 x 720 lg 150 x 870 lg 225 x 1060 lg 225 x 1170 lg 225 x 1430 lg

Connecting strap

Connection FHK/reducing joint CLW 145 lg 145 lg 145 lg 145 lg 145 lg 220 lg

Connection pipe lining/reducing joint CLW 145 lg 145 lg 145 lg 220 lg 220 lg 220 lg

RunnerHP PE reducing cap

Steel pipe lining construction-side (with corrosion protection)



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3.306House Connection Bend

D2

700

6

7

5

1 2 3 4

D1

1 FLEXWELL heating cable with connector(A, DE, G or GR)

2 Shrink collar3 HP PE shrink joint4 Shrink collar5 Bend 90O preinsulated, 1.5 x 1.5, steel or special steel6 Labyrinth gland7 End cap

All dimensions in mm

Type FHK FHK external Ø Bend dimensionsD1 DN/D2

[mm] [mm]

30/91 94 25/90

30/116 121 25/11039/116 121 32/11039/148 156 32/12560/148 156 50/12575/171 178 65/14098/171 178 80/16098/220 233 80/200

127/220 233 100/200147/220 233 125/225200/310 313 150/250

07.03



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3.414

07.03

Typ Dmax

[mm]

FZ

[KN]

Empf. min.Bohrlochradius

[m]

Empf. min.Bohrlochdurchm.

[mm]

NormaleBohrungslänge

[m]FHK 30/ 91 100 12 25 150 121FHK 39/116 125 15 30 185 112FHK 60/148 160 20 35 240 110FHK 75/171 180 30 50 270 141FHK 98/171 180 40 50 270 190FHK 127/220 230 50 100 345 167FHK 147/200 230 60 100 345 201FHK 200/310 320 100 150 480 224

0

50

100

150

200

250

300

350

400

450

500

30/9

1

39/1

16

60/1

48

75/1

71

98/1

71

127/

220

147/

220

200/

310

FLEXWELL-Fernheizkabel

Boh

rung

slän

ge (

m)

The “normal drilling length = � ” is a standard value and can be achieved under soil and workingconditions with no particular difficulties. The “maximum drilling length“ for the specific projectmust be determined taking into consideration the local conditions and permissible tractional forcesin each case.

FZ = permissible tractional force using waterjet drilling techniqueA special traction head must be used for this.The borehole should be widened to the recommended minimum borehole diameter before pullingin the FLEXWELL district heating cable..

Laying without trenches

FLEXWELL district heating cable

drill

ing

leng

th (

m)

recommendedmin. borehole radius

recommendedmin. borehole diam.

normaldrilling length

Type



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3.501.1Instructions for Excavation WorksTechnical Codes, Standards,Guidelines for Construction

Technical codes, standards

At least the following standards, codes and directives must be followed for the underground works forFLEXWELL heating cable:

DIN 1072 Road and Foot Bridges, Design LoadsDIN 4033 Drainage Channels and Lines of Prefabricated Pipes, Guidelines for ConstructionDIN 4124 Building Trenches and Trenches, Embankments, Working Space Widths, SheetingDIN 18300 VOB, Part C, General Technical Specifications; EarthworksDIN 18303 VOB, Part C, General Technical Specifications; Excavation Lining WorksDIN 18304 VOB, Part C, General Technical Specifications; PilingDIN 18305 VOB, Part C, General Technical Specifications; De-watering WorksDIN 18307 VOB, Part C, General Technical Specifications; Underground Gas and Water Piping WorksDIN 18308 VOB, Part C, General Technical Specifications; Drainage WorksDIN 18320 VOB, Part C, General Technical Specifications; Landscape Gardening WorksDIN 18330 VOB, Part C, General Technical Specifications; Bricklaying WorksDIN 18337 VOB, Part C, General Technical Specifications; Sealing against Non-pressing WaterDIN 18354 VOB, Part C, General Technical Specifications; Asphalt Coating WorksInstruction Sheet “Protection of Pipe Trenches and Building Trenches“1

Instruction Sheet on the Filling of Pipe Trenches2

Accident Prevention Regulations

The trench widths “B“ given in the table in worksheet FHK 3.501.2 are recommended values. They do notfree the construction company of its obligation to pay due regard to accident prevention regulations andthe above-mentioned standards and codes

Guidelines for construction

The minimum distances from other supply lines given in worksheet FHK 3.506 must be complied with.

For trench-work specifications for straight through connections see worksheet FHK 3.502, for T-piecesFHK 3.503.

1 Employers’ Liability Insurance Association for the Building Trade2 Society for the Research into Roads, Work Group Underground, Maastrichter Str. 45, D-50672 Cologne




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FLEXWELL heating cable (FHK) Type 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

External diameter FHK d [mm] 94 121 156 178 233 313

Trench depth Tmin for SLW 60 1) [m] 0.80 0.85 0.85 0.90 0.95 1.05

Minimum covering t for SLW 60 [m] 0.60 0.60 0.60 0.60 0.60 0.60

Trench width B [m] 0.50 0.55 0.60 0.65 0.75 0.95

Working space width 2B [m] 1.00 1.10 1.20 1.30 1.50 2.00

Working space length Lk [m] 0.50 0.50 1.00 1.00 1.50 2.50

Minimum trench radius2) Rmin. [m] 1.00 1.20 1.50 2.00 4.00 6.00

Excavation 3) for SLW 60 [m3/m] 0.40 0.47 0.51 0.59 0.72 1.00

Sand filling [m3/m] 0.14 0.16 0.18 0.20 0.24 0.39

3.501.2Instructions for Excavation WorksTrench Dimensions

1) SLW 60 = 100 kN wheel load according to DIN 10722) Smaller radii only after consultation with BRUGG Rohrsysteme3) Excavation quantities without consideration of the slope inclination

Trench and working space dimensions, excavation and sand-filling quantitiesThe trench widths “B“ are recommended values. Please pay attention to valid technical rules, directives andaccident prevention regulations.

2B

LK

A

Rmin

A

B

2 3 1 4

Trench dimensions

Fig. 1: Trench plan

0.1

0.1

d

min. 0.6

0.3

x xB

x

Tmin

1 5 6 7

Fig. 2: Trench sectional view A-A(dimensions in m)

1 FLEXWELL heating cable (FHK)2 Connector3 Wall sealing ring (wall duct)4 Working space in front of buildings and shafts5 Trench warning strip (delivery by BRUGG; laying

construction-side)6 Sand filling (grain size 0 - 4 mm)7 Filling material (reusable excavated material)

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3.501.3Instructions for Excavation WorksWall Openings

Fig. 3: Wall opening FLEXWELL connector

a b

min. 0.35 m

h

a

min.0.35 m

32

4

1

min. 2 x h

min. 2 x b min. 0.35 m

b

a

h

a

min.0.35 m

Fig. 4: Wall opening for loop-in method

For the loop-in method the wall openings must be enlarged according to thepipe route and the dimensions below (check building statics if necessary).

1 FLEXWELL heating cable (FHK)2 Connector3 Wall duct4 Concrete (wall opening - watertight sealing on site)

Dimensions wall opening, wall distances Dimensions in m

FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

a 0.26 0.24 0.22 0.21 0.18 0.10

b 0.35 0.45 0.50 0.55 0.65 0.85h 0.20 0.25 0.30 0.35 0.40 0.50




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3.501.4Core Drill Holes*)*) only applies to standard wall duct

Ø D Ø BA Axial spacingB Core drill hole diameterC Distance trench ground-pipe axisD Diameter wall duct

Type FHK A B C D

30/91 260 250 50 160

30/116 310 300 60 18539/11639/148 310 300 80 22160/14875/171 360 350 90 24398/17198/220127/220 410 400 120 298147/220200/310 460 450 155 378

Minimum dimensions in mm

B

For core drill holes for Doyma seals see worksheet 3.305.2

A

B

Top of trench groundC



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3.502Instructions for Excavation WorksStraight Through Connections

Fig. 1: Working space for straight through connections (side view)

0.1

0.1

0.3

42

3

1

1 FLEXWELL heating cable2 Straight through connection3 Sand filling (0 - 4 mm round grain)4 Filling material (reusable excavated material)

Type FHK A A1 Trench width Min. trench widthB B1

30/91 0.5 1.530/116 0.55 1.5539/116 1.5 2.5 0.55 1.5539/148 0.6 1.660/148 0.6 1.675/171 0.65 1.6598/171 0.65 1.6598/220 2.0 4.0 0.75 1.75127/220 0.75 1.75147/220 0.75 1.75200/310 2.0 5.0 1.00 2.00

Dimensions in mm

In event of repair dimension A1 has to be increased by 2.5 m to bend out the FLEXWELL heating cable.

Fig. 2: Working space for straight through connections (ground plan)

B1B

A

A1

0.1



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3.503.1Instructions for Excavation WorksT-Piece ConnectionsBranch downwards

H = Difference in height between trench ground main pipe and trench ground branch pipe

FHK Dimension H FHK branch pipemainpipe

30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

30/91 0.23

30/116 0.23 0.24

39/116 0.23 0.24 0.25

39/148 0.23 0.24 0.25 0.26

60/148 0.23 0.24 0.25 0.26 0.28

75/171 0.23 0.24 0.25 0.26 0.28 0.30

98/171 0.23 0.24 0.25 0.26 0.28 0.30 0.32

98/220 0.23 0.24 0.25 0.26 0.28 0.30 0.32 0.34

127/220 0.23 0.24 0.25 0.26 0.28 0.30 0.32. 0.34 0.36

147/220 0.23 0.24 0.25 0.26 0.28 0.30 0.32 0.34 0.36 0.36

200/310 0.19 0.20 0.21 0.22 0.24 0.26 0.28 0.30 0.32 0.32 0.36

Table 1 Branch downwards (fig. 2) Dimensions H in m

~1.3 m 1.8 m 1.8 m ~1.3 m0.9 m 0.9 m

0.250.25

0.9 m

0.9 m

1.8 m

Fig.1: T-piece connection, working space(ground plan)Dimensions apply to all FHK types

4 2 3 1

0.10.3

H

Fig. 2: T-piece connection, working spaceBranch downwards (sectional view)

Min. covering 0.6 mm

Trench ground main pipe1 FLEXWELL heating cable (FHK)2 T-branch3 Sand filling (0 - 4 mm round grain)4 Filling material (reusable excavated material)




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H = Difference in height between trench ground main pipe and trench ground branch pipe

FHK Dimension H FHK branch pipemainpipe

30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310

30/91 0.23

30/116 0.24 0.24

39/116 0.25 0.25 0.25

39/148 0.26 0.26 0.27 0.27

60/148 0.28 0.28 0.28 0.28 0.28

75/171 0.30 0.30 0.30 0.30 0.30 0.30

98/171 0.32 0.32 0.32 0.31 0.31 0.32 0.33

98/220 0.34 0.34 0.34 0.34 0.34 0.34 0.35 0.35

127/220 0.36 0.36 0.36 0.36 0.36 0.36 0.38 0.38 0.36

147/220 0.36 0.36 0.36 0.36 0.36 0.36 0.38 0.37 0.36 0.36

200/310 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.36

Table 1 Branch upwards (fig. 2) Dimension H in mm

3.503.2Instructions for Excavation WorksT-Piece Connections

Branch Upwards

Fig.1: T-piece connection, working space(ground plan)Dimensions apply to all FHK types

Fig. 2: T-piece connection, working spaceBranch upwards (sectional view)

1 FLEXWELL heating cable2 T-branch3 Sand filling (0 - 4 mm round grain)4 Filling material (reusable excavated material)

4 2 3 1

0.1

0.3

H

~1.3 m 1.8 m 1.8 m ~1.3 m0.9 m 0.9 m

0.250.25

0.9 m

0.9 m

1.8 m

Min. covering 0.6 m

Trench ground mainpipe



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3.504Instructions for Excavation WorksHouse Connection Bend

h

a2

1.50

B1)2xB

a1

b

Type FHK Minimum dimensionsB a a2

2) b h T max.Trench width Side wall Wall distance Length Width Distance

distance to to centre of of the of the to bottomcentre of breakthrough breakthrough breakthrough of the

breakthrough foundation

30/91 0.50 0.30 0.15 0.49 0.20 1.00

30/116 0.55 0.32 0.16 0.52 0.25 1.0039/116 0.55 0.32 0.16 0.53 0.25 1.0039/148 0.60 0.34 0.16 0.56 0.30 0.9860/148 0.60 0.34 0.16 0.57 0.30 0.9875/171 0.65 0.36 0.17 0.62 0.35 0.9898/171 0.65 0.38 0.18 0.66 0.35 0.9798/220 0.75 0.41 0.20 0.72 0.40 0.96127/220 0.75 0.42 0.20 0.74 0.40 0.95147/220 0.75 0.43 0.21 0.77 0.40 0.93200/310 0.95 0.53 0.26 0.95 0.50 0.92

1) Measured to trench ground2) Dimension a2 calculated on the assumption that there are no obstacles in the way of the bends in the

form of foundations, etc.

Fig.2: House connection bendGround plan

Fig.1: House Connection bendSectional view

0.20

0.10

1 8 7 2 4 35

6

0.10

Tmax.

1 FLEXWELL heating cable (FHK)2 HP PE shrink joint3 House connection bend4 Shrink collar5 Labyrinth gland6 End cap7 Sand filling (0 - 4 mm round grain)8 Filling material

(reusable excavated material)



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3.506Distances to OtherSupply Lines

The temperature of the earth in the immediate vicinity of underground heating cables is higher thannormal.

The transmission capacity of underground electric cables can be influenced by this. Reasonable minimumdistances between the supply lines and heating cables are therefore necessary (see also VDE 0100 and VDE0101).

Fig. 1: Crossing lines

Table 1:Minimum distance to crossing lines

Type of minimum supply line distance

1-kV, signal, measuring cables 0.3

10-kV or one 30-kV cable 0.6

Several 30-kV cables or 1.0cables above 60 kV

Gas and water pipes 0.2

Dimensions in m

Table 2:Minimum distance to parallel lines

Type of Min. distance supply line Parallel lines

Length5 m > 5 m

1-kV, signal, measuring cables 0.3 0.3

10-kV or one 30-kV cable 0.6 0.7

Several 30-kV cables or 1.0 1.5cables above 60 kV

Gas and water pipes 0.4 0.4

Dimensions in m

1

2

3

Fig. 2: Parallel lines

1

3

2

1 Heating cable2 Other supply lines3 Distance lines

07.03



PIPE2000 Ltd





FLEXWELL® FSR SAFETY PIPE

PIPE2000 Ltd




PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email [email protected]

FLEXWELL Safety Pipe®

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3.101Systems Description

FLEXWELL Safety Pipe

FLEXWELL Safety Pipe is a coaxial double-walled, fl exible and endless piping system supplied ex works coiled on reels. It is designed for permanent leak monitoring and approved for the transport of water pollutant, hazardous and fl ammable products.It is available in sizes from DN 15 to DN 150 with pres-sure ratings up to PN 25.

Leak monitoringThe annular gap between the primary and outer containment pipes forms a surveillance space which enables permanent leak monitoring by approved leak detectors working on the vacuum or positive pressure principle.

Type approvalFLEXWELL Safety Pipe with leak monitoring is a recog-nized leak detection system within German regulati-ons.

There a leak detection system is defi ned as all the equipment necessary for the detection of leaks (the monitoring space, the leak alarm, double-walled piping system, leak detection medium)

Legal basis- environmental legislation and water protection

requirements- European standards for leak detection systems- Product is in compliance with all German environ-

mental and water purity legislation as well as- constructional regulations and industrial safety acts

in respect of fi re and explosion prevention.

The operation of this system complies with the high-est European safety level. Systems of this class show a leak either above or below the fl uid surface in double-walled safety systems. They are constructed for safety and ensure that no leaking product can escape into the environment.

Laying and installation- above and below ground - can be laid as a continuous length direct from the

drum/coil into the trench or onto the pipework trestles

- fast and simple to lay from A to B- short installation times- no welding necessary along pipe route- during laying no construction or pressure tests

needed- no fi eld joints needed, bendable- changes of direction are taken up by the fl exible

pipe system- highly eff ective corrosion-proofi ng along the entire

length- high degree of corrosion safety- acceptance test only after complete laying/instal-

lation by function testing of the leak detection system

- installation/laying carried out by trained and licensed contractors

- - support from BRUGG installation and service orga-nization

Advantages of the system- planning security through type-approved system- lengths up to 500m available- clearly defi ned procedures for approval, acceptance

and operational readiness of - your installation- ex works system with all necessary expertises, test

and quality control documentation

Construction of FLEXWELL Safety Pipe 1 primary pipe (copper, stainless steel, thermo plastics)2 surveillance space3 outer containment pipe4 corrosion-proofi ng5 connecting joint

5 1 2 3 4 5 1 2 3 4

Quality, process, pressure and material testing are carried out by qualifi ed independent test institutes and our internal quality control department as required by the compliance certifi cation.

PIPE2000 LtdTel No 01268 759567Fax No 01268 569932email [email protected]


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3.102FLEXWELL Safety Pipe SystemProduct Range

The FLEXWELL Safety Pipe Systemis a family of pipework assemblies supplied in “endless” lengths, capable of leak-monitoring and suitable for the transport of water pollutant, fl ammable/non-fl am-mable or otherwise hazardous fl uids and gases. The system is supplied with all components for installation of the piping and a complete range of leak detection equipment.

FLEXWELL Safety PipeDN-15 with smooth-bore copper primary pipe and corrugated copper outer containment pipeWorksheet FSR 3.201

FLEXWELL Safety PipeDN 20 - DN 150 with thermoplastic primary pipe and corrugated steel outer containment pipe (only on corrugated steel outer containment pipe (only on request)

FLEXWELL Safety Pipe Componentsf. i.: Connecting jointsWorksheet FSR 3.300 ...

Leak monitoring for FLEXWELL Safety PipeWorksheets LDS 3.400 ...

Important data sheets forFLEXWELL Safety Pipes:– head loss diagrams: Worksheets FSR 3.800– Details for underground installation: Worksheet FSR 3.800 ...– Wall and manhole entry: Worksheets FSR 3.700 ...

FLEXWELL Safety PipeDN 25 - DN 80 with corrugated copper primary pipe and corrugated steel outer containment pipeWorksheet FSR 3.201

FLEXWELL Safety PipeDN 25 - DN 50 - with corrugated stainless steel prima-ry pipe and outer containment pipe and protective jacket Worksheet FSR-M 3.211

DN 25 - DN 100, except DN 40 with corrugated stain-less steel primary pipe and corrugated steel outer containment pipe Worksheet FSR 3.202

Consisting of a primary pipe, reinforcing bands, a cor-rugated outer containment pipe, a surveillance space, a double layer of BRUGG bitumen and a polyethylene jacket as external corrosion-proofi ng. Refer to the separate and special documentation co-vering technical details of this variant !



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Product DescriptionFlanged system fi ttings

with monitored gasket seals

3.103

Flanged pipe fi tting with monitored gasket sealsfor the transport of hazardous substances

Solvents, i. e. tri/perchloroethylene, toluene, etc.petrolalcoholsoils, emulsionslyesacidsgases

The safe transport of hazardous substances makes continually growing demands on the constructors of fuel depots and industrial plants. In order to optimize the use of FLEXWELL safety piping, which already off ers a high level of safety anyway due to its double-walled construction, special fl anged pipe connections, elbows, T-pieces and through-connections with mo-nitored gasket seals are available. They can be inte-grated into the leak monitoring system so that per-manent, uninterrupted monitoring of the entire pipe system from the tank to the user becomes possible.

These double-walled and monitored fi ttings must be located where they are clearly visible. It is not permit-ted to install fl anged fi ttings below ground.

The principle of monitoring gasket seals consists in

having a radial groove extending full circle over the sealing surface of the fl anged fi tting that connects via a drilled port hole to the surveillance space of the safety pipe.

The complete system comprises the double-walled, fl exible FLEXWELL Safety Pipe, the monitored pipe fi ttings and the leak monitoring system.

Due to the fl exibility of the pipe, the use of elbow fi t-tings is unnecessary within certain bending radii, and the entire pipe length can be laid in one piece.



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3.201FLEXWELL Safety Pipewith copper primary pipe

Product Description

1. FLEXWELL Safety Pipe with smooth-bore copper primary pipe

2. FLEXWELL Safety Pipe with corrugated copper primary pipe

type DN PN d D wall of internal volume weight bending article PE-HD primary surveillance radius No. jacket pipe space mm mm mm l/m l/m kg/m cm


PE-HD primary surveillance radius No. jacket pipe space mm mm mm l/m l/m kg/m cm

FSR 16/30 FSR 16/30 15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90 15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90

copper primary pipe surveillancespace

corrugated copper outer containment pipe

corrosion-proofi ng(bitumen)

PE-HD jacket

dd D

corrugated copper primary pipe surveillance space

corrugatedsteel outer

containment pipecorrosion-proofi ng

(bitumen)

PE-HD jacket

D

helically wrappedsteel banding


type DN PN d D wall of internal volume weight bending article PE-HD primary surveillance radius No. jacket pipe space mm mm mm l/m l/m kg/m cm jacket pipe space mm mm mm l/m l/m kg/m cm

FSR 30/48 FSR 30/48 25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 25 25 30 48 2 0.8 0,38 1.9 50 821 005 90FSR 39/60 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90FSR 48/71 40 25 48 71 2 2 0.65 3.8 60 821 004 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90

FSR 60/83 FSR 60/83 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 FSR 83/120 FSR 83/120 80 16 83 120 3 6 2 9.2 100 821 009 90 80 16 83 120 3 6 2 9.2 100 821 009 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90

type DN PN d D wall of internal volume weight bending article PE-HD primary surveillance radius No.

mm mm mm l/m l/m kg/m cm

25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90



25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90


25 25 30 48 2 0.8 0,38 1.9 50 821 005 90 32 25 39 60 2 1.3 0.41 2.3 60 821 006 90 40 25 48 71 2 2 0.65 3.8 60 821 004 90 50 25 60 83 2.5 3 0.73 4.8 70 821 007 90 80 16 83 120 3 6 2 9.2 100 821 009 90

dd


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90



15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90



15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90


15 25 16 30 1.5 0.2 0.12 1.0 30 821 003 90



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3.202FLEXWELL Safety Pipewith stainless steel primary pipe

Product Description

3. FLEXWELL Safety Pipe with corrugated stainless steel primary pipe Material No. 1.4571 and 1.4539

corrugatedstainless steelprimary pipe

surveillance space

corrugatedsteel outer

containment pipe corrosion-proofi ng

(bitumen)

PE-HD jacket

dd D

helically wrappedsteel banding

Primary pipe: Material No. 1.4539

FSR 30/48 25 25 30 48 2 0,8 0,38 1,8 50 821 105 95FSR 39/60 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95FSR 60/83 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95

FSR 30/48 25 25 30 48 2 0,8 0,38 1,8 50 821 105 91FSR 39/60 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91FSR 60/83 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91FSR 83/120 80 25 83 120 3 6 2 9,2 100 821 109 91FSR 127/175 100 25 127 175 4 14 4 18,4 150 821 110 91




25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91

25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91


25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91



25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91



25 25 30 48 2 0,8 0,38 1,8 50 821 105 91 32 25 39 60 2 1,3 0,41 2,4 60 821 106 91 50 25 60 83 2,5 3 0,73 4,8 70 821 107 91 80 25 83 120 3 6 2 9,2 100 821 109 91 100 25 127 175 4 14 4 18,4 150 821 110 91





25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95

25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95



25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95



25 25 30 48 2 0,8 0,38 1,8 50 821 105 95 32 25 39 60 2 1,3 0,41 2,4 60 821 106 95 50 25 60 83 2,5 3 0,73 4,8 70 821 107 95


Other materials for primary and outer containment pipe available on request.

Primary pipe: Material No. 1.4571



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3.211

1. FLEXWELL Safety Pipe® with smooth-bore copper inner pipe

copper inner pipe 18 x 1 corrugated copper outer pipe protective jacket

d D1

surveillance space

FSR-M 16/30 15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90

Typ DN PN d D D1 Volume Weight radius Article- inner pipe surveillance No. mm mm mm l/m space l/m kg/m cm

Typ DN PN d D D1 Volume Weight radius Article- inner pipe surveillance No. mm mm mm l/m space l/m kg/m cm inner pipe surveillance No. mm mm mm l/m space l/m kg/m cm

15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90

Typ DN PN d D D1 Volume Weight radius Article- inner pipe surveillance No.

15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90

2. FLEXWELL Safety Pipe® with corrugated stainless steel inner pipe

15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


15 25 16 24,5 27 0,2 0,12 0,95 30 821 013 90


FSR-M 30/48 25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91FSR-M 39/60 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91FSR-M 60/83 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


Typ DN PN d D D1 Volume Weight radius Article- inner pipe surveillance No. mm mm mm l/m space l/m kg/m cm inner pipe surveillance No. mm mm mm l/m space l/m kg/m cm

25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91

Typ DN PN d D D1 Volume Weight radius Article- inner pipe surveillance No.

25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91


25 25 30 43 46,2 0,8 0,38 1,3 50 821 115 91 32 25 39 53,5 57,1 1,3 0,41 2,1 60 821 116 91 50 25 60 76,5 80,5 3 0,73 3,6 70 821 117 91

corrugated inner pipematerial: 1.4404 oder

1.4571

surveillance space

corrugated outer pipe material: 1.4301 oder 1.4404

protective jacket

d D1

steel reinforcing bands

DDD

FLEXWELL Safety Pipewith protective jacket type: FSR-M

Product Description



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Standard ConnectingJoint with stub end,

jointing of primary pipe: brazing

3.301

Material: threaded sleeve made of brass

Warning: Only brazing materials approved by BRUGG may be used.

For installing the connection: see Installation Instructions FSR 3.920 ...

threaded sleeve

primary tubebrazed to sleeve

heat-shrink sleeve

containment pipebrazed to sleeve

measuring branch forconnection to leak detectorsee worksheet FSR 3.350

copper pipe18 x 1

PE jacketremoved from

containment pipe

overlapheat-shrink sleeve -

PE jacket

Reference measuring line for cutting to lengthof pre-manufactured coils of

FLEXWELL safety piping FSR 16/30

approx. 100 26 60 min. 80

∠ 4

0

screw plug, to be removed whenconnecting to leak detector

FLEXWELL safety pipe type FSR 16/30



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type DN d d1 flange acc. DIN 2656 A B C article No. article No.DN D ø k bolts* collar split collar

mm mm mm mm No. off mm mm mm flange flange

FSR 30/48 25 50 68 25 115 85 M12 x 75 4 1.5 55 80 829 355 90 829 355 50FSR 39/60 32 60 78 32 140 100 M16 x 80 4 1.5 54 80 829 356 90 829 356 50FSR 48/71 40 70 88 40 150 110 M16 x 80 4 1.5 51 80 829 354 90 829 354 50FSR 60/83 50 84 102 50 165 125 M16 x 85 4 1.5 49 100 829 357 90 829 357 50FSR 83/120 80 120 138 80 200 160 M16 x 90 8 1.5 54 100 829 359 90 829 359 50

3.302Standard Connecting Joint with collarand single or split collar flanges,jointing of primary pipe: brazing

Ø d

Ø D

threaded sleevewith collar flangeas per DIN 2656

primary copper pipebrazed to sleeve

heat-shrink sleeve

containment pipebrazed to threaded sleeve


brazed banding

PE jacket removedfrom convolutedcontainment pipe


PE jacket

A B C min. 80

screw plug, to beremoved whenconnecting toleak detector

two set of splitcollar flanges

see WorksheetFSR 3.340

cutback lengthof casing pipe

Ø k

Ø d

1

Material:Threaded sleeve made ofsteel R-St 37.0 acc. DIN 1629Collar flange and split collar flangesmade of steel USt 37-2acc. DIN 17100,hot-dipped galvanized

* The lengths of bolts shown in table above are intended for bolting to a standard welding neck flange acc. toDIN 2635. For the double set of split flanges use bolts 10 mm longer. Bolts and nuts are not included in the setsupplied.Warning: Only brazing materials approved by BRUGG may be used.For installing the connection: see Installation Instructions FSR 3.920 ...

FLEXWELL safety pipe type FSR 30/48 to FSR 83/120



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3.303Connecting Jointwith threaded male end,

jointing of primary pipe: brazing

d

primary copper pipebrazed to sleeve

heat-shrink sleeve



brazed banding



PE jacket

A B C min. 80



R

Material:Threaded sleeve made of steel R-St 37.0 acc. DIN 1629

Warning: Only brazing materials approved by BRUGG may be used.For installing the connection: see Installation Instructions FSR 3.920 ...

FSR 30/48 25 R 1 1/2 40 52 5 73 80 829 353 93FSR 39/60 32 R 2 50 65 5 72 80 829 354 93FSR 48/71 40 R 2 1/2 65 76 5 79 80 829 355 93FSR 60/83 50 R 2 1/2 65 85 5 87 100 829 356 93

type DN Connection d A B C article No.Whitworth - DNpipe thread mm mm mm mm

FLEXWELL safety pipe type FSR 30/48 to FSR 60/83



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3.308Monitored connectionwith slide-on flange – Part 1

Joined by: hard-soldering

type DN d d1 d2 flange acc. to DIN 2656 A B C Art.-No. without measuring branch

DN D ø k bolts* slide-on two-partmm mm mm mm mm Stück mm mm mm flange slide-on flange

FSR 30/48 25 50 91 60 40 150 110 M16 x 70 4 3 60 80 829 481 91 829 481 80FSR 39/60 32 60 105 75 50 165 125 M16 x 80 4 3 59 80 829 482 91 829 482 80FSR 48/71 40 70 126 94 65 185 145 M16 x 80 8 3 61 80 829 483 91 829 483 80FSR 60/83 50 84 126 94 65 185 145 M16 x 80 8 3 59 100 829 484 91 829 484 80FSR 83/120 80 120 167 130 100 235 190 M20 x 90 8 3 69 100 829 485 91 829 485 80

Screw socket with and without measuring branch available (Article No. for Measuring branch 829 335 00)* * The screw length given is intended for joining to a blank flange acc. to DIN 2635. For two-part flanges use screwlengths 10mm longer. Screws and nuts are not included in the material delivered.Only BRUGG solder Type 8.50.34 may be used!Installation of the connection see installation instructions FSR 3.920 ...

dD

MeaScrew socketwith slide-on flange

acc. to DIN 2656

hard-solderingcopper inner

pipe

shrink sleeve

hard-solderingouter pipe

Measuring branch for theconnection to leak detector

see Worksheet 3.350

hard-solderingreinforcing bands

Removing thePE jacket fromthe outer pipe

Overlapshrink sleeve –

PE jacket

A B C min. 80

two-partslide-on flangessee WorksheetNo.FSR 3.340

Pulling off the outerpipe from the inner

pipe

Ø k d1

Material:Screw socket made of steel St 37.0 acc. to DIN 1629slide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100,hot-galvanized

d2

Remove the lockingscrew whenconnecting to theleak detector.

Leak-monitored connection Type: Part 1for connection to leak-monitored elbow Worksheet 3.502and leak-monitored T-piece Worksheet 3.503



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3.309Monitored connectionwith slide-on flange – Part 2Joined by: hard-soldering

type DN d d1 d2 flange acc. to DIN 2656 A B C Art.-No. without measuring branch

DN D ø k bolts* slide-on two-partmm mm mm mm mm Stück mm mm mm flange slide-on flange

FSR 30/48 25 50 87 60 40 150 110 M16 x 70 4 1,5 61,5 80 829 481 92 829 481 81FSR 39/60 32 60 101 75 50 165 125 M16 x 80 4 1,5 60,5 80 829 482 92 829 482 81FSR 48/71 40 70 121 94 65 185 145 M16 x 80 8 1,5 62,5 80 829 483 92 829 483 81FSR 60/83 50 84 121 94 65 185 145 M16 x 80 8 1,5 60,5 100 829 484 92 829 484 81FSR 83/120 80 120 161 130 100 235 190 M20 x 90 8 1,5 70,5 100 829 485 92 829 485 81


hard-solderingcopper inner pipe

A B C min. 80

Material:Screw socket made of steel St 37.0 acc. to DIN 1629slide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100, hot-galvanized O washer seal: Choice of material acc. to material to be transportedOnly to be supplied by BRUGG

dD

Ø k d1 d2

Leak-monitored connection Type: Part 2Of Part 1 as leak-monitored through-connection acc. to Worksheet 3.501


acc. to DIN 2656

shrink sleeve



see Worksheet 3.350





PE jacket



pipe



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3.310Standard Connecting Joint with collarand single or split collar flanges,

jointing of primary/containment pipe: WIG welding/brazing

Type DN d d1 Flange acc. DIN 2656 B C Article No. Article No. Article No. Article No.DN D ø k screws* 1.4571 1.4571 1.4539 1.4539

mm mm mm mm no. mm mm slide-on flange two-part flange slide-on flange two-part flange

FSR 30/48 25 50 68 25 115 85 M12 x 85 4 63 80 829 355 91 829 355 51 829 345 91 829 345 51FSR 39/60 32 60 78 32 140 100 M16 x 90 4 62 80 829 356 91 829 356 51 829 346 91 829 346 51FSR 60/83 50 84 102 50 165 125 M16 x 95 4 62 100 829 357 91 829 357 51 829 347 91 829 347 51FSR 83/120 80 120 138 80 200 160 M16 x 110 8 72 100 829 359 91 829 359 51 – –FSR 127/175 100 172 190 125 270 220 M24 x 120 8 74 130 829 360 91 829 360 51 – –

threaded sleevewith collar flangeas per DIN 2656

primary stainlesspipe TIG-welded

to sleeve

heat-shrink sleeve



brazed banding



PE jacket

B C min. 80


two set of splitcollar flanges

see WorksheetFSR 3.340


Material:DN 25, DN 32 and DN 50: Threaded sleevemade of Mat. No. 1.4571, 1.4539 acc. to DIN 17440.DN 80 and DN 100: Threaded sleeve ofMat. No. R-St 37.0 + 1.4571.Choice of material acc. to primary pipe materialof the FLEXWELL Safety Pipe.Collar flange and split collar flanges made of steelUSt 37-2acc. DIN 17100, hot-dipped galvanized.

* The lengths of bolts shown in table above are intended for bolting to a standard welding neck flange acc. toDIN 2635. For the double set of split flanges use bolts 10 mm longer. Bolts and nuts are not included in the setsupplied.Warning: Only brazing materials approved by BRUGG may be used.For installing the connection: see Installation Instructions FSR 3.920 ...

Ø d

Ø D

Ø k

Ø d

1FLEXWELL safety pipe type FSR 30/48 to FSR 127/175



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3.311Connectionwith thread lug

Joined by: WIG welding/hard-soldering

Material:Screw socket –stainless steelMaterial No.: 1.4571, 1.4539*acc. to DIN 17440Choice of material depends onmaterial of inner pipe ofFLEXWELL Safety Pipe

* Material: 1.4539 – only on request

Only BRUGG solder Type 8.50.34 may be used!Installation of the connection see installation instructions FSR 3.920 ...

FSR 30/48 25 R 1 1/2 40 52 71 80 829 355 97 829 345 41FSR 39/60 32 R 2 50 63,5 72 80 829 356 97 829 346 41FSR 60/83 50 R 2 1/2 65 85 82 100 829 358 97 829 347 41

type DN Connection d B C Article-No. Article-No.Whitworth- DN

pipe thread lug mm mm mm 1.4571 1.4539

WIG weldingstainless steel

inner pipe


see Worksheet 3.350



PE jacket

B C min. 80

Remove thelocking screwwhen connecting tothe leak detector.


pipe

FLEXWELL-Safety Pipe® Ttype FSR 30/48 bis FSR 60/83

d R

shrink sleeve

hard-solderingouter pipehard-soldering

reinforcing bands



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type DN d d1 d2 flange acc. to DIN 2656 A B C Art.-No. without measuring branchDN D ø k bolts* 1.4571 1.4571 1.4539 1.4539

m mm m m m mm mm Stck. mm mm mm slide on flangetwo- part slide onslide on flangetwo-part silide onFSR 30/48 25 50 91 60 40 150 110 M16 x 70 4 2,5 60,5 80 829 481 95 829 481 84 829 481 97 829 481 88FSR 39/60 32 60 105 75 50 165 125 M16 x 80 4 2,5 59,5 80 829 482 95 829 482 84 829 482 97 829 482 88FSR 60/83 50 84 126 94 65 185 145 M16 x 80 8 2,5 59,5 100 829 484 95 829 484 84 829 484 97 829 484 88FSR 83/120 80 120 167 130 100 235 190 M20 x 100 8 2 90 100 829 485 95 829 485 84 – –FSR 127/175100 172 223 186 150 300 250 M24 x 110 8 2 87 130 829 486 95 829 486 84 – –


inner pipe

B C min. 80

Material:DN 25, DN 32 and DN 50: screw socket made of stainless steelDN 80 and DN 100: screw socket made of steel and stainless steelMaterial No. 1.4571, 1.4539 acc. To DIN 17440Choice of material depends on material of inner pipe of FLEXWELL Safety PipeSlide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100, hot-galvanized


dD

Ø k d1 d2

A

Leak-monitored connection Type: Part 1for connection to leak-monitored elbow Worksheet 3.512and leak-monitored T-piece Worksheet 3.513


acc. to DIN 2656

shrink sleeve



see Worksheet 3.350





PE jacket



pipe



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type DN d d1 d2 flange acc. to DIN 2656 A B C Art.-No. without measuring branchDN D ø k bolts* 1.4571 1.4571 1.4539 1.4539

m mm m m m mm mm Stck. mm mm mm slide on flangetwo- part slide onslide on flangetwo-part silide on

FSR 30/48 25 50 87 60 40 150 110 M16 x 70 4 1 62 80 829 481 96 829 481 85 829 481 98 829 481 89FSR 39/60 32 60 101 75 50 165 125 M16 x 80 4 1 61 80 829 482 96 829 482 85 829 482 98 829 482 89FSR 60/83 50 84 121 94 65 185 145 M16 x 80 8 1 61 100 829 484 96 829 484 85 829 484 98 829 484 89FSR 83/120 80 120 161 130 100 235 190 M20 x 100 8 0,5 129,5 100 829 485 96 829 485 85 – –FSR 127/175100172 217 186 150 300 250 M24 x 110 8 0,5 139,5 130 829 486 96 829 486 85 – –


dD

Ø k d1 d2

Leak-monitored connection Type: Part 2Of Part 1 as leak-monitored through-connection acc. to Worksheet 3.511


inner pipe


acc. to DIN 2656

shrink sleeve



see Worksheet 3.350



B C min. 80A



PE jackettwo-part

slide-on flangessee WorksheetNo.FSR 3.340


pipe

Material:DN 25, DN 32 and DN 50: screw socket made of stainless steelDN 80 and DN 100: screw socket made of steel and stainless steelMaterial No. 1.4571, 1.4539 acc. To DIN 17440Choice of material depends on material of inner pipe of FLEXWELL Safety PipeSlide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100, hot-galvanized



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FSR 30/48 25 52 85 115 4 12 24 M 12 x 85 (95)FSR 39/60 32 62 100 140 4 12 24 M 16 x 90 (95)FSR 48/71 40 72 110 150 4 12 24 M 16 x 90FSR 60/83 50 86 125 165 4 12 24 M 16 x 95 (105)

FSR 83/120 80 122 160 200 8 14 28 M 16 x 100 (120)FSR 127/175 125 174 220 270 8 16 32 M 24 x (130)

two-part slide-on flange DN Ø d Ø k Ø D Number of b 2b screwsfor Cu and stainless steel drilling holes for steel

(for stainless steel)

The screw length given is intended for joining to a blank flange acc. to DIN 2635.Screws and nuts are not included in the material delivered.

FLEXWELL-Safety Pipe®

4 segments arrangedat 90° angles

Ø D

Ø k

Ø d

2b

b

3.340Two-part slide-on flangefor standard connection

U-St 37-2 acc. to DIN 17100, hot-galvanizedstainless steel acc. to DIN 17440 – on request



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3.350Monitoring systemMeasuring branch

Measuring branch Type MA, longfor connection with slide-on flange/two-part slide-on flange

Type I without flanged copper pipeArticle No. 829 331 00

Type II with flanged copper pipeArticle No. 829 332 00

Cusleeve

joint Ø 6clamping nut

copper pipe6 x 1 mm

G1/8AISO 228/1

Type I copper pipe endlessflanged using hand flanging device

Type II copper pipe 200 mm flanged

straight screw-in inset,long, DN 4

intermediatespacer with O

washers

thrust collar

Cu seal

Installation instructions for- screwed flange connection see Worksheet No. ISI 8.60.01- hand flanging tool, see Worksheet No. ISI 8.60.02

MaterialIn series production: steel, galvanized, chromatedOn request: stainless steel

Measuring branch Type MAfor connection with screw or soldered end

Type I without flanged copper pipeArticle No. 829 333 00

Type II with flanged copper pipeArticle No. 829 332400

G1/8AISO 228/1

straight screw-in inset,DN 4

intermediatespacer with O

washersCu seal

Cusleeve

joint Ø 6clamping nut

copper pipe6 x 1 mm

Type I copper pipe endlessflanged using hand flanging device

Type II copper pipe 200 mm flanged

thrust collar



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3.351Monitoring systemTest valve

Test valve Type PV, longfor connection

– with slide-on flange– with two-part slide-on flangeArticle No. 829 448 90

locking screw(cylindrical) G1/4

Test valve Type PV, shortfor connection

– with external thread lug– with soldered endArticle No. 829 448 93

nippleG1/8, R1/4

Material

In series production:stopcock – brass, nickel-platedlong nipple - steel galvanized, chromated

On request:stainless steel

Material

In series production:stopcock – brass, nickel-platednipple – steel galvanized, chromated

sealingwasher (Cu)

two-waystopcock

long nippleG1/8A, R1/4

copperseal

copperseal



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3.352Monitoring systemTest valve – assembled

Test valve Type PV, long - assembledwith extended copper pipe

for connection– with slide-on flange– with two-part slide-on flange

Type I without flanged copper pipesArticle No. 829 448 70Type II with flanged copper pipesArticle No. 829 448 71

Test valve Type PV, short - assembledwith extended copper pipe

for connection– with soldered end– with external thread lug

Type I without flanged copper pipesArticle No. 829 448 80Type II with flanged copper pipesArticle No. 829 448 81

Secure two-way stopcock(e.g. at edge of manhole) to ensure that joint isscrewed tight to prevent leaks.

Secure two-way stopcock(e.g. at edge of manhole) to ensure that joint isscrewed tight to prevent leaks.

A copper pipecan be usedwhen a handflanging deviceis available.

Screwed flangeconnection

G1/8A

A copper pipecan be usedwhen a handflanging deviceis available.

MaterialIn series production:screwed flange connection – steel galvanized,chromatedstopcock – brass, nickel-plated

locking screw(cylindrical) G1/4

sealingwasher (Cu)

two-waystopcock

screwed flangeconnection

R1/4-DIN 2999/1

flangedcopper pipe

Cu sleevejointcopper pipe

6x1 mm by site

Cu sleevejoint

flangedcopper pipe

screwed flangeconnection,long G1/8A

copper seal

copper seal


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Leak Detection Systems LDS3.401Leak detection

for FLEXWELL safety pipeSystem description

Leak monitoring

FLEXWELL safety piping is permanentlymonitored using pneumatic leak detectionequipment/ leak detectors. These regulate themonitoring pressure in the surveillance space andregister any changes of pressure which may occur.

The surveillance space is filled with the leak detectionmedium (an inert gas) and prevents uncontrolledspillages of the transported product when leaksoccur. The surveillance space must be soconstructed that the functioning and operativesecurity of the leak detection system (the leakdetector) is assured at all times when the leakmonitoring system is connected.

If the pipe is damaged the alarm is emitted byacoustic and optical signals.

Definition of leak detection equipment/leak detector“Leak detection equipment/leak detector”according to the currently valid regulations refers toa device which automatically and under alloperating conditions gives warning of leaks in thewalls of double-walled piping in which waterhazardous, (flammable and non-flammable) fluidsare transported.

The term “leak detection equipment/leak detector”includes all the equipment necessary for thedetection of leaks.

The main components are:the leak detector/leak detection equipment (LAZ)the connection between the surveillance space(UR) and leak detector (LAZ)double-walled pipingthe surveillance space (UR)a leak detection medium

The use of this system complies with the moststringent European safety standards (Class 1).Systems of this class give warning of a leak aboveor below the fluid level in a double-walledprotective system. They are constructed on theprinciples of absolute safety and ensure thatspillages of products into the environment cannotoccur.

Leak detection equipment/leak detector (LAZ)We distinguish two types of differential pressureleak detection equipment:Leak surveillance to detect leaks in double-walledpiping on the vacuum principle and on the positivepressure principle (using an inert gas)

FLEXWELL Safety Pipe with a vacuum leakdetector.FLEXWELL Safety Pipe with a positive-pressureleak detector.

FLEXWELLSafety Pipe withvacuum leakmonitoring

FLEXWELLSafety Pipe withpressured gasleak monitoring


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Approval/suitabilityAll leak detection equipment/leak detectors in usemust comply with the basic criteria laid down forconstruction and testing standards. All suchpreconditions which could have a bearing on thefunctional and operative safety of the system musttherefore be observed.

It therefore goes without saying that the conditionsfor operative use have been tested by thecompetent authorities and clearly defined and setdown in the documents of approval issued bythem.

FLEXWELL Safety Pipe with leak monitoring is anapproved leak detection equipment/leak detectorsystem.

The advantages of the systemUsing double-walled FLEXWELL Safety Pipe withleak monitoring offers, besides a high degree ofoperative safety, substantial economic advantages:

- the entire system can be easily and simplymonitored at any time without interruptingoperations

- requirements such as e.g. pressure/volumemeasurements, pressure tests or route surveyscan be dispensed with.


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Leak Detection Systems LDS3.410Leak detection systems

on the vacuum principle

Leak detector on the vacuum principle are suitablefor monitoring FLEXWELL Safety Pipes for thetransport of:- water-hazardous, flammable substances- water-hazardous, flammable substances

<=55°C only in the Ex-variant- water-hazardous, non-flammable substances

Principles of functioningThe vacuum pump installed in the leak detectorcreates a partial vacuum.By monitoring this partial vacuum, leaks in thewalls of the piping are automatically detected.

In the event of a drop in the partial vacuum (a risein pressure) due to a leak below the lower value ofthe monitoring level of partial vacuum, the opticaland acoustic alarm is triggered.

Minimal, unavoidable permeability (not leaks) areregulated automatically by the leak detector,without triggering the alarm if they lie between theupper and lower values of the monitoring partialvacuum. Subsequent evacuation is carried out bythe vacuum pump in the leak detector.

In every case in which the alarm is triggered, thevacuum pump is automatically switched off. It canonly be switched on again by throwing the toggleswitch mounted on the outside of the leak detectorfor this purpose.

Technical basisThe scope of application of the leak detectiondevice must be limited to fixed maximum pipelengths due to the laws of physics. These dependon the diameter of the FLEXWELL safety pipeused and the type of laying. The methods of layingcan be seen from the worksheets and approvaldocumentation.

Installation/Commencement of operations/Operation/Function testingDetailed descriptions can be seen from theapproval documentation of the leak detectors andthe worksheets for FLEXWELL safety piping.

The conditions set out in the approval forFLEXWELL safety piping and the leak detectorsused must be complied with.



FLEXWELL safety pipe with leak monitoring is anapproved leak detection equipment/leak detectorsystem.

Leak detection on the vacuum principleIllustration

Leak detection systems on the vacuum principle


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Leak Detection Systems LDS

3.450Leak monitoringon the positive pressure principle

Positiv pressure leak detectors are approved as aleak detection device suitable for monitoringFLEXWELL Safety Pipes for the transport of :- water hazardous flammable substances- water hazardous non-flammable substances

Principles of functioningThe necessary pressure in the surveillance spaceof the FLEXWELL safety pipe depends on theactual operating pressure in the medium pipe(inner pipe) and is generated:

- by topping up, regulated by pressure changes,from a stationary nitrogen pressure reservoirwhich is constantly connected with thesurveillance spaceOperating mode S

- from a mobile pressure reservoir which is onlyconnected when the line is put into operation orduring a function test.Operating mode M

The surveillance space is connected with the leakdetector by means of the connecting leads. Thepressure which builds up is measured by thepressure sensor. If pressure drops to the value setpreviously for ALARM ON due to a leak, the opticaland acoustic alarm will be triggered.

In stationary operating mode the monitoringpressure is regulated after putting the system intooperation by pressure changes which top up froma stationary nitrogen pressure reservoir which isconstantly connected with the surveillance spaceand equipped with a pressure reducing valve.

In mobile operating mode the monitoring pressure(TOP-UP OFF) is set just once when the system isput into operation by a pressure reservoir which isnot constantly connected.

Installation/Commencement of operations/Operation/Function testingDetailed descriptions can be seen from theapproval documentation of the leak detectors usedand the approval documentation for FLEXWELLsafety piping. The conditions set out in theapproval for FLEXWELL safety piping and the typeof leak detector used must be complied with.




Leak detection on the positive pressure principleIllustration

Pressurized gas leak detection



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Anchoring to buildings,pipe-supporting bridges etc.

1. Anchoring in buildings or on supporting structures

2. Bending radius and distance between brackets

Anchoring the FSR to existing anchor railsmounted on the wall surface (profile A8 orequivalent) by menas of saddle brackets.

Anchoring the FSR to existing metal profile anchorrails recessed into the concrete (Jordahl No. 14 orequivalent strength) by means of saddle brackets. N.B.:

Commercially available brackets with suitabledimensions can be used for anchoring instead ofthe components shown in these drawings.

The conditions on site should be taken account of.

Anchoring on anchor rails or metal profil rods does,however, have the following advantages comparedwith anchoring to a fixed point

1. The FLEXWELL safety pipe® can beprovisionally secured during laying.

2. The anchoring brackets only need to beloosened, pushed a little to one side and afteraligning, to be tightened again.

Installation example No. 1



Type bending radius distance between brackets max. brackets provided byhorizontal vertical the contractor must fit

followingpipe-Ø

m m m mmFSR 16/30 0,30 1,20 1,40 30 - 33FSR 30/48 0,50 1,20 1,40 48 - 52FSR 39/60 0,60 1,40 1,60 60 - 65FSR 48/71 0,60 1,50 1,70 70 - 75FSR 60/83 0,70 1,60 1,80 83 - 90

FSR 83/120 1,00 1,60 2,00 120 - 125FSR 127/175 1,50 1,60 2,00 170 - 180

3.710



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3.720Wall Entry SealsTechnical data

General

Wall entry seals for FLEXWELL Safety Pipe are tobe cast in concrete by the client. With correctinstalla-tion, the tightness between concrete and

The sealing element consists of a cross linkedpolyo-lefin heat-shrink sleeve, buttressed internallyby a galvanized steel spiral. The outside of theconvoluted surface has a special coating, whichforms a longitu-dinally watertight bond with wetconcrete or mortar.Both ends are coated inside with a plastic sealingcompound. When heated using a gas flame theends shrink and the sealing compound melts andis pressed into any grooves or irregularities.

MD for L A B max* D1 article No.type FSR mm mm mm mmFSR 16/30 150 700 450 67 829 393 90FSR 30/48 200 700 450 67 829 393 90FSR 39/60 200 750 450 71 829 394 90FSR 48/71 200 750 450 71 829 394 90FSR 60/83 200 750 450 71 829 394 90

MD for L A D D1 article No.type FSR mm mm mm mm

FSR 83/120 250 45 300 186 829 395 90FSR 127/175 250 45 350 243 829 396 90

The sealing element consists of a cast iron sleeve,a sealing ring and a collar flange. The sleeve isfitted with radial grooves which effect the longitudi-nal water tightness in the concrete or mortar insimilar fashion to a labyrinth gland. TheFLEXWELL Safety Pipe is sealed with a sealingpacking, which is pressed into the sleeve upontightening of the bolts of the collar flange.

* With thicker walls, two wall sleeves can be pushedinto each other to make up the extra length required.

the wall duct as well as between the wall duct andthe FSR is 0.2 bar against water, 0.1 bar againstgas pressure.

Wall entry seals type MD for FSR 16/30 - FSR 60/83

Wall entry seals type MD for FSR 83/120 and FSR 127/175

set up measure = L B max.

A

D

set up measure = L

A

DD1

Warning!Slide wall sleevesover the pipe beforeassembling theconnecting joint.



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Type dimensions in mmØ D Ø D H B B

screw socket flange 1 pipe 2 pipesFSR 16/30 40 –FSR 30/48 – 115

FSR 39/60 – 140 min. Ø D min. Ø D min. Ø DFSR 48/71 – 150 + + +FSR 60/83 – 165 100 mm 100 mm 150 mm

FSR 83/120 – 200FSR 127/175 – 270

Wall breakthroughs, boreholes 3.721

Wall breakthroughs for connections with slide-on flange acc. to DIN 2656

Boreholes for connections with slide-on flange acc. to DIN 2656

Boreholes for connections with two-part slide-on flange

TTake care to observe the external diameter of the wall entries.See worksheet No. FSR 3.720

Type dimensions in mmØ D Ø KD

FSR 16/30 40 100FSR 30/48 115 120FSR 39/60 140 150FSR 48/71 150 170FSR 60/83 165 180

FSR 83/120 200 220FSR 127/175 270 290

Only applies to wall entries as per Worksheet FSR 3.720

Ø Dflange

H

Ø KDborehole flange

Ø Dflange

B



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3.722Entry pipe sleeves for steel manholesand pipe wall sleeve for wall entries

set up measure = L 150

d

150

masonry wallpipe sleeve

split spacer former

heat shrink sleeve

wall plate of steelmanhole assembly

pipe sleeve

split collar flanges

General note:

The steel manhole and jacket pipe wall entriesType SSE for FLEXWELL Safety Pipe aredesigned to fit sleeves made from standard steelpipe. For standard sizes refer to table below. Thepipe sleeves must be supplied, set and sealed intothe steel manhole or masonry wall by the client.

Warning ! If FLEXWELL Safety Pipe connecting joints are tobe fitted later, use split collar flanges. Standardcollar flanges are larger in diameter than the pipesleeves and won’t fit.

steel manhole entry

jacket pipe wall entry

SSE for pipe sleeve set up measure article No.FSR type (building contractor)

o. D. x wall d Lmm mm mm

FSR 16/30 48,3 x 2,6 40 150 829 313 90FSR 30/48 76,1 x 2,9 68 200 829 315 90FSR 39/60 88,9 x 3,2 78 200 829 316 90FSR 48/71 114,3 x 3,6 88 200 829 314 90FSR 60/83 114,3 x 3,6 102 200 829 317 90FSR 83/120 168,3 x 4,5 138 250 829 319 90FSR 127/175 219,1 x 5,9 190 250 829 320 90

For installation of FSR connecting joints see respective installation instructions.



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3.723Doyma wall entry with borehole orfibre-cement jacket pipe

Technical details

For screw sockets with a collar, two-part slide-onflanges must always be used, since they have anexternal diameter greater than the borehole or theinternal diameter of the casing tube.

Type DN d L D1 D2mm mm mm mm

FSR 16/30 15 40 150 30 80

Type DN d D L D1 D2mm mm mm mm mm

FSR 30/48 25 68 115 200 48 100FSR 39/60 32 78 140 200 60 125FSR 48/71 40 88 150 200 71 125FSR 60/83 50 102 165 200 83 150FSR 83/120 80 138 200 250 120 200FSR 127/175100 190 270 250 175 250

One sealing pack each of Type C 40and Type A is needed for each pipe conduit.The position of the pipe must not be axiallychanged after installing the Doyma sealing pack.

protrudin lenght = L

casing pipesealing packType C 40

sealing packType A

D1

D2d

inte

rnal

dia

met

er o

f ca

sing

diam

eter

of

bore

hole

protrudin lenght = L

dD

borehole

casing pipesealing packType C 40

sealing packType A

D1

D2

inte

rnal

dia

met

er o

f ca

sing

diam

eter

of

bore

hole

Attention!Slide the wall entry overthe pipe before install-ing the connection!

borehole



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3.730Firewall entryFire-retardant seal

Technical details

Piping non-flammable

To be provided by the contractor:Recommended values forDouble-sided cladding with mineral wool:Thickness: 80 mmDensity: 80 kg/m3

Length: 500 mm for R90600 mm for R120

ComponentsFire-retardant pipe seal, gasproof, watertightunder pressure, with fire-retardant sealingpack and noise insulation tested acc. to DIN4109

Type: FSR-M ___________ 2A + BSHNcomprising: 2 sealing packs

1 fire-retardant packType: FSR-M ___________ 3110BSHNcomprising: 2 sealing packs

1 casing pipe1 fire-retardant pack

Metal parts: Steel hot-galvanizedyellow-chromated and sealed(standard)

Seal: EPDM, to withstand temperaturesfrom -40°C to +140°C (standard)

Casing pipe: special fibre cement

Fire-retardant pack R90 oder R120

Please enclose a filled-in checklist with everyorder.

Why a checklist?

The data on the checklist enable us to supply youwith a solution for a firewall entry with the approvalstailored to your situation on site. On top of that, thechecklist makes it easier for you to be sure you arewithin the law: if you give all the data correctly youcan be certain of getting the firewall entry you needfor your specific site.

Checklist – Worksheet No. 3.732

Typ DN D D1 D2mm mm mm

FSR-M 16/30 15 24,5 27 80FSR-M 30/48 25 43 46,2 100FSR-M 39/60 32 53,5 57,1 100FSR-M 60/83 50 76,5 80,5 150

Fire protection requirements as per thegeneral test certificate for constructioninspections No. P-3024/0148-MPA BS

borehole

casing pipe

FLEXWELL-Sicherheitsrohr®

Typ: FSR-M

sealing pack

D1

D2D

inte

rnal

dia

met

er o

f ca

sing

diam

eter

of

bore

hole



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Piping non-flammable

To be provided by the contractor:Recommended values forDouble-sided cladding with mineral wool:Thickness: 80 mmDensity: 80 kg/m3

Length: 700 mm for R90

ComponentsRohrabschottung

Typ: FSR-M _________ 11.500 BSRN

bestehend aus:1 Buchsenrohr__________ mm lang2 Steckrosetten1 sealing packs1 fire-retardant pack

Type: FSR-M _________ 12.500 BSRN

bestehend aus: 1 Buchsenrohr, geteilt __________ mm lang2 Steckrosetten, geteilt1 sealing packs, geteilt1 fire-retardant pack

Buchsenrohr: Kunststoff

Brandschutzpackung R90

Please enclose a filled-in checklist with everyorder.

Why a checklist?

The data on the checklist enable us to supply youwith a solution for a firewall entry with the approvalstailored to your situation on site. On top of that, thechecklist makes it easier for you to be sure you arewithin the law: if you give all the data correctly youcan be certain of getting the firewall entry you needfor your specific site.

Checklist – Worksheet No. 3.732

Type DN D D2mm mm

FSR-M 16/30 15 24,5 42FSR-M 30/48 25 43 61FSR-M 39/60 32 53,5 61FSR-M 60/83 50 76,5 106

FLEXWELL-SicherheitsrohrTyp: FSR-M

verklebenAbdichtung

D2D

Inne

ndur

chm

esse

r Bu

chse

nroh

r

BuchsenrohrType 11.500 BSRN

BuchsenrohrType 12.500 BSRN geteilt

3.731Firewall entryAbschottung für Leichtbauwände F 90

Technical details



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3.732ChecklistFire-retardant seal

FSR-M

Fire-retarding class: R 90 for pipe fire-retardant seal R 120 for pipe fire-retardant seal

Flexwell safety pipe: non-flammable pipes

Type FSR-M 16/30 FSR-M 30/48 FSR-M 39/60 FSR-M 60/83

External diameter D 24,5 mm 43,0 mm 53,5 mm 76,5 mmwithout protective jacket

External diameter D1 27,0 mm 46,2 mm 57,1 mm 80,5 mmwith protective jacket

Application Supply line Medium: ____________________ Return line Medium: ____________________

With multiple entries, exact details of each individual pipe must be given.

Construction site data:

Entry for Wall Ceiling

Thickness of wall/ceiling 100 - 149 mm 150 - 174 mm 175 - 300 mm > 300 mm

(exact thickness) = _________mm = _________mm = _________mm = ________mm

Material concrete borehole casing pipe

stonework casing pipe

brickwork casing pipe

ligtweight construction acc. to DIN 4102 T4

FSR-M without protective jacket

other: __________________________________

Building:

Description _________________________________________________

Town _________________________________________________

Client _________________________________________________

Please fax checklist to: 0049 (0) 50 31 - 170 145


PIPE2000 Ltd




PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email [email protected]


FLEXWELL® FSR LEAK DETECTION

PIPE2000 Ltd




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Leak monitoring

FLEXWELL safety piping is permanentlymonitored using pneumatic leak detectionequipment/ leak detectors. These regulate themonitoring pressure in the surveillance space andregister any changes of pressure which may occur.

The surveillance space is filled with the leak detectionmedium (an inert gas) and prevents uncontrolledspillages of the transported product when leaksoccur. The surveillance space must be soconstructed that the functioning and operativesecurity of the leak detection system (the leakdetector) is assured at all times when the leakmonitoring system is connected.

If the pipe is damaged the alarm is emitted byacoustic and optical signals.

Definition of leak detection equipment/leak detector“Leak detection equipment/leak detector”according to the currently valid regulations refers toa device which automatically and under alloperating conditions gives warning of leaks in thewalls of double-walled piping in which waterhazardous, (flammable and non-flammable) fluidsare transported.

The term “leak detection equipment/leak detector”includes all the equipment necessary for thedetection of leaks.

The main components are:the leak detector/leak detection equipment (LAZ)the connection between the surveillance space(UR) and leak detector (LAZ)double-walled pipingthe surveillance space (UR)a leak detection medium

The use of this system complies with the moststringent European safety standards (Class 1).Systems of this class give warning of a leak aboveor below the fluid level in a double-walledprotective system. They are constructed on theprinciples of absolute safety and ensure thatspillages of products into the environment cannotoccur.

Leak detection equipment/leak detector (LAZ)We distinguish two types of differential pressureleak detection equipment:Leak surveillance to detect leaks in double-walledpiping on the vacuum principle and on the positivepressure principle (using an inert gas)

FLEXWELL Safety Pipe with a vacuum leakdetector.FLEXWELL Safety Pipe with a positive-pressureleak detector.

FLEXWELLSafety Pipe withvacuum leakmonitoring

FLEXWELLSafety Pipe withpressured gasleak monitoring


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FLEXWELL Safety Pipe with leak monitoring is anapproved leak detection equipment/leak detectorsystem.

The advantages of the systemUsing double-walled FLEXWELL Safety Pipe withleak monitoring offers, besides a high degree ofoperative safety, substantial economic advantages:

- the entire system can be easily and simplymonitored at any time without interruptingoperations

- requirements such as e.g. pressure/volumemeasurements, pressure tests or route surveyscan be dispensed with.


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Leak Detection Systems LDS3.410Leak detection systems

on the vacuum principle

Leak detector on the vacuum principle are suitablefor monitoring FLEXWELL Safety Pipes for thetransport of:- water-hazardous, flammable substances- water-hazardous, flammable substances

<=55°C only in the Ex-variant- water-hazardous, non-flammable substances

Principles of functioningThe vacuum pump installed in the leak detectorcreates a partial vacuum.By monitoring this partial vacuum, leaks in thewalls of the piping are automatically detected.

In the event of a drop in the partial vacuum (a risein pressure) due to a leak below the lower value ofthe monitoring level of partial vacuum, the opticaland acoustic alarm is triggered.

Minimal, unavoidable permeability (not leaks) areregulated automatically by the leak detector,without triggering the alarm if they lie between theupper and lower values of the monitoring partialvacuum. Subsequent evacuation is carried out bythe vacuum pump in the leak detector.

In every case in which the alarm is triggered, thevacuum pump is automatically switched off. It canonly be switched on again by throwing the toggleswitch mounted on the outside of the leak detectorfor this purpose.

Technical basisThe scope of application of the leak detectiondevice must be limited to fixed maximum pipelengths due to the laws of physics. These dependon the diameter of the FLEXWELL safety pipeused and the type of laying. The methods of layingcan be seen from the worksheets and approvaldocumentation.

Installation/Commencement of operations/Operation/Function testingDetailed descriptions can be seen from theapproval documentation of the leak detectors andthe worksheets for FLEXWELL safety piping.

The conditions set out in the approval forFLEXWELL safety piping and the leak detectorsused must be complied with.




Leak detection on the vacuum principleIllustration

Leak detection systems on the vacuum principle


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Leak Detection Systems LDS

3.450Leak monitoringon the positive pressure principle

Positiv pressure leak detectors are approved as aleak detection device suitable for monitoringFLEXWELL Safety Pipes for the transport of :- water hazardous flammable substances- water hazardous non-flammable substances

Principles of functioningThe necessary pressure in the surveillance spaceof the FLEXWELL safety pipe depends on theactual operating pressure in the medium pipe(inner pipe) and is generated:

- by topping up, regulated by pressure changes,from a stationary nitrogen pressure reservoirwhich is constantly connected with thesurveillance spaceOperating mode S

- from a mobile pressure reservoir which is onlyconnected when the line is put into operation orduring a function test.Operating mode M

The surveillance space is connected with the leakdetector by means of the connecting leads. Thepressure which builds up is measured by thepressure sensor. If pressure drops to the value setpreviously for ALARM ON due to a leak, the opticaland acoustic alarm will be triggered.

In stationary operating mode the monitoringpressure is regulated after putting the system intooperation by pressure changes which top up froma stationary nitrogen pressure reservoir which isconstantly connected with the surveillance spaceand equipped with a pressure reducing valve.

In mobile operating mode the monitoring pressure(TOP-UP OFF) is set just once when the system isput into operation by a pressure reservoir which isnot constantly connected.

Installation/Commencement of operations/Operation/Function testingDetailed descriptions can be seen from theapproval documentation of the leak detectors usedand the approval documentation for FLEXWELLsafety piping. The conditions set out in theapproval for FLEXWELL safety piping and the typeof leak detector used must be complied with.




Leak detection on the positive pressure principleIllustration

Pressurized gas leak detection


PIPE2000 Ltd





FERWAG® - The Professional Solution for Engineers

PIPE2000 Ltd




FER

7.0

15.10.2003

Contents

7.0 Contents


7.100 System description (general)7.105 System description (data)

7.2 Engineering

7.200 Laying Engineering, Contents

7.3 Components

7.300 FERWAG - District heating pipe, heating and sanitaryConstruction, Dimensions, Material, Weight and Delivery lengths

7.305 Elbow, short-legged7.310 Elbow, 1.0 x 2.0 m7.312 T-pieces, branch-off, Insulation thickness 17.313 T-pieces, branch-off, Insulation thickness 27.314 T-pieces, branch-off, Insulation thickness 37.316 Parallel T-pieces with steel pipe, Insulation thickness 17.317 Parallel T-pieces with steel pipe, Insulation thickness 27.318 Parallel T-pieces with steel pipe, Insulation thickness 37.320 Anchors7.325 Preinsulated valves for underground laying, description, installation7.330 Shut-off valve, ball valve7.335 Fitting for shut-off valve, ball valve 7.340 Pipe joints connection, shrink-on sleeve SMPE-2D7.345 Pipe joints connection, end sockets, shrink-on seal7.351 Pipe joints connection, EWELCON-Fusion Welded Joint, System description7.352 Pipe joints connection, EWELCON-Fusion Welded Joint, Technical specifications7.355 Wall sealing ring, Trench warning tape7.360 Wall duct (Doyma - for civil defence structures)

7.4 Transport and storage

7.400 Transport and storage

7.5 Data for excavation, Installation

7.500 Civil engineering works, laying pipes (trench profile)7.501 Civil engineering works, laying pipes7.502 Filling the pipe trenches7.505 House connection (wall penetration, core drilled holes)7.510 Assembly rules7.515 Concrete block for an anchor7.520 Draining and venting arrangements7.525 Underground installation for ballvalves7.530 Hot tapping, system description7.531 Hot tapping, dimensions and measurements7.532 Hot tapping, preparation weld seam and weld composition

7.6 Tendering text

FERWAG -District heating pipe®

®


Tel No 01268 759567Fax No 01268 569932email: [email protected]

FERWAG -District heating pipe FER

7.100

15.10.2003

System description

FERWAG district heating pipe is the registe-red name for a pre-insulated plastic casingpipe system used to transport district heat.The pipe system is designed to be laid directlyin the earth, without ducts. It has proven itsexcellence over several decades and isnowadays acknowledged as the industrialstandard in normal cases.

Depending on the purpose for which it isused, FERWAG district heating pipe has acarrier pipe made either of steel (welded,seamless or galvanised), copper or specialsteel. This means that FERWAG districtheating pipe is suitable for transportingheating water, hot water for industrial ordomestic use, condensate and other fluids,but not for steam.

The heat insulation of the FERWAG hea-ting pipe is provided by a rigid polyurethanefoam offering resistance up to 140 ° C. Theouter protection is provided by an HDPE (highdensity polyurethane) casing pipe. All threecomponents form a fixed unit, making thispipe system a member of the composite pipefamily.

FERWAG district heating pipe is available inthree categories of insulation thickness.Depending on the dimensions, the pipeconstruction units can be supplied in lengthsof 6 + 12 (or 16) m. The construction unitsand all the associated moulded fittings suchas elbows or bends, T-pieces, fixed points oranchors and so on, are prefabricated in thefactory. This results in a modular kit systemwhich is correspondingly simple to plan andassemble.

All the components are connected on site,using circumferential seams. The weld seamsand the end sockets are subsequentlyinsulated with joint sleeves. Subsequentinsulation work is usually carried out on ourbehalf by the system supplier or by qualifiedspecialist companies. During the planningphase, we will assist system users on requestby placing our experience with the system attheir disposal free of charge, as part of ourservice.

®

®

®

®

®

®PIPE2000 LtdUK Distributor


FERWAG®- District heating pipe

Description du matériel

FER

7.105

26.8.2003

Materials supplied

FERWAG® district heating pipe system for con-stant medium temperatures up to a maximumof 140 °C, comprising:

• FERWAG® district heating pipes• FERWAG® moulded fittings (elbows, T-

pieces, fixed points, HDPE sleeves, etc.)• FERWAG® accessories (MDR, pipe under-

lay, line warning tape, etc.).

Conception / structureHeating

Straight pipes (bar stock)

Longitudinal seam-welded or spiral seam-welded steel pipes

Material St 37.0 to DIN 17120Standard: DIN 2458/1626; EN 253Acceptance test certificate: DIN 50.049-3.1 BWelding bevel: Ø ≥114.3, DIN 2559-22

Pipes for T-pieces and fixedpoints

T-pieces and fixed points with the same wallthicknesses as the pipes; end sockets of com-pensators and fittings with the same wall thick-nesses as the welded pipes; material matchesthe straight welded pipes.

Steel pipe elbows for mouldedelbow fittings

DN 20-125

Cold-bent (seamless or welded) steel pipes

Material St 37.0Standard: DIN 2448/1629; EN 448,

DIN 2458/1626Dimensions: Same as straight pipesFactory certificate: DIN 50.049-2.2 orAcceptance test DIN 50.049-3.1 B

DN 150 (80)-500

Longitudinal seam-welded elbows withlongitudinal or spiral seam-welded steel pipeend sockets.

Material St 37.0Standard: DIN 2605, DIN 2458/1626;EN 448Dimensions: Same as straight pipesFactory certificate: DIN 50.049-2.2 orAcceptance test certificate: DIN 50.049-3.1 B

End sockets: 150-200 mm

Technical data: Same as for straight pipes.

Sanitary

Pipes and moulded fittings

Threaded pipes: DIN 2440, longitudinally wel-ded, galvanised to DIN 2444

Thread: DIN 2999 Part 1; over 2 1/2” -ends without thread.

Medium pipes made of other materials areavailable on request.

Casing pipe

Material HDPE, Hoechst, GM 5010 T2 orUnifos NCPE 3316

Standard: EN 253Factory certificate:DIN 50.049-2.2

External diameter90

110125140160180200225250280315355400450500560630710800

Dimensions of HDPE casing pipesInternal diameter

85,6104,0118,8133,0152,0172,0192,0216,2240,2269,0302,6341,0384,4432,4480,4538,0605,2682,0768,6

Minimum wall thickness2,22,52,53,03,03,03,23,53,94,44,95,66,37,07,88,89,8

11,112,5

Heat insulation (EN 253)

Polyurethane foam (pentane blown)Polyurethane foam manufactured from 3components:polyol, isocyanate and pentaneMixing and metering takes place in high-pressure systems.

Core pipe density: Min. 60 kg/m3Closed cell percentage: ≥ 96%Thermal conductivity coefficient: ≤ 0.0260W/mK for an average temperature of theinsulating layer of 50°C

Joint sleeve / subsequent insulation

Standard: EN 489• carried out by trained installation staff• foaming and sealing of the sleeve joints

with polyurethane foam• sealed with heat shrinkable seal and

electric-welded sleeve• connection of leak monitoring leads• installation of expansion pads consisting

of an elastic ageing-resistant foamedmaterial.



FER

7.200

15.10.2003

Laying EngineeringContents

7.20 Principles, theory7.201 Layout of the line 7.202 Laying length, Lmax7.203 Natural fixed point (maximum laying length)

7.21 Tables: max. covering, Lmax., thermal prestressing

7.210 Maximum permissible covering height 7.211 Lmax, laying without prestressing, insulation thickness 17.212 Lmax, laying without prestressing, insulation thickness 2 and 37.214 Thermal prestressing (description)7.215 Laying with thermal prestressing, DN 20-300, insulation thickness 17.216 Laying with thermal prestressing, DN 20-300, insulation thickness 2 7.217 Laying with thermal prestressing, DN 350-500, insulation thickness 1 and 27.218 Laying with thermal prestressing, DN 20-200, insulation thickness 3

7.22 Expansion calculation7.220 Restricted expansion7.221 Restricted expansion up tp 90 ° C, DN 20-125, insulation thickness 27.222 Restricted expansion up tp 90 ° C, DN 20-125, insulation thickness 37.223 Restricted expansion

7.23 Design of expansion elements7.230 L-elbow, Z-elbow, U-elbow - sheet 17.231 Elbow < 90° (bend in the line) - sheet 27.232 Location of expansion pads

7.24 Dimensioning, heat loss7.240 Pressure losses7.241 Heat loss, insulation thickness 17.242 Heat loss, insulation thickness 27.243 Heat loss, insulation thickness 3

7.25 Laying direction7.250 Laying direction, sheet 1 7.251 Laying direction, sheet 27.252 Laying direction, pipe elbows, min. bending radius, small bends, sheet 3 7.253 Laying direction, changes of direction at 40-50° and 40-50° , sheet 47.254 Connecting instruction, transition flexible pipe to plastic sheath pipe

FERWAG -District heating pipe®PIPE2000 LtdUK Distributor


FER

7.201

15.10.2003

a b

a a

aa

a

b

b

b

b

b

3 m

FP L

Layout of the line for FERWAG district heating pipes is not subject to any special requirements. Withrespect to the pipe, it should fundamentally be selected with consideration to possible expansion. Forthis purpose, changes of direction in the normal layout of the line using L elbows are an initialoption. In addition there are Z elbows and U elbows, which are capable of taking up the expansionarising at precisely defined points.

The angle sizes of the "expansion elbows" should not exceed 90 ° , since otherwise considerablylonger expansion legs are needed. If possible a right angled line course should always be aimed for.

FERWAG -District heating pipe

Layout of the line

Fig. 1 Straight line layout between two buildings. The expansion of the district heating pipes must be taken up in building A or B by pipe legs or similar.

Fig. 2 Angled line layout, expansion taken up by natural change of direction in L elbow and building a.

Fig. 3 Straight line layout between two buildings with expansion taken up within the line by Z elbows.

Fig. 4 Straight line layout between two buildings with expansion taken up within the line by U elbows.

Fig. 6 Straight line layout, expansion taken up within the line by U elbows.

Fig. 5 Angled line layout between two buildings. Expansion taken up within the line by Z elbows.

If no expansions are provided in the houses, then anchor must be fitted in the building wall or approx. 3 m before it.

Building

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FER

7.202

15.10.2003

Laying length, Lmax

H

FP FP

FP

FP

LmaxLmaxLmax

LmaxLmax

Lmax

ALmax =Fr'•

[m]

Fr'= µ[G + D(2H + Kd (H +D/2)( –2))]

= 190 N/mm = 0.5 = 19 kN/mKd = 0,463G [N/m]D [m]H [m]A [mm ]

µ2

3

2

Components to compensate the temperaturerelated length-differences can almost berejected.

In order to avoid destruction of the carrier pipeduring normal laying (without thermalprestressing), the friction force may only riseup to the maximum permissible force ofpressure on the carrier pipe. The districtheating pipe laid underground therefore mustnot be fixed, it must slide within the earth. Theexpansion occurring must be taken up in anexpansion elbow. The length of the slidingarea is identified for the remote heating linewith the term "laying length - Lmax".

The laying length indicates at what distancefrom a fixed point the first expansion capabilitymust be created. The friction forces add upwithin this laying length up to a value which isstill below the maximum permissiblepressure force of the inner pipe.

The FERWAG district heating pipe is a pipesystem in which the carrier pipe, heat insulationand sleeve pipe form a composite whole. As aresult, the expansion occurring in the carrier pipeis transferred to the polyurethane foam and tothe HDPE sleeve pipe. The polyurethane foamand the sleeve pipe thus expand to the samedegree as the steel pipe.

Expansion of the district heating pipe is howeverrestricted to a certain extent in the sand bed byfriction between the sand and the sleeve pipe.The friction force may become so great in acorresponding pipe length, that the districtheating pipe is "fixed" in the earth andexpansion is completely prevented. The force ofpressures in the carrier pipe, which arecounteracting the external friction forces, thenbecome so great that impermissibly high stressescan occur in the carrier pipe.In the case of long pipes with an adhesion area,another possible way of reducing the amount ofmaximum tension is by thermal prestressing ofthe pipe.


Maximum permissible laying length between expansion legs, Lmax

L elbow

Z elbow

U elbow

Maximum permissible laying length, Lmax:

Friction force, Fr' [N/m]

permissible stress (after creasing)friction factor, ground / PE specific gravity of ground pressure coefficient at rest weight of steel pipe + water sleeve pipe external diameter covering height steel pipe profile

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FER

7.203

15.10.2003

NFP

NFP

NFP

NFP

NFP NFP NFP

Lmax

2 LmaxLmax Lmax

LmaxLmax 2 Lmax

Lmax

NFP Fr'1 Fr'2H1

H2

LL2L1

L2 = L

12 ( 2+1) – 1

– 1

Fr'2

Fr'1 =

L1 = L – L2

In the case of unequal covering height, the NFPis displaced. When calculating the maximumlaying length Lmax and the expansion l, thismust be taken into account. In the case ofdoubt, a fixed point should be set.

( > 1 )

A natural fixed point NFP is located, as a result ofthe friction forces at the same covering heightbetween the sand and the PE sleeve pipe, in thecentre of a line section, between two possibleexpansion points.

Natural fixed point, L elbow

Natural fixed point, Z elbow

Natural fixed point, U elbow

"Natural fixed point" at changing covering height H1, H2 = Covering height

Natural fixed point Maximum laying length



FER

7.210

15.10.2003

Where no shear stresses occur, i.e. there areno relative movements between the earth andthe pipe, e.g. in an adhesion area or in thearea between two fixed point structures ofprestressed pipelines, there is nocorresponding restriction in laying depth.

=

20 25 32 40 50 65 80100125150200250300350400450500

90 90110110125140160200225250315400450500560630710

110110125125140160180225250280355450500560630710800

125125140140160180200250280315400

26,9 33,7 42,4 48,3 60,3 76,1 88,9114,3139,7168,3219,1273,0323,9355,6406,4457,2508,0

DN Hmax [m] Hmax [m] Hmax [m]d D D D

1.51.91.92.22.42.72.82.93.13.43.53.43.63.53.63.63.6

1.21.51.71.92.12.42.52.52.83.03.13.03.23.13.23.23.2

1.01.31.51.71.92.12.22.32.52.62.8

Fr' = · [G + · D · (2 · H + Kd · (H + D/2)·( – 2))] µ

where:

= 0.5 = 19 kN/mKd = 0,463G [N/m]d [mm]D [m]H [m]

µ2

3

max = 0,04 N/mm

[N /mm ]

[N /m]

2Fr'

·d

The maximum permissible covering height (Hmax)is determined from the permissible shear stress of = 0.04 N/mm between the PU foam insulation

and the steel carrier pipe, as a function of thefriction force and the pipe size.

Maximum permissiblecovering height


Steel pipe Insulation thickness 1 Insulation thickness 2 Insulation thickness 3

The shear stress and friction force may be calculated using the following formulae:

Shear stress:

Friction force:

permissible shear stress friction factor, ground / PE specific gravity of ground pressure coefficient at rest weight of steel pipe + water carrier pipe external diameter sleeve pipe external diameter (PE) covering height (the dimension H is measured from the pipe apex to the consolidated or compressed ground surface)

2



FER

7.211

15.10.2003

DNH = 0,6 m H = 0,8 m H = 1,0 m H = 1,2 m

Lmaxm

Lmaxm

Lmaxm

Lmaxm

Fr'kN/m

Fr'kN/m

Fr'kN/m

Fr'kN/m

Dmm

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6

139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

20253240

50 65 80100

125150200250300

Lmax Lmax 0.15

H

90 90110110

125140160200

225250315400450

28353742

51586575

81 97110118136

1,31,31,61,6

1,92,12,43,1

3,53,95,16,67,6

21262832

39445057

62 74 85 91106

1,71,82,22,2

2,52,83,24,0

4,65,16,68,59,6

17212225

31354046

5060697487

2,22,22,72,7

3,03,44,05,0

5,7 6,3 8,110,411,9

14171821

26303339

4250586374

2,62,63,23,2

3,74,14,75,9

6,7 7,5 9,612,414,1

350400450500

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

500560630710

133149147143

8,5 9,811,212,8

104117116113

10,912,514,216,3

85969593

13,315,217,219,7

72828179

15,717,820,323,1


Insulation thickness 1

Steel piped x smm

Laying without prestressingMaximum permissible laying length, Lmax

Covering height, H [m] Friction force, Fr' [kN/m]Permissible stress, =185 N/mm2Friction factor ground/PE, µ = 0,5Specific gravity of ground, = 19 kN/m3

Pressure coefficient at rest, Kd = 0,463



FER

7.212

15.10.2003

DNH = 0,6 m H = 0,8 m H = 1,0 m H = 1,2 m

Lmax m

Lmax m

Lmax m

Lmax m

Fr'kN/m

Fr'kN/m

Fr'kN/m

Fr'kN/m

Dmm

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6

139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

20253240

50 65 80100

125150200250300

110110125125

140160180225

250280355450500

23283237

46515867

73 86 98105123

1,61,61,81,9

2,12,42,73,5

3,94,45,77,48,4

17212428

35394451

5666758196

2,12,12,42,5

2,83,23,64,5

5,1 5,7 7,4 9,610,8

14171922

28313641

4554616678

11141619

23263034

3845525666

2,72,73,13,1

3,43,94,55,6

6,3 7,1 9,111,713,2

3,23,23,73,7

4,14,75,36,7

7,5 8,410,813,915,6

DNH = 0,6 m H = 0,8 m H = 1,0 m H = 1,2 m

Lmaxm

Lmaxm

Lmaxm

Lmaxm

Fr'kN/m

Fr'kN/m

Fr'kN/m

Fr'kN/m

Dmm

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6

139,7 x 3,6168,3 x 4,0219,1 x 4,5

20253240

50 65 80100

125150200

125125140140

160180200250

280315400

20252933

40455260

657787

1,81,82,02,1

2,42,73,03,8

4,45,06,5

15192225

30344046

505967

2,42,42,72,7

3,23,64,05,0

5,76,58,4

12151720

24283237

404855

10121417

20212731

344046

3,03,03,43,4

3,94,44,96,2

7,08,0

10,3

3,63,64,14,1

4,75,35,97,4

8,49,5

12,2

Lmax Lmax 0.15

H

350400450500

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

560630710800

119133130126

9,611,012,614,5

92104103100

12,214,016,018,3

76868482

14,917,019,422,2

64737270

17,620,022,826,0


Laying without prestressingMaximum permissible laying length, Lmax


Steel piped x smm


Steel piped x smm

Covering height, H [m] Friction force, Fr' [kN/m]Permissible stress, =185 N/mm2Friction factor ground/PE, µ = 0,5Specific gravity of ground, = 19 kN/m3

Pressure coefficient at rest, Kd = 0,463



FER

7.214

15.10.2003

Thermal prestressing

Thermal prestressingIn the case of long pipes with an adhesion area,another possible way of reducing the amount ofmaximum tension is by thermal prestressing of thepipe. In this case, the pipe which has been laid in theopen trench is heated up to the approximate meantemperature between the laying and operatingconditions; in this heated condition, it is sanded in andthen allowed to cool off again.

At ambient temperature, this means that the pipe issubject to a constant tensile stress which reduces in alinear manner when the pipe is heated; the tensilestress becomes zero at the mean (or prestressing)temperature, and it changes into a compressive stresswhen further heating takes place.

The maximum stress difference is split up into twoapproximately equal ”compressive” and ”tensile stress”components, each of an amount which is less than thepermissible maximum stress.

vmax = ± ±±± ES · t · ( T - TV) [N/mm2]At a prestressing temperature of 70 ° C, that is to saythe temperature difference Tv = 60 K, this gives amaximum value of vmax = 147 N/mm2 for St 37.0.

Furthermore, it is advantageous if the pipe stress atnormal operating temperature (80-90 ° C) isapproximately equal to zero, so that the pipe is laidvirtually stress-free for the greater part of the year.

By shifting the prestressing temperature upwardsbeyond the mean temperature, it is possible to takeaccount of the fact that the key material valuesbecome less favourable as the temperature rises.

Procedure:

a) Lay the pipe in the open pipe trench. The expansionabsorbers should already be welded on. To ensure thatthe expansion of the pipe is directed, an artificial fixedpoint can be created by filling with earth over a lengthLs.

Ls = L · Gges · µµµµ/FR'

b) Position measuring points at suitable locations.

c) Calculate the ideal length change (free expansion)using the measuring points.

d) Calculate an optimal prestressing temperature, atwhich the maximum permissible stress is exceededneither in the operating condition nor in the cooling-off condition.

e) Heat the pipe up to the specified prestressingtemperature. When doing this, it is particularlybeneficial to carry out the preheating withdisconnected recirculating water from a heatingnetwork which already exists. Apart from this, otherpossibilities are vacuum steam, hot air or electricalprestressing. Electrical prestressing is the mostadvantageous as regards the outlay.Prestressing can also be carried out section by section,since the complete line is seldom open, particularly ininner city areas.

f) Measure the real expansion and compare it with theideal values. If the expansion obtained turns out to betoo low, the pipe can be briefly overheated in order toovercome the friction on the base of the trench. Whenthe calculated expansion is attained, return to therequired prestressing temperature again.

g) Position the expansion pads and secure them sothat they cannot move.

h) Align the pipes.

I) Fill in the pipe trench and compact the earth. Whendoing this, the prestressing temperature must bemaintained, with a permissible variance of ± 5° C.

j) Cool off and withdraw the pipe. This will bend theexpansion components up and draw them into thepad, meaning that they are also prestressed and aresubject to constant tensile stress in the laid condition.

k) Measure the residual expansion after cooling hasbeen completed.

TBTV

TU

+

–

max

Vmax

Vmax

without prestressing

with prestressing

Since this maximum stress remains constant throughoutthe entire adhesion area, the prestressed section of pipecan be of any length. Moreover, the sliding area turnsout to be very small on account of the low temperaturedifferences. Given that instances of thermal expansionoccur solely in the sliding area, only slight instances ofresidual expansion take place; these should be absorbedby the expansion components. Consequently, thedimensions of these components can be substantiallyreduced in comparison with non-prestressed pipes. Inaddition, a certain number of expansion absorbers canbe saved, since there is no need to subdivide the wholepipe into maximum laying lengths.

The sliding area Lg and the residual expansion lcan be calculated as follows:

Lg = [ES · AS · t · ( T - TV) + Fp-Fel]/FR‘ [m]

L = [ t · ( T - TV) + (Fp-Fel)/Es · As] · Lg/2 [mm]


Progression of stress over pipe temperature



FER

7.215

15.10.2003

Steel piped x s

mm

90° °°° Tv=50 ° C ( T=40 ° C)

DN D

mm20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

Tv=60 ° C ( T=50 ° C)

Tv=65 ° C ( T=55 ° C)

Tv=70 ° C ( T=60 ° C)

100 ° °°° 110 ° °°° 120 ° °°° 130 ° °°° Tv=75 ° C ( T=65° C)

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

TB

H =

0,6

m

H =

0,8

m

H =

1,0

m

H =

1,2

m

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

90 90110110125140160200225250315400450 90 90110110125140160200225250315400450 90 90110110125140160200225250315400450

90 90110110125140160200225250315400450

DN 20-300, Insulation thickness 1

l

Lg DS

FP

14,516192227303439

3,544,55

0,5111

1820,52427

5,5678

0,5111

2022,52630

6,5 7,5 8,510

1111

2224.528,532,5

8 8,51011.5

1111

23,526,53135,5

9101214

1111,5

6,5789

1,51,51,52

33,537,542,548,5

101112,514,5

1,51,522,5

36,541,546,553,5

1213,51517,5

1,5222,5

4045,55158,5

14,5161820,5

222,53

43,5495563

171921,524,5

2,52,52,53

4250576170,5

101213,514,517

2,5333,54,5

52,562,571.57688

15,518,52122,526

33445

586978,58497

1922,525,527,531,5

33,544,55,5

63 75 85,5 91,5106

22,52730,532,538

3,53,54,556

68,5 81,5 92,5 99115

26,531,53638,544

3,544,55,56,5

111214,516,5

2,533,54

0,5111

13,515,51820,5

44,55,56

0,5111

15172022,5

55,56,57,5

1111

16,518,521,524,5

66,57,59

1111,5

182023,527

7 7,5 910,5

111,51,5

202325,529,5

55,567

11,51,52

25,528,53237

7,5 8,5 9,511

1,51,51,52,5

2831,535,540,5

910,511,513,5

1,51,522,5

30,534,538,544,5

11121416

1,51,522,5

33374248

1314,51618,5

1,522,53

3238,5444755

7,5 910,51113

22,5333,5

4048555968,5

121416,517,520

2,533,53,54,5

445360,56575,5

14,517202124,5

33445

4857,5667182

1720,523,52529,5

33,544,55,5

5262,571,576,589

202427,529,534,5

3,544,556

91011,513

22,52,53

0,50,50,51

1112,514,516,5

33,54,55

0,50,50,51

1213,51618

44,556

1111

131517,520

4,55,567

1111

14,5161921,5

5,5678,5

1111

1618,520,524

44,555,5

1111

20,5232630

677,59

1111,5

22,525,528,533

7,5 8,5 9,510,5

111,52,5

24,527,53136

8,5101113

11,51,52,5

26,53033,539

1011,51315

1,51,522,5

26313638,545

6 7,5 8,5 911

1,51,5233,5

32,53944,54856

9,511,513,514,517

2333,54

35,542,5495362

11,5141617,520

2,53344,5

3946,553,55867

1416,51920,524

2,53445

4250,55862,573

16,519,522,52428

3344,55,5

7,589,511

1,522,52,5

0,50,50,50,5

0,50,50,50,5

910,51214

2,533,54

1011,513,515

33,54,55

0,5111

1112,514,516,5

44,556

1111

1111

1213,515,518

4,5567

13,515,517,520

33,545

0,5111

1719,521,525

55,56,57,5

1111

18,5212427,5

6789

111,52

20,5232630

7 8 9,510,5

111,52,5

22252832,5

8,5 9,51112,5

2222,5

22263032,538

5677,59

1,51,51.52,53

27,532,537,540,547,5

8 9,5111214

22334

303641,544,552

101213,514,517

2333,54

32,539454957

11,5141617,520

2,53344,5

35,545,5495362

13,516,51920,524

2,53445


Laying with thermalprestressing

Operating temperature TB [° C]Preheating temperature Tv [ ° C]Laying temperature Tk=10 [ ° C],

T = Tv–TkSliding range when cooling Lg [m]Elastic recovery when cooling l [mm]Permissible stress = 190 N/mm2

Friction factor ground/ PE, µ=0,5Specific gravity of ground, = 19 kN/m3

Coefficient of compression, Kd=0,463Covering height H [m]Expansion leg DS [m]



FER

7.216

15.10.2003

Steel piped x s

mm

90° °°° Tv=50 ° C ( T=40 ° C)

DN D

mm20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

20253240

50 65 80100125150200250300

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

Tv=60 ° C ( T=50 ° C)

Tv=65 ° C ( T=55 ° C)

Tv=70 ° C ( T=60 ° C)

100 ° °°° 110 ° °°° 120 ° °°° 130 ° °°° Tv=75 ° C ( T=65° C)

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

TB

H =

0,6

m

H =

0,8

m

H =

1,0

m

H =

1,2

m

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5273,0 x 5,0323,9 x 5,6

l

Lg DS

FP

1213,516,519

33,544,5

0,5111

1516,52124

4,5567

1111,5

16,518,52326,5

5,567,58,5

1111,5

18202528,5

6,5 7 910

111,51,5

19,521,52731

7,5 8,510,512

11,51,51,5

2426,53034,5

110110125125140160180225

5,56,578

11,51,52

303337,543

9101113

1,5222,5

32,536,541,547,5

10,51213,515,5

1,522,53

35,539,54552

12,5141618,5

22,52,53

38,5434956

1516,51921,5

232,53

250280355450500

37,544,550,55463,5

910,5121315

2,52,533,54

47,55663,567,579

1416,5192023,5

2,53444,5

5261,569,574,587

17202324,528,5

33,544,55

56,567768195

2024272934

3,53,54,555,5

61,5 72,5 82,5 88103

23,528323440

3,544,55,56

110110125125

91012,514,5

22,533,5

0,50,50,51

1112,51618

3,53,54,55,5

0,5111

0,5111

12,51417,520

44,55,56,5

13,5151921,5

4,55,56,57,5

1111

14,516,520,523,5

5,56,589

1111,5

140160180225

18202326,6

4,54,55,56,5

1111,5

22,52528,533

6,5 7,5 8,510

11,51,52,5

2527,531,536

8 91012

1,51,522,5

273034,539,5

9,510,51214

1,51,522,5

29,532,53743

11,512,514,516,5

1,51,523

250280355450500

2934,5394249,5

7 8 91012

222,533,5

36434952,562

1112,514,515,518,5

2,533,53,54,5

39,54753,557,568

1315,517,518,522

2,533,544,5

43,551,558,56374

15,518,52122,526,5

3344,55

4755,563,56880,5

1821,524,526,531

33,5455,5

110110125125

7 81011,5

1,522,53

0,50,50,50,5

91012,514,5

2,5344,5

0,50,511

10111416

33,54,55

0,50,511

11121517,5

44,55,56

1111

1111

11,51316,519

4,556,57,5

140160180225

14,51618,521,5

3,544,55

1111

18202326,5

5,5678

111,51,5

111,51,5

202225,529

6,578,59,5

222427,532

8 8,51011,5

11,522,5

23,5263034,5

91011,513,5

1,51,522,5

250280355450500

23,52831,53440,5

5,56,57,589,5

11,5223

2934,539,54350,5

8,510,51212,515

22,5334

323843,54755,5

10,512,514,515,518

2,533,53,54,5

3541,547,551,560,5

12,5151718,521,5

2,533,544,5

384551,555,566

14,517,52021,525,5

2,53445

110110125125

66,58,59,5

1,51,522,5

0,50,50,50,5

7,5 8,510,512

22,533,5

0,50,50,51

8 9,511,513,5

2,5344,5

0,50,50,51

91012,514,5

33,54,55

0,5111

10111416

445,56

1111

140160180225

1213,515,518

33.53.54

0,5111

151719,522,5

4,555,56,5

1111

16,518,52124,5

5,5678

1111,5

18202327

6,578,59,5

1112,5

19,5222529

7,5 8,5 9,511

11,51,52,5

250280355450500

19,523,526,52934

4,55,56,578

1122,53

24,52933,53643

7,5 8,51010,513

1,51,5333,5

2732374047

910,5121315,5

22,533,54

29,5354043,551,5

10,512,514,515,518,5

2,5333,54,5

323843,54755,5

12,514,5171821,5

2,533,544,5

DN 20-300, Insulation thickness 2









FER

7.217

15.10.2003

l

Lg DS

FP

Steel piped x s

mm

90° °°° Tv=50 ° C ( T=40 ° C)

DN D

mm

350400450500

Tv=60 ° C ( T=50 ° C)

Tv=65 ° C ( T=55 ° C)

Tv=70 ° C ( T=60 ° C)

100 ° °°° 110 ° °°° 120 ° °°° 130 ° °°° Tv=75 ° C ( T=65° C)

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

TB

0,6

m0,

8 m

1,

0 m

1,

2 m

m

H

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

Steel piped x s

mm

90° °°° Tv=50 ° C ( T=40 ° C)

DN D

mm350400450500

Tv=60 ° C ( T=50 ° C)

Tv=65 ° C ( T=55 ° C)

Tv=70 ° C ( T=60 ° C)

100 ° °°° 110 ° °°° 120 ° °°° 130 ° °°° Tv=75 ° C ( T=65° C)

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

TB

0,6

m0,

8 m

1,

0 m

1,

2 m

m

H

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3


355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

350400450500

350400450500

350400450500

350400450500

350400450500

350400450500

500560630710

500560630710

500560630710

500560630710

560630710800

560630710800

560630710800

560630710800

6977,57674

16,518,51818

86 979592

25,5292827,5

95106105102

313534,533

103116114111

3741,54139,5

112126124120

4348,54846,5

54616058

13141414

67767575

2022,52221,5

748382,580,5

24272726

81 91 90 87,5

2932,53231

879997,595

34383836,5

445049,548

10,511,51211,5

55626260,5

16,518,518,518

61696866,5

19,522,522,522

66757472

23,526,526,526

728180,578,5

2831,53130,5

37,542,54241

9101010

47535352

1415,515,515,5

51,5585856,5

17191918,5

56646361,5

202322,522

60,56968,567

23,526,526,526

61,56967,565,5

14,5161615,5

778684,582

2325,52524,5

84,594,59390

27,53130,529,5

9210310198

33373635

100112110107

38,54342,541

48545352

11,51312,512,5

6067,566,565

182020,519,5

66747371

21,5242423,5

72818078

25,52928,528

7887,586,584

383433,532,5

39,5444443

9,510,510,510

4955,55553,5

14,516,516,516

546160,559

17,5202019

5966,56664

2123,523,523

64727169,5

24,527,527,527

33,537,537,536,5

8999

41,5474746

12,5141413,5

4651,551,550

15171716,5

5056,55655

17,5202019,5

54616159,5

2123,523,523

4,5566

44,54,54,5

3,544,54,5

3,5444,5

5,566,57

55,55,55,5

4,555,56

44,555,5

66,57,57,5

5,566,56,5

55,55,56

4,555,56

6,577,58,5

66,577,5

5,5666,5

55,566,5

788,59,5

6,577,57,5

66,577,5

5,566,57

44,555,5

3,54,54,54,5

3,5444

3,544,54,5

5,566,57

4,555,56

44,54,55

44,555

66,577,5

55,566,5

4,555,56

455,56

677,58

5,566,57

55,566,5

4,555,55,5

6,57,588,5

6,56,577,5

5,566,57

55,567

DN 350-500 Insulation thickness 1 + 2










FER

7.218

15.10.2003

Steel piped x s

mm

90° °°° Tv=50 ° C ( T=40 ° C)

DN D

mm20253240

50 65 80100125150200

20253240

50 65 80100125150200

20253240

50 65 80100125150200

20253240

50 65 80100125150200

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5

Tv=60 ° C ( T=50 ° C)

Tv=65 ° C ( T=55 ° C)

Tv=70 ° C ( T=60 ° C)

100 ° °°° 110 ° °°° 120 ° °°° 130 ° °°° Tv=75 ° C ( T=65° C)

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

Lgm

lmm

DS m

TB

H =

0,6

m

H =

0,8

m

H =

1,0

m

H =

1,2

m

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5

26,9 x 2,6533,7 x 2,342,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5

26,9 x 2,6533,7 x 2,642,4 x 2,648,3 x 2,6

60,3 x 2,9 76,1 x 2,9 88,9 x 3,2114,3 x 3,6139,7 x 3,6168,3 x 4,0219,1 x 4,5

l

Lg DS

FP

125125140140

10,511,51517

2,533,54

0,50,511

1314,51821,5

44,55,56,5

1111

14,51620,523,5

4,55,56,57,5

1111,5

15,517,522,525,5

5,56,589

1111,5

17192427,5

6,5 7,5 9,510,5

111,51,5

160180200250

2123,52731

55,56,57,5

111,51,5

2629,53439,5

7,5 8,51011,5

1,51,522,5

28,5323742,5

9,510,51214

1,51,522,5

313540,546,5

1112,514,516,5

1,51,52,53

34384450,5

1314,51719,5

1,5233

280315400

33,539,545

89,5

10,5

22,53

4249,556

12,514,516,5

2,533,5

46,554,561,5

151820

334

50,559,567,5

182124

33,54

5564,573

212528

444,5

125125140140

8 911,513

222,53

0,50,50,51

10111416

33,545

0,5111

0,5111

111215,517,5

3,5456

12131719,5

44,567

1111

1111

1314,518,521

55,578

160180200250

15,517,520,523,5

3,5455,5

1111

19,52225,529,5

66,57,58,5

111,51,5

21,524,52832,5

7 8 910,5

11,51,52,5

23,526,53135,5

8,5 9,51112,5

11,522,5

25,52933,538,5

10111315

1,51,522,5

280315400

25,530,534,5

678,5

1,51,52,5

323843,5

9,511,513

22,53

35,54247,5

11,513,515,5

2,533,5

38,545,552

141618,5

2,533,5

4249,556

161921,5

33,54

125124140140

6,5 7 910,5

1,51,522,5

0,50,50,50,5

8 911,513

2,52,534

0,50,511

8,5 9,512,514,5

3344,5

0,50,511

9,510,513,515,5

3,5455,5

0,5111

10,511,514,517

44,55,56,5

1111

160180200250

12,514,516,519

33,544,5

1111

161820,524

4,55,567

1111,5

17,519,52326

5,56,57,58,5

111,52

1921,52528,5

6,5 7,5 910

11,51,52,5

20,523,52731

8 910,512

1,51,522,5

280315400

2124,528,5

567

11,52,5

263135,5

7,59

10,5

1,52,53

28,53438,5

9,51112,5

2,533

31,53742

111315

2,533,5

344046

1315,517,5

2,533,5

125125140140

5,567,58,5

1,51,522

0,50,50,50,5

6,5 7,5 9,511

2233

0,50,50,51

7,5 810,512

2,52,53,54

0,50,50,51

8 911,513

3344,5

0,5111

8,5 9,512,514

3,53,54,55,5

1111

160180200250280315400

10,512141617,520,524

2,533,54455,5

1111

131517,520

44,556

1111

14,516,51922

4,55,567

1111,5

16182124

5,56,57,58,5

1112

1719,522,526

6,5 7,5 8,510

11,51,52,5

11,52

222629,5

6,57,59

1,523

2428,532,5

89,5

10,5

1,52,53

263135,5

9,51112,5

2,533

28,533,538,5

111315

2,533,5

DN 20-200 Insulation thickness 3









FER

7.220

15.10.2003

12050 60 70 80 90 100 110

120

110

100

90

80

70

60

50

40

30

20

1010

20

30

40

50

60

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

10

20

4050120 100 90 80 70 60

2030

4050

60

90100110120

Lmax [m

]

15

30

Restricted expansion

7080


Temperature difference T1) [K]

Expansion hindered by earth friction

Ratio

L/L

max

Ex

pans

ion

L

[mm

]

Pipe length L [m]

Pipe

leng

th L

[m]

Pipe

leng

th L

[m]

DN 125/250, welded inner pipepipe length L = 30 mH = 0,8 m

T = 100 KLmax = 56 m(from worksheet 7.212)L/Lmax = 0,53

Example:

l = 28 mm

2)

3)

(free expansion = 36 mm)

Temperature difference: operating temperature minus laying temperature Pipe length L measured from fixed point to axis of expansion leg Dimension H is the covering height measured from the pipe apex to the consolidated or compressed ground surface

1)2)3)



FER

7.221Expansion up to 90° C, DN 20-125

Insulation 2, permissible without prestressing

H=0.70 m • DS 2

H=0.70 m • DS 2

76.1-160

Exp

ansi

on

l [

mm

]Ex

pan

sio

n

l [m

m]

Laying length of pipe L [m]

Exp

ansi

on

l [

mm

]

H=0.70 m • DS 2

2

4

6

8

10

12

14

16

10 15 20 25 30 35 40 45 50 55 60 65 70

5

10

15

20

25

10 15 20 25 30 35 40 45 50 55 60 65 70

5

10

15

20

25

30

35

10 15 20 25 30 35 40 45 50 55 60 65 70

TB=65 ° C( T=55 ° C)

TB=80 ° C( T=70 ° C)

TB=90 ° C( T=80 ° C)

139.7-250

114.3-225

88.9-180

76.1-16060.3-140

48.3-12542.4-125

33.7-11026.9-110

114.3-225

88.9-180

76.1-160

48.3-12542.4-125

33.7-110

26.9-110 33.7-110

42.4-125

60.3-140

88.9-180

114.3-225

48.3-125

Adhesion areaSliding area

60.3-140

139.7-250

p

The maximum permissible laying length may be exceeded. Temperature stress at 90 ° max. 190 N/mm .

Coverage correction factor:H = 0.60 m l graph + 12%H = 0.80 m l graph – 12%

Maximum permissible coverage height: see sheet 7.210Expansion members:see sheet 7.230.

26.9-110

139.7-250

TB [° C]L [m]H [m]

l [mm]DS [m]Fr' [kN/m] =190 N/mm =0,5 =19 kN/m

Kd=0,463

µ2

3

Operating temperatureLaying length of pipeCoverage heightExpansionExpansion legFrictional forcePermissible stressFriction factor, earth / PEWeight of earth per unit of volumeCoefficient of earth pressure at rest

Example (sheet 7.230):Pipe 76.1-160 (insulation thickness 2)Operating temperature TB = 80° CPipe length L = 40 m or moreSliding area Lg = 40 mExpansion l = 17 mmExpansion leg DS = 2.4 m

DS

= 2

.4 m

l = 17 mm

DK

l = 17 mm

DS = 2.4 m

l

Lg

NFP

LDSFr'[kN/m]


15.10.2003





2



FER

7.222Expansion up to 90° C, DN 20-125

Insulation 3, permissible without prestressing

Exp

ansi

on

l [

mm

]Ex

pan

sio

n

l [m

m]


Exp

ansi

on

l [

mm

]

The maximum permissible laying length may be exceeded. Temperature stress at 90 ° max. 190 N/mm .

Coverage correction factor:H = 0.60 m l graph + 12%H = 0.80 m l graph – 12%

Maximum permissible coverage height: see sheet 7.210Expansion members:see sheet 7.230.

TB [° C]L [m]H [m]

l [mm]DS [m]Fr' [kN/m] =190 N/mm =0,5 =19 kN/m

Kd=0,463

µ2

3

Operating temperatureLaying length of pipeCoverage heightExpansionExpansion legFrictional forcePermissible stressFriction factor, earth / PEWeight of earth per unit of volumeCoefficient of earth pressure at rest

Example (sheet 7.230):Pipe 76.1-180 (insulation thickness 3)Operating temperature TB = 80° CPipe length L = 40 m or moreSliding area Lg = 35 mExpansion l = 15 mmExpansion leg DS = 2.2 m

DS

= 2

.2 m

l = 15 mm

DK

l = 15 mm

DS = 2.2 m

l

Lg

NFP

LDSFr'[kN/m]


15.10.2003




Laying length of pipe L [m]H=0.70 m • DS 3

H=0.70 m • DS 3

H=0.70 m • DS 3

139.7-280

114.3-250

88.9-200

76.1-18060.3-160

48.3-14042.4-140

33.7-12526.9-125

2

4

6

8

10

12

14

10 15 20 25 30 35 40 45 50 55 60 65 70

5

10

15

20

25

10 15 20 25 30 35 40 45 50 55 60 65 70

5

10

15

20

25

30

10 15 20 25 30 35 40 45 50 55 60 65 70

TB=65 ° C( T=55 ° C)

TB=80 ° C( T=70 ° C)

TB=90 ° C( T=80 ° C)

139.7-280

114.3-250

88.9-200

76.1-180

60.3-160

48.3-140

42.4-140 33.7-125

26.9-125

139.7-280

114.3-25088.9-200

76.1-180

60.3-160

48.3-140

42.4-14033.7-125

26.9-125


2



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FER

7.230

15.10.2003

Expansion elements

DS

DS

l

l

DK

A

DS

l

DK

B

DS

l1DK

x xFP

B

DS/2

C

DS/2

DS

l1

l2DK

l2

DN

20, 25 32, 40 50 65, 80100

125150200250300*

10 15 20 25 30 35 40 50 601,21,41,61,82,1

1,31,61,92,22,5

1,622,22,62,9

1,72,22,52,93,3

22,52,73,33,7

2,12,633,54

2,333,23,94,5

2,633,64,65

2,93,4455,7

2,42,72,93,23,4

2,83,63,844,2

3,34,54,75,15,2

3,655,55,96,0

45,96,577,1

4,56,577,57,8

5788,28,6

5,6 8 91010,2

6,5 9111212,5

DN 10 15 20 25 30 35 40 50 60

15 20 30 40 50 60 70 80 90 100DN

DN

20, 2532, 40506580

100125150200250, 300*

11,31,51,71,8

1,21,522,12,2

1,41,82,22,42,5

1,522,42,62,8

1,72,32,72,93,1

1,92,42,83,13,3

2,12,633,43,5

2,42,93,43,74

2,63,23,744,5

2,32,32,72,83,1

2,52,72,83,33,7

2,93,23,23,74,1

3,23,53,644,6

3,53,944,55,1

3,74,14,44,75,2

44,54,755,9

4,555,566,6

4,95,5677,6

20, 2532, 405065

80100125150*

11,21,3

20, 2532, 4050

65, 80100, 125150, 200250300*

1,21,41,5

30 40 50 60 70 80 90 100

1,51,61,8

1,622,3

1,92,32,5

2,12,42,7

2,32,63

2,42,83,2

2,533,5

2,73,23,7

1,62,222,32,4

1,82,42,42,62,8

2,32,63,13,53,7

2,63,244,24,5

33,74,555,3

3,44,15,25,76

3,64,55,96,36,7

456,377,3

4,45,477,68

4,65,87,688,5

1111,6

111,21,6

1111,6

11,21,41,6

11,31,51,6

1,21,41,62

1,31,51,82

1,41,722

1,61,651,651,65

1,61,651,652,2

1,61,651,651,65

1,61,6522,5

1,6222,8

222,33,3

22,32,53,5

2,22,52,74

Sheet 1


Requisite minimum length of the expansion leg, DS The length and location of the expansion pads may be seen from the tables and from worksheet 7.232. The maximum permissible expansion for expansion is 45 mm. Operating pressure 16 bar.

L elbow

Z elbow

U elbow

L elbow

DK = expansion padsFP = fixed point

Do not add l of both sides!

l = l1+ l2

C = 1 m whereDN is 20 - 50;C = 2 m whereDN is 65 - 250

A = DS/2 whereDN is 20 - 125;A = DS whereDN is 150 - 250

l = l1+ l2

B = DS/2 whereDN is 20 - 125;B = DS whereDN is 150 - 250

Expansion leg DS in m

Expansion l in mm

Expansion l in mm

Expansion l = l1 + l2 in mm

*for larger dimensions, values must be calculated

Expansion l = l1 + l2 in mm



FER

7.231

15.10.2003

Expansion elementsElbow < 90° (bend in the line); sheet 2

In order to determine the expansion leg length (DS) and expansion pad location (DK) for elbows< 90° , the lateral displacement (deflection) Q is a determining factor. The lateral displacement Q maybe a maximum of 45 mm where the line is being laid using expansion pads. Anchors may ifnecessary be arranged before bends in the line, or else the elbows should be mechanically orthermally prestressed, causing the values for Q to be halved. The total lateral displacement Q shouldbe used in all cases for calculating the thickness of the expansion areas without thermalprestressing.

l1 l2

Q1 Q2l1

l1

l2

l2

Q1 =

Q2 =

sin

sin

tan

tan

+

+

20 25 30

30°25°20°15°10°

18,522,52838

37,545

43

353841,545,5

90°85°80°75°70°65°60°55°50°45°40°35°

55,566,57899,5

11121416

10111213141617,519

21,52427,532

15161819,521,523,5262932364147,5

2022242628,531,534,538,5

25273033363943

3033363943

4043,547,5

5 10 15 35 40


Determining the features of expansion legs DS

Determining the features of expansion pads DK, DN 20 - DN 250Thickness of the pad: Q [mm] is a determining factor Length: expansion leg length Location: see worksheet 7.232, location of expansion pads

DN 20 - DN 100: by Q [mm] from table of expansion elements L elbow, sheet 7.230DN 125 - DN 250: by Q [mm] x 1.1, from table of expansion elements L elbow, sheet 7.230

Table for Q where l1 = l2

Expansion l1 = l2 [mm]

Lateral displacement Q1 = Q2 [mm]

Bend

Calculation of lateral displacement, Q:

If l1 = l2 => Q = l/sin + l/tan



FER

7.232

15.10.2003

Expansion pads are located in the area of expansion elbows, T pieces and reducing sockets, in orderto allow the FERWAG pipe to move in the earth. They are located in layers around the pipe in such away that the length alteration determined according to worksheets can be fully taken up.At least one expansion pad should be fitted in the incoming pipe leg in the area of the pipe elbow.If additional expansion pad has to be taken up in the pipe leg, accordingly more expansion, the padsmust be fitted there, according to the length alteration.

Location ofexpansion pads

l

DS / 2

DS

FPl [mm]

3

4 – 23

24 – 45

without expansion pads

1 layer (thickness 40 mm)

2 layers (thickness 80 mm)(2nd layer = 1/2 of the 1st layer)

DK


1 layer of expansion pads where there is the same expansion from both directions

2 layers of expansion pads where there is the same expansion from both directions

Expansion pads in the sliding area of the main line on reducing sockets

Expansion pads on T branches Fitting the expansion pads to the pipelines

Example FERWAG pipe, DN 80

l = 40 mm, expansion leg DS = 3,9 m1st layer = 4 pads (metre)2nd layer = 1/2 of 1st layer = 2 pads (m)

Expansion pads[quantity]

Number of expansion pads

®

®

®



FER

7.240

15.10.2003

Pressure losses

.1

1

10

100

.1 1

1000 000

100 000

10 000

1 000

500400

50 200 300 2000 3000100 1000500

5 10 20 30 50 100 200 300

Pa/m

mmWC/m

Pressure loss, p

2 000

3 000

4 0005 000

20 000

30 000

40 00050 000

200 000

300 000

400 000500 000

kgh

Flo

w q

uan

tity

, m

•

DN 20

25

3240

50

65 80

100

125

150

200

250300

350

0.3

5000

500

100

50

30

20

10

5

3

2

1

0,5

0,3

0,2

0,15

kgs

Flow

qua

ntity

, m

•

20 25 32 40 50 65 80100125150200250300350400450500

21,6 29,1 37,2 43,1 54,5 70,3 82,5107,1132,5160,3210,1263,0312,7344,4393,8444,6495,4

DN D inter.mm

DN

Water velocity w

[m/s]

Average water temperature 80 ° C

0.4 m/s

0.5

0.6

0.8

1.0

3.63.22.82.4

1.21.4

1.61.8

2.0

m Q · 860

T

Surface roughness value = 0.045 mm

(1 mmWC = 9.81 Pa)


Average water temperature 80 ° C

m = Flow rate in kg/hQ = Power requirement in kW

T= Temp. difference, forward and return flow in ° C




Heat lossInsulation thickness 1

FER

7.241

26.8.2003

TypeFERWAG®

26,9 - 90

33,7 - 90

42,4 - 110

48,3 - 110

60,3 - 125

76,1 - 140

88,9 - 160

114,3 - 200

139,7 - 225

168,3 - 250

219,1 - 315

273,0 - 400

323,9 - 450

355,6 - 500

406,4 - 560

457,2 - 630

508,0 - 710

U-value [W/mK]

0.132

0.161

0.165

0.190

0.212

0.250

0.257

0.268

0.311

0.370

0.403

0.388

0.446

0.433

0.460

0.457

0.441

50°

5.3

6.5

6.6

7.6

8.5

10.0

10.3

10.7

12.5

14.8

16.1

15.5

17.8

17.3

18.4

18.3

17.6

60°

6.6

8.1

8.2

9.5

10.6

12.5

12.9

13.4

15.6

18.5

20.1

19.4

22.3

21.7

23.0

22.9

22.0

70°

7.9

9.7

9.9

11.4

12.7

15.0

15.4

16.10

18.70

22.2

24.2

23.3

26.8

26.0

27.6

27.4

26.5

80°

9.2

11.30

11.5

13.3

14.8

17.5

18.0

18.8

21.8

25.9

28.2

27.2

31.2

30.3

32.2

32.0

30.9

90°

10.56

12.91

13.18

15.18

16.95

19.97

20.57

21.47

24.91

29.58

32.22

31.06

35.67

34.67

36.80

36.58

35.27

100°

11.9

14.5

14.8

17.1

19.1

22.5

23.1

24.2

28.0

33.3

36.2

34.9

40.1

39.0

41.4

41.2

39.7

110°

13.2

16.1

16.5

19.0

21.2

25.0

25.7

26.8

31.1

37.0

40.3

38.8

44.6

43.3

46.0

45.7

44.1

120°

14.5

17.8

18.1

20.9

23.3

27.5

28.3

29.5

34.3

40.7

44.3

42.7

49.0

47.7

50.6

50.3

48.5

130°

15.8

19.4

19.8

22.8

25.4

30.0

30.9

32.2

37.4

44.4

48.3

46.6

53.5

52.0

55.2

54.9

52.9

Heat losses q [W/m] for a pipe

Operating temperature TB [°C]

Heat loss during operation: q = U (TB - TE) [W/m] U = Specific heat losses [W/mK]TB = Average operating temperature [ °C]TE = Average ground temperature [ °C]

2 pipes laid a = 0,20 mTE = 10 °CH = 0,6 mλE = 1,2 W/mKλPU= 0,0260 W/mK

Method of laying:Distance between pipes:Earth temperature:Covering height:Conductivity of ground:Conductivity of PU foam:

TE

E λ

a

H





FER

7.242

26.8.2003

TypeFERWAG®

26,9 - 110

33,7 - 110

42,4 - 125

48,3 - 125

60,3 - 140

76,1 - 160

88,9 - 180

114,3 - 225

139,7 - 250

168,3 - 280

219,1 - 355

273,0- 450

323,9 - 500

355,6 - 560

406,4 - 630

457,2 - 710

508,0 - 800

U-value [W/mK]

0.113

0.134

0.145

0.165

0.184

0.207

0.216

0.225

0.260

0.295

0.312

0.304

0.347

0.334

0.346

0.343

0.334

50°

4.5

5.4

5.8

6.6

7.4

8.3

8.7

9.0

10.4

11.8

12.5

12.2

13.9

13.4

13.8

13.7

13.4

60°

5.6

6.7

7.3

8.2

9.2

10.3

10.8

11.3

13.0

14.8

15.6

15.2

17.4

16.7

17.3

17.2

16.7

70°

6.8

8.0

8.7

9.9

11.0

12.4

13.0

13.5

15.6

17.7

18.7

18.2

20.8

20.1

20.8

20.6

20.1

80°

7.9

9.4

10.2

11.5

12.9

14.5

15.1

15.8

18.2

20.7

21.9

21.3

24.3

23.4

24.2

24.0

23.4

90°

9.0

10.7

11.6

13.2

14.7

16.5

17.3

18.0

20.8

23.6

25.0

24.3

27.8

26.7

27.7

27.5

26.8

100°

10.2

12.0

13.1

14.8

16.6

18.6

19.5

20.3

23.4

26.6

28.1

27.4

31.3

30.1

31.2

30.9

30.1

110°

11.3

13.4

14.5

16.5

18.4

20.7

21.6

22.5

26.0

29.5

31.2

30.4

34.7

33.4

34.6

34.3

33.4

120°

12.4

14.7

16.0

18.1

20.3

22.7

23.8

24.8

28.6

32.5

34.4

33.4

38.2

36.8

38.1

37.8

36.8

130°

13.5

16.1

17.4

19.7

22.1

24.8

26.0

27.0

31.2

35.4

37.5

36.5

41.7

40.1

41.5

41.2

40.1






TE

E λ

a

H





FER

7.243

26.8.2003

TypeFERWAG®

26,9 - 125

33,7 - 125

42,4 - 140

48,3 - 140

60,3 - 160

76,1 - 180

88,9 - 200

114,3 - 250

139,7 - 280

168,3 - 315

219,1 - 400

U-value [W/mK]

0.104

0.121

0.132

0.147

0.160

0.179

0.190

0.203

0.221

0.244

0.255

50°

4.1

4.8

5.3

5.9

6.4

7.2

7.6

8.1

8.8

9.8

10.2

60°

5.2

6.0

6.6

7.4

8.0

9.0

9.5

10.1

11.0

12.2

12.8

70°

6.2

7.2

7.9

8.8

9.6

10.8

11.4

12.2

13.3

14.6

15.3

80°

7.2

8.5

9.2

10.3

11.2

12.6

13.3

14.2

15.5

17.1

17.9

90°

8.3

9.7

10.5

11.8

12.8

14.4

15.2

16.2

17.7

19.5

20.4

100°

9.3

10.9

11.9

13.3

14.4

16.1

17.1

18.2

19.9

22.0

23.0

110°

10.4

12.1

13.2

14.7

16.0

17.9

19.0

20.3

22.1

24.4

25.5

120°

11.4

13.3

14.5

16.2

17.6

19.7

20.9

22.3

24.3

26.8

28.1

130°

12.4

14.5

15.8

17.7

19.2

21.5

22.8

24.3

26.5

29.3

30.6






TE

E λ

a

H



FER

7.250

15.10.2003

Laying directionsheet 1

When locating branches, e.g. house connection lines to the main line, the particular features ofthe plastic sleeve pipe system must be observed. Even short connection lines of small dimensionare held by the surrounding earth, so that their movement is restricted. The natural fixed point isagain created within the length of the connection line, so that restoring forces act on the mainline. The differing movements and force conditions of main lines and the connection line musttherefore be taken into account in all cases.

DK

NFP

max. 6m

Mai

n lin

eBuilding

DK

FP

> 6m

max. 3m

DK

NFP

bl

a

> 6 m


Location of branches

Fig. 1Connection line 6m1.1 Direct connection

Fig. 2Connection line > 6m 2.1 With anchor

2.2 With L-elbow adjacent to main line

NFP = natural fixed point DK = expansion pad

Mai

n lin

eM

ain

line

Building

Building



FER

7.251

15.10.2003


The leg length a depends on length l. Length b is based on the possible movement of the main line.The total length a + b should be surrounded by expansion pads. Expansions of the main line are alsopossible on connections in the adhesion area, as a result of subsequent repair measures, so thatexpansion pads must be fitted as a precautionary measure. The thickness of the expansion pads thenneeded can be reduced if the connection lines remain free and are laid with low stress, where themain line is prestressed.

bl

a

NFP

Main line

NFP

Main line

Building

DK

DK


Fig. 3

3.1 With L-elbow above main line (special manufacture)

NFP = natural fixed point DK = expansion pad



FER

7.252

15.10.2003


Pipe elbows, minimum bending radiusIf district heating pipes have to be laid along roads, it may be necessaryto follow curves in the road by means of elbows or bends in the pipe. Insuch cases, the elbows may be composed of several straight lengths ofpipe. If the angle is up to 3 ° , these elbows can be created with bevelledcuts, but for greater angles, they can only be created with mouldedfittings.

This curvature of the line creates bending stresses in the pipe, making itnecessary to specify a minimum radius of bending in relation to the pipedimensions. The minimum bending radius and the resulting maximumdeflection can be obtained as follows:

Laying with small bendsSliding area: bends of a maximum of 3° are permissible in bevelled cuts.Adhesion area: bends of a maximum of 5° are permissible in bevelled cuts.The bends must be laid without expansion pads.

Reductions in the adhesion areaDepending on the different stress cross-sections, there is bound to be a shift in the progression ofthe axial pressure force in the reduction.The higher pressure force in the area of the larger dimension may lead to an overload in the smallerstress cross-section, as a reaction force. This may be excluded either by avoiding reductions in theadhesion area, or by positioning a fixed point on the larger dimension side.

DN

26.933.742.448.3

60.3 76.1 88.9114.3

139.7168.3219.1273.0

323.9355.6406.4457.2508.0

da Rminm

Reductions in the adhesion area

d1 d2

Fixed point

Rzul = Es · da/ b 2000 [mm]

h = R · [1 – 1 – (s/(2 · R))2] [m]

h

Rzul

s

= minimum radius of bending [m]= chord length [m]= maximum deflection [m]= external diameter of steel pipe [m]= modulus of elasticity for steel 210000 [N/mm2]= permissible bending stress 104 [N/mm2]

RzulShdaEs

b

20253240

506580

100

125150200250

300350400450500

27344248

617790

115

141170221275

327359410461513


mm



FER

7.253

15.10.2003


45°FP

L

L

L

L

At 40 - 50 ° °°°

L

L L

L

< 40 °

> 50 °

40°

50°


Changes of direction over long line lengths

At 40° °°° - 50° °°°

a) For angles a < 40 ° an additional 90° elbow should be laid on the outside (see illustration)

b) For angles a > 50° the additional 90° elbow should be attached on the inside (see illustration)

The second, newly formed angle is always larger in both cases, thus achieving more gradual compensation.



FER

7.254

15.10.2003

Connecting instructionTransition flexible pipe to plastic sheath pipe


2.0*

KMR

FP

l

Pipe joint

FP

KMR

l

DS 2.5*

Pipe joint

Transit from T-Piece KMR

min 1.0

KMR

l

Pipe joint

2.0 m

KMR

l

DK

GFK Shell

Transition with fixed point

Transition with Z elbow

1.0 m

DK

KMR

DS 2.5*

Pipe joint

1.0 m

DK

l L

Transition with expansion elbow

• Design of expansion elements• Location of expansion pads according the Chapter Plastic sheath pipe from the main catalogue.

DK

Rmin

Rmin

DS 2.0*

3

1 2

4

Laying instruction for transition flexible pipes on plastic sheath pipe (KMR)

The lateral expansion l must only be sufficient for the expansion to be absorbed by the T-branch DS and by flexibles district heating pipes.

The expansion l, owing to increase of temperature, must not be compensated by the flexibles district heating pipes.Installation of a fixed point.

Laying of Z elbow according of the expansion l, which must be compensated by section DS.

DS l

FP DK

= Expansion leg = Expansion = Plastic sheath pipe - fixed point = Expansion pads

If pipe length L resp. l is > than permitted, a fixed point should be included to allow exact check of the expansions.


flexible pipe

*FHK: 5 m possible*FHK: 5 m possible

*FHK: 5 m possible*FHK: 5 m possible



FER

7.300

15.10.2003

District heating pipe

s

d D

t

L

DN d x s

Hea

tin

gSa

nit

ary

202532

mm

40506580

100125

150200250

1/2"3/4"1"

5/4"1 1/2"2"2 1/2"3"4"

26,9 x 2,6533,7 x 2,642,4 x 2,6

48,3 x 2,660,3 x 2,976,1 x 2,988,9 x 3,2

114,3 x 3,6139,7 x 3,6

168,3 x 4,0219,1 x 4,5273,0 x 5,0

300350400450500

323,9 x 5,6355,6 x 5,6406,4 x 6,3457,2 x 6,3508,0 x 6,3

21,3 x 2,6526,9 x 2,6533,7 x 3,25 42,4 x 3,2548,3 x 3,2560,3 x 3,65

76,1 x 3,65 88,9 x 4,05114,3 x 4,50

666

66/126/126/12

6/1212

121212

1212121212

666

666

666

Dmm

tmm kg/m

90 90110

292631

2,83,04,1

l/mD

mmD

mmt

mmt

mmkg/m kg/m

110125140160

200225

250315400

28292932

3939

364256

4,55,97,39,3

13,416,4

21,231,545,8

110110125

125140160180

225250

280355450

110110110

125125140 160180225

393538

35373942

5150

516180

423936

383536 384151

2,93,24,1

5,15,57,3 9,211,616,9

3,23,54,5

4,96,37,99,9

14,617,7

23,034,650,4

125125140

140160180200

250280

315400

464346

43474852

6365

6884

3,63,94,9

5,36,98,5

10,715,919,5

25,337,3

0,370,671,09

1,462,333,885,35

9,0113,79

20,1834,6754,33

0,200,370,58

1,011,372,213,725,138,71

125125125

140140160

180200250

494643

464347

485163

3,33,64,4

5,55,97,9

9,812,418,3

450500560630710

5563664149

59,267,485,798,5124,0

500560630710800

7991997587

64,574,694,9

109,8141,0

76,80 93,16121,80155,25192,75

909090

110110125

140160200

312926 312829

293239

2,52,83,6

4,75,26,9

8,611,015,8

L m

Heating, Sanitary

16 m exceeding DN 200 on request


Steel pipe Standardlength

Insulation thickness 1 Watercontent

Insulation thickness 2 Insulation thickness 3

D – external diameter, t - insulation thickness



FER

7.305

15.10.2003

Elbows, short-legged

s

d D

L

t

R

L

R

90° 5° – 85 °

DN d x s

202532

mm

405065

80100125

150200250

1/2"3/4"1"

5/4"1 1/2"2"2 1/2"3"4"

26,9 x 2,6533,7 x 2,642,4 x 2,6

48,3 x 2,660,3 x 2,976,1 x 2,9 88,9 x 3,2

114,3 x 3,6139,7 x 3,6

168,3 x 4,0219,1 x 4,5273,0 x 5,0

450500

457,2 x 6,3508,0 x 6,3

21,3 x 2,6526,9 x 2,6533,7 x 3,25 42,4 x 3,2548,3 x 3,2560,3 x 3,65

76,1 x 3,65 88,9 x 4,05114,3 x 4,50

Dmm

tmm

Dmm

Dmm

tmm

tmm

125125140

140160180 200250280 315400

125125125

140140160

180200250

464346

434748

526365 6883

494643 464347 485163

R L m

3d3d3d

3,5d3,5d3,5d

3,5d2,5d1,5d

1,5d1,5d1,5d

1,5d1,5d

3d3d3d

3,5d3,5d2,5d

300350400

323,9 x 5,6355,6 x 5,6406,4 x 6,3

1,5d1,5d1,5d

90 90110

110125140160200225

250315400

630710

909090

110110125

140160200

450500560

292631

282929 323939 364256

556366

312926 312829

293239

4149

110110125

125140160 180225250 280355450

110110110

125125140 160180225

500560630

710800

393538

353739

425150

516180

423936

383536 384151

7587

7991 99

3,5d3,5d3,5d

L m

L m

0.50.50.5

0.50.50.65

0.650.650.65

0.651.01.0

1.01.1

1.01.01.0

0.50.50.5

0.50.50.65

0.650.650.65

1.01.01.0

1.01.5

1.01.01.0

0.50.50.5

0.50.50.5

0.60.60.6

0.50.50.5

0.50.50.5

0.60.60.6

0.50.50.5

0.50.50.5

0.60.60.6

0.50.50.5

0.50.50.65

0.650.650.65

1.01.0



Hea

tin

gSa

nit

ary




FER

7.310

15.10.2003

Elbows 90 ° , 1.0 x 2.0 m

DN d x s

202532

mm

405065

80100125

150200250

1/2"3/4"1"

5/4"1 1/2"2"2 1/2"3"4"

26,9 x 2,6533,7 x 2,642,4 x 2,6

48,3 x 2,660,3 x 2,976,1 x 2,9

88,9 x 3,2114,3 x 3,6139,7 x 3,6

168,3 x 4,0219,1 x 4,5273,0 x 5,0

21,3 x 2,6526,9 x 2,6533,7 x 3,25 42,4 x 3,2548,3 x 3,2560,3 x 3,65

76,1 x 3,65 88,9 x 4,05114,3 x 4,50

Dmm

tmm

90 90110

292631

Dmm

Dmm

tmm

tmm

110125140 160200225

250315400

282929

323939

364256

110110125

125140160 180225250

280355450

110110110

125125140 160180225

393538

353739 425150

516180

423936

383536

384151

125125140

140160180 200250280

315400

464346

434748

526365

6883

125125125

140140160

180200250

494643 464347 485163

909090

110110125

140160200

312926 312829

293239

R

3d3d3d

3,5d3,5d3,5d

3,5d2,5d1,5d

1,5d1,5d1,5d

1,5d1,5d1,5d

1,5d1,5d1,5d 2,5d2,5d2,5d

s

d D

t

R 1000

2000

Hea

tin

gSa

nit

ary





FER

7.312

15.10.2003

T pieces, branch-off at 45 °

L1 [m] L2 [m]

45 °

Heating, Insulation thickness 1

H [m

m]

DD d


DN D [mm]

90

90

110

110

125

140

160

200

225

250

315

400

450

500

560

630

710

DN

20

25

32

40

50

65

80

100

125

150

200

250

300

350

400

450

500

1.0/1.0180

L1/L2H

20 25 32 40 50 65 80 100 125 200 250 300 350 400150

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

1.0/1.0180

1.0/1.0180

1.0/1.0190

1.0/1.0190

1.0/1.0195

1.0/1.0200

1.0/1.0190

1.0/1.0195

1.0/1.0195

1.0/1.0195

1.0/1.0200

1.0/1.0210

1.0/1.0215

1.0/1.0205

1.0/1.0215

1.0/1.0220

1.0/1.0225

1.0/1.0215

1.0/1.0225

1.0/1.0230

1.0/1.0240

1.0/1.0250

1.0/1.0230

1.0/1.0235

1.0/1.0230

1.0/1.0240

1.0/1.0275

1.0/1.0245

1.0/1.0240

1.0/1.0250

1.0/1.0245

1.0/1.0240

1.0/1.0250

1.0/1.0250

1.0/1.0245

1.0/1.0260

1.0/1.0260

1.0/1.0255

1.0/1.0270

1.0/1.0270

1.0/1.0265

1.0/1.0280

1.0/1.0295

1.0/1.0285

1.0/1.0300

1.0/1.0300

1.0/1.0310

1.0/1.0320

1.0/1.0285

1.0/1.0285

1.0/1.0295

1.0/1.0300

1.0/1.0310

1.0/1.0330

1.0/1.0345

1.0/1.0365

1.0/1.0390

1.0/1.0325

1.0/1.0325

1.0/1.0335

1.0/1.0340

1.0/1.0350

1.0/1.0370

1.3/1.0385

1.3/1.0395

1.0/1.0385

1.0/1.0360

1.0/1.0365

1.0/1.0375

1.0/1.0395

1.5/1.0410

1.5/1.0420

1.0/1.0385

1.0/1.0390

1.0/1.0400

1.0/1.0420

1.5/1.0435

1.5/1.0445

1.0/1.0420

1.0/1.0430

1.0/1.0450

1.5/1.0465

1.5/1.0475

1.0/1.0465

1.0/1.0485

1.5/1.0500

1.5/1.0510

1.0/1.0525

1.5/1.0540

1.5/1.0550

1.3/1.0430

1.5/1.0455

1.5/1.0480

1.5/1.0510

1.5/1.0545

1.5/1.5585

1.3/1.0470

1.5/1.0495

1.5/1.0520

1.5/1.0550

1.5/1.0585

1.5/1.0625

1.5/1.0520

1.5/1.0545

1.5/1.0575

1.5/1.0610

1.5/1.0650

1.5/1.5570

1.5/1.5600

1.5/1.5635

1.5/1.5675

1.0/1.0190

1.0/1.0195

1.0/1.0205

1.0/1.0215

1.0/1.0235

1.0/1.0230

1.0/1.0240

1.5/1.5630

1.5/1.5665

1.5/1.5705

Main line Branch line

Casingpipe



FER

7.313

15.10.2003


L1 [m] L2 [m]

45 °


H [m

m]

DD d


DN D [mm]

110

110

125

125

140

160

180

225

250

280

355

450

500

560

630

710

800

DN

20

25

32

40

50

65

80

100

125

150

200

250

300

350

400

450

500

1.0/1.0180

L1/L2H

20 25 32 40 50 65 80 100 125 200 250 300 350 400150

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

1.0/1.0180

1.0/1.0180

1.0/1.0190

1.0/1.0190

1.0/1.0195

1.0/1.0200

1.0/1.0190

1.0/1.0195

1.0/1.0195

1.0/1.0195

1.0/1.0200

1.0/1.0210

1.0/1.0215

1.0/1.0205

1.0/1.0215

1.0/1.0220

1.0/1.0225

1.0/1.0215

1.0/1.0225

1.0/1.0230

1.0/1.0240

1.0/1.0250

1.0/1.0230

1.0/1.0235

1.0/1.0250

1.0/1.0265

1.0/1.0300

1.0/1.0245

1.0/1.0255

1.0/1.0275

1.0/1.0245

1.0/1.0255

1.0/1.0275

1.0/1.0250

1.0/1.0265

1.0/1.0280

1.0/1.0260

1.0/1.0275

1.0/1.0290

1.0/1.0270

1.0/1.0285

1.0/1.0300

1.0/1.0295

1.0/1.0305

1.0/1.0320

1.0/1.0320

1.0/1.0335

1.0/1.0350

1.0/1.0310

1.0/1.0310

1.0/1.0320

1.0/1.0330

1.0/1.0340

1.3/1.0360

1.3/1.0370

1.3/1.0390

1.3/1.0425

1.0/1.0360

1.0/1.0360

1.0/1.0365

1.0/1.0375

1.0/1.0385

1.3/1.0410

1.3/1.0420

1.3/1.0435

1.0/1.0385

1.0/1.0390

1.0/1.0400

1.0/1.0410

1.5/1.0435

1.5/1.0445

1.5/1.0460

1.0/1.0420

1.0/1.0430

1.0/1.0440

1.5/1.0465

1.5/1.0475

1.5/1.0490

1.0/1.0465

1.0/1.0475

1.5/1.0495

1.5/1.0510

1.5/1.0525

1.0/1.0515

1.5/1.0540

1.5/1.0550

1.5/1.0565

1.5/1.0585

1.5/1.0595

1.5/1.5610

1.3/1.0475

1.5/1.0495

1.5/1.0530

1.5/1.5560

1.5/1.0605

1.5/1.0650

1.3/1.0520

1.5/1.0545

1.5/1.0575

1.5/1.0610

1.5/1.0650

1.5/1.0695

1.5/1.5570

1.5/1.5600

1.5/1.5635

1.5/1.5675

1.5/1.5720

1.5/1.5630

1.5/1.5665

1.5/1.5705

1.5/1.5750

1.0/1.0190

1.0/1.0195

1.0/1.0205

1.0/1.0215

1.0/1.0235

1.0/1.0250

1.0/1.0265

Main line

Casingpipe

Branch line



FER

7.314

15.10.2003


L1 [m] L2 [m]

45 °


H [m

m]

DD d


DN D [mm]

125

125

140

140

160

180

200

250

280

315

400

DN

20

25

32

40

50

65

80

100

125

150

200

1.0/1.0180

L1/L2H

20 25 32 40 50 65 80 100 125 200150

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

L1/L2H

1.0/1.0180

1.0/1.0180

1.0/1.0190

1.0/1.0190

1.0/1.0195

1.0/1.0200

1.0/1.0190

1.0/1.0195

1.0/1.0195

1.0/1.0195

1.0/1.0200

1.0/1.0210

1.0/1.0215

1.0/1.0205

1.0/1.0215

1.0/1.0220

1.0/1.0225

1.0/1.0215

1.0/1.0225

1.0/1.0230

1.0/1.0240

1.0/1.0250

1.0/1.0230

1.0/1.0235

1.0/1.0275

1.0/1.0295

1.0/1.0335

1.0/1.0245

1.0/1.0280

1.0/1.0300

1.0/1.0245

1.0/1.0280

1.0/1.0300

1.0/1.0250

1.0/1.0290

1.0/1.0310

1.0/1.0260

1.0/1.0300

1.0/1.0320

1.0/1.0270

1.0/1.0310

1.0/1.0330

1.0/1.0295

1.0/1.0335

1.0/1.0355

1.0/1.0350

1.0/1.0370

1.0/1.0385

1.0/1.0340

1.0/1.0340

1.0/1.0350

1.0/1.0360

1.0/1.0370

1.3/1.0395

1.3/1.0410

1.3/1.0430

1.3/1.0470

1.0/1.0190

1.0/1.0195

1.0/1.0205

1.0/1.0215

1.0/1.0235

1.0/1.0275

1.0/1.0295


Casingpipe



FER

7.316

15.10.2003

Parallel T pieceswith steel pipe

DN Casingpipe

D [mm]

90

90

110

110

125

140

160

200

225

250

315

400

450

500

560

Main line Branch line DN


20

25

32

40

50

65

80

100

125

150

200

250

300

350

400

1.0240

LH

20 25 32 40 50 65 80 100 125 200 250 300 350 400150

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

1.0240

1.0250

1.0250

1.0260

1.0265

1.0275

1.0295

1.0310

1.0320

1.0240

1.0250

1.0250

1.0260

1.0265

1.0275

1.0295

1.0310

1.0320

1.0355

1.0260

1.0260

1.0270

1.0275

1.0285

1.0305

1.0320

1.0330

1.0365

1.0405

1.0260

1.0270

1.0275

1.0285

1.0305

1.0320

1.0330

1.0365

1.0405

1.0430

1.0275

1.0285

1.0295

1.0315

1.0325

1.0340

1.0370

1.0415

1.0440

1.0465

1.0310

1.0330

1.0345

1.0355

1.0390

1.0430

1.0455

1.0480

2.0900

2.0825

1.5750

2.0800

1.5700

1.5725

1.0290

1.0300

1.0320

1.0335

1.0345

1.0380

1.0420

1.0445

1.0470

1.0350

1.3375

1.3450

1.5565

1.5610

1.5635

1.5660

1.3485

1.3525

1.3550

1.3575

1.3390

1.3420

1.3465

1.3490

1.3515

1.0365

1.0375

1.0410

1.0450

1.0475

1.0500

L [m]

D d1

L/2 [m]

d2

H [m

m]

LH

1.0500

1.0510

1.0530

1.3545

1.3605

1.5690

1.5780

2.0855

2.0930

2.0960



FER

7.317

15.10.2003



L [m]D d1

L/2 [m]

d2

H [m

m]


DN D [mm]

110

110

125

125

140

160

180

225

250

280

355

450

500

560

DN

20

25

32

40

50

65

80

100

125

150

200

250

300

350

1.0260

LH

20 25 32 40 50 65 80 100 125 200 250 300 350 400150

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

1.0260

1.0270

1.0270

1.0275

1.0285

1.0295

1.0320

1.0330

1.0345

1.0260

1.0270

1.0270

1.0275

1.0285

1.0295

1.0320

1.0330

1.0345

1.0385

1.0275

1.0275

1.0285

1.0295

1.0305

1.0325

1.0340

1.0355

1.0390

1.0440

1.0275

1.0285

1.0295

1.0305

1.0325

1.0340

1.0355

1.0390

1.0440

1.0465

1.0290

1.0300

1.0310

1.0335

1.0345

1.0360

1.0400

1.0445

1.0470

1.0500

1.0330

1.0355

1.0365

1.0380

1.0420

1.0465

1.0490

1.0520

2.0960

2.0880

2.0805

2.0850

2.0750

2.0775

1.0310

1.0320

1.0335

1.0355

1.0370

1.0410

1.0455

1.0480

1.0510

1.3375

1.3400

1.3480

1.5605

1.5655

1.5680

1.5710

1.3520

1.3565

1.3590

1.3620

1.3415

1.3455

1.3500

1.3525

1.3555

1.3390

1.3405

1.3440

1.3490

1.3515

1.3545

Branch lineMain line

Casingpipe



FER

7.318

15.10.2003



L [m]

D d1

L/2 [m]

d2

H [m

m]


DN D [mm]

125

125

140

140

160

180

200

250

280

315

400

DN

20

25

32

40

50

65

80

100

125

150

200

1.0275

LH

20 25 32 40 50 65 80 100 125 200150

LH

LH

LH

LH

LH

LH

LH

LH

LH

LH

1.0275

1.0285

1.0285

1.0295

1.0305

1.0315

1.0340

1.0355

1.0370

1.0275

1.0285

1.0285

1.0295

1.0305

1.0315

1.0340

1.0355

1.0370

1.0415

1.0290

1.0290

1.0300

1.0310

1.0320

1.0345

1.0360

1.0380

1.0420

1.0290

1.0300

1.0310

1.0320

1.0345

1.0360

1.0380

1.0420

1.0310

1.0320

1.0330

1.0355

1.0370

1.0390

1.0430

1.0350

1.0375

1.0390

1.0410

1.0450

1.0330

1.0340

1.0365

1.0380

1.0400

1.0440

1.3400

1.3430

1.5515

1.5650

1.5560

1.3450

1.3490

1.3415

1.3435

1.3475

Casingpipe




FER

7.320

15.10.2003

Anchors

d D

L

axial = 185 N/mm

Ds = 165 N/mm 2

2

DN d x D

202532

mm

405065

80100125

150200250

26,9 x 11033,7 x 11042,4 x 125

48,3 x 12560,3 x 14076,1 x 160

88,9 x 180114,3 x 225139,7 x 250

168,3 x 280219,1 x 355273,0 x 450

300350400

323,9 x 500355,6 x 560406,4 x 630

Fr kN

Ds mm

L mm

200020002000

200020002000

250025002500

25002500

394760

69 97123

160231,5285

382,5610,6778,5

103611361467

240240250

250265290310360385

420520650

715780860

200020002000

450500

457,2 x 710508,0 x 800

16481832

860950

250025002500

Fr Fr Ds


Disc - anchor, thermally and electrically insulatedInsulation thickness 2

Permissible axial compressive stress:Permissible bending stress(in the disc):

Fr = max. load in kN Ds = external diameter of the steel disc in mm

For mass of the concrete block (foundation mass) and concrete quality;see catalogue page FER 7.515



FER

7.325

15.10.2003

Preinsulated valvesfor underground laying

Description, installation and assembly


GeneralBall valves and slide valves are only heat insulated by us as standard provided they are suitable for direct underground laying with or without prestressing, i.e.:A. where the test conditions to AGFW are met (Code of Practice 2.5/volume: Flat laying of KMR for district heating pipes)B. where no screwed connections are located in the insulation area

Range of application• to max. 140 ° C, to max. 25 bar operating pressure• processed, fully desalinated, deoxigenated, clean pipe water• unsuitable for installation in bends and expansion leg areas

Material• Body made of steel, forged and welded• Welded ends in St 35.8 to DIN 17175• Ball and wedge sealing surfaces (VAG gate valve) in stainless steel• Actuating spindle in stainless steel• Seals reinforced with Teflon• Ball seal spring-supported• Spindle seal, multiple, top seal replaceable• Leak monitoring wire foamed in• Heat insulation in PUR hard foam• HDPE casing

Testing• Type test to AGFW Code of Practice 2.5, volume 4, members' information no. 32, 23.7.84• Inspection certificate to DIN 50049.2.2• Pressure test on each fitting to DIN 3230, sheet 3: BA, BN or BO (BN/BO leakage rate 1) same test for spindle seal• any equivalent test

Delivery and storage• Ball valves in the open position• Slide valves in ready to close position (to protect sealing surfaces)• Protective caps on both pipe ends

Installation • Ball valves should only be welded in in the open position, with body protected from overheating (max. 150 ° C)• Slide valves should only be fitted in ready to close position and in prescribed flow direction• Expansion pads should be fitted as prescribed in the dome area

• Care should be taken particularly to ensure sufficient freedom of movement of the dome• Upper uninsulated spindle section must not stand in groundwater/water• First switching operation must not take place until the line has been flushed through (open slide valve first)• If there is a risk of frost, uncovered fittings must be completely emptied• Grease steel parts on dome well• At a provisional line end, exposed pipe end must be welded shut

Position indication (ball valve only)• Milled notch on actuating spindle square and pointer.• OPEN/CLOSED lettering below bell-shaped stop or notch on square protector

Actuation• Close by turning clockwise to stop (90° in the case of the ball valve)

Operation• Suitable socket wrenches are to be used for switching• For ball valves, plug-in gears with appropriate retaining parts are available (recommended from DN 100)• Do not use force on the switching shaft• Do not overtighten end stops• Intermediate positions in the case of ball valves are not permissible owing to possible wear on the ball seals• The prepared pipe water must not exhibit any solid material particles, owing to damage to the sealing faces.

Maintenance• Steel parts on the dome should be periodically cleaned and well greased• Operate at least every 3 months, moving from OPEN to CLOSED several times until moving freely• Ensure freedom of movement of the dome at all times• Check groundwater level and condition

Important

The above rules must be observed. We and the valve manufacturer can accept no liability for damage caused by incorrect assembly, handling and maintenance.



FER

7.330

15.10.2003

Shut-off valveBall valve BALLOMAX


DN 20 - DN 250, PN 25, insulation thickness 3, except DN 200 & 250, insulation thickness 2 Reduced bore, except in the case of DN 20

Rules for assembly, operation and maintenance as per sheet FER 7.325Fittings, see sheet FER 7.335

D d

1000

H

DN d x s

202532

mm

40506580

100125150

200250

26,9 x 3,233,7 x 3,242,4 x 3,2

48,3 x 3,260,3 x 3,676,1 x 3,688,9 x 4,0

114,3 x 4,0139,7 x 4,5168,3 x 5,0

219,1 x 6,3273,0 x 7,1

Dmm

D1mm

Hmm

125125 140

140160180200

250280315

355450

mm

d1SW

202525

32405065

80100125

150200

110110110

110110110110

125125125

180180

400405405

427432440454

486499518

560595

191919

19191919

272727

2750

6-squaremm

D1

SW - Wrench size

d1

Dome with actuating spindleHDPE casing pipe Steel pipe

Standard design

®



FER

7.335

15.10.2003

Fitting for shut-off valveBall valve


6-square Wrench

Plug-in gears may be supplied on request(recommended from DN 200 and above)

4-square, 27/32

6-squareSW 50

6-squareSW 27

6-square Wrench, 27/32

ø 24

1100

Ball valve

50

27SW19

6-squareSW 19

4-square, 27/32

4-square27/32

6-square

6-square

6-square protector



FER

7.340

15.10.2003

Pipe jointsSealed with shrink-on SMPE-2D

The joints (subsequent insulations) between the pipes and the moulded fittings must be foamed and sealed onthe site. The FERWAG system includes various types of sleeves. The subsequent insulation is normally under-taken by our fitters.

1. HDPE shrink-on sleeve with internal and external seal, SMPE-2DSMPE = non-interconnected shrink-on sleeve, 2D = double internal and external seal

A) PUR site foam

Before sealing, the sleeve isfoamed using 2-componentPUR foam.

1.1 Fitting the joint (repair joint)If, for any reason, it is not possible to push the sleeve on before welding (2 short elbows, etc.) the sleeve maybe divided and one half can be pushed on to either side, or else the sleeve must be slit open by our fitter andlongitudinally welded on site.

B) Sealing with shrink-on seal

The unit consists of a shrink-on seal and a sealing patch. The inside of theshrink-on seal consists of a special hot-melt adhesive. When it is heatedwith an open flame, the shrink-on seal shrinks on to the sleeve and thepipe.

2. HDPE reduction jointReduction sleeves are requiredwhen the pipe cross-sectionchanges (pipe reduction, T-pieces, fixed points). Fittingand sealing follow the sameprocedure as for the HDPEsleeve.

Foaming cannot take place in heavy rain or snow, or in cold weather (temperatures below 0 ° °°° C).

L = 720 – 780

600

D1

D2


7 Welding plug8 Shrink-on seal9 Alarm wires

1 Carrier pipe2 PE-casing pipe3 Non interconnected sleeve pipe

4 Rigid PUR foam manufactured by customer on site5 Rigid PUR foam manufactured in the factory6 Permanently elastic sealing adhesive

6 9

1

5

3 6

1

5

8

2

4 7

Joint length 600 mm

For additional double security (2D), the shrink-onsleeve is sealed externally with a seal (external seal).It is possible to carry out a tightness test beforefoaming. PUR installation foam is used to providethe heat insulation. The filling holes are welded witha conical HDPE plug.

The shrink-on sleeve consists of a non-interconnectedshrink-on sleeve pipe which is expanded at the factory.Before welding, the shrink-on sleeve must be pushed onto the pipe. The seal (internal seal) is fitted, and thenthe shrink-on sleeve is pushed over the joint. Next, theshrink-on sleeve is shrunk on to the casing pipe with agentle gas flame.

Product description

Before shrinking After shrinking

2

®

®



FER

7.345

15.10.2003

Pipe joint connection

20 25 32 40 50 65 80100125150200250300

90 90110110125140160200225250315400450

DHEC 2100DHEC 2100DHEC 2200DHEC 2300DHEC 2400DHEC 2400DHEC 2500DHEC 2600DHEC 2600DHEC 2700DHEC 2800DHEC 2900DHEC 3000

110110125125140160180225250280355450500

DHEC 2200DHEC 2200DHEC 2200DHEC 2300DHEC 2400DHEC 2500DHEC 2500DHEC 2600DHEC 2700DHEC 2700DHEC 2900DHEC 3000DHEC 3000

125125140140160180200250280315400500560

DHEC 2200DHEC 2200DHEC 2300DHEC 2300DHEC 2500DHEC 2500DHEC 2600DHEC 2630DHEC 2800DHEC 2800DHEC 2900 • •

min 120

D

400

D

400

End sockets, Shrink-on seal


3. HDPE end socketsEnd sockets are required at provisional line ends in the earth. An end socket must always be fittet to protect PUR and steel pipes. Sealing is as in the case of the HDPE socket.

Shrink-on seal

FERWAG shrink-on seals protect the PUR insulation on the front of the FERWAG pipes from sprayed water, inbuildings and shafts. In the case of standing water (flooding), the shrink-on seal is not necessarly watertight.The shink-on seal also prevents the PUR insulation at the end of the pipe from escaping in gas form.

The FERWAG shrink-onseals should be pushedonto the end of theFERWAG pipes beforewelding the inner pipes,and protected from theeffects of heat duringwelding.

Important assemblyinstruction

Material:Heat shrinkable, cross-linked polyolefin. Coating with sealing adhesive.

Indicator wires

Table: Allocation of FERWAG -dimensions/shrink-on seal type

DN inner pipe


Outer pipemm

Type designationof end cap

Insulation thickness 2 Insulation thickness 3



Outer pipemm

Outer pipemm

®

®

®

®

®

®



FER7.351

15.10.2003

FERWAG®-District heating pipe

EWELCON-Fusion Welded JointSystem Description

EWELCON Fusion Welded Joint is the registered brand name of a weld collar produced by BRUGGRohrsysteme GmbH and suitable for making structurally sound water- and gas-tight joints betweenpipes of plastic material, particularly standard plastic cased pre-insulated pipes with a HDPE casing asused in underground district heating mains.

The EWELCON Fusion Welded Joint is an entirely prefabricated HDPE sheet which is wrapped aroundthe two pipe ends immediately prior to welding. This simplifies the process of installation and isdecisively important in achieving uniform and high joint quality, even when installing pipes underdifficult and cramped conditions. The weld seam area can be cleaned and dried easily.

These features make the EWELCON system particularly suitable for repair and cleanup jobs in existingmains networks.

The HDPE sheet of the EWELCON Fusion Welded Joint is fitted with a heating element and atemperature sensor on the “inside” surface. The heating element, a meander strip of copper wire,forms a heating coil about 27 mm wide. This coil is placed so as to enclose the entire inner area ofthe collar when the sheet is wrapped around.The material of the sheet and the pipe along the meander strip is plasticized (melted) during welding,and becomes fused into a homogenous mass due to the high dilation pressure of the melt. After themolten zone has cooled down, the annular space has effectively been sealed shut by a weld seamsome 30 mm wide.

The temperature of the fusion zone and the pressure holding together the two weld surfaces are thevital elements in achieving a high quality weld seam with plastic materials.

This mechanism is put effectively into practice in the EWELCON system.

The required pressure holding the weld surfaces together is reliably applied by a specially developedclamping device.

The welding process is controlled by a microprocessor-controlled welding set, which monitors andstores the temperature of the fusion weld zone and heating coil throughout the welding process.This guarantees that the temperature of the fusion welding zone is largely independent of externalinfluences (e. g. weather conditions), and is uniform from one welding job to the next.

Every completed weld collar joint is subjected to a close visual examination as well as to a leak test,and is afterwards foamed out and the filling and ventilation drill holes closed off with weld plugs.



Dimensions Weight Packing unit

Casing - Ø

[mm]

W1)

[mm]

L

[mm]

s

[mm]

W 700

[kg]

W 850

[kg]

W 700

[pc.]

W 850

[pc.]

FERWAG®-District heating pipe FER7.352

15.10.2003

Sheet thickness: s

Temperature sensorHeating coilHeating coilconnection lead

Heating coilconnection lead

L

B

EWELCON Fusion welded jointTechnical specifications

Other dimensions on request.

Joints up to ∅ 225 mm are delivered in rolls. 1) Standard width: W=700; Repair width: W=850

Material: PE80 - DIN EN 32 162 (PE-HD)

90 700/850 450 4 1.2 1.5 18

110 700/850 515 4 1.3 1.6 18

125 700/850 560 4 1.5 1.8 18

140 700/850 610 4 1.7 2.1 16

160 700/850 675 4 1.9 2.3 16

180 700/850 740 4 2.1 2.6 16

200 700/850 805 4 2.3 2.8 15

225 700/850 885 4 2.4 2.9 15

250 700/850 950 4 2.5 3.0 20/40/80

280 700/850 1050 4 2.7 3.2 20/40/80

315 700/850 1160 4 3.0 3.6 20/40/80

355 700/850 1290 4 3.3 4.0 20/40/80

400 700/850 1440 4 3.7 4.5 20/40/80

450 700/850 1600 4 4.2 5.0 20/40/60

500 700/850 1830 6 7.0 8.5 20/40

560 700/850 2020 6 7.7 9.5 20/40

630 700/850 2250 6 8.7 10.5 20/40

710 700/850 2580 8 13.2 16.0 20

800 700/850 2870 8 14.7 17.8 20

900 700/850 3190 8 16.5 20.0 20

1000 700/850 3510 8 18.0 22.0 10/20



FER 7.353

FERWAG® District heating pipe

EWELCON®-S

24.09.04Electro-Welding-Coupling

- Te

chni

sche

Änd

erun

gen

vor

beha

lten

-

The EWELCON®-S Electro-Welding Cou-pling Sleeve is an integral part of the „EWELCON®-Family“. It is the ideal com-plement to the approved EWELCON® Wel-ding Coupling Sleeve for the sleeve tech-nique in the dimensional range below.

The EWELCON®-S Electro-Welding Coupling, the shrink sleeve and the pre-constructed heating elements will be supplied in separate packing units. The shrink sleeve provided with sun protection foil will already be inser-ted over the inner pipe - casing pipe weld. The heating elements will be supplied in handy packing units that protect against soiling and are suitable for construction sites. The hea-ting elements will firstly be directly laid over the weld on both the KMR-ends. The weld seam area can be lightly cleaned and dried. This substantially contributes to the high and constant quality of the joint, especially in complex and cramped assembly conditions.

These characteristics make the EWELCON®-S System particularly suitable for rewiring. Re-pairs and reconstruction of existing pipelines can be carried out using the EWELCON® Wel-ding Coupling Sleeve for the sleeve technique. For reasons of quality, only fitters who have completed the basic training by our commis-sioned trainers, who have acquired the ne-cessary qualifications, assemble these joints.

The EWELCON® Electro-Welding Coupling Sleeve shrink sleeve is made from bimodal PE-HD thus ensuring optimal long-term ca-pacity. The serpentine heating element with copper wire terminals is embedded into one of the PE-HD lead frames. Each set of

heating elements is fitted with a temperature sensor. The heating elements are then fixed to the previously prepared casing pipe, they conform to component tolerances. Thanks to the special construction at the connection ends, constant welding conditions are ensu-red all round the circumference of the pipe.

It will be possible to conventionally shrink the shrink sleeve onto the casing pipe using a soft liquefied petroleum gas flame; thus the heating elements will be optimally adhered.

The weld bath temperature near the con-tact pressure of the weld nugget interface is the most important criterion for pro-ducing a high quality plastic weld joint.T h e s e f a c t s a r e s u b s t a n t l y a p -p l ied in the EWELCON ®-S system.

The necessary contact pressure will be provi-ded by a specially developed clamping tool.

The weld procedure will be regulated by a microprocessor-controlled welding device. Thus the weld bath temperature and the heating element temperature are monito-red and saved throughout the whole weld process. In this way the weld bath tempe-rature is largely independent of external perturbations (e.g. atmospheric conditions) and can be compared between welds.

The parameters for each weld procedure are saved in the welding computer and can be read and documented at a later stage. In addi-tion, each sleeve joint provided will undergo visual and density tests, be packed with foam and the vent holes sealed with weld stoppers.



FER 7.354

FERWAG® District heating pipe

EWELCON®-S

24.09.04Electro-Welding-Coupling

- Te

chni

sche

Änd

erun

gen

vor

beha

lten

-

casing pipe

PE-HD-Casing pipe (before shrinkage) Weld stopper

Heating element set

Ø D[mm]

Outer-Ø DM[mm]

Wall thickness at least [mm]

L[mm]

Ø dB[mm]

Ø dS[mm]

Length LSS[mm]

Width BSS[mm]

90 107 2,9 310

110 129 2,9 370

125 143 3,0 420

140 156 3,4 460

160 178 3,5 600 24,5 28 520 100

180 198 3,5 580

200 224 3,8 650

225 255 4,3 730

250 278 4,4 810

280 306 4,9 900



FER

7.355

15.10.2003

Wall sealing ringTrench warning tape

Wall sealing ring

Trench warning tape

ACH

TUN

G !

FERNW

ÄRM

ELEITUN

G

Da D

50

Da D

type A type B Data tableWall sealing ring


Trench warning tape for underground

laying

Lenght 250 m

Laying depth; see page FER 7.500


90110125140160180

200225250315400450500560630710800

D

133153168183203223

Typ ADa

Typ BDa

240265290355440490540600670750840



FER

7.360

15.10.2003

Wall duct (DOYMA)Watertight, for civil defence structures

3Exte

rnal

Inte

rnal

D

R

2

3

D

R

2

1

1


DOYMA wall duct Type C 40for HDPE sleeve pipe diameter Ø110 to 800 mm

DOYMA wall duct type F/ZS, civil defence tested for HDPE sleeve pipe diameter Ø110 to 800 mm

Prerequisites for installation are perfect drill holes. Since hairline cracks can exist in concrete or can arise as a result of the work, we recommend sealing the drill hole walls over the entire lengths with a sealant (e. g. AQUAGARD).

Core drill holes

Assembly / Trench filling

In order to avoid deformation at the sealing point, special care should be taken during assembly or filling of the trench that no sinking of the pipes can subsequently occur. We also recommend that the pipe should be supported or hung inside the building. We cannot guarantee a good seal if these recommendations are not observed.

Suitability • Against pressurised water • Civil defence tested, T 86-008

Sealing capacity • Impermeable to gas

Load-bearing capacity• Axial movements

1 FERWAG pipe 2 Sealing set F/ZS, double sealing 3 Pipe liner made of fibre cement or coated core drill hole

Suitability• against pressurised water (Up to diameter Ø180 mm is sufficient, for non- pressurised water, sealing set A)

Sealing capacity• Impermeable to gas

1 FERWAG pipe2 Sealing set C, double sealing3 Pipe liner made of fibre cement or coated core drill hole

Load-bearing capacity• Axial movements

Exte

rnal

Inte

rnal

150200250300350400450500600700

90110, 125140, 160180, 200225, 250280, 315355400450500

RPipeline diameter

PE Ø mm

DPipe liner

Core drill holeØ mm

®

®

®



FER

7.400

15.10.2003

Transport and storage

min

0,0

6 m

0,4 max. 1,90 m

max

. 2,0

m

max

. 2,0

m

ca. 0

,15

m


Delivery of the pipes, mouldings and fittings is generally undertaken by lorry, free of charge to the site /dispatch address. Owing to transfer of the risk at the time of delivery, it is recommended that the customershould appoint and make available a responsible person to receive the goods. In order to avoid costly waitingtimes, the unloading areas should be prepared accordingly.

Transport

Unloading, handling Unloading is the responsibility of the customer / consignee.With the exception of pipes up to approximately DN 80, which can still be unloaded manually, lifting gearshould be used for unloading. In order to avoid damage, in paticular of the heat insulation, the mouldings andpipes must not be thrown or rolled.

Diagonal ropes, sufficiently far away from the sleeve pipe, only attach hooks to the steel pipe

Moving with textile straps, min 100 mm wide

Fig. 1: Hanging appliances for safe, protective handling

Up to DN 150 min. 0.20 mDN 150 min. 0.25 mFig. 3: Intermediate storage on wooden planks

Fig. 2: Intermediate storage on a levelled sand bed

even surface

levelled sand bed

The pipes must be stored as dry as possible and in such a way that the pipe ends do not lie in water. The endsof the heat insulation and the stee pipe ends are treated with a damp protection product by the factory, butthis is only of limited effect and is not effective on a long term basis. Mouldings and fittings should be storedon planks or wooden pallets, if possible under cover and dry.

®

l



FER

7.500

15.10.2003

Civil engineering worksLaying pipes

1.451.551.70

90110125

140160180200225250280315355400450500

0.700.700.75

0.800.900.951.001.051.101.201.301.35

.

. ..

..

.

. ...

.

.

..

.

.

..

..

.

...

. .

.. .. ..

..

..

...

. .. ..

.

• • • •

0.10

m

in 0

.15

0.40

..

ca. 0.20D D

min

0.6

0

ca. 0.20

B

0.20

...

. .... . ... .

560630710800

1.801.902.102.30

1.121.291.52

0.280.300.36

0.370.440.490.540.590.660.760.870.97

1.741.992.402.75


Laying pipes

• It is vital to ensure that the PE outer sleeve is not damaged.• Before welding, the PE socket pipes must be pushed over one pipe end in each case. Subsequently they are pulled back over the connection points in order to protect the insulation.• When laying pipes, the monitoring wires must always be on top.• Care must be taken that sufficient space is left around the sockets to set up the secondary insulation (at least 15 or 20 cm respectively below and between the sockets).

Civil engineering works

• When excavating the pipe trenches, general building regulations must be observed.• In difficult ground conditions, subsidence etc., an assembly proposal should be requested from us.• The pipe trench must be kept free of water during the entire assembly period. • The FERWAG district heating pipes should be laid on foam material pipe bases (sand sacks) which are approximately 1 m from the welding points in each case.• After assembly, the line must be backfilled on all sides to match the profile of the trench, with noncohesive, round-edged sand (grain size 0 - 3/4 mm).• The trench should then be filled to 30 cm below ground level with excavated material and compacted.• Lay BRUGG warning strip, fill trench completely and compact.

Trench profile EWELCON see down! Trench dimensions

PE external pipeD [mm]

WidthB [m]

Polystirol pipe base BRUGGevery 3 m

Line warning stripWashed sand, grain size 0 - 3/4 mm

*Sand contents[m3/m]

*Sand contents according trench dimensions +10%

The head holes should be provided at every pipe joint, between the pipes min. 23 cm (see sheet 7.501)

EWELCONFusion Welded Joints:



FER

7.501

15.10.2003

1.80

0.20

B + 0.40

0.35

2- 4 m

0.10

0.10


Civil engineering worksLaying pipes

Trench preparation around expansion pads The trench around the expansion pads must be widened on both sides and deeper by at least 10 cm.

Trench profile with head hole

Head holes should be provided for larger sizes at each weld seam, and at least at elbows and T pieces, so that the steel pipes can easily be welded together and the socket connections cleanly executed. The width of the normal trench profile can thereby be reduced.

expansion pad

10 cm deeper



FER

7.502

15.10.2003

Filling the pipe trenches

• The rest of the trench must be filled up with compactable material, such as excavation material and/or fine sand, and it must be well compacted. The national and local regulations govern the use of excavation material and/or the minimum layer thickness of the fine sand. • Compact the material using a vibrator with a maximum surface pressure of 100 kPa. Earliest compression is after the pipe apex is covered up to a height of 30 cm. Do not forget: fit line warning tape and any protective pipes (not over the pipes - approx. 30 cm. above the pipe apex). • Topmost layer: incorporate humus or HMT, depending on the regulations.

If the coverage is insufficient (minimum of 60 cm), or for areas subject to heavy traffic loads, pressure distribution plates must be incorporated above the sand layer in order to relieve the stress on the pipes.

Covering material (sand)

• round-edged washed sand, maximum grain size 4 mm (0 - 3/4 mm)• proportion of ultra-fine grains 0.25 mm: if possible, not above 8%.• non-cohesive, or with the lowest possible proportion of loam.

As an alternative, so-called cyclonic sand (sludge sand), grain size 0-1 mm, is permissible (the ”waste” from washed sand). Broken glass is not permissible as a substitute for sand in the case of FERWAG pipes (it is permissible for FLEXWELL ).

Embedding the pipe in sand (as shown on the Trench Profile sheet)

As a general rule, all construction and safety regulations must be followed!

• We recommend that welding pits and trench fillings are first filled with lean concrete. • Cover the pipe apex to a height of at least 10 cm.• Compacting - very important!• Between, underneath and next to the pipes, the sand must be tamped down or compacted by hand, layer by layer, using suitable implements (such as a shovel or pick stem). No cavities must be created. Important: do not damage the seals or the pipe!

Residual filling of the pipe trench

FERWAG -District heating pipe®

®®



FER

7.505

15.10.2003

House Connection

B

80 D 200

H

60 50 min.120

Wall duct

Wall penetration

D

B

H

Core drilled holes*

Wall penetration • Neoprene rubber

710

1780

900

850

630

1620

800

770

560

1480

750

700

400

1160

550

530

450

1260

600

580

500

1360

650

630

280

920

450

400

315

990

450

435

355

1070

500

475

250

860

400

370

225

810

400

345

200

760

350

320

180

720

350

300

160

680

350

280

140

640

350

260

125

610

300

240

110

580

300

220

90

540

250

200D1

D1

dimension in mm

80

FERWAG

800

1960

990

940


Wall sealing ring made of profiled neoprene rubber; see sheet FER 7.355 Cellar / shaft

Monitoring socket

Shrink-on sealsee sheet FER 7.345

dimension in mm

dimension in mm*Wall duct DOYMA see sheet FER 7.360

®

®



FER

7.510

15.10.2003

Assembly rules

6, 12 m

� min 120 mm

min 300 mm�

� min 750

�

�

min 120 mm

min 150 mm

min 170 mm

�

�

�

< 300 mm



FER

7.515

15.10.2003

Concrete block for anchor

. ...

. . ...

.

.

....

.

. ..

..

.

. .. .. .

.

..

.

.

.

.

.

.

... ..

. . .

..

.

.

.

..

...

a

B

A

A1

.

...

.. .. . .

.

.

. ...

...

.

.

. ...

. ..

.

.

.

H

µ

L *

DN d

202532

mm

40506580

100125

150200250

26,933,742,4

48,3 60,3 76,1 88,9

114,3139,7

168,3 219,1273,0

300350400450500

323,9 355,6 406,4 457,2 508,0

2,02,52,9

0,400,400,40

1,31,31,3

66,5 83,7 107,2

123,1 172,4 219,9 284,1

412,9 507,6

680,91000,61388,518472052259229203240

0,80,80,8

Bm

0,91,11,21,3

1,61,8

3,73,84,45,35,5

m m m A1 A L

0,450,550,650,80

0,951,15

1,401,702,102,252,402,402,602,60

0,80,80,8

0,91,01,11,3

1,51,7

2,02,42,9

3,13,33,33,53,5

0,80,80,8

0,81,01,01,0

1,01,0

1,31,31,31,31,3

270270280

280295320340

390415

450550680

745810890890980

mmFs max

kN *

For maximum anchor forces


L* must not be any wider!

Steel pipe Distancebetweenpipes, a

Concrete block dimensions Fixed point force

In the event of different fixed point forces and ground conditions, the foundation dimensions must be calculated.

Basis of calculation for concrete block size

• Max. shearing force for 2 pipes: Fs max = 2·As· T, [ T = 165 N/mm2, T = 70 ° K ]• Covering height H = 0,8 m• Foundation dimensions are based on an angle of friction of = 32,5 ° for non-cohesive ground (friction factor µ = 0,64 )• Piled density = 18 kN/m3

Concrete quality • P 350 to DIN 1045, water impermeable, with reinforcement



FER

7.520

15.10.2003

...

..

... .. . .

..

.... ..

...

..

... ..

3

1

5

2

1000

min 100

500

.. .

...

...

... .. . .

. ...

.

.

.

.

.

.

. .

..

..

... .

.

.

.

.

.

...

.

.. ...

.

..

...

.

.. . .. . .. .. .

.. . . .. . . ..

. . . .

.

12

6

min.120 150

3

150

5

Draining and ventingarrangements

L as specified

5

4

4

L as

spe

cifie

d

dimensions in mm

1 Valve, supplied by customer 2 Shrink-on seal, supplied separately 3 Expansion pad

4 Sand 5 Lean-mixed concrete6 Gravel for drainage



FER

7.525

15.10.2003

Underground installationfor ball valves

.

.

.

..

.

..

.

.

.

.

...

.

.

.

..

.

.

.

.

.

..

.

..

.

..

..

.

. . .

.

..

.

..

.

.

..

..... .

.

D 2

.

..

..

.

.

...

. ..

...

..

..

..

.

..

.

.

.

..

.

.

.

.

.

.

.

.

...

...

.

.

..

.

..

.

..

..

.

.

.

..

.

H

D 2

1

2

4

6

.. .

200 200 200D 1 D 1

3

5

DN D1 H D2

20253240

506580

100125150

200250

125125140140

160180200

250280315

355450

mm

250

300

mm mm

470470470490

500510520

560570590

630670

..

..

. .

... .

> D

2

Inspection wells with heavy duty cast-iron lids

1 Heavy duty cast-iron round lids (for expl. Von Roll) 2 Concrete pipe3 Ball valve 4 Thermal expansion pads5 Supporting plate6 Sand bed, grain size 0-3/4 mm

dimensions in mm Top view




Hot tappingSystem description

FER

7.530

26.8.200340 c

m

The BRUGG-Ballomax hot tappingsystem is used to where branches aremade from main lines while the districtheating system is working. The todayused tools and components are the resultof a long term development processwhich combines experience and newtechnology.

This hot tapping method saves coststhanks to an economic and a safe execu-table drillling process withour serviceinterruption.

The hot tapping tool for weldable con-nections on steel pipes is designed forbranches in the dimensions DN 25 up toDN 100, a maximum pressure of 25 barand a temperature up to 140 (180) °C.

The hot tapping valve on branches can bewelded directly or where it requires witha welding ring on to the main line.

All hot tapping valves are designed witha reduced opening. They can be used indistrict heating networks or other pro-cess pipelines.

The hot tapping method features thepossibility to install belated branches onevery place of the Network.

Hot tapping for bigger dimensions ofbranches can be carried out on requestby an other system .




Hot tappingDimensions and measurements

FER

7.531

26.8.2003

Dimensions and measurements

L

A2

B

HA

1

Hex key

Dimensions DN 25* DN 32 DN 40* DN 50 DN 65 DN 80 DN 100

Ball opening 25 25 40 40 50 65 80

Drill size 24 24 40 40 48 65 79

Volumetric flow rate (KVS) [m3/h] 26 41 68 112 200 380 620

A1 (side house connection pipe) 33,7x2,9 42,4x2,9 48,3x2,9 60,3x3,1 76,1x3,1 88,9x3,2 114,3x3,6

A2 (side mainline pipe) 37,0x5,8 37,0x5,8 54,0x6,7 54,0x6,7 63,0x7,0 82,0x8,0 100,0x9,0

B 60,3 60,3 88,9 88,9 114,3 133,0 159,0

H 46,0 46,0 57,0 57,0 70,0 80,0 92,0

L 145,0 145,0 200,0 200,0 260,0 265,0 275,0

Hex bolt / hex key 10 10 10 10 14 14 14

Weight [kg] 1,3 1,2 3,5 3,4 5,1 6,7 11,3

min. diam. main line DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125

min. diam. PE casing (outflow) 110 125 125 140 160 180 225

Anschluss - Dimensionen DN 25 DN 32 DN 40 DN 50 DN 65 DN 80

Hot tapping valve DN 25 DN 40 DN 40 DN 65 DN 80 DN 100

Pipe diameter 24 40 40 48 65 79

Steel-pipe reduction 33,7x2,9 48,3x2,9 48,3x2,9 76,1x3,1 88,9x3,2 114,3x3,6

Diameter main line DN 32 DN 50 DN 50 DN 80 DN 100 DN 125

min. diam. PE casing 110 125 125 160 180 225


Application for brancheswithout reduced diameter

bigger dimensions with other system on request

Hot tapping valve with complete welded bodyBall is made of stainless steel / seals made of PTFE

*Ba

ll d

iam

ete

r is

no

t re

du

ce

d




Hot tappingPreparation weld seam and weld composition

FER

7.532

26.8.2003

Preparation weld seam and weld composition

Welding end with weld seampreparation

Outer thread for hot tapping tool

Place the hot tapping valve without crack directly on the main line

Take care that no welding materialis getting into the hot tappingvalve!

Chamfering of the welding endaccording DIN 2559, Splice type 22

Weld composition:Electric welding (2-3 layers) withKb-electrodes, basicType E5155B10 DIN 1913 ø 2.5 mm

Basic rules during welding operation:•The ball has to be opened!•to avoid over-heating on the teflon-sealings please cool down the hot tappingvalve between the itemized welding layers (Small waiting period or cooling witha wet cloth)

Hex bolt - to be tighted (blocked inthe ball) and welded together withthe body (around) after placing inoperation of the brach pipe.



PIPE2000 Ltd





WIREM® THE PROFESSIONAL SOLUTION FOR ENGINEERS

PIPE2000 Ltd




WIREM

10.0

15.10.2003

Table of contents

CH


10.1 General system description

10.100 System description10.110 Functional description10.120 Measuring description

10.2 Design and reference charts

10.200 Design and reference charts10.210 Welding plans

10.3 Control unit U89A

10.300 Unit description, technical data10.310 Unit description, page 210.320 Fault handling procedure10.330 Electrical circuit, wiring diagram10.340 Option: Remote control transmission



WIREM

10.100

15.10.2003

CH

The piping for district heating laid outunderground, is nowadays mostly equippedwith control equipment, to monitor itsoperation. The advantage of this lies in theearly detection and quick location ofdamages. Feeler wires melted into thethermal insulation in the factory perform,together with the monitoring equipment, agreat number of functions. The safety of theinstallation is improved and the costs ofrepairs reduced.

The systems FLEXWELL -cable, FERWAG -pipe and CASAFLEX -district heating pipe ofBRUGG Pipe Systems are equipped ex-workswith the Reference Resistance Measure-ment system (WIREM ). Other monitoringsystems can be supplied if specified. TheBRUGG STEEL PROTECTION PIPE is availableas an option.

WIREM and BRANDES are compatiblesystems.

The WIREM technology with its feeler wiresand control equipment makes manyfunctions possible:

• Check of the humidity in the thermal insulation starting at the production stage. Supply of data on the state of the insulation.

• Detection and identification of the feeler conductor making contact with the inner pipe, a breakage or damages anywhere in the circuit can be detected and identified.

General system description


• An entry of humidity through e.g. a faulty welding seam, loose sleeve or external damage can be detected, monitored located and reported during operation.

• A display reports a failure or interference basing on early detection and self diagnostics.

• Feeler gauges connected to the control system and situated in wells, can produce an alarm in case of entry of water.

• Alarms, measurands, state of contacts and other data can be registered and transmitted to other systems.

The network of monitoring, measuring andlocating units can be built up at willdepending on conditions of volume of datarequired and network size.

The range of units extends from the manualinstruments to measure the condition of theinsulating material and manual fault location(unit U 89A) to fully automatic monitoringand fault location, testing over dialog andstoring of results, as well as data transmissionto other computers and printers.

®

®

®

®

®

®



WIREM

10.110

15.10.2003

1 2 3

2 1

Structure of the feeler conductor1. Gaps in insulation at regular intervals for wet contact detection2. PTFE-Insulation, coloured red3. NiCr conductor

1. Copper core2. FEP-Insulation, coloured green

The physical principle for monitoring, as well as forfault location, is the resistance reference method(WIREM ), which is that of the unloaded resistancebridge principle.

A defined voltage is applied between the feeler wire,embedded in the thermal insulation, and the pipe (seefigure). Should the isolation resistance diminish, as willhappen when a wet spot occurs, a voltage rise will beregistered in the monitoring instrument and an alarmwill be released.


Monitoring unit

Feeler wire (red)

Return wire (green)

I

S


The reference resistance determines the tolerancethreshold and is adjustable.

Monitoring of the thermal insulation is performed bya special feeler wire (see figure). The wire itself isprotected against direct contacts to metal, by athermally stable PTFE sleeving. A contact between thenaked NiCr wire and wet spots occurs in perforationsalong the PTFE sleeve. This permits monitoring overthe entire length of the feeler wire.

The perforations allow an accurate evaluation of thewet spots regarding their intensity in the wholemonitored spectrum, from „dry“ with over 50M to„wet“ with under 10K insulation resistance.

For the monitoring itself, an FEP isolated, copper returnwire is laid out parallel to the feeler wire.

Both wires form a feeler loop (see figures), which canattain 1000 m in length and therefore is able to monitor1000 m of piping. Branches of piping are also followedby branches in feeler wires, i.e. feeler wire out, returnwire back (see figure).

Pipe center line

Layout of the feeler loop

Feeler loop with branch-off

Large pipe networks of several kilometers in length aredivided into monitoring sections of under 1000 meters.A monitoring unit is installed at each section.

Loop

Insulation

CH

Functional aspects

Position of the feeler cablesThe monitoring cables (feeler wire and return wire)are embendded in the insulating material betweenthe inner and outer pipes. In the FERWAG - andCASAFLEX - pipe they run parallel, on eiter side of the

inner pipe and about half way through the insulation,while in the flexible system FLEXWELL -cable, they arewound around the inner pipe and run close to eachother.


Feeler wire (red)

Return wire (green)

Structure of the return wire

®

®

®

®



WIREM

10.120

15.10.2003

Determining thefault location

To locate the wet spot or contact fault, a voltage U isapplied across the loop.

At the end of the feeler loop, a part voltage U1caused by the wet spot, is measured between theinner pipe and the feeler cable.

The result is expressed not in Volt but in % of theapplied voltage.

5.7 /m and the return wire near zero , thefollowing relationship results:


A breakage in the feeler loop will be immediatelydetected in automatic installations, but the locationof the break has to be performed manually by othermeans.The usual method used in such cases is the timedelay measurement.A capacitance measurement can also be used.

To avoid subsequent faults and gaps in the feelerloop, strict quality control and measurement checks

. They target,

Locating a break in the feeler loop or in themonitoring circuit

U1

U= = =

R1

R 100%

x% L1

L

UU1RR1x %LL1

The gravity of the insulation fault (insulation resistance)has no influence on the precision of location, as it isbalanced out in the measurement concept.

CH

U1U

x%Fault location unit

Wet spot

100 %

= Applied voltage= Measured voltage= Total loop resistance= Part loop resistance= Part result= Total pipe length= Distance to fault


Feeler wire (red)

Return wire (green)


Since the feeler wire has a relatively high resistance of

during production are applied in generalamong others, the solidity of all wire connections.



WIREM

10.200

15.10.2003

Heating Plant

Block 1

U89A

21 2 3

U89A

11 2 3

Feeler Return

Wiring between the terminalsBrugg in the building, done by

an electrician

Monitoring terminals

CrNi wire (red)Cu wire (green)

Resistance / length (DR)R = 5.7 /m

Forward2219

Return2220

Insulation resistance (IR)Grade BS-MH-2

Forward0 = >50 M

Return0 = >50 M

The monitoring system BRANDES

Control units

Block 2

Block 3

T-pieces(downward)

Results of measurements

Design

The design of the control circuit isdone parallel to the design of thepiping. The whole installation is thendivided into separate loops with amaximal length of 1000 to 1200 mper unit. All units can be placedcentrally in one building. For futureexpansion of the network, it is goodpractice to insert some spare cablesbeside the pipes.

Reference drawings (Wiring diagrams)

CH

TT 1,5 mm2, or U 72 0,8 mmLength 9m : armoured wire

Wiring by an electrician

Design and ReferenceDrawings

Block 4


T-pieces(downward)



WIREM

10.210Reference DrawingsWelding plans

Heating Plant

Block 1

Block 2

Block 3

Pipe

Materials

To find the exact location of thefault above earth, it is veryimportant to have access toreference drawings. The moreprecise these are, the easier andquicker the spot can be found.Welding plans have proved to bethe best reference.

CH

FER 60.3-140FER 76.1-160FER 88.9-180

Stand. L Elbow [m]

6 m6 m

12 m

0.5x0.50.65x0.650.65x0.65

FER 60.3-140FER 76.1-160

FER 88.9-180

6.74

12.0

12.0

12.0

12.0

12.0

Bg 90° , 0.65x0.65

6.52

12.0

12.0

12.0

12.0

12.0

12.0Bg 90° , 1.56x0.92

7.9

7.9 1.0

1.0

12.0

12.0

1.826.57

Bg 86° , 0.65x0.65

Bg 61° , 0.65x0.65

Venting

Bg 90°

12.01.56

0.92

12.0

12.0

8.0

8.45

12.0

12.0

12.0

5.23 6.0

5.84

5.84

6.04.65

6.0

6.06.0 4.3

6.0

6.0

6.0

4.92

6.0

1.9

6.0

4.6

3.75

6.0

5.81

6.0 5.0

6.0

1.77

5.0

6.06.0

Bg 85 ° , 0.65x0.65

1.01.0

5.85.8

5.6

4.6

6.0

6.0

6.0

6.0Bg 90° , 0.50x0.50

Bg 90° , 0.65x0.65

Bg 61 ° , 0.65x0.65

Bg 86°0.65x0.65

1.0

Bg 90° , 0.65x0.65

Bg 85 ° , 0.65x0.65Block 4

A

View A

Elbow 90 °0.95x1.05

0.95

1.05

0.95

Bg 90 ° , 0.50x0.50

1.0

1.0

1.0

Draining, DN 320.55

1.0

1.0

Bg 90° , 0.50x0.50

Bg 90° , 0.50x0.50

Bg 76.5 ° , 0.65x0.65

12.0

15.10.2003


Reference DrawingWelding plan

Reference Drawings

T-pieces(downward)

Bg = Elbow



WIREM

10.300

15.10.2003

The instrument monitors theelectrical insulation resistancebetween the detector leadand pipe (earth). A break inthe detector lead or earthleakage (<5 kOhm) is signalledsimultaneously. The earthleakage signalling can also beused as a shaft monitor. Byconnecting a level switch (e.g.EHS-JOLA 6M, Otto FischerAG) between the direct leadreturn and pipe.

The unit is suitable for fittingin a switch cabinet and forsurface mounting.

Function

Unit description

Button and 2 signal lamps are mounted on the instrument.

Lamps

green : operatingred : fault

Surface mounting

For operation, an additional button and 2 signal lamps must be fitted in the cabinet door.

Fitting in switch cabinet

If the electrical insulation resistance is exceeded (moist insulation), if there is a failure or earth leakage (shaft monitoring), a horn, lamp or central alarm system is triggered. At the same time the fault signal lamp lights up on the instrument or cabinet door as follows:

Fault

Insulation moist

Failure in monitoring loop

Earth leakage, shaft monitoring with float switch

Brugg Rohrsystem AG 5200 Brugg

CH

Unit description U89Atechnical data



WIREM

10.310

15.10.2003

75

150

107

A

View A

Unit descriptionU89A

CH


Alarm output for external fault displayThe instrument has an alarm output to supply a horn, a lamp or a central alarm system.

AcknowledgementBy pressing the double function button (instrument test + acknowledgment button), the alarm output isswitched off. The fault lamp remains alight until the fault has been remedied.

Instrument testThe instrument is maintenance-free. However, we recommend that you implement a monthly operatingcheck. By pressing the button a fault is simulated. As a result, a check is made of all the electronics.During this, the fault lamp must be alight. During the test, the alarm output can be blocked orconnected through by means of the switch fitted on the printed circuit board. The switch should be setto the required position during installation.

Technical data• Supply voltage • Voltage tolerance • Power consumption • Output • Breaking capacity • Cable inlet • Connection type • Protection system • Ambient temperature • Max. loop length

220 V 50 Hz± 10 %1.5 VAHigh-tension current contactmax. 250 V AC 5 A (alternating current)max. 30 V DC 5 A (direct current)6 paracril cable sleeves mounted on sides2 break-through apertures in casing bottomConnection screws with terminal plates, max. 2 x 1.5 mm2IP 40-10 ° to +50 ° C0 to 10 kOhm (0 - 1200 m)

Casing dimensions

Break through for wall fastening ø 4.2 mm.

Break through for wall fastening ø 4.2 mmBreak through for clamp fastening to 35 mm standard bar DIN 46277.Clamp in instrument.



WIREM

10.320

15.10.2003

CH


Fault handling procedure

Possible fault causes

Procedure in the event of a fault CautionBefore opening the instrument,switch off the main switch

Fault

1. Green lamp not alight

2. Fault lamp (red) alight

a) continuously

b) flashes

c) flashes intermittently

Possible cause

• no mains voltage• 50 mA fuse on pc board defective

• Insulation in pipe moist

• Break in monitoring loop (in the pipe or in the sockets)

• Earth leakage in shaft monitoring with level switch (water in shaft)• Detector lead (loop) short circuit to earth (< 5k )

Equipment test without pipe system

Procedure

1. Loop. Remove terminal 1 + 2

2. Connect terminal 1 + 2

3. Press button (instrument test)

4. Connect terminals 1, 2 + 5

Fault lamp display

must flash

must go out

must be alight

must flash intermittently

If all 4 states are OK, then the cause should be sought in the pipe system (sockets, connecting lines).



WIREM

10.330

15.10.2003

CH

Electrical circuit,wiring diagram


Terminal 3potential freeWith direct connectionterminals A - Bno connectionterminal 3

4

5

6

7

8

9

10

11

12

13

14

15

16

PC b

oard

con

nect

ors

•

Mains 220 V 1.5 VA

Be sure to connect earth, in special cases connect to pipe.

50 mA

Terminals

Contact load 250 V AC / 5 ANot applicable for surface mounting

Shaft monitoringwith float switch

•

Connection pipe

term

inal

Cor

1

Ala

rm o

utpu

t fo

r "F

ault

exte

rnal

"in

inst

rum

ent

test

on p

c bo

ard

free

b

lock

ed

N

P

Supply for fault external

horn, lamp, collective alarm

red

greenoperating

fault

Supply for display

1

2

3

Cu (green or blue)

A

B


C

DH - Line


DH - Line

insulation moist break loop short circuit shaft

1

2

3

Cu (green or blue)

TT 1,5 mm , or U 72 0,8 mm

A

B


FW - Leitung


2

DH - Line

DH - Line

DH - Line

DH - Line

FW -

Lei

tung

DH - Line

BRU

GG

Wiring for branched network, example only Wiring principle: Always probe loop

Term

inal

s

Wiring between the sockets by an electrician (by the owner)

Cab

inet

Faul

tex

tern

al

*

* e.g. level regulatorEHS - JOLA 6 MOtto Fischer AG

Acknowledge instrument test

CC

C

Switc

h

TT 1,5 mm , or U 72 0,8 mm2

Caution: Before opening the instrument, switch off main switch.

Weak currentmax. 12 V

Weak current

Brea

king

cap

acity

max

imum

250

V A

C 5

A, 3

0 V

DC

5A

Monitoring socket

Monitoring socket

Cu (green or blue)


Cu (green or blue)


Cab

inet

Assembly limitBRUGG

Assembly limitBRUGG

Wiring by electricianLength 9 m: armoured wire

Length 9 m: armoured wireWiring by electrician



WIREM

10.340

15.10.2003

Option:Remote control transmission

13

12

11

10

9

R1

R2

R1 R2

0

II

0

01

0

I

CH


Version for remote control transmission e.g. "Ridat Rittmeyer"

The U 89 instrument is also suitable for computer controlled remote transmission. In this case, there is no need for wiring the cabinet door. These outputs are wired as followed by a change on the PC board.

The functions of the network and fault lamp on the instrument, and also "Fault external" (terminals 6 to 8) remain unchanged.The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission.

Terminals 9 to 13 Logical states

Everything OK

Insulation moist

Earth leakage in shaft monitoringwith level switchDetector lead has short circuit to earth

Break in loop



PIPE2000 Ltd




Pipes Full Data V11006 06Jul09

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Transcript of Pipes Full Data V11006 06Jul09