product guide
taking care of energy and environment
Contents Projects since 1981 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FLEXALEN product overview . . . . . . . . . . . . . . . . . . . . . . 4 FLEXALEN 600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FLEXALEN 600 - Insulation values . . . . . . . . . . . . . . . . . . 7 FLEXALEN Straight Lengths . . . . . . . . . . . . . . . . . . . . . . 8 FLEXALEN Straight Lengths - Insulation values . . . . . . . 9 FLEXALEN 1000+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FLEXALEN 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transition Fittings, Compression Fittings . . . . . . . . . . . 12 Pupped Composite Union . . . . . . . . . . . . . . . . . . . . . . . 12 Pupped stub flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transition from plastic to steel . . . . . . . . . . . . . . . . . . . 13 Measurements of flange connections. . . . . . . . . . . . . . 13 Rubber end caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Anchor point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wall Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrofusion couplings . . . . . . . . . . . . . . . . . . . . . . . . . 16 Pre-insulated Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Tee-Half Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Polybutene – the perfect material . . . . . . . . . . . . . . . . 18 Lifetime table for PB pipes . . . . . . . . . . . . . . . . . . . . . . 18 FLEXALEN material properties . . . . . . . . . . . . . . . . . . . 19 Trenching Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electrofusion welding . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Insulation coupler Installation. . . . . . . . . . . . . . . . . . . . 25 Branches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Building Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Expansion Compensation . . . . . . . . . . . . . . . . . . . . . . . 30 FLEXALEN Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Nomogramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pipes sizing ready reckoner . . . . . . . . . . . . . . . . . . . . . . 33 European approvals – 3rd Party . . . . . . . . . . . . . . . . . . 34 When using our material please take into account the set Standards, installation instructions, building regulations, our factory standards and laying instructions for the respective field of application. Flexalen reserves the right to change product and installation detail without prior notice.
2
World leaders since 1981
3
FLEXALEN product overview for Heating – Hot Water – Chilled Water
6 6
5
3
4
1
FLEXALEN 600 Single pipe (25 mm – 110 mm O.D.)
2
FLEXALEN 600 Twin pipe (25 mm – 63 mm O.D.)
3
FLEXALEN 1000+ Multi pipe
Temperature Range – 15° C to + 95° C
2
5
1
4
4
FLEXALEN Cold water (HDPE)
5
FLEXALEN Straight lengths (63 mm – 225 mm O.D.)
6
FLEXALEN 60 (16 mm – 32 mm O. D.)
5
FLEXALEN 600 ■ The compact standard system Main advantages ● Unique construction ● Water tight bond between corrugated outer pipe and polyolefine insulation. ● Top foam quality – proven λ = 0,031 W/mK at 50° C ● Water diffusion resistance µ>3.500
Twin pipes up to 63 mm, Single pipes up to 110 mm
● Light weight system (1.6 kg for 2x32 in 125 outer casing) ● High flexibility at low temperatures <0°C ● Highly flexible – easy to bend around corners ● Single lines 25 – 110 mm and twin lines 25 – 63 mm ● Easy to install, full range of easy to use fittings ● Built in expansion compensation ● Very low friction loss – proven for high flow speed Watertight bond between foam and outer casing
● Pressure hammer absorption
FLEXALEN 600 Dimensions D.N.
Inch
Casing Pipe O.D. [mm]
Wall thickness [mm]
No. of medium pipes
Minimum bending radius [m]
Standard coil length [m]
Weight [kg/ metre]
VS-RS125A2/25
20
¾
125
25
20,4
2,3
2
0,6
100
1,40
VS-RS125A2/32
25
1
125
32
26,0
3,0
2
0,6
100
1,60
VS-RS160A2/40
32
1¼
160
40
32,6
3,7
2
0,8
100
2,50
VS-RS160A2/50
40
1½
160
50
40,8
4,6
2
0,8
100
3,00
VS-RS200A2/63
50
2
200
63
51,4
5,8
2
1,25
50
4,25
VS-RS90A25
20
¾
90
25
20,4
2,3
1
0,4
100
0,75
VS-RS90A32
25
1
90
32
26,0
3,0
1
0,4
100
0,85
VS-RS90A40
32
1¼
90
40
32,6
3,7
1
0,5
100
1,00
VS-RS125A50
40
1½
125
50
40,8
4,6
1
0,7
100
1,75
VS-RS125A63
50
2
125
63
51,4
5,8
1
0,8
100
2,05
VS-RS160A75
65
2½
160
75
61,2
6,9
1
0,8
100
3,05
VS-RS160A90
80
3
160
90
73,6
8,2
1
1,0
100
3,60
VS-R200A110
100
4
200
110
90,0
10,0
1
1,25
50
5,00
Product code
Carrier pipe O.D. I.D. [mm] [mm]
Temperature/Pressure rating for PB carrier pipes: Operating Temperature in °C
-15° C
0° C
20° C
40° C
60° C
70° C
80° C
95° C
Operating Pressure in bar
16 bar
16 bar
16 bar
15 bar
12 bar
10 bar
9 bar
8 bar
Peak temperature 95 °C Temperature range –15° C to +95° C
6
Wärmeverlust Einzelleitungen-Rohrpaar FLEXALEN 600 – Insulation values (Vorlauf + Rücklauf)
Wärmeverlust Doppelleitungen
Heat loss twin pipe (Heating flow & return)
Heat loss single pipe (Heating flow & return) W/m
W/m 30
60
1: VS-R125A2/25 2: VS-R125A2/32 VS-R160A2/40 3: VS-R160A2/50 VS-R200A2/63
25 20
4: 5: 6: 7: 8: 9: 10:
3
50 2 1
40
15
30
10
20
5
10
Heat loss for chilled- and cold water 60 70 80 temperature >10°C Single pipe
20pipes 30 for 40 50 medium
90°C
20
VS-RS90A25 VS-RS90A32 VS-RS90A40 VS-RS125A50 VS-RS125A63 VS-RS160A75 VS-RS160A90 VS-R200A110
30
40
10 8 9 6 7 5 4
50
60
70
80
90°C
Tflow + Tret. 2
Domestic Hot Water W/m
10
Wärmeverlust Einzelleitungen
1: VS-RS90A25
W/m 2: VS-RS90A32
7
3: VS-RS90A40
30
VS-RS125A50 4:4:VS-R90A25 5:5:VS-R90A32 VS-RS125A63 6:6:VS-R90A40 VS-RS160A75 25 7:7:VS-R125A50 VS-RS160A90 5 8: VS-R125A63 VS-R200A110 20 9: VS-R160A75 10: VS-R160A90 VS-R200A110 15
5
10 8 9 6 7 5 4
10
6 3 4 2 1
Chart data based on following criteria: Soil temperature: Covering: Heat Conductivity soil:
10° C 0,8 m 0,8 W/mK
The Lambda conductivity for the soil varies between 0,3-3,0 W/mK depending on the humidity. Now with improved insulating value λ50 = 0,031 W/mK
5
10
20
20
30
40
40°C
30
50
60
70
80
90°C
Heat transmission of chilled- and cold water for medium Heat pipes transmission of chilledtemperature and cold water<10°C pipes Single for medium temperature <10°pipe C
Heat loss for chilled- and cold water pipes for medium Heat loss for chilled and coldtemperature water pipes >10°C Single for medium temperature >10° pipe C
Single pipe
Single pipe W/m
W/m -10
1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A40 4: VS-RS125A50 5: VS-RS125A63 6: VS-RS160A75 7: VS-RS160A90 VS-R200A110
7 5 6 3 4
-5
10
1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A40 4: VS-RS125A50 5: VS-RS125A63 6: VS-RS160A75 7: VS-RS160A90 VS-R200A110
5
7
5 6 3 4 2 1
2 1
-15°C
-10
-5
0
5
10
10
20
30
40°C
Heat transmission of chilled- and cold water pipes for medium temperature <10°C Single pipe W/m
1: VS-RS90A25 2: VS-RS90A32
-10
7
FLEXALEN Straight Lengths Heating/Hot water FLEXALEN straight lengths with PB (Polybutene) carrier pipes – acc. to EN-ISO 15876 – PUR insulation and HDPE outer casing. Alternatively metal outer casings can be offered. Pipe length 3mtr, 6mtr or 12mtr. Product code
D.N.
Inch
Casing pipe O.D. [mm]
Carrier pipe O.D. I.D. [mm] [mm]
Insulation thickness [mm]
No. of medium pipes
Minimum bending radius [m]
Length [m]
Weight [kg/ metre]
FV-RS125A63
50
2
125
63
51,4
28,0
1
10
6
2,8
FV-RS160A75
65
2½
160
75
61,4
39,0
1
12
6
4,4
FV-RS160A90
80
3
160
90
73,6
30,0
1
12
6
4,8
FV-R200A110
100
4
200
110
90,0
40,0
1
16
12
6,3
FV-R200A125
100
4
200
125
102,2
32,0
1
16
12
7,4
FV-R250A160
150
6
250
160
130,8
38,0
1
20
12
11,7
FV-R315A225
200
8
315
225
184,0
35,0
1
26
5,80
22
Cold/Chilled Water FLEXALEN straight lengths with HDPE (Polyethylene) carrier pipes – PUR insulation and HDPE outer casing. Alternatively metal outer casings can be offered. Pipe length 3mtr, 6mtr or 12mtr. Product code
D.N.
Inch
Casing pipe O.D. [mm]
Insulation thickness [mm]
No. of medium pipes
Minimum bending radius [m]
Length [m]
Weight [kg/ metre]
FV-R125A63PE
50
2
125
63
51,4
28,0
1
10
6
2,8
FV-R160A75PE
65
2½
160
75
61,4
39,0
1
12
6
4,4
FV-R160A90PE
80
3
160
90
73,6
30,0
1
12
6
4,8
FV-R200A110PE 100
4
200
110
90,0
40,0
1
16
6
6,3
FV-R200A125PE 100
4
200
125
102,2
32,0
1
16
6
7,4
FV-R225A140PE 125
5
225
140
114,6
37,0
1
18
6
9,0
FV-R250A160PE 150
6
250
160
130,8
38,0
1
20
6
11,7
FV-R250A180PE 150
6
250
180
147,2
29,0
1
20
6
14,2
FV-R280A200PE 200
8
280
200
163,6
33,0
1
23
6
17,8
FV-R280A225PE 200
8
280
225
184,0
21,0
1
23
6
19,9
FV-R315A250PE 250
10
315
250
204,6
23,0
1
26
6
24,5
PB carrier pipe
Carrier pipe O.D. I.D. [mm] [mm]
PE carrier pipe with trace heating
Please note, that these products are only fabricated according to special request. This may lead to extended delivery time.
8
FLEXALEN Straight Lengths – Insulation values
Heat loss single pipe (Heating flow & return)
Domestic Hot Water
Heat losspipe for(Heating chilled-flow and&cold water Heat loss single return)
Domestic Hot Water
pipes for medium temperature >10°C W/m Single pipe
W /m
65
6
1: FV-RS125A63 W/m FV-RS160A75 60 2: FV-RS160A90 30 3: FV-R200A110 1: FV-R125A63 50 4: FV-R200A125 FV-R160A75 25 FV-R225A140 2: FV-R160A90 5: FV-R250A160 FV-R200A110 40 6: FV-R315A225 3: FV-R200A125 20 FV-R225A140 30 FV-R250A160 15 4: FV-R250A180 FV-R280A200 20 5: FV-R280A225 10 FV-R315A250
40 35
5 4 3 2 5 1 4 3 2 1
10 5
6
1: FV-RS125A63 FV-RS160A75 2: FV-RS160A90 3: FV-R200A110 4: FV-R200A125 FV-R225A140 5: FV-R250A160 6: FV-R315A225
30 25
5 4 3 2 1
20 15 10
20 10
30
40
50
60
20
80
70 30
90°C 40°C
5
Tflow + Tret. 2
30
20
40
50
60
80
70
Heat transmission of chilled- and cold water Heat pipes transmission of chilledtemperature and cold water<10°C pipes for medium for medium temperature < 10°pipe C Single
Heat loss for chilled- and cold water pipes for medium Heat loss for chilled and coldtemperature water pipes >10°C for medium temperature >10° C Single pipe
Single pipe
Single pipe W/m
W/m
1: FV-R125A63 FV-R160A75 2: FV-R160A90 FV-R200A110 3: FV-R200A125 FV-R225A140 FV-R250A160 4: FV-R250A180 FV-R280A200 5: FV-R280A225 FV-R315A250
5
4 3 2 1
-15°C
-30
30
-25
25
-20
20
-15
15
-10
10
-5
-10
-5
0
5
Chart data based on following criteria: Soil temperature: Covering: Heat Conductivity soil:
10° C 0,8 m 0,8 W/mK
90°C
1: FV-R125A63 FV-R160A75 2: FV-R160A90 FV-R200A110 3: FV-R200A125 FV-R225A140 FV-R250A160 4: FV-R250A180 FV-R280A200 5: FV-R280A225 FV-R315A250
5
4 3 2 1
5
10
10
20
40°C
30
Heat transmission of chilled- and cold water pipes for medium temperature <10°C Single pipe W/m
The Lambda conductivity for the soil varies between 0,3-3,0 W/mK depending on the humidity.
5
4 3 2 1
-15°C
-30
1: FV-R125A63 FV-R160A75 2: FV-R160A90 FV-R200A110 3: FV-R200A125 FV-R225A140 FV-R250A160 4: FV-R250A180 FV-R280A200 5: FV-R280A225 FV-R315A250
-25 -20 -15 -10 -5
-10
-5
0
5
10
9
FLEXALEN 1000+ ■ FLEXALEN 1000+ The multi functional system Flexalen 1000+: Carefully selected & matched components combine to make a system that offers easy installation and superior insulation for special requirements ● Free moving carrier pipes ● Single line, double line and quattro-pipes multi-line capability ● Cellular waterproof insulation ● Top foam quality – proven λ = 0,031 W/mK at 50 °C ● Superior flexibility at low temperatures < 0°C ● Smooth sliding PB carrier pipes offer easy installation ● Good interconnection between jacket pipe and insulation ● Full compatibility with Flexalen 1000 and Flexalen 600 ● Fit to meet future standards ● It satisfies the requirements for sustainable construction ● Certified by KIWA in accordance with BRL policy
FLEXALEN 1000+ Dimensions Product code
D.N.
Inch
25 20 32 20 40 20 50 25 20 15 20 15 25 20 15 25 15 32 20 15 32 25 20 40 20 15 40 25 20
1 ¾ 1¼ ¾ 1½ ¾ 2 1 ¾ ½ ¾ ½ 1 ¾ ½ 1 ½ 1¼ ¾ ½ 1¼ 1 ¾ 1½ ¾ ½ 1½ 1 ¾
FV+RS125A32A25 FV+RS160A40A25 FV+RS200A50A25 FV+RS200A63A32 FV+R160A2/25A2/20 FV+R160A3/25A20 FV+R160A2/32A25A20 FV+R200A3/32A20 FV+R200A2/40A25A20 FV+R200A2/40A32A25 FV+R200A2/50A25A20 FV+R200A2/50A32A25
Casing Pipe O.D. [mm] 125 160 200 200 160 160 160 200 200 200 200 200
Carrier pipe O.D. I.D. [mm] [mm] 32 25 40 25 50 25 63 32 25 20 25 20 32 25 20 32 20 40 25 20 40 32 25 50 25 20 50 32 25
Wall thickness [mm]
No. of medium pipes
3,0 2,3 3,7 2,3 4,6 2,3 5,8 3,0 2,3 2,8 2,3 2,8 3,0 2,3 2,8 3,0 2,8 3,7 2,3 2,8 3,7 3,0 2,3 4,6 2,3 2,8 4,6 3,0 2,3
1 1 1 1 1 1 1 1 2 2 3 1 2 1 1 3 1 2 1 1 2 1 1 2 1 1 2 1 1
26,0 20,4 32,6 20,4 40,8 20,4 51,4 26,0 20,4 14,4 20,4 14,4 26,0 20,4 14,4 26,0 20,4 32,6 20,4 14,4 32,6 26,0 20,4 40,8 20,4 14,4 40,8 26,0 20,4
Minimum bending radius[m]
Standard coil lenght [m]
Weight [kg / metre]
0,60
100
1,50
0,80
100
2,60
0,90
100
2,90
1,00
100
3,35
0,8
50
2,05
0,8
50
2,10
0,8
50
2,35
0,8
50
2,95
0,8
50
3,15
0,8
50
3,30
0,9
50
3,65
0,9
50
3,80
Temperature/Pressure rating for PB carrier pipes: Operating Temperature in °C
-15° C
0° C
20° C
40° C
60° C
70° C
80° C
95° C
Operating Pressure in bar
16 bar
16 bar
16 bar
15 bar
12 bar
10 bar
9 bar
8 bar
Temperature range –15° C to +95° C
Do not combine heating and hot water with cold water lines!!!
10
FLEXALEN 60 Continuous pre-insulated connection line for Heating and Cooling Installations FOR ● Split Air-conditioning ● Reversible Heating- Cooling Units ● Heat Pumps ● Domestic Water ● Fluid Connection lines for Beer, soft drinks etc. IN ● Office Buildings ● Shopping Centres ● Leisure Parks ● Domestic Houses ● Industry APPLICABLE in ● False ceilings ● Concrete ducts ● Embedded into concrete
Technical data: Dimensions: Product code FS-RS42A16 FS-RS46A20 FS-RS51A25 FS-RS58A32
PB carrier pipe O.D. [mm] I.D. [mm] 16 11,6 20 14,4 25 20,4 32 26,0
Insulation [mm] 13 13 13 13
Bending radius [m] 0,16 0,20 0,25 0,32
Coil length [m] 50 50 50 50
Weight [kg/lm] 0,20 0,29 0,33 0,40
Temperature and Pressure resistance: Polybutene PB-1 Carrier Pipes Operation Temperature (°C)
-15° C
0° C
20° C
40° C
60° C
70° C
80° C
95° C
max. operation pressure (bar)
16 bar
16 bar
16 bar
15 bar
12 bar
10 bar
9 bar
8 bar
BS 476 Part6
Class 1
(GB)
BS 476 Part7
Class 0
(GB)
ÖNORM B3800
B1
(AT)
DIN 4102
B1
(DE)
P-92507
M1
(FR)
NEN 6065
Class 1
(NL)
NEN 6066
Class 0
(NL)
Insulation: Material: Temperature range: Volume weight: Insulation thickness: Heat conductivity at 10°C: Heat conductivity at 40°C: Vapour resistance [µ] :
New ThermoplastElastomere foam -80 to +95°C (Insulation only) 25-35 kg/m3 min. 13 mm 0,035 W/m*K 0,038 W/m*K ≥ 7000
Fire resistance
11
Fittings and flanges ■ Transition Fittings, Compression Fittings Compression BSP thread fitting
Product code
Pipe OD
DN
Thread in inch
BCA-PB25/2,3
25
20
¾
BCA-PB32/3,0
32
25
1
BCA-PB40/3,7
40
32
1¼
BCA-PB50/4,6
50
40
1½
BCA-PB63/5,8
63
50
2
BCA-PB75/6,8
75
65
2½
WAK90/8,2
90
80
3
WAK110/10,0
110
100
3
Pipe OD
DN
Thread in inch
GF-HVEM25/R3/4
25
20
¾
GF-HVEM32/R1
32
25
1
GF-HVEM40/R5/4
40
32
1¼
GF-HVEM50/R6/4
50
40
1½
GF-HVEM63/R2
63
50
2
Pipe OD
DN
Inch
GF-FLANSCH63
63
50
2
GF-FLANSCH75
75
65
2½
GF-FLANSCH90
90
80
3
GF-FLANSCH110
110
100
4
GF-FLANSCH125
125
100
4
GF-FLANSCH140
140
125
5
GF-FLANSCH160
160
150
6
GF-FLANSCH225
225
200
8
Type
Made of brass with a BSP thread connection to metal
■ Pupped Composite Union PB weld x BSP thread
Product code
Type
Connected to carrier pipes
■ Pupped stub flanges Pupped PB weld x NP flange
12
Product code
Type Consisting of a loose galvanised backing ring, pupped stub flange and sealing gasket. Connected to carrier pipe by electrofusion coupler
Connection to carrier pipe by butt fusion
Transition and Measurements Transition from plastic to steel â&#x2013;
Item
BCA-PB
BCA-PB
WAK
PB flange
PB-HV
Description
compression fitting
compression fitting
compression fitting
flange connection
composite union
Dimensions
OD 16 - 50
OD 63 - 75
OD 90 - 110
OD 63 - 225
OD 25 - 63
Transition
BSP thread
BSP thread
BSP thread
flange PN 10
BSP thread
Underground laying
Yes
Yes
No
No
No
Assembly
easy fitting without any special tools
easy fitting without any special tools
easy fitting without any special tools
by electrofusion (63-110) or butt welding (110-225)
by electrofusion welding
* Underground laying may be allowed, if fitting is made traceable for inspecion.
Measurements of flange connections â&#x2013; OD 125 - 225 mm
OD 63 - 110 mm
.ds
D1
D
.dB
.d
.k .D1
B
.s .b
Pipe diameter [mm]
63
75
90
110
125
140
160
225
50PN10
65PN10
80PN10
100PN16
100PN16
125PN16
150PN16
200PN16
d1 Backing ring diameter [mm]
165
185
200
220
226
250
296
350
D1 Flange face diameter [mm]
90
106
125
150
160
188
216
268
B Flange thickness [mm]
14
15
16
18
25
25
25
32
d Internal diameter (bore) [mm]
78
92
110
133
135
158
178
238
dB Bolt hole diameter [mm]
18
18
18
18
18
18
22
22
k Bolt circle diameter [mm]
125
145
16
180
180
210
240
295
b Backing ring thickness [mm]
18
18
20
20
23
26
28
31
100
142
135
188
6
8,6
8
8
Flange drilling
ds Sealing ring diameter [mm] s Sealing ring thickness [mm]
A check should always be made to ensure a complete seal between flange face and metal valve/metal flange
13
Rubber end caps Rubber end caps Multipipe system FLEXALEN 1000+ end caps Product code
Type Rubber end caps serving as a seal between the individual carrier pipes and the corrugated casing pipe (incl. zip ties)
FV-MAN160ML FV-MAN200ML
Rubber end caps single FLEXALEN 600 end caps Product code
Rubber end caps double
Carrier pipe O.D.
VS-MAN90A40-A25
25/32/40
VS-MAN125A63-A50
50/63
VS-MAN160A90-A75
75/90
VS-MAN200A110
Rubber end caps serving as a seal between the carrier pipe and the corrugated casing pipe (incl. zip ties)
110
VS-MAN125A2/32-A2/25
2x25/2x32
VS-MAN160A2/50-A2/40
2x40/2x50
VS-MAN200A2/63
Type
Rubber end caps serving as a seal between the two carrier pipes and the corrugated casing pipe (incl. zip ties)
2x63
Heat shrink end caps FLEXALEN straight lengths
14
FV-MAN110/140FL
Heat shrink end caps to suit 110 –140 mm carrier / 200 – 225 mm casing
FV-MAN160FL
Heat shrink end caps to suit 160 mm carrier / 250 mm casing
FV-MAN225FL
Heat shrink end caps to suit 225 mm carrier / 315 mm casing
Anchor Point and Wall Entry Anchor Point ■ Product code
Pipe OD
DN
Inch
FV-FlXSCH2/25
25
20
2x¾
FV-FIXSCH2/32
32
25
2 x1
FV-FIXSCH2/40
40
32
2 x 1¼
FV-FIXSCH2/50
50
40
2 x 1½
FV-FIXSCH2/63
63
50
2x2
FV-FIXSCH25
25
20
¾
FV-FIXSCH32
32
25
1
FV-FIXSCH40
40
32
1¼
FV-FIXSCH50
50
40
1½
FV-FIXSCH63
63
50
2
FV-FIXSCH75
75
65
2½
FV-FlXSCH90
90
80
3
FV-FIXSCH110
110
100
4
FV-FIXSCH110ST
110
100
4
FV-FIXSCH125
125
100
4
FV-FIXSCH140
140
125
5
FV-FIXSCH160
160
150
6
FV-FIXSCH225
225
200
8
Type
Double pipe anchors Anchor points recommended at transition points to other materials
Single pipe anchors
Anchor points recommended at transition points to other materials
Single pipe anchors
Anchor points recommended at transition points to other materials
Single pipe anchors
Anchor points recommended at transition points to other materials
End caps are not included.
Installation guideline: It is recommended that outer surface of the polybutylene pipe is wiped clean with a TANGIT cleaning fluid and a lint free cloth prior to installation of anchor.
Wall Entry ■ Product code
Diameter Outer casing [mm]
Core drill diameter [mm]
FV-MD90KB
90
120
FV-MD125KB
125
150
FV-MD160KB
160
200
FV-MD200KB
200
250
FV-MD225KB
225
250
FV-MD250KB
250
300
FV-MD315KB
315
400
Type
Ring-sealing for wall entry suitable for water pressure up to 1,5 bar
15
Electrofusion couplings Electrofusion welding socket GF
Product code
Pipe OD
DN
Inch
GF-EM25
25
20
¾
GF-EM32
32
25
1
GF-EM40
40
32
1¼
GF-EM50
50
40
1½
Type
Electrofusion coupler PB GF-EM63
63
50
2
GF-EM75
75
65
2½
GF-EM90
90
80
3
GF-EM110
110
100
4
Note: Full range of electrofusion elbows, reducers + tees avaible (25 mm - 110 mm)
16
Pre-insulated Fittings and Tee-Half Shells Pre-insulated Fittings ■ The following pictures represent only a small part of the possibilities available from our frabrication department. Please forward any design requirements to us, and we will be happy to supply prices.
Pre-insulated T-piece for twin pipe
Pre-insulated twin branch piece, which connects two single pipes with a twin-pipe house service connection
Pre-insulated T-piece used for single and twin pipes
Pre-insulated Y-piece used for the transition from two single pipes to a twin one
Pre-insulated elbow 90º and 45º for twin pipes
Pre-insulated elbow 90º and 45º for single pipes
Tee-Half Shells ■
Insulation Half Shells available in Single and Double Format. Complete Set with pipe insulation, Sealing mastic and fixing material. Suitable for all pipe formats with outer casing of 125/160/200. Can also be adapted to 90 mm od casings.
17
Polybutene ■ Polybutene – the perfect material Our carrier pipes are made from Polybutene (PB-1), commercially available and used successfully for over 35 years ● Temperature range -15 °C up to 95 °C ● Compression end connections for small, simple jobs ● Completely welded jointing system produces homogenous connections ● No build up of scale and calcification PB pipes for heating and domestic hot water with drinking water approvals
● Very low resistance / pressure loss due to smooth interior walls ● High chemical resistance (also suitable for Geothermal water) ● Drinking water certification for Polybutene grey with international approvals (e.g. KIWA, CSTB)
That Polybutene is the only plastic pipe system currently used in heating systems that can be fully fusion welded and operate up to 95° C!
Compression Fittings
And, polybutene fusion welded pipes have been used for almost 40 years! You can use PB pipe systems in complete confidence, with the knowledge that you are using a tried and trusted welding system. Electrofusion - the safe connection (longitudinal section)
■ Lifetime table for PB pipes The life cycle of plastics mainly depends on the surrounding temperature. The data required for a calculation are the following: running season (winter/summer season) running time (in hrs) with the operating temperature
The calculation is based on the results of internal pressure/pull-out tests and the extrapolation time factors for polybutylene.
We are founding members of the Polybutene Piping Systems Association. For more information on the principles of the PBPSA, please contact www.pspba.com.
18
FLEXALEN material properties Polybutene carrier
Polyethylene casing
Temperature resistance
– 15° C to + 95° C
Stretch tension
22 N/mm2
Volume weight 50 - 80 kg/m3
Density
0,940 g/cm3
Tearing strength
32 N/mm2
Temperature resistance
– 40° C to + 110° C
Melt index
0,4 g/10 min
λ−value
0,033 W/mK
Stretch tension
20 N/mm2
Closed cells
94%
Tearing strength
35 N/mm2
Load resistance:
>0,2 N/mm2
Tearing expansion 300 %
Tearing expansion 800 % E-module
800 N/mm2
Notch ductility
without breakage
Ductility
without breakage
E-module
420 N/mm2
Length expansion coefficient 0,18 mm/mK
Shore hardness
D53
λ−value
Notch ductility
without breakage
Ductility
without breakage
Length expansion coefficient
0,13 mm/mK
λ−value
Polyurethane insulation
Polyethylene insulation
0,43 W/mK
0,16 W/mK
Volume weight 30 - 40 kg/m3 Temperature resistance
– 80° C to + 95° C
λ−value
0,031 W/mK
Closed cells
That Polybutene pipes are far more flexible that other plastic pipes? Comparison Material
E-module (stiffness) [N/mm2]
Polybutene PE-X Polypropylene
420 600 (40% stiffer than Polybutene) 800 (90% stiffer than Polybutene)
Polybutene is the most flexible pipe system for heating and cooling.
We test our Polybutene pipes to ONORM B5153 for 1000 hrs at 95°C. Our Polybutene pipes are tested to higher pressures than other plastic pipes. Comparison of test Material Test pressure Polybutene PE-X Polypropylene
15 Bar 9.8 Bar (tested to a pressure 34% lower than PB) 5.6 Bar (tested to a pressure 62% lower than PB)
Polybutene is the proven, reliable, robust pipe system.
19
Trenching Details Structure of the pipe trench for long-distance heating pipes The structure of a long-distance heating pipe is determined by the designer on the basis of the instructions supplied by the pipe manufacturer, the valid standards and the individual circumstances in the building. A sand bed of at least 10 cm in any direction must surround the pipeline after the sand has been compressed. The granulation of the sand (= riddle line) is determined by the pipe manufacturer. There must be no coarse grains. After the back filling, the sand is compressed. Thus some small air holes remain in the sand which are only connected by narrow channels (high flow resistance - no air convection in the sand).
The ditch must be prepared in accordance with the above pictures. For those areas that must bear transport loads, the law provides a minimum cover of 0.8 m (load class SLW 60); in areas without transport load a minimum cover of 0.5 m is required.
20
Further back filling is normally undertaken using spoil from the trench. Coarse-grain gravel or road metal with or without a small soil portion are not suitable for the filling as they produce air channels with relatively big cross-sections and thus encourage the convection of the encircled air or the water which has invaded the trench. The filling must have a portion of fine-grained material, which prevents the development of continuous air channels. After the filling has been poured in, it must be compressed to produce a compact packing of the material. The covering depends on the location of the ditch. In roads it is formed by the building profile of the road, in meadows and fields it is formed by a â&#x20AC;&#x17E;humus layerâ&#x20AC;&#x153;. In no case the filling may reach the surface. A clear layering of the materials represents an additional barrier for the heat transportation in transitional areas between the different layers.
Please consider the corresponding standards and regulations regarding the pipeline course of long-distance heating pipes. During construction, the trench must be kept dry. For very damp soil, drainage of the trench is recommended to improve the heat insulation effect of the distributing network.
Welding The polybutylene medium pipes can be connected homogeneously by means of fusion welding. The following welding procedures are applied: ● GF electrofusion welding (dimensions 25 mm – 110 mm) ● Butt welding (dimensions 110 mm – 225 mm) Call your local representative for details on butt fusion hire facilities It is recommended that all welding of PB pipes must be undertaken only by trained operatives. Furthermore our laying instructions and the instruction manual for the recommended individual welding machines and equipment must be considered.
Electrofusion
Please see our laying instructions for the laying and processing guidelines.
Butt Fusion
21
Electrofusion welding Pipe Cutting The casing pipe should be cut using a sharp cable knife or similar. Cut evenly all the way around the corrugation. Carefully cut away / remove insulation. Cut the carrier pipe with an appropriate pipe cutter as shown.
Use only a wheel cutter for plastic pipe.
Attach rubber end caps. Pull the end cap over the first or second complete corrugation of the casing pipe. Use the supplied zip ties to seal the end cap to the casing pipe and the carrier pipe(s).
Electrofusion welding â&#x20AC;&#x201C; Pipe preparation Clean the pipe ends Pipe ends must be cleaned and free from oil, dirt and grease. We recommend the use of Tangit fluid cleaner or Tangit cleaning wipes.
Do not chamfer pipe ends. Abrade Pipe Ends Abrade outer surface of pipe ends with emery cloth (180 grade waterproof) in a radial direction. Make sure that at least the insertion depth is abraded. Do not abrade the outer surface of the pipe ends in the longitudinal direction.
Clean the pipe ends and internal weld area of the fitting Pipe ends and internal weld area of the fitting must be cleaned and free from oil, dirt and grease. We recommend the use of Tangit fluid cleaner or Tangit cleaning wipes.
22
Electrofusion welding Mark Insertion depth Mark the depth of insertion on the pipe. Insertion depth guides are marked on the fitting.
Do not use a wax pencil!
Insert pipes into the fitting Insert pipes into the fitting as far as the insertion mark.
Do not tighten the fitting screws! Use only separate alignment clamps. See next step.
Fix and Tighten Fitting Alignment Clamps Alignment clamps must be used for all pipe sizes 25mm to 110mm.
Execution of Electrofusion Connect the fusion control box to the power supply. Connect fusion cable to fitting terminal. Start the fusion operation by pressing the START button. Fusion process runs automatically.
Fusion Check The optical fusion check is verified by the appearance of the welding indicators. Fitting must be allowed to cool with clamps in place for the following Cooling times: 25 mm – 50 mm: 63 mm – 110 mm:
10 mins 15 mins
Clamps must not be removed before cooling time has elapsed.
Max. ambient temperature +5° C to +35° C
23
Pressure Testing Pressure Testing
b
max. 0.2 bar
a
c
Test pressure in bar
Test pressure
max. 0.6 bar
Pressure Test Diagram
0 10 20 30
Preliminary test
60
d
(time in minutes)
Main test
Ptest = 1.5 x Poperating Test pressure: For an operating pressure of 10 bar*, a testing pressure of 15 bar should be used. * according to DIN 1988 TRWI
180
Start pressure testing not earlier than 1 hour after cooling down period
Preparations: Measurement devices have to be installed at the lowest point of the piping system. The piping system should be filled with potable water thoroughly ventilated and separated from main supply. Preliminary test: The duration depends on the size of the system. Usually it takes 1 hour. Test pressure is 1,5 times working pressure. The pressure has to be checked and built up again after 10, 20 and 30 mins. The pre-test is successful, if the pressure drop between 30 mins and 1 hour is less than 0,6 bar. Main Test: Should be carried out immediately after the preliminary test. The duration is 2 hours. The main test is successful if the pressure drop is less than 0,2 bar.
24
Insulation coupler Installation
Slide the tubular heat shrink sleeves and the PE casing sleeve over one pipe end. Weld the carrier pipe(s) with electrofusion coupler(s).
Place the PUR half shells over the e/f joint and fix them with tape or a zip tie. Clean both ends of the casing pipe (+ 10 cm on each side) using tangit cleaner.
Slide the PE casing sleeve over the PUR half shells.
Remove the wrapping and the protective polythene covers from the tubular heat shrinks. Place the tubular heat shrink over the transition area between the casing pipe and the PE casing sleeve.
Heat the tubular heat shrink sleeve gently and uniformly using a soft (yellow) flame.
Take care while heating to prevent any damage to the casing pipe.
Remark: instead of PUR half shells other insulation materials can be used e.g. PE foam mats.
25
Branches Tee Half Shell Installation 1. Half Shell Tees Our half shell tees come as two part mouldings. The tees are designed to accommodate casing sizes of 200mm, 160, 125mm and 90mm (using the adapter). The tee can be cut to suit the casing size by using a sharp wood saw or hacksaw.
2. Prepare Pipe / Fuse fittings Flexalen pipe and fittings should be prepared and fused as shown in our electrofusion welding instruction.
3. Fit Insulation Use tubular insulation material to insulate the inner tee areas. Apply two runs of mastic underneath each pipe leg prior to fitting of bottom half shell.
4. Fit bottom half shell Place bottom half shell (with flat face flange) underneath the pipework.
26
Branches
5. Apply Sealant Fit bottom half shell. Run two beads of mastic sealant along flange face and run two beads around area where half shell meets casing pipe. Apply mastic in two beads around top of pipe.
6. Fit top half shell Place top half shell on top of bottom half and secure using zip ties.
7. Drill holes and secure top half shell Drill the flange area and fix top half shell with supplied screws and flat nuts.
8. Allow mastic to set. Leave shells to allow mastic to set for approx 30 mins.
27
Building Entry
Wall
There are several methods of entering a building with Flexalen ...
1. Compression End connection Typical On Line Termination Detail
Compression Union
Anchor
End Cap
Space between Flexalen casing and wall to filled with our waterseal fitting or waterproof grout.
Wall
2. Electrofusion end connection Typical On Line Termination Detail
E/F Coupler Composite Union
Anchor
End Cap
Elbow riser C/W end terminations on Wall Flexalen Pipe
E/F Coupler
Rubber End Cap
28
Space between Flexalen casing and wall to filled with our waterseal fitting or waterproof grout.
3. Pre fabricated building entry elbow detail The exposed joint area is then covered with the insulation coupling set (see broken out line) comprising of 1. Two half shells of pre cast foam 2. One large wrap aroundheat shrink wrap
Building Entry 4. Bending the pipe using its flexibility
Termination fitting
5. Riser Entry Detail using Flexalen 60
Section of Flexalen 60 jointed to carrier pipe by electrofusion elbow
6. Entry using Flexalen 60 and builder supplied duct pipe
Termination fitting
Heat Shrink connection between insulation casing and duct entry pipe
Section of Flexalen 60 jointed to carrier pipe by electrofusion coupler and ducted
29
Expansion Compensation PB has 35% lower expansion rate than PE-X The elasticity of the system allows the total pipe system to self compensate, so that expansion loops and bellows are not required.
Only at the building entry point must the pipe ends be fixed with our recommended fixing anchor system, in order to avoid excess stress on transitional fitting(s). Standard building entry elbow risers do not require anchors
Building connection twin pipe (DIA 25 - 63 mm)
Building connection single pipe (DIA 63 - 110 mm)
Carrier pipe O.D./[mm]
Max. expansion forces per carrier pipe [N]
X [mm]
Y [mm]
Z [mm]
Carrier pipe O.D./[mm]
Max. expansion forces per carrier pipe [N]
X [mm]
Y [mm]
25
250
~175
~335
~52
63
1600
~174
~420 - 475
32
410
~175
~345
~55
75
2200
~174
~435 - 485
40
640
~175
~360
~57
50
1000
~175
~375
~68
90
3200
~174
~455 - 515
63
1600
~175
~410
~78
110
4700
~174
~485 - 540
External pipelines, internal pipelines: For above ground horizontal lines, we recommend that all coiled FLEXALEN pipelines are supported along their entire length by securing to an angle bar bed or adequate cable tray with strong clips or ties placed every metre. The FLEXALEN anchoring system must be used with transition ends. External pipelines, internal pipelines: For vertical lines we recommend that the pipeline is secured to the wall or cable tray with strong clips or ties every metre. Transition ends must be used with our anchoring system. Non-insulated polybutene pipelines: Precautious must be taken against expansion and contraction, as well as for pipe support, when using un-insulated PB. Please refer to the comprehensive instructions supplied in the GF Georg Fischer +GF+Instaflex Manual. However, you can find some values regarding the expected length changes and the maximum expansion forces in the following table.
Pipe length
Temperature difference Î&#x201D;t [K]
[m]
50
60
70
80
35 40 45 50 60 70 80 90 100
0,23 0,26 0,29 0,32 0,39 0,45 0,52 0,58 0,65
0,27 0,31 0,35 0,39 0,47 0,55 0,62 0,70 0,78
0,32 0,36 0,41 0,45 0,55 0,64 0,73 0,82 0,91
0,36 0,42 0,47 0,52 0,62 0,73 0,83 0,94 1,04
Other dimensions on request
That Polybutene has a 35% lower expansion rate than PE-X? All plastic PB & PE-X pipes carrying hot water require anchoring at transition ends. All good system manufacturers should recommend anchoring!
30
FLEXALEN Software Please use our technical support which is available on our FLEXALEN software. 1 Free program: FLEXALEN QUICKCALC for source to building applications
Data required for the calculation: Temperature of the flow run [°C] Load [kW] Temperature of the return run [°C] Depth [m] Trench Length of the main line [m] Heat conductivity soil [W/mK]
FREE E AR SOFTW
After calculation the following data is available as a hard copy: ● Pipe size (OD) [mm] ● Flow speed [m/s] ● Quantity [l/s and/or m3/h] ● Pressure loss [Pa and/or bar] ● Pressure reserve [bar] ● Temperature drop in flow run [°C] ● Usable load [kW] ● The network volume [l] 2 FLEXALEN FASTNET for large networks support for network estimation Data required for the calculations: Sketch of the location line with the load [kW] and the lengths of the pipeline [m] and/ or a verified scale and the geodetic level of the network points Temperature of the flow run [°C] Temperature of the return run [°C] Pre-pressure for the transmitting-station to the house [bar] Depth [m] Heat conductivity soil [W/ mK] After the calculation, the following data is available as hard copy: ● Recommended pipe sizes (OD) [mm] ● Flow speed [m/ s] ● Quantity [l/ s and/ or m3/ h] ● Pressure loss [Pa and/ or bar] ● Simultaneous use ● Pressure reserve [bar] ● Length of the location line in total [m] ● Network volume [l] ● Network code line ● Pump pressure with simulation in relation to variable load requirements ● Another calculation module allows a dynamic analysis of the pipeline [heat loss, fall in temperature] Data from fastnet provided by Flexalen for products. Ask your representative for details of this service!
31
Nomogramm "Nomogramm" to determine the pressure losses when using FLEXALEN pipe systems at a temperature of 90째 C. FLEXALEN pipe type
Water quantity Heat load at a difference l/s temperature in K
Velocity of flow m/s
Pressure loss Pa / m 600
8 - Bar System
20 200
35
50
500 kW 4
150 100 A 225
A 160 A 140 A 125 A 110
A 90
A 75
A 63
A 50
A 40
80 60 50 40 30 20 15 10 8 6 5 4 3
2 1,5 1 0,8 0,6 0,5 0,4 0,3
20.000 15.000 10.000 7.500 5.000 4.000 3.000 2.500 2.000 1.500 1.250 1.000
400
3,5
300
3
250
2,5
200
2
150
1,5
100 90 80 70
1,0 0,9
60
0,8
50
0,7
40
750
0,6
30
500
0,5
25
0,4
20
400 300 250 200 150 125
0,35 0,3 0,25
15
100 80
0,2
0,2
50 40
10 9 8 7
0,15
6
0,15
30
0,1 0,08
20 15
0,06 0,05
10
5 0,1 0,09 0,08 0,07 0,06
A 32
A 25
0,05
Dimensioning example in red colour At a temperature of 60째 C the pressure loss has to be assumed 10% higher.
The "Nomogramm" is useful for quick dimensioning of district heating networks with FLEXALEN pipes. The data is exact enough in most cases. No responsibility is taken for the correctness of data for an individual application.
32
4 3,5 3 2,5 2
Pipe sizing ready reckoner DN
30
25
32
40
50
65
80
100
100
125
150
200
¾
1
1¼
1½
2
2½
3
4
4
5
6
8
ID
20,4
26
32,6
40,8
51,4
61,2
73,6
90
102,2
114,4
130,8
184,0
OD
25
32
40
50
63
75
90
110
125
140
160
225
DN = diameter standard OD = diameter external ID = diameter internal
5 K (e.g.: 7º C - 12º C chilled water) kW
6
11
17
27
43
61
89
133
172
215
282
557
38
60
95
135
196
293
378
474
619
1226
69
110
173
246
356
533
687
861
1126
2228
87
137
217
308
445
666
859
1077
1408
2785
104
165
260
370
534
800
1031
1292
1690
3342
140
220
346
494
712
1066
1375
1722
2253
4456
300
231
175
140
112
88
75
66
56
38
510
410
319
274
239
204
135
595
520
440
284
v=1m/s (velocity)
11 K (e.g.: 82º C - 71º C) kW
14
24
v=1m/s (velocity) 20 K (e.g.: 90º C - 70º C) kW
25
44
v=1m/s (velocity) 25 K (e.g.: 90º C - 65º C) kW
31
56
v=1m/s (velocity) 30 K (e.g.: 90º C - 60º C) kW
38
67
v=1m/s (velocity) 40 K (e.g.: 90º C - 50º C) kW
50
89
v=1m/s (velocity)
Pressure loss approx: Pa/m (1m/s)
555
402
Pa/m (2m/s)
Pa/m (3m/s)
Please use the following multipliers for authorized higher flowing speeds:
v=2m/s
Factor: 2
v=3m/s
Factor: 3
The factors only refer to the transmittable performance, not to the pressure loss!!!!
33
European approvals â&#x20AC;&#x201C; 3rd Party
Test reports and Approvals for POLYBUTENE and FLEXALEN pipes and fittings
FLEXALEN products are carefully monitored and tested by 3rd party test institutes. Approvals for the use in Domestic Hot & Cold Water, Heating and Thermal Water applications are made e.g. in: France: CSTB Netherlands: ISO, KIWA
34
Notes
35
AUSTRIA (central support)
NEW ZEALAND
UK & IRELAND
THERMAFLEX-FLEXALEN Rohr- und Isoliersysteme GmbH Kaiserstrasse 45, 1070 Wien
ENERGY PRODUCTS INTERNATIONAL Gallagher Drive, P.O. Box 15058 Hamilton
Phone: +43.1.523 26 25.0 Fax: +43.1.523 26 25.24 E-Mail: info@flexalen.com www.flexalen.com www.thermaflex.com
Phone: +64.07.847 27 05 Fax: +64.07.847 42 22 E-Mail: pmckenzie@energy-products.co.nz www.energy-products.co.nz
FLEXALEN Heating & Cooling Products Limited Unit 1, Station Ind Est Station Road, Methil, Fife, KY8 3 HA, United Kingdom Phone: +44.845.644 37 93 Fax: +44.845.644 38 93 E-Mail: ian@flexalen.co.uk www.flexalen.co.uk
S
PART A
SY AT E D PIPE
906072-EN
IN
BRL k17401 BRL 5609
EMS
P R E-
UL
ST
CER TI
KIWA CERTIFIED
B LE XI
TE FOR FL CA E FI