Flexalen Product Guide
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Transcript of Flexalen Product Guide
taking care of energy and environment
product guide
22
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.
Contents
33
World leaders since 1981
44
5
3
66
FLEXALEN product overviewfor Heating – Hot Water – Chilled Water
1
2
FLEXALEN 600 Single pipe(25 mm – 110 mm O.D.)
FLEXALEN 600 Twin pipe(25 mm – 63 mm O.D.)
3 FLEXALEN 1000+ Multi pipe
55
4
1
2
5 FLEXALEN Straight lengths(63 mm – 225 mm O.D.)
6 FLEXALEN 60(16 mm – 32 mm O. D.)
4 FLEXALEN Cold water (HDPE)
Temperature Range– 15° C to + 95° C
5
66
Peak temperature 95 °CTemperature range –15° C to +95° C
Casing Carrier pipe Wall No. of Minimum Standard Weight Product D.N. Inch Pipe O.D. O.D. I.D. thickness medium bending coil length [kg/ code [mm] [mm] [mm] [mm] pipes radius [m] [m] 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
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
● 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
● Pressure hammer absorption
■ The compact standard system
Temperature/Pressure rating for PB carrier pipes:
FLEXALEN 600 Dimensions
Twin pipes up to 63 mm, Single pipes up to 110 mm
Watertight bond between foam and outer casing
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
FLEXALEN 600
77
Heat loss twin pipe (Heating flow & return)
Domestic Hot Water
Heat loss single pipe (Heating flow & return)
Chart data based on following criteria:
Soil temperature: 10° CCovering: 0,8 mHeat Conductivity soil: 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
2
3
1
5
10
20 30 40 50 60 70 80 90°C Tflow + Tret.
2
15
20
25
30
W/m
1: VS-R125A2/252: VS-R125A2/32 VS-R160A2/403: VS-R160A2/50 VS-R200A2/63
Wärmeverlust Doppelleitungen
8 9
10
4 5 7 6
5
10
20 30 40 50 60 70 80 90°C
15
20
25
30
W/m
4: VS-R90A25 5: VS-R90A32 6: VS-R90A40 7: VS-R125A50 8: VS-R125A63 9: VS-R160A7510: VS-R160A90 VS-R200A110
Wärmeverlust Einzelleitungen
Wärmeverlust Einzelleitungen-Rohrpaar(Vorlauf + Rücklauf)
4: VS-RS90A25 5: VS-RS90A32 6: VS-RS90A40 7: VS-RS125A50 8: VS-RS125A63 9: VS-RS160A7510: VS-RS160A90 VS-R200A110
10
20
20 30 40 50 60 70 80 90°C
30
40
50
60
89
10
4576
W/m
Heat loss for chilled and cold water pipes for medium temperature >10° C
Single pipe
7
634
2
1
W/m
5
10
10 20 30 40°C
7
5
36
1
W/m
-5
-10
-15°C -5 5 100-10
Heat loss for chilled- and cold water pipes for medium temperature >10°C
Single pipe
Heat transmission of chilled- and cold water pipes for medium temperature <10°C
Single pipe
1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A110
5
1: VS-RS90A25 2: VS-RS90A323: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A1104
2
Heat transmission of chilled and cold water pipes for medium temperature <10° C
Single pipe
7
634
2
1
W/m
5
10
10 20 30 40°C
7
5
36
1
W/m
-5
-10
-15°C -5 5 100-10
Heat loss for chilled- and cold water pipes for medium temperature >10°C
Single pipe
Heat transmission of chilled- and cold water pipes for medium temperature <10°C
Single pipe
1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A110
5
1: VS-RS90A25 2: VS-RS90A323: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A1104
2
FLEXALEN 600 – Insulation values
88
Heating/Hot waterFLEXALEN 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 Carrier pipe Insulation No. of Minimum Length Weight pipe O.D. O.D. I.D. thickness medium bending [m] [kg/ [mm] [mm] [mm] [mm] pipes radius [m] 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 WaterFLEXALEN 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 Carrier pipe Insulation No. of Minimum Length Weight pipe O.D. O.D. I.D. thickness medium bending [m] [kg/ [mm] [mm] [mm] [mm] pipes radius [m] 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 PE carrier pipe with trace heating
FLEXALEN Straight Lengths
Please note, that these products are only fabricated according to special request. This may lead to extended delivery time.
99
Chart data based on following criteria:
Soil temperature: 10° CCovering: 0,8 mHeat Conductivity soil: 0,8 W/mK
The Lambda conductivity for the soil varies between 0,3-3,0 W/mK depending on the humidity.
Domestic Hot WaterHeat loss single pipe (Heating flow & return)
5 4
2
3
1
W/m
10
20
30
40
50
60
20 30 40 50 60 70 80 90°C
1: FV-RS125A63 FV-RS160A75 2: FV-RS160A90 3: FV-R200A110 4: FV-R200A125 FV-R225A140 5: FV-R250A160 6: FV-R315A225
65
Heat loss single pipe (Heating flow & return)
6
Tflow + Tret.2
54
2
3
1
W /m
1: FV-RS125A63 FV-RS160A752: FV-RS160A903: FV-R200A1104: FV-R200A125 FV-R225A1405: FV-R250A1606: FV-R315A225
5
10
15
20
25
30
Domestic Hot Water
20 30 40 50 60 70 80 90°C
35
40 6
Heat loss for chilled and cold water pipes for medium temperature >10° C
Single pipe
Heat transmission of chilled and cold water pipes for medium temperature < 10° C
Single pipe
5
4
2
3
1
1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250
FV-R160A75
W/m
5
10
15
20
30
25
10 20 30 40°C
5
4
2
3
1
W/m
-5
-10
-15
-20
-30
-25
-15°C -5 5 100-10
Heat loss for chilled- and cold water pipes for medium temperature >10°C
Single pipe
Heat transmission of chilled- and cold water pipes for medium temperature <10°C
Single pipe
1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250
FV-R160A75
5
4
2
3
1
1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250
FV-R160A75
W/m
5
10
15
20
30
25
10 20 30 40°C
5
4
2
3
1
W/m
-5
-10
-15
-20
-30
-25
-15°C -5 5 100-10
Heat loss for chilled- and cold water pipes for medium temperature >10°C
Single pipe
Heat transmission of chilled- and cold water pipes for medium temperature <10°C
Single pipe
1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250
FV-R160A75
FLEXALEN Straight Lengths – Insulation values
1010
■ FLEXALEN 1000+ The multi functional system
Flexalen 1000+: Carefully selected & matched compon-ents combine to make a system that offers easy installati-on 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
Product code D.N. InchCasing
Pipe O.D.[mm]
Carrier pipeO.D.[mm]
I.D.[mm]
Wallthickness
[mm]
No. ofmedium
pipes
Minimumbendingradius[m]
Standardcoil lenght
[m]
Weight[kg /
metre]
FV+RS125A32A25 25 1
125 32 26,0 3,0 1
0,60 100 1,50 20 ¾ 25 20,4 2,3 1
FV+RS160A40A25 32 1¼
160 40 32,6 3,7 1
0,80 100 2,60 20 ¾ 25 20,4 2,3 1
FV+RS200A50A25 40 1½
200 50 40,8 4,6 1
0,90 100 2,90 20 ¾ 25 20,4 2,3 1
FV+RS200A63A32 50 2
200 63 51,4 5,8 1
1,00 100 3,35
25 1 32 26,0 3,0 1
FV+R160A2/25A2/20 20 ¾ 160
25 20,4 2,3 2 0,8 50 2,05
15 ½ 20 14,4 2,8 2
FV+R160A3/25A20 20 ¾ 160
25 20,4 2,3 3 0,8 50 2,10
15 ½ 20 14,4 2,8 1
25 1 32 26,0 3,0 2 FV+R160A2/32A25A20
20 ¾ 160 25 20,4 2,3 1 0,8 50 2,35
15 ½ 20 14,4 2,8 1
FV+R200A3/32A20 25 1 200 32 26,0 3,0 3 0,8 50 2,95
15 ½ 20 20,4 2,8 1
32 1¼ 40 32,6 3,7 2 FV+R200A2/40A25A20
20 ¾ 200 25 20,4 2,3 1 0,8 50 3,15
15 ½ 20 14,4 2,8 1
32 1¼ 40 32,6 3,7 2 FV+R200A2/40A32A25
25 1 200 32 26,0 3,0 1 0,8 50 3,30
20 ¾ 25 20,4 2,3 1
40 1½ 50 40,8 4,6 2 FV+R200A2/50A25A20
20 ¾ 200 25 20,4 2,3 1 0,9 50 3,65
15 ½ 20 14,4 2,8 1
40 1½ 50 40,8 4,6 2 FV+R200A2/50A32A25
25 1 200 32 26,0 3,0 1 0,9 50 3,80
20 ¾ 25 20,4 2,3 1
FLEXALEN 1000+ Dimensions
Temperature/Pressure rating for PB carrier pipes:
Temperature range –15° C to +95° C
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
FLEXALEN 1000+
Do not combine heating and hot water with cold water lines!!!
1111
Technical data:Dimensions:
Temperature and Pressure resistance:Polybutene PB-1 Carrier Pipes
Product code PB carrier pipe Insulation Bending radius Coil length Weight O.D. [mm] I.D. [mm] [mm] [m] [m] [kg/lm]
FS-RS42A16 16 11,6 13 0,16 50 0,20
FS-RS46A20 20 14,4 13 0,20 50 0,29
FS-RS51A25 25 20,4 13 0,25 50 0,33
FS-RS58A32 32 26,0 13 0,32 50 0,40
Material: New Thermoplast- Elastomere foamTemperature range: -80 to +95°C (Insulation only)Volume weight: 25-35 kg/m3
Insulation thickness: min. 13 mmHeat conductivity at 10°C: 0,035 W/m*KHeat conductivity at 40°C: 0,038 W/m*KVapour resistance [µ] : ≥ 7000
Fire resistance 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:
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
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
FLEXALEN 60
1212
■ Pupped stub flanges
■ Pupped Composite Union
Compression BSP thread fitting Product code Pipe OD DN Thread in inch Type
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
Made of brass with a BSP threadconnection to metal
Product code Pipe OD DN Inch Type
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
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
Pupped PB weld x NP flange
Product code Pipe OD DN Thread in inch Type
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
PB weld x BSP thread
Connected to carrier pipes
Fittings and flanges
■ Transition Fittings, Compression Fittings
1313
Transition from plastic to steel ■
Measurements of flange connections ■
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 easy fitting without easy fitting without by electrofusion by electrofusion any special tools any special tools any special tools (63-110) welding or butt welding (110-225)
* Underground laying may be allowed, if fitting is made traceable for inspecion.
A check should always be made to ensure a complete seal between flange face and metal valve/metal flange
OD 125 - 225 mmOD 63 - 110 mm
Pipe diameter [mm] 63 75 90 110 125 140 160 225
Flange drilling 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
ds Sealing ring diameter [mm] 100 142 135 188
s Sealing ring thickness [mm] 6 8,6 8 8
.k. d D1
.
dB
.
b.
ds
.
s.
D D1
B
Transition and Measurements
1414
Product code Carrier pipe O.D. Type
VS-MAN90A40-A25 25/32/40
VS-MAN125A63-A50 50/63
VS-MAN160A90-A75 75/90
VS-MAN200A110 110
VS-MAN125A2/32-A2/25 2x25/2x32
VS-MAN160A2/50-A2/40 2x40/2x50
VS-MAN200A2/63 2x63
Rubber end caps double
Rubber end caps single
Rubber end caps Multipipe system
Heat shrink end caps
Rubber end caps serving as a seal between the two carrier pipes and the corrugated casing pipe (incl. zip ties)
Rubber end caps serving as a seal between the carrier pipe and the corrugated casing pipe (incl. zip ties)
FV-MAN110/140FL
FV-MAN160FL
FV-MAN225FL
Heat shrink end caps to suit 110 –140 mm carrier / 200 – 225 mm casing
Heat shrink end caps to suit 160 mm carrier / 250 mm casing
Product code Type
FV-MAN160ML
FV-MAN200ML
Rubber end caps serving as a seal between the individual carrier pipes and the corrugated casing pipe (incl. zip ties)
FLEXALEN 1000+ end caps
FLEXALEN 600 end caps
FLEXALEN straight lengths
Rubber end caps
Heat shrink end caps to suit 225 mm carrier / 315 mm casing
1515
Anchor Point ■
Wall Entry ■
Double pipe anchors
Product code Pipe OD DN Inch Type
FV-FlXSCH2/25 25 20 2 x ¾
FV-FIXSCH2/32 32 25 2 x 1
FV-FIXSCH2/40 40 32 2 x 1¼
FV-FIXSCH2/50 50 40 2 x 1½
FV-FIXSCH2/63 63 50 2 x 2
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
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.
Anchor points recommended at transition points to other materials
Product code Diameter Core drill Type Outer casing diameter [mm] [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
Single pipe anchors
Single pipe anchors
Ring-sealing for wall entrysuitable for water pressure up to 1,5 bar
Anchor Point and Wall Entry
Anchor points recommended at transition points to other materials
Anchor points recommended at transition points to other materials
Anchor points recommended at transition points to other materials
Single pipe anchors
1616
Note: Full range of electrofusion elbows, reducers + tees avaible (25 mm - 110 mm)
Product code Pipe OD DN Inch Type
GF-EM25 25 20 ¾
GF-EM32 32 25 1
GF-EM40 40 32 1¼
GF-EM50 50 40 1½
GF-EM63 63 50 2
GF-EM75 75 65 2½
GF-EM90 90 80 3
GF-EM110 110 100 4
Electrofusion coupler PB
Electrofusion welding socket GF
Electrofusion couplings
1717
Pre-insulated Fittings ■
Tee-Half Shells ■
Pre-insulated T-piece for twin pipe
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.
Pre-insulated Y-piece used for the transi-tion 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
Pre-insulated twin branch piece, which connects two single pipes with a twin-pipe house service connection
Pre-insulated T-piece used for singleand twin pipes
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 Fittings and Tee-Half Shells
1818
■ 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
● 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)
PB pipes for heating and do-mestic hot water with drinking water approvals
Compression Fittings
Electrofusion - the safe con-nection (longitudinal section)
That Polybutene is the only plastic pipe system currently used in heating systems that can be fully fusion welded and ope-rate up to 95° C!
And, polybutene fusion welded pipes have been used for al-most 40 years!
You can use PB pipe systems in complete confidence, with the knowledge that you are using a tried and trusted welding system.
We are founding members of the Polybutene Piping Systems Association. For more information on the principles of the PBPSA, please contact www.pspba.com.
■ Lifetime table for PB pipesThe life cycle of plastics mainly depends on the surroun-ding 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 pres-sure/pull-out tests and the extrapolation time factors for polybutylene.
Polybutene
1919
Polybutene carrier
Temperature resistance – 15° C to + 95° C
Density 0,940 g/cm3
Melt index 0,4 g/10 min
Stretch tension 20 N/mm2
Tearing strength 35 N/mm2
Tearing expansion 300 %
E-module 420 N/mm2
Shore hardness D53
Notch ductility without breakage
Ductility without breakage
Length expansion coefficient 0,13 mm/mK
λ−value 0,16 W/mK
Polyethylene casing Stretch tension 22 N/mm2
Tearing strength 32 N/mm2
Tearing expansion 800 %
E-module 800 N/mm2
Notch ductility without breakage
Ductility without breakage
Length expansion coefficient 0,18 mm/mK
λ−value 0,43 W/mK
Polyurethane insulation
Volume weight 50 - 80 kg/m3
Temperature – 40° C to + 110° Cresistance
λ−value 0,033 W/mK
Closed cells 94%
Load resistance: >0,2 N/mm2
Polyethylene insulation
Volume weight 30 - 40 kg/m3
Temperature – 80° C to + 95° Cresistance
λ−value 0,031 W/mK
Closed cells
That Polybutene pipes are far more flexible that other plastic pipes?
ComparisonMaterial E-module (stiffness) [N/mm2]
Polybutene 420PE-X 600 (40% stiffer than Polybutene)Polypropylene 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 testMaterial Test pressure
Polybutene 15 BarPE-X 9.8 Bar (tested to a pressure 34% lower than PB)Polypropylene 5.6 Bar (tested to a pressure 62% lower than PB)
Polybutene is the proven, reliable, robust pipe system.
FLEXALEN material properties
2020
Structure of the pipe trench for long-distance heating pipes
The structure of a long-distance heating pipe is determi-ned by the designer on the basis of the instructions sup-plied 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 gra-nulation 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).
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-sec-tions 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 pre-vents 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 „humus layer“. In no case the filling may reach the surface. A clear layering of the materi-als represents an additional barrier for the heat transpor-tation in transitional areas between the different layers.
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.
Please consider the corresponding standards and regulati-ons 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.
Trenching Details
2121
The polybutylene medium pipes can be connected homogeneously by means of fu-sion 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 ope-ratives. Furthermore our laying instructions and the instruction manual for the recom-mended individual welding machines and equipment must be considered.
Please see our laying instructions for the laying and processing guidelines.
Electrofusion
Butt Fusion
Welding
2222
Electrofusion welding – 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 EndsAbrade 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.
Pipe CuttingThe 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
2323
Mark Insertion depthMark 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 fittingInsert 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 ClampsAlignment clamps must be used for all pipe sizes 25mm to 110mm.
Execution of ElectrofusionConnect 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 CheckThe 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: 10 mins63 mm – 110 mm: 15 mins
Clamps must not be removed before cooling time has elapsed.
Max. ambient temperature +5° C to +35° C
Electrofusion welding
2424
Pressure Testing
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.
a
c
b
d
max
. 0.6
bar
max
. 0.2
bar
Test
pre
ssu
re in
bar
Testpressure
0 10 20 30 60 180(time in minutes)
Preliminary test Main test
Test pressure:For an operating pressure of 10 bar*,a testing pressure of 15 bar should be used.
* according to DIN 1988 TRWI
Ptest = 1.5 x Poperating
Pressure Test Diagram
Pressure Testing
2525
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 tu-bular 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 (yel-low) flame.
Take care while heating to prevent any damage to the casing pipe.
Insulation coupler Installation
Remark: instead of PUR half shells other insulation materials can be used e.g. PE foam mats.
2626
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) underne-ath the pipework.
Branches
2727
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.
Branches
2828
There are several methods of entering a building with Flexalen ...
2. Electrofusion end connection Typical On Line Termination Detail
1. Compression End connection Typical On Line Termination Detail
3. Pre fabricated building entry elbow detail The exposed joint area is then covered with the insula- tion coupling set (see broken out line) comprising of
1. Two half shells of pre cast foam 2. One large wrap aroundheat shrink wrap
Anchor End Cap
Compression Union
Wall
Space betweenFlexalen casingand wall to filled withour waterseal fitting orwaterproof grout.
Anchor End Cap
E/F Coupler
Composite Union
Wall
Space betweenFlexalen casingand wall to filled withour waterseal fitting orwaterproof grout.
Elbow riserC/W end
terminations on
Rubber End Cap
E/F CouplerFlexalen Pipe
Wall
Building Entry
2929
5. Riser Entry Detail using Flexalen 60
6. Entry using Flexalen 60 and builder supplied duct pipe
4. Bending the pipe using its flexibility
Termination fitting
Section of Flexalen 60jointed to carrier pipeby electro-fusion elbow
Heat Shrink connectionbetween insulation casing and duct entry pipe
Termination fitting
Section of Flexalen 60jointed to carrier pipeby electro-fusion couplerand ducted
Building Entry
3030
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
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. Ple-ase 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.
Building connection twin pipe (DIA 25 - 63 mm)
Building connection single pipe (DIA 63 - 110 mm)
Carrier pipe Max. expansion forces X Y Z O.D./[mm] per carrier pipe [N] [mm] [mm] [mm]
25 250 ~175 ~335 ~52
32 410 ~175 ~345 ~55
40 640 ~175 ~360 ~57
50 1000 ~175 ~375 ~68
63 1600 ~175 ~410 ~78
Carrier pipe Max. expansion forces X Y O.D./[mm] per carrier pipe [N] [mm] [mm]
63 1600 ~174 ~420 - 475
75 2200 ~174 ~435 - 485
90 3200 ~174 ~455 - 515
110 4700 ~174 ~485 - 540
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!
Expansion Compensation
Pipe length Temperature difference Δt [K]
[m] 50 60 70 80 35 0,23 0,27 0,32 0,36
40 0,26 0,31 0,36 0,42
45 0,29 0,35 0,41 0,47
50 0,32 0,39 0,45 0,52
60 0,39 0,47 0,55 0,62
70 0,45 0,55 0,64 0,73
80 0,52 0,62 0,73 0,83
90 0,58 0,70 0,82 0,94
100 0,65 0,78 0,91 1,04
Other dimensions on request
3131
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] 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 FASTNETfor 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 net-work pointsTemperature of the flow run [°C] Temperature of the return run [°C] Pre-pressure for the trans-mitting-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!
FREE
SOFTWARE
FLEXALEN Software
3232
"Nomogramm" to determine the pressure losses when using FLEXALEN pipe systems at a temperature of 90° C.
At a temperature of 60° C the pressure loss has to be assumed 10% higher.
Dimensioning example in red colour
FLEXALEN pipe type Water quantity
l/s Velocity of flow m/s
Heat load at a difference temperature in K
Pressure loss Pa / m
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.
4
3,5
3
2,5
2
1,5
1,00,9
0,8
0,7
0,6
0,5
0,4
0,35
0,3
0,25
0,2
0,15
0,1
0,090,08
0,07
0,06
0,05
600
500
400
300
250
200
150
100908070
60
50
40
30
20
10987
6
5
4
3
2
3,5
2,5
25
15
kW
150
60504030
1520
108654
21,5
0,80,60,50,40,3
0,2
0,15
10
1520
30
40
50
80100
125150
200
250300
400
500
750
1.0001.2501.500
2.0002.5003.000
4.0005.000
7.500
10.000
15.000
20.000
0,10,08
0,060,05
1
3
80100
200
20 35 50 8 - Bar System
A 25
A 32
A 40
A 50
A 63
A 75
A 90
A 110
A 125
A 140
A 160
A 225
Nomogramm
3333
Please use the following multipliers for authorized higher flowing speeds:
The factors only refer to the transmittable performance, not to the pressure loss!!!!
v=2m/s Factor: 2
v=3m/s Factor: 3
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
kW 25 44 69 110 173 246 356 533 687 861 1126 2228
v=1m/s (velocity)
kW 31 56 87 137 217 308 445 666 859 1077 1408 2785
v=1m/s (velocity)
kW 38 67 104 165 260 370 534 800 1031 1292 1690 3342
v=1m/s (velocity)
kW 50 89 140 220 346 494 712 1066 1375 1722 2253 4456
v=1m/s (velocity)
Pa/m(1m/s)
555 402 300 231 175 140 112 88 75 66 56 38
Pa/m(2m/s)
510 410 319 274 239 204 135
Pa/m(3m/s)
595 520 440 284
kW 14 24 38 60 95 135 196 293 378 474 619 1226
v=1m/s (velocity)
kW 6 11 17 27 43 61 89 133 172 215 282 557
v=1m/s (velocity)
DN = diameter standard OD = diameter external ID = diameter internal
Pressure loss approx:
25 K (e.g.: 90º C - 65º C)
30 K (e.g.: 90º C - 60º C)
40 K (e.g.: 90º C - 50º C)
20 K (e.g.: 90º C - 70º C)
11 K (e.g.: 82º C - 71º C)
5 K (e.g.: 7º C - 12º C chilled water)
3434
Test reports andApprovals 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: CSTBNetherlands: ISO, KIWA
European approvals – 3rd Party
3535
Notes
AUSTRIA (central support)
THERMAFLEX-FLEXALENRohr- und Isoliersysteme GmbHKaiserstrasse 45, 1070 Wien
Phone: +43.1.523 26 25.0Fax: +43.1.523 26 25.24E-Mail: [email protected]
NEW ZEALAND
ENERGY PRODUCTS INTERNATIONALGallagher Drive, P.O. Box 15058Hamilton
Phone: +64.07.847 27 05Fax: +64.07.847 42 22E-Mail: [email protected]
UK & IRELAND
FLEXALEN Heating & Cooling Products LimitedUnit 1, Station Ind EstStation Road,Methil, Fife, KY8 3 HA, United Kingdom
Phone: +44.845.644 37 93Fax: +44.845.644 38 93E-Mail: [email protected]
9060
72-E
N
PR
E-INSULATED PIPE SYST
EMS
CER
TI
FICATE FOR FLEXIBLE
CERTIFIEDKIWA
BRL k17401BRL 5609
PART A