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: pipe@pipe2000.co.uk www.pipe2000.co.uk

TECHNICAL INFORMATION SHEETS P RE - INSULATED P IPES

CALPEX® -

The Professional Solution for Engineers

PIPE2000 Ltd
3 Kelvin Road Manor Trading Estate Benfleet, Essex SS7 4QB
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk www.pipe2000.co.uk

CALPEX® district heating pipe

CPX 1.0

Table of Contents
1.0 1.1 1.100 1.105 1.110 1.115 Table of Contents System description System description (general) System description (data) Long-term behaviour/lifetime calculation CALPEX® UNO/DUO range, heating 6 bar – structure, dimensions, materials, weights and delivery lengths CALPEX® UNO/DUO range, sanitary 10 bar – structure, dimensions, materials, weights and delivery lengths CALPEX® QUADRIGA range, heating 6 bar, sanitary 10 bar – structure, dimensions, materials, weights and delivery lengths Planning, design engineering Pressure loss chart, heating, 6 bar Pressure loss chart, sanitary, 10 bar Heat loss, heating, 6 bar Heat loss, sanitary, 10 bar Heat loss, heating 6 bar, sanitary 10 bar, QUADRIGA Planning and connection technology, heating strip, sanitary, 10 bar Components House entry bend 90°, heating 6 bar, UNO and DUO House entry bend 90°, sanitary 10 bar, UNO and DUO House entry bend 90°, heating 6 bar, sanitary 10 bar, QUADRIGA CALPEX® L-shell, DN 20 - DN 50 CALPEX® Big L-shell, DN 20 - DN 50 Joint (PE-HD shrink sleeve), DN 20 - DN 100 CALPEX® I-shell, DN 20 - DN 50 CALPEX® Big I-shell, DN 65 - DN 125 CALPEX® T-shell, DN 20 - DN 50 CALPEX® Big T-shell, DN 65 - DN 100 T-joint, dimension DN 150 Y-pipe, heating, 6 bar Distribution chamber, dimensions DN 20 - DN 100 Distribution chamber, installation for dimensions DN 20 - DN 100 Concrete protective plate for distribution shaft Insulation material, PE foam (DN 20 - DN 100), PUR foam containers (DN 20 - DN 150) Screwed connectors, outer thread, weld end Screwed connectors, coupling: equal, reduced Screwed connectors, T-piece 1.385 1.390 1.395 1.400 1.405 1.410 1.415 1.420 1.425 1.430 1.5 1.500 1.505 1.510 1.515 1.520 1.525 1.515 1.520 1.525 1.530 1.535 1.540 Compression connectors, thread, weld end with sliding sleeve Compression connectors, coupling, angle 90° with sliding sleeve Compression T-piece, with sliding sleeve Electro-fusion joint, dimensions DN 65 - DN 150 End cap, standard, shrinkable Wall sealing ring, for wall openings Building entry, wall opening/core bore Wall seal, core bores/cement pipe liners Building entry, core bores/cement pipe liners Pipe warning tape Underground construction, installation Pipe routing Trench dimensions Connection (rigid/flexible), CALPEX® plastic casing pipe House entry, screwed connector, shaft entry, fixed point forces House connection, compression joint, shaft entry, fixed point forces Installation of house connection House connection, screwed connector House connection, joint with sliding sleeves Installation of house entry Installation tool, general and for screwed connector Installation tool, for joint with sliding sleeves Heating strip, sanitary, 10 bar, drawing in, sensor, joint

1.120

1.125

1.2 1.200 1.205 1.210 1.215 1.220 1.225

1.3 1.300 1.305 1.310 1.315 1.316 1.320 1.325 1.326 1.330 1.335 1.340 1.345 1.350 1.355 1.360 1.365 1.370 1.375 1.380

UK DISTRIBUTOR PIPE2000 Ltd
15.04.2009
Subject to technical changes

T: 01268 759567

F: 01268 569932

e: pipe@pipe2000.co.uk

www.pipe2000.co.uk

CALPEX® district heating pipe

CPX 1.100

System description
1. General CALPEX® district heating pipe is the registered trade name for a flexible pipe system from Brugg Pipe Systems, specifically 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 drinking 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 flexible 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 flexible 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 fitted 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 °C Max. permitted operating temp. Tmax: 95 °C (fluctuating) 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 °C Max. permitted operating temp. Tmax: 95 °C (fluctuating) Max. permitted operating pressure p: 10 bar
see sheet CPX 1.110

UK DISTRIBUTOR PIPE2000 Ltd
15.04.2009
Subject to technical changes

T: 01268 759567

F: 01268 569932

e: pipe@pipe2000.co.uk

www.pipe2000.co.uk

CALPEX® district heating pipe

CPX 1.105

System description
1. Carrier pipe Materials Bonding agent Oxygen barrier layer Requirements Impermeability to oxygen Pipe series DIN 16893 Long-term behaviour Properties Basic material: High-density polyethylene (PE-HD), peroxide cross-linked (PEXa), colour: natural PE-modified, heat-stabilized, colour: red (heating), white (sanitary) Ethylene / vinyl alcohol (EVOH), heat-stabilized, colour: natural As per DIN 16892 / DIN 16893 and E DIN EN 12318-2, pipes in series 3.2 as per DVGW worksheet W 544 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) Series 5 (SDR 11): for heating (with EVOH barrier) Series 3.2 (SDR 7.4): for sanitary (without EVOH barrier) See catalog sheet CPX 1.110 Unaffected by aggressive water; low pressure losses; very good chemical and mechanical resistance
Reference temperature °C 20 80 20 80 20 100 20 / 40 / 60 Value 938 – 940 kg/m3 0.38 W/mK 26 – 30 N/mm2 18 – 20 N/mm2 600 – 900 N/mm2 300 – 400 N/mm2 1.4 · 10 E-4 1/K 2.0 · 10 E-4 1/K 130 – 136 °C Test standard DIN 53479 DIN 52612 DIN 53455 DIN 53455 DIN 53457 DIN 53457 DIN 8075 B.1

PEXa carrier pipe Density Thermal conductivity Tensil strength Tensil strength Modulus of elasticity Modulus of elasticity Linear expansion coefficient Linear expansion coefficient Crystallite melting range Chem. resistance

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.
Reference temperature °C 50 CALPEX® heating > 60 kg/m3 ≤ 0.0237 W/mK ≥ 90 % ≤ 10 % CALPEX® sanitary > 60 kg/m3 ≤ 0.032 W/mK ≥ 90 % ≥ 10 % Test standard ISO 845 EN 253 and ISO 8497 EN 253

PUR insulation Density Thermal conductivity Percentage of closed cells Water absorption after 24 hours

3. Protective casing Materials: Purpose:
LLD-PE protective casing Density Thermal conductivity Crystallite melting range

linear polyethylene, low density (LLD-PE), seamlessly extruded mechanical protection and moisture resistance
Reference temperature °C Value 918-922 kg/m3 0.33 W/mK 122 °C Test standard ISO 1183 DIN 52612 ISO 11357-3

UK DISTRIBUTOR PIPE2000 Ltd

T: 01268 759567

F: 01268 569932

e: pipe@pipe2000.co.uk

www.pipe2000.co.uk

15.04.2009
Subject to technical changes

CALPEX® district heating pipe

CPX 1.110

Long-term behaviour
Lifetime calculation
Operating temperature: °C 10 20 30 40 50 60 70 80 90 95 1 MPA = 10 bar Heating, (pipe series 5 SDR 11) Operating pressure (bar) 1 year 10 years 17.9 17.4 15.8 15.4 14.0 13.7 12.5 12.1 11.1 10.8 9.9 9.7 8.9 8.6 8.0 7.7 7.2 6.9 6.8 6.5 Sanitary (pipe series 3.2 SDR 7.4) Operating pressure (bar) 1 years 10 years 25 years 50 years 28.3 27.6 27.3 27.1 25.1 24.4 24.2 24.0 22.3 21.7 21.4 21.3 19.8 19.3 19.1 18.9 17.7 17.2 17.0 16.8 15.8 15.3 15.2 15.0 14.1 13.7 13.6 13.4 12.7 12.3 12.1 10.8 11.4 11.0 10.6 10.2 10.8 10.3 10.0 9.6 Values extrapolated 25 years 50 years 17.2 17.1 15.2 15.1 13.5 13.4 12.0 11.9 10.7 10.6 9.5 9.5 8.5 8.5 7.6 7.0 6.0 5.4 5.8 5.3 Values extrapolated

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 confirmed by the competent organizations in various countries. A typical fluctuating temperature distribution for the flow in a district heating system gives an average temperature/year of approx. 66 °C.

Example of lifetime calculation The basis is a typical temperature collective over one year, with fluctuating 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 f2 f3 f4 f5 f6 f7 1090 hours 1360 hours 1600 hours 1210 hours 1850 hours 1050 hours 600 hours Pressure Dn* bar Years 6.0 100 years 6.0 80 years 6.0 75 years 6.0 55 years 6.0 45 years 6.0 25 years 6.0 16 years *Values from table interpolated

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: D= 1 (f1/D1 + f2/D2 + f3/D3 + … + fn/Dn) lifetime in years for operation with alternating temperatures between T1 … Tn Maximum lifetime in years for operation with constant temperatures T1 … Tn and pressure Proportionate operating periods at constant temperatures T1 … Tn

Calculated lifetime: D= 1 1090/8760 1360/8760 1600/8760 + + 100 80 75 1 1050/8760 25

D=

+

D1 … Dn =

1210/8760 55

f1 … fn =

+

1850/8760 45

+

+

600/8760 16

= 47.10

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

UK DISTRIBUTOR PIPE2000 Ltd
15.04.2009
Subject to technical changes

T: 01268 759567

F: 01268 569932

e: pipe@pipe2000.co.uk

www.pipe2000.co.uk

00 1.3 2 x 32 x 2.30 2.3 183 x 3. 6 bar.8 90 x 8.4 1. .4 – Volume carrier pipe l/m 0.2 1.9 1.6 63 x 5.0 1.0 125 x 11.3 32 x 2.8 75 x 6.37 11.DN 125 s1 UNO DUO PEXa carrier pipe PUR foam PE foil LLD-PE casing d PEXa carrier pipe PE-HD casing pipe s DN Inches “ ¾“ 1“ 1¼“ 1½“ 2“ 2½“ 3“ 4“ 4“ 5“ 6” 20 25 32 40 50 65 80 100 100 125 150 PEX carrier pipe dxs mm 25 x 2.8 Outer casing D x s1 mm 93 x 2.7 50 x 4.34 1.4 128 x 2.0 93 x 2.2 163 x 3.2 183 x 3.pipe2000.115 CALPEX® UNO/DUO range Heating.4 128 x 2.31 Maximum delivery lengths Jumbo coil Maxi coil m m 520 807 520 807 377 590 271 429 192 305 143 229 92 149 92 149 52 86 52 86 12 12 DN Inches “ 2 2 2 2 2 20 + 20 25 + 25 32 + 32 40 + 40 50 + 50 x x x x x ¾“ 1“ 1¼“ 1½“ 2“ PEX carrier pipe dxs mm 2 x 25 x 2.4 3 Weight kg/m 0.96 4.3 Minimum bending radius m 0.53 2 x 0.87 2.7 2 x 50 x 4.Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width) UK DISTRIBUTOR PIPE2000 Ltd 15.0 110 x 10.co.10 5.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.We will produce different dimensions or special items on request (> 500 m).56 5.60 3.97 2.7 0. 6 bar CALPEX® in coils: Dimensions: DN 20 .9 Minimum bending radius m 0.7 163 x 3.96 5.9 2 x 40 x 3.6 Outer casing D x s1 mm 78 x 2.68 6. 6 bar.2 1.48 3.2 110 x 10.4 160 x 14.28 Maximum delivery lengths Jumbo coil Maxi coil m m 377 590 271 429 192 305 92 149 52 86 CALPEX® in straight lengths: Dimensions: DN 150 D CALPEX® heating.20 13.9 40 x 3.2 183 x 3.Larger or smaller delivery lengths can be supplied on drums if requested.07 2.1 1.9 1.36 6.7 0.CALPEX® district heating pipe CPX 1.83 2 x 1.04.6 2 x 63 x 5.07 Weight kg/m 1.8 0.co.36 8.3 250 x 3.39 4.32 0.2 113 x 2.2 113 x 2.39 1.4 Volume carrier pipe l/m 2 x 0.uk www.32 2 x 0.30 2 x 2.7 143 x 3.25 6. .uk s D d .90 1.83 1.0 1.2 1. DUO Type 25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182 . UNO Type 25/ 76 32/ 76 40/ 91 50/111 63/126 75/142 90/162 110/162 110/182 125/182 160/250 CALPEX® heating.53 0.0 163 x 3.8 0.0 78 x 2.

co.Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width) UK DISTRIBUTOR PIPE2000 Ltd T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.660 + 0.0 32 x 4.60 2.9 1.0 0.201 0.7 Minimum bending radius m 0.201 0.4 128 x 2.uk s D d www.8 0.95 2.0 78 x 2.06 1.423 Weight kg/m 1.06 1.0 40 x 5.49 2.0 1.4 Outer casing D x s1 mm 93 x 2.029 1.7 Minimum bending radius m 0.423 + 0.7 113 x 2.660 1.9 63 x 8.We will produce different dimensions or special items on request (> 500 m). .7 128 x 2.56 2.0 32 x 4.7 128 x 2.314 0.9 + 32 x 4.8 0.76 Maximum delivery lengths Jumbo coil Maxi coil m m 520 807 520 807 520 807 377 590 271 429 192 305 271 429 192 305 192 305 22/ 76 28/ 76 32/ 76 40/ 91 50/111 63/126 32/111 HBK 40/126 HBK 50/126 HBK 16 20 25 32 40 50 25 32 40 5 CALPEX® sanitary. DUO Type DN Inches “ ¾“ + 5⁄8“ 1“ + 5⁄8“ 1¼“ + ¾“ 1½“ + 1“ PEX carrier pipe dxs mm 28 x 4.7 0.5 50 x 6.0 1.5 50 x 6.0 + 22 x 3.0 93 x 2.pipe2000.4 128 x 2.029 + 0.2009 Subject to technical changes .423 0. 10 bar.540) 18 ∞ CALPEX® sanitary.660 1.0 Volume carrier pipe l/m 0.029 Weight kg/m 0.225.04.47 1.CALPEX® district heating pipe CPX 1.633 0.4 + 22 x 3.120 CALPEX® UNO/DUO range Sanitary.4 40 x 5.201 0.5 + 28 x 4.0 Volume carrier pipe l/m 0.7 32 x 4.2 113 x 2.314 + 0.7 0.12 1.9 1.25 3. UNO Type DN Inches “ ⁄ 8“ ¾“ 1“ 1¼“ 1½“ 2“ 1“ 1¼“ 1½“ PEX carrier pipe dxs mm 22 x 3.96 Maximum delivery lengths Jumbo coil Maxi coil m m 377 590 271 429 192 305 192 305 28 + 22/ 91 32 + 22/111 40 + 28/126 50 + 32/126 20 + 16 25 + 16 32 + 20 40 + 25 . 10 bar. 1.7 0.uk 15.9 1.2 113 x 2.co. 10 bar s1 UNO DUO PEXa carrier pipe PUR foam PE foil LLD-PE casing Heating strip channel (HBK) (see sheets CPX 1.0 50 x 6.314 1.4 128 x 2.Larger or smaller delivery lengths can be supplied on drums if requested.4 40 x 5.96 1.0 28 x 4.0 78 x 2.423 0. .83 2.9 Outer casing D x s1 mm 78 x 2.

1 Volume carrier pipe l/m 0.4 5⁄ “ 22 x 3. heating 6 bar.539 0.25 Maximum delivery length Jumbo coil Maxi coil m m 110 169 H25 + 25/S28 + 22/142 H32 + 32/S28 + 22/142 H32 + 32/S32 + 22/142 H40 + 40/S40 + 28/162 20 20 20 16 25 25 20 16 25 25 25 16 32 32 32 20 s D 110 143 x 3.uk www.CALPEX® district heating pipe CPX 1.9 1“ 32 x 2. sanitary 10 bar.314 Weight kg/m 3. sanitary 10 bar s1 d PEXa carrier pipe PUR foam PE foil LLD-PE casing CALPEX® .3 ¾“ 25 x 2.835 0.39 169 143 x 3.539 0.7 1¼“ 40 x 3.9 ¾“ 28 x 4.0 1.We will produce different dimensions or special items on request (> 500 m).1 3.41 110 169 163 x 3.pipe2000.201 0.835 0.Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width) UK DISTRIBUTOR PIPE2000 Ltd 15.539 0.1 3.201 0.327 0.327 0.co.15 65 101 .201 0.5 ¾“ 28 x 4.2 1. .Larger or smaller delivery lengths can be supplied on drums if requested.539 0.0 8 1¼“ 40 x 3.314 0. .0 8 1“ 32 x 2.125 CALPEX® QUADRIGA range Heating 6 bar.9 1“ 32 x 4.0 Minimum bending radius m 1.2 4.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.04. QUADRIGA Type DN Inches Carrier pipe dxs mm “ 25 x 2.7 1¼“ 40 x 5.0 5⁄ “ 22 x 3.0 8 1“ 32 x 2.9 1“ 32 x 2.uk .0 1.co.3 ¾“ 28 x 4.0 Outer casing D x s1 mm 143 x 3.423 0.314 0.660 0.0 ¾“ 5⁄ 22 x 3.

4 mm (DN 50. 5”) 110/90. ¾”) 0.0 m/ s 50/40.co.4 mm (DN 65.CALPEX® district heating pipe CPX 1.200 Pressure loss chart Heating. 6”) Q·860 m≈ ˙ ∆T Q [kW] 200000 125/102.pipe2000.5 40/32.4 m/ 50 2000 75 25/20.4 mm (DN 20.0 mm (DN 100.007 mm (PEXa) (1 mmWS = 9.3 m/ s 40 s 50 30 30 20 15 20 10 300 500 20 1000 30 40 50 80 120 140 160 ∆T 30 °C 20 °C 100 180 200 300 400 500 800 1200 1400 1600 1000 1800 Pressure loss ∆p [Pa/m] UK DISTRIBUTOR PIPE2000 Ltd T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.0 m/ 70000 90/73. 4”) ter Wa 5000 o vel 3000 city 3000 2000 100000 4.8 mm (DN 40. 2”) s 2000 Mass flow rate m [kg/h] ˙ 1000 500 20000 30000 40000 1000 60000 3. 1½”) 500 2. 3”) 75/61.0 300 m/ 10000 s 1. 1”) 5000 0.2 mm (DN 25.2009 Subject to technical changes 2000 www.co.2 mm (DN 125.uk .8 mm (DN 150.5 3000 75 m/ 100 s 0.7 5m /s 0.0 150 m/ 200 s 150 100 4000 32/26.6 mm (DN 32. 2½”) 63/51.uk 15.04. 1¼”) 300 200 m/ s 1. 6 bar Water temperature 80 °C Surface roughness ε = 0.6 mm (DN 80.81 Pa) m = ˙ Q = ∆T = Flow rate in kg/h Power requirement in kW Temperature difference VL (flow)/RL (return) in °C 160/130.

10 bar Water temperature 60 °C Surface roughness ε = 0.0 mm (DN 20.6 mm (DN 50.81 Pa) m = ˙ Q = ∆T = Flow rate in kg/h Power requirement in kW Temperature difference VL (flow)/RL (return) in °C Q·860 m≈ ˙ ∆T Q [kW] 1000 30000 40000 Mass flow rate m [kg/h] ˙ 500 20000 63/45. ¾“) s 1. 1“) 28/20.04.co.0 mm (DN 16.007 mm (PEXa) (1 mmWS = 9.2 mm (DN 40.0 300 m/ s 300 200 10000 50/36.CALPEX® district heating pipe CPX 1.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.2 mm (DN 25.uk www.uk 2000 .0 m/ 3000 32/23.4 m/ s s 0.5 100 m/ s 50 2000 1.7 50 22/16. 1¼“) ter Wa o vel 4000 5000 city 100 2.co.0 mm (DN 32. 5⁄8“) 5m 30 /s 1000 0.pipe2000.3 20 500 m/ s 10 300 20 30 40 50 80 120 140 160 100 180 200 300 400 500 800 1200 1400 1600 ∆T 30 °C 20 °C 1000 1800 Pressure loss ∆p [Pa/m] UK DISTRIBUTOR PIPE2000 Ltd 15. 1½“) 200 40/29.0 m/ s 0. 2“) 500 3.5 30 20 m/ 0.205 Pressure loss chart Sanitary.

0 18.0 20.7 40/ 91 0.8 75/142 0.1 9.3 23.173 5. CPX UNO: Type of installation.0 50/111 0.0 10.9 8.2 12.8 5.04.7 90/162 0.co.8 90° 15.8 15.9 20.0 25. 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.9 7.uk www.9 19.1 15.5 a = 0.2 17.6 32/ 76 0.60 m TE = 10 °C = 1.4 13.33 W/mK Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefficient [W/mK] TB = Average operating temperature [°C] TE = Average ground temperature [°C] VL = Flow RL = Return UK DISTRIBUTOR PIPE2000 Ltd 15.9 10.6 12.8 15.0237 W/mK PEXa = 0.7 12.38 W/mK PE = 0.uk H = 0.4 8.7 125/182 0.262 7.6 12.2 TE E Type of installation.8 11.0 18.229 6. 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° 25/ 76 0.7 50 + 50/162 0.co.337 10.7 32 + 32/111 0.195 5.2 W/mK E PU = 0.4 8.9 13.318 9.7 8.2 21.8 9.8 6.4 10.0 8.2 6.5 16.6 22.2 12.8 13.6 16.1 13.10 m H = 0.161 4.6m H = 0.1 m TE E CALPEX® DUO (flow and return in one pipe) RL (return) 80° 13.0 12.210 Heat loss Heating.4 63/126 0.0 16.196 5.2 160/250 0.3 11.9 17.4 19.8 16.3 VL (flow) Heat losses q [W/m] for one DUO pipe CALPEX® DUO U-value Average operating temperature TB [°C] [W/mK] 40° 50° 60° 70° 25 + 25/ 91 0.254 7.6 10.7 12.7 14.0 14.4 7.9 7.4 13.0 23.213 6.1 80° 8.212 6.8 11.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.1 13.9 11.CALPEX® district heating pipe CPX 1. laid in the ground 1-pipe.5 13.7 10.pipe2000.3 90° 10. laid in the ground a = 0.6m .5 10.7 110/182 PLUS 0.7 17.328 9.1 16.8 9.7 110/162 0.2 11.127 3.7 14.9 9.200 6.7 15.5 13.0 27.0 6.0 40 + 40/126 0.1 6.4 8.0 18.167 5.3 26.8 63 + 63/182 0.228 6.8 9.5 10.1 11.

9 9.261 50 + 32/126 0.6 8.6 6.9 17.4 11.6 7. laid in the ground 1-pipe.2 11.230 50/111 0.8 10.6 6.3 4.7 5.5 7.5 9.1 7. 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 H = 0.204 Average operating temperature TB [°C] 40° 50° 60° 4.0 10.0 9.236 40 + 28/126 0.4 8.4 6.2 70° 9.187 32/ 76 0.1 9.3 6.2 15.pipe2000.6 13.6m 70° 17.0 12.0 14.8 7.7 20.154 40/126 HBK 0.6m .8 13.2 7.7 5.347 Average operating temperature TB [°C] 40° 50° 60° 8.uk www.2 7.2 10.2 12.CALPEX® district heating pipe CPX 1.4 13.1 8.153 28/ 76 0.0 9.0 6.234 63/126 0.8 14.284 32 + 22/111 0.215 Heat loss Sanitary.2 TE E CALPEX® DUO Heat losses q [W/m] for one DUO pipe CALPEX® DUO U-value [W/mK] 28 + 22/ 91 0.1 10. CPX UNO: Type of installation.co.032 W/mK PEXa = 0.5 10.4 11.5 11.04.4 13.60 m TE = 10 °C = 1. 10 bar CALPEX® UNO Heat losses q [W/m] for one UNO pipe CALPEX® UNO U-value [W/mK] 22/ 76 0.2 W/mK E PU = 0.2 11.7 8.2 10.4 TE E Type of installation.33 W/mK Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefficient [W/mK] TB = Average operating temperature [°C] TE = Average ground temperature [°C] UK DISTRIBUTOR PIPE2000 Ltd 15.co.4 14.7 6.213 40/ 91 0.38 W/mK PE = 0.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.0 16.uk H = 0.166 50/126 HBK 0.266 32/111 HBK 0.8 H = 0.

pipe2000. sanitary 10 bar.1 13.7 65° 13. QUADRIGA CALPEX® QUADRIGA Heat losses q [W/m] for one QUADRIGA pipe CALPEX® QUADRIGA U-value [W/mK] H 25 + 25/S 28 + 22/142 0.1 13.3 11.4 H = 0.co.6m TE E 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.5 13.heat loss during operation Example of calculation for average operating temperature TB [°C] Flow .38 W/mK PE = 0.uk www. laid in the ground H = 0.sanitary: 60 °C Return .co.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.4 12.288 H 32 + 32/S 32 + 22/142 0.heating: 70 °C Return .6 18.6 15.032 W/mK PEX = 0.uk .1 16.sanitary: 50 °C 70° + 40° + 60° + 50° = 55 °C 4 TB = UK DISTRIBUTOR PIPE2000 Ltd 15.335 Average operating temperature TB [°C] 50° 55° 60° 9.2 W/mK E PU = 0.60 m TE = 10 °C = 1.8 16.0 14.8 11.246 H 32 + 32/S 28 + 22/142 0.04.CALPEX® district heating pipe CPX 1.heating: 40 °C Flow .1 12.302 H 40 + 40/S 40 + 28/162 0.220 Heat loss Heating 6 bar.4 15.33 W/mK Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefficient [W/mK] TB = Average operating temperature [°C] TE = Average ground temperature [°C] CALPEX® QUADRIGA .5 15.

T-branch Supply End closure Through connection L ≤ Lmax* Supply End closure Through connection L ≤ Lmax* For the T-branch.8 W/m 7.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. heating circuit length in relation to a cut-in temperature of 12 °C (HWAT) or 0 °C (FS-B-2X) Heating strip type HWAT-R Fuse 13 A 16 A 20 A 10 A 16 A Length Lmax 60 m 80 m 100 m 65 m 105 m FS-B-2X Fuse protection using automatic cutouts with characteristic C 2. Requirements for heating strip 1.co. T-switches cannot be supplied.04. permitted length for heating strip The heating strip and the accessories are installed by the electrician! UK DISTRIBUTOR PIPE2000 Ltd 15.3 W/m 8. sanitary.uk . 60 °C Automatic power adjustment with HWAT-ECO Frost protection: FS-B-2X from Raychem requires thermostat with temperature sensor.uk www.co.3 W/m 7. Joint L ≤ Lmax* Through connection Supply Through connection L ≤ Lmax* Separation of heating strip End closure Supply Supply 3.1 Minimum power In relation to a maintained temperature of: 40 °C 50 °C 5.8 W/m 1.2 Recommendations for heating strip Hot water: HWAT-R from Raychem meets the requirement for Ø 50/126. UTR15 Max.3 W/m Type CALPEX® UNO 32/111 40/126 50/126 60 °C 9.3 W/m 10.CALPEX® district heating pipe CPX 1.8 W/m 6.pipe2000. * Lmax = max.225 Planning and connection technology Heating strip. 10 bar 1. note that the sum of two connected pipes must not be > Lmax*.6 W/m 10.4 W/m 12.

90° Heating 6 bar.8 Outer casing D x s1 mm 90 x 3.40 14.7 2 x 50 x 4.50 3.DN 125 (PEXa) Bend.32 2 x 0.6 63 x 5.9 2 x 40 x 3.9 90 x 3.43 Weight kg/unit 2.96 25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182 20 + 20 25 + 25 32 + 32 40 + 40 50 + 50 x x x x x ¾“ 1“ 1¼“ 1½“ 2“ UK DISTRIBUTOR PIPE2000 Ltd 15.7 50 x 4.6 250 x 6.4 160 x 14.uk www.19 17.8 90 x 8. 90° DN 20 .30 2.4 160 x 5.47 4.6 Volume carrier pipe l/m 2 x 0.3 2 x 32 x 2.co.3 32 x 2.6 Outer casing D x s1 mm 75 x 2.36 6.96 4.23 16.9 140 x 4.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. 90° DN 150 (St 37.20 13.2 Volume carrier pipe l/m 0.32 0.50 8.5 110 x 4.96 25/ 76 32/ 76 40/ 91 50/111 63/126 75/142 90/162 110/162 110/182 125/182 160/250 20 25 32 40 50 65 80 100 100 125 150 CALPEX® DUO Type DN Inches “ 2 2 2 2 2 PEX carrier pipe dxs mm 2 x 25 x 2.co.9 40 x 3.9 75 x 2.8 75 x 6. UNO and DUO Bend.04.300 House entry bend.6 2 x 63 x 5.67 7.5 110 x 4.36 8.CALPEX® district heating pipe CPX 1.92 6.83 1.0) With welded-on compression coupling 1114 1100 UNO DUO 1600 250 250 1114 A Figures in mm CALPEX® UNO Type DN Inches “ ¾“ 1“ 1¼“ 1½“ 2“ 2½“ 3“ 4“ 4“ 5“ 6“ PEX carrier pipe dxs mm 25 x 2.0 180 x 5.0 125 x 11.0 180 x 5.25 6.42 9.53 2 x 0.47 11.uk .32 4.07 2.9 160 x 5.3 125 x 4.pipe2000.07 Weight kg/unit 4.0 110 x 10.6 180 x 5.30 2.20 13.3 125 x 4.0 160 x 5.90 13.30 2 x 2.53 0.83 2 x 1.2 110 x 10.

9 125 x 4.4 40 x 5.04.9 75 x 2.0 x 3. 10 bar.67 4.9 + 32.7 Outer casing D x s1 mm 75 x 2.4 + 22.40 2.0 40.0 x 4.0 x 4.0 x 4.co.0 + 22.uk www.31 1.30 28 + 22/ 91 32 + 22/111 40 + 28/126 50 + 32/126 20 + 16 25 + 16 32 + 20 40 + 25 UK DISTRIBUTOR PIPE2000 Ltd 15.9 90 x 3.20 0.42 Weight kg/unit 3. 90° Sanitary.0 50.62 7.42 0.co.0 32.9 Volume carrier pipe l/m 0.0 x 4.20 0.5 110 x 4.31 + 0.66 + 0.20 0.5 110 x 4.3 125 x 4.0 28 x 4.02 1.0 x 5.50 7.80 3.90 5.pipe2000.65 CALPEX® DUO Type DN Inches “ ¾“ + 5⁄8“ 1“ + 5⁄8“ 1¼“ + ¾“ 1½“ + 1“ PEX carrier pipe dxs mm 28.uk .4 Outer casing D x s1 mm 90 x 3.5 50 x 6.0 x 6.63 Weight kg/unit 2.3 125 x 4.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.87 6.305 House entry bend.CALPEX® district heating pipe CPX 1.9 63 x 8.9 75 x 2.02 + 0.9 Volume carrier pipe l/m 0.0 x 3.66 1. UNO and DUO Bend.65 2.42 + 0.5 + 28.31 0. 90° DN 16 .DN 50 (PEXa) 1100 UNO DUO 1600 A 250 250 Figures in mm CALPEX® UNO Type DN Inches “ ⁄ 8“ ¾“ 1“ 1¼“ 1½“ 2“ 5 22/ 76 28/ 76 32/ 76 40/ 91 50/111 63/126 16 20 25 32 40 50 PEX carrier pipe dxs mm 22 x 3.0 32 x 4.

co.310 House entry bend.3 28 x 4. 90° DN 16 .37 UK DISTRIBUTOR PIPE2000 Ltd 15.9 32 x 2. 90° Heating 6 bar.04.423 0.314 Weight kg/unit 8.660 0.201 0.539 0.0 22 x 3.0 Outer casing D x s1 mm 140 x 4.539 0.uk www.0 32 x 2.47 140 x 4.327 0.539 0.DN 50 (PEXa) 1100 250 1600 250 Figures in mm CALPEX® QUADRIGA Type DN Inches “ ¾“ ¾“ ¾“ 5⁄ “ 8 1“ 1“ ¾“ 5 ⁄ 8“ 1“ 1“ 1“ 5 ⁄ 8“ 1¼“ 1¼“ 1¼“ ¾“ PEX carrier pipe dxs mm 25 x 2.9 28 x 4.9 32 x 2.4 22 x 3.0 40 x 3.835 0. QUADRIGA Bend.0 32 x 2.4 8.0 10.0 22 x 3.7 40 x 5.314 0.201 0. sanitary 10 bar.4 Volume carrier pipe l/m 0.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.4 8.52 160 x 5.5 28 x 4.12 H25+25/S28+22/142 H32+32/S28+22/142 H32+32/S32+22/142 H40+40/S40+28/162 20 20 20 16 25 25 20 16 25 25 25 16 32 32 32 20 140 x 4.pipe2000.201 0.co.327 0.835 0.314 0.9 32 x 4.3 25 x 2.539 0.CALPEX® district heating pipe CPX 1.7 40 x 3.uk .

co.CALPEX® district heating pipe CPX 1. UNO/DUO Outer casing Ø d1 76 91 111 126 Ø d2 76 x 91 x x x 111 126 d2 CALPEX Structure of the half-shell 1 2 3 4 5 6 ABS half-shells PEX angle coupling.390 Sealing clamps (14 pcs.co. see CPX 1. see CPX 1.315 CALPEX® L-shell Dimensions DN 20 .uk .pipe2000.126 mm) d1 CALPEX 1 4 3 5 2 376 6 Figures in mm 376 CALPEX® L-shell. UK DISTRIBUTOR PIPE2000 Ltd 15.350).2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.) Insulation material.365 Glued surface Reduction ring or sealing ring CALPEX® shells are freely reducable from Ø 126 mm to Ø 76 mm CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.04.uk www.DN 50 (Ø 76 .

UK DISTRIBUTOR PIPE2000 Ltd 15.126 mm) d1 CALPEX 1 4 3 5 2 508 6 Figures in mm 508 CALPEX® Big L-shell.DN 50 (Ø 76 .316 CALPEX® Big L-shell Dimensions DN 20 . see CPX 1.) Insulation material.CALPEX® district heating pipe CPX 1.uk .390 Sealing clamps (22 pcs.pipe2000.365 Glued surface Reduction ring or sealing ring CALPEX® Big-shells are freely reducable from Ø 182 mm to Ø 76 mm CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.04.uk www. UNO/DUO Outer casing Ø d1 76 91 111 126 142 162 182 Ø d2 76 x 91 x x x x x x x 111 126 142 162 182 d2 CALPEX Structure of the half-shell 1 2 3 4 5 6 ABS half-shells PEX angle coupling.350).2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.co.co. see CPX 1.

pipe2000. see sheet 1.04.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.365 Shrink sleeve pipe Shrink hose Installation note: Weld on 1 CALPEX d2 CALPEX CALPEX Insulated steel pipe 2 Install CALPEX®-CALPEX® Ø d2 76 76 x 91 111 Ø d1 126 142 162 182 250 91 x x 111 x x x 126 x x x 142 162 182 250 CALPEX® to insulated steel pipe Ø d2 76 91 111 126 142 162 182 250 90 x x x 110 x x x x 125 x x x x x 140 x x x x x x 160 x x x x x x x 180 200 225 250 280 315 x x x x x x Ø d1 x x x x x x x x x x x x x x x x x x x x x x UK DISTRIBUTOR PIPE2000 Ltd 15.uk .390 Insulation material.uk www.CALPEX® district heating pipe CPX 1.co. see sheet 1.320 Joint using PE-HD shrink sleeve Dimensions DN 20 .DN 150 CALPEX® joint 1 2 3 4 CALPEX d1 CALPEX d2 1 2 CALPEX® reduction joint d1 CALPEX® – Insulated steel pipe CALPEX d1 Insulated steel pipe d2 1 2 3 4 PEX coupling. PUR or PE.co.

uk . UK DISTRIBUTOR PIPE2000 Ltd 15.pipe2000.) Insulation material.390 Sealing clamps (12 pcs. see CPX 1.04.126 mm) 1 4 3 2 5 6 CALPEX d1 Figures in mm 578 CALPEX® I-shell.DN 50 (Ø 76 .365 Glued surface Reduction ring or sealing ring x x x CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.co.CALPEX® district heating pipe CPX 1.co.325 CALPEX® I-shell Dimensions DN 20 .uk d2 CALPEX www.350). UNO/DUO Outer casing Ø d1 76 91 111 126 Ø d2 76 x x x x 91 x x x 111 126 Structure of the half-shell 1 2 3 4 5 6 ABS half-shells PEX coupling.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. see CPX 1.

see CPX 1.DN 125 (Ø 142 .CALPEX® district heating pipe CPX 1.365 Glued surface Reduction ring or sealing ring x x x x x x x x x x x x CALPEX® Big-shells are freely reducable from Ø 182 mm to Ø 76 mm CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.uk d2 CALPEX www.182 mm) 1 4 3 2 5 6 CALPEX d1 Figures in mm 752 CALPEX® BIG I-shell. UNO/DUO Outer casing Ø d1 76 91 111 126 142 162 182 Ø d2 76 x x x x 91 x x x x 111 126 142 162 182 Structure of the half-shell 1 2 3 4 5 6 ABS half-shells PEX coupling.uk .co.390 Sealing clamps (22 pcs. UK DISTRIBUTOR PIPE2000 Ltd 15.04. see CPX 1.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.326 CALPEX® Big I-shell Dimensions DN 65 .350).pipe2000.) Insulation material.co.

uk d3 CALPEX www. UK DISTRIBUTOR PIPE2000 Ltd 15. UNO/DUO Outer casing Ø d1 . Ø d2 76 91 x x x x x x x x x x x x x x x x x x x x 111 x x x x x x x x x x 126 x x x x x x x x x x Structure of the half-shell 1 2 3 4 5 6 ABS half-shells PEX T-piece.76 91 .365 Glued surface Reduction ring or sealing ring CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.91 91 .91 111 .111 111 .CALPEX® district heating pipe CPX 1.76 111 .76 Branch.pipe2000.uk .DN 50 (Ø 76 .350).395 Sealing clamps (16 pcs. see CPX 1.co.126 126 .04.co.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.330 CALPEX® T-shell Dimensions DN 20 . see CPX 1.126 mm) d2 CALPEX 3 4 6 373 5 1 2 CALPEX d1 578 Figures in mm CALPEX® T-shell.) Insulation material.Ø d3 76 .76 126 .91 126 .111 126 .

111 162 .pipe2000.142 162 .126 142 .365 5 Glued surface 6 Reduction ring or sealing ring CALPEX® shells are not suitable for use with CALPEX® QUADRIGA (distribution chamber: see CPX 1.co.126 162 .91 142 .2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.) Insulation material.182 mm) d2 1 CALPEX 3 2 4 6 CALPEX d1 508 d3 Figures in mm 5 CALPEX 752 CALPEX® Big T-shell. see CPX 1. Ø d2 76 91 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 111 x x x x x x x x x x x x x x x x x x 126 x x x x x x x x x x x x x x x x x x 142 x x x x x x x x x x x x x x x x x x 162 x x x x x x x x x x x x x x x x x x 182 x x x x x x x x x x x x x x x x x x Structure of the half-shell 1 2 3 4 ABS half-shells PEX T-piece.co.335 CALPEX® Big T-shell Dimensions DN 65 .111 142 .142 182 .76 Branch.182 182 .142 142 . UNO/DUO Outer casing Ø d1 .DN 125 (Ø 142 .uk www.126 182 .76 182 .76 162 .uk .91 162 .CALPEX® district heating pipe CPX 1.395 Sealing clamps (27 pcs.162 162 .Ø d3 142 .350). see CPX 1. UK DISTRIBUTOR PIPE2000 Ltd 15.91 182 .04.111 182 .162 182 .

160/250 Branch. Ø d2 25/76 32/76 x x 40/91 x 50/111 x 63/126 x 75/142 x 90/162 x 110/162 x 110/182 x 125/182 x 160/250 x We can supply T-pieces with different branches on request UK DISTRIBUTOR PIPE2000 Ltd 15.uk .0) Shrink-on hoop Shrink sleeve pipe In-situ PUR foam CALPEX connector CALPEX pipe 4 5 CALPEX 6 View A CALPEX® T-joint.04.2009 Subject to technical changes In su lat ed st ee lp ip 45° CALPEX e T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.340 T-joint Dimension DN 150 (Ø 250 mm) CALPEX CALPEX 1 A 2 3 Structure of T-joint 1 2 3 4 5 6 T-piece.co.uk www.CALPEX® district heating pipe CPX 1.co. DN 150 Outer casing Ø d1 Ø d3 160/250 .pipe2000. insulated steel pipe (St 37.

110 33.uk www.A Note: With UNO pipe.9/110 33. the forward flow (VL) is always on the right and with DUO pipe.A Note: With UNO pipe.3 + 60. the forward flow (VL) is always on the right and with DUO pipe.7 + 33.4 .4 + 42.3 .pipe2000. it is always at the bottom. it is always at the bottom.3 + 48.9 + 26. steel pipe A D steel pipe C CPX DUO 250 400 300 2020 250 11 0/+1 Figures in mm VL (flow) (bottom) RL (return) 300 RL (return) VL (flow) (right) VL (flow) (right) CALPEX® DUO / 2 x pre-insulated steel pipe (St 37. in the direction of flow. CPX UNO A D CPX UNO C CPX DUO 250 400 300 2020 250 11 0/+1 Figures in mm VL (flow) (bottom) RL (return) RL (return) 300 VL (flow) (right) VL (flow) (right) CALPEX® DUO / 2 x CALPEX® UNO UNO pipes mm 2 x 25/ 76 2 x 32/ 76 2 x 40/ 91 2 x 50/ 111 2 x 63/ 126 DN 20 25 32 40 50 ØD mm 75 75 90 110 125 DUO CPX pipe mm 25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182 ØC mm 90 110 125 160 180 View: A .125 48.co.3/180 DUO CPX pipe mm 25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182 ØC mm 110 110 125 160 180 UK DISTRIBUTOR PIPE2000 Ltd 15.04.3/160 60.4/125 48. 6 bar View: A . in the direction of flow.uk .110 42.7 .345 Y-pipe Heating.9 .0) UNO pipes mm 26.co.CALPEX® district heating pipe CPX 1.140 DN 20 25 32 40 50 ØD mm 110 110 125 125 140 DUO steel pipe mm 26.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.125 60.7/110 42.3 .

162* Ø outer.co. 8 mm Ø Chamber exit Pipe dimensions (outer diameter) Ø outer.04.DN 125) The distribution chamber is used to cover and protect completed BRUGG pipe joints. 126* Ø outer. The distribution chamber is a watertight structure made of polyethylene.co. 206 x 8 mm Leadthrough for outer Ø Ø 182.350 Distribution chamber Dimensions DN 20 .CALPEX® district heating pipe CPX 1.uk . its multi-functional design makes it possible to use one chamber type for all pipe dimensions (DN 20 . 136 x 8 mm Leadthrough for outer Ø Ø 111. 76* * with additional centering ring UK DISTRIBUTOR PIPE2000 Ltd 15. 166 x 8 mm Leadthrough for outer Ø Ø 142.DN 125). 270 145 130 6 13 6 16 10 475 40 120 360 120 200 8 80 120 0 Wall thickness approx.pipe2000. shut-off valves or junction branches.uk 20 Figures in mm 6 www. 91*.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.DN 125 Distribution chamber for all joints (DN 20 .

pipe2000.CALPEX® district heating pipe CPX 1.DN 125 1 2 CAL P EX® 166 206 3 136 4 Two-part reduction ring 5 See CPX installation instructions 6 ▲ Flat seal 29 x 12 M10 x 35 7 8 UK DISTRIBUTOR PIPE2000 Ltd 15.uk www.2009 Subject to technical changes 166 T: 01268 759567 206 F: 01268 569932 e: pipe@pipe2000.co.co.uk .04.355 Distribution chamber Installation for dimensions DN 20 .

For subsequent work on the inspection chamber. the cover plate has lifting eyes. A Proctor density of dpr = 96 % should be the target for compaction.8 continuous meters 10 Figures in cm UK DISTRIBUTOR PIPE2000 Ltd 15. The maximum load per unit of area must not exceed q = 153 kN/m² (SLW 60 to DIN 1055). compacted e: pipe@pipe2000. Note The plate must be located so that it completely covers the chamber below (see illustration). Likewise.5 m) Total length 8.55 m 7.uk .5 12 21 16 21 15 Sand.04.Armaflex or Tubolit .Bulk polystyrene material .uk www.pipe2000. compacted pla te Co ve r 20 o1 Insp ectio 20 n ch amb er Figures in cm Armouring 6 GOK 50 10/20 21 bo tto 3 17 x m 2 4 3x Q1 3 op 1t 12 110 120 5 ME.5 m 4 3 x 12 mm (L = 0.1 10 2 Q131 top 1 Q221 bottom 5 3.85 m) Total length 2.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 20 94 1 Q2 Sand. Filling/insulation material Some suggestions for filling and insulation materials that can be used are listed below: .5 21 21. 133 Inspection chamber 80 3 10/20 1 Q 221 bottom 2 Q 131 bottom 3 17 x 10/20 mm (L = 0. After completing the work and refilling the pit. it is not essential to insulate the pipes! The decision is up to the customer.CALPEX® district heating pipe CPX 1. make sure that the infill between the inspection chamber and concrete slabs is restored correctly.co.Foam using BRAG PUR foam canister Note There is no need to use filling material in the distribution shaft.360 Protective concrete plate for distribution chamber Schematic diagram showing installation of cover plate Load The cover plate has to be used wherever there might be public traffic and for low-depth installations.co. 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.

(DN 20 . The components are supplied separately in two bottles and are only mixed together when needed. Safety regulations Protective goggles and gloves must be worn when using this product. excellent for insulating CALPEX® shrink joints (not for CALPEX® shells).uk .co.DN 150) Insulation material for shrink joints Polyethylene foam tube. The insulation must be fitted precisely into the joints on site.DN 125). PUR foam container(s) (DN 20 .uk www.DN 125) Extruded pipe insulation made of closed-cell polyethylene.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. Synthetic gloves Protective goggles UK DISTRIBUTOR PIPE2000 Ltd 15.04.pipe2000. 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.co.365 Insulation material PE foam (DN 20 .CALPEX® district heating pipe CPX 1. Various thicknesses of insulation are available for the most common pipe diameters. Please note the safety regulations in the installation instructions supplied with the product. The insulation material (thickness and length) is supplied for the relevant joint types. PE PUR foam for shrink joints and CALPEX® shells CFC-free.

8 75 x 6.7 50 x 4.7 42.9 33.370 Screwed connectors Outer thread.65 32 x 2.0 32 x 4.9 40 x 3.0 26.9 x 2.9 x 2.0 PEX pipe Weld end mm mm 22 x 3.3 32 x 2.3 40 x 3.7-1¼“ 50 x 4.3 x 2.2 88.0-4“ L mm 53 63 67 71 80 92 92 102 Screwed connector mm 22 x 3.2 110 x 10.9 75 x 6.uk www.8 60.5 50 x 6. 6 bar Material: brass PEX pipe mm 25 x 2.9-1“ 40 x 3.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.0 PEX 90-110 L Heating.65 25 x 2.3 x 2.3 26.8-2½“ 90 x 8.0 Sanitary.6 63 x 5.uk .7-2“ 75 x 6.2-3“ 110 x 10.4-1“ 40 x 5.0 L PEX 22-75 St 37.65 28 x 4.4 40 x 5.7-2“ L mm 51 58 63 67 71 80 PEX 90-110 L Connection with weld end St 37.7 Screwed connector mm 25 x 2.3-¾“ 32 x 2.9 x 3.0 28 x 4.co.2 110 x 10.0-¾“ 28 x 4.0 26.5-1¼“ 50 x 6. 10 bar Material: brass PEX pipe mm 22 x 3.6 48.6-1½“ 63 x 5.9 63 x 8.8 76.1 x 3.2 90 x 8. 6 bar Material: brass / St 37.7 x 2.6 L mm 180 180 180 180 185 190 195 200 240 280 UK DISTRIBUTOR PIPE2000 Ltd 15.0-¾“ 32 x 4.6 50 x 4.CALPEX® district heating pipe CPX 1.co. weld end Connection with external thread PEX 22-75 L Heating.4 x 2.6 63 x 5.pipe2000.04.9-1½“ 63 x 8.3 x 3.9 x 2.8 90 x 8.0 114.

3 32 x 2.7 63 x 5.7 50 x 4.7 75 x 6.9 63 x 8. coupling: reduced Coupling.0 40 x 5.2 110 x 10.9 50 x 4.7 Coupling mm 25 x 2.4 40 x 5.0 28 x 4.0 Sanitary.4 50 x 6.CALPEX® district heating pipe CPX 1.uk .8 90 x 8.9 / 25 x 2.8 / 63 x 5.5 50 x 6. 10 bar Material: brass PEX pipe mm 22 x 3. reduced PEX 22-75 L PEX 90-110 Heating.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.5 50 x 6.8 75 x 6.8 / 50 x 4.4/28 x 4.9 Coupling mm 32-1“ / 28-¾“ 40-1¼“/ 32-1“ 50-1½“/ 40-1¼“ 63-2“ / 50-1½“ L mm 58 87 96 110 140 175 315 L UK DISTRIBUTOR PIPE2000 Ltd 15.7 / 32 x 2.co.3 32 x 2.uk www.7 50 x 4.0 / 90 x 8.0 32 x 4.pipe2000. 6 bar Material: brass PEX pipe mm 32 x 2.0 32 x 4.5/32 x 4.9 40 x 3.co. 10 bar Material: brass PEX pipe mm 32 x 4.9/40 x 5.04.3 40 x 3.9 63 x 8.9 40 x 3.8 90 x 8.8 90 x 8.5 63 x 8.375 Screwed connector Coupling: equal.2 Coupling mm 32-1“ / 25-¾“ 40-1¼“/32-1“ 50-1½“/40-1¼“ 63-2“ / 50-1½“ 75-2½“/ 63-2“ 90-3“ / 75-2 ½“ 110-4“ / 90-3“ Sanitary.0 28 x 4. 6 bar Material: brass PEX pipe mm 25 x 2.6 63 x 5.7 L mm 58 65 67 71 75 81 PEX 22-75 L PEX 90-110 L Coupling.2 110 x 10.6 / 40 x 3.6 75 x 6.0 L mm 60 67 71 75 81 89 130 130 Coupling mm 22 x 3.8 110 x 10.2 / 75 x 6.7/50 x 6.6 63 x 5. equal Heating.4 40 x 5.

9 40 x 3.3 .50 x 4.2 90 x 8.380 Screwed connectors T-piece d2 d2 d1 d3 d1 PEX 22-75 PEX 90-110 Heating.8 .8 75 x 6.6 63 x 5. 6 bar Material: brass Ø d1 Ø d3 mm 22 x 3.63 x 5.co.25 x 2.32 x 2.90 x 8.8 .90 x 8.63 x 5.co.8 75 x 6.0 25 x 2.0 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 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 x x x x Other T-pieces can be supplied on request.7 .8 .CALPEX® district heating pipe CPX 1.9 . Ø d2 mm 22 x 3.2 .0 32 x 2.3 28 x 4.7 .3 x x x x x x x x x x x x x x x x x 28 x 4.0 32 x 2.pipe2000.0 32 x 2.110 x 10.75 x 6.6 .8 110 x 10.8 90 x 8.uk d3 .75 x 6.2 .3 40 x 3.32 x 2.7 40 x 3.8 .6 50 x 4.7 63 x 5.2 110 x 10.0 .6 75 x 6.9 .uk www.0 .25 x 2.40 x 3.28 x 4.7 50 x 4.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.9 .9 50 x 4.40 x 3.04.50 x 4.0 25 x 2.28 x 4.0 .8 90 x 8.9 32 x 2.8 63 x 5.0 110 x 10.22 x 3. UK DISTRIBUTOR PIPE2000 Ltd 15.2 Branch.6 .0 .

2 110 x 10.7 50 x 4.co.3 x 2.6 48.8-2½“ 90 x 8.uk www.co.3 x 4.9 x 2.1 x 3.7-2“ 75 x 6.0 25 x 2.2-3“ 110 x 10.6 139.6 168.0 32 x 2.4 40 x 5.8 90 x 8.3-¾“ 32 x 2.5 50 x 6.4 160 x 14.9-1“ 40 x 3.9-1½“ 89 63 x 8. 10 bar Material: brass PEX pipe mm 22 x 3.0 32 x 4.uk .9 40 x 3.385 Compression connectors Outer thread.4 160 x 14.4 x 2.65 33.65 26.2 114.0-¾“ 58 28 x 4.3 32 x 2.3 28 x 4.4-5” 160 x 14.0-4“ 125 x 11.5-1¼“ 82 50 x 6.0 125 x 11.6 63 x 5.9 x 3.65 26.0-¾“ 62 32 x 4.9 x 2.6-1½“ 63 x 5.3 42.7 Screwed connector mm 25 x 2.7-2“ 109 L Connector with weld end L2 St 37 L1 Heating.6 Sanitary.7-1¼“ 50 x 4.3 x 3. weld end Connector with external thread Heating.6 63 x 5.1 L1 mm 50 50 50 60 70 85 90 95 95 90 108 114 L2 mm 20 20 24 24 29 37 32 35 35 30 48 50 UK DISTRIBUTOR PIPE2000 Ltd 15. 6 bar Material: Steel PEX pipe mm 22 x 3.6 60.9 40 x 3.9 x 2.7 x 2.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.7 x 3.0 28 x 4.2 88.04.CALPEX® district heating pipe CPX 1.9 76.0 125 x 11.6 Weld end mm 26.9 63 x 8.8 75 x 6.4-1“ 72 40 x 5.7 50 x 4.2 110 x 10.8 90 x 8.8 75 x 6.3 x 2.6-6” L mm 62 72 82 89 109 110 115 120 125 130 Screwed connector L mm mm 22 x 3.pipe2000. 6 bar Material: brass PEX pipe mm 25 x 2.

2 110 x 10.6/125 x 11.8 75 x 6.6 a mm – – 66 74 87 106 z mm – – 39 42 39 60 z a UK DISTRIBUTOR PIPE2000 Ltd 15.9 63 x 8.2 125 x 11.4/28 x 4.7 50 x 4.9 63 x 8.0 32 x 4.CALPEX® district heating pipe CPX 1.7 63 x 5.8/ 50 x 4.9 40 x 3.8 90 x 8.0 28 x 4.uk . 10 bar Material: brass PEX pipe mm 22 x 3.2 110 x 10.2 110 x 10.8 90 x 8.0 28 x 4.0 32 x 4.9 50 x 4.9/ 25 x 2.9 63 x 8.8 75 x 6.4 40 x 5.5 50 x 6.5 63 x 8. coupling: reduced.4/110 x 10.6 75 x 6. reduced L Heating. angle piece: 90° Coupling Heating.390 Compression connectors Coupling: equal.8/ 63 x 5.3 40 x 3.6 63 x 5. 10 bar Material: brass PEX pipe mm 22 x 3.9 40 x 3.4* Coupling mm 32-1“ / 25-¾“ 40-1¼“/ 32-1“ 50-1½“/ 40-1¼“ 63-2“ / 50-1½“ 75-2½“/ 63-2“ 90-3“ / 75-2½“ 110-4“ / 90-3“ 125-5“ / 110-4“ 160-6“ / 125-5“ Sanitary.4 40 x 5.0 40 x 5. 6 bar Material: Brass/steel* PEX pipe mm 32 x 2.2009 Subject to technical changes T: 01268 759567 a F: 01268 569932 e: pipe@pipe2000.9 Coupling mm 32-1“ / 28-¾“ 40-1¼“/ 32-1“ 50-1½ / 40-1¼“ 63-2“ / 50-1½“ L mm 76 86 97 113 124 127 127 228 262 Angle piece.co.4 40 x 5.5 50 x 6.8 90 x 8.7/ 32 x 2.0/ 90 x 8.3 32 x 2.0 32 x 4. 10 bar Material: brass PEX pipe mm 32 x 4.9 40 x 3.5/32 x 4.3 32 x 2.7 50 x 4.0 PEX pipe mm 25 x 2.7 50 x 4.4 40 x 5.8 90 x 8. 6 bar Material: brass PEX pipe mm 25 x 2.0 28 x 4.04.7 50 x 4.0 125 x 11.pipe2000.8 75 x 6.9/40 x 5.0 a mm 54 64 74 87 106 117 127 137 z mm 32 37 42 48 60 67 76 87 Sanitary.0 32 x 4.8 90 x 8.5 50 x 6.co.4 160 x 14.6 63 x 5.uk www.0 125 x 11.6 Sanitary.7/50 x 6.1* 160 x 14. 90° z Heating.7 Coupling mm 25 x 2.9 63 x 8.2 110 x 10.3 32 x 2.2/ 75 x 6.7 75 x 6.0 28 x 4.5 50 x 6.9 40 x 3.6 PEX pipe mm 22 x 3. 6 bar Material: brass PEX pipe mm 25 x 2.6 L mm 69 82 90 104 122 127 127 127 133 143 Coupling mm 22 x 3.8 110 x 10.4 50 x 6.6/ 40 x 3.3 32 x 2.6 63 x 5.4 160 x 14.6 63 x 5.7 L mm 58 70 82 90 104 122 L Coupling.

6 75 x 6. Ø d2 mm 25 x 2. Ø d2 mm 22 x 3.25 x 2. 1.9 6.8 90 x 8.0 5.2 .9 o/x o/x o/x¹ o/x o/x o/x o/x o/x o/x o/x o/+ o/x o/+ o 40 x 3.5 5.0 4.0 3.7 .9 63 x 8.4 4.5 x x x x x x x x x x x x x 50 x 6.40 x 3.0 Heating.9 5.90 x 8.co.25 x 2.7 . 37.8 .125 x 11.7 8.0 125 x 11.4435 (316L) UK DISTRIBUTOR PIPE2000 Ltd 15.4 5.4404.4 x x x x x x x x x x 40 x 5.uk d3 .3 40 x 3.9 32 x 2.6 .2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.8 63 x 5.63 x 5.4 4.0 x x x x x x x x x x x x 28 x 4. 1.4 .DN 100) o = St 37.7 x x x x x x x x x x x ¹ Soldered fittings .0 4.7 63 x 5. welded + = CrNi 1. 6 bar Ø d1 Ø d3 mm 25 x 2.2 110 x 10.50 x 4.5 3.3 32 x 2.8 90 x 8.9 .pipe2000.8 .2 .2 125 x 11.7 8.32 x 2.T-pieces made of steel can be supplied on request .CALPEX® district heating pipe CPX 1.4432.63 x 5.9 8.8 110 x 10.5 5.2 90 x 8.uk www.0.5 4.0 4.9 .Other T-pieces can be supplied on request.0 8. Gunmetal Rg7 (DN 65 .40 x 3.0 x x x x x x x x x x x x x 32 x 4.75 x 6.8 .Dimension DN 150 is supplied in prefabricated and pre-insulated form (see sheet CPX 1.4 4.6 63 x 5.75 x 6.7 40 x 3.0 .90 x 8.6 50 x 4.7 6.04.0 .9 6.9 5.8 .5 6.8 75 x 6. 10 bar Ø d1 Ø d3 mm 22 x 28 x 28 x 32 x 32 x 40 x 40 x 40 x 50 x 50 x 50 x 50 x 63 x 63 x 63 x 3.0 6.6 .395 Compression connectors T-piece d2 d2 d1 d3 d1 Brass/CrNi St.7 22 x 28 x 28 x 32 x 28 x 40 x 32 x 28 x 50 x 40 x 32 x 28 x 63 x 50 x 40 x 3.3 .co.3 o/x o/x o/x o/x o/x¹ o/x o/x o/x o/+ o/x o/+ o/+ o/+ o/+ o/+ o 32 x 2.9 6. Material: x = Brass CuZn39Pb3 (DN 20 .340).8 75 x 6.0 110 x 10.110 x 10.4 Branch.7 50 x 4.DN 50).50 x 4.0 4.5 Branch.9 50 x 4.0 4.32 x 2.0 4.4 o/x o/x o/x¹ o/x o/x o/x o/+ o/x o/+ o/+ o/+ o o/x o/x o/x o/x o/x o/+ o/+ o/x o/+ o o/x o/x o/x o/x o/+ o/x o/+ o o/x o/+ o/+ o/+ o/+ o o/x o/+ o/+ o o/x o o Sanitary. .

4 125 x 11.8 90 x 8. UK DISTRIBUTOR PIPE2000 Ltd 15.2 90 x 8.6 Only trained personnel.0 110 x 10.2 90 x 8.6 Transition sleeve/joint with thread (AG) Can be supplied on request Transition sleeve/joint. using suitable fusion equipment.4 160 x 14. with flange Can be supplied on request Angle piece.4 125 x 11.4 160 x 14.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.2 110 x 10.400 Electro-fusion joints Dimensions DN 65 .DN 150 Coupling Heating.0 110 x 10. may install the electro-fusion joints for PEXa connections.co.uk www.co.pipe2000.CALPEX® district heating pipe CPX 1. 6 bar Material: cross-linked polyethylene PEX pipe PEX pipe mm mm 75 x 6.8 90 x 8.8 75 x 6.2 110 x 10. 90° Heating.uk .6 160 x 14.0 125 x 11.6 160 x 14.0 125 x 11.8 75 x 6. 6 bar Material: cross-linked polyethylene PEX pipe PEX pipe mm mm 75 x 6.04.

UNO End cap.CALPEX® district heating pipe CPX 1. UNO (LD-PE) LD-PE end caps are fitted on. suitable for dry rooms Shrink-on end cap. shrinkable Shrink-on end cap.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.uk www. DUO (LD-PE) Shrink-on end cap.405 End cap Standard.uk .04.pipe2000. QUADRIGA End cap.co. QUADRIGA (LD-PE) A A View A View A 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 UK DISTRIBUTOR PIPE2000 Ltd 15. DUO End cap.co.

uk .415) UK DISTRIBUTOR PIPE2000 Ltd 15.co.pipe2000. inner mm 74 88 107 122 137 155 175 243 Ø Da.co.04.410 Wall sealing ring for wall openings for pipes up to O/D 182 mm for pipes over O/D 250 mm Ø Da Ø Da 50 Ø Di Ø Di 50 Figures in mm CALPEX® UNO.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.uk www. DUO. QUADRIGA Outer casing diameter mm 76 91 111 126 142 162 182 250 Neoprene wall sealing ring Ø Di.CALPEX® district heating pipe CPX 1. outer mm 118 133 153 168 183 203 223 290 Building entry (see sheet CPX 1.

370 or sheet 1.115.405 Wall seal: see sheet 1.co.uk www.uk .415 Building entry Wall opening Wall leadthrough PEX connection piece: see sheet 1.04.2009 Subject to technical changes T: 01268 759567 H F: 01268 569932 e: pipe@pipe2000.410 Wall opening Outer casing ØD mm 78 93 113 128 143 163 183 250 Figures in mm L min mm 450 500 500 550 600 650 670 810 H min mm 250 250 300 300 350 350 380 450 80 D 100 L D 80 UK DISTRIBUTOR PIPE2000 Ltd 15.CALPEX® district heating pipe CPX 1. see sheets 1.pipe2000. 80 mm CALPEX® D CALPEX pipe.120 End cap: see sheet 1.co. 1.390 80 mm approx.

Tightness can only be guaranteed if this recommendation is followed.CALPEX® district heating pipe CPX 1.pipe2000. double-seal* 2 x 40 mm.co.co.uk .uk www. single-seal 1 x 40 mm. Shore hardness D 35 4 Liner pipe: made of fibre cement or coated core bore * Suitable for pressure from water up to 0. it is advisable to seal the entire length of the borehole with suitable sealant (such as AQUAGARD).04.425) UK DISTRIBUTOR PIPE2000 Ltd 15. 1 CALPEX® district heating pipe 2 Seal set. core bore ØD mm 150 150 200 200 200 250 250 350 Seal set Ø R1 inner mm 78 93 113 128 143 163 183 251 Seal set Ø D1 outer mm 150 150 200 200 200 250 250 350 Building entry (see sheet CPX 1. As hairline cracks may be present in the concrete or result from drilling.5 bar Outer pipe ØR mm 76 91 111 126 142 162 182 250 Liner pipe.420 Wall seal Core bores/cement liner pipes Standard Outer side of basement Inner side of basement With additional centering ring Outer side of basement Inner side of basement 3 R D 4 3 2 R D 1 1 4 Core bores Perfect bores are required for installation. Shore hardness D 35 3 Seal set.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.

390 80 mm CALPEX® pipe: see sheets CPX 1.2009 Subject to technical changes T: 01268 759567 D1 Figures in mm F: 01268 569932 e: pipe@pipe2000. 30 Outer casing ØD mm 78 93 113 128 143 163 183 250 D1 mm 150 150 200 200 200 250 250 350 A mm 180 180 230 230 280 280 330 380 A UK DISTRIBUTOR PIPE2000 Ltd 15.425 Building entry Core bores/cement pipe liners Wall leadthrough PEX connection piece: see sheet CPX 1.04.co.120 CALPEX® D End cap: see sheet CPX 1.370 or CPX 1.uk .co. 1.pipe2000.420 Core bores min.uk www.405 Wall seal: see sheet CPX 1.CALPEX® district heating pipe CPX 1.115.

CALPEX® district heating pipe CPX 1.430 Pipe warning tape CALPEX® pipe warning tape Pipe warning tape to be laid in the ground.2009 Subject to technical changes 10 D 10 T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. Roll length: 250 m CALPEX® trench structure 1 2 3 1 Pipe warning tape 2 Excavated material 3 Washed sand 60 30 Installation depth.505 T UK DISTRIBUTOR PIPE2000 Ltd 15.uk www. see sheet CPX 1.pipe2000.co.uk .04.co.

04.uk .uk www.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.co.CALPEX® district heating pipe CPX 1.pipe2000.500 Pipe routing CALPEX® – Connection to insulated steel pipe CALPEX® B CALPEX® A Insulated steel pipe C CALPEX® Loop-in method CALPEX® – CALPEX® connection A CALPEX® B D A C C B D CALPEX® E UK DISTRIBUTOR PIPE2000 Ltd 15.co.

QUADRIGA 1 2 3 1 2 3 60 30 60 T 30 10 10 D 10 D 10 B D 10 10 D 10 10 D B 10 T Figures in cm Minimum bending radius m 0. max.1 1. see sheet CPX 1.pipe2000.4 Trench profile.1 1. installation depth: 2.430 2 Excavated material 3 Sand.4 Casing pipe ØD mm 93 113 128 143 163 183 Width B cm 30 30 35 35 35 38 Depth T cm 80 85 85 85 90 95 Casing pipe ØD mm 78 93 113 128 143 163 183 250 Width B cm 45 50 55 55 60 65 70 80 Depth T cm 80 80 85 85 85 90 95 100 Minimum bending radius m 0. With no traffic load.2 1.7 0.9 1. 4 CALPEX® pipes 1 2 3 1 2 3 60 60 T 10 D 5 D 10 30 D 10 30 10 10 D 10 D 10 D 10 D 10 B (4 x D + 5 x 10) 10 D 10 D 10 B Figures in cm 1 Pipe warning tape. if subject to higher traffic loads (e. SLW 30 300 kN total load as per DIN 1072.g. SLW 60).2 1.04.6 m Our approval is required for installation at greater depths. the minimum trench depth T can be reduced by 20 cm. grain size 8 mm Installation depth: Max. UK DISTRIBUTOR PIPE2000 Ltd 15.co.0 1.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.8 0.8 0.uk T www. a load-distributing superstructure as per RStO75 is required.505 Trench dimensions Trench profile.9 1.co. 2 CALPEX® pipes UNO DUO. washed.0 1.CALPEX® district heating pipe CPX 1.uk .

5 CALPEX® Joint/sleeve DK Insulated steel pipe CALPEX® ∆I FP ∆I Figures in m L Joint/sleeve DK Insulated steel pipe Static design of the Z-bend according to expansion variable ∆l.0 DS ≤ 2.0 DS ≤ 2.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.uk .Positioning of expansion pads as per the section on PREMANT® UK DISTRIBUTOR PIPE2000 Ltd 15.pipe2000. a fixed anchor point must be installed. The thermal movement Δl of the insulated steel pipe cannot be compensated by the CALPEX® pipes.uk www.5 4.Design of expansion components .0 DS ≤ 2. Transition with fixed point Joint/sleeve CALPEX® Rmin 2. A fixed point must be installed.co. 3.510 Connection (rigid/flexible) CALPEX® to insulated steel pipes Installation instructions for transition from CALPEX® to insulated steel pipe (KMR) 1. . Transition with expansion bend 1. DS ∆l FP DK = Expansion limb = Thermal movement = Fixed point (plastic casing pipe) = Expansion pad If pipe length L or ∆l is more than permitted for DS.04. Transition with Z-bend 1. Junction with T-piece min 1.0 m Insulated steel pipe Joint/sleeve FP Insulated steel pipe CALPEX® Figures in m ∆I DK CALPEX® Rmin CPX T-shell Insulated steel pipe The transverse expansion ∆l must not exceed the expansion that can be accommodated by junction pipe DS and the CALPEX® pipe.0 ∆I 2.co.0 CALPEX® ∆I ≤ 2.CALPEX® district heating pipe CPX 1.

0 270 Sanitary.7 220 50 x 4.515 House entry.9 220 40 x 3. pB = 6 bar Type DN 25/ 76 20 32/ 76 25 40/ 91 32 50/111 40 63/126 50 75/142 65 90/162 80 110/182 100 CALPEX® sanitary. 100 *80 Figures in mm Heating. pB = 6 bar Type DN Fmax [N] 25/ 76 20 925 32/ 76 25 1495 40/ 91 32 2365 50/111 40 3685 63/126 50 5785 75/142 65 8205 90/162 80 11860 110/182 100 17675 TB = 60 °C.120 Connection with weld end 1 Weld on approx. 6 bar PEX pipe mm 25 x 2. 6 bar PEX pipe A mm mm 25 x 2. 6 bar Maximum fixed point forces occurring per pipe for: TB = 90 °C.0 210 32 x 4.370 Fixed point End cap: see sheet 1.7 230 Fixed point PEX connecting piece with external thread: see sheet 1.0 B mm 340 340 340 360 340 340 410 450 PEX connecting piece with weld end: see sheet 1.6 63 x 5.CALPEX® district heating pipe CPX 1.2 110 x 10. 80 *A max. 80 *B *80 2 Install Figures in mm Heating. Fixed point forces occurring CALPEX® heating.uk www.8 230 75 x 6.pipe2000.4 220 40 x 5.9 220 63 x 8.8 235 90 x 8.3 210 32 x 2.410 CALPEX® pipe see sheets 1. fixed point forces Connection with external thread approx. 10 bar 22 x 3.8 90 x 8.04. screwed connector Shaft entry. 10 bar Maximum fixed point forces occurring per pipe for: TB = 60 °C.370 End cap: see sheet 1.9 40 x 3.5 220 50 x 6.co. 60 mm if end cap is walled in.6 220 63 x 5.0 210 28 x 4.405 Wall sealing ring: see sheet 1.7 50 x 4.405 * Dimensions can be reduced by max.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.3 32 x 2. 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 Fmax [N] 755 1225 1940 3015 4740 6720 9720 14480 UK DISTRIBUTOR PIPE2000 Ltd 15.co.uk .115 and1.2 260 110 x 10.8 75 x 6.

uk .410 CALPEX® pipe: see sheets 1.8 90 x 8.115 and 1. 80 *A max. 10 bar 22 x 3.7 50 x 4. 100 *80 Figures in mm Heating. Fixed point forces occurring CALPEX® heating. 6 bar PEX pipe mm 25 x 2. 6 bar Maximum fixed point forces occurring per pipe for: TB = 90 °C.0 125 x 11.pipe2000.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.CALPEX® district heating pipe CPX 1.6 PEX connecting piece with weld end: see sheet 1. 6 bar PEX pipe A mm mm 25 x 2.405 B mm 250 250 260 270 310 310 310 310 310 310 * Dimensions can be reduced by max. 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 Fmax [N] 755 1225 1940 3015 4740 6720 9720 14480 18745 30730 UK DISTRIBUTOR PIPE2000 Ltd 15.04.370 Fixed point End cap: see sheet 1.9 40 x 3. 80 *B 2 *80 Install Figures in mm Heating.5 270 50 x 6.120 Connection with weld end 1 Weld on approx.6 63 x 5.8 320 90 x 8. pB = 6 bar Type DN 25/ 76 20 32/ 76 25 40/ 91 32 50/111 40 63/126 50 75/142 65 90/162 80 110/182 100 125/182 110 160/250 125 CALPEX® sanitary.8 320 75 x 6. 10 bar Maximum fixed point forces occurring per pipe for: TB = 60 °C.520 House entry.co.0 340 125 x 11. 60 mm if end cap is walled in. compression joint Shaft entry.7 320 Fixed point PEX connecting piece with external thread: see sheet 1. fixed point forces Connection with external thread approx. pB = 6 bar Type DN Fmax [N] 25/ 76 20 925 32/ 76 25 1495 40/ 91 32 2365 50/111 40 3685 63/126 50 5785 75/142 65 8205 90/162 80 11860 110/182 100 17675 125/182 110 22878 160/250 125 37510 TB = 60 °C.405 Wall sealing ring: see sheet 1.9 260 40 x 3.2 330 110 x 10.uk www.2 110 x 10.4 340 160 x 14.4 260 40 x 5.0 260 32 x 4.4 160 x 14.3 32 x 2.9 270 63 x 8.385 End cap: see sheet 1.3 260 32 x 2.6 340 Sanitary.8 75 x 6.6 270 63 x 5.7 270 50 x 4.0 260 28 x 4.co.

40: Y = 60 mm DN 16 .525 Installation of house entry 3 UNO CALPEX® x 4 DUO CALPEX® y z 1 Align pipe and cut to length at right-angles.co.04.40: Z = 180 mm Joint/sleeve: DN 16 . 6 Peel off the casing.co. Tighten the clamps (if present). (Z) Important: Do not scrape or score the outer surface of the carrier pipe! 8 Fit the wall sealing ring. UNO screwed connector House connection: DN 16 .uk www.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.40: Z = 160 mm UNO compression joint House connection: DN 16 .Z = 110 mm DN 50 Y. UK DISTRIBUTOR PIPE2000 Ltd 15.100: X = 140 mm Joint/sleeve: DN 16 . split the casing. 2 Using pipe cutter or saw. 7 Cut back/remove the insulation along length X. 10 Install the fitting as per the enclosed installation instructions for BEULCO (screwed connector) or REHAU (compression joint).Z = 140 mm 5 Using a knife blade to a maximum depth of 5 mm.CALPEX® district heating pipe CPX 1.125: X = 180 mm Joint/sleeve: DN 16 .40: X = 140 mm DN 50 .uk .150: X = 150 mm DUO compression joint House connection: DN 16 .65: X = 70 mm DN 80 . 9 Carefully shrink on the pipe end closure according to the Raychem DHEC installation instructions which are enclosed in the package.40: Y.100: X = 140 mm DUO screwed connector House connection: DN 16 -40: Y = 80 mm DN 16 .40: X = 110 mm DN 50 .Z = 140 mm DN 50 Y.100: X = 140 mm DN 125 .40: Y.pipe2000.Z = 160 mm Joint/sleeve: DN 16 .65: X = 90 mm DN 80 . cut through casing at distance X (UNO) or Z (DUO).

04. Fit of connection piece Cleaning products and cleaning cloths Pipe cutter for PEX pipe Spanner wrench UK DISTRIBUTOR PIPE2000 Ltd 15.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 25 mm 25 mm flat bit for cutting filler hole e: pipe@pipe2000.co.uk .CALPEX® district heating pipe CPX 1.uk www.530 Installation tools general and for screwed connector Cut to length and strip insulation Shrink procedure The saw is used to cut the casing pipe and the insulation The gas burner is used to shrink hoses and joints Knife to split casing and remove insulation Hammer as auxiliary tool It is recommended that gloves are worn for shrinking work.pipe2000.co.

over Ø 40 mm Press yoke.535 Installation tools for press fit joints Manual tool for PEX Ø 22 .40 mm Hydraulic tool for PEX Ø 50 .2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000.110 mm Press yoke Ø 50. up to Ø 32 mm Expander head. 63 mm Reducer Ø 75/90 mm for yoke.pipe2000.co. Ø 22 .160 mm (packed in two cases) Hydraulic press and expander tool Ø 125 .co.160 mm including foot pump (basic tool) Case with basic tool (without heads and yoke) Expander head Ø 125 . Ø 160 mm Case with expander heads and press yoke UK DISTRIBUTOR PIPE2000 Ltd 15.04.110 mm (packed in two cases) Hydraulic press and expander tool Ø 50 . up to Ø 40 mm Expander tool for Ø 40 mm (basic tool) Case with basic tool including head and yoke Expander head.CALPEX® district heating pipe CPX 1.uk www.uk .40 mm (packed in one case) Expander tool.160 mm Press yoke Ø 160 mm Reducer Ø 125 mm for yoke.110 mm including foot pump (basic tool) Case with basic tool (without heads and yoke) Expander head Ø 50 . Ø 110 mm Case with expander heads and press yoke Electro-hydraulic tool for PEX Ø 125 . up to Ø 32 mm (basic tool) Press tool.

The heating strip can be pushed in for straight lengths of up to 30 m.2009 Subject to technical changes T: 01268 759567 F: 01268 569932 e: pipe@pipe2000. 10 bar Drawing in. Remove the insulation CALPEX® approx. approx. 120 mm Detail D Shorten the casing by 120 mm and cut off the exposed channel. joint 1. Connect the heating strip or pull cord to the wire (drill a hole in the strip) and pull through the heating strip.04. It must be installed at the coldest point of the pipe (outside the building). FS-B-2X) Detail E Heating strip joint (S-06 for HWAT-R and FS-B-2X) Heating strip (HWAT-R. cut open 10 x 7 cm of foam. Unroll the pipe so that it is straight. 7 cm Temperature sensor Detail C 300 mm CALPEX® End closure (E-03 for HWAT-R and FS-B-2X) Detail F CALPEX® Temperature sensor cable CALPEX® Shrink hose Filling adhesive.co. sanitary. permitted length for heating strip The heating strip and the accessories are supplied and installed by the electrician! UK DISTRIBUTOR PIPE2000 Ltd 15. fill the hole with the insulation material supplied.120.co. push the glass fibre wire (ø 6.uk www. 4. FS-B-2X) Protect the heating strip against moisture * Lmax = max.CALPEX® district heating pipe CPX 1. 10 cm approx. next to the trench (without bends). 2. opposite the heating strip. Installation of the temperature sensor for frost protection The temperature sensor has to be installed on the carrier pipe. S 1113. For this purpose.pipe2000. fix the temperature sensor onto the carrier pipe with adhesive tape. apply filling adhesive S1113 below and above the temperature sensor cable (see Detail B). 60 mm long Detail B Shrink hose 3. Pulling through the heating strip CALPEX® Glass fibre wire CALPEX® Heating strip Detail A 1.uk . Shorten the casing and cut back the channel.540 Heating strip. See also CPX 1. From one end. and seal with the sealing set. sensor. 2. cut open an area of the casing measuring 10 x 7 cm and peel it off.5 mm) through the channel. Joint Through connection L ≤ Lmax* Feed in from one end 250 mm Separate of heating strips L > Lmax* Feed in from both end (each strip ≤ Lmax) CALPEX® CALPEX® CALPEX® Heating strip (HWAT-R.

INSULATED P IPES CASAFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.uk www. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.pipe2000.uk .co.co.TECHNICAL INFORMATION SHEETS P RE .

Dimensions.0 5. Installation Trench dimensions Building entry.111 Contents System description System description Quality certificate CASAFLEX (CFL) .305 5.UNO Heat loss CASAFLEX .UNO DN 100 Connecting piece CASAFLEX .2 5.225 5.District heating pipe Contents CFL 5.216 5.UNO Connecting piece CASAFLEX .DUO Combination CASAFLEX .500 5.co.220 5.5 5.3 5.300.110 5. Weight and Delivery length 5.2 5. anchor forces Construction work Over ground laying Installation of house connection . Material.505.uk 5.316 5.515 Data for excavation.UNO Typ 25 Connecting piece CASAFLEX . Trench warning tape – Subject to technical change – 5.1 5. Wall breakthrough Building entry.DUO Connecting socket Wall sealing ring Wall duct Accessory equipment Connecting piece .301.5 5.505 5.100 5.320 Components Connecting piece CASAFLEX .200 5.505.DUO Y-pipe CASAFLEX .0 03.505. Material.105 5.315 5. Weight and Delivery length CASAFLEX (CFL) .District heating pipe UNO Construction.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.210 5. building entry 5.District heating pipe DUO Construction.3 5. Dimensions.PIPE2000 Ltd UK Distributor CASAFLEX .215 5.301.300 5.Insulating material.240 Engineering Method of laying Pressure loss diagram Heat loss CASAFLEX .5 5.6.1 5.300.2 5.plastic sheath pipe Transit T-Piece KMR Pit constructions.1 5.

Regardless of the conventional structure of pipework. Existing service pipes and other obstacles can be crossed over.co. either from above or below and routed easily around any obstacles.100 03.6. it is possible with the CASAFLEX district heating pipe system to select the shortest route. it is also the key to saving time and money when laying district heating pipe systems. General Remarks CASAFLEX district heating pipe system is the name given to a flexible domestic connection system made by BRUGG Rohrsysteme. below or bypassed easily. which means the trenches can be considerably narrower than usual. the CASAFLEX district heating pipe is not only the technically perfect solution. in industry and agriculture. The CASAFLEX district heating pipe system has a corrugated carrier pipe made of stainless steel (X5 CrNi 18/9). The CASAFLEX district heating pipe can be supplied to the site in the desired length.uk 1. either in a single piece or in coils or on drums. The flexibility of the CASAFLEX district heating pipe allows it to follow the conditions of almost any route. 2. If you consider the short laying time. but because of the reduction in coordinating work and the fast and easy way it is laid. The physical properties of the corrugated carrier pipe make it possible to lay it without having to take thermal expansion into account. considerable time can be saved on excavation work. The corrugated pipe has been designed on fluid dynamic lines. Range of Application • Operating temperature up to 160 °C Highest temperature up to 180 °C • Operating pressure PN 16 up to PN 25 – Subject to technical change – . It is designed for use in small and medium-sized district and local heating networks. Under the sheath pipe of PE-LD is a safety foil which prevents the diffusion of the gases.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. The pipes can be laid across existing pipework.PIPE2000 Ltd UK Distributor CASAFLEX . It can be laid in earth largely without connection points. The heat insulation consists of a chlorofluoro-carbonfree and flexible polyurethane foam with outstanding heat insulating properties.District heating pipe System description CFL 5. As a consequence. in solar collector systems and swimming pools. Assembly of the connections is extremely user-friendly with simple screw connection enabling the joints to be assembled quickly and in complete safety.

uk – Subject to technical change – .05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.105 03.co.District heating pipe Quality certificate ISO 9001 CFL 5.6.PIPE2000 Ltd UK Distributor CASAFLEX .

025 W/mK at 50 °C average temperature Only DN 100 Flexibel insulation of CFC-free polyurethane foam.UNO CFL 5.10 5.02 4.0 1.8 1. to EN 10088 1.35 2.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.0 1.6.2 1. Detection monitoring wires: (a) 1 x NiCr.44 0.110 03.15 2. thermal conductivity λ = 0.04 3.PIPE2000 Ltd UK Distributor CASAFLEX . (c) 1 x Cu ^ Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System 3 4 5 6 Type CASAFLEX d DN Inch ["] Carrier pipe d [mm] 22 30 39 48 60 75 98 127 Casing pipe D [mm] 91 91 111 111 126 142 162 184 min.DN 80 Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam).48 2.4301 / AISI 304 or 1. PE-LD black (VDE 0209) seamless extruded.District heating pipe District heating pipe CASAFLEX .8 0.12 8. delivery length Drum1) Coil2) [m] 570 570 370 370 230 210 180 [m] 245/370* 245/370* 200/260* 200/260* 160/190* 110/140* 90/125* 86 [kg/m] 1.3 Weight max. or 1.8 2.co.uk 6 1 2 3 4 5 Pos Material 1 2 Corrugated stainless steel carrier pipe of nickel-chromium steel acc.30 1.0255 W/mK at 50 °C average temperature Expanded metal (only DN 20 to DN 80) Multi-layer barrier foil Casing pipe from low density polyethylene.4404 / AISI 316L Only DN 20 . Protection against mechanical influence and moisture. (b) 1 x Cu insulated.80 1.40 – Subject to technical change – 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 20 25 32 40 50 65 80 100 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 1) Dimension of drums Ø 3000 x 1600 (large). thermal conductivity λ = 0. type EX20 2) Dimension of coils Ø 2800 x 800 (large) * on request D . usable up to 130 °C.0 Capacity carrier pipe [l/m] 0.12 5. up to 160 °C operating temperature (180 °C peak).4571 / AISI 316Ti.46 3.70 7.43 14.5 1. bending radius [m] 0.

4301 / AISI 304 or 1.35 2. bending radius [m] 1.8 Capacity carrier pipe [l/m] 0.1 1.4571 / AISI 316Ti.025 W/mK at 50 °C average temperature Expanded metal Multi-layer barrier foil Casing pipe from low density polyethylene.1 3.80 1.5 1.4404 / AISI 316L Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam). (b) 1 x Cu insulated. thermal conductivity λ = 0.PIPE2000 Ltd UK Distributor CASAFLEX .7 4.uk 6 1 2 3 4 5 d Pos Material 1 2 3 4 5 6 Corrugated stainless steel carrier pipe of nickel-chromium steel acc. delivery length Drum1) Coil2) [m] 370 230 210 180 [m] 200/260* 160/190* 110/140* 90/125* 1) Dimension of drums Ø 3000 x 1600 (large).DUO CFL 5.4 1. or 1. Detection monitoring wires: (a) 1 x NiCr.5 3.6. PE-LD black (VDE 0209) seamless extruded.District heating pipe District heating system CASAFLEX . type EX20 2) Dimension of coils Ø 2800 x 800 (large) * on request .44 0.co.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.2 D max. Protection against mechanical influence and moisture.04 Weight [kg/m] 2. (c) 1 x Cu ^ Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System Type CASAFLEX DN Inch – Subject to technical change – ["] 22 + 22/111 30 + 30/126 39 + 39/142 48 + 48/162 20 25 32 40 3/4 1 1 1/4 1 1/2 Carrier pipe d [mm] 22 30 39 48 Casing pipe D [mm] 111 126 142 162 min. to EN 10088 1. up to 160 °C operating temperature (180 °C floating).111 03.

uk Connection CASAFLEX .PIPE2000 Ltd UK Distributor CASAFLEX .200 03.District heating pipe Method of laying CFL 5.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.6.plastic sheath pipe CASAFLEX plastic sheath pipe CASAFLEX CASAFLEX CASAFLEX Looping-in method – Subject to technical change – Laying from building to building .

9 s m/ 0.4 s m/ 0.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.District heating pipe Pressure loss (diagram) CFL 5.5 0.8 m 0.1 s m/ 1 CFL 27/ 182 CFL 98/ 162 7 CFL 5/1 42 6 CFL 0/1 26 CFL 111 48/ CFL 39/ 111 30/ 91 CFL CFL 91 22/ – Subject to technical change – [mmWS/m] Pressure loss 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. average temperature = 80 °C Flow quantity [kg/h] s m/ 1.PIPE2000 Ltd UK Distributor CASAFLEX .6 0.210 03.uk Water.7 0.co.3 m/ s /s s m/ s m/ 0. 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.0 s m/ 0. In accordance with the rules of sound engineering practice.6. The sizing ranges of this specification should be respected. 2 s m/ 0. .

6 26.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.153 0.9 7.District heating pipe Heat loss CASAFLEX .591 average operating temperature TB [°C] 40° 50° 60° 70° 80° 7.6 6.266 0.6 29.4 4.217 0.0 10.0 13.3 26.2 18.2 5.8 21.7 16.uk CASAFLEX.5 23.8 13.43 W/mK λ PIR = 0.7 21.6 m λ = 0.4 15.4 12.5 17.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6 33.5 59.5 35.6 4.215 03.0255 W/mK Heat loss during operation: q = K · (TB .197 0.0 10.1 m H = 0.UNO CFL 5.2 10.3 5.2 11.2 53.8 15.9 10.5 41.5 5.2 18.9 – Subject to technical change – 20 25 32 40 50 65 80 100 3.3 19.1 8.5 8.4 16.8 11.7 19.7 23.PIPE2000 Ltd UK Distributor CASAFLEX .8 4.335 0.4 .4 23.7 6.0 11.9 10.7 7.3 14.1 12.co.3 15.1 17.7 13.113 0.1 13.0 31.9 40.8 6.1 7.8 17.9 29.7 23.2 W/mK a = 0.7 26. parallel laying of 2 single lines TE = 10 °C λ E = 1.2 12. parallel laying Type CASAFLEX 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 DN K-value [W/mK] 0.8 47.2 70.6 13.2 15.6.3 15.8 17.7 10.9 30.3 90° 100° 110° 120° 130° 9.143 0.6 13.6 9.025 W/mK λ PUR = 0.8 20.0 8.9 9.9 65.4 21.2 36.6 23.

uk CASAFLEX DUO pipe TE = 10 °C λ E = 1.8 70° 80° 90° 100° 110° 120° 130° 20 25 32 40 9.2 18.1 19.9 20.DUO CFL 5.43 W/mK λ PIR = 0.0 10.2 13.2 22.PIPE2000 Ltd UK Distributor CASAFLEX .224 0.181 0.6 25.7 50° 6.5 14.5 15.2 60° 7.4 15.9 12.9 21.5 10.6 20.1 22.9 11.5 16.District heating pipe Heat loss CASAFLEX .co.4 6.6.1 27.7 5.6 m K = Specific heat losses [W/mK] TB = Average operating temperature [°C] TE = Average earth temperature [°C] – Subject to technical change – Heat loss q [W/m] for single pipe Type CASAFLEX 22 + 22/111 30 + 30/126 39 + 39/142 48 + 48/162 DN K-value [W/mK] 0.025 W/mK Heat loss during operation: q = K · (TB .0 17.4 24.251 average operating temperature TB [°C] 40° 4.TE) [W/m] H = 0.7 8.2 7.7 17.6 30.6 17.216 03.7 14.9 12.3 18.0 12.0 15.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.7 9.4 10.2 W/mK λ = 0.9 7.6 26.1 .156 0.

05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.220 03.0 CASAFLEX Δl CASAFLEX ≤ 2.co.PIPE2000 Ltd UK Distributor CASAFLEX .District heating pipe Connecting instruction CASAFLEX .0 1 Transition with fixed point DP CASAFLEX Rmin.6. 1.5 CASAFLEX DP Pipe joint KMR CASAFLEX Pipe joint DP KMR FP Δl Δl L – Subject to technical change – Laying of Z elbow according to the expansion Δl.5 1 Transition with expansion elbow 1. Pipe joint KMR ≥ 2.fixed point DP = Expansion pads . • Design of expansion elements • Location of expansion pads according to the Chapter Plastic Sheath Pipe from the main catalogue. does not need to be compensated by the CASAFLEX 1 Transition with Z elbow 1.plastic sheath pipe CFL 5. If pipe length L resp.0 DS ≤ 2.0 Pipe joint FP KMR CASAFLEX Δl CASAFLEX Flex-T-piece Rmin. owing to increase of temperature. DS = Expansion leg Δl = Expansion FP = Plastic sheath pipe .uk Laying instructions for combination CASAFLEX (CFL) on plastic sheath pip (KMR) all dimensions in m 1 Transition from T-piece KMR min.0 DS ≤ 2. Δl is > than permissible. The expansion Δl. DP KMR 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. which must be compensated by section DS.0 Δl DS ≤ 2. a fixed point should be included to allow exact checking of the expansion.

PIPE2000 Ltd UK Distributor CASAFLEX .uk Construction of T-piece KMR KMR KMR 1 A 2 1 2 3 4 5 6 7 T-Piece KMR Shrink-on seal PE-Pipe joint Polyurethane hard foam Monitor leads CASAFLEX Connecting piece CASAFLEX District heating pipe 3 4 5 6 KMR = Plastic sheath pipe View A – Subject to technical change – 45° CASAFLEX KM R CFL 7 .05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.225 03.6.District heating pipe Transition T-Piece KMR CFL 5.

It is also possible to deliver them with protection against surface water. especially at operating temperatures. where necessary. but any protracted flooding. where there is pressure from the ground water an adjustable packing seal is almost always needed. Due to these requirements.uk Planing and engineering of pit constructions Pit constructions in district and local heating networks are normally very work-and time-intensive to build and maintain. pre-insulated shut-off and evacuation/ventilation valves are fitted.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. depending on the local conditions. The pipe endings are mostly only equipped with a splash water guard.PIPE2000 Ltd UK Distributor CASAFLEX . the use of pit constructions has today largely been discontinued. should be avoided even then. In this way it is possible to save costs for the construction and maintenance of pits. In the case of surface water which exerts no pressure. must be furnished with a watertight seal. frequently quite considerable. a simple labyrinth seal will be sufficient. They must be constructed so as to be watertight.6. In their place pre-insulated T-pieces and.240 03. however. while at the same time increasing operating safety. The pipe entries.District heating pipe Pit construction Building entries CFL 5. and any surface water which may get in must be removed as soon as possible in order to prevent damage to the pits and the heat insulation of the pipes feeding into them.co. – Subject to technical change – .

7. It is designed for all installation of house connections and for connections in the dry shafts.6.2 60.2 42.4 x 3. The CASAFLEX connecting piece is intended for use with hot water pipes (PN 16). Protection cap is not necessary see CFL 5.UNO .1 Data Table Type DN Inches ["] 3/4" 1" 11/4" 11/2" 2" Steel carrier pipe dxs mm 26.6 33.3 x 3.3 x 3. as 3 5 2 1 6 4 well as transition with expansion elbow and as transition from T-pieces.9 x 2.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6 Shaft 22/91 30/91 39/111 48/111 60/126 20 25 32 40 50 . 7 8 1 2 3 4 5 6 7 8 9 – Subject to technical change – Support ring Sealing ring Connection piece Pressure ring Allen screws Detection conductors Protection caps.PIPE2000 Ltd UK Distributor CASAFLEX . two pieces CASAFLEX heating pipe Stretching tape d s 9 Execution Type building dry T-Piece / Pipe joint Execution See design on the drawing Pos.Type 16 CFL 5.240 + 5.300 03.7 x 3.300.District heating pipe Connecting piece CASAFLEX .2 48.co.uk The CASAFLEX connecting piece is especially designed for the connection of CASAFLEX district heating pipes.

3x3.Type 25 CFL 5. which is necessary when operating pressures exceed 16 bar.2 60.6.100) rib mesh shrink sleeve Type CASAFLEX DN Inches ["] pipe connection dxs [mm] 26.1 03.6 33.uk In the connection Type 25 the rib mesh is integrated via a metal cap or clamping ring.6 88.1 x 3. The connections are intended for use with hot water pipes.District heating pipe Connection CASAFLEX .2 48. this increases the mechanical stability of the assembly.PIPE2000 Ltd UK Distributor CASAFLEX .4x3.UNO .7x3.2 42.300.9x2.3x3. 3 5 1 2 4 6 9 8 10 – Subject to technical change – 1 2 3 4 5 6 7 8 9 10 11 back-up ring graphite sealing ring connection piece pressure ring hexagonal socket head screw monitor leads protective cap and monitor lead exit CASAFLEX cable clamping ring (DN 65 .co.0 22/91 30/91 39/111 48/126 60/126 75/142* 98/162* 20 25 32 40 50 65 80 3/4” 1” 1 1/4” 1 1/2” 2” 2 1/2” 3” * PN 16 without clamping ring for the rib mesh .9 x 4.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6 76.

3 x 4.uk 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.300.Type 16 CFL 5.PIPE2000 Ltd UK Distributor CASAFLEX . The connection units are intended for use with hot water pipes up to PN 16.co.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 11 10 3 5 2 4 1 7 6 8 12 9 – Subject to technical change – 1 2 3 4 5 6 7 8 9 10 11 12 internal backing sleeve graphite packing connection piece thrust collar cylindrical screw O-ring screw protective cap shrink sleeve detection conductors connector for monitoring wires CASAFLEX pipe Type CASAFLEX DN Inches ["] pipe connection dxs [mm] 114.6.5 127/182 100 4” .District heating pipe Connection Unit DN 100 .5 03.

3 x 3.co.4 x 3.District heating pipe Connection CASAFLEX . It is used to establish all connections to pipe installations in buildings and shafts as well as for transition and T-connections.4 * L [mm] ∼ 138 ∼ 141 ∼ 208 * D2 [mm] 131 145 164 * 20 25 32 40 3/4” 1” 1 1/4” 1 1/2” * on request D2 .6.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 4 5 8 10 A dxs 7 L 1 2 3 4 5 – Subject to technical change – core piece graphite packing connecting end pressure ring press plate A Type CASAFLEX 22 + 22/111 30 + 30/126 39 + 39/142 48 + 48/162* DN 6 7 8 9.DUO .2 48.301.2 03.10 cone plate B allen bolts end cap (2 pieces) clamps Inches ["] pipe connection dxs [mm] 26.2 42.uk The CFL connection unit is a connection element specially designed for CASAFLEX district heating pipes.9 52.7 x 3.PIPE2000 Ltd UK Distributor CASAFLEX . 3 2 6 1 9 The connection units are intended for use with hot water pipes.9 x 2.Type 16 CFL 5.2 A [mm] 45.7 61.6 33.

uk RL øD 300 A View A VL ø øC C 90 VL RL A 150 CFL .7 x 3.2 48.6.9 x 2.DUO CFL 5.9 x 2.3 x 3.6 33.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.alarm wires 300 250 170 2150 Typ CASAFLEX DN Inches ["] Pipe connection dxs [mm] ØC [mm] A [mm] 2 x single KMR steel pipe [mm] ØD [mm] – Subject to technical change – 22 + 22/111 30 + 30/126 39 + 39/142 48 + 48/162 20 25 32 40 3/4" 1" 1 1/4" 1 1/2" 26.2 48.2 140 160 180 200 65 75 80 93 26.7 x 3.301.District heating pipe Y Pipe CASAFLEX .4 x 3.co.2 42.2 42.PIPE2000 Ltd UK Distributor CASAFLEX .6 33.4 x 3.3 03.2 90 90 110 110 .3 x 3.

plastic sheath pipe (KMR) 2 3 CASAFLEX d1 KMR d2 1 2 3 4 5 Coupling (2 Connecting pieces ME welded by installer) Connecting piece.co.CASAFLEX d2 91 111 d1 126 142 162 182 91 111 126 142 162 X .District heating pipe Connecting socket CFL 5.KMR 182 d2 91 X X X X RMBD 4 d1 111 126 142 162 182 91 111 126 142 162 X X X X X X X X X X X RMBD 4 RMBD 4 182 200 – Subject to technical change – CASAFLEX .320 Shrinking socket Shrink sleeve CASAFLEX . position 3 Insulation material (PUR-foam hose). see page CFL 5.300.305 03.uk CASAFLEX connecting socket 1 3 4 5 CASAFLEX CASAFLEX d2 Ø carrier pipe equal CASAFLEX .PIPE2000 Ltd UK Distributor CASAFLEX .6. see page CFL 5.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.

6.District heating pipe Wall sealing ring CFL 5.co.PIPE2000 Ltd UK Distributor CASAFLEX .uk Ø Da ØD 50 mm Data table Type CASAFLEX 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 Protective sheath ØD Ø Da mm mm 93 93 113 113 128 144 164 183 133 133 153 153 168 183 203 218 – Subject to technical change – .315 03.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.

we recommend sealing the drill hole walls over the entire lengths with a sealant (e. Core drill holes A prerequisite for installation are perfect drill holes. double sealing large 2 x 40 mm.co. g. After the installation of the sealing set the axial alignment of the pipe may not be changed. please state the diamaters D internal and D external. (centering) large 1 x 20 mm Pipe liner made of fibre cement or 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! Pipeline diameter PE Ø mm 91 111 126 142 162 182 Pipe liner core drill hole Ø mm 150 200 200 250 250 300 casing tube DN 150 200 200 250 250 300 sealing set A/B Ø D internal mm 93 113 128 144 163 183 Ø D external mm 150 200 200 250 250 300 – Subject to technical change – When ordering the sealing sets. hardness 35 Sealing set A.316 03. We cannot guarantee a good seal if these recommendations are not observed.uk Sealing set B. .05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6. AQUAGARD).District heating pipe Wall duct CFL 5. Since hairline cracks can exist in concrete or can arise as a result of the work.PIPE2000 Ltd UK Distributor CASAFLEX .

Applications with higher operatings temperature (max. CFC-free PUR-Foam Safety precautions for the foam insulation Componend A plastic gloves Separating clip eye protection Componend B Note: PUR-Foam is suitable for constant operatings temperature up to 120°C. PUR .500 .District heating pipe Insulation material CFL 5. 160°C) only on request.PIPE2000 Ltd UK Distributor CASAFLEX . – Subject to technical change – Trench warning tape for laying under ground Standard length 100 m Laying depth.6. see work sheet CFL 5.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.foam package The required volume of polyurethane foam is supplied in the appropriate foam package for the various sockets and T-pieces. The two components will be mixed together by removing the separating clip.uk T-piece sets and sockets PUR .foam package Base: CO2-blown.co.320 03.

300 kN total load = according to DIN 1072.2 1.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6. see work sheet CFL 5. 2 m max.320 2 Excavated material 3 Sand washed.District heating pipe Trench dimensions CFL 5. SLW 30 ^ 50 kN wheel load. Without traffic load the minimum covering hight may be reduced by 20 cm. resp.0 5 Covering depth maximum covering depth: 2.500 03. see work sheet CFL 5.5 x B 4 2. 1 m – Subject to technical change – 1.8 2.0 m .0 1. grain size 0-3/4 mm 4 CASAFLEX District heating pipe 5 Connecting piece. bending radius m 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 93 93 113 113 128 144 163 184 50 50 55 55 55 60 65 65 80 80 85 85 85 85 90 90 1.300 Trench section by the connection of T-piece max. 1 Trench warning tape.6 m Higher covering only after consultation with us.e.PIPE2000 Ltd UK Distributor CASAFLEX .co.5 m Rmin B 1. For bigger loads (i.0 1.0 1.5 1.0 1. SLW 60) a load distribution superstructure according to RStO75 is required.uk Trench section 1 2 3 Trench section by house connection 60 10 D 10 30 All dimension in cm 10 D 10 D 10 4 4 Type Casing Width pipe B ØD mm cm Depth T cm min.

(see work sheet CFL 5.505.505 03. mm 500 500 550 600 650 700 H mm 300 300 300 350 350 400 80 D 100 L min.110 Wall sealing ring. 80 Monitoring socket on the wall all dimensions in mm Wiring to the socket min. For this reason a fixing point clamp must be mounted. D 80 – Subject to technical change – Breakthrough bored 30 H A Casing pipe Ø D mm 93 113 128 144 163 182 D1 min.300 160 CASAFLEX district heating pipe.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. .co. see work sheet CFL 5. mm 200 220 240 260 280 300 A mm 230 250 270 290 310 330 D1 min.uk Connection with weld-on end Monitor leads Monitoring socket on the pipe ca. see work sheet CFL 5. see text Connecting piece. 250 Fixed point. see work sheet CFL 5.PIPE2000 Ltd UK Distributor CASAFLEX .6.District heating pipe Building entry Wall breakthrough CFL 5.315 End-cap Fixed point The connection and the CASAFLEX pipe are not suitable for absorbing the expansion of the continued pipe.1) Wall breakthrough Casing pipe Ø D mm 93 113 128 144 163 182 L min.

0 1.7 10.8 1.8 2.District heating pipe Building work Anchor forces CFL 5.1 8.1 3.9 21.1 5. the system takes up longitudinal heat expansion internally.4 2.505.2 5.uk CASAFLEX district heating pipe is a selfcompensating.2 F (25 bar) (KN) 1.0 F (21 bar) (KN) 1.7 23. Depending on the selfcompensation and pressure inside the pipe.3 1.8 1. statically neutral system – i.9 4.4 5.3 13.2 3.e.9 30.1 8.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.2 8.6 F (10 bar) (KN) 0.1 03.1 3.4 8. Loads and deformation due to external influences can however only be taken up by the system to a limited extent. the following anchor forces per pipe should be observed.2 2.PIPE2000 Ltd UK Distributor CASAFLEX . Anchor forces per pipe Typ F (6 bar) (KN) 0.0 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 – Subject to technical change – .0 12.5 6.4 F (16 bar) (KN) 0.5 0. Connection to conventional systems should involve as little loading as possible.6.9 17.4 2.9 3.3 36.5 0.8 1.3 0.5 14.co.5 5.

sand saddles can be placed at the prescibed intervals.6 0.6.co. LS ≈ 4 x DA T-pieces must be secured by additional sand saddles.6 0.6 Open trench length L LS Open trench length L Sand saddle – Subject to technical change – BS A . If greater lengths need to be laid bare.5 0.2 03. the following separation distance must be observed: Type (m) DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 Length (for 6 bar) (m) 6 6 6 5 5 5 5 5 Length (for 10 bar) (m) 4 4 4 4 4 4 4 4 Length (for 16 bar) (m) 3 3 3 3 3 3 3 3 Length (for 21 bar) (m) 2 2 2 2 2 2 2 2 Length (for 25 bar) (m) 2 2 2 2 2 2 2 2 A 0.505. BS ≈ 7 x DA. If trenches are excavated parallel to the CASAFLEX routing.5 0. the alignment and position of the pipe must be secured.5 0.District heating pipe Building work CFL 5.5 0. The following open trench lengths should not be exceeded.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.5 0.uk When carrying out building work on CASAFLEX district heating pipework.PIPE2000 Ltd UK Distributor CASAFLEX . Dimensions of the saddles HS ≈ 2 x DA.

Secure the ends with anchor points.8 m 1. 3 clamps in a 90° curve.0 m 1.0 m 1.uk When CASAFLEX piping is to be laid in the open.8 m 2. Make use of BRUGG's help when making project plans and laying the cable Support during planning and laying by BRUGG Intervals between clamps 2m 2m 2m 2m 2m 2m 2m 2m Min. galvanized) 2.5 03. Limit PN 10 5.05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co. Changes of direction should also be supported (wherever possible on a pre-bent angled profile) 3. 6.PIPE2000 Ltd UK Distributor CASAFLEX . Type CFL 22/91 CFL 30/91 CFL 39/111 CFL 48/111 CFL 60/126 CFL 75/142 CFL 98/162 CFL 127/182 Angled steel section (galv.) 60 x 60 x 6 60 x 60 x 6 70 x 70 x 7 70 x 70 x 7 80 x 80 x 8 90 x 90 x 9 90 x 90 x 9 90 x 90 x 9 4.0 m – Subject to technical change – . Lay a continuous mounting rail (very economic: angled profile steel.0 m 1.2 m 1.5 m 1. bending radius 0.6. Reinforced at prescribed intervals with clamp rings and pressure distribution plates. the following precautions must be taken: 1.505.District heating pipe Laying in the open CFL 5.

515 03.uk – Subject to technical change – .05 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.PIPE2000 Ltd UK Distributor CASAFLEX .6.CFL 60/126 CFL 5.District heating pipe Installation house connection PN 16 CFL 22/91 .

co. Via L. 022/ 722 56 26. Tel. o.-Nr : 66356 CASAFLEX Montageanleitung Installation instructions DE CH: D: A: B: I: PL: SK: SF: BRUGG Rohrsystem AG. 07723 / 439 620. Fax 015/ 621 167 BRUGG Pipesystem srl. Bertolini 27. Fax 056/ 268 78 79 BRUGG Rohrsysteme GmbH. Sp. Adolf-Oesterheld-Str. Fax 0523 / 594 369 BRUGG Systemy Rurowe. Tel. Industriestrasse 39.uk UK Distributor Ausgabe: 05/1-01 DE Technische Änderungen vorbehalten/Subject to technical changes Art. O. 00358 641 77 000 Ausgabe: 05 / 1-01 DE. CH-5314 Kleindöttingen.pipe2000. 05031/170-0. Tel. V. Fax 05031/170 170 BRUGG Rohrsysteme Ges. Fax 07/ 716 443 BRUGG PEMA OY. Freigabe: 16.co. z o.. B-1982 Elewijt (Zemst). 00358 400 560 719 . Tel. Tel. I-29100 Piacenza. Tel. 015/ 621 050.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. PL-05-860 Plochocin. Reischlgasse 5. P. . Kampenhoutsebaan 16. Tel. A-4950 Altheim. 0523 / 590 431.2001 RD . Fax 022/ 722 51 97 BRUGG Rohrsysteme.01. Tel. SK-84105 Bratislava.uk Web: www. D-31515 Wunstorf.Ul. mbH. 31. SF-60101 Seinäjoki. 056/ 268 78 78. Beniakova 6. Lipowa 1. 07/ 716 443. Fax 07723 / 439 623 BRUGG Pipesystems N. Box 707.

in Sonnenkollektoranlagen. wird keine Haftung übernommen. Für weitere Informationen wenden Sie sich bitte an Ihren örtlichen Verkaufsberater. Das Rohrsystem CASAFLEX eignet sich für den unter. Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht.12) • Erstellung der Verbindung im Haus (Bild 13 .PIPE2000 Ltd UK Distributor Montageanleitung CASAFLEX deutsch/english Art. 66356 Art. DIN 17 441 • Dämmung aus FCKW-freiem.-Nr. Sie ist für den Einsatz in kleinen und mittleren Fern. Rohrkonstruktion CASAFLEX • Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr. Empfang und Verlegung der Rohre • Montage bei tiefen Temperaturen • Verarbeiten des Rohres für Verbindungen (Bild 1 . Anwendungsbereich CASAFLEX-Fernwärmeleitung ist der Name für eine biegbare Hausanschlussleitung der Brugg Rohrsysteme. sollten Sie sorgfältig jede Phase dieser Montageanleitung durchlesen. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben.-Nr. 66356 Seite: 1 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes 1. italienisch sowie englisch vor. 130 °C und max. Sie sind das Ergebnis umfangreicher Entwicklungsarbeiten und der praktischen Erfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. Danach führen Sie Schritt für Schritt aus. 16 bar Dauerdruck. sowie in Industrie und Landwirtschaft.6 Seite 7 Art.-Nr. Seite 1 Seite 2 Seite 3 Seite 3 Seite 4 Seite 5. Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgänge für Verlegung und Montage. 1. Allgemeines Diese neu überarbeitete Montageanleitung für das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch.17) 2. Kopieren verboten. Tragen Sie Handschuhe und Schutzbrille. .4301. 100 % CO2-geblasenem PUR-Schaum • Schutzmantel aus Polyäthylen LDPE 4. Es gelten die allgemeinen Verkaufsbedingungen. und in der Schwimmbadtechnik gedacht. Bevor Sie mit der Arbeit beginnen.und Nahwärmenetzen. 3. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. 66356 Für Schäden und Betriebsstörungen. Sie ersetzt alle früheren Ausgaben und ist Bestandteil jeder Materiallieferung. französisch.und oberirdischen Transport von Heizungswasser bis max. Inhaltsverzeichnis / Content D: • Allgemeine Hinweise E: • General instructions • Dimensionen • Transport.

The pipe system CASAFLEX is designed for under. The pipe-type and range of application is printed on the jacket. french and italian. page 1 page 2 page 3 page 3 page 4 page 5. solar energy and swimming pool technology. Please study this installation instruction carefully before starting. we do not undertake any liability. resulting from application of system components which are not recommended by our company or in case of not following the installation instruction.and above ground transport of heating water up to max. Adhere to the local security regulations for installation work. 66356 For damages and operating troubles. 130 °C and up to max.-no. agriculture. 66356 art. CASAFLEX is for the use of small and middle district heating systems as well as for industrial use. reception and laying of pipes • Installation at low temperatures • Convert pipe for connections (picture 1 .12) • Installation of a house connection (picture 13 . General This completely revised installation instruction for the pipe-system CASAFLEX is held in english. Then follow it step-by-step. Carry gloves and safetyglasses. 16 bar permanent pressure.17) 2. .-no. They are a result of comprehensive development and practical experience of the producer Brugg Pipe Systems and its suppliers.-no: 66356 page: 2 from 7 issue: 05 / 1-01 DE Subject to technical changes/Technische Änderungen vorbehalten 1. Content / Inhaltsverzeichnis D: • Allgemeine Hinweise E: • General instructions • Dimensions • Transport.4301. For further information please contact your local sales engineer. Pipe construction CASAFLEX • Service-pipe of nickel-chromium steel X5 CrNi 18/9. DIN 17 441. • Insulation of CFC-free.6 page 7 art. It replaces all earlier versions and is included in any material delivery. 1. Wno. Copies are prohibited. The following chapters describe all steps of laying and installing. Our general terms and conditions are applicable. Application CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems.PIPE2000 Ltd UK Distributor Installation instruction CASAFLEX english/deutsch art. german. 100 % CO2-blown polyurethane-foam • Jacket-pipe of polyethylene LDPE 4. 3.

4 x 0.16 1.0 1. 66356 Seite: 3 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes Dimensionen/Dimensions Baureihe Range Mediumrohr Service-pipe Mantel Jacket ø mm 78 93 113 113 128 113 128 128 143 Inhalt Volume Liter/m 0.04 3. Empfang und Verlegung der Rohre E: Transport. 60 °C Rmin 2 Rmin 10 0 8 0 D D 8 0 A Mantelrohr Ø D mm D1 min mm A mm 78 93 113 128 143 180 200 220 240 260 210 230 250 270 290 Für Schäden und Betriebsstörungen.8 1.2 1.4 39.02 3.4 x 0. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben.4 x 0.35 2. reception and laying of pipes Sandschicht.5 60.04 2.5 48. Kopieren verboten.80 1.12 Gewicht Weight kg/m 1.4 48. wird keine Haftung übernommen. 600 mm D1 1 .46 2.0 1.5 D: Transport.60 2.0 x 0. Es gelten die allgemeinen Verkaufsbedingungen.2 1.5 60.35 1.54 Biegeradius Bending radius R min m 0.68 2.80 0.3 39.3 DN 22/76 30/91 30/111 PLUS 39/111 39/126 PLUS 48/111 48/126 PLUS 60/126 60/142 PLUS 20 25 25 32 32 40 40 50 50 dxs mm 22. Korngrösse 0-4 mm Sand. grain size 0-4 mm Alle Masse in mm Dimensions in mm 600 mm 30 80 D 8 0 600 mm ca.12 3.4 x 0.-Nr.8 0.0 1.4 x 0.PIPE2000 Ltd UK Distributor Montageanleitung CASAFLEX deutsch/english Art.2 x 0.2 1.92 3.3 30.93 1.4 x 0.2 x 0.44 0.10 1.3 30.

Laying and installation of CASAFLEX pipes 1. Laying and installation with low outer temparature (<5°C) Store coil. Laying (sketch) Cut fixing ribbons one after the other from outside to inside while unwinding the coil in the trench or adjacent. 2. 60 °C 3. Spannbänder fixing ribbons 2.-Nr. wird keine Haftung übernommen. . indoor or warm up the outer jacket with a heating appliance and lay immediately. Rohrende richten (Skizze) Aussenmantel auf ca. 66356 Seite: 4 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes Verlegung und Montage von CASAFLEX-Rohren 1. Disassemble directional tool. ca. 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. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben.PIPE2000 Ltd UK Distributor Montageanleitung Assembly Instructions deutsch CASAFLEX english Art. Für Schäden und Betriebsstörungen. 3. Rohrende wie oben beschrieben richten. Es gelten die allgemeinen Verkaufsbedingungen. Richtschiene vom Rohr lösen. Direct pipe-end (sketch) Heat up outer jacket to approx. 60°C (surface shines) and cool it down in a fixed situation. Verlegung (Skizze) Spannbänder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen. if possible. Kopieren verboten. Direct pipe-end as described above. 60°C wärmen (Oberfläche glänzt) und im eingespannten Zustand abkühlen.

Brenner E: Requested tool Saw. The saw deeps into foam max. gas burner. E: Lay open the detector wires and pull them out. Säge max. Messer. Zollstock. E: Cut the service pipe square to its axis. E: Remove coat. high grade steel brush.1 D: Einzelteile der Verbindung 1 Druckring 2 Stützring 3 Graphit . allen spanner*. Für Schäden und Betriebsstörungen. D: Innenrohr auf Länge rechtwinklig absägen. marking pen. Zange. folding role.2 D: Meldedern am Rohrende freilegen und herausziehen. Es gelten die allgemeinen Verkaufsbedingungen. 5 6 Ø22-39: 50-60 mm Ø48-60: 60-70 mm 4. E: Separate with saw the jacket from the pipe end and open it longitudinally. D: Mantel entfernen. E: Convert pipes for connections. Innensechskantschlüssel*.-Nr. 5 mm tief einstecken. 5 mm 200 mm 5 D: Benötigte Werkzeuge Handsäge. spanner. *SW 6 DN 20 + 25 *SW 8 DN 32 + 40 30-100 mm *SW 10 DN 50 4 4. knife. .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 D: Mantel vom Rohrende mit Säge durchtrennen und längs aufschneiden. Ratsche. Markierungsstift. 66356 Seite: 5 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes D: Verarbeiten des Rohres für Verbindungen. Edelstahlbürste. Feile (H2). Kopieren verboten. 5 mm. 1 2 3 5 4 3 2 1 max.PIPE2000 Ltd UK Distributor Montageanleitung CASAFLEX deutsch / english Art. file (H2). pliers. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. wird keine Haftung übernommen.

Gewinde-Ansatz muss mit Rohrende abschliessen. Gegen Verdrehen festhalten.5 mm gegen Anschlussstück vorschrauben. Attention: pipe surface = seal surface. Schrauben anziehen bis Anschlussstück am Druckring anliegt. E: Move connection piece (4) without sealing ring onto the support ring and push together. 11. Druckring nicht mehr drehen.5 mm 11 11. Druckring (1) bis 0. E: Move sealing ring (3) onto the supporting ring. wird keine Haftung übernommen. Stützring (2) einschrauben. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. E: Cut the service pipe with help of the pressure ring square to its axis. D: Innenrohr mit Hilfe des Druckrings rechtwinklig auf Länge absägen.PIPE2000 Ltd UK Distributor Montageanleitung CASAFLEX deutsch / english Art. Attachement thread must close together with the pipe end. controlling 1-2 mm D: Dichtring (3) auf den Stützring aufschieben. Hold it to avoid distort. Achtung: Rohroberfläche ist die Dichtfläche.-Nr. . Für Schäden und Betriebsstörungen. E: Lubricate the screws! Tighten up the screws to the pressure ring. D: Druckring (1) ganz nach hinten schrauben. Es gelten die allgemeinen Verkaufsbedingungen. E: Convert pipes for connections. E: Clean pipe end to the flare surface with steel brush and make it free of dust. Screw on supporting ring (2).2 3 D: Schrauben ölen! Anschlussstück aufschieben. 7 8 Ø 22–39: 35 mm Ø 48–60: 45 mm 9 1 2 D: Rohrende mit Drahtbürste metallisch blank säubern + entstauben.1 12 Öl 0 mm 4 1 D: Anschlussstück (4) ohne Dichtring auf den Stützring aufschieben und gegendrücken.5 mm against connection piece. E: Screw pressure ring (1) backwards. do not turn the pressure ring. 10 0. Screw pressure ring (1) up to 0. 66356 Seite: 6 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes D: Verarbeiten des Rohres für Verbindungen. Kopieren verboten.

the detector wires push out. D: Die Anschlussverbindung resp. E: The connection resp. 16 17 Überwachungsdose an Wand Monitoring socket on the wall D: Überwachungsdose am Rohr E: Monitoring socket on the pipe ca. see text D: Schutzkappe montieren. That‘s why a fixing point clamp must be mounted. E: Mount the protection caps. the CASAFLEX pipe is not suitable for absorbing the expansion of the continued pipe. Für Schäden und Betriebsstörungen. Meldeadern herausziehen.-Nr. Aus diesem Grunde ist eine Festpunktschelle zu montieren. 66356 Seite: 7 von 7 Ausgabe: 05 / 1-01 DE Technische Änderungen vorbehalten/Subject to technical changes D: Erstellung der Verbindung im Haus E: Installation of a house connection 13 14 15 D: Mauerdichtring montieren. siehe Text Fixing point. WIREM/BRANDES: rot + grün. 5-10 s). wird keine Haftung übernommen. 250 . die CASAFLEX-Leitung ist nicht geeignet um Dehnungen der weitergehenden Leitung aufzunehmen. Kopieren verboten. Es gelten die allgemeinen Verkaufsbedingungen. min. E: Push shrink sleeves above 2 detector wires. shrink with small flame (max. mit weicher Flamme schrumpfen (max. 80 160 Festpunkt. E: Cut the remain detection conductor WIREM/BRANDES: red + green North System: Cu-white + green D: Schrumpfschläuche über die 2 Adern ziehen. D: Überflüssige Meldeader zurück schneiden. 5-10 s).PIPE2000 Ltd UK Distributor Montageanleitung CASAFLEX deutsch / english Art. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. Nordisches System: Cu-weiss + grün. E: Mount the wall sealing ring.

1.6 7 Art.Technische Änderungen vorbehalten . sowie in Industrie und Landwirtschaft.-Nr. Inhaltsverzeichnis / Content D:• Allgemeine Hinweise Seite E:• General instructions Seite • Dimensionen Seite • Transport. Das Rohrsystem CASAFLEX eignet sich für den unter. Kopieren verboten. Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht.und Nahwärmenetzen. Sie sind das Ergebnis umfangreicher Entwicklungsarbeiten und der praktischen Erfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. sollten Sie sorgfältig jede Phase dieser Montageanleitung durchlesen. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. . Sie ist für den Einsatz in kleinen und mittleren Fern.17) Seite 1 2 3 3 4 5. 16 bar Dauerdruck. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. Empfang und Verlegung der Rohre Seite • Montage bei tiefen Temperaturen Seite • Verarbeiten des Rohres für Verbindungen (Bild 1 .-Nr.-Nr. 66356 Art. italienisch sowie englisch vor. wird keine Haftung übernommen. 66356 2. und in der Schwimmbadtechnik gedacht. DIN 17441 • Dämmung aus FCKW-freiem. Tragen Sie Handschuhe und Schutzbrille.4301. Rohrkonstruktion CASAFLEX • Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr.Subject to technical change - Für Schäden und Betriebsstörungen. französisch.und oberirdischen Transport von Heizungswasser bis max. . Bevor Sie mit der Arbeit beginnen. 100 % CO2-geblasenem PUR-Schaum • Schutzmantel aus Polyäthylen LDPE 4.PIPE2000 Ltd UK Distributor flexible solutions Montageanleitung CASAFLEX® 75/142 + 98/162 PN 16 Art. in Sonnenkollektoranlagen. 3. 66356 Seite: 1 von 7 Ausgabe: 06 / 1-07 DE 1. Anwendungsbereich CASAFLEX-Fernwärmeleitung ist der Name für eine biegbare Hausanschlussleitung der Brugg Rohrsysteme. Es gelten die allgemeinen Verkaufsbedingungen. Sie ersetzt alle früheren Ausgaben und ist Bestandteil jeder Materiallieferung.12) Seite • Erstellung der Verbindung im Haus (Bild 13 . Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgänge für Verlegung und Montage. Für weitere Informationen wenden Sie sich bitte an Ihren örtlichen Verkaufsberater. 130 °C und max. Allgemeines Diese neu überarbeitete Montageanleitung für das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch. Danach führen Sie Schritt für Schritt aus.

The pipe-type and range of application is printed on the jacket. 66356 Seite: 2 von 7 Ausgabe: 06 / 1-07 DE 1.Technische Änderungen vorbehalten . General This completely revised installation instruction for the pipe-system CASAFLEX is held in english. DIN 17 441 • Insulation of CFC-free. Empfang und Verlegung der Rohre Seite • Montage bei tiefen Temperaturen Seite • Verarbeiten des Rohres für Verbindungen (Bild 1 . 1. 66356 Art. . The following chapters describe all steps of laying and installing.PIPE2000 Ltd UK Distributor flexible solutions Montageanleitung CASAFLEX® 75/142 + 98/162 PN 16 Art. wird keine Haftung übernommen. Wno.and above ground transport of heating water up to max. solar energy and swimming pool technology. CASAFLEX is for the use of small and middle district heating systems as well as for industrial use.Subject to technical change - Für Schäden und Betriebsstörungen. Adhere to the local security regulations for installation work.-Nr. 3. agriculture. Carry gloves and safetyglasses. It replaces all earlier versions and is included in any material delivery. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. Then follow it step-by-step. Please study this installation instruction carefully before starting. 100 % CO2-blown polyurethane-foam • Jacket-pipe of polyethylene LDPE 4. 66356 2.-Nr. Es gelten die allgemeinen Verkaufsbedingungen. french and italian. Kopieren verboten. Application CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems.4301. The pipe system CASAFLEX is designed for under. They are a result of comprehensive development and practical experience of the producer Brugg Pipe Systems and its suppliers. For further information please contact your local sales engineer.-Nr. Inhaltsverzeichnis / Content D:• Allgemeine Hinweise Seite E:• General instructions Seite • Dimensionen Seite • Transport. 130 °C and up to max. 16 bar permanent pressure. Pipe construction CASAFLEX • Service-pipe of nickel-chromium steel X5 CrNi 18/9. german. .17) Seite 1 2 3 3 4 5.12) Seite • Erstellung der Verbindung im Haus (Bild 13 .6 7 Art.

80 D: Transport.Subject to technical change - Rmin 100 80 D D 80 80 Rmin A Manteau Ø D mm 78 min mm 180 200 220 240 260 280 300 D1 A mm 210 230 250 270 290 310 330 600 mm 93 113 128 143 163 183 D1 D . reception and laying of pipes Alle Masse in mm Dimensions in mm 600 mm 30 80 600 mm . 66356 Seite: 3 von 7 Ausgabe: 06 / 1-07 DE Dimensionen/Dimensions Baureihe Range Zoll Inches (") Rohranschluss Pipe connector dxs mm Aussenrohr Outer pipe mm Inhalt Volume Liter/m Gewicht Weight kg/m Biegeradius Bending radius R min m DN 75/142 98/162 65 80 2½ 3 76.-Nr.70 1.6 88.50 1.Technische Änderungen vorbehalten .43 4.1 x 3.12 8.10 5. Empfang und Verlegung der Rohre E: Transport.0 142 162 5.PIPE2000 Ltd UK Distributor flexible solutions Montageanleitung CASAFLEX® 75/142 + 98/162 PN 16 Art.9 x 4.

60°C (surface shines) and cool it down in a fixed situation. 60°C wärmen (Oberfläche glänzt) und im eingespannten Zustand abkühlen. Laying (sketch) Cut fixing ribbons one after the other from outside to inside while unwinding the coil in the trench or adjacent. Laying and installation with low outer temparature (<5°C) Store coil. 3. Disassemble directional tool. . die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. wird keine Haftung übernommen. Direct pipe-end (sketch) Heat up outer jacket to approx. Kopieren verboten. indoor or warm up the outer jacket with a heating appliance and lay immediately. 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. 2. Verlegung (Skizze) Spannbänder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen.-Nr. Richtschiene vom Rohr lösen. Laying and installation of CASAFLEX pipes 1.PIPE2000 Ltd UK Distributor flexible solutions Montageanleitung CASAFLEX® 75/142 + 98/162 PN 16 Art.Subject to technical change - 3. if possible. Es gelten die allgemeinen Verkaufsbedingungen. 66356 Seite: 4 von 7 Ausgabe: 06 / 1-07 DE Verlegung und Montage von CASAFLEX-Rohren 1. Rohrende richten (Skizze) Aussenmantel auf ca. Rohrende wie oben beschrieben richten. Spannbänder fixing ribbons 2. Für Schäden und Betriebsstörungen. ca. 60 °C . Direct pipe-end as described above.Technische Änderungen vorbehalten .

folding role. 5 mm tief einstecken. E: Cut the service pipe square to its axis. E: Lay open the detector wires and pull them out. 4 4. spanner. marking pen. Ratsche. . D: Innenrohr auf Länge rechtwinklig absägen.2 D: Meldedern am Rohrende freilegen und herausziehen. Es gelten die allgemeinen Verkaufsbedingungen.Subject to technical change - D: Mantel entfernen. allen spanner*.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 200 mm D: Mantel vom Rohrende mit Säge durchtrennen und längs aufschneiden. 1 2 3 5 4 3 2 1 max. Für Schäden und Betriebsstörungen. 66356 Seite: 5 von 7 Ausgabe: 06 / 1-07 DE D: Verarbeiten des Rohres für Verbindungen. Markierungsstift.PIPE2000 Ltd UK Distributor flexible solutions Montageanleitung CASAFLEX® 75/142 + 98/162 PN 16 Art. Messer. 5 mm 5 D: Benötigte Werkzeuge Handsäge. Säge max. Edelstahlbürste. E: Separate with saw the jacket from the pipe end and open it longitudinally.1 5 6 Ø75-98: 100 mm 4. wird keine Haftung übernommen. gas burner. Kopieren verboten. . Feile (H2). Zange. E: Convert pipes for connections.Technische Änderungen vorbehalten . Zoll-stock. The saw deeps into foam max.-Nr. high grade steel brush. D: Einzelteile der Verbindung 1 Druckring 2 Stützring 3 Graphit . file (H2). E: Remove coat. knife. Brenner E: Requested tool Saw. Innensechs-kantschlüssel*. 5 mm. die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben. pliers.

PIPE2000 Ltd UK Distributor
flexible solutions

Montageanleitung CASAFLEX®
75/142 + 98/162 PN 16

Art.-Nr. 66356 Seite: 6 von 7 Ausgabe: 06 / 1-07 DE

D: Verarbeiten des Rohres für Verbindungen. E: Convert pipes for connections. 7 8
Ø 75: 70 mm Ø 98: 80 mm

9

1

2

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.

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.

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.

10

0.5 mm

11
11.1

12
0 mm
Öl

4
1
D: Anschlussstück (4) ohne Dichtring auf den Stützring aufschieben und gegendrücken. Druckring (1) bis 0.5 mm gegen Anschlussstück vorschrauben. 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.

11.2

3

- Technische Änderungen vorbehalten - Subject to technical change -

D: Schrauben ölen! Anschlussstück aufschieben, Schrauben anziehen bis Anschlussstück am Druckring anliegt. Gegen Verdrehen festhalten. E: LUBRICATE THE SCREWS! Tighten up the screws to the pressure ring. Hold it to avoid distort.

controlling ø75: 3 mm ø98: 8 mm

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.

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.

PIPE2000 Ltd UK Distributor
flexible solutions

Montageanleitung CASAFLEX®
75/142 + 98/162 PN 16

Art.-Nr. 66356 Seite: 7 von 7 Ausgabe: 06 / 1-07 DE

D: Erstellung der Verbindung im Haus E: Installation of a house connection 13 14 15

D: Mauerdichtring montieren. E: Mount the wall sealing ring.

D: Überflüssige Meldeader zurück schneiden. WIREM/BRANDES: rot + grün; Nordisches System: Cu-weiss + grün. E: Cut the remain detection conductor WIREM/BRANDES: red + green North System: Cu-white + green

D: Schrumpfschläuche über die 2 Adern ziehen; mit weicher Flamme schrumpfen (max. 510s). E: Push shirnk sleeves above 2 detector wires; shrink with small flame (max. 5-10s).

16

17

D: Überwachungsdose an Wand E: Monitoring socket on the wall

D: Überwachungsdose am Rohr E: Monitoring socket on the pipe

ca. 80

160

Festpunkt; siehe Text Fixing point; see text

- Technische Änderungen vorbehalten - Subject to technical change -

D: Schutzkappe montieren, Meldeadern herausziehen. E: Mount the protection caps, the detector wires push out.

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 absorbing the expansion of the continued pipe. That‘s why a fixing point clamp must be mounted.

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.

min. 250

PIPE2000 Ltd UK Distributor

CASAFLEX® - Fernwärmeleitung Montageanleitung DN65 - DN80
CFL - Anschlussverbindung PN 25

CFL

1
07.05

Montageanleitung / Installation instruction
CASAFLEX - Anschlussverbindung Typ PN25
DN 65 + DN 80

6 4 2 7 9 10 11 8

5 3

1

1 2 3 4 5 6 7 8 9 10 11
- Technische Änderungen vorbehalten - Subject to technical change -

Stützring Graphitdichtring Anschlussstück Druckring Innen-Sechskantschraube Meldeadern Schutzkappe und Aderherausführung CASAFLEX-Leitung Klammersegmente Streckgitter Schrumpfmanschette

1 2 3 4 5 6 7 8 9 10 11

back-up ring graphite sealing ring connection piece pressure ring hexagonal socket head screw monitor leads protective cap and monitor lead exit CASAFLEX pipe clamping ring rib mesh shrink sleeve

Bei der Anschlussverbindung Typ PN 25 wird das Streckgitter über eine Blechkappe mit einbezogen; dies erhöht die mechanische Stabilität, was bei Betriebsdrücken oberhalb von 16 bar notwendig ist. Die Anschlussverbindungen sind für Heizwasserleitungen bestimmt.

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.

PIPE2000 Ltd UK Distributor

CASAFLEX® - Fernwärmeleitung Montageanleitung DN65 - DN80
CFL - Anschlussverbindung PN 25

CFL

2
07.05

1

Anschlussverbindung The connector assemply
Schelle Clip collar Klammersegmente Clamp segments Blechkappe Metal cap Schrauben Screws

Druckring Pressure ring

Stützring Back-up ring

Graphit - Dichtring Graphite sealing ring

Anschlussstück Connector

2

Montage - Werkzeug Tools for installation
Persönliche Schutzausrüstung: Schutzhandschuhe Achtung: Unfallverhütungsvorschriften beachten! Personal protective clothing: protective gloves Attention! Be careful to observe all safety regulations
- Technische Änderungen vorbehalten - Subject to technical change -

Handsäge Handsaw Markierungsstift Marker Zollstock / Ruler Messer / Knife Edelstahl - Drahtbürste Stainless steel wire brush Halbrund - Feile (Hieb 2) Half-round file (No. 2) Zange Pliers

Innensechskantschlüssel Hexagonal socket head screwdriver Ratsche Ratchet

PIPE2000 Ltd UK Distributor

CASAFLEX® - Fernwärmeleitung Montageanleitung DN65 - DN80
CFL - Anschlussverbindung PN 25

CFL

3
07.05

3

4

A
Achtung: Blechkappe über das Rohr ziehen. Absetzmaß auf PE-Mantel am Umfang markieren. A=100mm Attention: Pull the metal protective on the pipe. Mark the length to be stripped off on the circumference of the PE jacket. A=100mm PE-Mantel mit Messer in Umfangsrichtung und in Längsrichtung aufschneiden. Cut open the jacket using the knife around the circumference and lengthwise.

5

6

- Technische Änderungen vorbehalten - Subject to technical change -

B
PE-Mantel abschälen. Achtung: Blechkappe Peel off the PE jacket. Streckgitter mit Handsäge am Umfang durchsägen. B = 80mm Saw through the rib mesh on the circumference with the handsaw. B = 80mm

PIPE2000 Ltd UK Distributor

CASAFLEX® - Fernwärmeleitung Montageanleitung DN65 - DN80
CFL - Anschlussverbindung PN 25

CFL

4
07.05

7

8

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!

Streckgitter mit Blechschere 4 mal am Umfang in Achsrichtung einschneiden, nach hinten wegklappen. Schaum vom Innenrohr entfernen, das freigelegte Innenrohr mit Drahtbürste metallisch blank bürsten! Cut into the rib mesh in 4 places on the circumference 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!

9

10

Druckring bis gegen den Schaum aufschrauben, Sägering gegen den Druckring schrauben. Screw the pressure ring up against the foam, Screw the saw collar up against the pressure ring.

Innenrohr am Sägering entlang absägen. Saw off the inner pipe along the line of the saw collar.

- Technische Änderungen vorbehalten - Subject to technical change -

Place the connector over the assembly. 14 13 . The end of the screw thread must form a close fit with the end of the corrugated pipe. Push the graphite sealing ring over the backup ring. Remove the saw collar. smooth off any ridges in the saw cut with the file. Stützring in das Innenrohr einschrauben. Gewindeende muß mit dem Wellrohrende abschließen.DN80 CFL .Technische Änderungen vorbehalten .05 11 12 Sägering entfernen.Anschlussverbindung PN 25 CFL 5 07. Sägeschnitt mit Feile entgraten. .Subject to technical change - Graphit-Dichtring auf den Stützring aufschieben. Screw the back-up ring into the inner pipe. Anschlussstück aufsetzen.PIPE2000 Ltd UK Distributor CASAFLEX® .Fernwärmeleitung Montageanleitung DN65 .

Anschlussverbindung PN 25 CFL 6 07.DN80 CFL .Technische Änderungen vorbehalten .PIPE2000 Ltd UK Distributor CASAFLEX® . Streckgitter um den Druckring umformen. Mould the rib mesh around the pressure ring. Druckring und Anschlussstück müssen auf Block liegen. 17 18 Blechhaube vorziehen. Mit Klammersegmenten die Blechhaube gegen den Druckring fixieren. The pressure ring and the connector must be in alignment. . dabei Überwachungsadern durch die Gewindehülse herausführen.Subject to technical change - . taking care to lead out the monitor leads through the thread socket. Secure the metal sheath with the clamp segments against the pressure ring. Pull the metal protective sheath forwards.05 15 16 Schrauben einsetzen und schrittweise im Uhrzeigersinn festziehen.Fernwärmeleitung Montageanleitung DN65 . Put in the screws and tighten them gradually clockwise.

DN80 CFL . Überwachungsadern mit Siliconkabel verbinden.Fernwärmeleitung Montageanleitung DN65 . Connect the monitor leads with the silicon cable.05 19 20 Schelle aufsetzen und festschrauben. .PIPE2000 Ltd UK Distributor CASAFLEX® .Anschlussverbindung PN 25 CFL 7 07.Subject to technical change - .Technische Änderungen vorbehalten . Slip the clip collar over the assembly and screw it tight.

PIPE2000 Ltd UK Distributor CASAFLEX . 1 6 11 5 Fig.0 Introduktion 114.Subject to technical change - 1 2 3 4 5 6 7 8 9 10 11 12 13 in t e r n a l b a c k in g s le e v e g r a p h it e p a c k in g c o n n e c t io n p ie c e t h r u s t c o lla r c y lin d r ic a l s c r e w .311. M 1 2 x 5 0 O .5 3 Fig. M 1 2 x 7 0 8 3 2 4  Do not begin work until you have read the installation instruktions carefully.6 page 1 25.02.3 x 4. 2 13 .03 1. 1 5 2 4 1 7 6 8 12 9 .r in g sc re w p r o t e c t iv e c a p s h r in k s le e v e d e t e c t io n c o n d u c t o r s c o n n e c t o r f o r m o n it o r in g w ir e s C A S A F L E X p ip e p r e in s t a lla t io n s c r e w .District heating pipe Installation instructions DN 100 11 10 CFL 5.

ratchet 6. gloves 2. 3 5 6 7 8 9 10 11 Fig.Subject to technical change - Aligning the pipe ends Straighten out a length of approx. Fig. using a bending device if necessary. hexagonal tool 5. 4 Make a mark at a length of 120 mm on the casing pipe.g. saw 10.02. on an assembly stand). Always use pipe clamping jaws when fixing the pipe in the vice.District heating pipe Installation instructions DN 100 2. 1.1 Preparing the pipe end tools 1 2 3 4 Fig. knife 9. 5 Make a mark around the casing pipe using the protection cap as a guide. .0 2. yardstick 2. clamp 110 x 30 3.6 page 2 25. Fix the piping securely in place before fitting the connector assembly (e. stainless steel brush 7.2 .PIPE2000 Ltd UK Distributor CASAFLEX . 1 m of the pipe.2 Stripping off the PE jacket CFL 5.311. file 8. wrench 4.03 2. marker 11.

8 Remove the casing pipe. . 6 Cut radially using the saw. 10 Bend the monitoring wires backwards. Fig. 9 Remove the foam using the knife.03 Fig.02.311. Warning: take care of the monitoring wires! Fig.District heating pipe Installation instructions DN 100 CFL 5.Subject to technical change - Fig. Fig.PIPE2000 Ltd UK Distributor CASAFLEX .6 page 3 25. . 7 Cut the casing pipe longitudinally using the knife.

12 Fit the clamp at that mark and check the distance 3 times around the pipe.Subject to technical change - Fig. Fig. 13 Saw through the corrugated pipe using the face of the clamp as a guide.6 page 4 25.03 Fig.02. .PIPE2000 Ltd UK Distributor CASAFLEX . .311. 11 Make a mark on the corrugated pipe 90mm far from the end of casing pipe. 14 and 15 Insert a cloth and remove ridges from the pipe end inside and outside.District heating pipe Installation instructions DN 100 CFL 5. Fig.

19 .District heating pipe Installation instructions DN 100 3.0 Fitting the connector CFL 5. 16 Clean the outer surface using a stainless steel brush: Fig. 18 Screw the internal backing sleeve (1) up to 2/3 of its length into the corrugated pipe.311. 17 Remove the cloth and all shavings. .02.6 page 5 25.PIPE2000 Ltd UK Distributor CASAFLEX . Fig. Fig.Subject to technical change - Screw the thrust collar (4) against the end of the corrugated pipe.03 Fig.

Use oil to grease all screws! .5-2mm. oil . 20 Push the connecting piece (4) right up against the internal backing sleeve.District heating pipe Installation instructions DN 100 CFL 5.6 page 6 25. 22 Push the connection piece (3) right up against the thrust collar using the preinstallation screws (13).311. The connecting piece (4) and the thrust collar (1) must be screwed together face to face until seated snugly against each other. Fig. 21 Pull out the connection piece (3) and push the graphite packing (2) in its whole length inside the gap between the internal backing sleeve and the thrust collar.PIPE2000 Ltd UK Distributor CASAFLEX . Replace all preinstallation screws (13) with cylindrical screws. Fig. 23 Tighten the preinstallation screws (13) until the cylindrical screws can be used. You can screw the internal backing sleeve in or out until you reach this setting. The distance between the connecting piece (4) and the thrust collar must be 1.02.Subject to technical change - Fig. Tighten all cylindrcal screws clockwise.03 1.5-2mm Fig.

03 Fig. Screw the connector for monitoring wires (11). . 24 If required: fit the O-ring (6) . 25 Push the connecting cable through its bore and connect it with the monitoring wires. Fig. If required: fit shrinking sleeve half to half on casing pipe and protective cap.PIPE2000 Ltd UK Distributor CASAFLEX . Note seperate installation instruction. Fit the protective cap with a strong push til the beveled edge of the thrust collar.6 page 7 25. Grease the O-ring (6) .02. 26 0 mm Fig.District heating pipe Installation instructions DN 100 CFL 5.311.Subject to technical change - Fig. Note seperate installation instruction . 27 Fix the protective cap with its screws (7) .

Subject to technical change - .03 Wall sealing ring Da D 50 mm Data table CASAFLEX Type 22/76 22/91 PLUS 30/91 30/111 PLUS 39/111 39/126 PLUS 48/111 48/111 PLUS 60/126 60/142 PLUS 75/142 75/162 PLUS 98/162 127/182 Protective sheath ¬ D mm 78 93 93 113 113 128 113 128 128 144 144 164 164 183 ¬ Da mm 118 133 133 153 153 168 153 168 168 183 183 203 203 218 .PIPE2000 Ltd UK Distributor CASAFLEX .02.315 26.District heating pipe Wall sealing ring CFL 5.

depth=depth of saw blade. Markierung am Mantelrohrende = 50mm Marking at casing pipe end = 50mm 50mm 3.05 2 4 1 6 1. 6-cone plate (marking "B") .Technische Änderungen vorbehalten - Saw casingpipe along marking.PIPE2000 Ltd UK Distributor CASAFLEX .560. 4-connection end. 5-Grapitdichtring. 2-Druckring . Mantel entlang der Markierung einsägen. Mantelrohr mit Messer axial einschneiden. . 6-Konusplatte (Markierung "B"). 3-Stützring. 5-graphite packing ring.Fernwärmeleitung DUO Anschlußverbindung Montageanleitung Art.69727 CFL 5.02. Sägetiefe = Sägeblatthöhe. 7-allen bolts In addition: end cap.Nr. Überwachungsader-Set 3 7 Parts: 1-pressure plate (marking "A"). 2-pressure ring . connection set for monitoring wires 5 2. ACHTUNG: Innenrohre und Überwachungsadern nicht beschädigen! . Bauteile: 1-Druckplatte (Markierung "A"). 7-Innensechskantschrauben Zusätzlich: Endkappe.1 24. Attention: do not damage service-pipes or monitoring wires! 4. Cut casingpipe axial with knife. 3-core piece. 4-Anschlußstück.

Fernwärmeleitung DUO Anschlußverbindung Montageanleitung 5.02. 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 CFL 5.05 6. Innenrohre mit Edelstahldrahtbürste sorgfältig metallisch blank 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 verdrilltem Schleifleinen sorgfältig metallisch blank reinigen Clean the outer surface of the servicepipes between the pipes using a drilled abrasive paper .PIPE2000 Ltd UK Distributor CASAFLEX .560.Technische Änderungen vorbehalten - 8. Sägeschnitt mit Feile entgraten Remove burrs from pipe end inside and outside using a halfround file .2 24.

The thread must end flush with the inner pipe.5 mm verbleibt. The distance between the connecting end and the pressure ring must be approx.5mm 12. die Druckringe werden soweit verdreht. daß zwischen Anschlußstück und Druckring ein Spalt von 0. die Stützringe(3) in die Innenrohre einschrauben.PIPE2000 Ltd UK Distributor CASAFLEX . Anschlußstücke(4) über die Stützringe schieben.02. The wards have to point to the pipe end. 0.5mm. Screw the pressure ring in or out until you reach this setting. dabei die Rohre mit dem Holzkeil spreizen Die Aussparungen müssen zum Rohrende weisen. Druckringe(2) auf die Innenrohre aufschrauben. Der zylindrische Ansatz muß mit dem Wellrohrende abschließen. . 10. the greater diameter points towards the pressure plate 11.Fernwärmeleitung DUO Anschlußverbindung Montageanleitung CFL 5. die Druckplatte(1) über die Innenrohre schieben.3 24. 0.05 9. Pull pressure plate(1) over the servicepipes using the wooden wedge as a spread.560. . der größere Durchmesser zeigt zur Druckplatte Screw the pressure rings(2) up to the service pipes. Push the connecting end(4) right up against the core piece.Technische Änderungen vorbehalten - Screw the core piece(3) into the servicepipe up to the end of the thread.

Anschlußstücke wieder abnehmen.560. Konusplatte(6) über die Anschlußstücke schieben.Technische Änderungen vorbehalten - 16. The core piece and the pressure ring must not be rotated doing this.Fernwärmeleitung DUO Anschlußverbindung Montageanleitung CFL 5. Anschlußstücke wieder aufsetzen Refit the connecting ends .05 13.PIPE2000 Ltd UK Distributor CASAFLEX . Grapitringe(5) auf die Rohrenden aufschieben Place the graphite packing ring(5) onto the pipe end 15. der größere Durchmesser zeigt dabei zum Rohr. Remove connecting ends and push the pressure rings into the wards of the pressure plate. Druckringe und Stützringe hierbei nicht mehr verdrehen. 14.4 24. Push the cone plate(6) over the connecting ends. Die Druckringe in die Aussparungen der Preßplatte drükken. the greater diameter has to point towards the pipe .02.

half round file.Schrauben(7) einsetzen und schrittweise umlaufend festziehen. Markierungsstift. Edelstahldrahtbürste. knife. Schrauben mit säurefreiem Öl schmieren! Fit the allen head bolts(7) and tighten them gradually in a clockwise pattern.560. Fertig! Ready! . allen key.Technische Änderungen vorbehalten - 20. Messer.PIPE2000 Ltd UK Distributor CASAFLEX . pliers.5mm 19. Insert the bolts with a non acid based grease! OIL 18. ratchet Special tools: wooden wedge. Falls erforderlich: Überwachungsadern verbinden Endkappe aufsetzen und mit Schlauchschellen befestigen If required: Connect monitoring wires Fit end cap and fix it with clamps 0. Zange. yardstick. Druckplatte und Konusplatte müssen auf Block liegen. Ratsche Sonderwerkzeug: Holzkeil. Halbrundfeile (Hieb 2). Zollstock.05 0mm 17.02. Schleifleinen K 180 ( im Lieferumfang) Persönliche Schutzausrüstung: Schutzhandschuhe Tools: saw. abrasive paper K 180 (delivered) For safety: gloves . Innensechskantschlüssel. Werkzeug: Handsäge.5 24. marker.Fernwärmeleitung DUO Anschlußverbindung Montageanleitung CFL 5. stainless steel brush.

PIPE2000 Ltd-For Information District Heating Control Table of contents WIREM 10. page 2 Fault handling procedure Electrical circuit.210 Design and reference charts Design and reference charts Welding plans 10.co. wiring diagram Option: Remote control transmission CH .0 10.3 10.uk 10.110 10.330 10. technical data Unit description.340 Control unit U89A Unit description.200 10.320 10.10.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.100 10.120 Table of contents General system description System description Functional description Measuring description 10.1 10.310 10.0 15.300 10.2 10.

a great number of functions. • Alarms. as well as data transmission to other computers and printers.g. together with the monitoring equipment. a breakage or damages anywhere in the circuit can be detected and identified. testing over dialog and storing of results. The WIREM® technology with its feeler wires and control equipment makes many functions possible: • Check of the humidity in the thermal insulation starting at the production stage. FERWAG®pipe and CASAFLEX® -district heating pipe of BRUGG Pipe Systems are equipped ex-works with the Reference Resistance Measurement system (WIREM® ). loose sleeve or external damage can be detected. can produce an alarm in case of entry of water.uk The piping for district heating laid out underground. Other monitoring systems can be supplied if specified. • 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. The systems FLEXWELL® -cable.100 15. measuring and locating units can be built up at will depending on conditions of volume of data required and network size. • An entry of humidity through e. is nowadays mostly equipped with control equipment. state of contacts and other data can be registered and transmitted to other systems.co. Feeler wires melted into the thermal insulation in the factory perform. The BRUGG STEEL PROTECTION PIPE is available as an option. • Detection and identification of the feeler conductor making contact with the inner pipe.PIPE2000 Ltd-For Information District Heating Control General system description WIREM 10. a faulty welding seam. The safety of the installation is improved and the costs of repairs reduced.10. measurands. The range of units extends from the manual instruments to measure the condition of the insulating material and manual fault location (unit U 89A) to fully automatic monitoring and fault location. The network of monitoring. WIREM ® and BRANDES are compatible systems. monitored located and reported during operation. to monitor its operation. Supply of data on the state of the insulation. CH .2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. The advantage of this lies in the early detection and quick location of damages.

The perforations allow an accurate evaluation of the wet spots regarding their intensity in the whole monitored spectrum. NiCr conductor inner pipe and about half way through the insulation. an FEP isolated. i. This permits monitoring over the entire length of the feeler wire. from „dry“ with over 50M to „wet“ with under 10K insulation resistance. CH .2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. coloured red 3. copper return wire is laid out parallel to the feeler wire. Principle of monitoring Feeler wire (red) Layout of the feeler loop Feeler wire (red) Return wire (green) S Loop Return wire (green) Pipe center line I Insulation Monitoring unit Feeler loop with branch-off The reference resistance determines the tolerance threshold and is adjustable. a voltage rise will be registered in the monitoring instrument and an alarm will be released. Monitoring of the thermal insulation is performed by a special feeler wire (see figure). Should the isolation resistance diminish. on eiter side of the Structure of the feeler conductor 1. Copper core 2. which can attain 1000 m in length and therefore is able to monitor 1000 m of piping. PTFE-Insulation. Both wires form a feeler loop (see figures).co. and the pipe (see figure). which is that of the unloaded resistance bridge principle. return wire back (see figure). FEP-Insulation. they are wound around the inner pipe and run close to each other. A contact between the naked NiCr wire and wet spots occurs in perforations along the PTFE sleeve.e. Gaps in insulation at regular intervals for wet contact detection 2. while in the flexible system FLEXWELL ® -cable. In the FERWAG ® . Branches of piping are also followed by branches in feeler wires. Large pipe networks of several kilometers in length are divided into monitoring sections of under 1000 meters.uk Position of the feeler cables The monitoring cables (feeler wire and return wire) are embendded in the insulating material between the inner and outer pipes. A defined voltage is applied between the feeler wire.and CASAFLEX ®. is the resistance reference method (WIREM ®).pipe they run parallel. 2 3 1 2 1 Structure of the return wire 1. feeler wire out. coloured green Principle of monitoring The physical principle for monitoring. by a thermally stable PTFE sleeving.10. as will happen when a wet spot occurs.110 15.PIPE2000 Ltd-For Information District Heating Control Functional aspects WIREM 10. as well as for fault location. embedded in the thermal insulation. For the monitoring itself. A monitoring unit is installed at each section. The wire itself is protected against direct contacts to metal.

2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. The usual method used in such cases is the time delay measurement.PIPE2000 Ltd-For Information District Heating Control Determining the fault location WIREM 10. Determining the fault location 100 % Fault location unit x% Wet spot Feeler wire (red) U U1 Return wire (green) CH . a voltage U is applied across the loop. is measured between the inner pipe and the feeler cable. as it is balanced out in the measurement concept.uk Determining the fault location To locate the wet spot or contact fault. the following relationship results: Locating a break in the feeler loop or in the monitoring circuit A breakage in the feeler loop will be immediately detected in automatic installations. strict quality control and measurement checks during production are applied in general . Since the feeler wire has a relatively high resistance of 5. U1 U = R1 R = x% 100% = L1 L U U1 R R1 x% L L1 = Applied voltage = Measured voltage = Total loop resistance = Part loop resistance = Part result = Total pipe length = Distance to fault The gravity of the insulation fault (insulation resistance) has no influence on the precision of location. a part voltage U1 caused by the wet spot.co.120 15. A capacitance measurement can also be used. but the location of the break has to be performed manually by other means. The result is expressed not in Volt but in % of the applied voltage. To avoid subsequent faults and gaps in the feeler loop.7 /m and the return wire near zero . the solidity of all wire connections. At the end of the feeler loop. among others. They target.10.

200 15.8 mm Length 9m : armoured wire Wiring by an electrician Block 3 Monitoring terminals T-pieces (downward) Wiring between the terminals Brugg in the building.5 mm2.7 /m Forward 2219 Return 2220 Insulation resistance (IR) Grade BS-MH-2 Forward 0 = >50 M Return 0 = >50 M CH . All units can be placed centrally in one building. done by an electrician Block 4 T-pieces (downward) Block 2 Results of measurements Resistance / length (DR) R = 5. The whole installation is then divided into separate loops with a maximal length of 1000 to 1200 m per unit.10.co. For future expansion of the network. it is good practice to insert some spare cables beside the pipes.PIPE2000 Ltd-For Information District Heating Control Design and Reference Drawings WIREM 10. or U 72 0. Reference drawings (Wiring diagrams) Control units Feeler Return 1 2 U89A 1 3 1 2 U89A 2 3 Heating Plant Block 1 The monitoring system BRANDES CrNi wire (red) Cu wire (green) TT 1.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.uk Design The design of the control circuit is done parallel to the design of the piping.

0 12.0 6. 0.65 FER 88.0 7.9-180 Bg 61 .65 0.6 6. L Elbow [m] 6m 6m 12 m 0. 0.95x1.PIPE2000 Ltd-For Information District Heating Control Reference Drawings Welding plans Reference Drawing Welding plan View A WIREM 10.0 3. 0.0 (downward) 4.57 1. 0.65x0.56x0.3 1. 1.0 6.3-140 FER 76.65 1.56 0.3 R7 -14 0 6.0 12.81 0.0 5.74 12. 0.84 4.50x0.210 15.95 1.65x0. Welding plans have proved to be the best reference.65x0.uk Reference Drawings To find the exact location of the fault above earth.0 5.50 Bg 90 .0 1.0 1.0 6.0 6.23 6.50 x0 k3 12.9 Bg 86 .65x0.92 12.5 0. 0.65x0.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.5 .50 Block 4 x0 .0 12. the easier and quicker the spot can be found.65 5.9 Bg 61 .50x0.6 5.0 5.8 Bg 90 .0 6.0 12.65x0.92 . DN 32 1.65 Bg 90 .0 1. 0.65x0.0 6.0 1.65 6.65 12.0 5.92 1.65 Materials Pipe FER 60.0 6.6 6.65x0.0 12.1 -16 Bg 90 0 .50x0.0 4.8 5.52 12.0 6.0 4.55 Bg = Elbow Draining.0 6.0 6.84 6.65 1.0 Bg 85 . Heating Plant Block 1 0.9-180 Stand.82 12.0 5.0 Bg 90 .0 12.0 CH .0 Bg 90 .50 6.9 6. 0.0 12.5x0.0 Bg 76.05 Elbow 90 0.1-160 FER 88.0 4.65 1. it is very important to have access to reference drawings. 0.0 12.75 5.0 Bl oc Bg FER FE 60.0 T-pieces Blo ck 8.77 12.0 12.0 12.50 Bg 90 .0 6.65 6.45 2 8.05 A 0.0 Bg 90 .co. The more precise these are.0 1.0 6.95 6. 0 .0 Bg 90 12. 0 85 . 0.65x0.0 12.0 1.0 12.0 7.10.65x0.65 Venting Bg 86 0. 0.0 1.65 .65x0.65 6.

By connecting a level switch (e. A break in the detector lead or earth leakage (<5 kOhm) is signalled simultaneously. Surface mounting Button and 2 signal lamps are mounted on the instrument.co.g. EHS-JOLA 6M.10.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.uk Unit description Function The instrument monitors the electrical insulation resistance between the detector lead and pipe (earth). lamp or central alarm system is triggered. if there is a failure or earth leakage (shaft monitoring). At the same time the fault signal lamp lights up on the instrument or cabinet door as follows: Insulation moist Failure in monitoring loop Earth leakage.PIPE2000 Ltd-For Information District Heating Control Unit description U89A technical data WIREM 10.300 15. Lamps green : operating red : fault Brugg Ro hrsystem AG 5200 Brugg Fitting in switch cabinet For operation. Otto Fischer AG) between the direct lead return and pipe. an additional button and 2 signal lamps must be fitted in the cabinet door. The unit is suitable for fitting in a switch cabinet and for surface mounting. The earth leakage signalling can also be used as a shaft monitor. a horn. Fault If the electrical insulation resistance is exceeded (moist insulation). shaft monitoring with float switch CH .

As a result.10.2 mm Break through for clamp fastening to 35 mm standard bar DIN 46277. loop length 220 V 50 Hz  10 % 1. a check is made of all the electronics.co. we recommend that you implement a monthly operating check. Clamp in instrument. 107 75 View A CH .5 mm2 IP 40 -10 to +50 C 0 to 10 kOhm (0 .310 15. 30 V DC 5 A (direct current) 6 paracril cable sleeves mounted on sides 2 break-through apertures in casing bottom Connection screws with terminal plates.uk Alarm output for external fault display The instrument has an alarm output to supply a horn.1200 m) Casing dimensions 150 A Break through for wall fastening ø 4. max.2 mm. Acknowledgement By pressing the double function button (instrument test + acknowledgment button). During the test. the alarm output is switched off. During this. 2 x 1.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.PIPE2000 Ltd-For Information District Heating Control Unit description U89A WIREM 10. a lamp or a central alarm system. However. The fault lamp remains alight until the fault has been remedied. Technical data • Supply voltage • Voltage tolerance • Power consumption • Output • Breaking capacity • Cable inlet • • • • Connection type Protection system Ambient temperature Max. By pressing the button a fault is simulated.5 VA High-tension current contact max. the fault lamp must be alight. the alarm output can be blocked or connected through by means of the switch fitted on the printed circuit board. Instrument test The instrument is maintenance-free. 250 V AC 5 A (alternating current) max. The switch should be set to the required position during installation. Break through for wall fastening ø 4.

co. Fault lamp (red) alight a) continuously b) flashes c) flashes intermittently • 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 ) Possible cause • no mains voltage • 50 mA fuse on pc board defective Equipment test without pipe system Procedure 1.320 15.uk Procedure in the event of a fault Caution Before opening the instrument. CH . connecting lines). Connect terminal 1 + 2 3. switch off the main switch Possible fault causes Fault 1. Green lamp not alight 2. 2 + 5 Fault lamp display must flash must go out must be alight must flash intermittently If all 4 states are OK. Press button (instrument test) 4. Connect terminals 1. Remove terminal 1 + 2 2. then the cause should be sought in the pipe system (sockets.PIPE2000 Ltd-For Information District Heating Control Fault handling procedure WIREM 10.10.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. Loop.

2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.JOLA 6 M Otto Fischer AG Wiring for branched network.uk Caution: Before opening the instrument. in special cases connect to pipe.Line A Cr Ni (red or brown) Cu (green or blue) B FW .B no connection terminal 3 Weak current Breaking capacity maximum 250 V AC 5A.PIPE2000 Ltd-For Information District Heating Control Electrical circuit.5 mm 2 .Line Cr Ni (red or brown) Assembly limit BRUGG TT 1. 12 V Terminal 3 potential free With direct connection terminals A .Line DH .5 VA 50 mA 16 * e.Line Cabinet C DH .330 15.Line Cr Ni (red or brown) Assembly limit BRUGG TT 1.8 mm Length 9 m: armoured wire Wiring by electrician 4 5 6 7 8 9 10 11 12 13 14 15 N P red green Acknowledge instrument test Supply for fault external horn. 30 V DC 5A Contact load 250 V AC / 5 A Monitoring socket 1 2 3 Cu (green or blue) A DH . Not applicable for surface mounting Terminals on pc board Switch blocked free Alarm output for "Fault external" in instrument test Weak current max. wiring diagram WIREM 10. switch off main switch. example only Wiring principle: Always probe loop Wiring between the sockets by an electrician (by the owner) BRUGG C DH . lamp. collective alarm fault insulation moist break loop short circuit shaft Supply for display PC board connectors • operating Be sure to connect earth.5 mm 2 or U 72 0.8 mm .g. Length 9 m: armoured wire Assembly limit BRUGG Wiring by electrician CH .Leitung DH . or U 72 0.Leitung Cu (green or blue) C Assembly limit BRUGG DH .Line Monitoring socket 1 2 3 Terminals FW .Line C Connection pipe • terminal C or 1 Shaft monitoring with float switch * Fault Cabinet external Cr Ni (red or brown) Cu (green or blue) B DH .co. level regulator EHS . Mains 220 V 1.10.

uk Version for remote control transmission e. The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission.g. In this case.340 15.10.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. "Ridat Rittmeyer" The U 89 instrument is also suitable for computer controlled remote transmission. and also "Fault external" (terminals 6 to 8) remain unchanged.PIPE2000 Ltd-For Information District Heating Control Option: Remote control transmission WIREM 10. CH . These outputs are wired as followed by a change on the PC board. there is no need for wiring the cabinet door. Terminals 9 to 13 Logical states 13 R1 Everything OK R2 I 12 R1 Insulation moist I 0 0 11 Earth leakage in shaft monitoring with level switch Detector lead has short circuit to earth 1 0 10 R2 Break in loop 0 I 9 The functions of the network and fault lamp on the instrument.co.

uk www.uk . Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.co.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.pipe2000.

co.TECHNICAL INFORMATION SHEETS P RE .uk www.pipe2000. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk .INSULATED P IPES COPPERFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.

7.0 9. design engineering Pipe routing Pipelaying instructions.PIPE2000 Ltd UK Distributor Copper Heating Piping Table of contents CCO 9. part 1 Pipelaying instructions.365 9.3 9. part 2 Copper heating piping for local networks Structure.345 9.100 9. assembly Trench dimensions Pipe entry into buildings .co.201 9.500 9. weights and supplied lengths 9.0 4. dimensions.2 9.370 Components Joint sleeve / Fitting the T-piece Insulating material Soldered fittings / soldering instructions Connection of copper heating pipe to KMR End cap Wall sealing ring / Pipe warning tape 9.340 9.355 9. part 3 Pressure losses Heat losses 9.1 9.5 9.220 Planning.320 9.203 9.210 9. materials. part 2 Pipelaying instructions.200 9.202 9.105 9.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.505 Underground construction work.uk 9.115 Table of contents System description System description part 1 System description.

Another feature: only a very short time is required to lay the pipe.uk 1. The heat insulation consists of a flexible CFCfree hard polyurethane foam with outstanding heat insulation characteristics. By and large.thanks to the reduced outlay on coordination at the site. All of these benefits mean that CCO Heating Piping for Local Networks is not only a technically perfect solution.co. 2. General CCO Copper Heating Piping for Local Networks is a flexible pipe system suitable for temperatures of up to 120 °C.7.PIPE2000 Ltd UK Distributor Copper Heating Piping System Description Part 1 CCO 9. Pipes can cross above or below existing supply lines.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. The flexibility of the CCO Heating Piping for Local Networks means that it can be adapted to virtually any pipe conditions with no problems.100 4. 120 °C and max 16 bar operating pressure CCO Heating Piping for Local Networks can be supplied with one or two inner pipes. and obstacles can be easily bypassed. CCO Copper Heating Piping for Local Networks has a medium pipe made of copper. This is particularly true of DUO lines. Range of application Heating: max. but also that it offers the key to saving time and costs when constructing local heating networks . . Manual processing of this piping is very easy. CCO Heating Piping for Local Networks is supplied to the site as one piece in the desired length. and the fast and simple installation procedure. the pipe can be laid in the ground without any connection points so that the pipe trenches can be considerably narrower. This piping is intended for use in small and medium-sized local heating networks. CCO Heating Piping for Local Networks makes it possible to choose the shortest pipe route. in rings. making substantial savings possible on the underground construction work. without taking classical pipe construction methods into consideration.

Heat insulation Material: PUR insulation Density Heat conductivity Closed cells Water absorption after 24 hours CFC-free. extruded seamless Protection against mechanical effects and moisture Reference temperature °C – – – Value 928-938 kg/m3 0.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 140 220 to 270 40 to 70 125‘000 16. deoxidised with phosphorus SF-Cu F22 to DIN17671 Meets the requirements specified by EN 1057 (mechanical values in the delivered state) Reference temperature °C Examination norm kg/dm3 N/mm 2 2 N/mm N/mm 1/K 2 Characteristics: Cu medium pipe Density Elongation limit Ultimate tensile strength Hardness Modulus of elasticity Linear expansion coefficient Value 8. Protective casing Material: Purpose: Polyethylene of low density.105 4.7. 100% CO2-driven polyurethane foam (PUR) Reference temperature °C – 50 – – Value > 60 ≤ 0.uk 3. Medium pipe Material: Soft copper.93 max. PE-LD.43 W/mK 105-110 °C Examination norm DIN 53479 DIN 52612 – PE-LD protective casing Density Heat conductivity Crystallite melting range .032 ≥ 90 < 10 kg/m W/mK % % 3 Examination norm DIN 53420 DIN 52612 – EN 253 5.co.PIPE2000 Ltd UK Distributor Copper Heating Piping System Description Part 2 CCO 9. R220 to EN1057 Oxygen-free copper.6 · 10 E-6 DIN 17671 DIN 17671 DIN 17671 - 4.

Bending Carrier pipe Cu sheath radius dxs D x s1min.co.03 280 300 200 200 130 130 .31 0.uk UNO DUO 1 2 3 4 Pos 1 2 3 4 Material Medium pipe in soft copper.0 22 x 1.0 18 x 1.0 15 x 1. R220.31 1 x 0.51 0.8 75 x 2. UNO and DUO CCO 9.51 1 x 0.0 28 x 1.27 1.8 – 2 x 0.0 18 x 1.0 90 x 2.7 0. UNO Type 15/63 15/75 18/63 18/75 22/63 22/75 28/75 35/90 DN 10 10 15 15 20 20 25 32 Protective Min.83 0.8 75 x 2.20 1 x 0.27 280 280 300 300 200 200 130 On request Ring dimensions: Ø 2800 x 800 mm (width) / pipe length without interrelated fittings CCO. mm m mm Capacity carrier pipe l/m Weight kg/m max.13 2 x 0.7 0.93 1.20 0.5 63 x 1. Protection against mechanical effects and moisture.7 0.51 1 x 0.0 75 x 2.7 0.13 1 x 0.01 1.032 W/mK at 50 °C average temperature PE-LD film Outer casing in black PE-LD polyethylene (VDE 0209). Bending sheath dxs radius D x s1min.2 – 0.12 1.115 4. DUO Type 15+15/90 18+18/90 22+15/90 22+22/90 28+15/90 28+22/90 DN 10 15 20 10 20 25 10 25 20 Protective Carrier pipe Cu Min.0 22 x 1.0 28 x 1. CFC-free polyurethane foam.8 0.2 90 x 2.0 22 x 1.2 35 x 1. mm m mm Capacity carrier pipe l/m Weight kg/m max.35 1.8 – 0.2 22 x 1.2 – 90 x 2.8 75 x 2. SF-Cu F22 to DIN 1787/17671/1754 Flexible.8 – 0.2 90 x 2.57 2.72 1.13 2 x 0.8 0.0 15 x 1.0 22 x 1.20 0. 16 bar.7 0. extruded seamless.2 28 x 1. Delivery length Ring without connections m 15 x 1.8 0.0 90 x 2. to EN1057.13 0.13 0.0 63 x 1.50 1.0 63 x 1.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.51 1. Delivery length Ring without connections m 15 x 1.31 1 x 0. resistant up to 130 °C Thermal conduction coefficient λ = 0.92 2.17 1.PIPE2000 Ltd UK Distributor Copper Heating Piping Local heating and house connection piping Heating. CCO.2 0.7.8 0.31 0.0 18 x 1.2 – 90 x 2.7 0.7 0.2 90 x 2.31 1. 120 °C.09 1.2 15 x 1.

202 and 9.200 4.203 Copper local heating pipe Looping-in method A Copper-copper connection B D C A C D B E Note expansion pad as shown on catalogue pages CCO 9.201.PIPE2000 Ltd UK Distributor Copper Heating Piping Examples of pipe routing CCO 9. 9.201.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.201.203 Note expansion pad as shown on catalogue pages CCO 9. 9. 9.202 and 9.7.202 and 9.203 .uk Connection: copper local heating pipe plastic casing pipe Copper local heating pipe B Copper local heating pipe A C Note expansion pad as shown on catalogue pages CCO 9.

This also includes rolling apart and rolling together.co. The soldering instructions / manufacturer's instructions for the soldered connections must be followed without fail. The shape of the copper piping should not be bent more than three times.201 4.7.PIPE2000 Ltd UK Distributor Copper Heating Piping Pipelaying instructions Part 1 CCO 9. amplitude: 10 x outer diameter of copper local heating pipe).2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.10 m . ≤ 10 m Copper local heating pipe Examples of pipe routes Bild 3 Expansion pad for sinusoidal curves Copper local heating pipe B <5m > 10 m Expansion pad for sinusoidal curves Copper local heating pipe Bild 3 B Bild 3 Copper local heating pipe B Expansion pad for sinusoidal curves 5 . Expansion pad Expansion pad for sinusoidal curves 10 x Ø outer casing Copper local heating pipe Bild 3 2m > 10 m B Special solder must be used to solder the pipes together (this must be resistant to galvanic or electrochemical corrosion).uk Pipelaying instructions If the lengths of pipe to be laid exceed 5 m. the copper junction pipes must first be bent into a sinusoidal shape (curve length: L = 2 m.

2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. The 3 illustrations shown below provide the basic rules: Expansion pad 40 ≤ ∆ l ≤ 60 mm Illustration 1 CCO or PLASTIC CASING PIPE 3m Illustration 3 Thickness of expansion pads: 40 mm Expansion pad ∆ l ≤ 20 mm 1m The expansion pads must be applied as far as the casing of the main pipe (i. The second and third layers of expansion pad are only applied at the sides (i.uk Pipe junctions from copper or steel Main pipes on copper Local heating pipes The copper local heating pipe can only accommodate forces and deformations from connected external pipes to a limited extent. The foregoing illustrations assume that junction sleeves are used.7. they are positioned on top).202 4. The first layer of expansion pad is positioned around the local copper heating pipe which branches off (the junction pipe). Expansion padding has to be applied to copper local heating junction pipes.PIPE2000 Ltd UK Distributor Copper Heating Piping Pipelaying instructions Part 2 CCO 9. they are placed adjacently). The number of expansion pads required depends on the movement of the main pipe.co.e. CCO or KMR Illustration 2 Expansion pad 20 ≤ ∆ l ≤ 40 mm 2m CCO oder KMR .e.

Expansion padding is required.203 4. Expansion padding is required. Expansion padding is required. No sinusoidal curve is required on the copper pipe.uk . reduced KMR CCO max. 5 m max. Straight transitions from plastic casing pipes to the copper local heating pipe For transitions from plastic casing pipes to the copper local heating pipe. If gunmetal reductions are used. The following instructions refer to reductions with normal copper soldered sleeves Reduction The maximum length of the plastic casing pipe is 10 m. . no particular instructions need to be followed. 10 m CCO 1.210) upstream of the T-junction. CCO CCO CCO.PIPE2000 Ltd UK Distributor Copper Heating Piping Pipelaying instructions Part 3 CCO 9.co.7. it should be noted that the copper local heating pipe can only absorb the heat expansion to a limited extent. The maximum length of the plastic casing pipe is 20 m. CCO more than 20 m Instructions for reducing the medium pipe The following rules must be followed for a reduction of the medium pipes: KMR max. The maximum length of the plastic casing pipe is 5 m. The following examples show how this can be guaranteed: KMR CCO KMR max. 2. 5 m The length of the plastic casing pipe may exceed 20 m. Expansion padding is required. Expansion padding is required.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 20 m The heat expansion is absorbed by the sinusoidal curve (see page CCO 9.

∆p .2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd UK Distributor Copper Heating Piping Pressure loss CCO 9.uk Water. average temperature 80 °C Roughness ε = 0.co.7.81 Pa) Q · 860 ∆T m = flow in kg/h Q = power required in kW ∆T = temperature difference forward and return flow in °C m≈ kg/h 3 4 5 7 10 20 30 40 50 100 1 mbar/m 200 300 500 700 1000 10 mbar/m 2000 3000 Pa/m Pressure loss.0015 mm (copper) (1 mm water column = 9.210 4.

6 10.8 11. 120°C.6 10. .1 8.7 16.5 13. . .1m .13 0.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. .3 15.032 W/mK Conductivity of PEX-pipe: λ PEX = 0.4 16. . a=0. .2 17.26 . .18 0.16 0.6 12.15 0.2 90° 12. .2 20.6 0. .4 9.0 110° 13.0 11.2 W/mK Conductivity of PUR-foam: λ PU = 0.2 17.7 10.60 m Earth-temperature: TE = 10 °C Conductivity of ground: λ E = 1.2 17..2 9. ..0 12. .1 12.1 19. .0 15.4 10.5 9.0 10.19 0.8 7.6 80° 11. .6 23.0 26.2 16..2 16. .9 28.29 0.0 22.5 15. . λE Copper heating pipe (Forward and return flow in the same protective sheath) Heating loss q [W/m] for twin-line pipe DUO Type CCO DUO 15+15/90 18+18/90 22+15/90 22+22/90 28+15/90 28+22/90 K-Value [W/mK] average operating temperature TB [°C] 70° 9. .12 0.0 E 0.3 14.15 0.0 100° 11.0 15.1 23.2 31. TE λE Method of laying: 2 separate UNO pipes underground Covering height: H = 0.0 19...8 19.20 .0 7.0 15. 16 bar.8 13.22 0.8 26. ..3 19.0 18.9 22.0 19.. ..8 100° 110° 14.8 14.5 11.4 12.2 13.5 14.4 13.4 12.43 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] . .0 120° 17.4 15. .0 120° 14..1 18. UNO and DUO CCO 9.8 10.0 90° 10.3 13.0 13. .PIPE2000 Ltd UK Distributor Copper Heating Piping Heat loss Heating.0 80° 9.19 0.7.6 13.4 16.4 20.5 20.8 24.co.4 14.38 W/mK Conductivity of PE-casing: λ PE = 0. .13 0.0 20.6 19.3 18.8 16. .0 29.uk Copper heating pipe Heat loss q [W/m] for single-line pipe UNO Type CCO UNO 15/63 15/75 18/63 18/75 22/63 22/75 28/75 35/90 K-Value [W/mK] average operating temperature TB [°C] 70° 7.0 18. .2 12.8 9.220 4..18 0. .5 17.

90 75 .340 4 Reducer ring 5 Special sealing compound GFK fibreglass-shell tested by Fernwärme-Forschungsinstitut (FFI) of Hannover 1 2 3 4 CCO CCO CCO 5 Dimensions of GFK shell Ø external d1 d3 63 . see sheet CCO 9.63 63 .PIPE2000 Ltd UK Distributor Copper Heating Piping Connecting socket Tee Branch insulation kit CCO 9. see sheet COO 9. see sheet CCO 9. d2 63 75 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 .co.63 75 .2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.345 2 GFK half-shells 3 Insulating material.uk Connecting socket 1 2 3 4 d2 d1 63 75 90 63 x 75 x 90 x 1 2 3 4 CCO joint.320 4.90 Junction.345 Insulation material.75 63 .90 90 . see sheet COO 9.7.63 90 .75 75 .75 90 .340 Shrinking socket Shrinking hose all dimensions in mm Tee Branch insulation kit d2 1 Copper T-piece.

For fitting.uk T-piece sets and sockets PUR . PE-foam hose CCO 9.7.PIPE2000 Ltd UK Distributor Copper Heating Piping Insulation material PUR-foam pack.co.foam bottle The required volume of polyurethane is supplied in the appropriate container size for the various sleeves or T-pieces.340 4.foam bottle Base: CO2 -blown. PUR . the mixing rod supplied with the container is pushed through the container and the components are mixed together with a hand drill.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. CFC-free PUR-foam Security requirement for the foam insulation Component A plastic gloves plastic gloves Separating rail eye protection Component B eye protection .

7. etc. Suitable for Cu pipe installation to DVGW working sheet GW 2. copper and copper alloys. reduced Acetylene/oxygen mixture The oxy-fuel gas flame must be set to neutral. For solder points with operating temperatures up to 200 °C. All joints and T-pieces. reduced Capillary brazing joints soldering for steels. equal Type Euro standardisation ISO 3677 BRL 8. Rods thinly covered with flux 710 °C 630-730 °C 360 N/mm2 480 N/mm2 9. equal.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. Article number 7130 +GF+ Caution! Solder sleeves with notches are available in the trade. from the Georg Fischer company (+GF+). nickel and nickel alloys.1-02 36 Article number 7270 +GF+ Composition Ag Guideline analysis (%) 34 Application Joint.PIPE2000 Ltd UK Distributor Copper Heating Piping Soldering instructions Soldered fittings Soldering instructions CCO 9. Joint.0 g/cm3 > 12 % 14 Sm/mm2 Article number 7240 +GF+ Flux Connection with external thread Technical information Working temperature Melting range Tensile strength St 37 St 50 Specific gravity Elongation Electrical conductivity Heat sources Article number 7271 +GF+ T-connection piece.uk Soldered fittings Brugg Pipe Systems recommends fittings The special BRUGG solder must be used to solder the fittings.50.co. can be obtained in all dimensions from 18 to 35 Solder with high silver content mm.345 4.34 pr EN 1044 B Cu Ag Zn Sn 630-730 Zn 27 Sn 3 Si Cu 0. under no circumstances must these be used! .

250 mm 280 . double internal and external sealed KMR-Pipe Outer ø 90 mm 110 .2 x 15 26.9 x 22 33.140 mm 160 .355 3.7.uk St-Cu-Fitting 70 45° Cu The branche line of the Copper Heating pipe to KMR (plastic sheath pipe) would be connected using prefactored St-Cu-fitting.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.7 x 28 42. The fitting would be welded on his steel end and would be connected with soldered fitting on his copper end. Connecting joint Outer ø in mm St x Cu L1 mm L2 mm St-Cu-Fitting 17.315 mm Branche line Outer ø mm 63 75 90 X X X X X X X X X X X X X X X .200 mm 225 .co.9 x 18 26.4 x 35 215 215 215 215 225 185 185 185 185 145 Flex-T-Socket The branche line would be insulated by the shrinking socket.PIPE2000 Ltd UK Distributor Copper Heating Piping Connection of copper heating pipe to KMR CCO 9.

7.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.365 4. Suitable for moist rooms and introduction into shafts. Data table Copper heating pipe Type CCO 15/63 15/75 18/63 18/75 22/63 22/75 28/75 35/90 15+15/90 18+18/90 22+15/90 22+22/90 28+15/90 28+22/90 Shrinkdown end cap DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2100 DHEC 3200 DHEC 3200 DHEC 3250 DHEC 3250 P604 DHEC 3250 DHEC 3250 P604 .uk Shrinkdown end cap The cap is shrunk onto the pipe end with a gas flame or hairdryer.PIPE2000 Ltd UK Distributor Copper Heating Piping End cap CCO 9.

co.370 4.uk Wall sealing ring all dimensions in mm Datentabelle Copper heating pipe Type CCO 15/63 15/75 18/63 18/75 22/63 22/75 28/75 35/90 15+15/90 18+18/90 22+15/90 22+22/90 28+15/90 28+22/90 Wall sealing ring Outer pipe casing D 65 78 65 78 65 78 78 93 93 93 93 93 93 93 Da 102 118 102 118 102 118 118 133 133 133 133 133 133 133 50 Pipe warning tape To be laid in the ground Standard roll length: 250 m Laying depth: see sheet CCO 9.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.500 .PIPE2000 Ltd UK Distributor Copper Heating Piping Wall sealing ring Pipe warning tape CCO 9.7.

all dimensions in cm 1 2 3 . . . 10 10 D 10 D 10 B Pipe casing Ø D cm Width Depth Minimum radius of B T curvature. 10 D D D D 10 10 D B B (4xD + 2x10) D 10 1 Pipe warning tape 2 Excavated material 3 Washed sand. . . . . .7 0. . . .. . . . ... . . .0 30 80 0. for exposure to higher operating loads (such as SLW 60). . .. . . . . ... . .. . . . . . . . . .7 0.. . . . . . . . . . .8 9.. . grain size 0-3/4 mm Laying depth: maximum laying depth: 2. .. .. . .. . . . . . . . .PIPE2000 Ltd UK Distributor Copper Heating Piping Trench dimensions CCO 9. . .. . . m cm cm Pipe casing Ø D cm Width B cm D B 10 Depth Minimum radius of T cm curvature.. . . . . . . . SLW 30 = 300 kN total load to DIN 1072. .. . . . . . . . . . . m 6. .. . . . . . . . . . . . . . When digging the pipe trench. . DUO all dimensions in cm 1 2 3 . . . . . . . . . . .. . 2 . 4 copper local heating pipes (loop-in method) 1 . . . .. . . . . .6 m Our approval is required before laying at greater depths.. . . . . . . . ..co...2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. a loaddistributing superstructure to RStO75 is required.. . . . . .. .3 7. .. . . . 3 . . . . the minimum trench depth T can be reduced by 20 cm.. . . . .5 9. . .. .. . . . .0 43 45 48 77 78 79 0. .500 4. . .uk Trench profile. . .8 Trench profile. and that there is coverage of the same thickness above.. .. . . .7.. make sure that the pipes lie in a sand bed (grain size: 0-8 mm) of at least 10 cm. . .. . . With no traffic load. 2 copper local heating pipes UNO Normal trench cross-section in road area 1 2 3 .. . . . .. . .

7.co. see sheet CCO 9.PIPE2000 Ltd UK Distributor Copper Heating Piping Entry into buildings CCO 9.uk Entry into buildings Wall openings ca 80 mm 60 mm 80 mm CCO Copper connection piece.370 End cap.365 Wall opening Outer casing Ø D mm L min mm H mm 63 75 90 400 450 500 250 250 250 80 D 100 D 80 L Dimensions in mm Breakthrough bored 30 Outer casing Ø D mm D1 min mm A mm 63 78 93 160 180 200 190 210 230 A Dimensions in mm . see sheet CCO 9.505 4.115 Wall sealing ring.345 Pipe.2000 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. see sheet CCO 9. see sheet CCO 9.

Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.pipe2000.uk .uk www.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.

pipe2000.uk .INSULATED P IPES EIGERFLEX® THE PROFESSIONAL SOLUTION FOR ENGINEERS PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.uk www. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.TECHNICAL INFORMATION SHEETS P RE .co.co.

1 4.2 4.frost protection strip T-piece . design engineering Pressure loss Heat losses Connection to end of frost protection strip Sleeve joint .co.0 4.215 4.0 15.uk 4.3 4.210 4.500 Underground construction work.340 4.5 4. weights and supplied lengths 4. Ø Carrier pipe 25 –110 mm EIGERFLEX® pipe DN 20–40.345 Components Joint sleeve Fitting the T-piece Insulating material Screwed PE joint PE T-piece End cap Wall sealing ring Pipe warning tape Wall sealing ring (DOYMA) 4.310 4. Ø Carrier pipe 63 – 110 mm Structure.100 4.320 4.330 4. assembly Trench dimensions Pipe entry into buildings Openings in walls .10.300 4.205 4.frost protection strip 4. Ø Carrier pipe 25 – 50 mm EIGERFLEX® pipe DN 50 –100.220 Planning.200 4.PIPE2000 Ltd UK Distributor EIGERFLEX® Table of contents CPE 4. dimensions.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.115 Table of contents System description System description DN 20 –100.110 4.

to DIN EN ISO 12162 50 years at 20° C and 10 bar continuous load (30° C and 6.8 · 10 E-4 127 .032 90 10 kg/m W/mK % % 3 Test standard DIN 53420 DIN 52612 – EN 253 4.co. to -30° C 102 m / 16 A. Thickness 5. Test standard Value temperature ° C – – 20 20 20 – 950 0. Frost protection strip Material: Outer casing Screened protective braiding Insulation Conductive heating element Copper conductor Frost protection strip. self regulating 25 .uk Flexible pipe system with frost protection strip 1.110 mm Power delivery 17 W/m Width 7. temperature ° C – – – Value 928-938 kg/m3 0. Thickness 5. Medium pipe Material: Life expectancy: Characteristics: PE medium pipe Polyethylene class PE with high density. Heat insulation Material: PUR-insulation Density Heat conductivity Closed cellular structure Water absorption after 24 hrs. (84 m / 13 A) 17 W/m Power delivery 11 W/m Width 7. permissible ambient temperature Continuous operation 65 ° C. we basically specify a 30 mA residual current-operated device (FI).9 mm.131 kg/m W/mK 2 N/mm N/mm2 1/K °C 3 Density Heat conductivity Ultimate tensile strength (tearing resistance) Modulus of elasticity Linear expansion coefficient Crystallite melting range DIN 53479 DIN 52612 DIN 53455 DIN 53457 DIN 52328 – 2.6 mm 20 mm 230 V AC Continuous operation 65 ° C.43 W/mK 105-110 ° C Test standard DIN 53479 DIN 52612 – .100 15.PIPE2000 Ltd UK Distributor EIGERFLEX ® System description CPE 4.3 bar respectively Ref. short periods 85 ° C. extruded seamless Protection against mechanical effects and moisture Ref. 100% CO 2-driven polyurethane foam (PUR) Ref.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. Protective casing Material: Purpose: PE-LD .protective casing Density Heat conductivity Crystallite melting range Polyethylene of low density.6 mm Dimensions 20 mm Minimum bending radius 230 V AC Operating voltage Max. PE-LD. short periods 85 ° C. (118 m / 13 A) Maximum heating circuit length 11 W/m Power delivery (W/m at 5° C) To protect people and equipment. to -30° C 128 m / 16 A. CFC-free.3 bar) Suitable for cold water and sewage/waste water pipes operating at up to 20° C/10 bar and 30° C/6. temperature ° C – 50 – – Value > 60 0.9 mm.50 mm 63 . 3.43 32 600-900 1.10.

8 0. shorter lengths will be supplied on drums.uk Aluminium foil. D d .7 0.327 0.00 1.539 0. 50 mm wide s1 EIGERFLEX® PE Medium pipe PUR-Foam PE-Foil PE-LD casing.PIPE2000 Ltd UK Distributor EIGERFLEX® EIGERFLEX ®.co.7 0.6 78 x 2.0 93 x 2.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.10. On request. delivery length Jumbo-Coil m s Maxi-Coil m 25 x 2.3 32 x 2.835 1. 50 mm wide Frost protection strip Freezstop 11FSM2-CT Aluminium foil.54 520 520 377 377 760 760 560 560 • Dimension on request Further insulation thickness classes on request Ring dimensions: Jumbo Coil Maxi Coil Outer diameter 2800 mm x 800 mm (width) Outer diameter 2800 mm x 1200 mm (width) Larger lengths can be supplied on request. corrugated EIGERFLEX ® Frost protection strip: Power delivery 11 W/m EIGERFLEX® pipe Type DN Inches Medium pipe PE Outher casing Min.8 0.7 50 x 4.2 0.0 78 x 2. bending Medium ["] • 25/76 32/76 40/91 50/91 20 25 32 40 3/4" 1" 11/4" 11/2" dxs mm D x s1 mm radius m pipe volume Weight kg/m max.307 0.50 mm with frost protection strip CPE 4.39 1. Delivery is on drums.110 15.90 1.pipe 25 .2 93 x 2.9 40 x 3.

8 75 x 6.0 1.115 15. delivery length Jumbo-Coil Maxi-Coil m s m 63 x 5.2 163 x 3.8 90 x 8. corrugated EIGERFLEX ® 18 8 Frost protection strip channel Frost protection strip: Power delivery 17 W/m EIGERFLEX® pipe Type DN Inches ["] 63/126 75/126 90/162 110/162 50 65 80 100 2" 21/2" 3" 4" Medium pipe PE Outher casing Min.PIPE2000 Ltd UK Distributor Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.091 2.56 5.2 1.uk EIGERFLEX ® EIGERFLEX ®.254 6.pipe 63 . On request.7 163 x 3.2003 Aluminium foil. Delivery is on drums. 102 mm wide Frost protection Frost strip Freezstop protection strip 17FSM2-CT channel s1 EIGERFLEX ® PE Medium pipe PUR-Foam PE-Foil PE-LD casing.2 110 x 10.10.0 1.362 2. D d .2 1. 102 mm wide CPE 4. bending dxs D x s1 radius mm mm m Medium pipe volume Weight kg/m max.7 128 x 2.75 4. shorter lengths will be supplied on drums.110 mm with frost protection strip Aluminium foil.0 128 x 2.69 192 192 92 92 280 280 144 144 Ring dimensions Jumbo Coil Maxi Coil Outer diameter 2800 mm x 800 mm (width) Outer diameter 2800 mm x 1200 mm (width) Larger lengths can be supplied on request.2 2.60 2.co.961 4.

2 2/2 5) 3 2 (DN m/ 0.5 3000 m/ 2000 0.4 3/5 0) 6 5 (DN Flow in m [kg/h] 0.6 /73 80) N (D 1.3 s m/ 30 s 300 20 500 1000 100 200 300 400 500 800 40 50 80 1000 Pressure loss p [Pa/m] 2000 1200 1400 1600 1800 120 140 160 180 .uk Water.7 5m s 4000 /s 0.5 m/ s s 1.0 m/ 2. average temperature 20 ° C Roughness = 0.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd UK Distributor EIGERFLEX ® Pressure loss PE-Pipe CPE 4.45) 5/6DN 6 7 ( 1.0 5000 6.0 s 10000 m/ .co.81 Pa) Water speed 20000 30000 40000 /90 ) 10N 100 1 (D 90 .8 0/4 0) 5 4 (DN 3.4 5/2 0) 2 2 (DN 0.01 mm (PE) (1 mmWS = 9.10.6 /32 40N 32) (D 1.200 15.4 s m/ 0.

0 5.0 9.9 8.0 3.1 10.7 4.4 23.2 11.3 1.8 15.2 5.3 14.7 4.1 11.8 8.2 4.5 2.1 7.8 5.8 7.9 9.4 12.1 1.2 3.7 1.7 5.7 1.8 15.6 8.1 2.2 10.8 8.4 9.9 3.7 11.2 2.8 17.0 9.4 9.2 16.3 13.9 10.5 5.2 7.6 16. surface temperatures Tmed = 2 ° C If the pipes are laid underground (covered height H = 0.6 11.6 2.8 2.8 3.6 5.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.6 7.7 6.2 8.9 5.3 4.1 1.0 9.1 4.4 3.9 11.9 3.3 8.4 5.1 3.6 6.5 13.3 4.6 1.7 4.4 17.8 1.3 13.4 7.0 0.4 8.8 4.1 6.5 6.3 8.7 21.2 1.0 5.4 5.8 1.9 1.2 11.0 1.3 5.5 4.2 12.7 14.4 4.1 3.0 5.2 2.5 11.8 7.9 5.9 8.4 3.6 4.8 17.0 14.6 15.0 4.8 15.9 2.0 2.6 9.0 4.8 8.6 2.3 9.3 5.6 2.1 3.4 7.9 5.0 14.3 4.0 6.2 6.8 8.0 7.9 2.1 0.2 7.4 7.5 .4 1.8 7.1 10.1 12.2 6.0 4.5 5.0 5.7 1.3 1.1 8.2 1.9 3.7 7.6 7.6 9.6 7.8 6.7 10.6 4.3 8.3 4.0 23.5 1.3 12.3 21.8 6.2 11.9 18.5 10.2 12.0 5.2 3.6 9.5 2.1 9.4 3.9 12.1 15.7 10.7 16.3 7.5 6.3 3.0 13.4 10.6 20.1 2.4 9.1 1.2 2.8 2.7 10.3 5.4 9.7 13.0 9.0 19.4 10.co.5 11.8 3.1 1.0 7.4 8.6 7.6 4.1 4.0 4.5 6.4 4.1 9.7 14. the heat losses are reduced by at least 20%.6 0.0 7.8 10.3 6.0 16.5 6.9 4.1 10.4 10.8 8.0 Medium temperature: 2° C 1.8 11.5 5.9 3.8 7.9 13.6 3.8 12.2 8.8 10.1 0.7 6.4 3.8 12.2 2.6 m).5 11.0 1.6 9.5 10.PIPE2000 Ltd UK Distributor EIGERFLEX ® Heat losses CPE 4.9 12.4 7.5 6.9 6.8 4.9 3.4 3.1 10.7 6.0 7.9 10.6 1.2 3.1 8.9 6.2 20.6 9.6 3.1 6.10.6 4.0 14.6 3.2 10.7 7.4 2.6 13.7 9.1 6.4 1.8 2.3 7.2 11.7 5. Medium temperature: 2 ° C The frost protection strip can no longer compensate for a heat loss of more than 10 W/m.9 4.0 6.2 1.4 16.2 15.8 7.2 1.0 1.6 8.5 5. surface temperature of the outher casing [°° C] -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 EIGERFLEX® Pipe-dimensions 25/76 32/76 40/91 50/91 63/126 75/126 90/162 110/162 q W/m 0.5 11.uk Heat losses at different external temperatures or surface temperatures of the casing pipe.4 14.7 7.1 13.9 12.8 4.7 13.7 5.8 9.4 14.3 2.0 13.8 11.5 2.4 9.5 19.2 7.4 1.7 2.5 6.9 2.2 7.4 9.7 5.7 2.2 6.9 1.3 12.0 9.5 2.6 13.4 14.2 4.9 8.2 2.3 5.1 5.5 7.6 9.5 2.8 22.8 6.1 6.2 6.205 15.9 14.9 3. and there is a danger of freezing.3 2.

3. 7 cm Filling adhesive S 1113. seal with shrinkdown tube. and fix the temperature sensor on the inner pipe with adhesive tape. Installing the temperature sensor on the pipe The temperature sensor has to be installed on the medium pipe opposite the heating strip.required by regulations! • Automatic fuse. 100 m (13 A max.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 100 m 4.PIPE2000 Ltd UK Distributor EIGERFLEX ® Connection and end Frost protection strip CPE 4. 60 mm long Shrinkdown tube Temperature sensor EIGERFLEX® Temperature sensor cable Shrinkdown tube . Installation procedure • Electrical installation according to local regulations • Only to be connected by an authorised electrical installer • 30 mA residual current-operated device (FI) . It must be fitted at the coldest point on the pipe (outside the building). 10 cm approx. 80 m) Regulation: Thermostat UTR 15 • adjustment range: –5° C to 15 ° C • pipe contact thermostat or ambient thermostat 2.210 15. cut out 10x7cm foam. with screened cable. cut open a 10x7 cm area of the outer casing and peel back.10. Preparation 35-40 cm EIGERFLEX® Shorten as described in fitting instructions Remove 35-40 cm of insulation at the ends and carefully expose the strip. For this purpose. heating circuit length based on switch-on temperature of 5 ° C: self regulating 16 A max. Fill the hole with the insulating material that is provided: apply filling adhesive S1113 below and above the temperature sensor cable (see sketch). C-characteristic 230 V Protect the heating strip against moisture Connection box (provided by customer) Thermostat UTR 15 with temperature sensor Frost protection strip Sensor cable length 3 m. Technical data Heating strip type Max. Then shorten the inner pipe to length according to the fitting instructions.5 mm 2 Temperature sensor on pipe Temperature sensor in open air End closure EA-H Connection heating strip / cold lead A-H/K max. can be extended to a maximum of 100 m. 1.uk 1. approx.co.

80 m/13 A) * for larger lengths see catalogue sheet CPE 4. 4. Technical data Heating strip type: Max. 100 m max. *100 m/16 A (max.100 2. 100 m 3. 100 m max. Planning L 100 m Continuous joint Connection Frost protection strip/ frost protection strip V-H/H Supply End closure EA-H L > 100 m Separation End closure EA-H Supply Supply max.uk 1.215 15.10. Sleeve joint Continuous joint L 100 m 40 cm Connection Frost protection strip/ frost protection strip V-H/H Separation L > 100 m 30 cm Screwed joint or welded sleeve 30 cm 30 cm End closure EA-H Seal with sleeve set Catalogue page 4 300 + 4. Then shorten the inner pipe to length as shown in illustration 2. heating circuit length at switch on temperature of 5° C: self-regulating max.co. Preparation 40 cm Illustration 1 Illustration 2 EIGERFLEX® Shorten as shown in illustration 2 15 cm 15 cm Remove 40 cm of insulation at the ends and carefully expose the strip.310 Protect heating strip against moisture .PIPE2000 Ltd UK Distributor EIGERFLEX ® Sleeve joint Frost protection strip CPE 4.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.

uk 1. End closure EA-H Connection V-H/H End closure EA-H L Example 1: total lenght Supply (using connection A-H/K) 100 m Example 2: total length 100 m 100 m 2.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 80 m /13 A) * for larger lenghts see catalogue sheet CPE 4.co.100 100 m. 4.PIPE2000 Ltd UK Distributor EIGERFLEX® T-piece Frost protection strip CPE 4.10. make sure that the sum of the connected pipes is not End closure EA-H T-piece Micro Uni Clip MUC Supply A-H/K Supply (using connection A-H/K) Connection V-H/H End closure EA-H L 100 m Protect heating strip against moisture End closure EA-H Example 3: total length 100 m 3. Preparation 50 cm EIGERFLEX® Remove 50 cm of insulation at the ends and carefully expose the strip. Fitting T-piece with T-junction Screwed T-piece or electro welded T T-Piece Micro Uni Clip MUC . heating circuit length at switch on temperature of 5° C: self-regulating max. Technical data Frost protection strip Heating strip type: Max. *100 m /16 A (max. Then shorten the inner pipe to length according to the fitting instructions. Planning At the T-junction.220 15.

63/126 90/162 .320 GFK half-shells Insulating material.2003 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. see sheet CPE 4.32/76 50/91 .uk Joint sleeve 1 2 3 4 d1 EIGERFLEX® d2 76 d1 91 126 162 76 x 91 x 126 162 x x 1 2 3 4 PE joint.25/76 32/76 .75/126 75/126 .50/91 50/91 .90/162 90/162 . see sheet CPE 4.40/91 40/91 .75/126 110/162-110/162 110/162. see sheet CPE 4. see sheet CPE 4.50/91 75/126 .63/126 63/126 . Ø d2 Ø d1 Ø d3 25/76 .300 15.40/91 63/126 . 490 mm 1 3 2 4 5 d2 .310 Reducer ring Special sealing compound d3 max.32/76 40/91 .320 Insulation material.co.PIPE2000 Ltd UK Distributor EIGERFLEX® Joint sleeve Fitting the T-piece CPE 4.310 Shrinkdown sleeve pipe Shrinkdown tube all Ø dimensions in mm Fitting the T-piece d2 d1 645 mm Junction.90/162 25/76 32/76 40/91 50/91 63/126 75/126 90/162 110/162 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 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 1 2 3 4 5 PE T-piece.10.

PIPE2000 Ltd UK Distributor

EIGERFLEX ® Insulation material
PE-foam hose, PUR-foam pack

CPE 4.310
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Sockets Polyethylene foam hose
Pipe-extruded insulation of closed cell, high-quality polyethylene, ideally suited for insulating CALPEX ® 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.

PE

T-piece sets and sockets 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 bottle
Base: CO2-blown, CFC-free PUR-Foam

Security requirement for the foam insulation

Component A

plastic gloves

Separating rail

Component B

eye protection

PIPE2000 Ltd UK Distributor

EIGERFLEX® Screwed PE joint Screwed PE T-piece

CPE 4.320
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Connection

coupling

all dimensions in mm

Ø 75
L L

Ø 75

PE-Pipe 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

Type 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“

L 53 63 67 71 80 92 92 102

Type 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

L 60 67 71 75 81 89 130 130

Ø 90
L

Ø 90
L

Screwed PE T-piece
d2

Junction, Ø d2
110 x 10 32 x 2.9 50 x 4.6 40 x 3.7 63 x 5.8 75 x 6.8 90 x 8.2

Ø d1

Ø d3

Ø 75

d2

Ø 90

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

x x x x x x x x x x x x x

d1

d3

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

d1

Alternative types of joint

d3

Electro-welded PE sleeve

Alternative types of joint (not in stock) • Electro-welded PE sleeve • Electro-welded T, PET-T with welded sleeve • Pipe coupling Straub or Norma

PE pipe coupling

PIPE2000 Ltd UK Distributor

EIGERFLEX® End cap

CPE 4.330
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Heat shrinkable 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.

Data table

EIGERFLEX®
Type CPE
25/76 32/76 40/91 50/91 63/126 75/126 90/162 110/162

Shrink end cap
61031 61031 61031 86300 86326 86326 60999 63340

PIPE2000 Ltd UK Distributor

EIGERFLEX® Wall sealing ring Pipe warning tape

CPE 4.340
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Wall sealing ring

Data table

all dimensions in mm

EIGERFLEX®
Da

Typ CPE
D 32/76, 25/76 40/91 50/91 63/126 75/126 90/162 110/162

Wall sealing ring Outher casing pipe D
78 93 93 128 128 163 163

Da
118 133 133 168 168 203 203

50

Pipe warning tape

Tape for laying underground Standard length: 250 m Laying depth; see page CPE 4.500
! LEIT E NG TU RM CH NWÄ A R FE UN G

PIPE2000 Ltd UK Distributor

EIGERFLEX® Wall duct DOYMA Core drilling

CPE 4.345
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Standard DOYMA C40 Cellar/shaft (Internal) External

DOYMA C40 with additional centering ring DOYMA A40 Cellar/shaft (Internal) 4
Ø D external, mm 150 150 200 200 250 250 300

3

External

2

3

R

R

D

1 4

1

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 Core drill holes
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.

R Outer diameter EIGERFLEX® PE Ø mm 76 91 111 126 142 162 182

D Pipe liner Core drill hole Ø mm 150 150 200 200 250 250 300

Doyma Type C40 Doyma Type A40 Ø D internal, mm 78 93 113 128 143 163 183

D

PIPE2000 Ltd UK Distributor

EIGERFLEX® Trench dimensions Building entry

CPE 4.500
15.10.2003

Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk

Trench section, 1 CPE Leitung
all dimensions in cm . .. . . . . . .. . . . . . . . . .. . . . .. . . . . .. . . 10 D 10 30

1 2 3

min 60

Outher casing Ø D mm

Large B cm

Depth min. bending radius T cm m

76 93 113 128 143 163

25 30 30 35 35 35

80 80 85 85 85 90

0.7 0.8 0.9 1.0 1.1 1.2

10

D B

10

1 Pipe warning tape; see page CPE 4.340 2 Excavated material 3 Sand washed, grain size 0-3/4 mm Covering hight maximum covering hight: 2.6 m The higher covering needs our according.

T

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 RStO75 is required. Without traffic load the minimum covering hight may be reduced by 20 cm.

Building entry Wall entry
ca 80 mm

60 mm 80 mm

EIGERFLEX®
D PE-connecting piece, see page CPE 4.320 End cap; see page CPE 4.330 EIGEFLEX® -Pipe, see page CPE 4.110 Wall sealing ring, see page CPE 4.340

Wall breakthrough

Outher casing Ø D mm

mm

A

Breakthrough bored

Outher casing Ø D mm

D
mm

113 128
80 D 80

270 290 320
Dimensions in mm

D

78 93

240 250

78 93 113 128 163

180 200 220 240 280

A

A
Dimensions in mm

163

pipe2000.uk www.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk .co.

Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk .TECHNICAL INFORMATION SHEETS P RE .uk www.co.INSULATED P IPES FLEXWELL® THE PROFESSIONAL SOLUTION FOR ENGINEERS PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.pipe2000.

0 3.213 3.506 3.504 3.210 3.98 07.211 3.3 3.uk 28.414 3.co.1 3.301 3. dimensions.501 – Subject to technical change – 3.03 3.502 3. installation Instructions for excavation works Technical codes.0 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.4 3. materials.305 3.503 3.602 . pipe-connection dimensions. axial and wall-spacing dimensions Laying through protective pipes Horizontal jet drilling method Components Connectors Straight through connection T-connections Wall ducts Standard Doyma duct Pipe lining connection House connection bend Technic of application Trenchless laying Excavation works.5 3.6 3. guidelines for construction Trench dimensions wall opening Core drill holes Instructions for excavation works Straight through connection Instructions for excavation works T-piece connections Instruction for excavation works House connection bends Distances to other supply lines Master texts for tenders Supply and laying of FLEXWELL heating cable Supply of steel shafts 3.600 3. weights and delivery lengths Planning.304 3.212 3.201 3.110 Contents System description Technical specifications Design.306 3.303 3.2 3. standards. design Pressure loss diagram Heat loss diagram Loop-in method Laying method House connections (spacing and axial dimensions) Connectors Nominal widths.02.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Contents FHK 3.203 3.

Without regard to classical pipe construction. This method is used wherever valuable surfaces have to be protected or difficult crossings made. Due to its flexibility. The FLEXWELL heating cable is a safe solution especially in earth subsidence zones and in very wet ground (high groundwater level).uk 28. the FLEXWELL heating cable is especially well suited for the horizontal jet drilling method. This material is extremely corrosion resistant and therefore best suited to transport various media like heating water. which with operating temperatures of up to 150 oC withstands higher temperatures than conventional PUR-insulated pipes. condensation and others. which is laid underground. If one also considers the very short laying time.98 07. drinking water. outer multilayer corrosion protection provides incomparable safety in the ground during operation. It can be laid in water (under water) without problem. – Subject to technical change – . With its corrugated steel sheath pipe the FLEXWELL heating cable belongs to the family of steel casing pipes as far as its expected lifetime is concerned.1 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. The flexibility of the FLEXWELL heating cable enables unproblematic adaptation to virtually all route conditions. L-limbs. The pipe trenches for the FLEXWELL heating cable can be dimensioned considerably narrower than for rigid pipe systems. This pipe. The corrugations of the carrier pipe not only give the district heating pipe its flexibility.02. fixed points) as required in rigid pipe systems are not necessary.03 FLEXWELL heating cable is the protected name for a flexible pipe system from BRUGG Rohrsysteme to transport district heating and warm tap water. The continuous. but also compensate the temperature related length changes of the pipe. but also very economical solution for the transport of district heating with least-possible nuisance to the district heating customer and general public during the construction period.PIPE2000 Ltd UK Distributor FLEXWELL heating cable System Description FHK 3. The heat insulation of the FLEXWELL heating cable consists of flexible polyurethane hard foam (CFHC-free). warm tap water.co. the FLEXWELL heating cable is not only a technically perfect. the shortest route can be selected with the FLEXWELL heating cable. FLEXWELL heating cable is equiped with a corrugated carrier pipe of special steel. has proven itself in practical applications under extreme and very different conditions for many years. Obstacles like existing supply lines present no problem because the pipe can simply be passed over. under or around them. Elements to absorb the elongation (U-bends. This makes significant savings in underground construction projects possible.

EN 10088).81 3.9 233 17.2 480 2 0.43 12.9 1. DIN 1624 3 Heat insulation of flexible polyurethane hard foam (CFHC-free). EN 10088).6 50 60 0. (b) 1 x Cu insulated.8 0.7 156 3. Materials.3 270 4 0.0 0.2 0.2 150 6 1 – Subject to technical change – Comparable nominal width Special steel carrier pipe 25 30 0. resistant up to 150 oC.3 20.3 313 23.110 28.6 94 0.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.75 125 147 1.3 19.2 33. delivery lengths Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/22 147/22 [DN] d1 s1 Steel sheath pipe External diameter Carrier pipe volume Weight Max.75 [mm] [mm] [mm] [mm] [dm /m] [kg/m] [m] [m] [m] 3 *) according to maximum possible drum capacity and normal manufacturing length .6 590 1.12 9.1 590 1.35 5.5 30 0.8 0.4 640 1.9 233 14.4571.5 1. Weights and Delivery Lengths FHK 3.6 121 1.5 0.3 0.8 0.2 1.9 0.uk 1 6 s2 2 3 4 5 s1 d1 D3 1 Corrugated carrier pipe of nickel-chromium steel X5 CrNi 18-10 (1.000 1 0.7 640 1.5 0.9 233 8.032 W/mk 4 Two layers of rubber/bitumen polyment separated by a plastic film 5 Protective sheath of polyethylene 2YM1 (PE) according to VDE 0209 6 Electronic detection conductors: (a) 1 x NiCr.co.43 19.35 8. (AISI 316L) 2 Corrugated sheath pipe of steel Ast 4 LG.8 480 2 0.6 65 75.8 270 4 0.6 121 0. (AISI 316Ti) or X2 CrNiMo 17-12-2 (1.3 250 4 0.8 178 5.4 0.6 156 1.6 0. (AISI 304) or X6 CrNiMoTi 17-12-2 (1.3 0.65 98 0. EN 10088).4301.5 0.55 32 38.9 0.65 80 98 0.4404.Dimensions. thermal conductivity at 50 oC: 0. Dimensions.2 0. delivery length*) Minimum bending radius Trench width D S2 3max 200/31 150 197.55 38.4 0.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Design.12 12.02.9 0. (c) 1 x Cu Wire pair: a + b (red + green) = WIREM/BRANDES System b + c (green + Cu-white) = Nordic System Table 1 FLEXWELL heating cable .81 5.75 100 127 0. weights.8 178 8.

6 s m/ 0.0 s m/ 0.4 2 171 75/ FHK 148 60/ FHK s m/ 0.000 9 8 7 6 5 4 3 m/s 1.7 FHK 220 98/ HK F 171 98/ s m/ 0.2 1.000 [kg/h] 100. FLEXWELL heating cable type 75/171 → pressure loss 90 Pa/m .000 200.3 s m/ 0.01 Average water temperature = 80°C 300.co.uk 28.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Pressure Loss Diagram FHK 3.000 9 8 7 6 5 Flow rate 4 3 2 310 00/ K2 FH 0 /22 147 FHK 220 27/ K1 FH 10.5 1.98 01.201 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.1 91 30/ FHK 16 0/1 K3 FH – Subject to technical change – 2 100 1 2 3 4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 100 2 3 4 5 6 7 8 9 1000 [Pa/m] 0.03.02.8 s m/ 0.9 s m/ 0.000 9 8 7 6 5 4 3 116 39/ HK F 48 9/1 K3 FH s m/ 0.5 s m/ 0.0 5 10 50 100 [mmWS/m] Pressure loss Example: Flow rate 7000 kg/h.1 0.

FH 1u 30/9 /148 FHK K 39 u.2 W/mK 20 0/ 31 0 u.203 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. FH 16 30/1 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 0 Carrier pipe temperature [°C] – Subject to technical change – Example: Carrier pipe temperature 110° C FLEXWELL heating cable type 127/220 → heat loss 40 W/m or 34 kcal/mh Conductivity of ground Earth temperature λE = 1.co.98 70 Heat loss [W/mK] 0.02.6 m 60 Heat loss [kcal/mh] 50 tE = 10 °C 40 λE = 1.uk 28. FH K 14 7/ 22 0 60 50 FH K 40 1 17 8/ 9 K 0 FH 22 7/ 12 K FH 30 30 20 10 FHK 71 5/1 K7 FH 20 8/2 K9 FH 48 0/1 K6 FH /116 K 39 .2 W/mK tE = 10° C .PIPE2000 Ltd UK Distributor FLEXWELL heating cable Heat Loss Diagram FHK 3.

the FLEXWELLâ heating cable is suitable for laying by the „loop-in method“ from cable technology.no underground branches or connections .reduction in costs . The advantages are: . 2 Loop-in method.reduction in risks .increase in safety . 1 Conventional method of laying.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.1 28.co. connections in the building – Subject to technical change – .02.uk Due to its flexible construction.210. connections and branches underground Fig.possibility for inexpensive installation of fittings inside the building Fig.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Loop-in Method Laying Method FHK 3.

4. 350 1 3 Field-run pipes min.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Loop-in Method House Connections FHK 3.501. low).3 and FHK 3. a drain or vent possibility must be provided on construction side.2 28.98 07.02. .210.co.501.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.uk 4 min. 350 2 Return Flow Flow Return incoming pipes – Subject to technical change – 1 2 3 4 FLEXWELL heating cable Connector Wall duct Wall opening (watertight sealing on site) Depending on the altitude (high. For the size and arrangement of the wall openings see worksheets FHK 3.

501.501.98 07.4 x 2. pipe-connection.9 240 145 280 75/171 DN 65 76.02.3 and FHK 3.co.3 x 2. 350 e1 min.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Axial and Wall-Spacing Dimensions Connection Unions Type 30/91 to 75/171 FHK 3.6 200 130 230 200 130 240 42.1 28.4) – Subject to technical change – Nominal widths. 350 3 1 2 1 2 3 4 FLEXWELL heating cable Wall duct Connector type GR Wall opening (watertight sealing on site) (for size and position of the wall openings see worksheets FHK 3.uk Connector with graphite sealing ring type GR l1 L1 4 min.211.6 240 135 245 .03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.1 x 2.7 x 2.9 270 145 300 165 120 220 33. wall and axial-spacing dimensions Type FHK Comparable nominal widths Dxs e1 L1 I1 30/91 30/116 DN 25 39/116 39/148 DN 32 Dimensions in mm 60/148 DN 50 60.

PIPE2000 Ltd UK Distributor FLEXWELL heating cable Axial and Wall-Spacing Dimensions Connectors Type 98/171 to 147/220 Connector type B Bend position optional l2 D r 4 FHK 3.2 270 235 122 385 385 400 98/220 127/220 DN 100 114. 350 1 2 min. pipe-connection. 350 e1 min.3 x 3.501.211.9 x 3.501. 350 1 2 3 4 5 FLEXWELL heating cable Wall duct Connector type A Connector type B Connector type DE 6 Wall opening watertight sealing on site (for size and position of the wall openings see worksheets FHK 3.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. 350 Connector type DE l3 L1 5 Axial and wall-spacing dimensions min.4) – Subject to technical change – Nominal widths.2 28.co.3 and FHK 3.98 07. wall and axial-spacing dimensions Type FHK Comparable nominal widths Dxs e1 L1 r l1 l2 l3 98/171 DN 80 88.uk Connector type A l1 3 D L1 6 L1 min.0 310 280 180 430 490 445 310 280 .02.7 x 4.6 310 280 150 430 455 445 Dimensions in mm 147/220 DN 125 139.

03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. Rohranschluss-.3 28.9 240 230 383 75/171 DN 65 76.3 x 3.6 139.501.1: Connection variant G.6 165 215 377 200 215 DN 32 42. 350 (550)1) e1 1 2 3 4 FLEXWELL district heating cable wall through-connection connection wall entry with watertight seal made on site (size and alignment of wall entry see worksheets FHK 3.02.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Centre distances and wall clearances for welded connection Typ 30/91 to 200/310 FHK 3.1 x 2.4) min. Wand.9 x 3. welded l1 L1 3 1 D 2 4 Fig.0 168.3 x 2.4 x 2.6 200 215 373 240 230 DN 80 88.5 310 280 426 310 280 426 410 210 (310) 1) 300 (400)1) Dimensions in brackets apply when connection is installed on site.3 x 4.und Achsabstandsmasse Nominal bores. wall and centre distances FHK type FHK-Typ vergleichbare comparable Nennweite nominal bore Dxs e1 L1 l1 1) Masse in mm dimensions in [mm] 98/220 127/220 DN 100 147/220 DN 125 200/310 DN 150 30/91 30/116 39/116 39/148 60/148 DN 50 60. .211.9 270 235 388 98/171 DN 25 33.3 and FHK 3. those without brackets for pipework assembled at our works.7 x 2.uk Fig. pipe connection.7 x 4.2 270 235 385 310 280 114.98 07.501.co. 350 (550)1) – Subject to technical change – Nennweiten. 2: Wall clearances and centre distances min.

212. In such cases it is necessary to contact us beforehand to arrange a constructive solution. – Subject to technical change – . If this cannot be guaranteed. PE or asbestos cement the FHK is pulled through the protective pipe without runners and with runners in the case of protective pipes of steel and concrete. Bends in the route directly in front of and behind the protective pipes are to be avoided.02.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Laying through Protective Pipes FHK 3.uk 28.co.212. 3.2.98 The following instructions must be followed when laying FLEXWELL heating cables (FHK) through protective pipes: 1. The protective pipe must run straight without any bends. There may also not be any offsets at the joints between protective pipes that severely impede pulling in of the FHK or render same impossible or could cause damage to the protective PE sheath. In the case of through-pressing it is not always possible to introduce two small protective pipes into the ground next to each other. 5.1 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. In the case of protective pipes made of PVC. 4. A protective pipe is basically needed for every FHK to guarantee sound guidance when pulling the FHK through the protective pipe. A large protective pipe is then pressed in instead. 1 and 2). 2. The internal diameter of the protective pipes must be at least 20 mm larger than the external diameter of the FHK or runners (FHK 3. the routing must be arranged with us beforehand. fig. There must be enough work space at ground level in front of and behind the protective pipe for the traction engine with cable trailer to be able to manoeuvre without difficulty and pull the FHK into the protective pipe without deviating from the route axis.

1 x 4.60 m 4) Joints without root seam – Subject to technical change – 156 178 2.co.6 313 3 F + 1 G25 30 400 x 9.6 32 168 x 9 150 29 219.80 m.1 35 60 220 x 10 274 x 12 200 250 44 72 with runners 219.5 210 4 S19 51 39/148 60/148 75/171 98/171 Max. Max.98 07.00 200/310 313 4.4 x 6. well-aligned protective pipes without runners.60 m 3) Min. 20 mm FHK max.00 125 x 3 24 141 x 8 125 30 168. protective pipe length = 30 m1) Clearance min. 2: Laying of district heating pipe through straight. covering for SLW 60 = 0. 1. 1: Laying of district heating pipe through straight. FHK casing pipe Ø Runner spacing L PVC sewer pipe acc.00 without runners 200 x 4.0 mm runner distance L from end Type FHK Protective pipe of steel4) or concrete Plastic runner 30/91 30/116 39/116 121 2.1 x 4.2 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Laying through Protective Pipes FHK 3.uk 28.00 160 x 3.7 67 328 x 14 300 67 323. well-aligned protective pipes with runners.3 x 4 160 3 S19 27 315 x 7. Max. covering = 0. to DIN 19 850 2) Internal pipe Ø Clearance between FHK and AZ pipe Steel pipe acc. protective pipe length = 30 m1) Clearance min.8 67 436 x 18 400 87 406. to DIN 2458 3) 4) Internal pipe Ø Runner (made by Frankenplastik) Clearance between FHK and pipe [mm] [m] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] 95 2.3 394 4 F + 1 G25 31 1) Deviations only after consultation with BRUGG Rohrsysteme 2) Min.03 Fig.50 3.9 x 5.5 250 x 6.212.5 273 x 5 210 263 4 T19 2 F + 1 G25 20 35 98/220 127/220 147/220 233 3. 20 mm Plug joint for PVC sewer pipe PE sewer pipe AZ sewer pipe PVC/PE/AZ sewer pipe FHK Fig.00 .02. for SLW 30 or under a road pavement 0. to DIN 19 534 2) Clearance between FHK and PVC pipe AZ sewer pipe acc.

The special shape of the drill head enables a controlled change in direction and exact control of drilling.co.uk Due to its flexibility.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Horizontal Jet Drilling Method FHK 3. railway lines. pedestrian zones.02. At the same time as the drill rod is retracted the FLEXWELL heating cable is pulled into the bore hole expanded and supported by the water-bentonite suspension.213 28.) have to be protected or where difficult crossings (water. buildings. busy roads. At the end of the pilot hole the drill head is replaced with an expansion head equipped with nozzles and the FLEXWELL heating cable is coupled to it. etc. canals.) have to be made. the FLEXWELL heating cable is especially well suited for the horizontal jet drilling method described below. Short description of the method The drill consists of a single screwed hollow drill rod and a drill head equipped with nozzles. Advantages of the system • No trenches. It is used wherever valuable surfaces (parks. This method can be applied to the complete dimensional series from FHK 30/91 to FHK 200/310.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. nature reserves. earthworks only for assembly trenches • Little damage to the surface • No consequential damage. etc. paved paths. dams.g. front gardens. 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 – Subject to technical change – .98 07. The horizontal jet drilling method was developed for trenchless laying of supply lines. e. A water-bentonite mixture injected under high pressure and in small quantities cuts and loosens the ground and stabilises and lubricates the bore hole.

9 R 2 1/2 Nominal widths.02. The electronic detection conductors are passed out of the connectors watertight.9 R2 75/171 65 76.3 x 2.1 x 2.6 R1 1) In pressure tests in partially filled trenches or with unfixed connectors max.4 x 2.1 28.6 R 1 1/4 60/148 50 60.uk The district heating pipe connectors with graphite sealing ring type GR (fig.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. pipe union dimensions Type FHK Comparable nominal width Pipe union dimensions heating water pipe Pipe thread tap water pipe [DN] [mm] 30/91 30/116 25 33. permissible pressure = 0.5 bar .7 x 2.1) is a connection element specially designed for FLEXWELL heating cables for heating and tap water pipes up to a size of DN 65.98 07.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Connectors PN 25 Type 30/91 to 75/171 Version GR FHK 3. It is used to establish all connections to pipe installations in buildings and Fig. This connector can withstand a maximum temperature of 150 OC up to nominal pressure stage PN 161).co.301. 9 6 X 1 2 3 4 5 6 7 8 9 10 11 2 12 13 14 15 Header ring Back-up ring Graphite sealing ring Connection piece Fillister head screw Screw cap O-ring Washer Clamp Electronic detection conductors Electronic detection conductor screw fitting Silicon cable Insulation Compression joint Heat-shrink sleeve 5 8 Detail X 15 14 13 10 Detector wire NiCr red insulation Nordic wire white insulation Copper wire green insulation – Subject to technical change – 12 Version for tap water pipes 39/116 39/148 32 42. 1: Connector with graphite sealing ring type GR 4 3 7 1 12 11 10 shafts as well as for transition and T-connections.

It comes with an PTFE-surrounded IT seal. It is used to establish all connections to pipe installations in buildings and shafts as well as for straight through and T-connections (FHK 3. B.0 Type A Heating Type B Heating Type DE Sanitary + Heating Flange connection dimensions according to PN 16 1) In pressure tests in partially filled trenches or with unfixed connectors max. The electronic detection conductors are passed out of the connector watertight.303 and FHK 3.98 07.304). The connectors type A and B (fig.5 bar .9 x 3.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Connectors PN 16 Type 98/171 to 147/220 Versions A. These connectors can withstand a maximum temperature of 150 OC up to nominal pressure stage PN 161). permissible pressure = 0.7 x 4.3 x 3.co.1) is a connection element specially designed for FLEXWELL heating cable.02. The connector comes in three variants (fig. B and DE FHK 3. The connector type DE also comes in a special version for tap water pipes. 2) are intended for heating water pipes. pipe union dimensions – Subject to technical change – Type FHK Comparable nominal width Pipe union dimensions Figure 2: Connector versions [DN] [mm] 98/171 98/220 80 88. DE) 3 Lead sealing ring 4 Inner wire ring 5 Outer wire ring 6 Flange ring 7 Stud bolt 8 Washer 9 Hex nut 10 Hex nut Cross hole 11 Seal wire 12 Lead seal 13 Creased packing 14 Strain washer 15 Permanently plastic synthetic band 16 PE corrosion protection band 17 Silicon cable 18 Cable bushing 19 Copper sealing ring 20 Electronic detection conductors 21 Insulation 22 Compression joint 23 Heat-shrink sleeve 24 Protective cap Nominal widths. This PTFE sleeve may not be removed or damaged. Figure 1: Connection union (type A) 24 7 10 8 6 2 5 3 17 18 19 4 14 1 13 15 16 X 9 11 12 Detail X 23 22 21 20 Detector wire NiCr red insulation Nordic wire white insulation Copper wire green insulation 17 1 Front ring 2 Supporting socket (alternatively type A.6 147/220 125 139.301.uk The heating cable connector (fig. On delivery the pipe ends are protected by plastic caps to protect the carrier pipe from dirt.2 127/220 100 114. 2).03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.2 28.

3x2.4x2.9 98/171 98/220 80 88.6 39/116 39/148 32 42.3x4.5 bar.7x2.02.7x4.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Connectors PN 25 Type 30/91 to 200/310 Version G.9 168.9x3.1x2.301. . permissible pressure = 0.3x3.co.uk 1 9 8 6 7 3 FLEXWELL heating cable Type FHK 30/91 . welded 2 11 10 4 5 FHK 3. pipe union dimensions Type FHK Comparable nomina width Pipe union dimensions [DN] [mm] 30/91 30/116 15 33.147/220 WIG seam X 1 Connection piece with welding socket piece 2 Protective cap 3 Threaded piece R 1/2" 4 Permanently plastic jointing compound 5 Heat-shrink sleeve 6 Electronic detection conductor bushing R 1/2" 7 Sealing ring 8 Heat-shrink sleeve 9 Silicon cable 10 Electronic detection conductors 11 Heat-shrink sleeve 12 Compression joint 13 Heat-shrink sleeve 14 Insulation Detail X 13 12 14 10 TIG seam Detector wire NiCr red insulation Nordic wire white insulation Copper wire green insulation 1 12 9 8 3 2 4 7 5 13 10 11 Y 14 15 13 – Subject to technical change – Detail Y 7 16 6 17 5 FLEXWELL® heating cable Type FHK 200/310 Detector wire NiCr red insulation Nordic wire white insulation Copper wire green insulation 1 Connection piece with welding socket piece 2 Protective cap 3 Reducing nipple 4 Silicon cable 5 Electronic detection conductors 6 Compression joint 7 Glass fabric sleeve 8 Sealing ring 9 Screwed cable gland 10 Permanently plastic seal 11 Shrink collar 12 Weld seam (protective cap/connection) 13 Weld seam (protective cap/connection) 14 Weld seam (“black“ / “white“) 15 Weld seam (“white“ / “white“) 16 Heat-shrink sleeve 17 Insulation 4 Nominal widths.5 Note: In pressure tests in partially filled trenches or with unfixed connectors max.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.98 07.9 75/171 65 76.3 28.6 139.2 127/220 100 147/220 125 200/310 150 114.6 60/148 50 60.

02.co.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Straight through Connections PN 16 Type 30/91 to 147/220 FHK 3.uk Construction of the Straight through connection PN 16 7 4 3 6 2 4 5 1 L 1 2 3 4 5 6 7 FLEXWELL heating cable with connectors Electronic detection conductors Joint pipe with supporting sockets HP PE reducing socket type RMA Shrink collar Shrink collar PUR hard foam ∅ Dmax – Subject to technical change – Dimensions of the straight through connection Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220-147/220 L [mm] 800 800 800 800 800 850 850 850 850 ∅ Dmax [mm] 215 235 235 265 265 290 320 355 355 Shrink collar 5 WTD CLW 150x430 lg 150x520 lg 150x520 lg 150x630 lg 150x630 lg 150x700 lg 150x700 lg 150x890 lg 150x890 lg 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg Shrink collar 6 WTD CLW 150x780 lg 150x840 lg 150x840 lg 150x940 lg 150x940 lg 225x1020 lg 225x1110 lg 225x1220 lg 225x1220 lg 145 lg 145 lg 145 lg 145 lg 145 lg 220 lg 220 lg 220 lg 220 lg .1 28.303.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.

303.39/116 39/148 .98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.02.147/220 FLEXWELL heating cable Type FHK 200/310 1 ∅ Dmax L 1 2 3 4 5 6 7 FLEXWELL heating cable Shrink collar Metal collar Plug Welding ring PUR hard foam Jointing compound ∅ Dmax Dimensionof the straight through connection Type FHK 30/91 30/116 .uk 6 L 1 2 3 4 5 6 7 FLEXWELL heating cable with connector Orbital weld (construction-side) Joint pipe with welding lip HP PE shrink joint Shrink collar PUR hard foam Electronic detection conductors 1 3 4 5 6 2 7 FLEXWELL heating cable Type FHK 30/91 .PIPE2000 Ltd UK Distributor FLEXWELL heating cable Straight through Connections PN 25 Type 30/91 to 200/310.127/220 . Welded 4 3 2 7 5 1 FHK 3.co.60/148 75/171 98/171 98/220 .2 28.147/220 200/310 L [mm] 800 800 800 850 850 850 900 ∅ Dmax (mm) 215 235 265 290 320 355 320 – Subject to technical change – .

02. .uk 28. the T-pieces are supplied with the standard or welded connector.PIPE2000 Ltd UK Distributor FLEXWELL heating cable T-Connection FHK 3.98 Construction of the T-connection ~1400 1000 500 A 3 6 2 7 4 5 1 1 2 3 4 5 6 7 FLEXWELL heating cable with connector Electronic detection conductors T-piece HP PE shrink joint Shrink collar Shrink collar PUR hard foam View A (all dimensions in mm) 45° D1 – Subject to technical change – H D2 50 100 H = D1+D2 + 50 2 1000 ~1350 Depending on the pressure stage.co.304 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.

uk 3 4 For dimensions see worksheets 3.4 A 6 1 2 3 4 5 6 Fastening ring Hexagon screw M6 x 20 Washer Cast ring Sealing ring FLEXWELL heating cable – Subject to technical change – Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 A 160 186 186 221 221 243 243 298 298 298 378 B 40 40 40 40 40 40 40 40 40 40 75 Number of sealing rings 1 1 1 1 1 1 1 1 1 1 2 All dimensions in mm .3 bar FHK 3.3 and 3.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.305.02.501.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Wall duct Watertight ≤ 0.co.1 28.501.

3 bar FHK 3. – Subject to technical change – Ø Core drill hole or pipe lining 3000 150 200 200 250 250 250 250 350 350 350 400 D internal 94 121 121 156 156 178 178 233 233 233 313 Doyma sealing set D external 150 200 200 250 250 250 250 350 350 350 400 .305.uk Doyma sealing set type C40 1 piece per duct Doyma sealing set type A 1 piece per duct Core drill hole or asbestos cement pipe lining type 3000 construction-side ØDinternal ØDexternal FHK DN 25 25 32 32 50 65 80 80 100 125 150 Type 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 The internal diameter of the core drill hole or asbestos cement pipe lining (= ØDexternal) must be specified when ordering the Doyma sealing set.2 28. The pipe may not be moved axially after mounting the Doyma sealing set.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Doyma Wall Duct with Core Drill Hole or Asbestos Cement Pipe Lining Presswater-tight > 0.co.02.

3 323.9x7. . The pipe may not be moved axially after mounting the Doyma sealing set.02.5x6.uk Doyma sealing set type C40 1 piece per duct Doyma sealing set type A 1 piece per duct Steel pipe lining construction-side (with corrosion protection) ØDinternal ØDexternal ØDH FHK Steel pipe lining DN 25 25 32 32 50 65 80 80 100 125 150 Type 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 168.1 406.3 244.1 323.9x7.3 219.9x7.5 219.3x4.3 244.5x6.3 273.1x6.3 bar FHK 3.0x6.1x6.0x6.1 323.4x6.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.3 28.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Doyma Wall duct with Steel pipe lining Presswater-tight ≤ 0.305.3 D internal 94 121 121 156 156 178 178 233 233 233 313 Doyma sealing set D external 159 206 206 231 231 260 260 309 309 309 393 – Subject to technical change – The internal diameter of the steel pipe lining (= ØDexternal) must be specified when ordering the Doyma sealing set.co.3 273.

8 245x4.3x4.0 150 200/310 310 DN 400 (406.uk min.3) 560 2 M + 2 N36 339x4.0 303x5.5 150 178 DN 250 (273.3) 460 2 M36 196x4.9) 410 2 F + 1 G25 175x3.0 150 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 233 DN 300 (323.0 150 156 DN 200 (219.8 196x4.3x4.5) 360 2 C 15 137x2.1x5. 250 mm Shrink collar Ø Da pipe lining HP PE reducing cap Runner Steel pipe lining constructionside (with corrosion protection) Minimum axial axial spacing a of the pipe linings HP PE reducing cap D2 x s2 D 1 x s1 l1 l2 FLEXWELL heating cable 30/91 External Ø FHK over PE Pipe lining of steel with corrosion protection Minimum axial spacing a FP runner type HP PE reducing cap HP PE reducing cap Shrink collar Connection FHK/reducing joint Connection pipe lining/ reducing joint Connecting strap Connection FHK/reducing joint Connection pipe lining/ reducing joint CLW CLW 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg 145 lg 220 lg 145 lg 220 lg 220 lg 220 lg WTD 150 x 450 lg WTD 150 x 720 lg 150 x 530 lg 150 x 720 lg 150 x 650 lg 150 x 870 lg 150 x 720 lg 225 x 1060 lg 150 x 890 lg 225 x 1170 lg 225 x 1170 lg 225 x 1430 lg Ø D1 x s1 Ø D2 x s2 l1 and l2 [mm] [mm] [mm] Ø Da x s [mm] [mm] [mm] 94 DN 150 (168.3 bar FHK 3.5 150 – Subject to technical change – .PIPE2000 Ltd UK Distributor FLEXWELL heating cable Pipe Lining Connection Presswater-tight > 0.305.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.9 340x6.4x6.4 28.5) 360 1 F + 1 G25 110x3.5 422x6.0 150 121 DN 150 (168.1) 500 2 M + 1 N36 250x4.0x6.0 196x4.co.9x7.02.

G or GR) 2 Shrink collar 3 HP PE shrink joint 4 Shrink collar 5 Bend 90O preinsulated.02. 1.co.5 x 1. steel or special steel 6 Labyrinth gland 7 End cap Type FHK – Subject to technical change – FHK external Ø D1 [mm] 94 121 121 156 156 178 178 233 233 233 313 Bend dimensions DN/D2 [mm] 25/90 25/110 32/110 32/125 50/125 65/140 80/160 80/200 100/200 125/225 150/250 All dimensions in mm 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 .5.98 07. DE.uk 28.306 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd UK Distributor FLEXWELL heating cable House Connection Bend FHK 3.03 7 6 1 2 3 4 D2 5 D1 700 1 FLEXWELL heating cable with connector (A.

FHK 30/ 91 FHK 39/116 FHK 60/148 FHK 75/171 FHK 98/171 FHK 127/220 FHK 147/200 FHK 200/310 500 450 400 350 300 250 200 150 100 50 0 [m] 25 30 35 50 50 100 100 150 [mm] 150 185 240 270 270 345 345 480 normal Normale drilling length Bohrungslänge [m] 121 112 110 141 190 167 201 224 drilling length (m) Bohrungslänge (m) 39/116 60/148 75/171 98/171 127/220 147/220 – Subject to technical change – FLEXWELL-Fernheizkabel FLEXWELL district heating cable The “normal drilling length = n ” is a standard value and can be achieved under soil and working conditions with no particular difficulties. Bohrlochradius Bohrlochdurchm. borehole radius min.98 07. min.414 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. borehole diam. Empf.. The “maximum drilling length“ for the specific project must be determined taking into consideration the local conditions and permissible tractional forces in each case. 200/310 30/91 . min.03 Type Typ Dmax [mm] 100 125 160 180 180 230 230 320 FZ [KN] 12 15 20 30 40 50 60 100 recommended recommended Empf. The borehole should be widened to the recommended minimum borehole diameter before pulling in the FLEXWELL district heating cable.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Laying without trenches FHK 3.02.uk 28. FZ = permissible tractional force using waterjet drilling technique A special traction head must be used for this.co. min.

Bricklaying Works DIN 18337 VOB. Earthworks DIN 18303 VOB. D-50672 Cologne . General Technical Specifications. Part C. Piling DIN 18305 VOB. Underground Gas and Water Piping Works DIN 18308 VOB. For trench-work specifications for straight through connections see worksheet FHK 3. General Technical Specifications. Embankments. Drainage Works DIN 18320 VOB. Sheeting DIN 18300 VOB. General Technical Specifications. Part C. 45. Working Space Widths. Guidelines for Construction FHK 3.501. Sealing against Non-pressing Water DIN 18354 VOB. Part C. General Technical Specifications. Part C. Design Loads DIN 4033 Drainage Channels and Lines of Prefabricated Pipes. Excavation Lining Works DIN 18304 VOB. General Technical Specifications.02. Landscape Gardening Works DIN 18330 VOB. for T-pieces FHK 3.co. They do not free the construction company of its obligation to pay due regard to accident prevention regulations and the above-mentioned standards and codes Guidelines for construction The minimum distances from other supply lines given in worksheet FHK 3.502. standards At least the following standards. Maastrichter Str. codes and directives must be followed for the underground works for FLEXWELL heating cable: DIN 1072 Road and Foot Bridges.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000. Work Group Underground. Part C.501. Part C. General Technical Specifications. General Technical Specifications. De-watering Works DIN 18307 VOB.506 must be complied with.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works Technical Codes. General Technical Specifications.uk Technical codes.503.2 are recommended values. General Technical Specifications. Part C. Part C. General Technical Specifications. Part C. Standards. Part C.1 28. Guidelines for Construction DIN 4124 Building Trenches and Trenches. 1 2 – Subject to technical change – Employers’ Liability Insurance Association for the Building Trade Society for the Research into Roads. Asphalt Coating Works Instruction 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.

2 28.20 0.60 0.60 0.00 1.00 2.3 0.10 0.90 0. Excavation 3) Sand filling Type d for SLW 60 1) for SLW 60 [mm] [m] [m] [m] [m] [m] [m] for SLW 60 [m 3/m] [m 3/m] 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 94 0.95 2.1 d B LK 1 2 3 4 5 0.uk Trench dimensions Fig.50 6.72 0.50 0. .00 0.30 1.75 1.00 0.50 4. 1: Trench plan Fig. 2: Trench sectional view A-A (dimensions in m) 1 A Rmin A 5 6 7 min.00 2. 0.40 0.85 0.39 1) SLW 60 = 100 kN wheel load according to DIN 1072 2) Smaller radii only after consultation with BRUGG Rohrsysteme 3) Excavation quantities without consideration of the slope inclination – Subject to technical change – Trench and working space dimensions.50 1.60 0.02.60 0. laying construction-side) 6 Sand filling (grain size 0 .03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.00 1.98 07.65 1.05 0.24 200/310 313 1. excavation and sand-filling quantities The trench widths “B“ are recommended values.80 0.59 0. Please pay attention to valid technical rules.co.4 mm) 7 Filling material (reusable excavated material) x Tmin 2 3 1 4 FLEXWELL heating cable (FHK) External diameter FHK Trench depth Tmin Minimum covering t Trench width B Working space width 2B Working space length Lk Minimum trench radius2) Rmin.00 0.60 0.47 0.85 0.14 121 0.20 1.6 0.50 1.95 0. directives and accident prevention regulations.60 0.50 1.00 0.501.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works Trench Dimensions FHK 3.50 1.51 0.1 x x B 2B FLEXWELL heating cable (FHK) Connector Wall sealing ring (wall duct) Working space in front of buildings and shafts Trench warning strip (delivery by BRUGG.00 0.55 1.60 1.20 233 0.16 156 0.18 178 0.

2 x h h a min.22 0. 0.35 0. 4: Wall opening for loop-in method b min.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works Wall Openings FHK 3.30 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 .10 0.50 0. 2 x b a min.uk Fig.65 0. wall distances FHK a b h 30/91 0.25 0.50 Dimensions wall opening.24 0.35 m Fig.85 0.watertight sealing on site) Dimensions in m 0.55 0.3 28.35 m – Subject to technical change – min.40 0.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.35 m a min.20 0.45 0. 0. 0. 0.35 0. 3: Wall opening FLEXWELL connector a 2 3 4 h b 1 min.18 0.02. 1 2 3 4 FLEXWELL heating cable (FHK) Connector Wall duct Concrete (wall opening .26 0.co.21 0.501.35 m For the loop-in method the wall openings must be enlarged according to the pipe route and the dimensions below (check building statics if necessary).

uk A B B C Top of trench ground For core drill holes for Doyma seals see worksheet 3.305.co.02.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.2 ØD A B C D Axial spacing Core drill hole diameter Distance trench ground-pipe axis Diameter wall duct ØB Minimum dimensions in mm Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 A 260 310 310 360 B 250 300 300 350 C 50 60 80 90 D 160 185 221 243 – Subject to technical change – 410 460 400 450 120 155 298 378 .4 28.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Core Drill Holes*) *) only applies to standard wall duct FHK 3.501.

75 1.55 0.55 1.5 0.75 0.1 1 2 3 4 FLEXWELL heating cable Straight through connection Sand filling (0 .55 1.5 1.5 2.4 mm round grain) Filling material (reusable excavated material) 0.0 4.65 1.65 0.6 1.0 2.6 0.6 0.0 5.1 Fig.75 2.02.uk Fig.00 In event of repair dimension A1 has to be increased by 2. .75 1.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.1 B B1 A A1 Dimensions in mm Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 – Subject to technical change – A A1 1.3 0.75 0. 2: Working space for straight through connections (ground plan) 0.6 1.0 Trench width B 0.502 28.00 Min.55 0.65 1.75 1.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works Straight Through Connections FHK 3. trench width B1 1.co.5 2.5 m to bend out the FLEXWELL heating cable.65 0. 1: Working space for straight through connections (side view) 4 2 3 1 0.

8 m Fig.4 mm round grain) Filling material (reusable excavated material) Trench ground main pipe H 0.30 0.24 0.36 0.36 0.36 H = Difference in height between trench ground main pipe and trench ground branch pipe .22 0.25 0.02.26 0.28 0.23 0.1 28. 0.32 0.30 0.23 0.23 0.23 0.26 0.26 0. covering 0.24 0.26 0.9 m 1.25 0. working space (ground plan) Dimensions apply to all FHK types ~1.3 m 1.32 0.30 0.32 0.28 0.24 0.26 0. 2) FHK main pipe 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 Dimension H FHK branch pipe Dimensions H in m – Subject to technical change – 30/91 0.8 m 0.20 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 0.9 m 0.30 0.28 0.24 0.24 0.9 m 0.32.19 30/116 0.32 0.uk Fig.30 0.26 0.co.34 0.28 0.9 m 0.24 0.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.34 0.24 0.24 0.25 0.28 0.25 ~1. 2: T-piece connection.3 Table 1 Branch downwards (fig.23 0.6 mm 2 3 1 1 2 3 4 FLEXWELL heating cable (FHK) T-branch Sand filling (0 .25 0.23 0.21 0.25 0.23 0.25 1. working space Branch downwards (sectional view) 4 Min.34 0.8 m 0.1 0.30 0.23 0.24 0.25 0.26 0.23 0.26 0.28 0.32 0.24 0.36 0.1: T-piece connection.25 0.3 m 0.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works T-Piece Connections Branch downwards FHK 3.25 0.23 0.28 0.503.

27 0.31 0.40 0.34 0.40 0.32 0.1 H Trench ground main pipe 0.6 m 0.32 0.34 0.34 0.27 0.40 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 0.23 0.32 0.8 m Fig.34 0.3 m 1.30 0.40 0.36 H = Difference in height between trench ground main pipe and trench ground branch pipe – Subject to technical change – .40 0. working space Branch upwards (sectional view) 4 2 3 1 1 2 3 4 FLEXWELL heating cable T-branch Sand filling (0 .30 0.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works T-Piece Connections Branch Upwards FHK 3.36 0.25 1.9 m 0.1: T-piece connection.9 m 1.3 m 0.8 m 0.9 m 0.32 0.24 0.9 m 0.02.40 0.28 0.30 0.36 0.33 0.34 0.40 30/116 0.38 0.40 0.26 0.28 0.35 0.36 0.36 0.25 ~1.36 0. covering 0.28 0.8 m 0.36 0.40 0.25 0.3 Table 1 Branch upwards (fig.38 0.co.503.30 0.36 0.36 0.uk Fig. working space (ground plan) Dimensions apply to all FHK types ~1.28 0.36 0.2 28.4 mm round grain) Filling material (reusable excavated material) Min.25 0.36 0. 2) FHK main pipe 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 Dimension H FHK branch pipe Dimension H in mm 30/91 0.30 0.25 0.36 0.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.31 0.24 0.36 0.36 0.37 0.36 0.40 0. 2: T-piece connection.36 0.26 0.30 0.35 0.34 0.38 0.28 0.

40 0.34 0.20 0. 0.50 1.30 0.21 0.97 0.38 0.41 0.93 0.98 0.53 0.34 0. .10 Tmax.uk Fig.55 0.95 0.25 0.43 0.15 0. a2 2) Wall distance Length Width Distance to centre of of the of the to bottom breakthrough breakthrough breakthrough of the foundation 0.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Instructions for Excavation Works House Connection Bend FHK 3.30 0.98 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.30 0.95 0.504 28.32 0.65 0.02.2: House connection bend Ground plan 1.40 0. etc.1: House Connection bend Sectional view 1 2 3 4 5 6 7 8 FLEXWELL heating cable (FHK) HP PE shrink joint House connection bend Shrink collar Labyrinth gland End cap Sand filling (0 .00 1.75 0.95 – Subject to technical change – 1) Measured to trench ground 2) Dimension a2 calculated on the assumption that there are no obstacles in the way of the bends in the form of foundations.35 0.16 0.65 0.60 0.18 0.52 0.98 0.50 0.25 0.16 0.55 0.20 Fig.42 0.77 0.75 0.92 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310 0.49 0.20 0.74 0.00 0.10 0.96 0.35 0.32 0.56 0.16 0.40 0.50 a1 2xB B1) b a2 h Type FHK B Trench width a Side wall distance to centre of breakthrough 0.57 0.53 Minimum dimensions b h T max.60 0.36 0.72 0.16 0.17 0.66 0.00 1.co.62 0.4 mm round grain) Filling material (reusable excavated material)  6 1 8 7 2 4 3 5 0.20 0.98 0.75 0.26 0.

uk The temperature of the earth in the immediate vicinity of underground heating cables is higher than normal. Fig.3 0.03 Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.02.3 0.0 0.3 0. Reasonable minimum distances between the supply lines and heating cables are therefore necessary (see also VDE 0100 and VDE 0101).6 1. 2: Parallel lines 2 3 1 Table 1: Minimum distance to crossing lines – Subject to technical change – Table 2: Minimum distance to parallel lines Type of supply line Min.7 1.PIPE2000 Ltd UK Distributor FLEXWELL heating cable Distances to Other Supply Lines FHK 3.4 Dimensions in m . signal. The transmission capacity of underground electric cables can be influenced by this. distance Parallel lines Length 5m >5m Type of supply line minimum distance 1-kV.0 0.98 07.co. measuring cables 10-kV or one 30-kV cable Several 30-kV cables or cables above 60 kV Gas and water pipes 0.2 Dimensions in m 1-kV. signal.506 28.6 1.4 0. 1: Crossing lines 2 1 1 Heating cable 2 Other supply lines 3 Distance lines 3 Fig. measuring cables 10-kV or one 30-kV cable Several 30-kV cables or cables above 60 kV Gas and water pipes 0.5 0.

Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk .co.pipe2000.co.uk www.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.

TECHNICAL INFORMATION SHEETS P RE .co.INSULATED P IPES FLEXWELL® FSR SAFETY PIPE PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.pipe2000.co.uk .uk www.

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co.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.uk .

leak detection medium) Legal basis .can be laid as a continuous length direct from the drum/coil into the trench or onto the pipework trestles .your installation . stainless steel. The operation of this system complies with the highest European safety level.. the leak alarm. There a leak detection system is defined as all the equipment necessary for the detection of leaks (the monitoring space.Product is in compliance with all German environmental and water purity legislation as well as . flexible and endless piping system supplied ex works coiled on reels. bendable .highly effective corrosion-proofing along the entire length . acceptance and operational readiness of . Laying and installation .uk FLEXWELL Safety Pipe® Systems Description FSR 3. process. pressure and material testing are carried out by qualified independent test institutes and our internal quality control department as required by the compliance certification.no field joints needed.short installation times .acceptance test only after complete laying/installation by function testing of the leak detection system .04 FLEXWELL Safety Pipe FLEXWELL Safety Pipe is a coaxial double-walled.high degree of corrosion safety . .101 12.changes of direction are taken up by the flexible 5 1 2 3 4 Construction of FLEXWELL Safety Pipe 1 primary pipe (copper.installation/laying carried out by trained and licensed contractors .environmental legislation and water protection requirements . They are constructed for safety and ensure that no leaking product can escape into the environment.European standards for leak detection systems .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.fast and simple to lay from A to B .support from BRUGG installation and service organization Advantages of the system .during laying no construction or pressure tests needed .constructional regulations and industrial safety acts in respect of fire and explosion prevention.no welding necessary along pipe route .ex works system with all necessary expertises. Type approval FLEXWELL Safety Pipe with leak monitoring is a recognized leak detection system within German regulations. It is available in sizes from DN 15 to DN 150 with pressure ratings up to PN 25.planning security through type-approved system .clearly defined procedures for approval. hazardous and flammable products.co. Leak monitoring The 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. double-walled piping system. It is designed for permanent leak monitoring and approved for the transport of water pollutant. thermo plastics) 2 surveillance space 3 outer containment pipe 4 corrosion-proofing 5 connecting joint pipe system . Systems of this class show a leak either above or below the fluid surface in doublewalled safety systems.lengths up to 500m available .above and below ground . test and quality control documentation – Subject to technical modifications – Quality.

The system is supplied with all components for installation of the piping and a complete range of leak detection equipment. a surveillance space.with corrugated stainless steel primary pipe and outer containment pipe and protective jacket Worksheet FSR-M 3. i. Consisting of a primary pipe. except DN 40 with corrugated stainless steel primary pipe and corrugated steel outer containment pipe Worksheet FSR 3. reinforcing bands.uk FLEXWELL Safety Pipe® FLEXWELL Safety Pipe System Product Range FSR 3.DN 100..DN 80 with corrugated copper primary pipe and corrugated steel outer containment pipe Worksheet FSR 3. flammable/non-flammable or otherwise hazardous fluids and gases.400 .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.300 ... – Wall and manhole entry: Worksheets FSR 3. Leak monitoring for FLEXWELL Safety Pipe Worksheets LDS 3..co..DN 50 . a corrugated outer containment pipe.201 FLEXWELL Safety Pipe DN 20 .700 . .202 Important data sheets for FLEXWELL Safety Pipes: – head loss diagrams: Worksheets FSR 3.. a double layer of BRUGG bitumen and a polyethylene jacket as external corrosion-proofing.102 12.800 – Details for underground installation: Worksheet FSR 3.: Connecting joints Worksheet FSR 3... capable of leak-monitoring and suitable for the transport of water pollutant.04 The FLEXWELL Safety Pipe System is a family of pipework assemblies supplied in “endless” lengths.201 FLEXWELL Safety Pipe DN 25 . Refer to the separate and special documentation covering technical details of this variant ! FLEXWELL Safety Pipe DN-15 with smooth-bore copper primary pipe and corrugated copper outer containment pipe Worksheet FSR 3.DN 150 with thermoplastic primary pipe and corrugated steel outer containment pipe (only on request) FLEXWELL Safety Pipe DN 25 .211 DN 25 .800 . – Subject to technical modifications – FLEXWELL Safety Pipe Components f.

which already offers a high level of safety anyway due to its doublewalled construction. etc. These double-walled and monitored fittings must be located where they are clearly visible.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. the monitored pipe fittings and the leak monitoring system.uk FLEXWELL Safety Pipe® Product Description Flanged system fittings with monitored gasket seals FSR 3.co. They can be integrated into the leak monitoring system so that permanent. In order to optimize the use of FLEXWELL safety piping. It is not permitted to install flanged fittings below ground. tri/perchloroethylene. e. i. Due to the flexibility of the pipe. and the entire pipe length can be laid in one piece. toluene. emulsions lyes acids gases – Subject to technical modifications – The safe transport of hazardous substances makes continually growing demands on the constructors of fuel depots and industrial plants. elbows.103 12.04 Flanged pipe fitting with monitored gasket seals for the transport of hazardous substances Solvents. special flanged pipe connections. flexible FLEXWELL Safety Pipe. petrol alcohols oils. . uninterrupted monitoring of the entire pipe system from the tank to the user becomes possible. the use of elbow fittings is unnecessary within certain bending radii. T-pieces and through-connections with monitored gasket seals are available. The complete system comprises the double-walled. The principle of monitoring gasket seals consists in having a radial groove extending full circle over the sealing surface of the flanged fitting that connects via a drilled port hole to the surveillance space of the safety pipe.

3 2 3 6 0. kg/m 1.2 0.8 1.8 4.9 2. type DN PN d D mm FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 25 32 40 50 80 25 25 25 25 16 30 39 48 60 83 mm 48 60 71 83 120 wall of PE-HD jacket mm 2 2 2 2.12 bending radius cm 30 article No.65 0.2 D d D d .0 821 003 90 2.38 0.201 12. FLEXWELL Safety Pipe with smooth-bore copper primary pipe copper primary pipe surveillance space d D corrugated copper outer containment pipe wall of PE-HD jacket mm 1.3 3.04 1.8 9.5 3 internal volume primary surveillance pipe space l/m l/m 0.co.73 2 kg/m 1.41 0.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.5 corrosion-proofing (bitumen) weight PE-HD jacket type DN PN mm FSR 16/30 15 25 16 mm 30 internal volume primary surveillance pipe space l/m l/m 0. FLEXWELL Safety Pipe with corrugated copper primary pipe – Subject to technical modifications – corrugated copper primary pipe helically wrapped steel banding surveillance space corrugated steel outer containment pipe PE-HD jacket corrosion-proofing (bitumen) weight bending radius cm 50 60 60 70 100 821 005 90 821 006 90 821 004 90 821 007 90 821 009 90 article No.uk FLEXWELL Safety Pipe® FLEXWELL Safety Pipe with copper primary pipe Product Description FSR 3.

4539 corrugated stainless steel primary pipe helically wrapped steel banding surveillance space corrugated steel outer containment pipe PE-HD jacket corrosion-proofing (bitumen) Primary pipe: Material No.41 0.4539 type DN PN d D wall of PE-HD jacket mm 2 2 2.4 4.3 3 0.4571 type DN PN d D wall of PE-HD jacket mm 2 2 2.8 Other materials for primary and outer containment pipe available on request. mm FSR 30/48 25 FSR 39/60 32 FSR 60/83 50 FSR 83/120 80 FSR 127/175 100 25 25 25 25 25 30 39 60 83 127 mm 48 60 83 120 175 kg/m 1.8 9.73 2 4 weight bending radius cm 50 60 70 100 150 821 105 91 821 106 91 821 107 91 821 109 91 821 110 91 article No.202 12.5 3 4 internal volume primary surveillance pipe space l/m l/m 0.4 4.8 2.73 weight bending radius cm 50 60 70 821 105 95 821 106 95 821 107 95 article No. 1. mm FSR 30/48 FSR 39/60 FSR 60/83 25 32 50 25 25 25 30 39 60 mm 48 60 83 kg/m 1.41 0.4 D d Primary pipe: Material No.3 3 6 14 0.38 0.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.04 3. 1. FLEXWELL Safety Pipe with corrugated stainless steel primary pipe Material No. 1.4571 and 1.2 18.38 0.5 internal volume primary surveillance pipe space l/m l/m 0. – Subject to technical modifications – .co.8 1.8 2.uk FLEXWELL Safety Pipe® FLEXWELL Safety Pipe with stainless steel primary pipe Product Description FSR 3.8 1.

5 76.95 radius cm 30 ArticleNo.co.38 0.4404 oder 1. FLEXWELL Safety Pipe® with corrugated stainless steel inner pipe D1 steel reinforcing bands surveillance space corrugated outer pipe material: 1.3 3 0.04 1.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.4404 protective jacket DN PN d mm D mm 43 53.uk FLEXWELL Safety Pipe® FLEXWELL Safety Pipe with protective jacket type: FSR-M Product Description FSR 3.2 0.8 1.4301 oder 1.211 12.1 3. FLEXWELL Safety Pipe® with smooth-bore copper inner pipe copper inner pipe 18 x 1 surveillance space corrugated copper outer pipe protective jacket Typ DN PN d mm D mm 24.41 0.6 radius cm 50 60 70 821 115 91 821 116 91 821 117 91 ArticleNo.4571 Typ FSR-M 30/48 FSR-M 39/60 FSR-M 60/83 d d .5 D1 mm 27 Volume inner pipe surveillance l/m space l/m 0.12 Weight kg/m 0. 25 32 50 25 25 25 30 39 60 D1 D D – Subject to technical modifications – corrugated inner pipe material: 1.5 Volume inner pipe surveillance l/m space l/m 0.5 D1 mm 46. 821 013 90 FSR-M 16/30 15 25 16 2.3 2.2 57.1 80.73 Weight kg/m 1.

80 Reference measuring line for cutting to length of pre-manufactured coils of FLEXWELL safety piping FSR 16/30 Material: threaded sleeve made of brass Warning: Only brazing materials approved by BRUGG may be used.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000..04 FLEXWELL safety pipe type FSR 16/30 screw plug. – Subject to technical modifications – . 100 26 60 overlap heat-shrink sleeve PE jacket min. jointing of primary pipe: brazing FSR 3.301 12. For installing the connection: see Installation Instructions FSR 3.920 .350 containment pipe brazed to sleeve heat-shrink sleeve primary tube brazed to sleeve copper pipe 18 x 1 ∠ 40 PE jacket removed from containment pipe approx. to be removed when connecting to leak detector threaded sleeve measuring branch for connection to leak detector see worksheet FSR 3.co.uk FLEXWELL Safety Pipe® Standard Connecting Joint with stub end..

co. Bolts and nuts are not included in the set supplied. jointing of primary pipe: brazing FSR 3.04 FLEXWELL safety pipe type FSR 30/48 to FSR 83/120 measuring branch for connection to leak detector see worksheet FSR 3.5 B mm 55 54 51 49 54 C mm 80 80 80 100 100 article No. to DIN 2635.5 1.340 B cutback length of casing pipe C overlap heat-shrink sleeve PE jacket min. DIN 2656 D øk bolts* mm mm No. DIN 1629 Collar flange and split collar flanges made of steel USt 37-2acc. to be removed when connecting to leak detector primary copper pipe brazed to sleeve heat-shrink sleeve Ø d1 ØD Øk Ød PE jacket removed from convoluted containment pipe A two set of split collar flanges see Worksheet FSR 3. 80 Material: Threaded sleeve made of steel R-St 37.0 acc. collar flange 829 829 829 829 829 355 356 354 357 359 90 90 90 90 90 article No. . off 115 140 150 165 200 85 100 110 125 160 M12 M16 M16 M16 M16 x x x x x 75 80 80 85 90 4 4 4 4 8 A mm 1.5 1. Warning: Only brazing materials approved by BRUGG may be used. For the double set of split flanges use bolts 10 mm longer.350 threaded sleeve with collar flange as per DIN 2656 containment pipe brazed to threaded sleeve brazed banding screw plug. split collar flange 829 829 829 829 829 355 356 354 357 359 50 50 50 50 50 * The lengths of bolts shown in table above are intended for bolting to a standard welding neck flange acc.uk FLEXWELL Safety Pipe® Standard Connecting Joint with collar and single or split collar flanges. DIN 17100.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000..5 1.302 12. hot-dipped galvanized – Subject to technical modifications – type DN d d1 DN mm mm FSR FSR FSR FSR FSR 30/48 39/60 48/71 60/83 83/120 25 50 32 60 40 70 50 84 80 120 68 78 88 102 138 25 32 40 50 80 flange acc..5 1. For installing the connection: see Installation Instructions FSR 3.920 .

0 acc.co. to be removed when connecting to leak detector primary copper pipe brazed to sleeve containment pipe brazed to threaded sleeve brazed banding heat-shrink sleeve d R cutback length of casing pipe A B PE jacket removed from convoluted containment pipe C overlap heat-shrink sleeve PE jacket min.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.350 screw plug. FSR FSR FSR FSR 30/48 39/60 48/71 60/83 25 32 40 50 Warning: Only brazing materials approved by BRUGG may be used. 80 Material: Threaded sleeve made of steel R-St 37.uk FLEXWELL Safety Pipe® Connecting Joint with threaded male end. For installing the connection: see Installation Instructions FSR 3.303 12. jointing of primary pipe: brazing FSR 3.. – Subject to technical modifications – . DIN 1629 type DN Connection Whitworth pipe thread R 1 1/2 R2 R 2 1/2 R 2 1/2 d DN mm 40 50 65 65 52 65 76 85 mm 5 5 5 5 mm 73 72 79 87 mm 80 80 80 100 829 829 829 829 353 354 355 356 93 93 93 93 A B C article No.04 FLEXWELL safety pipe type FSR 30/48 to FSR 60/83 measuring branch for connection to leak detector see worksheet FSR 3..920 .

.308 12. Screws and nuts are not included in the material delivered.350 MeaScrew socket with slide-on flange acc.340 B Pulling off the outer pipe from the inner pipe C Overlap shrink sleeve – PE jacket min. to DIN 2656 hard-soldering outer pipe Remove the locking screw when connecting to the leak detector. for Measuring branch 829 335 00) * * The screw length given is intended for joining to a blank flange acc.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. Only BRUGG solder Type 8.. 80 – Subject to technical modifications – Material: Screw socket made of steel St 37..uk FLEXWELL Safety Pipe® Monitored connection with slide-on flange – Part 1 Joined by: hard-soldering FSR 3.920 . hot-galvanized type DN d d1 d2 DN mm mm mm FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 25 50 32 60 40 70 50 84 80 120 91 105 126 126 167 60 75 94 94 130 40 50 65 65 100 flange acc.04 Leak-monitored connection Type: Part 1 for connection to leak-monitored elbow Worksheet 3.34 may be used! Installation of the connection see installation instructions FSR 3.-No.50. hard-soldering copper inner pipe hard-soldering reinforcing bands shrink sleeve Øk d1 d2 D d Removing the PE jacket from the outer pipe A two-part slide-on flanges see Worksheet No. to DIN 17100. without measuring branch slide-on two-part flange slide-on flange 829 481 91 829 482 91 829 483 91 829 484 91 829 485 91 829 481 80 829 482 80 829 483 80 829 484 80 829 485 80 Screw socket with and without measuring branch available (Article No.co. to DIN 2635. For two-part flanges use screw lengths 10mm longer.502 and leak-monitored T-piece Worksheet 3.0 acc. to DIN 1629 slide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 2656 A B D øk bolts* mm mm Stück mm mm 150 110 165 125 185 145 185 145 235 190 M16 x 70 M16 x 80 M16 x 80 M16 x 80 M20 x 90 4 4 8 8 8 3 3 3 3 3 60 59 61 59 69 C mm 80 80 80 100 100 Art.503 Measuring branch for the connection to leak detector see Worksheet 3.FSR 3.

For two-part flanges use screw lengths 10mm longer.340 B Pulling off the outer pipe from the inner pipe C Overlap shrink sleeve – PE jacket min.34 may be used! Installation of the connection see installation instructions FSR 3. hard-soldering copper inner pipe hard-soldering reinforcing bands shrink sleeve Øk d1 d2 D d Removing the PE jacket from the outer pipe A two-part slide-on flanges see Worksheet No.5 60.. to DIN 2656 A D øk bolts* mm mm Stück mm 150 165 185 185 235 110 125 145 145 190 M16 x 70 M16 x 80 M16 x 80 M16 x 80 M20 x 90 4 4 8 8 8 1. to DIN 2635. to DIN 2656 hard-soldering outer pipe Remove the locking screw when connecting to the leak detector.50.0 acc.501 Measuring branch for the connection to leak detector see Worksheet 3.-No.5 62.309 12.FSR 3.co. Screws and nuts are not included in the material delivered.04 Leak-monitored connection Type: Part 2 Of Part 1 as leak-monitored through-connection acc. to DIN 1629 slide-on flange and two-part slide-on flange made of steel USt 37-2 acc.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.5 70.5 B mm 61.uk FLEXWELL Safety Pipe® Monitored connection with slide-on flange – Part 2 Joined by: hard-soldering FSR 3.5 1.350 MeaScrew socket with slide-on flange acc.5 C mm 80 80 80 100 100 Art. 80 type DN d d1 d2 DN mm mm mm FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 25 50 32 60 40 70 50 84 80 120 87 101 121 121 161 60 75 94 94 130 40 50 65 65 100 flange acc. hotgalvanized O washer seal: Choice of material acc. for Measuring branch 829 335 00) * * The screw length given is intended for joining to a blank flange acc. – Subject to technical modifications – Material: Screw socket made of steel St 37. to material to be transported Only to be supplied by BRUGG .5 1.920 .5 1.. Only BRUGG solder Type 8.5 60. without measuring branch slide-on two-part flange slide-on flange 829 481 92 829 482 92 829 483 92 829 484 92 829 485 92 829 481 81 829 482 81 829 483 81 829 484 81 829 485 81 Screw socket with and without measuring branch available (Article No. to DIN 17100.5 1. to Worksheet 3.

Bolts and nuts are not included in the set supplied. DN 32 and DN 50: Threaded sleeve made of Mat. For the double set of split flanges use bolts 10 mm longer.4571. 1.04 FLEXWELL safety pipe type FSR 30/48 to FSR 127/175 measuring branch for connection to leak detector see worksheet FSR 3.920 .4539 two-part flange slide-on flange two-part flange slide-on flange 829 345 51 829 346 51 829 347 51 – – * The lengths of bolts shown in table above are intended for bolting to a standard welding neck flange acc.4571 829 355 51 829 356 51 829 357 51 829 359 51 829 360 51 Article No. mm mm 115 140 165 200 270 85 100 125 160 220 M12 x 85 M16 x 90 M16 x 95 M16 x 110 M24 x 120 4 4 4 8 8 63 80 62 80 62 100 72 100 74 130 Article No. 80 – Subject to technical modifications – Material: DN 25. to DIN 17440. Warning: Only brazing materials approved by BRUGG may be used. . R-St 37.310 12. 1.350 primary stainless pipe TIG-welded to sleeve threaded sleeve with collar flange as per DIN 2656 containment pipe brazed to threaded sleeve brazed banding screw plug. No. For installing the connection: see Installation Instructions FSR 3.4539 829 345 91 829 346 91 829 347 91 – – Article No. 1.uk FLEXWELL Safety Pipe® Standard Connecting Joint with collar and single or split collar flanges.0 + 1.4571. Collar flange and split collar flanges made of steel USt 37-2acc.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.4539 acc. hot-dipped galvanized. DN 80 and DN 100: Threaded sleeve of Mat. DIN 2656 B C D øk screws* mm mm no.4571 829 355 91 829 356 91 829 357 91 829 359 91 829 360 91 Article No.340 cutback length of casing pipe C overlap heat-shrink sleeve PE jacket min. to be removed when connecting to leak detector heat-shrink sleeve Ø d1 ØD Øk Ød PE jacket removed from convoluted containment pipe B two set of split collar flanges see Worksheet FSR 3. jointing of primary/containment pipe: WIG welding/ brazing FSR 3. No. DIN 17100. Type DN d d1 DN mm mm FSR FSR FSR FSR FSR 30/48 39/60 60/83 83/120 127/175 25 32 50 80 100 50 60 84 120 172 68 78 102 138 190 25 32 50 80 125 Flange acc. to primary pipe material of the FLEXWELL Safety Pipe. 1. 1. Choice of material acc. 1. to DIN 2635.co...

WIG welding stainless steel inner pipe Measuring branch for the connection to leak detector see Worksheet 3.: 1. 1..4539 829 345 41 829 346 41 829 347 41 FSR 30/48 FSR 39/60 FSR 60/83 25 32 50 Only BRUGG solder Type 8.311 12.co.5 85 B mm 71 72 82 C mm 80 80 100 Article-No. 80 * Material: 1.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. 1. 1.920 . to DIN 17440 Choice of material depends on material of inner pipe of FLEXWELL Safety Pipe .4571 829 355 97 829 356 97 829 358 97 Article-No. – Subject to technical modifications – Material: Screw socket –stainless steel Material No.04 FLEXWELL-Safety Pipe® Ttype FSR 30/48 bis FSR 60/83 Remove the locking screw when connecting to the leak detector.4539 – only on request type DN Connection Whitworthpipe thread lug R 1 1/2 R2 R 2 1/2 d DN mm 40 50 65 52 63..50.34 may be used! Installation of the connection see installation instructions FSR 3.4571.uk FLEXWELL Safety Pipe® Connection with thread lug Joined by: WIG welding/hard-soldering FSR 3.4539* acc.350 hard-soldering outer pipe hard-soldering reinforcing bands shrink sleeve d R Pulling off the outer pipe from the inner pipe B Removing the PE jacket from the outer pipe C Overlap shrink sleeve – PE jacket min.

4539 slide on flangetwo. to DIN 2635.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.5 59.4571.5 2.uk FLEXWELL Safety Pipe® Monitored connection with slide-on flange – Part 1 Joined by: WIG welding/hard-soldering FSR 3. for Measuring branch 829 335 00) * * The screw length given is intended for joining to a blank flange acc.5 2.920 . without measuring branch 1. Screw socket with and without measuring branch available (Article No.318 12. Screws and nuts are not included in the material delivered. hotgalvanized type D N d d1 d2 m mm m m m 30/48 25 50 91 60 39/60 32 60 105 75 60/83 50 84 126 94 83/120 80 120 167 130 127/175100 172 223 186 DN FSR FSR FSR FSR FSR flange acc. hard-soldering reinforcing bands Øk d1 d2 D d two-part slide-on flanges see Worksheet No.5 2 2 B mm 60. to DIN 2656 D øk bolts* mm mm Stck. .5 59.part slide onslide on flangetwo-part silide on 829 481 95 829 482 95 829 484 95 829 485 95 829 486 95 829 481 84 829 482 84 829 484 84 829 485 84 829 486 84 829 481 97 829 482 97 829 484 97 – – 829 481 88 829 482 88 829 484 88 – – lengths 10mm longer.34 may be used! Installation of the connection see installation instructions FSR 3. to DIN 2656 hard-soldering outer pipe shrink sleeve Remove the locking screw when connecting to the leak detector.co.4539 acc. 1.4539 1.4571 1.4571 1. To DIN 17440 Choice of material depends on material of inner pipe of FLEXWELL Safety Pipe Slide-on flange and two-part slide-on flange made of steel USt 37-2 acc.04 Leak-monitored connection Type: Part 1 for connection to leak-monitored elbow Worksheet 3.513 WIG welding stainless steel inner pipe Measuring branch for the connection to leak detector see Worksheet 3. DN 32 and DN 50: screw socket made of stainless steel DN 80 and DN 100: screw socket made of steel and stainless steel Material No.512 and leak-monitored T-piece Worksheet 3.350 MeaScrew socket with slide-on flange acc. to DIN 17100.FSR 3. 80 – Subject to technical modifications – Material: DN 25.340 A B Pulling off the outer pipe from the inner pipe Removing the PE jacket from the outer pipe C Overlap shrink sleeve – PE jacket min. 40 150 110 M16 x 70 4 50 165 125 M16 x 80 4 65 185 145 M16 x 80 8 100 235 190 M20 x 100 8 150 300 250 M24 x 110 8 A mm 2. For two-part flanges use screw Only BRUGG solder Type 8.50.5 90 87 C mm 80 80 100 100 130 Art..-No. 1..

34 may be used! Installation of the connection see installation instructions FSR 3. to DIN 2656 hard-soldering reinforcing bands hard-soldering outer pipe shrink sleeve Remove the locking screw when connecting to the leak detector. for Measuring branch 829 335 00) * * The screw length given is intended for joining to a blank flange acc.4539 mm mm Stck. without measuring branch D øk bolts* 1. – Subject to technical modifications – Material: DN 25.4571 1.5 139. 1.co.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.511 WIG welding stainless steel inner pipe Measuring branch for the connection to leak detector see Worksheet 3..FSR 3. Only BRUGG solder Type 8. 80 type D N d d1 d2 DN m mm m m m flange acc.319 12.50. DN 32 and DN 50: screw socket made of stainless steel DN 80 and DN 100: screw socket made of steel and stainless steel Material No.04 Leak-monitored connection Type: Part 2 Of Part 1 as leak-monitored through-connection acc.part slide onslide on flangetwo-part silide on 150 165 185 235 300 110 M16 x 70 125 M16 x 80 145 M16 x 80 190 M20 x 100 250 M24 x 110 4 4 8 8 8 1 62 80 1 61 80 1 61 100 0. 1.uk FLEXWELL Safety Pipe® Monitored connection with slide-on flange – Part 2 Joined by: WIG welding/hard-soldering FSR 3. hotgalvanized .5 100 0.340 A B Pulling off the outer pipe from the inner pipe Removing the PE jacket from the outer pipe C Overlap shrink sleeve – PE jacket min.4539 acc.350 MeaScrew socket with slide-on flange acc. Screws and nuts are not included in the material delivered. mm mm mm slide on flangetwo.4539 1. to Worksheet 3.5 129.4571.. To DIN 17440 Choice of material depends on material of inner pipe of FLEXWELL Safety Pipe Slide-on flange and two-part slide-on flange made of steel USt 37-2 acc.5 130 829 481 96 829 482 96 829 484 96 829 485 96 829 486 96 829 481 85 829 482 85 829 484 85 829 485 85 829 486 85 829 481 98 829 482 98 829 484 98 – – 829 481 89 829 482 89 829 484 89 – – FSR FSR FSR FSR FSR 30/48 25 50 39/60 32 60 60/83 50 84 83/120 80 120 127/175100 172 87 101 121 161 217 60 75 94 130 186 40 50 65 100 150 Screw socket with and without measuring branch available (Article No.920 . Øk d1 d2 D d two-part slide-on flanges see Worksheet No. to DIN 17100.4571 1. to DIN 2635. For two-part flanges use screw lengths 10mm longer. to DIN 2656 A B C Art.-No.

to DIN 17100. hot-galvanized stainless steel acc.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. to DIN 17440 – on request two-part slide-on flange for Cu and stainless steel FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 FSR 127/175 DN Ød Øk ØD Number of drilling holes 4 4 4 4 8 8 b 2b screws for steel (for stainless steel) 25 32 40 50 80 125 52 62 72 86 122 174 85 100 110 125 160 220 115 140 150 165 200 270 12 12 12 12 14 16 24 24 24 24 28 32 M 12 x 85 (95) M 16 x 90 (95) M 16 x 90 M 16 x 95 (105) M 16 x 100 (120) M 24 x (130) The screw length given is intended for joining to a blank flange acc. Screws and nuts are not included in the material delivered. to DIN 2635.04 Pip ety af L-S EL XW FLE e ® 4 segments arranged at 90° angles b – Subject to technical modifications – 2b U-St 37-2 acc.co.340 12. ØD Ød Øk .uk FLEXWELL Safety Pipe® Two-part slide-on flange for standard connection FSR 3.

hand flanging tool.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. long. long for connection with slide-on flange/two-part slide-on flange Type I without flanged copper pipe Article No. galvanized. 829 332400 G1/8A ISO 228/1 Type I copper pipe endless flanged using hand flanging device Type II copper pipe 200 mm flanged Material In series production: steel.co. 829 332 00 straight screw-in inset.04 Measuring branch Type MA. ISI 8. DN 4 intermediate thrust collar spacer with O clamping nut washers Cu seal Cu sleeve joint Ø 6 copper pipe 6 x 1 mm G1/8A ISO 228/1 Type I copper pipe endless flanged using hand flanging device Type II copper pipe 200 mm flanged Measuring branch Type MA for connection with screw or soldered end Type I without flanged copper pipe Article No. see Worksheet No.screwed flange connection see Worksheet No. Cu DN 4 sleeve clamping nut intermediate joint Ø 6 Cu seal spacer with O copper pipe washers 6 x 1 mm .60. 829 333 00 Type II with flanged copper pipe Article No. 829 331 00 Type II with flanged copper pipe Article No.350 12. chromated On request: stainless steel Installation instructions for . ISI 8.02 – Subject to technical modifications – thrust collar straight screw-in inset.01 .uk FLEXWELL Safety Pipe® Monitoring system Measuring branch FSR 3.60.

chromated On request: stainless steel Material In series production: stopcock – brass. nickel-plated long nipple .351 12. chromated .co. short for connection – with external thread lug – with soldered end Article No. R1/4 copper seal – Subject to technical modifications – Material In series production: stopcock – brass. 829 448 90 Test valve Type PV. long for connection – with slide-on flange – with two-part slide-on flange Article No.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. nickel-plated nipple – steel galvanized.uk FLEXWELL Safety Pipe® Monitoring system Test valve FSR 3.steel galvanized. 829 448 93 locking screw (cylindrical) G1/4 sealing washer (Cu) two-way stopcock nipple G1/8.04 Test valve Type PV. R1/4 copper seal long nipple G1/8A.

locking screw (cylindrical) G1/4 sealing washer (Cu) two-way stopcock Secure two-way stopcock (e. A copper pipe can be used when a hand flanging device is available.352 12. long .assembled with extended copper pipe for connection – with slide-on flange – with two-part slide-on flange Type I without flanged copper pipes Article No.uk FLEXWELL Safety Pipe® Monitoring system Test valve – assembled FSR 3. long G1/8A A copper pipe can be used when a hand flanging device is available. Screwed flange connection G1/8A copper seal copper seal Material In series production: screwed flange connection – steel galvanized. 829 448 81 Secure two-way stopcock (e. 829 448 71 Test valve Type PV.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. 829 448 80 Type II with flanged copper pipes Article No. nickel-plated – Subject to technical modifications – . chromated stopcock – brass. at edge of manhole) to ensure that joint is screwed tight to prevent leaks.assembled with extended copper pipe for connection – with soldered end – with external thread lug Type I without flanged copper pipes Article No.04 Test valve Type PV. short . screwed flange connection R1/4-DIN 2999/1 flanged copper pipe Cu sleeve joint copper pipe 6x1 mm by site Cu sleeve joint flanged copper pipe screwed flange connection.co. 829 448 70 Type II with flanged copper pipes Article No. at edge of manhole) to ensure that joint is screwed tight to prevent leaks.g.g.

They are constructed on the principles of absolute safety and ensure that spillages of products into the environment cannot occur.04 Leak monitoring FLEXWELL safety piping is permanently monitored using pneumatic leak detection equipment/ leak detectors. Leak detection equipment/leak detector (LAZ) We distinguish two types of differential pressure leak detection equipment: Leak surveillance to detect leaks in double-walled piping on the vacuum principle and on the positive pressure principle (using an inert gas) FLEXWELL Safety Pipe with a vacuum leak detector. The surveillance space must be so constructed that the functioning and operative security of the leak detection system (the leak detector) is assured at all times when the leak monitoring system is connected. These regulate the monitoring pressure in the surveillance space and register any changes of pressure which may occur.co. If the pipe is damaged the alarm is emitted by acoustic and optical signals.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. FLEXWELL Safety Pipe with a positive-pressure leak detector.401 12.uk Leak Detection Systems Leak detection for FLEXWELL safety pipe System description LDS 3. (flammable and non-flammable) fluids are transported. The main components are: the leak detector/leak detection equipment (LAZ) the connection between the surveillance space (UR) and leak detector (LAZ) double-walled piping the surveillance space (UR) a leak detection medium The use of this system complies with the most stringent European safety standards (Class 1). The term “leak detection equipment/leak detector” includes all the equipment necessary for the detection of leaks. Systems of this class give warning of a leak above or below the fluid level in a double-walled protective system. – Subject to technical change – FLEXWELL Safety Pipe with pressured gas leak monitoring FLEXWELL Safety Pipe with vacuum leak monitoring . Definition of leak detection equipment/ leak detector “Leak detection equipment/leak detector” according to the currently valid regulations refers to a device which automatically and under all operating conditions gives warning of leaks in the walls of double-walled piping in which water hazardous. The surveillance space is filled with the leak detection medium (an inert gas) and prevents uncontrolled spillages of the transported product when leaks occur.

– Subject to technical change – . It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. pressure/volume measurements. FLEXWELL Safety Pipe with leak monitoring is an approved leak detection equipment/leak detector system.g. The advantages of the system Using double-walled FLEXWELL Safety Pipe with leak monitoring offers.the entire system can be easily and simply monitored at any time without interrupting operations .402 12.requirements such as e. substantial economic advantages: .04 Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards.co.uk Leak Detection Systems Leak detection for FLEXWELL safety pipe System description LDS 3. pressure tests or route surveys can be dispensed with.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. besides a high degree of operative safety.

Installation/Commencement of operations/ Operation/Function testing Detailed descriptions can be seen from the approval documentation of the leak detectors and the worksheets for FLEXWELL safety piping. FLEXWELL safety pipe with leak monitoring is an approved leak detection equipment/leak detector system.04 Leak detection systems on the vacuum principle Leak detector on the vacuum principle are suitable for monitoring FLEXWELL Safety Pipes for the transport of: . These depend on the diameter of the FLEXWELL safety pipe used and the type of laying. The methods of laying can be seen from the worksheets and approval documentation. Minimal. Technical basis The scope of application of the leak detection device must be limited to fixed maximum pipe lengths due to the laws of physics. non-flammable substances In every case in which the alarm is triggered. It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. In the event of a drop in the partial vacuum (a rise in pressure) due to a leak below the lower value of the monitoring level of partial vacuum.water-hazardous. leaks in the walls of the piping are automatically detected. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. Subsequent evacuation is carried out by the vacuum pump in the leak detector. flammable substances <=55°C only in the Ex-variant . the vacuum pump is automatically switched off. flammable substances .co.uk Leak Detection Systems Leak detection systems on the vacuum principle LDS 3. – Subject to technical change – .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. It can only be switched on again by throwing the toggle switch mounted on the outside of the leak detector for this purpose.water-hazardous. Leak detection on the vacuum principle Illustration Principles of functioning The vacuum pump installed in the leak detector creates a partial vacuum.water-hazardous. unavoidable permeability (not leaks) are regulated automatically by the leak detector. By monitoring this partial vacuum. without triggering the alarm if they lie between the upper and lower values of the monitoring partial vacuum. The conditions set out in the approval for FLEXWELL safety piping and the leak detectors used must be complied with. Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards. the optical and acoustic alarm is triggered.410 12.

by topping up.co.04 Pressurized gas leak detection Positiv pressure leak detectors are approved as a leak detection device suitable for monitoring FLEXWELL Safety Pipes for the transport of : .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. Operating mode M The surveillance space is connected with the leak detector by means of the connecting leads. – Subject to technical change – Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards.water hazardous non-flammable substances Principles of functioning The necessary pressure in the surveillance space of the FLEXWELL safety pipe depends on the actual operating pressure in the medium pipe (inner pipe) and is generated: . It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. the optical and acoustic alarm will be triggered. If pressure drops to the value set previously for ALARM ON due to a leak. In mobile operating mode the monitoring pressure (TOP-UP OFF) is set just once when the system is put into operation by a pressure reservoir which is not constantly connected.450 12.water hazardous flammable substances . In stationary operating mode the monitoring pressure is regulated after putting the system into operation by pressure changes which top up from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space and equipped with a pressure reducing valve. The pressure which builds up is measured by the pressure sensor. from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space Operating mode S . Installation/Commencement of operations/ Operation/Function testing Detailed descriptions can be seen from the approval documentation of the leak detectors used and the approval documentation for FLEXWELL safety piping.uk Leak Detection Systems Leak monitoring on the positive pressure principle LDS 3. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. The conditions set out in the approval for FLEXWELL safety piping and the type of leak detector used must be complied with. Leak detection on the positive pressure principle Illustration . regulated by pressure changes.from a mobile pressure reservoir which is only connected when the line is put into operation or during a function test. FLEXWELL safety pipe with leak monitoring is an approved leak detection equipment/leak detector system.

04 1.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. Anchoring on anchor rails or metal profil rods does.co.20 1. 14 or equivalent strength) by means of saddle brackets. The anchoring brackets only need to be loosened.50 0. 2 Anchoring the FSR to existing anchor rails mounted on the wall surface (profile A8 or equivalent) by menas of saddle brackets. however.65 70 .30 0.75 83 . Bending radius and distance between brackets Type bending radius distance between brackets max. 2.80 2.20 1.40 1.00 2. 3 Anchoring the FSR to existing metal profile anchor rails recessed into the concrete (Jordahl No.60 0.710 12.70 1.00 – Subject to technical change – . FSR 3.52 60 . Anchoring in buildings or on supporting structures Installation example No.40 1. pushed a little to one side and after aligning.60 m 1.60 1. 2. pipe-supporting bridges etc.: Commercially available brackets with suitable dimensions can be used for anchoring instead of the components shown in these drawings. The FLEXWELL safety pipe® can be provisionally secured during laying.180 FSR 16/30 FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 FSR 127/175 m 0. have the following advantages compared with anchoring to a fixed point 1. N. The conditions on site should be taken account of.50 1.125 170 . to be tightened again.90 120 . horizontal vertical brackets provided by the contractor must fit following pipe-Ø mm 30 .60 1.uk FLEXWELL-Safety Pipe® Anchoring to buildings.00 1. 1 Installation example No.60 0.50 m 1.40 1.B.70 1.60 1.33 48 . Installation example No.

two wall sleeves can be pushed into each other to make up the extra length required.04 General Wall entry seals for FLEXWELL Safety Pipe are to be cast in concrete by the client. the tightness between concrete and the wall duct as well as between the wall duct and the FSR is 0. The FLEXWELL Safety Pipe is sealed with a sealing packing. The sleeve is fitted with radial grooves which effect the longitudinal water tightness in the concrete or mortar in similar fashion to a labyrinth gland. With correct installa-tion.co.FSR 60/83 The sealing element consists of a cross linked polyo-lefin heat-shrink sleeve. mm mm mm 700 450 67 829 393 90 700 450 67 829 393 90 750 450 71 829 394 90 750 450 71 829 394 90 750 450 71 829 394 90 * With thicker walls. which is pressed into the sleeve upon tightening of the bolts of the collar flange. mm 186 829 395 90 243 829 396 90 – Subject to technical change – A D1 D Warning! Slide wall sleeves over the pipe before assembling the connecting joint.720 12. Wall entry seals type MD for FSR 16/30 . When heated using a gas flame the ends shrink and the sealing compound melts and is pressed into any grooves or irregularities. buttressed internally by a galvanized steel spiral.1 bar against gas pressure. MD for type FSR FSR 16/30 FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 L mm 150 200 200 200 200 A B max* D1 article No. which forms a longitu-dinally watertight bond with wet concrete or mortar. 0. a sealing ring and a collar flange. Wall entry seals type MD for FSR 83/120 and FSR 127/175 The sealing element consists of a cast iron sleeve. The outside of the convoluted surface has a special coating. A D set up measure = L B max.2 bar against water. Both ends are coated inside with a plastic sealing compound.uk FLEXWELL-Safety Pipe® Wall Entry Seals Technical data FSR 3. set up measure = L . MD for L A D type FSR mm mm mm FSR 83/120 250 45 300 FSR 127/175 250 45 350 D1 article No.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.

to DIN 2656 Type FSR 16/30 FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 FSR 127/175 dimensions in mm ØD Ø KD 40 100 115 120 140 150 150 170 165 180 200 220 270 290 Ø KD borehole flange H ØD flange Boreholes for connections with two-part slide-on flange TTake care to observe the external diameter of the wall entries. FSR 3. to DIN 2656 Type ØD screw socket 40 – – – – – – ØD flange – 115 140 150 165 200 270 dimensions in mm H B 1 pipe B 2 pipes FSR 16/30 FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 FSR 127/175 min. Ø D + 150 mm B ØD flange Boreholes for connections with slide-on flange acc.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.uk FLEXWELL-Safety Pipe® Wall breakthroughs. boreholes FSR 3.720 – Subject to technical change – . Ø D + 100 mm min.co.721 12. See worksheet No. Ø D + 100 mm min.720 Only applies to wall entries as per Worksheet FSR 3.04 Wall breakthroughs for connections with slide-on flange acc.

set and sealed into the steel manhole or masonry wall by the client. D.co.6 76. Warning ! If FLEXWELL Safety Pipe connecting joints are to be fitted later.9 x 3. 829 313 90 829 315 90 829 316 90 829 314 90 829 317 90 829 319 90 829 320 90 For installation of FSR connecting joints see respective installation instructions.2 114.6 114. .3 x 3. steel manhole entry split collar flanges 150 wall plate of steel manhole assembly pipe sleeve heat shrink sleeve d split spacer former masonry wall set up measure = L 150 pipe sleeve jacket pipe wall entry – Subject to technical change – SSE for FSR type FSR FSR FSR FSR FSR FSR FSR 16/30 30/48 39/60 48/71 60/83 83/120 127/175 pipe sleeve (building contractor) o. Standard collar flanges are larger in diameter than the pipe sleeves and won’t fit.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.04 General note: The steel manhole and jacket pipe wall entries Type SSE for FLEXWELL Safety Pipe are designed to fit sleeves made from standard steel pipe.3 x 2. x wall mm 48.5 219.uk FLEXWELL-Safety Pipe® Entry pipe sleeves for steel manholes and pipe wall sleeve for wall entries FSR 3. For standard sizes refer to table below.6 168.3 x 4.722 12.9 set up measure d mm 40 68 78 88 102 138 190 L mm 150 200 200 200 200 250 250 article No.1 x 5.1 x 2. use split collar flanges. The pipe sleeves must be supplied.9 88.3 x 3.

04 For screw sockets with a collar.uk FLEXWELL-Safety Pipe® Doyma wall entry with borehole or fibre-cement jacket pipe Technical details FSR 3. since they have an external diameter greater than the borehole or the internal diameter of the casing tube. The position of the pipe must not be axially changed after installing the Doyma sealing pack. two-part slide-on flanges must always be used. Type FSR 16/30 DN 15 d mm 40 L mm 150 D1 mm 30 D2 mm 80 sealing pack Type C 40 casing pipe sealing pack Type A internal diameter of casing diameter of borehole internal diameter of casing diameter of borehole D1 protrudin lenght = L borehole Attention! Slide the wall entry over the pipe before installing the connection! sealing pack Type C 40 casing pipe sealing pack Type A D1 D2 D d D2 d borehole protrudin lenght = L Type FSR FSR FSR FSR FSR FSR One sealing pack each of Type C 40 and Type A is needed for each pipe conduit. d mm 30/48 25 68 39/60 32 78 48/71 40 88 60/83 50 102 83/120 80 138 127/175100 190 DN D mm 115 140 150 165 200 270 L D1 D2 mm mm mm 200 48 100 200 60 125 200 71 125 200 83 150 250 120 200 250 175 250 – Subject to technical change – .co.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.723 12.

Why a checklist? The data on the checklist enable us to supply you with a solution for a firewall entry with the approvals tailored to your situation on site. watertight under pressure.uk FLEXWELL-Safety Pipe® Firewall entry Fire-retardant seal Technical details FSR 3.730 12. to DIN 4109 Type: comprising: – Subject to technical change – Typ FSR-M 16/30 FSR-M 30/48 FSR-M 39/60 FSR-M 60/83 DN 15 25 32 50 Type: comprising: Metal parts: Seal: Casing pipe: FSR-M ___________ 2A + BSHN 2 sealing packs 1 fire-retardant pack FSR-M ___________ 3110BSHN 2 sealing packs 1 casing pipe 1 fire-retardant pack Steel hot-galvanized yellow-chromated and sealed (standard) EPDM.732 Fire-retardant pack R90 oder R120 . Checklist – Worksheet No. P-3024/0148-MPA BS Components Fire-retardant pipe seal. with fire-retardant sealing pack and noise insulation tested acc. the checklist makes it easier for you to be sure you are within the law: if you give all the data correctly you can be certain of getting the firewall entry you need for your specific site. gasproof.5 76.04 Piping non-flammable casing pipe sealing pack FLEXWELL-Sicherheitsrohr® Typ: FSR-M borehole To be provided by the contractor: Recommended values for Double-sided cladding with mineral wool: Thickness: 80 mm Density: 80 kg/m3 Length: 500 mm for R90 600 mm for R120 Fire protection requirements as per the general test certificate for construction inspections No.2 57. 3. On top of that.1 80.5 internal diameter of casing diameter of borehole D1 D2 D D1 mm 27 46.5 D2 mm 80 100 100 150 Please enclose a filled-in checklist with every order.5 43 53.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.co. to withstand temperatures from -40°C to +140°C (standard) special fibre cement D mm 24.

5 43 53. Why a checklist? The data on the checklist enable us to supply you with a solution for a firewall entry with the approvals tailored to your situation on site.731 12. On top of that. geteilt __________ mm lang 2 Steckrosetten.500 BSRN geteilt To be provided by the contractor: Recommended values for Double-sided cladding with mineral wool: Thickness: 80 mm Density: 80 kg/m3 Length: 700 mm for R90 Type FSR-M FSR-M FSR-M FSR-M 16/30 30/48 39/60 60/83 DN 15 25 32 50 Components Rohrabschottung Typ: FSR-M _________ 11. 3. Checklist – Worksheet No.5 D2 D D2 mm 42 61 61 106 Please enclose a filled-in checklist with every order. geteilt 1 sealing packs.uk FLEXWELL-Safety Pipe® Firewall entry Abschottung für Leichtbauwände F 90 Technical details FSR 3.732 Type: FSR-M _________ 12.500 BSRN verkleben Abdichtung Innendurchmesser Buchsenrohr FLEXWELL-Sicherheitsrohr Typ: FSR-M Buchsenrohr Type 12.500 BSRN D mm 24.co. geteilt 1 fire-retardant pack Buchsenrohr: Kunststoff Brandschutzpackung R90 – Subject to technical change – bestehend aus:1 Buchsenrohr __________ mm lang 2 Steckrosetten 1 sealing packs 1 fire-retardant pack .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.500 BSRN bestehend aus: 1 Buchsenrohr.5 76.04 Piping non-flammable Buchsenrohr Type 11. the checklist makes it easier for you to be sure you are within the law: if you give all the data correctly you can be certain of getting the firewall entry you need for your specific site.

uk FLEXWELL-Safety Pipe® Checklist Fire-retardant seal FSR-M FSR 3.0 mm 46.0 mm FSR-M 30/48 43.5 mm Supply line Medium: ____________________ Return line Medium: ____________________ With multiple entries.170 145 .1 mm FSR-M 60/83 76.149 mm Ceiling 150 .5 mm 80.174 mm 175 .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.04 Fire-retarding class: R 90 for pipe fire-retardant seal R 120 for pipe fire-retardant seal Flexwell safety pipe: Type External diameter D without protective jacket External diameter D1 with protective jacket Application non-flammable pipes FSR-M 16/30 24.co.732 12.5 mm 57.2 mm FSR-M 39/60 53. to DIN 4102 T4 FSR-M without protective jacket other: __________________________________ – Subject to technical change – Building: Description Town Client _________________________________________________ _________________________________________________ _________________________________________________ Please fax checklist to: 0049 (0) 50 31 .300 mm > 300 mm = _________mm = _________mm = _________mm = ________mm concrete stonework brickwork borehole casing pipe casing pipe casing pipe ligtweight construction acc.5 mm 27. exact details of each individual pipe must be given. Construction site data: Entry for Thickness of wall/ceiling (exact thickness) Material Wall 100 .

PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.uk www.uk .pipe2000. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.

uk .PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.co.

uk .co. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk www.co.pipe2000.INSULATED P IPES FLEXWELL® FSR LEAK DETECTION PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.TECHNICAL INFORMATION SHEETS P RE .

Leak detection equipment/leak detector (LAZ) We distinguish two types of differential pressure leak detection equipment: Leak surveillance to detect leaks in double-walled piping on the vacuum principle and on the positive pressure principle (using an inert gas) FLEXWELL Safety Pipe with a vacuum leak detector. Systems of this class give warning of a leak above or below the fluid level in a double-walled protective system. They are constructed on the principles of absolute safety and ensure that spillages of products into the environment cannot occur. The main components are: the leak detector/leak detection equipment (LAZ) the connection between the surveillance space (UR) and leak detector (LAZ) double-walled piping the surveillance space (UR) a leak detection medium The use of this system complies with the most stringent European safety standards (Class 1). The surveillance space is filled with the leak detection medium (an inert gas) and prevents uncontrolled spillages of the transported product when leaks occur.401 12. FLEXWELL Safety Pipe with a positive-pressure leak detector. These regulate the monitoring pressure in the surveillance space and register any changes of pressure which may occur.04 Leak monitoring FLEXWELL safety piping is permanently monitored using pneumatic leak detection equipment/ leak detectors. The surveillance space must be so constructed that the functioning and operative security of the leak detection system (the leak detector) is assured at all times when the leak monitoring system is connected. If the pipe is damaged the alarm is emitted by acoustic and optical signals. (flammable and non-flammable) fluids are transported. – Subject to technical change – FLEXWELL Safety Pipe with pressured gas leak monitoring FLEXWELL Safety Pipe with vacuum leak monitoring .PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.co.uk Leak Detection Systems Leak detection for FLEXWELL safety pipe System description LDS 3. Definition of leak detection equipment/ leak detector “Leak detection equipment/leak detector” according to the currently valid regulations refers to a device which automatically and under all operating conditions gives warning of leaks in the walls of double-walled piping in which water hazardous. The term “leak detection equipment/leak detector” includes all the equipment necessary for the detection of leaks.

pressure/volume measurements.g.requirements such as e. It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed.402 12. pressure tests or route surveys can be dispensed with.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. – Subject to technical change – . FLEXWELL Safety Pipe with leak monitoring is an approved leak detection equipment/leak detector system.04 Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards.the entire system can be easily and simply monitored at any time without interrupting operations . besides a high degree of operative safety. The advantages of the system Using double-walled FLEXWELL Safety Pipe with leak monitoring offers.uk Leak Detection Systems Leak detection for FLEXWELL safety pipe System description LDS 3. substantial economic advantages: .co.

Technical basis The scope of application of the leak detection device must be limited to fixed maximum pipe lengths due to the laws of physics.water-hazardous.04 Leak detection systems on the vacuum principle Leak detector on the vacuum principle are suitable for monitoring FLEXWELL Safety Pipes for the transport of: . non-flammable substances In every case in which the alarm is triggered. These depend on the diameter of the FLEXWELL safety pipe used and the type of laying. without triggering the alarm if they lie between the upper and lower values of the monitoring partial vacuum.uk Leak Detection Systems Leak detection systems on the vacuum principle LDS 3. It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. Subsequent evacuation is carried out by the vacuum pump in the leak detector. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed.water-hazardous. unavoidable permeability (not leaks) are regulated automatically by the leak detector. – Subject to technical change – .co.water-hazardous. It can only be switched on again by throwing the toggle switch mounted on the outside of the leak detector for this purpose. In the event of a drop in the partial vacuum (a rise in pressure) due to a leak below the lower value of the monitoring level of partial vacuum. The conditions set out in the approval for FLEXWELL safety piping and the leak detectors used must be complied with. Minimal.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000. Installation/Commencement of operations/ Operation/Function testing Detailed descriptions can be seen from the approval documentation of the leak detectors and the worksheets for FLEXWELL safety piping. Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards.410 12. the vacuum pump is automatically switched off. The methods of laying can be seen from the worksheets and approval documentation. leaks in the walls of the piping are automatically detected. Leak detection on the vacuum principle Illustration Principles of functioning The vacuum pump installed in the leak detector creates a partial vacuum. flammable substances . FLEXWELL safety pipe with leak monitoring is an approved leak detection equipment/leak detector system. By monitoring this partial vacuum. the optical and acoustic alarm is triggered. flammable substances <=55°C only in the Ex-variant .

from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space Operating mode S .04 Pressurized gas leak detection Positiv pressure leak detectors are approved as a leak detection device suitable for monitoring FLEXWELL Safety Pipes for the transport of : . FLEXWELL safety pipe with leak monitoring is an approved leak detection equipment/leak detector system.water hazardous flammable substances . – Subject to technical change – Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards.by topping up.from a mobile pressure reservoir which is only connected when the line is put into operation or during a function test. The conditions set out in the approval for FLEXWELL safety piping and the type of leak detector used must be complied with. regulated by pressure changes. Operating mode M The surveillance space is connected with the leak detector by means of the connecting leads. If pressure drops to the value set previously for ALARM ON due to a leak.co.water hazardous non-flammable substances Principles of functioning The necessary pressure in the surveillance space of the FLEXWELL safety pipe depends on the actual operating pressure in the medium pipe (inner pipe) and is generated: .450 12. The pressure which builds up is measured by the pressure sensor. the optical and acoustic alarm will be triggered. It therefore goes without saying that the conditions for operative use have been tested by the competent authorities and clearly defined and set down in the documents of approval issued by them. In mobile operating mode the monitoring pressure (TOP-UP OFF) is set just once when the system is put into operation by a pressure reservoir which is not constantly connected. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. Leak detection on the positive pressure principle Illustration . In stationary operating mode the monitoring pressure is regulated after putting the system into operation by pressure changes which top up from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space and equipped with a pressure reducing valve.PIPE2000 Ltd Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.uk Leak Detection Systems Leak monitoring on the positive pressure principle LDS 3. Installation/Commencement of operations/ Operation/Function testing Detailed descriptions can be seen from the approval documentation of the leak detectors used and the approval documentation for FLEXWELL safety piping.

pipe2000. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk .PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.uk www.

INSULATED P IPES FERWAG® - The Professional Solution for Engineers PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.TECHNICAL INFORMATION SHEETS P RE .co.co.uk .uk www.pipe2000. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.

description. Insulation thickness 1 T-pieces.501 7.co.105 Contents System description System description (general) System description (data) 7.320 7.335 7.100 7. short-legged Elbow.530 7.400 Transport and storage Transport and storage 7.351 7. EWELCON-Fusion Welded Joint. Insulation thickness 3 Parallel T-pieces with steel pipe. System description Pipe joints connection. 1. laying pipes (trench profile) Civil engineering works.3 7.5 7.for civil defence structures) 7.310 7. Insulation thickness 2 T-pieces. end sockets. shrink-on sleeve SMPE-2D Pipe joints connection. ball valve Fitting for shut-off valve.502 7.318 7.10. branch-off.532 Data for excavation.312 7. dimensions and measurements Hot tapping. Insulation thickness 3 Anchors Preinsulated valves for underground laying.0 15. Insulation thickness 2 Parallel T-pieces with steel pipe.325 7.0 x 2. Weight and Delivery lengths Elbow.0 7.305 7.505 7. branch-off. Insulation thickness 1 Parallel T-pieces with steel pipe. heating and sanitary Construction.500 7.200 Engineering Laying Engineering. shrink-on seal Pipe joints connection.525 7.345 7.4 7. Installation Civil engineering works. EWELCON-Fusion Welded Joint.340 7. branch-off.313 7.300 7.317 7.0 m T-pieces. installation Shut-off valve.uk FERWAG® -District heating pipe Contents FER 7. Trench warning tape Wall duct (Doyma .510 7. Material. Dimensions.515 7.2003 7. Technical specifications Wall sealing ring.330 7.2 7.520 7.316 7.6 Tendering text .314 7. core drilled holes) Assembly rules Concrete block for an anchor Draining and venting arrangements Underground installation for ballvalves Hot tapping.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.531 7.355 7. system description Hot tapping.360 Components FERWAG® -District heating pipe. laying pipes Filling the pipe trenches House connection (wall penetration. preparation weld seam and weld composition 7.352 7.1 7. Contents 7. ball valve Pipe joints connection.

the pipe construction units can be supplied in lengths of 6 + 12 (or 16) m. as part of our service. fixed points or anchors and so on. we will assist system users on request by placing our experience with the system at their disposal free of charge. T-pieces. The pipe system is designed to be laid directly in the earth.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. FERWAG® district heating pipe is available in three categories of insulation thickness. condensate and other fluids.100 15. All the components are connected on site. Depending on the dimensions. using circumferential seams. . but not for steam. Depending on the purpose for which it is used.co. The construction units and all the associated moulded fittings such as elbows or bends. Subsequent insulation work is usually carried out on our behalf by the system supplier or by qualified specialist companies. making this pipe system a member of the composite pipe family. During the planning phase. The weld seams and the end sockets are subsequently insulated with joint sleeves. All three components form a fixed unit. are prefabricated in the factory. It has proven its excellence over several decades and is nowadays acknowledged as the industrial standard in normal cases. seamless or galvanised). hot water for industrial or domestic use. This means that FERWAG ® district heating pipe is suitable for transporting heating water. FERWAG® district heating pipe has a carrier pipe made either of steel (welded.10. without ducts. The heat insulation of the FERWAG® heating pipe is provided by a rigid polyurethane foam offering resistance up to 140 ° C.uk FERWAG® -District heating pipe System description FER 7. The outer protection is provided by an HDPE (high density polyurethane) casing pipe.2003 FERWAG ® district heating pipe is the registered name for a pre-insulated plastic casing pipe system used to transport district heat. This results in a modular kit system which is correspondingly simple to plan and assemble. copper or special steel.

Tpieces. .6 Conception / structure Heating Straight pipes (bar stock) Longitudinal seam-welded or spiral seamwelded steel pipes Material Standard: Acceptance test certificate: Welding bevel: St 37.0 DIN 2448/1629.2 85.0 180 3. galvanised to DIN 2444 Thread: DIN 2999 Part 1.2 or DIN 50.8 140 3.6 110 2. DIN 2458/1626.) • FERWAG® accessories (MDR.0 432.4 450 7. Same as straight pipes DIN 50. end sockets of compensators and fittings with the same wall thicknesses as the welded pipes. St 37.9 302.2 192.2003 Sanitary Materials supplied FERWAG® district heating pipe system for constant medium temperatures up to a maximum of 140 °C.8.0 160 3.6 355 5.co. line warning tape. Core pipe density: Min.2 280 4. Medium pipes made of other materials are available on request.6 341. over 2 1/2” ends without thread.2 or DIN 50.049-2.049-2.0 400 6. Steel pipe elbows for moulded elbow fittings DN 20-125 Cold-bent (seamless or welded) steel pipes Material Standard: Dimensions: Factory certificate: Acceptance test DN 150 (80)-500 Longitudinal seam-welded elbows with longitudinal or spiral seam-welded steel pipe end sockets.5 104.5 118.0 125 2.0 152.0 630 9.3 384. etc.1 B 150-200 mm Same as for straight pipes.0 to DIN 17120 DIN 2458/1626.4 560 8.8 480.1 B Heat insulation (EN 253) Polyurethane foam (pentane blown) Polyurethane foam manufactured from 3 components: polyol.049-3.3.District heating pipe FER 7.0 315 4.0 200 3. EN 448. GM 5010 T2 or Unifos NCPE 3316 Standard: EN 253 Factory certificate:DIN 50. Hoechst.0 225 3.049-2. DIN 2458/1626 Same as straight pipes DIN 50.049-3.0 DIN 2605. Pipes and moulded fittings Threaded pipes: DIN 2440.5 768. Material Standard: EN 448 Dimensions: Factory certificate: Acceptance test certificate: End sockets: Technical data: St 37.4 269. fixed points. DIN 2559-22 Pipes for T-pieces and fixed points T-pieces and fixed points with the same wall thicknesses as the pipes.2 Material Dimensions of HDPE casing pipes External diameter Internal diameter Minimum wall thickness 90 2. 60 kg/m3 Closed cell percentage: ≥ 96% Thermal conductivity coefficient: ≤ 0. comprising: • FERWAG® district heating pipes • FERWAG® moulded fittings (elbows. isocyanate and pentane Mixing and metering takes place in high-pressure systems.2 710 11.049-3.0 133.8 605. EN 253 DIN 50.1 682.0 172.5 216.0260 W/mK for an average temperature of the insulating 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 foamed material. etc.).uk FERWAG®. Casing pipe HDPE.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.105 Description du matériel 26.4 500 7. longitudinally welded.0 800 12.2 250 3.8 538. HDPE sleeves.1 B Ø ≥114. pipe underlay.9 240. material matches the straight welded pipes.

sheet 2 Laying direction.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.210 7.220 7. sheet 4 Connecting instruction.253 7. insulation thickness 3 7. insulation thickness 2 Laying with thermal prestressing.240 7.211 7.24 7. thermal prestressing Maximum permissible covering height Lmax. DN 20-300. min. small bends.216 7. insulation thickness 1 Laying with thermal prestressing. pipe elbows.sheet 2 Location of expansion pads 7. insulation thickness 2 and 3 Thermal prestressing (description) Laying with thermal prestressing.2003 7.218 Tables: max.251 7. insulation thickness 1 Heat loss. DN 20-200. transition flexible pipe to plastic sheath pipe .241 7.252 7. DN 20-125.232 Design of expansion elements L-elbow. insulation thickness 2 Restricted expansion up tp 90 ° C. insulation thickness 3 Restricted expansion 7. DN 350-500. DN 20-300.25 7. sheet 1 Laying direction. Lmax Natural fixed point (maximum laying length) 7.254 Laying direction Laying direction.242 7.222 7.21 7. theory Layout of the line Laying length.230 7. DN 20-125.201 7.214 7. insulation thickness 2 Heat loss.202 7.231 7.223 Expansion calculation Restricted expansion Restricted expansion up tp 90 ° C. U-elbow .243 Dimensioning. sheet 3 Laying direction. insulation thickness 1 Lmax. bending radius.215 7. laying without prestressing.200 15.uk FERWAG® -District heating pipe Laying Engineering Contents FER 7. insulation thickness 1 and 2 Laying with thermal prestressing. changes of direction at 40-50° and 40-50° .co. insulation thickness 3 7.203 Principles. laying without prestressing.10. covering..23 7.250 7. Lmax. heat loss Pressure losses Heat loss.sheet 1 Elbow < 90° (bend in the line) .20 7. Z-elbow.221 7.22 7.212 7.217 7.

co.10. a b Fig. a b Fig. a b a Fig. 3 Straight line layout between two buildings with expansion taken up within the line by Z elbows. 5 Angled line layout between two buildings.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.2003 Layout of the line for FERWAG® district heating pipes is not subject to any special requirements. L FP . For this purpose.201 15. expansion taken up by natural change of direction in L elbow and building a. expansion taken up within the line by U elbows. 4 Straight line layout between two buildings with expansion taken up within the line by U elbows. 2 Angled line layout. Expansion taken up within the line by Z elbows.uk FERWAG® -District heating pipe Layout of the line FER 7. The angle sizes of the "expansion elbows" should not exceed 90° . 3m Building If no expansions are provided in the houses. a b a Fig. changes of direction in the normal layout of the line using L elbows are an initial option. which are capable of taking up the expansion arising at precisely defined points. b Fig. 1 Straight line layout between two buildings. since otherwise considerably longer expansion legs are needed. b Fig. If possible a right angled line course should always be aimed for. With respect to the pipe. it should fundamentally be selected with consideration to possible expansion. 6 Straight line layout. In addition there are Z elbows and U elbows. 3 m before it. The expansion of the district heating pipes must be taken up in building A or B by pipe legs or similar. then anchor must be fitted in the building wall or approx.

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FERWAG® -District heating pipe Laying length, Lmax

FER 7.202
15.10.2003

The FERWAG® district heating pipe is a pipe system in which the carrier pipe, heat insulation and sleeve pipe form a composite whole. As a result, the expansion occurring in the carrier pipe is transferred to the polyurethane foam and to the HDPE sleeve pipe. The polyurethane foam and the sleeve pipe thus expand to the same degree as the steel pipe. Expansion of the district heating pipe is however restricted to a certain extent in the sand bed by friction between the sand and the sleeve pipe. The friction force may become so great in a corresponding pipe length, that the district heating pipe is "fixed" in the earth and expansion is completely prevented. The force of pressures in the carrier pipe, which are counteracting the external friction forces, then become so great that impermissibly high stresses can occur in the carrier pipe. In the case of long pipes with an adhesion area, another possible way of reducing the amount of maximum tension is by thermal prestressing of the pipe.

Components to compensate the temperature related length-differences can almost be rejected. In order to avoid destruction of the carrier pipe during normal laying (without thermal prestressing), the friction force may only rise up to the maximum permissible force of pressure on the carrier pipe. The district heating pipe laid underground therefore must not be fixed, it must slide within the earth. The expansion occurring must be taken up in an expansion elbow. The length of the sliding area is identified for the remote heating line with the term "laying length - Lmax". The laying length indicates at what distance from a fixed point the first expansion capability must be created. The friction forces add up within this laying length up to a value which is still below the maximum permissible pressure force of the inner pipe.

Maximum permissible laying length between expansion legs, Lmax
Maximum permissible laying length, Lmax:

L elbow
FP Lmax

• Lmax = A Fr'

H

[m]

Friction force, Fr' [N/m]

Z elbow
FP Lmax Lmax

Fr'= µ[G + D(2H + Kd (H +D/2)( –2))]

U elbow
FP Lmax Lmax FP Lmax

= 190 N/mm 2 permissible stress (after creasing) friction factor, ground / PE = 19 kN/m 3 specific gravity of ground Kd = 0,463 pressure coefficient at rest G [N/m] weight of steel pipe + water D [m] sleeve pipe external diameter H [m] covering height A [mm 2] steel pipe profile

µ = 0.5

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FERWAG® -District heating pipe Natural fixed point
Maximum laying length

FER 7.203
15.10.2003

A natural fixed point NFP is located, as a result of the friction forces at the same covering height between the sand and the PE sleeve pipe, in the centre of a line section, between two possible expansion points.

In the case of unequal covering height, the NFP is displaced. When calculating the maximum laying length Lmax and the expansion l, this must be taken into account. In the case of doubt, a fixed point should be set.

Natural fixed point, L elbow

NFP
Lmax Natural fixed point, U elbow Lmax

NFP
Lmax Lmax

NFP
2 Lmax

NFP

Natural fixed point, Z elbow

NFP NFP
Lmax 2 Lmax

NFP
Lmax

"Natural fixed point" at changing covering height H1, H2 = Covering height

Fr'1 Fr'2 H1 Fr'1
L1 L

=

NFP
L2

H2 Fr'2

L2 = L

1 2

( 2 +1) – 1 –1

( > 1)

L1 = L – L2

PIPE2000 Ltd
UK Distributor
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FERWAG® -District heating pipe Maximum permissible covering height

FER 7.210
15.10.2003

The maximum permissible covering height (Hmax) is determined from the permissible shear stress of = 0.04 N/mm2 between the PU foam insulation and the steel carrier pipe, as a function of the friction force and the pipe size.

Where no shear stresses occur, i.e. there are no relative movements between the earth and the pipe, e.g. in an adhesion area or in the area between two fixed point structures of prestressed pipelines, there is no corresponding restriction in laying depth.

Steel pipe DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500

Insulation thickness 1

Insulation thickness 2 D 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 710 800 Hmax [m] 1.2 1.5 1.7 1.9 2.1 2.4 2.5 2.5 2.8 3.0 3.1 3.0 3.2 3.1 3.2 3.2 3.2

Insulation thickness 3 D 125 125 140 140 160 180 200 250 280 315 400 Hmax [m] 1.0 1.3 1.5 1.7 1.9 2.1 2.2 2.3 2.5 2.6 2.8

d
26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273,0 323,9 355,6 406,4 457,2 508,0

D 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710

Hmax [m] 1.5 1.9 1.9 2.2 2.4 2.7 2.8 2.9 3.1 3.4 3.5 3.4 3.6 3.5 3.6 3.6 3.6

The shear stress and friction force may be calculated using the following formulae: Shear stress: = Fr' ·d [N /mm 2 ] · D · (2 · H + Kd · (H + D/2)·( – 2))] [N /m]

Friction force:
where:

Fr' = µ · [G +

max = 0,04 N/mm 2 permissible shear stress friction factor, ground / PE = 19 kN/m 3 specific gravity of ground Kd = 0,463 pressure coefficient at rest G [N/m] weight of steel pipe + water d [mm] carrier pipe external diameter D [m] sleeve pipe external diameter (PE) H [m] covering height (the dimension H is measured from the pipe apex to the consolidated or compressed ground surface)

µ = 0.5

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FERWAG® -District heating pipe Laying without prestressing
Maximum permissible laying length, Lmax

FER 7.211
15.10.2003

Insulation thickness 1 DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 Steel pipe dxs mm 26,9 x 2,65 33,7 x 2,6 42,4 x 2,6 48,3 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 3,6 168,3 x 4,0 219,1 x 4,5 273,0 x 5,0 323,9 x 5,6 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3

H = 0,6 m D
mm 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710 Lmax m 28 35 37 42 51 58 65 75 81 97 110 118 136 133 149 147 143 Fr' kN/m 1,3 1,3 1,6 1,6 1,9 2,1 2,4 3,1 3,5 3,9 5,1 6,6 7,6 8,5 9,8 11,2 12,8

H = 0,8 m
Lmax m 21 26 28 32 39 44 50 57 62 74 85 91 106 104 117 116 113 Fr' kN/m 1,7 1,8 2,2 2,2 2,5 2,8 3,2 4,0 4,6 5,1 6,6 8,5 9,6 10,9 12,5 14,2 16,3

H = 1,0 m
Lmax m 17 21 22 25 31 35 40 46 50 60 69 74 87 85 96 95 93 Fr' kN/m 2,2 2,2 2,7 2,7 3,0 3,4 4,0 5,0 5,7 6,3 8,1 10,4 11,9 13,3 15,2 17,2 19,7

H = 1,2 m
Lmax m 14 17 18 21 26 30 33 39 42 50 58 63 74 72 82 81 79 Fr' kN/m 2,6 2,6 3,2 3,2 3,7 4,1 4,7 5,9 6,7 7,5 9,6 12,4 14,1 15,7 17,8 20,3 23,1

Lmax

Lmax

H

0.15

Covering height, H [m] Friction force, Fr' [kN/m] Permissible stress, =185 N/mm2 Friction factor ground/PE, µ = 0,5 Specific gravity of ground, = 19 kN/m3 Pressure coefficient at rest, Kd = 0,463

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FERWAG® -District heating pipe Laying without prestressing
Maximum permissible laying length, Lmax

FER 7.212
15.10.2003

Insulation thickness 2 DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 Steel pipe dxs mm 26,9 x 2,65 33,7 x 2,6 42,4 x 2,6 48,3 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 3,6 168,3 x 4,0 219,1 x 4,5 273,0 x 5,0 323,9 x 5,6 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3

H = 0,6 m D
mm 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 710 800 Lmax m 23 28 32 37 46 51 58 67 73 86 98 105 123 119 133 130 126 Fr' kN/m 1,6 1,6 1,8 1,9 2,1 2,4 2,7 3,5 3,9 4,4 5,7 7,4 8,4 9,6 11,0 12,6 14,5

H = 0,8 m
Lmax m 17 21 24 28 35 39 44 51 56 66 75 81 96 92 104 103 100 Fr' kN/m 2,1 2,1 2,4 2,5 2,8 3,2 3,6 4,5 5,1 5,7 7,4 9,6 10,8 12,2 14,0 16,0 18,3

H = 1,0 m
Lmax m 14 17 19 22 28 31 36 41 45 54 61 66 78 76 86 84 82 Fr' kN/m 2,7 2,7 3,1 3,1 3,4 3,9 4,5 5,6 6,3 7,1 9,1 11,7 13,2 14,9 17,0 19,4 22,2

H = 1,2 m
Lmax m 11 14 16 19 23 26 30 34 38 45 52 56 66 64 73 72 70 Fr' kN/m 3,2 3,2 3,7 3,7 4,1 4,7 5,3 6,7 7,5 8,4 10,8 13,9 15,6 17,6 20,0 22,8 26,0

Insulation thickness 3 DN
20 25 32 40 50 65 80 100 125 150 200 Steel pipe dxs mm 26,9 x 2,65 33,7 x 2,6 42,4 x 2,6 48,3 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 3,6 168,3 x 4,0 219,1 x 4,5

H = 0,6 m D
mm 125 125 140 140 160 180 200 250 280 315 400 Lmax m 20 25 29 33 40 45 52 60 65 77 87 Fr' kN/m 1,8 1,8 2,0 2,1 2,4 2,7 3,0 3,8 4,4 5,0 6,5

H = 0,8 m
Lmax m 15 19 22 25 30 34 40 46 50 59 67 Fr' kN/m 2,4 2,4 2,7 2,7 3,2 3,6 4,0 5,0 5,7 6,5 8,4

H = 1,0 m
Lmax m 12 15 17 20 24 28 32 37 40 48 55 Fr' kN/m 3,0 3,0 3,4 3,4 3,9 4,4 4,9 6,2 7,0 8,0 10,3

H = 1,2 m
Lmax m 10 12 14 17 20 21 27 31 34 40 46 Fr' kN/m 3,6 3,6 4,1 4,1 4,7 5,3 5,9 7,4 8,4 9,5 12,2

Lmax

Lmax

H

0.15

Covering height, H [m] Friction force, Fr' [kN/m] Permissible stress, =185 N/mm2 Friction factor ground/PE, µ = 0,5 Specific gravity of ground, = 19 kN/m3 Pressure coefficient at rest, Kd = 0,463

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FERWAG® -District heating pipe Thermal prestressing

FER 7.214
15.10.2003

Thermal prestressing
In the case of long pipes with an adhesion area, another possible way of reducing the amount of maximum tension is by thermal prestressing of the pipe. In this case, the pipe which has been laid in the open trench is heated up to the approximate mean temperature between the laying and operating conditions; in this heated condition, it is sanded in and then allowed to cool off again. At ambient temperature, this means that the pipe is subject to a constant tensile stress which reduces in a linear manner when the pipe is heated; the tensile stress becomes zero at the mean (or prestressing) temperature, and it changes into a compressive stress when further heating takes place. The maximum stress difference is split up into two approximately equal ”compressive” and ”tensile stress” components, each of an amount which is less than the permissible maximum stress. vmax = ± E S · t · ( T - TV) [N/mm2] At a prestressing temperature of 70° C, that is to say the temperature difference Tv = 60 K, this gives a maximum value of vmax = 147 N/mm2 for St 37.0. Progression of stress over pipe temperature Vmax TU

Furthermore, it is advantageous if the pipe stress at normal operating temperature (80-90° C) is approximately equal to zero, so that the pipe is laid virtually stress-free for the greater part of the year. By shifting the prestressing temperature upwards beyond the mean temperature, it is possible to take account of the fact that the key material values become less favourable as the temperature rises. Procedure: a) Lay the pipe in the open pipe trench. The expansion absorbers should already be welded on. To ensure that the expansion of the pipe is directed, an artificial fixed point can be created by filling with earth over a length Ls. Ls = L · Gges · µ /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, at which the maximum permissible stress is exceeded neither in the operating condition nor in the coolingoff condition. e) Heat the pipe up to the specified prestressing temperature. When doing this, it is particularly beneficial to carry out the preheating with disconnected recirculating water from a heating network which already exists. Apart from this, other possibilities are vacuum steam, hot air or electrical prestressing. Electrical prestressing is the most advantageous as regards the outlay. Prestressing can also be carried out section by section, since the complete line is seldom open, particularly in inner city areas. f) Measure the real expansion and compare it with the ideal values. If the expansion obtained turns out to be too low, the pipe can be briefly overheated in order to overcome the friction on the base of the trench. When the calculated expansion is attained, return to the required prestressing temperature again. g) Position the expansion pads and secure them so that they cannot move. h) Align the pipes. I) Fill in the pipe trench and compact the earth. When doing this, the prestressing temperature must be maintained, with a permissible variance of ± 5° C. j) Cool off and withdraw the pipe. This will bend the expansion components up and draw them into the pad, meaning that they are also prestressed and are subject to constant tensile stress in the laid condition. k) Measure the residual expansion after cooling has been completed.

+
Vmax

TV
with pres

TB


tres sing

with

out

max

pres tres sin

g

Since this maximum stress remains constant throughout the entire adhesion area, the prestressed section of pipe can be of any length. Moreover, the sliding area turns out to be very small on account of the low temperature differences. Given that instances of thermal expansion occur solely in the sliding area, only slight instances of residual expansion take place; these should be absorbed by the expansion components. Consequently, the dimensions of these components can be substantially reduced in comparison with non-prestressed pipes. In addition, a certain number of expansion absorbers can be saved, since there is no need to subdivide the whole pipe into maximum laying lengths. The sliding area Lg and the residual expansion l can 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]

5 2 2.5 1 16.5 58.4 x 2.1 x 2.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 20 24 27.5 5.3 x 2.0 m H = 0.5 4 4.5 24 4 4.5 0.9 x 3.5 9 9.5 6 7 8.0 219.5 20 3 3.5 5.5 10 12 13.5 1 26.5 5.5 40 2 45.6 60.5 0.10.5 52 6.5 10 11 13 14 16.1 x 2.5 25.3 x 3.5 76 88 13.5 16.9 x 3.3 x 2.5 7.5 7.3 x 4. µ=0.5 0.5 273.6 48.6 139.5 16.5 40.5 8.5 3 3 4 4 5 0.5 1 28.2 114.5 0.6 168.4 x 2. Insulation thickness 1 FER 7.uk FERWAG® -District heating pipe Laying with thermal prestressing DN 20-300.5 2.5 1 32.9 76.5 42.5 2 51 2.6 168.5 31.5 44 7 7.5 5 6 7 8.3 x 2.5 3.5 5 5.5 31.5 3 18 20.5 9 0.5 1 21.9 x 2.5 2.5 75 85.5 5.5 5.5 5.5 20.5 16 19 21.5 28.7 x 3.5 6.5 26 30 36.5 40.5 3 3.5 30 33.5 5 6 7 8 9 10 12 13.6 168.5 8 9.0 x 5.5 7 8 9 10 12 13.5 24 28 4.5 3 3 4 4.5 1 20 24.5 13.5 11 1 12.5 1.5 18 20.9 x 5.5 16 18.5 81.5 7.5 26.5 1.5 58 62.5 46.3 x 4.5 49 53 62 10 11.5 3 3.9 x 3.3 x 3.5 2 43.5 1 1 1 1 2 2 2 2.5 1 1 1 1 1.7 x 2.0 323.3 x 4.6 139.5 0.5 32 38.5 1.5 48 56 9 10.0 323.5 33 35.8 m H = 0.5 20 22 26 30 32.5 3.3 x 2.5 18.5 106 1 16.0 219.5 19 20.5 273.5 30 36 41.5 73 12 13.5 1.5 12 14 17 19.5 3 3.6 168.5 49 53 62 9 10 12 14 17 19 21.5 0.9 88.5 44 53 60.5 26 4 4.5 24.5 2 2.0 323.5 48 3 52 3.5 3 4 4.6 48.5 Specific gravity of ground.1 x 4.5 34.5 25 27.5 2.5 11 13.5 48 3 57.5 16.5 42.5 16 18 22.5 2 2.7 x 3.5 91.1 x 2.5 3 3 4 4.7 x 2.5 17 1 22 1 24.5 1 24.65 33.5 67 0.2 114.5 1 1.2003 DN 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 Steel pipe dxs mm 26.5 2 2.5 3 4 4 5 1 1 1 1 1 1 1.5 24 1 1 1 1.5 18 22 25 28 32.5 11 12 14 0.5 15 18.5 4 58 4.5 4 5 5 6 7 7.5 5 5.5 2.5 32.5 1 1 1.5 13.5 1.5 17 2.7 x 3.5 2.5 9.5 19 22.5 5.6 60.5 71.5 37.5 14.5 4.5 11.9 x 2.5 2 2 2.5 11 12 14.5 65 75.5 2.6 139.5 19 20.5 2.5 25.5 5.9 88.5 21 22.6 m l DS Lg FP Operating temperature TB [° C] Preheating temperature Tv [° C] Laying temperature Tk=10 [° C].5 48.6 48.1 x 4.9 x 2.9 76.5 2 2.65 33.5 1 31 1 35.5 4 5 5.5 15.5 8.5 1.3 x 3.5 14.5 24 26 31 36 38.5 6 7.5 3 4 4 5 H = 1.5 1 23 1.5 11 12.6 42.6 42.5 3 3.5 10 11.9 x 5.3 x 3.5 44.5 13 14.5 1.3 x 2.5 6 7 8 10 11 12.5 0.5 53.5 14.5 9 10.5 44 47 55 9 10 11.5 36 38.5 62.5 2.5 89 1 1 1 1 1 1.5 6 7 8.5 6 7.5 5 6 1 1 1 1 1.5 0.5 20 1 23.5 47.5 15.9 88.5 4 4.5 273.5 39 3 46.5 13 16 18.5 0.5 39 44.9 x 5.5 10 11.5 5 6 7 7.0 323.463 Covering height H [m] Expansion leg DS [m] .5 1.3 x 2.6 60.5 41.2 114.5 55 3 63 3. = 19 kN/m3 Coefficient of compression.1 x 2.5 9 11 12 14 16 17 20.5 6 7 7.5 0.5 1 1 1 1 1 1.5 16 19 22 27 30 34 39 42 50 57 61 70.5 84 97 15 17 20 22.7 x 2.4 x 2.5 14.5 0.5 45.5 2.5 20 3 3.5 6.5 2.5 11 13 2 2.5 1.5 4.5 4 4.0 219.5 28.5 0.5 1.5 5 6.5 44. T = Tv–Tk Sliding range when cooling Lg [m] Elastic recovery when cooling l [mm] Permissible stress = 190 N/mm2 Friction factor ground/ PE.5 3 3.5 3 3 3.5 5 6 7 8 9.5 27 1.5 32.5 14 16 17.5 3 53.5 23.5 28 31.5 21 24 27.5 38 3.5 17.5 49 57 4 8 8.5 10.7 x 2.6 42.5 21.5 92.5 1.5 30.5 17 20 21 24.5 11.5 1.5 1 1 1 1.2 114.5 0.5 14.5 8.2 m H = 1.5 27.5 2.5 15 17.5 2 39 3 45 3 3.5 14 16 17.5 1.3 x 4.5 4 71.5 35.5 8.5 27 30.1 x 4.5 1 1 1 1 1.5 0.6 60.3 x 2.5 62.5 29.5 1.1 x 4.5 3 3.5 4.5 0.5 1 1 1 1 2 2 3 3 4 20 22.5 38 6 6.65 33.5 20.9 x 2.5 4.5 4 4.5 1 1 1 1.5 6.5 36 2.5 15.5 9 11 1.0 x 5.5 14.5 26 2 30 32.5 1 18.5 9 10.5 4 0.5 13 15 16.5 45 7.5 273.5 3 3 3.6 139.5 99 5 6 115 18 1 20 1 23.5 3 66 4 71 4 82 5 1 13 1 15 1 17.5 16 18 20.5 24 27 33.5 14.5 12 13.6 90°° Tv=50° C 100°° Tv=60° C 110°° Tv=65° C 120°° Tv=70° C 130°° Tv=75° C ( T=50° C) ( T=55° C) ( T=60° C) ( T=65° C) TB ( T=40° C) D Lg l DS Lg l DS Lg l DS Lg l DS Lg l DS mm m mm m m mm m m mm m m mm m m mm m 90 90 110 110 125 140 160 200 225 250 315 400 450 90 90 110 110 125 140 160 200 225 250 315 400 450 90 90 110 110 125 140 160 200 225 250 315 400 450 90 90 110 110 125 140 160 200 225 250 315 400 450 14.5 4.5 1 1 1 1.5 4.5 76.5 2.5 29.5 2 3 3 3.5 2.6 48.5 17.0 219.5 13.4 x 2.5 33 1.5 2 49 2.5 63 3 3.5 39 42 50.5 1 1.5 20 23 25.5 26.5 14.5 11.5 1 1 1 1.5 23 26 30 32.0 x 5.5 1 27.6 26.5 13.co.5 25.5 11.65 33.9 88.5 22.3 x 2.5 1.5 19.5 10.5 17 2.5 4 4.5 68.5 34.5 52.5 22.5 1 20.6 42.5 1 14.5 35.5 32 37 40 48 55 59 68.5 9.5 37.5 4.0 x 5.5 37 2 42 2.5 31 2.5 11 12.9 76.9 x 3.5 8 9.5 1.5 15.9 76. Kd=0.5 38.5 11 12 14 16.5 7.5 58 69 78.5 25 29.5 9.5 9 10.6 26.5 2 2.5 5 6 7.215 15.9 x 5.5 2 3 3.7 x 3.5 4 5 5.6 26.

5 18 20 23 26.5 6 7 8 9 10.9 88.5 4 4.5 36 43 4.5 51.5 10 11.9 x 3.5 4 4.5 6.5 0.5 38.5 2 2.5 16.5 20 24 27 29 34 4.5 14 17.5 11 12.0 219.5 3.5 12.5 Specific gravity of ground.5 18.5 29 34 3 3.5 23.5 0.5 33 36 43 49 52.5 30 34.0 x 5.5 4 18 20 25 28.5 49 2. = 19 kN/m3 Coefficient of compression.5 22 3 3.5 4 5 5.5 12 13 15.5 1.0 219.3 x 2.5 36.5 5 5.5 68 10 11 14 16 20 22 25.5 8.5 4.5 5.5 10.5 6 7 8 8.5 67 76 81 95 13.5 7.5 60.5 16.5 1 1 1 1 1 1.5 32.5 14.5 15 17 18.5 29.6 42.5 32 35 41.5 47.5 31.5 25.5 39 42 49.6 139.5 29 32 38 43.65 33.5 87 12.5 0.5 14.5 62 9 10 12.5 3.5 43 50.5 19 20 23.4 x 2.5 3 4 4.5 1 16.5 4 4.1 x 2.5 50.5 1 1 1 1 1.5 10 11 12.5 1 19 1 23.5 7.3 x 4.5 28.4 x 2.5 55.5 1 1 1 1 1 1.5 19 24 26.0 219.5 H = 1.5 1.5 2 2.9 x 5.5 0.9 x 2.3 x 3.5 3 3.9 76.5 2 2 3 0.5 4.5 23.5 3 3 4 0.5 57.5 74.5 4 4.6 139.5 9.5 7.5 17 18 21.5 7.5 18.5 273.5 43 47 3 55.2 114.5 17.5 6 8 8.5 7 8 9 10 12 1.0 x 5.6 m l Lg FP Operating temperature TB [° C] Preheating temperature Tv [° C] Laying temperature Tk=10 [° C].5 4.5 35.9 76.5 41.5 1 1 1 1 1.0 219.7 x 2.5 21.5 18.5 2 2 2.5 1 1.65 33.5 36 39.5 23.5 12 14 15.5 12 13.5 58.5 2 2.5 0.5 4 68 4.5 4.8 m H = 0.5 18.5 47.5 18 19.5 3 3 3.6 60.5 3 15 16.5 7 8 10 11.5 1.5 1 27 1.5 15 2 2.5 5.5 0.5 24.5 2 37 2.6 48.5 80.5 0.5 10 10.5 21 24 30 33 37.5 2 2.5 9.5 13.5 47 55.5 79 11 12.5 34.5 32.5 3 3.5 1.6 168.5 5.5 6 7.3 x 2.5 5.5 39.5 15.5 2.5 273.5 20 25 27.5 2.5 29 33.5 0.0 323.5 1 1 1 1 1.1 x 4.5 4 4.5 5.5 2.3 x 4.5 7 8.1 x 2.5 18 21.5 5 6 7 9 10 11 13 14 16. Kd=0.1 x 2.5 16.5 14.5 8 9.5 3 4 4.4 x 2.5 4 4.5 7.5 4.3 x 2.3 x 2.6 139.5 26.2 114.5 8.5 1.6 42.5 1.5 8 9.5 45 52 56.5 1.5 24.5 6.6 48.5 4 4.5 12.5 3 3.5 3 3.7 x 3.5 4 4 5.5 29 32 2.5 3.5 14.5 26.5 9.uk FERWAG® -District heating pipe Laying with thermal prestressing DN 20-300.5 0.65 33.7 x 2.5 7 8 9 10.5 3 63.5 12 13.10.5 5.5 9 10 11.6 139.5 0.7 x 3.5 1.4 x 2.5 10.5 18 20 23 26.5 22.5 39.5 13.5 3 3 3.9 76.5 0.6 29 34.5 5 6.5 1.5 10.5 8.5 5 88 5.5 2.216 15.5 0.5 3 3.5 2.9 88.5 6 7.5 0.5 28 32 34 40 5.5 1.5 3 3.5 1 20.7 x 2.5 31 1.3 x 4.65 33.5 37.5 9 10 12.5 2.5 14.5 1.5 0.5 17 20 23 24.5 15.5 17.0 323.5 54 63.3 x 3.5 39.5 1 1 1 1.2 114.6 60.0 m H = 0.5 55.5 2.0 323.6 60.5 29 34.5 14 16 18.5 7 8 0.9 x 3.5 2.5 6.5 8.5 6.5 56 3 3.5 1.5 14.5 3 3.9 88.5 18 20 23 27 29.5 6.5 4.5 52 61.5 1 1 1 1 1.5 34 40.1 x 4.5 61.5 26 2 30 2.5 28 31.5 1.9 88. µ=0.5 5 5.5 21 22.5 103 14.5 38 2.3 x 2.5 6.0 x 5.9 x 2.5 16.6 48.5 15 19 21.3 x 4.5 3.5 6.5 3.5 2 2.5 10.5 18.6 42.5 4 4.9 x 3.5 19.5 1 21.5 43 47.5 19 21.5 9 10 12.3 x 2.5 12.5 7.5 10.5 22 24 27.5 56 63.5 7 9 10 12.5 15.5 1 1 1 1 1.5 27 32 37 40 47 5.5 9.5 26.5 3 3.5 47 53.5 6.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 2 2.3 x 2.5 15.5 4.5 0.5 18.5 273.5 0.5 12 13 15 2 2.5 2 2.5 2 43 2.5 0.0 x 5.5 51. Insulation thickness 2 FER 7.5 3 3.5 2 2 2.5 1 1.5 6 6.9 x 2.5 14.5 11.5 6.1 x 4.5 31 4.6 90°° Tv=50° C 100°° Tv=60° C 110°° Tv=65° C 120°° Tv=70° C 130°° Tv=75° C ( T=50° C) ( T=55° C) ( T=60° C) ( T=65° C) TB ( T=40° C) D Lg l DS Lg l DS Lg l DS Lg l DS Lg l DS mm m mm m m mm m m mm m m mm m m mm m 110 110 125 125 140 160 180 225 250 280 355 450 500 110 110 125 125 140 160 180 225 250 280 355 450 500 110 110 125 125 140 160 180 225 250 280 355 450 500 110 110 125 125 140 160 180 225 250 280 355 450 500 12 13.5 3 4 4 5 1 1 1 1 1 1.5 3 3.1 x 2.5 6 1 1 1 1.5 25 28.6 26.5 8 9 11.5 7.5 12.463 Covering height H [m] Expansion leg DS [m] DS .7 x 3.5 10 1 11 1 14 1 16 1 19.5 3.5 21.1 x 4.2003 DN 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 20 25 32 40 50 65 80 100 125 150 200 250 300 Steel pipe dxs mm 26.5 14.5 8.3 x 2.5 1.5 1.0 323.co.5 27 30 34.5 5.7 x 2.5 3 3.5 8.5 4 66 4. T = Tv–Tk Sliding range when cooling Lg [m] Elastic recovery when cooling l [mm] Permissible stress = 190 N/mm2 Friction factor ground/ PE.5 51.5 1 1 1 1.5 5.5 7 8.5 15.9 x 5.6 42.5 14.5 10.5 6.6 168.5 45 3 51.5 14.5 2.5 1.5 5 0.5 20 21.5 273.5 1.5 1 22 1 25 2.9 x 5.5 1 1 1 1 1.6 168.5 5.5 44.5 2 2.9 x 5.6 26.5 5 6.9 x 3.5 13 1 1 1 1.5 4 0.5 23 26.5 4 4.5 12 12.5 4.9 x 2.2 114.5 0.5 72.5 0.3 x 3.5 9.5 21 24.5 3.5 3 3.5 18 2.6 26.5 1 23.5 1 1 1 1 1 2 2.5 5 6.5 4.5 12 15 17 19.5 35 40 43.5 5 1 11.5 8 9 10 12 13 15.5 1 1 1 1 1.9 76.5 3 4 4 4.6 48.5 38 3 43.5 16 18.5 16 18 22.5 67.5 5.5 2 3 3 3.5 82.5 69.3 x 3.2 m H = 1.5 1 13 1 16.5 3 47 3.5 63 74 11 12 15 17.6 168.5 10.5 43.5 8.5 1.5 2 3 2.5 0.6 60.5 0.5 3 3.5 12 15 16.5 4.7 x 3.5 2.

5 51.5 11.5 5.5 7 5 5.5 5 5 84.6 x 5.5 6.5 112 126 124 120 87 99 97.5 7 7.5 13 12.5 4 4 4 3.4 x 6.5 33 24 27 27 26 19.5 4.6 x 5.5 28 31.5 8 9 9 9 1.5 36.5 78.5 50 27.5 77 86 84.3 508.5 8 5.5 20 20 19.5 6 6.5 21.5 66.5 6 6.5 15.4 x 6.0 x 6.5 4.2 x 6.uk FERWAG® -District heating pipe Laying with thermal prestressing DN 350-500 Insulation thickness 1 + 2 FER 7.5 4.5 29 32.5 6 6.5 67 43 48.5 66 64 50 56.3 90°° Tv=50° C 100°° Tv=60° C 110°° Tv=65° C 120°° Tv=70° C 130°° Tv=75° C ( T=50° C) ( T=55° C) ( T=60° C) ( T=65° C) TB ( T=40° C) D Lg l DS Lg l DS Lg l DS Lg l DS Lg l DS mm m mm m m mm m m mm m m mm m m mm m 500 560 630 710 500 560 630 710 500 560 630 710 500 560 630 710 69 77.0 m 0.5 4 4.5 29 28.5 7.3 457.5 54 61 61 59.0 x 6.5 16 16 15.5 4.5 4.5 22.5 25 24.5 94.5 22.5 12.3 508.5 20 20 19 15 17 17 16.5 47 53 53 52 25.5 65.5 61 69 68 66.5 41 38 34 33.5 5 5.5 60.4 x 6.5 6 7 0. T = Tv–Tk Sliding range when cooling Lg [m] Elastic recovery when cooling l [mm] Permissible stress = 190 N/mm2 Friction factor ground/ PE.5 44 10.5 23 6.8 m 0.3 508.3 508.4 x 6.5 26 6.5 31 30.5 6 6.3 355.5 29.5 15.10.5 27 21 23.5 51.5 23 17.5 58 58 56.5 7 4.5 37.3 355.3 457.5 18 14 15.5 6 6.5 4.3 508.5 44 10.5 38.5 37.5 24.5 6 6 6.5 5.2 x 6.5 56 55 33 37 36 35 25.5 4 4 4.3 355.5 5.0 x 6.3 355.5 6.5 7.5 93 90 66 74 73 71 54 61 60.5 20 22.5 6.2 x 6.5 100 112 110 107 78 87.5 6 6.5 5 6 6 4 4.5 86.5 26.5 7 5 5.5 4.5 3.5 22 Insulation thickness 2 H m 350 400 450 500 350 400 450 500 350 400 450 500 350 400 450 500 1.6 x 5.6 406.0 m l Lg FP Operating temperature TB [° C] Preheating temperature Tv [° C] Laying temperature Tk=10 [° C].3 457.5 6 6.5 22 21.4 x 6.5 7 7.5 37 41.5 6 7 7.5 32.5 65 49 55.5 66 75 74 72 56 64 63 61.4 x 6.5 16.5 6 103 116 114 111 81 91 90 87.5 69 68.5 18.5 23.5 19.5 5 5.5 26 7 8 8.5 28 21 23.5 9 42.5 6.5 6 6.3 508.3 508.6 406. Kd=0.5 16 12.4 x 6.5 59 46 51.2 m 1.5 34 38 38 36.5 7 1.463 Covering height H [m] Expansion leg DS [m] DS .5 22 17 19 19 18.3 90°° Tv=50° C 100°° Tv=60° C 110°° Tv=65° C 120°° Tv=70° C 130°° Tv=75° C ( T=50° C) ( T=55° C) ( T=60° C) ( T=65° C) TB ( T=40° C) D Lg l DS Lg l DS Lg l DS Lg l DS Lg l DS mm m mm m m mm m m mm m m mm m m mm m 560 630 710 800 560 630 710 800 560 630 710 800 560 630 710 800 61.2 x 6.5 10 42 10 41 10 5 20 5.5 18 20 20.5 5 5.6 406.5 3.3 457.6 406.5 3.5 5 4 4.5 6 6.6 x 5.5 4.5 23.5 18.5 3.5 7 5 5.5 26.5 5 5.6 406.5 5 5.5 47 47 46 23 25.5 84 64 72 71 69.5 5.5 9.0 x 6.3 457.6 m 39.5 7.5 4 4.5 27.5 Specific gravity of ground.2003 Insulation thickness 1 H m 350 400 450 500 350 400 450 500 350 400 450 500 350 400 450 500 DN Steel pipe dxs mm 355.5 43 42.8 m 0.5 23 22.0 x 6.3 355.5 48 54 53 52 14.5 29 28 27.6 x 5.5 95 72 81 80.5 7.5 5 5.2 x 6. µ=0.5 6 6.5 5.5 6 6.5 6 4 5 5.5 5.3 457. = 19 kN/m3 Coefficient of compression.5 6 4 4.3 355.5 7 7.5 6 92 103 101 98 72 81 80 78 59 66.6 x 5.3 508.5 24 24 23.5 7 7.0 x 6.5 5 5.5 76 74 54 61 60 58 44 50 49.2 x 6.5 14 14 13.5 16.5 4.5 4.217 15.5 7 7.3 457.5 5.5 5.0 x 6.5 5.5 14.5 23.5 31 30.2 x 6.5 4.5 8 8.6 406.5 31 35 34.6 406.6 x 5.5 9.5 41 39.5 48 46.5 18 18 13 14 14 14 10.5 26.2 m DN Steel pipe dxs mm 355.5 95 106 105 102 74 83 82.5 32 31 23.5 12 11.5 6 4 4.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 5.5 5 5.5 11.5 17.0 x 6.5 82 60 67.5 4 4.6 m 37.5 48 16.5 18.5 6 4.5 69 67.5 8.6 x 5.5 5 5.5 86 97 95 92 67 76 75 75 55 62 62 60.co.6 406.4 x 6.5 41.5 43 10 33.5 4.5 80.5 55 53.5 16.5 6 6.3 457.5 27.2 x 6.5 26.5 7 7.5 6 6.

5 11. µ=0.3 x 2.5 11.5 1.5 2.uk FERWAG® -District heating pipe Laying with thermal prestressing DN 20-200 Insulation thickness 3 FER 7.5 1 1 1 1 1.5 2.5 7.5 14.5 0.5 1.5 23.4 x 2.5 4 1 1 1 1 1 1.5 3 3.5 125 124 140 140 160 180 200 250 280 315 400 6.5 2 2.5 11 13 15 17.5 4 5 6 7 8 9 10.4 x 2.5 1.5 23.1 x 4.5 6 7 8.5 12 13 15.5 6.5 8 9 10.5 0. = 19 kN/m3 Coefficient of compression.5 27 6.5 14 16 18.3 x 3.10.5 2.5 9.6 42.5 2.5 1.6 42.5 38.5 13 15.5 59.5 4.5 28.5 0.218 15.5 1.5 24 1.5 5.5 4 4.5 5.5 14 4 16 5 19.5 18 21.5 11.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 1.1 x 2.5 10.5 19 6 22 7 24 8 28.5 1.9 88.5 0.5 4 5 5.9 x 3.5 16 20.5 26 8.1 x 4.5 3 3 3.5 10 11.5 38.5 56 4 4.5 46.5 13 11 12 15.5 55 64.5 73 6.1 x 4.5 0.5 7.5 17 19.5 10.6 139.5 1.5 3 14.5 1 1 1 1 1 1.5 3 15 3.1 x 4.5 2 3 3 4 4 4.5 5.5 18 21 24 1 1 1 1.5 7.5 2.7 x 2.5 2.5 1 1 1 1 1.65 33.5 2 6.5 7.9 76.5 10.5 25 28.5 0.5 21 25.5 32 37 42.5 26.5 Specific gravity of ground.5 26 28.2003 DN 20 25 32 40 50 65 80 100 125 150 200 Steel pipe dxs mm 26.9 88.5 38.6 48.5 10.5 0.5 1 1 1 1 1 1.5 10.5 31 35 40.7 x 3.5 31 35.5 31.5 17 19 24 27.5 3.5 10.5 23.5 34 39.5 42 47.5 13.5 2 2 2.5 45.5 H = 0.5 17 20.5 0.6 60.5 6 7 8.5 31 9 35.5 3 3 4 15.5 9.5 0.65 33.5 11 12.5 3 3 8.6 139.5 2.5 3 3.9 76.5 17.5 42 49.5 1 1 1 1 1.5 34.5 9.7 x 3.5 21 7.5 29.9 76.9 x 3.5 0.8 m 20 25 32 40 50 65 80 100 125 150 200 26.5 9.5 1.5 1.1 x 2.5 23 7.0 219.3 x 2.5 29 33.6 42.6 60.5 1.9 x 2.5 17.5 28.463 Covering height H [m] Expansion leg DS [m] DS .5 33.5 2.5 12 13 17 19.0 219.5 1.co.5 3.6 139.5 13 14.6 168.5 27 31 34 40 46 4 4.5 6.5 3 13 14.2 114.3 x 2.7 x 2.5 1 1 1 1 1.9 x 2.9 x 3.5 2.5 15.3 x 3.6 168.5 4.5 26 29.9 x 2.3 x 3.5 4.5 0.5 1 1 1 1 1 1.5 5.6 m 20 25 32 40 50 65 80 100 125 150 200 26.5 2 2.5 4 H = 0.5 9 10 11 13 15 0.5 4 5 5.5 0.9 88.5 16.5 42 49.5 33.5 38 43.5 0.7 x 3.5 1 1 1 1 1.5 12 14 15 18 20 1 1 1 1.6 48.5 2 3 7.5 17.5 125 125 140 140 160 180 200 250 280 315 400 5.5 22.5 7.6 48.5 28.5 3 3.5 2.5 12.5 2 2.5 3 3.5 10.5 1.5 1.4 x 2.3 x 4.5 7 8 10 11 13 15 16 19 21.5 30.5 2 2.5 6 7.5 0.5 16.5 9.5 12. Kd=0.5 11 34 38.5 3 3.5 9.5 45 10.5 2 2.5 0.5 1.5 8 39.4 x 2.5 10.5 2.3 x 2.5 0.5 17 4 21 5 23.5 3 3 9.5 20 22 26 29.0 m 20 25 32 40 50 65 80 100 125 150 200 26.9 x 3.5 37 42 3.5 2 2.5 6.7 x 2.5 3 9.5 2.5 8 9 11 12.6 48.5 17.5 0.3 x 4.5 52 4 4.5 56 5 5.5 3 12.5 4.5 2 2 2.5 3 3.9 88.5 16 5.9 76.5 8.5 9 11.5 125 125 140 140 160 180 200 250 280 315 400 8 9 11.5 5.2 m l Lg FP Operating temperature TB [° C] Preheating temperature Tv [° C] Laying temperature Tk=10 [° C].5 2.5 1 1 1 1 1 1.6 60.5 18 5.5 25.5 12 14 16 17.5 20.5 8.5 3 3.5 24.5 0.5 6.5 16.5 32 11.5 12.5 25.5 5.0 219.5 24 8.5 9.5 90°° Tv=50° C 100°° Tv=60° C 110°° Tv=65° C 120°° Tv=70° C 130°° Tv=75° C ( T=50° C) ( T=55° C) ( T=60° C) ( T=65° C) TB ( T=40° C) D l DS Lg Lg l DS Lg l DS Lg l DS Lg l DS mm m mm m m mm m m mm m m mm m m mm m 125 125 140 140 160 180 200 250 280 315 400 10.1 x 2.7 x 2.5 6 22 6.5 5 6 7 0.5 10 11 13 15 1 1 1 1 1 1.5 2 2.5 26 11 31 35.5 0.5 23.5 18.5 14.5 14.0 219.5 1.2 114.5 1.5 6.5 2.3 x 2.5 4 4 5 5.5 9.5 3 3.5 12.3 x 4.5 19 21 24.5 5.5 2.6 168.5 32.5 16.5 21 25 28 1 1 1.5 1 1 1 1 1.5 15.5 67.5 0.3 x 2.1 x 2.6 60.5 14 17 19.5 8.5 25.5 5 6 6.5 1 1 1 1 1.5 4 14.5 H = 1.3 x 4.5 13 14.5 19 21.5 1 1 1 1 1.5 2.65 33.3 x 2.5 22.5 2.5 6.5 6.5 35.5 1.5 4 13 4.5 1 1 1 1 1 1 2 2.5 3 3.5 20.5 19.5 1.5 20.5 10 3 11 3.7 x 3.5 12 4 14.5 9 0.5 17.5 1 1 1 1 1 1.5 13.3 42.5 3.5 50.5 2 2.5 7 9 10.6 168.9 x 2.5 1 1 1 1 1 1.5 2 2 3 3 4 4.5 28 32.5 3 8 3 9 3 11.5 12.5 0.5 1.5 2 2. T = Tv–Tk Sliding range when cooling Lg [m] Elastic recovery when cooling l [mm] Permissible stress = 190 N/mm2 Friction factor ground/ PE.3 x 3.5 21.3 x 2.5 3.5 7.5 3 3.5 18 6.5 8 2.5 5.5 14.5 61.5 H = 1.5 0.5 7.5 0.5 8 2.6 139.5 9.2 114.5 7.5 6 24 7 26 7.5 3 4 13 16 4.2 114.5 3 8.5 8.5 31 7.5 0.5 9.65 33.5 54.5 46.5 34 38 44 50.

8 m T = 100 K Lmax = 56 m (from worksheet 7.10.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.7 0.uk FERWAG® -District heating pipe Restricted expansion FER 7.co.5 0.3 0.2003 Expansion hindered by earth friction Temperature difference T1) [K] 50 60 70 80 90 100 110 120 0.220 15. welded inner pipe pipe length L2) = 30 m H 3) = 0.9 1.53 l = 28 mm (free expansion = 36 mm) Expansion 40 50 30 60 120 100 90 80 70 Pipe length L [m] 60 50 40 1) Temperature difference: operating temperature minus laying temperature 2) Pipe length L measured from fixed point to axis of expansion leg 3) Dimension H is the covering height measured from the pipe apex to the consolidated or compressed ground surface .2 0.6 0.8 0.1 120 110 100 Lm 0.0 10 90 80 Pipe length L [m] 70 0 1210 1 00 1 90 80 70 60 50 40 ax ] [m 30 20 60 50 40 30 20 10 20 15 30 L [mm] 20 Pipe length L [m] 10 Example: DN 125/250.212) L/Lmax = 0.4 Ratio L/Lmax 0.

1-160 60.7-110 15 20 25 30 35 40 45 50 55 60 65 25 Expansion l [mm] H=0.9-180 76.7-250 114.7-250 114.7-110 26.3-140 42.3-225 88.230): Pipe 76.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.9-110 70 Example (sheet 7.4 m 35 Expansion l [mm] H=0.1-160 (insulation thickness 2) Operating temperature TB = 80° C Pipe length L = 40 m or more Sliding area Lg = 40 m Expansion l = 17 mm Expansion leg DS = 2.3-125 42.9-110 TB [° C] L [m] H [m] l [mm] DS [m] Fr' [kN/m] =190 N/mm 2 µ =0. DN 20-125 Insulation 2.60 m l graph + 12% H = 0.3-125 42. 190 N/mm2.210 Expansion members: see sheet 7.1-160 60.10.7-250 114.3-125 60.9-180 76. Coverage correction factor: H = 0.7-110 26.uk FERWAG® -District heating pipe Restricted expansion Expansion up to 90° C.4 m l = 17 mm l = 17 mm 20 15 10 5 10 15 20 25 30 35 40 45 50 55 60 65 Laying length of pipe L [m] DK DS = 2.230.3-140 48. earth / PE Weight of earth per unit of volume Coefficient of earth pressure at rest 30 25 20 15 10 5 10 15 20 25 30 35 40 45 50 55 60 65 Laying length of pipe L [m] l DS Adhesion area Sliding area NFP Lg L Fr'[kN/m] 70 . Temperature stress at 90° max.3-140 48.70 m • DS 2 TB=90° C ( T=80° C) 70 139.9-180 The maximum permissible laying length may be exceeded.4-125 33.463 Operating temperature Laying length of pipe Coverage height Expansion Expansion leg Frictional force Permissible stress Friction factor. Maximum permissible coverage height: see sheet 7.70 m • DS 2 TB=65° C ( T=55° C) Sliding area Adhesion area 139.4-125 33.5 =19 kN/m 3 Kd=0.80 m l graph – 12% 14 12 10 8 6 4 2 10 p 76.221 15.3-225 88. permissible without prestressing FER 7.70 m • DS 2 TB=80° C ( T=70° C) Laying length of pipe L [m] 139.4 m DS = 2.4-125 26.2003 16 Expansion l [mm] H=0.9-110 33.3-225 88.1-160 48.

1-180 60.2 m DS = 2. earth / PE Weight of earth per unit of volume Coefficient of earth pressure at rest 15 20 25 30 35 40 45 50 55 60 65 Laying length of pipe L [m] l DS Adhesion area Sliding area NFP Lg L Fr'[kN/m] 70 .7-280 The maximum permissible laying length may be exceeded.7-125 42. 190 N/mm 2.2 m l = 15 mm l = 15 mm 20 76.9-125 5 10 15 20 25 30 35 40 45 50 DK DS = 2.3-160 48. permissible without prestressing Adhesion area FER 7.60 m l graph + 12% H = 0.3-140 42.2003 14 Expansion l [mm] H=0.3-250 88. Maximum permissible coverage height: see sheet 7.3-160 48.uk FERWAG® -District heating pipe Restricted expansion Expansion up to 90° C.9-200 25 20 15 10 5 10 70 76.5 =19 kN/m 3 Kd=0.1-180 (insulation thickness 3) Operating temperature TB = 80° C Pipe length L = 40 m or more Sliding area Lg = 35 m Expansion l = 15 mm Expansion leg DS = 2.9-125 4 2 10 15 20 25 30 35 40 45 50 55 60 65 25 Expansion l [mm] H=0.1-180 60.4-140 33.1-180 60.3-160 48.7-280 88.9-200 114.7-280 114. Coverage correction factor: H = 0. Temperature stress at 90° max.2 m 55 60 65 30 Expansion l [mm] H=0.10.3-250 Example (sheet 7.70 m • DS 3 TB=65° C ( T=55° C) Sliding area 139.4-140 33.3-140 15 10 33.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.3-250 88.222 15.9-125 TB [° C] L [m] H [m] l [mm] DS [m] Fr' [kN/m] =190 N/mm 2 µ =0.4-140 26.7-125 26.230.80 m l graph – 12% 12 10 8 6 114.7-125 26.230): Pipe 76.210 Expansion members: see sheet 7.9-200 76. DN 20-125 Insulation 3.co.70 m • DS 3 TB=90° C ( T=80° C) Laying length of pipe L [m] 139.3-140 42.463 Operating temperature Laying length of pipe Coverage height Expansion Expansion leg Frictional force Permissible stress Friction factor.70 m • DS 3 TB=80° C ( T=70° C) Laying length of pipe L [m] 70 139.

uk � ������������������������������ ��� ����� ���������� �������������� ����������������������������� ��� �� ��� ��� ��� ��� ��� ��� �� �� �� �� ��������������� ����� ������������������� ������� � ���� ������������������ ��� �� ������� � ����� ������������������ ��� ���� ���� ���� ���� ���� ��� �� ��� �� � �� � �� � �� � �� � ��� �� �� ��� �� �� ��� �� �� ��� �� �� ��� �������������� �� �� �� �� ��� �� �� �� �� �� �� �� �� �� �� ��� ��� ��� ��� � ���������� ��������������������������� ���������� � ������������������� ����������������� �� � ��������������������������������������������������� .co.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.

8 3.3 2.6 1.6 2 2 2 2.3 3.250 DN Expansion l in mm 10 1 1.8 2.6 3.5 2.6 8 4.7 2. 125 150.6 1.2 60 2.9 3.5 3 3.3 6.9 50 2.2 2.4 2.5 7 7.7 l l DK DS 20. values must be calculated . 40 50 65.2 4.4 2.3 7 7.5 50 2.4 2.125.3 3.6 4.4 15 1.65 50 1 1 1.65 1.1 4.2 3.7 3.1 3.250 B DN 20.3 4.3 1.5 6 7 7.4 1.6 1.5 5 5.5 2.2 3.1 5.8 80 1.8 3. 25 32.7 40 2.7 2.9 2.8 7.4 1.65 1.8 3.2 2.5 7 7.1 25 1.5 3.8 3.8 2.6 1.3 2.5 U elbow l = l1+ l2 C = 1 m where DN is 20 .3 90 1.6 3 3.7 6 3. 300* l DK A Z elbow l = l1+ l2 B = DS/2 where DN is 20 .2 2.6 FP x x DS 20.1 2.230 15.9 6.9 3.5 1.9 2. A = DS where DN is 150 .0 30 2 2.3 20 1.5 3.2 2.6 5 60 2.4 4.65 40 1 1 1 1.250 l1 DS/2 DK = expansion pads FP = fixed point C DN 20.7 l2 DS DK l1 B 1.8 2 2 2.5 7.4 2.5 6.9 4 4. Operating pressure 16 bar.2 5.4 3. Expansion leg DS in m L elbow Do not add l of both sides! DN Expansion l in mm 10 1.7 2.6 30 1.4 2.65 2.4 1.2 3.9 4.6 1.6 2 2.5 2.4 4.5 5 5.7 4.2 4 4.6 4.6 1.7 4 4.2 3.7 4 5 6.7 4.3 3 3.3 2.5 2.6 3.65 1.7 2.1 2.65 1. 25 32.6 3.1 15 1.6 3 3.7 4.2 1.2 1.3 2.7 4 5.6 60 2.8 4 4.5 L elbow A = DS/2 where DN is 20 .2 25 1.7 5 5.5 5.3 1.9 2.4 2.5 6 6. 25 32.5 4 4.5 100 2.65 1.125.4 5.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.2 2.2 2.7 2.6 1.4 2.9 3. The maximum permissible expansion for expansion is 45 mm.6 5 5.7 3.4 1.6 6.5 4.5 1.3 1.8 2.5 5. 40 50 65 80 100 125 150 200 250.3 2. 25 32.6 10.3 3.5 3 3.2 10 12 8.3 3. B = DS where DN is 150 .8 40 2.2 60 1 1.6 1.2 1. 40 50 65.8 2.4 7 7.5 3.3 3.5 2 2.65 2 2.2 20 1.7 2.2 12.2 1.7 5.5 100 1.6 3.1 2.3 4.7 1.6 2 2.4 2.9 3.6 3 3.9 5.6 1.5 2 2.5 5. 40 50 65 80 100 125 150* Expansion l = l1 + l2 in mm 30 1 1 1 1.6 2 2 2. DS The length and location of the expansion pads may be seen from the tables and from worksheet 7.5 70 2.2003 Requisite minimum length of the expansion leg.5 1.2 3. 80 100 125 150 200 250 300* DS 5 5.9 3.5 4 4.4 3. 80 100.9 6.6 2.7 20 1.5 7 8 9 8 9 11 8.7 4 DK l2 DS/2 DS *for larger dimensions.3 2.6 8 8.2 2 2.6 2.5 70 1 1.4 2.2 1.1 2.4 1.5 2.6 5.8 3.6 3 80 2.5 4.7 4 4. 200 250 300* Expansion l = l1 + l2 in mm 15 1 1.7 5.7 2 2 2.1 35 2.6 1.7 2.3 2.1 5.co.2 1.2 1.5 30 1.50.3 3.6 4 4.8 3.1 2.2 90 2.3 1.3 50 1.1 3.1 3.9 3.uk FERWAG® -District heating pipe Expansion elements Sheet 1 FER 7.5 1.6 1.5 2.9 3.1 35 1.8 40 1.4 1.6 2.4 1.9 6.6 2.10.2 3.3 2.4 4 5 5.2 3.5 4.232.6 1.5 3.8 2. C = 2 m where DN is 65 .

5 23.5 45 15 15 16 18 19.DN 250: by Q [mm] x 1.231 15.co. causing the values for Q to be halved. sheet 2 FER 7.5 Lateral displacement Q1 = Q2 [mm] If l1 = l2 => Q = l/sin + l/tan . from table of expansion elements L elbow.DN 250 Thickness of the pad: Q [mm] is a determining factor Length: expansion leg length Location: see worksheet 7.5 11 12 14 16 18.DN 100: by Q [mm] from table of expansion elements L elbow.5 45. The lateral displacement Q may be a maximum of 45 mm where the line is being laid using expansion pads.5 32 37. location of expansion pads Calculation of lateral displacement. or else the elbows should be mechanically or thermally prestressed.5 26 29 32 36 41 47. Anchors may if necessary be arranged before bends in the line.5 6 6.5 47.5 34.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 22.5 l1 = l2 [mm] 20 20 22 24 26 28.10.uk FERWAG® -District heating pipe Expansion elements Elbow < 90° (bend in the line).230 DN 125 .232.5 24 27.5 38.5 21.5 40 40 43. sheet 7. Determining the features of expansion legs DS DN 20 .5 31.1. Q: Q1 Q2 Q1 = l1 sin l1 tan l2 + tan + l2 sin l1 Table for Q where l1 = l2 l2 Q2 = Expansion Bend 90° 85° 80° 75° 70° 65° 60° 55° 50° 45° 40° 35° 30° 25° 20° 15° 10° 5 5 5. The total lateral displacement Q should be used in all cases for calculating the thickness of the expansion areas without thermal prestressing.5 43 25 25 27 30 33 36 39 43 30 30 33 36 39 43 35 35 38 41.5 19 21.5 28 38 10 10 11 12 13 14 16 17.2003 In order to determine the expansion leg length (DS) and expansion pad location (DK) for elbows < 90° . DN 20 .230 Determining the features of expansion pads DK. the lateral displacement (deflection) Q is a determining factor. sheet 7.5 7 8 9 9.

the pads must be fitted there. according to the length alteration.2003 Expansion pads are located in the area of expansion elbows. DN 80 l [mm] 3 4 – 23 24 – 45 Expansion pads [quantity] without expansion pads 1 layer (thickness 40 mm) 2 layers (thickness 80 mm) (2nd layer = 1/2 of the 1st layer) FP DS l = 40 mm. expansion leg DS = 3. accordingly more expansion.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. T pieces and reducing sockets. At least one expansion pad should be fitted in the incoming pipe leg in the area of the pipe elbow.232 15.co. in order to allow the FERWAG ® pipe to move in the earth.10. They are located in layers around the pipe in such a way that the length alteration determined according to worksheets can be fully taken up. If additional expansion pad has to be taken up in the pipe leg.uk FERWAG® -District heating pipe Location of expansion pads FER 7. 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 DK Number of expansion pads Example FERWAG® pipe.9 m 1st layer = 4 pads (metre) 2nd layer = 1/2 of 1st layer = 2 pads (m) l DS / 2 .

045 mm Flow quantity.0 312.4 2.2 500 400 5 0.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.8 1.1 263.5 160.8 444.2 1 • 1.1 100 10 200 300 20 30 500 50 1 1000 100 2000 3000 200 300 5000 Pa/m (1 mmWC = 9.10.15 50 .2 3 2 1 10 000 2.6 1.uk FERWAG® -District heating pipe Pressure losses Average water temperature 80 ° C FER 7.7 344.0 Flow quantity.8 50 5 000 4 000 3 000 • 2.6 495. m 2 000 25 0.3 82. difference.3 210. forward and return flow in ° C 100 kg 1000 000 h 500 000 400 000 300 000 200 000 0 35 0 30 kg s DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 D inter.240 15.6 3.6 0.4 25 0 100 2 00 15 0 12 5 10 0 80 W ate 50 DN 10 100 000 30 20 rv elo cit yw 50 000 40 000 30 000 20 000 [m /s] 10 65 5 3. m 0.co.8 1.1 54.0 1.1 1 000 DN 20 0.3 0.5 70. mm 21.4 393.5 .2003 Average water temperature 80 ° C m Q · 860 T m = Flow rate in kg/h Q = Power requirement in kW T= Temp.1 37.2 43.4 m/ s 0.4 40 32 0.5 0.81 Pa) 500 mmWC/m Pressure loss. p Surface roughness value = 0.3 .1 132.5 107.6 29.

80 36.3 42.4 19.3 14.2 37.500 406.56 100° 11.441 Operating temperature TB [°C] 50° 5.8 22.132 0.5 10.0 41.241 26.1 .0 25.uk FERWAG®.3 46.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.90 33.57 21.3 6.9 .8 25.311 0.5 13.1 120° 14.400 323.7 12.7 15.6 60° 6.0 .200 139.22 31.3 36.7 110° 13.5 28.0 47.1 16.7 26.2 30.8 19.6 8.5 17.4 .1 15.4 .3 40.67 36.27 H a .95 19.3 46.30 12.8 31.18 16.2 31.2 27.5 17.225 168.2 .9 22.140 88.9 32.370 0.8 16.2 90° 10.90 42.9 13.1 37.2 54.0 33.5 14.2 24.5 23.5 6.3 10.2 34.0 55.460 0.2 32.9 .2 W/mK λPU= 0.457 0.70 22.0 40.1 24.91 11.1 19.4 16.161 0.2003 Method of laying: Distance between pipes: Earth temperature: Covering height: Conductivity of ground: Conductivity of PU foam: 2 pipes laid a = 0.06 35.3 21.1 8.8 17.0 15.257 0.9 .9 28.9 11.47 24.co.3 26.6 7.5 80° 9.9 14.160 114.5 14.0 45.190 0.8 25.0 70° 7.3 .212 0.67 34.3 32.58 32.1 19.560 457.110 60.0 10.433 0.4 15.0 30.9 9.7 44.9 11.5 52.630 508.3 .1 .9 23.403 0.3 .5 34.20 m TE = 10 °C H = 0.6 27.315 273.4 12.8 44.5 130° 15.0260 W/mK Heat loss during operation: q = U (TB .9 40.7 50.8 17.8 18.3 17.6 12.10 18.3 48.0 30.8 21.9 52.91 29.4 26.5 20.5 12.6 8.2 28.165 0.8 17.2 16.58 35.4 44.0 27.5 10.6 53.5 19.4 30.4 22.710 U-value [W/mK] 0.97 20.9 13.4 41.3 27.6 18.0 21.5 18.4 48.3 38.110 48.18 15.2 25.250 0.1 20.8 26.7 44.450 355.388 0.TE) [W/m] U = Specific heat losses [W/mK] TB = Average operating temperature [ °C] TE = Average ground temperature [ °C] λE TE Heat losses q [W/m] for a pipe Type FERWAG® 26.7 .0 22.3 18.7 23.2 39.6 43.4 18.7 .2 23.District heating pipe FER Heat loss Insulation thickness 1 7.7 49.1 39.250 219.268 0.125 76.0 .1 22.3 29.2 9.7 9.6 50.3 .6 .446 0.8.6 m λE = 1.0 18.

7 13.0 18.2 35.1 17.4 13.5 26.2 24.4 34.2 20.347 0.7 9.2003 Method of laying: Distance between pipes: Earth temperature: Covering height: Conductivity of ground: Conductivity of PU foam: 2 pipes laid = 0.4 20.2 17.4 60° 5.8 36.7 16.312 0.0260 W/mK Heat loss during operation: q = U (TB .8 26.5 16.134 0.6 15.6 18.1 41.3 8.9 .1 24.6 .9 11.125 48.1 20.7 9.1 14.3 .334 0.7 18.7 27.8 13.1 110° 11.295 0.5 17.1 .2 30.250 168.0 14.260 0.0 10.0 8.6 20.500 355.TE) [W/m] U = Specific heat losses [W/mK] TB = Average operating temperature [ °C] TE = Average ground temperature [ °C] λE TE Heat losses q [W/m] for a pipe Type FERWAG® 26.7 21.3 23.8 15.2 30.2 W/mK λPU= 0.8 100° 10.6 m λE = 1.3 .0 .3 10.180 114.6 25.4 8.343 0.5 12.7 21.355 273.7 33.0 29.0.7 .4 24.3 23.1 H a .0 27.6 17.5 34.800 U-value [W/mK] 0.9 30.8.7 40.4 13.7 22.184 0.7 27.6 19.8 26.8 20.5 20.4 26.5 41.8 6.4 38.9 13.8 16.20 m a TE = 10 °C H = 0.0 24.8 24.113 0.110 42.4 16.2 16.2 36.3 22.2 11.6 28.334 Operating temperature TB [°C] 50° 4.165 0.560 406.2 12.9 14.7 7.9 .District heating pipe FER Heat loss Insulation thickness 2 7.4 14.7 11.1 20.9 9.5 36.0 20.7 17.4 10.8 28.4 11.4 120° 12.3 8.8 18.co.5 26.8 23.2 .6 32.7 .4 .242 26.304 0.1 27.0 13.9 21.1 37.3 30.7 23.8 12.4 90° 9.3 13.5 18.6 13.2 13.4 33.450 323.346 0.3 18.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.225 0.4 31.145 0.3 13.8 20.0 10.6 7.710 508.7 16.8 38.0 13.2 20.225 139.8 130° 13.8 11.0 31.1 15.207 0.7 18.216 0.4 34.630 457.3 17.0 12.140 76.6 22.5 41.3 24.4 19.160 88.9 .2 10.1 .125 60.0 23.280 219.5 15.uk FERWAG®.3 .3 .5 5.5 16.4 5.3 33.2 40.4 37.7 70° 6.2 14.110 33.4 14.4 .5 31.5 15.1 80° 7.6 6.3 27.5 12.1 31.6 34.2 9.8 8.

5 20.9 11.6 7.8 28.3 .3 14.8 5.3 .1 11.3 5.255 H a .0 20.3 .3 80° 7.4 100° 9.1 17.140 48.0260 W/mK Heat loss during operation: q = U (TB .0 110° 10.5 10.4 16.8 12.250 139.4 8.2 14.1 13.4 7.160 76.5 15.1 .1 130° 12.3 .TE) [W/m] U = Specific heat losses [W/mK] TB = Average operating temperature [ °C] TE = Average ground temperature [ °C] λE TE Heat losses q [W/m] for a pipe Type FERWAG® U-value [W/mK] Operating temperature TB [°C] 50° 4.243 26.8 24.5 16.3 22.9 .9 .3 9.uk FERWAG®.6 13.7 .2 7.147 0.2 19.7 19.8 9.8 14.4 12.2 15.0 6.244 0.1 18.20 m TE = 10 °C H = 0.0 23.104 33.2 21.9 90° 8.179 0.221 0.200 114.0 12.180 88.7 19.6 m λE = 1.1 17.4 13.9 19.7 10.3 14.3 30.6 8.3 11.3 10.203 0.8 17.4 14.3 26.2 60° 5.5 11.9 22.5 29.6 10.3 14.5 9.400 0.2 10.9 8.160 0.2003 Method of laying: Distance between pipes: Earth temperature: Covering height: Conductivity of ground: Conductivity of PU foam: 2 pipes laid a = 0.0 9.8 11.4 12.2 17.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.0 17.125 0.7 16.1 8.9 13.125 42.121 0.315 219.0 9.4 15.8.2 12.7 .2 12.9 6.2 17.5 120° 11.9 22.3 26.4 25.8 70° 6.280 168.190 0.7 20.6 26.4 .3 24.2 7.2 W/mK λPU= 0.1 .2 13.6 15.5 22.2 16.1 4.5 17.8 9.3 14.1 24.2 7.2 8.2 6.140 60.8 10.co.6 19.District heating pipe FER Heat loss Insulation thickness 3 7.132 0.

house connection lines to the main line.co. the particular features of the plastic sleeve pipe system must be observed.2 With L-elbow adjacent to main line Building DK Main line NFP a b l >6m NFP = natural fixed point DK = expansion pad . 6m Fig. 1 Connection line 6m 1.10.1 With anchor max. Even short connection lines of small dimension are held by the surrounding earth.g. The natural fixed point is again created within the length of the connection line.250 15. so that their movement is restricted. The differing movements and force conditions of main lines and the connection line must therefore be taken into account in all cases. Fig. e. so that restoring forces act on the main line.1 Direct connection Main line NFP DK Building max.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. 2 Connection line > 6m 2. 3m Main line FP DK Building > 6m 2.2003 Location of branches When locating branches.uk FERWAG® -District heating pipe Laying direction sheet 1 FER 7.

The thickness of the expansion pads then needed can be reduced if the connection lines remain free and are laid with low stress. 3 3.10.1 With L-elbow above main line (special manufacture) Main line Building DK NFP b l a DK NFP Main line NFP = natural fixed point DK = expansion pad The leg length a depends on length l.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. where the main line is prestressed.co.251 15. Expansions of the main line are also possible on connections in the adhesion area. The total length a + b should be surrounded by expansion pads.2003 Fig. as a result of subsequent repair measures. . Length b is based on the possible movement of the main line.uk FERWAG® -District heating pipe Laying direction sheet 2 FER 7. so that expansion pads must be fitted as a precautionary measure.

3 139. The minimum bending radius and the resulting maximum deflection can be obtained as follows: Rzul = Es · da/ b 2000 [mm] DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 da mm 26. If the angle is up to 3° . or by positioning a fixed point on the larger dimension side.co.2003 Pipe elbows. they can only be created with moulded fittings. these elbows can be created with bevelled cuts. Adhesion area: bends of a maximum of 5° are permissible in bevelled cuts.1 88.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. but for greater angles.0 Rmin m 27 34 42 48 61 77 90 115 141 170 221 275 327 359 410 461 513 h h = R · [1 – Rzul S h da Es 1 – (s/(2 · R))2] [m] 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] b = permissible bending stress 104 [N/mm2] Laying with small bends Sliding area: bends of a maximum of 3° are permissible in bevelled cuts.9 33. This may be excluded either by avoiding reductions in the adhesion area. making it necessary to specify a minimum radius of bending in relation to the pipe dimensions. there is bound to be a shift in the progression of the axial pressure force in the reduction. Reductions in the adhesion area Depending on the different stress cross-sections. The higher pressure force in the area of the larger dimension may lead to an overload in the smaller stress cross-section. This curvature of the line creates bending stresses in the pipe. In such cases.252 15.9 355.3 76. minimum bending radius If district heating pipes have to be laid along roads. the elbows may be composed of several straight lengths of pipe.uk FERWAG® -District heating pipe Laying direction sheet 3 FER 7.3 60.7 42.10.9 114. Fixed point Reductions in the adhesion area d1 d2 .3 219.6 406.7 168. as a reaction force.2 508.4 457. The bends must be laid without expansion pads.1 273.4 48.0 323. it may be necessary to follow curves in the road by means of elbows or bends in the pipe.

50°° L L L < 40° L > 50° 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) At 40 .253 15. L L .PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk FERWAG® -District heating pipe Laying direction sheet 4 FER 7.50°° L FP 45° L The second.2003 Changes of direction over long line lengths At 40°° . newly formed angle is always larger in both cases. thus achieving more gradual compensation.co.10.

5* Transition with expansion elbow 1.0 m DS 2.co. DS l FP DK = Expansion leg = Expansion = Plastic sheath pipe . a fixed point should be included to allow exact check of the expansions.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5* Pipe joint DK KMR Pipe joint DK KMR *FHK: 5 m possible l FP *FHK: 5 m possible If pipe length L resp. l L . Laying of Z elbow according of the expansion l.10.uk FERWAG® -District heating pipe Connecting instruction Transition flexible pipe to plastic sheath pipe FER 7.254 15.fixed point = Expansion pads • Design of expansion elements • Location of expansion pads according the Chapter Plastic sheath pipe from the main catalogue. Installation of a fixed point. 3 4 Transition with Z elbow 1. *FHK: 5 m possible 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. must not be compensated by the flexibles district heating pipes.0* DK Pipe joint KMR Rmin 2. which must be compensated by section DS. owing to increase of temperature.2003 Laying instruction for transition flexible pipes on plastic sheath pipe (KMR) all dimensions in mm 1 Transit from T-Piece KMR min 1.0* 2 Transition with fixed point l 2.0 m DS 2. l is > than permitted.0 DS 2.0 m l FP Pipe joint KMR l flexible pipe Rmin GFK Shell DK KMR *FHK: 5 m possible The expansion l.

5 5.4 x 2.6 355.1 4.5 273.4 21.3 x 3.3 Heating 21.65 2" 2 1/2" 76.300 15.3 9.6 3.9 19.5 10.2 31.25 60.6 11.25 42.6 42.9 9.58 1.9 x 5.80 93.13 8.3 x 3.7 x 2.8 3.3 3.2003 t L DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 1/2" 3/4" 1" Steel pipe dxs mm 26.8 D mm 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 710 800 110 110 110 125 125 140 160 180 225 t mm 39 35 38 35 37 39 42 51 50 51 61 80 79 91 99 75 87 42 39 36 38 35 36 38 41 51 kg/m 3.insulation thickness 16 m exceeding DN 200 on request D d .72 5.3 x 4.0 15.37 0.3 508.6 94.6 60.65 88.16 121.0 323.5 4.7 23.33 3.3 9.6 139.88 5.79 20.4 16.35 9.6 16.3 x 3.6 4.6 x 5.2 11.3 37.3 x 2.4 18.5 45.1 5.9 x 2. t .1 x 2.9 4.3 x 2. Sanitary FER 7.2 67.71 D – external diameter.2 114.18 34.1 5.9 8.8 3.25 192.8 141.9 76.3 x 4.4 64.75 kg/m 3.3 0.3 13.37 0.5 4.9 x 3.5 25.0 2.01 1.9 7.6 17.3 6.0 219.9 14.9 5.25 5/4" 1 1/2" 48.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.6 4.0 4.01 13.1 x 4.9 88.4 x 6.9 8.50 4" 125 125 125 140 140 160 180 200 250 Sanitary 49 46 43 46 43 47 48 51 63 3.4 5.37 2.5 2.21 3.05 3" 114.20 0.3 457.7 98.67 54.2 3.8 59.0 x 5.9 9.9 6.5 7.7 5.6 48.2 4.3 x 2.9 x 4.7 15.0 x 6.7 x 3.5 74.0 34.65 33.9 D mm 125 125 140 140 160 180 200 250 280 315 400 t mm 46 43 46 43 47 48 52 63 65 68 84 Water content l/m 0.4 x 3.46 2.uk FERWAG® -District heating pipe District heating pipe Heating.3 Standard Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 length s L m 6 6 6 6 6/12 6/12 6/12 6/12 12 12 12 12 12 12 12 12 12 6 6 6 6 6 6 6 6 6 D t mm mm 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710 90 90 90 110 110 125 140 160 200 29 26 31 28 29 29 32 39 39 36 42 56 55 63 66 41 49 31 29 26 31 28 29 29 32 39 kg/m 2.9 3.6 168.4 85.5 5.09 1.10.7 x 3.5 124.2 x 6.8 12.9 7.co.3 7.65 26.33 76.65 33.80 155.2 6.6 50.1 x 3.0 2.67 1.6 406.9 109.9 x 2.

50 4" Sanitary 0.5d 1.0 219.5d 1. short-legged FER 7.1 x 3.65 2" 2 1/2" 76.5 273.3 x 4.5 0.5 0.5d 3.0 1.5d 2.0 1.5 0.5 0.3 x 3.6 168.3 508.05 3" 114.6 125 125 125 140 140 160 180 200 250 D – external diameter.4 x 6.2 x 6.0 L D mm 125 125 140 140 160 180 200 250 280 315 400 Heating 21.3 x 4.5d 1.co.10.65 0.0 323.0 1.9 x 2.4 x 3.5d L m 0.25 42.9 x 5.5d 3.6 0.5 0.5 0.5 0.5d 3.65 0.6 48.5 0.5 0.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.5 0.5 0.3 x 2.5 0.0 1.305 15.1 0.65 88.5d 1.0 1.6 0.0 1.65 33.0 1.0 1.5 0.5 0.65 0.6 139.65 33.0 1.5 0.65 0.5d 3.65 1.5 0.uk FERWAG® -District heating pipe Elbows.6 0.9 88.3 x 3.6 406.0 1.9 x 4.6 42.5 0.5d 1.2003 90° R 5° – 85° R t s L L Steel pipe Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 1/2" 3/4" 1" dxs mm 26.65 0.6 D mm 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 710 800 110 110 110 125 125 140 160 180 225 t mm 39 35 38 35 37 39 42 51 50 51 61 80 79 91 99 75 87 42 39 36 38 35 36 38 41 51 m 0.6 60.5d 3.1 x 4.65 0.5d 1.6 0.0 1.6 0.3 x 2.5d 2.3 R 3d 3d 3d 3.5d 3d 3d 3d 3.0 x 6.65 0.6 0.5 0.0 1.7 x 3.5 0.65 26.5d 1.0 1. t .2 114.5 0.9 x 2.0 x 5.5 0.5 0.1 x 2.65 0.7 x 3.5 0.5 0.insulation thickness D t mm 46 43 46 43 47 48 52 63 65 68 83 49 46 43 46 43 47 48 51 63 d .25 5/4" 1 1/2" 48.65 0.5d 3.5 0.5 0.3 x 3.3 457.5 0.65 1.9 76.5 0.7 x 2.5 0.5d 1.5d 1.5d 3.65 1.6 D mm 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710 90 90 90 110 110 125 140 160 200 t mm 29 26 31 28 29 29 32 39 39 36 42 56 55 63 66 41 49 31 29 26 31 28 29 29 32 39 L m 0.0 1.6 x 5.6 355.9 x 3.65 0.4 x 2.3 x 2.5 0.5 0.5 0.5 0.25 60.5 0.

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe Elbows 90° , 1.0 x 2.0 m

FER 7.310
15.10.2003

1000

R

t

s

2000

DN
20 25 32

Steel pipe dxs mm 26,9 x 2,65 33,7 x 2,6 42,4 x 2,6 48,3 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 3,6 168,3 x 4,0 219,1 x 4,5 273,0 x 5,0

Insulation thickness 1 Insulation thickness 2 Insulation thickness 3

R
3d 3d 3d 3,5d 3,5d 3,5d 3,5d 2,5d 1,5d 1,5d 1,5d 1,5d 1,5d 1,5d 1,5d 1,5d 1,5d 1,5d 2,5d 2,5d 2,5d

D mm 90 90 110 110 125 140 160 200 225 250 315 400 90 90 90 110 110 125 140 160 200

t mm 29 26 31 28 29 29 32 39 39 36 42 56 31 29 26 31 28 29 29 32 39

D mm 110 110 125 125 140 160 180 225 250 280 355 450 110 110 110 125 125 140 160 180 225

t mm 39 35 38 35 37 39 42 51 50 51 61 80 42 39 36 38 35 36 38 41 51

D mm 125 125 140 140 160 180 200 250 280 315 400

D
t mm 46 43 46 43 47 48 52 63 65 68 83 49 46 43 46 43 47 48 51 63

Heating

40 50 65 80 100 125 150 200 250 1/2" 3/4" 1"

21,3 x 2,65 26,9 x 2,65 33,7 x 3,25 42,4 x 3,25 5/4" 1 1/2" 48,3 x 3,25 60,3 x 3,65 2" 2 1/2" 76,1 x 3,65 88,9 x 4,05 3" 114,3 x 4,50 4"

125 125 125 140 140 160 180 200 250

D – external diameter, t - insulation thickness

Sanitary

d

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe T pieces, branch-off at 45°
Heating, Insulation thickness 1

FER 7.312
15.10.2003

D

45° H [mm]

D

d

L1 [m]

L2 [m]

Main line

Branch line 20
L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H 1.0/1.0 180 1.0/1.0 1.0/1.0 180 180 1.0/1.0 1.0/1.0 1.0/1.0 190 195 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 195 195 190 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 200 195 200 210 195 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 220 205 215 215 230 205 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 240 250 215 225 225 230 215

DN

DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500

Casing pipe D [mm]

25

32

40

50

65

80 100 125 150 200 250 300 350 400

90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710

1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 270 245 250 260 295 235 245 235 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 240 240 245 255 265 230 285 300 230 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 250 250 260 270 240 280 300 310 240 320 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 285 295 285 300 310 330 345 365 390 275 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.3/1.0 1.3/1.0 1.3/1.0 1.3/1.0 325 325 335 340 350 430 370 385 395 470 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 520 375 395 410 420 455 495 385 360 365 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 385 390 400 420 435 445 480 520 545 570 1.0/1.0 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 420 430 450 465 475 630 510 550 575 600 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 465 485 500 665 510 545 585 610 635 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 705 525 540 550 585 625 650 675

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe T pieces, branch-off at 45°
Heating, Insulation thickness 2

FER 7.313
15.10.2003

D

45° H [mm]

D

d

L1 [m]

L2 [m]

Main line

Branch line 20
L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H 1.0/1.0 180 1.0/1.0 1.0/1.0 180 180 1.0/1.0 1.0/1.0 1.0/1.0 190 195 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 195 195 190 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 200 195 200 210 195 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 220 205 215 215 230 205 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 240 250 215 225 225 230 215

DN

DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500

Casing pipe D [mm]

25

32

40

50

65

80 100 125 150 200 250 300 350 400

110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 710 800

1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 270 245 250 260 295 235 245 235 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 255 255 265 275 285 250 305 320 250 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 275 275 280 290 265 300 320 335 265 350 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.3/1.0 1.3/1.0 1.3/1.0 1.3/1.0 310 320 310 330 340 360 370 390 425 300 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.3/1.0 1.3/1.0 1.3/1.0 1.3/1.0 1.3/1.0 360 360 365 375 385 475 410 420 435 520 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 570 410 435 445 460 495 545 385 390 400 1.0/1.0 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 420 430 440 465 475 490 530 575 600 630 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.0 1.5/1.5 1.5/1.5 465 475 495 510 525 560 610 635 665 1.0/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 515 540 550 565 605 650 675 705 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.0 1.5/1.0 1.5/1.5 1.5/1.5 585 595 610 650 695 720 750

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe T pieces, branch-off at 45°
Heating, Insulation thickness 3

FER 7.314
15.10.2003

D

45° H [mm]

D

d

L1 [m]

L2 [m]

Main line

Branch line 20
L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H L1/L2 H 1.0/1.0 180 1.0/1.0 1.0/1.0 180 180 1.0/1.0 1.0/1.0 1.0/1.0 190 195 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 190 195 195 190 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 195 200 210 200 195 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 220 205 215 215 230 205 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 240 250 215 225 225 230 215

DN

DN
20 25 32 40 50 65 80 100 125 150 200

Casing pipe D [mm]

25

32

40

50

65

80 100 125 150 200

125 125 140 140 160 180 200 250 280 315 400

1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 260 270 245 245 250 295 235 235 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 280 290 275 280 300 310 335 350 275 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 300 300 310 320 330 295 355 370 385 295 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.0/1.0 1.3/1.0 1.3/1.0 1.3/1.0 1.3/1.0 340 340 350 360 410 335 370 395 430 470

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe Parallel T pieces with steel pipe
Heating, Insulation thickness 1

FER 7.316
15.10.2003

L/2 [m]

d2

L [m]

Main line

Branch line 20
L H L H L H L H L H L H L H L H L H L H L H L H L H L H L H 1.0 240 1.0 240 1.0 250 1.0 250 1.0 260 1.0 265 1.0 275 1.0 295 1.0 310 1.0 320 1.0 240 1.0 250 1.0 250 1.0 260 1.0 265 1.0 275 1.0 295 1.0 310 1.0 320 1.0 355 1.0 260 1.0 260 1.0 270 1.0 275 1.0 285 1.0 305 1.0 320 1.0 330 1.0 365 1.0 405 1.0 260 1.0 270 1.0 275 1.0 285 1.0 305 1.0 320 1.0 330 1.0 365 1.0 405 1.0 430 1.0 275 1.0 285 1.0 295 1.0 315 1.0 325 1.0 340 1.0 370 1.0 415 1.0 440 1.0 465 1.0 290 1.0 300 1.0 320 1.0 335 1.0 345 1.0 380 1.0 420 1.0 445 1.0 470 1.0 500 1.0 310 1.0 330 1.0 345 1.0 355 1.0 390 1.0 430 1.0 455 1.0 480 1.0 510

DN

DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400

Casing pipe
D [mm]

25

32

40

50

65

80 100 125 150 200 250 300 350 400

90 90 110 110 125 140 160 200 225 250 315 400 450 500 560

1.0 350 1.0 365 1.0 375 1.0 410 1.0 450 1.0 475 1.0 500 1.0 530 1.3 375 1.3 390 1.3 420 1.3 465 1.3 490 1.3 515 1.3 545 1.3 450 1.3 485 1.3 525 1.3 550 1.3 575 1.3 605 1.5 565 1.5 610 1.5 635 1.5 660 1.5 690 1.5 700 1.5 725 1.5 750 1.5 780 2.0 800 2.0 825 2.0 855 2.0 900 2.0 930 2.0 960

d1

D

H [mm]

PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk

FERWAG® -District heating pipe Parallel T pieces with steel pipe
Heating, Insulation thickness 2

FER 7.317
15.10.2003

L/2 [m]

d2

L [m]

Main line

Branch line 20
L H L H L H L H L H L H L H L H L H L H L H L H L H L H 1.0 260 1.0 260 1.0 270 1.0 270 1.0 275 1.0 285 1.0 295 1.0 320 1.0 330 1.0 345 1.0 260 1.0 270 1.0 270 1.0 275 1.0 285 1.0 295 1.0 320 1.0 330 1.0 345 1.0 385 1.0 275 1.0 275 1.0 285 1.0 295 1.0 305 1.0 325 1.0 340 1.0 355 1.0 390 1.0 440 1.0 275 1.0 285 1.0 295 1.0 305 1.0 325 1.0 340 1.0 355 1.0 390 1.0 440 1.0 465 1.0 290 1.0 300 1.0 310 1.0 335 1.0 345 1.0 360 1.0 400 1.0 445 1.0 470 1.0 500 1.0 310 1.0 320 1.0 335 1.0 355 1.0 370 1.0 410 1.0 455 1.0 480 1.0 510 1.0 330 1.0 355 1.0 365 1.0 380 1.0 420 1.0 465 1.0 490 1.0 520

DN

DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350

Casing pipe
D [mm]

25

32

40

50

65

80 100 125 150 200 250 300 350 400

110 110 125 125 140 160 180 225 250 280 355 450 500 560

1.3 375 1.3 390 1.3 405 1.3 440 1.3 490 1.3 515 1.3 545 1.3 400 1.3 415 1.3 455 1.3 500 1.3 525 1.3 555 1.3 480 1.3 520 1.3 565 1.3 590 1.3 620 1.5 605 1.5 655 1.5 680 1.5 710 2.0 750 2.0 775 2.0 805 2.0 850 2.0 880 2.0 960

d1

D

H [mm]

3 450 1.0 285 1.0 375 1.0 295 1.0 310 1.0 275 1.0 310 1.0 415 1. Insulation thickness 3 FER 7.0 355 1.0 330 1.0 315 1.10.0 300 1.3 430 1.0 355 1.0 290 1.0 390 1.2003 L/2 [m] d2 L [m] Main line Branch line 20 L H L H L H L H L H L H L H L H L H L H L H 1.0 295 1.0 320 1.0 285 1.0 420 1.3 490 1.0 310 1.0 320 1.0 285 1.0 380 1.0 370 1.0 430 1.0 345 1.3 475 1.0 305 1.0 380 1.0 365 1.0 290 1.0 420 1.0 380 1.0 370 1.0 360 1.0 285 1.0 290 1.0 345 1.0 370 1.5 515 1.0 275 1.0 390 1.0 450 DN 20 25 32 40 50 65 80 100 125 150 200 Casing pipe D [mm] 25 32 40 50 65 80 100 125 150 200 125 125 140 140 160 180 200 250 280 315 400 1.uk FERWAG® -District heating pipe Parallel T pieces with steel pipe Heating.0 355 1.0 340 1.0 340 1.0 315 1.0 410 1.0 340 1.5 650 d1 D DN H [mm] .0 360 1.5 560 1.0 350 1.0 320 1.3 415 1.0 300 1.0 400 1.0 305 1.0 440 1.0 275 1.co.318 15.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.3 435 1.0 330 1.3 400 1.

7 x 110 42.9 x 110 33.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. see catalogue page FER 7.3 x 125 60.7 x 250 168.9 x 500 355.4 x 630 457.3 x 225 139.anchor.6 778.1 x 355 273.2 x 710 508. load in kN Ds = external diameter of the steel disc in mm For mass of the concrete block (foundation mass) and concrete quality.9 x 180 114.6 x 560 406.515 D d .uk FERWAG® -District heating pipe Anchors FER 7.co.1 x 160 88.10.320 15.5 285 382.5 1036 1136 1467 1648 1832 Fr mm 240 240 250 250 265 290 310 360 385 420 520 650 715 780 860 860 950 Ds L mm 2000 2000 2000 2000 2000 2000 2000 2000 2000 2500 2500 2500 2500 2500 2500 2500 2500 Fr = max.3 x 280 219.0 x 800 kN 39 47 60 69 97 123 160 231.4 x 125 48.3 x 140 76.0 x 450 323. thermally and electrically insulated Insulation thickness 2 Permissible axial compressive stress: Permissible bending stress (in the disc): axial = 185 N/mm 2 Ds = 165 N/mm 2 Ds Fr Fr L DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 dxD mm 26.2003 Disc .5 610.

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. Maintenance • Steel parts on the dome should be periodically cleaned and well greased • Operate at least every 3 months. volume 4. exposed pipe end must be welded shut Position indication (ball valve only) • Milled notch on actuating spindle square and pointer. 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. to max. owing to damage to the sealing faces. 25 bar operating pressure • processed. forged and welded • Welded ends in St 35. 23. 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. 140 ° C.325 15.5. 32. 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. multiple.uk FERWAG® -District heating pipe Preinsulated valves for underground laying Description.84 • Inspection certificate to DIN 50049. handling and maintenance.co.10. members' information no.2 • Pressure test on each fitting to DIN 3230. • 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. sheet 3: BA. where the test conditions to AGFW are met (Code of Practice 2. i.2.8 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.2003 General Ball valves and slide valves are only heat insulated by us as standard provided they are suitable for direct underground laying with or without prestressing. with body protected from overheating (max.5/volume: Flat laying of KMR for district heating pipes) B. fully desalinated. installation and assembly FER 7.e. . We and the valve manufacturer can accept no liability for damage caused by incorrect assembly.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.: A. uncovered fittings must be completely emptied • Grease steel parts on dome well • At a provisional line end. deoxigenated. 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. clean pipe water • unsuitable for installation in bends and expansion leg areas Material • Body made of steel.7. where no screwed connections are located in the insulation area Range of application • to max.

9 x 4.0 219.3 273.3 x 3.4 x 3.co. insulation thickness 3.9 x 3. except DN 200 & 250.Wrench size 1000 Steel pipe d1 mm 20 25 25 32 40 50 65 80 100 125 150 200 HDPE casing pipe D mm 125 125 140 140 160 180 200 250 280 315 355 450 D1 mm 110 110 110 110 110 110 110 125 125 125 180 180 d1 D d Dome with actuating spindle H mm 400 405 405 427 432 440 454 486 499 518 560 595 SW 6-square mm 19 19 19 19 19 19 19 27 27 27 27 50 DN 20 25 32 40 50 65 80 100 125 150 200 250 dxs mm 26.6 88.0 139.1 x 6. except in the case of DN 20 Standard design D1 SW .325 Fittings.5 168.2 48. see sheet FER 7.0 x 7.335 H . PN 25.2 60.3 x 3.0 114.7 x 3.1 x 3.2 33. insulation thickness 2 Reduced bore.330 15. operation and maintenance as per sheet FER 7.DN 250.3 x 4.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.10.6 76.uk FERWAG® -District heating pipe Shut-off valve Ball valve BALLOMAX ® FER 7.7 x 4.1 Rules for assembly.3 x 5.2003 DN 20 .2 42.

27/32 1100 ø 24 6-square 6-square SW 19 SW 27 50 27 SW19 6-square 4-square 27/32 6-square SW 50 6-square Ball valve Plug-in gears may be supplied on request (recommended from DN 200 and above) . 27/32 4-square.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. 27/32 4-square.co.10.uk FERWAG® -District heating pipe Fitting for shut-off valve Ball valve FER 7.335 15.2003 6-square Wrench 6-square protector 6-square Wrench.

Foaming cannot take place in heavy rain or snow. Next. Before shrinking 6 2 5 1 4 For additional double security (2D).340 15. L = 720 – 780 2. it is not possible to push the sleeve on before welding (2 short elbows. for any reason. etc. the shrink-on sleeve is shrunk on to the casing pipe with a gentle gas flame. 4 Rigid PUR foam manufactured by customer on site 5 Rigid PUR foam manufactured in the factory 6 Permanently elastic sealing adhesive 7 Welding plug 8 Shrink-on seal 9 Alarm wires B) Sealing with shrink-on seal The unit consists of a shrink-on seal and a sealing patch. The subsequent insulation is normally undertaken by our fitters. fixed points). Fitting and sealing follow the same procedure as for the HDPE sleeve. or in cold weather (temperatures below 0°° C). the shrink-on seal shrinks on to the sleeve and the pipe.uk FERWAG® -District heating pipe Pipe joints Sealed with shrink-on SMPE-2D FER 7. 1.co. the shrink-on sleeve is sealed externally with a seal (external seal). The seal (internal seal) is fitted. HDPE reduction joint Reduction sleeves are required when the pipe cross-section changes (pipe reduction.) the sleeve may be divided and one half can be pushed on to either side. HDPE shrink-on sleeve with internal and external seal. 2D = double internal and external seal Product description The shrink-on sleeve consists of a non-interconnected shrink-on sleeve pipe which is expanded at the factory.2003 The joints (subsequent insulations) between the pipes and the moulded fittings must be foamed and sealed on the site. The inside of the shrink-on seal consists of a special hot-melt adhesive. The filling holes are welded with a conical HDPE plug.10. 600 D1 D2 . SMPE-2D SMPE = non-interconnected shrink-on sleeve. the shrink-on sleeve must be pushed on to the pipe.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. It is possible to carry out a tightness test before foaming. 1. When it is heated with an open flame. Before welding. and then the shrink-on sleeve is pushed over the joint. the sleeve is foamed using 2-component PUR foam.1 Fitting the joint (repair joint) If. PUR installation foam is used to provide the heat insulation. Tpieces. or else the sleeve must be slit open by our fitter and longitudinally welded on site. The FERWAG® system includes various types of sleeves. Joint length 600 mm 7 9 3 6 After shrinking 8 2 5 1 1 Carrier pipe 2 PE-casing pipe 3 Non interconnected sleeve pipe A) PUR site foam Before sealing.

Sealing is as in the case of the HDPE socket. D D 400 400 Shrink-on seal FERWAG ® shrink-on seals protect the PUR insulation on the front of the FERWAG® pipes from sprayed water. The shink-on seal also prevents the PUR insulation at the end of the pipe from escaping in gas form. Important assembly instruction The FERWAG ® shrink-on seals should be pushed onto the end of the FERWAG ® pipes before welding the inner pipes.2003 3. Coating with sealing adhesive. min 120 Table: Allocation of FERWAG ® -dimensions/shrink-on seal type Insulation thickness 1 DN inner pipe Outer pipe mm 20 25 32 40 50 65 80 100 125 150 200 250 300 90 90 110 110 125 140 160 200 225 250 315 400 450 Type designation of end cap DHEC 2100 DHEC 2100 DHEC 2200 DHEC 2300 DHEC 2400 DHEC 2400 DHEC 2500 DHEC 2600 DHEC 2600 DHEC 2700 DHEC 2800 DHEC 2900 DHEC 3000 Insulation thickness 2 Outer pipe mm 110 110 125 125 140 160 180 225 250 280 355 450 500 Type designation of end cap DHEC 2200 DHEC 2200 DHEC 2200 DHEC 2300 DHEC 2400 DHEC 2500 DHEC 2500 DHEC 2600 DHEC 2700 DHEC 2700 DHEC 2900 DHEC 3000 DHEC 3000 Insulation thickness 3 Outer pipe mm 125 125 140 140 160 180 200 250 280 315 400 500 560 Type designation of end cap DHEC 2200 DHEC 2200 DHEC 2300 DHEC 2300 DHEC 2500 DHEC 2500 DHEC 2600 DHEC 2630 DHEC 2800 DHEC 2800 DHEC 2900 • • .co.uk FERWAG® -District heating pipe Pipe joint connection End sockets. cross-linked polyolefin. and protected from the effects of heat during welding. Indicator wires Material: Heat shrinkable. In the case of standing water (flooding). in buildings and shafts. HDPE end sockets End sockets are required at provisional line ends in the earth. Shrink-on seal FER 7.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.10. the shrink-on seal is not necessarly watertight.345 15. An end socket must always be fittet to protect PUR and steel pipes.

particularly standard plastic cased pre-insulated pipes with a HDPE casing as used in underground district heating mains.uk FERWAG®-District heating pipe EWELCON-Fusion Welded Joint System Description FER 7. The weld seam area can be cleaned and dried easily. The required pressure holding the weld surfaces together is reliably applied by a specially developed clamping device. The welding process is controlled by a microprocessor-controlled welding set. a meander strip of copper wire. This coil is placed so as to enclose the entire inner area of the collar when the sheet is wrapped around. and is uniform from one welding job to the next.10. After the molten zone has cooled down. The heating element. These features make the EWELCON system particularly suitable for repair and cleanup jobs in existing mains networks.2003 EWELCON Fusion Welded Joint is the registered brand name of a weld collar produced by BRUGG Rohrsysteme GmbH and suitable for making structurally sound water. The HDPE sheet of the EWELCON Fusion Welded Joint is fitted with a heating element and a temperature sensor on the “inside” surface. which monitors and stores the temperature of the fusion weld zone and heating coil throughout the welding process. and becomes fused into a homogenous mass due to the high dilation pressure of the melt. This mechanism is put effectively into practice in the EWELCON system. This simplifies the process of installation and is decisively important in achieving uniform and high joint quality. The material of the sheet and the pipe along the meander strip is plasticized (melted) during welding.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. 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. .351 15. weather conditions). even when installing pipes under difficult and cramped conditions. The temperature of the fusion zone and the pressure holding together the two weld surfaces are the vital elements in achieving a high quality weld seam with plastic materials. g.and gas-tight joints between pipes of plastic material. This guarantees that the temperature of the fusion welding zone is largely independent of external influences (e. forms a heating coil about 27 mm wide. the annular space has effectively been sealed shut by a weld seam some 30 mm wide. The EWELCON Fusion Welded Joint is an entirely prefabricated HDPE sheet which is wrapped around the two pipe ends immediately prior to welding.co.

9 2.9 3.7 4.uk FERWAG®-District heating pipe EWELCON Fusion welded joint Technical specifications Heating coil Temperature sensor FER 7.0 1.5 1. Repair width: W=850 .5 18.5 2.7 3.0 3.4 2.0 4.Ø W1) [mm] L [mm] W 850 W 700 W 850 [kg] [pc.2 1.5 5.3 3.6 4.2003 Heating coil connection lead B Sheet thickness: s Heating coil connection lead L Dimensions Weight s [mm] W 700 [kg] Packing unit Casing .5 9.0 18 18 18 16 16 16 15 15 20/40/80 20/40/80 20/40/80 20/40/80 20/40/80 20/40/60 20/40 20/40 20/40 20 20 20 10/20 Material: PE80 .] [mm] 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 700/850 450 515 560 610 675 740 805 885 950 1050 1160 1290 1440 1600 1830 2020 2250 2580 2870 3190 3510 4 4 4 4 4 4 4 4 4 4 4 4 4 4 6 6 6 8 8 8 8 1.co.8 2.8 2.0 7.5 16.7 1.1 2.5 1.352 15.0 22.0 3. 225 mm are delivered in rolls.1 2.6 1.2 3.2 7.] [pc.5 10.3 2.DIN EN 32 162 (PE-HD) Other dimensions on request.7 16.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.7 8.7 13.8 20.2 14.0 8.6 2.3 2. Joints up to ∅ 1) Standard width: W=700.0 17.10.3 1.

The weld bath temperature near the contact pressure of the weld nugget interface is the most important criterion for producing a high quality plastic weld joint.04 The EWELCON ®-S Electro-Welding Coupling Sleeve is an integral part of the „EWELCON®-Family“. The serpentine heating element with copper wire terminals is embedded into one of the PE-HD lead frames. In addition. thus the heating elements will be optimally adhered. The EWELCON® Electro-Welding Coupling Sleeve shrink sleeve is made from bimodal PE-HD thus ensuring optimal long-term capacity.353 24. These characteristics make the EWELCON®-S System particularly suitable for rewiring. Thanks to the special construction at the connection ends.g. It will be possible to conventionally shrink the shrink sleeve onto the casing pipe using a soft liquefied petroleum gas flame. The necessary contact pressure will be provided by a specially developed clamping tool. These facts are substantly app l i e d i n t h e E W E L C O N ®. It is the ideal complement to the approved EWELCON® Welding Coupling Sleeve for the sleeve technique in the dimensional range below. The parameters for each weld procedure are saved in the welding computer and can be read and documented at a later stage. Each set of heating elements is fitted with a temperature sensor. The heating elements are then fixed to the previously prepared casing pipe.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. assemble these joints. Thus the weld bath temperature and the heating element temperature are monitored and saved throughout the whole weld process. each sleeve joint provided will undergo visual and density tests.co. The shrink sleeve provided with sun protection foil will already be inserted over the inner pipe . constant welding conditions are ensured all round the circumference of the pipe. The weld procedure will be regulated by a microprocessor-controlled welding device.Technische Änderungen vorbehalten - . In this way the weld bath temperature is largely independent of external perturbations (e. The heating elements will be supplied in handy packing units that protect against soiling and are suitable for construction sites. only fitters who have completed the basic training by our commissioned trainers.09. atmospheric conditions) and can be compared between welds. The weld seam area can be lightly cleaned and dried. .casing pipe weld. the shrink sleeve and the pre-constructed heating elements will be supplied in separate packing units. especially in complex and cramped assembly conditions. The heating elements will firstly be directly laid over the weld on both the KMR-ends.uk FERWAG® District heating pipe EWELCON®-S Electro-Welding-Coupling FER 7. Repairs and reconstruction of existing pipelines can be carried out using the EWELCON® Welding Coupling Sleeve for the sleeve technique. For reasons of quality. they conform to component tolerances. who have acquired the necessary qualifications. The EWELCON®-S Electro-Welding Coupling.S s y s t e m . This substantially contributes to the high and constant quality of the joint. be packed with foam and the vent holes sealed with weld stoppers.

Technische Änderungen vorbehalten - .0 3.9 600 24.354 24.5 L [mm] Ø dB [mm] Weld stopper Ø dS [mm] Heating element set Length LSS Width BSS [mm] [mm] 310 370 420 460 28 520 580 650 730 810 900 100 .4 4.3 4.04 casing pipe ØD [mm] 90 110 125 140 160 180 200 225 250 280 PE-HD-Casing pipe (before shrinkage) Outer-Ø DM [mm] 107 129 143 156 178 198 224 255 278 306 Wall thickness at least [mm] 2.9 2.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.9 3.5 3.5 3.4 3.uk FERWAG® District heating pipe EWELCON®-S Electro-Welding-Coupling FER 7.09.8 4.co.

2003 Wall sealing ring type A type B Data table Wall sealing ring Typ A Typ B Da Da 133 153 168 183 203 223 240 265 290 355 440 490 540 600 670 750 840 D 90 110 125 140 160 180 Da Da D D 200 225 250 315 400 450 500 560 630 710 800 50 all dimensions in mm Trench warning tape Trench warning tape for laying underground Lenght 250 m Laying depth.co.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.355 15.500 G UN EIT ! G EL UN RM HT Ä AC RNW FE . see page FER 7.10.uk FERWAG® -District heating pipe Wall sealing ring Trench warning tape FER 7.

360 15. for nonpressurised water. sealing set A) Sealing capacity • Impermeable to gas Load-bearing capacity • Axial movements External Internal D R 2 3 1 DOYMA wall duct type F/ZS. 125 140. civil defence tested for HDPE sleeve pipe diameter Ø110 to 800 mm External Internal 1 FERWAG® pipe 2 Sealing set F/ZS.uk FERWAG® -District heating pipe Wall duct (DOYMA) Watertight. 250 280.co. g. special care should be taken during assembly or filling of the trench that no sinking of the pipes can subsequently occur. 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.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.10. Assembly / Trench filling In order to avoid deformation at the sealing point.2003 DOYMA wall duct Type C 40 for HDPE sleeve pipe diameter Ø110 to 800 mm 1 FERWAG ® pipe 2 Sealing set C. . T 86-008 Sealing capacity • Impermeable to gas Load-bearing capacity • Axial movements D R 2 1 3 R Pipeline diameter PE Ø mm 90 110. We cannot guarantee a good seal if these recommendations are not observed. 315 355 400 450 500 D Pipe liner Core drill hole Ø mm 150 200 250 300 350 400 450 500 600 700 Core drill holes Prerequisites for installation are perfect drill holes. We also recommend that the pipe should be supported or hung inside the building. AQUAGARD). 200 225. we recommend sealing the drill hole walls over the entire lengths with a sealant (e. double sealing 3 Pipe liner made of fibre cement or coated core drill hole Suitability • Against pressurised water • Civil defence tested. Since hairline cracks can exist in concrete or can arise as a result of the work. for civil defence structures FER 7. 160 180.

protective handling levelled sand bed Fig.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. only attach hooks to the steel pipe Fig. free of charge to the site / dispatch address. 0. 1: Hanging appliances for safe. 2: Intermediate storage on a levelled sand bed min 0. 2.0 m . but this is only of limited effect and is not effective on a long term basis. in paticular of the heat insulation. 2.10.2003 Transport Delivery of the pipes.15 m max.4 max. which can still be unloaded manually. Unloading. the unloading areas should be prepared accordingly. Mouldings and fittings should be stored on planks or wooden pallets. With the exception of pipes up to approximately DN 80. min 100 mm wide Diagonal ropes.400 15. 0. In order to avoid costly waiting times.co. 3: Intermediate storage on wooden planks The pipes must be stored as dry as possible and in such a way that the pipe ends do not lie in water. mouldings and fittings is generally undertaken by lorry. The ends of the heat insulation and the steel pipe ends are treated with a damp protection product by the factory. the mouldings and pipes must not be thrown or rolled.25 m 0. max. In order to avoid damage. handling Unloading is the responsibility of the customer / consignee. lifting gear should be used for unloading. if possible under cover and dry.uk FERWAG® -District heating pipe Transport and storage FER 7. sufficiently far away from the sleeve pipe. Owing to transfer of the risk at the time of delivery. 0.20 m DN 150 min. 1. it is recommended that the customer should appoint and make available a responsible person to receive the goods.0 m ca.90 m even surface Fig. Moving with textile straps.06 m Up to DN 150 min.

. . between the pipes min.. .28 0.35 1. Trench profile EWELCON see down! Washed sand.2003 Laying pipes • It is vital to ensure that the PE outer sleeve is not damaged. the line must be backfilled on all sides to match the profile of the trench.97 1.87 0. ..59 0. general building regulations must be observed.75 0.54 0. • Before welding. with noncohesive. 0.uk FERWAG® -District heating pipe Civil engineering works Laying pipes FER 7.70 1. . . . .40 2.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. . . .10. 0. . . . • 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).12 1.90 2. • After assembly.20 • • D • ca.20 Polystirol pipe base BRUGG every 3 m • D 0.70 0.05 1. . .. . .80 0. .44 0.30 0.15 0. • The trench should then be filled to 30 cm below ground level with excavated material and compacted.3/4 mm Trench dimensions PE external pipe Width *Sand contents [m3/m] D [mm] B [m] 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 0. . . the monitoring wires must always be on top. 0. Subsequently they are pulled back over the connection points in order to protect the insulation..40 .30 1.80 1.95 1. .. .45 1. the PE socket pipes must be pushed over one pipe end in each case. an assembly proposal should be requested from us.10 ca. .52 1. Civil engineering works • When excavating the pipe trenches.76 0. .10 1. . ... .37 0. . • 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.30 0. .3/4 mm)..501) *Sand contents according trench dimensions +10% .49 0.36 0..55 1... • Lay BRUGG warning strip.90 0. • When laying pipes.co. . . . round-edged sand (grain size 0 . 23 cm (see sheet 7. .. . . .60 . EWELCON Fusion Welded Joints: The head holes should be provided at every pipe joint..75 Line warning strip min 0. . .66 0.00 1. . . .20 1. fill trench completely and compact. . • In difficult ground conditions.29 1... subsidence etc.500 15. • The pipe trench must be kept free of water during the entire assembly period. .20 B min 0. .10 2. grain size 0 .99 2.74 1.70 0.

2003 Trench preparation around expansion pads The trench around the expansion pads must be widened on both sides and deeper by at least 10 cm.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.10 10 cm deeper 0. The width of the normal trench profile can thereby be reduced.uk FERWAG® -District heating pipe Civil engineering works Laying pipes FER 7.co. so that the steel pipes can easily be welded together and the socket connections cleanly executed.20 0. 0. 0.10.35 B + 0.501 15.10 expansion pad 2.40 1.4 m Trench profile with head hole Head holes should be provided for larger sizes at each weld seam.80 . and at least at elbows and T pieces.

The national and local regulations govern the use of excavation material and/or the minimum layer thickness of the fine sand. Earliest compression is after the pipe apex is covered up to a height of 30 cm. • Topmost layer: incorporate humus or HMT. • Cover the pipe apex to a height of at least 10 cm. grain size 0-1 mm. As an alternative. • Compacting .uk FERWAG® -District heating pipe Filling the pipe trenches FER 7. underneath and next to the pipes. so-called cyclonic sand (sludge sand). or with the lowest possible proportion of loam. such as excavation material and/or fine sand.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. not above 8%. above the pipe apex). Broken glass is not permissible as a substitute for sand in the case of FERWAG® pipes (it is permissible for FLEXWELL® ). and it must be well compacted. As a general rule. is permissible (the ”waste” from washed sand).10. using suitable implements (such as a shovel or pick stem).very important! • Between. Embedding the pipe in sand (as shown on the Trench Profile sheet) • We recommend that welding pits and trench fillings are first filled with lean concrete. Important: do not damage the seals or the pipe! Residual filling of the pipe trench • The rest of the trench must be filled up with compactable material. pressure distribution plates must be incorporated above the sand layer in order to relieve the stress on the pipes. Do not forget: fit line warning tape and any protective pipes (not over the pipes approx.502 15. or for areas subject to heavy traffic loads. layer by layer. all construction and safety regulations must be followed! . • non-cohesive.3/4 mm) • proportion of ultra-fine grains 0. If the coverage is insufficient (minimum of 60 cm).25 mm: if possible. maximum grain size 4 mm (0 . the sand must be tamped down or compacted by hand.2003 Covering material (sand) • round-edged washed sand.co. No cavities must be created. • Compact the material using a vibrator with a maximum surface pressure of 100 kPa. depending on the regulations. 30 cm.

345 60 50 min.355 Cellar / shaft Monitoring socket FERWAG ® Shrink-on seal see sheet FER 7.505 15.co.uk FERWAG® -District heating pipe House Connection Wall penetration • Neoprene rubber FER 7.10.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.120 Wall penetration B Core drilled holes* 80 H 80 D 200 dimension in mm dimension in mm D B H D1 90 110 125 540 580 610 250 300 300 200 220 240 140 160 180 640 680 720 350 350 350 260 280 300 200 225 250 760 810 860 350 400 400 320 345 370 280 315 355 400 450 500 560 630 710 800 920 990 1070 1160 1260 1360 1480 1620 1780 1960 450 450 500 400 435 475 550 600 650 530 580 630 750 800 900 990 700 770 850 940 dimension in mm *Wall duct DOYMA see sheet FER 7.360 D1 . see sheet FER 7.2003 Wall duct Wall sealing ring made of profiled neoprene rubber.

10.510 15.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co. 12 m min 150 mm  min 750  min 120 mm  < 300 mm  min 300 mm min 120 mm   min 170 mm   .2003 6.uk FERWAG® -District heating pipe Assembly rules FER 7.

8 0. .4 457.2 1.3 1. .3 5. . .0 1. . .1 273. .6 1. . A a A1 H µ L* L* must not be any wider! B In the event of different fixed point forces and ground conditions.45 0. . . .8 0.1 3. . . .70 2. .40 2.15 1. . . a mm 270 270 280 280 295 320 340 390 415 450 550 680 745 810 890 890 980 DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 d mm 26. .8 2.0 1. . .40 0. .8 1. .0 1. . . .9 355.5 83. .515 15.0 323.co.8 0.64 ) • Piled density = 18 kN/m3 Concrete quality • P 350 to DIN 1045. .7 168.4 48.8 0. .1 88.10. T = 70 ° K ] • Covering height H = 0.40 2.8 0. with reinforcement . .9 3.3 3.3 1. . . . .0 2.1 412.60 A m 0. . .6 680. .8 0... .8 m • Foundation dimensions are based on an angle of friction of = 32.5° for non-cohesive ground (friction factor µ = 0.25 2.9 284.10 2.uk FERWAG® -District heating pipe Concrete block for anchor For maximum anchor forces FER 7. . .8 0.9 33. .0 1.40 1.3 76.60 2.5 1.7 3.7 42. .80 0.5 A1 m 0.5 3.40 0.2 508.6 406. .0 1.8 0. .3 60.1 1.3 1.6 1388.0 2.9 507.. . shearing force for 2 pipes: Fs max = 2·As· T.8 0. .1 1.9 1.3 219.3 1. . . .2003 . .9 1000.3 139. . . .0 1.0 Fs max kN 66.5 2. .3 1..4 219. Steel pipe Fixed point force Concrete block dimensions Distance between pipes.9 3.65 0. . . .3 3.5 * L m 0. .. . . . . . .2 123. . . .PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.9 1. . water impermeable. .7 107. .55 0.4 2.3 Basis of calculation for concrete block size • Max.95 1.1 172.3 1. [ T = 165 N/mm2.9 114. .40 0. . . . . .4 5..3 1. . .5 1847 2052 2592 2920 3240 B m 0. .7 2.3 1.8 4.3 1. . the foundation dimensions must be calculated.

520 15. . . . . . . . . . ..10. . 120 2 1 150 . . 150 . . . . .. .uk FERWAG® -District heating pipe Draining and venting arrangements FER 7. . ..co. . . . . . . supplied separately 3 Expansion pad 4 Sand 5 Lean-mixed concrete 6 Gravel for drainage . . . ...2003 . . . . 3 . . . . . . . . . . . . 5 4 1000 dimensions in mm 1 Valve. . . .. .. ... .PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. . ... supplied by customer 2 Shrink-on seal. .. . .. . . . .. . . .. . . .. . . 4 .... 500 5 L as specified 1 3 L as specified 2 5 min 100 . .. . . . . .. . . min. . . . . . . . . 6 ..

.. .. .. . . . . . .. ..10. . . .525 15. . . .. . . . . .co. . .. . . . . .uk FERWAG® -District heating pipe Underground installation for ball valves FER 7.... . . . .. ... .. . .. . . 1 H 2 3 4 5 6 > D2 200 D1 200 D1 200 dimensions in mm Top view DN 1 Heavy duty cast-iron round lids (for expl. ... . .. . . .. . ... . .. .PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. ... . . .. .. .. . .. .. Von Roll) 2 Concrete pipe 3 Ball valve 4 Thermal expansion pads 5 Supporting plate 6 Sand bed. . . . . ... .. . . .. . . .. . . . . . ... . . .. . grain size 0-3/4 mm 20 25 32 40 50 65 80 100 125 150 200 250 D1 mm H mm D2 mm 125 125 140 140 160 180 200 250 280 315 355 450 470 470 470 490 500 510 520 560 570 590 630 670 300 250 .2003 Inspection wells with heavy duty cast-iron lids D2 D2 . . . ... ... . . .

The hot tapping tool for weldable connections on steel pipes is designed for branches in the dimensions DN 25 up to DN 100.uk FERWAG®. The hot tapping method features the possibility to install belated branches on every place of the Network. 40 cm The hot tapping valve on branches can be welded directly or where it requires with a welding ring on to the main line. a maximum pressure of 25 bar and a temperature up to 140 (180) °C. Hot tapping for bigger dimensions of branches can be carried out on request by an other system . They can be used in district heating networks or other process pipelines. . All hot tapping valves are designed with a reduced opening.530 26. This hot tapping method saves costs thanks to an economic and a safe executable drillling process withour service interruption. The today used tools and components are the result of a long term development process which combines experience and new technology.District heating pipe FER Hot tapping System description 7.8.co.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.2003 The BRUGG-Ballomax hot tapping system is used to where branches are made from main lines while the district heating system is working.

9 57.2 114.531 26. diam.0 10 1. PE casing (outflow) DN 25* 25 24 26 DN 32 25 24 41 DN 40* 40 40 68 DN 50 40 40 112 B DN 65 50 48 200 DN 80 65 65 380 DN 100 80 79 620 33.0 275.0 92.3 DN 125 225 bigger dimensions with other system on request Application for branches without reduced diameter Anschluss .8 54.0 100.3x2.0 14 6.0 14 11.3 46.co.0x5.0x6.0 200.7 54.1 88.1x3.3 DN 32 110 60.3 70.8 37. PE casing all dimensions in mm DN 25 DN 25 24 DN 32 110 DN 32 DN 40 40 DN 50 125 DN 40 DN 40 40 DN 50 125 DN 50 DN 65 48 DN 80 160 DN 65 DN 80 65 DN 100 180 DN 80 DN 100 79 DN 125 225 33.1 DN 80 160 133.1 76.9 48.7x2.0 10 3.3x2.7 DN 100 180 159.3 46.8.1 88.9 60.0 82.6 .5 DN 50 125 88.uk FERWAG®.0 10 3.9 57. diam.6 37.7x2.9 48.0 145.Dimensionen Hot tapping valve Pipe diameter Steel-pipe reduction Diameter main line min.4 DN 65 140 114.PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000. main line min.2003 Dimensions and measurements Hex key *Ball diameter is not reduced A1 H A2 L Hot tapping valve with complete welded body Ball is made of stainless steel / seals made of PTFE Dimensions Ball opening Drill size Volumetric flow rate (KVS) [m3/h] A1 (side house connection pipe) A2 (side mainline pipe) B H L Hex bolt / hex key Weight [kg] min.0 260.3x3.9 48.0x8.0 80.0 60. diam.0 200.3x2.0 14 5.3x3.0x7.0x6.7 63.3x3.9x3.2 114.2 DN 40 125 88.9 42.0 145.0 265.9 76.0x9.9x3.District heating pipe FER Hot tapping Dimensions and measurements 7.0 10 1.4x2.1x3.0x5.

5 mm Take care that no welding material is getting into the hot tapping valve! Chamfering of the welding end according DIN 2559.uk FERWAG®. basic Type E5155B10 DIN 1913 ø 2.to be tighted (blocked in the ball) and welded together with the body (around) after placing in operation of the brach pipe.2003 Preparation weld seam and weld composition Welding end with weld seam preparation Outer thread for hot tapping tool Hex bolt .co. Splice type 22 Basic rules during welding operation: • The ball has to be opened! • to avoid over-heating on the teflon-sealings please cool down the hot tapping valve between the itemized welding layers (Small waiting period or cooling with a wet cloth) .PIPE2000 Ltd UK Distributor Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.District heating pipe FER Hot tapping Preparation weld seam and weld composition 7.532 26. Place the hot tapping valve without crack directly on the main line Weld composition: Electric welding (2-3 layers) with Kb-electrodes.8.

co. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.pipe2000.co.uk .uk www.

pipe2000.co. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.uk .INSULATED P IPES WIREM® THE PROFESSIONAL SOLUTION FOR ENGINEERS PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.co.uk www.TECHNICAL INFORMATION SHEETS P RE .

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0 10.100 10.1 10.co.200 10.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.0 15.300 10. page 2 Fault handling procedure Electrical circuit. wiring diagram Option: Remote control transmission CH .320 10.330 10.210 Design and reference charts Design and reference charts Welding plans 10.3 10. technical data Unit description.340 Control unit U89A Unit description.2 10.110 10.uk 10.310 10.120 Table of contents General system description System description Functional description Measuring description 10.10.PIPE2000 Ltd-For Information District Heating Control Table of contents WIREM 10.

is nowadays mostly equipped with control equipment. Feeler wires melted into the thermal insulation in the factory perform. The network of monitoring.co.g. can produce an alarm in case of entry of water. testing over dialog and storing of results. Supply of data on the state of the insulation.100 15. • A display reports a failure or interference basing on early detection and self diagnostics. • Detection and identification of the feeler conductor making contact with the inner pipe. The WIREM® technology with its feeler wires and control equipment makes many functions possible: • Check of the humidity in the thermal insulation starting at the production stage. The range of units extends from the manual instruments to measure the condition of the insulating material and manual fault location (unit U 89A) to fully automatic monitoring and fault location. WIREM ® and BRANDES are compatible systems. together with the monitoring equipment. • An entry of humidity through e.10. CH .2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. to monitor its operation. a faulty welding seam. measurands. Other monitoring systems can be supplied if specified. The advantage of this lies in the early detection and quick location of damages. state of contacts and other data can be registered and transmitted to other systems. measuring and locating units can be built up at will depending on conditions of volume of data required and network size. The safety of the installation is improved and the costs of repairs reduced. The systems FLEXWELL® -cable. The BRUGG STEEL PROTECTION PIPE is available as an option. • Feeler gauges connected to the control system and situated in wells. monitored located and reported during operation. a breakage or damages anywhere in the circuit can be detected and identified. loose sleeve or external damage can be detected. FERWAG®pipe and CASAFLEX® -district heating pipe of BRUGG Pipe Systems are equipped ex-works with the Reference Resistance Measurement system (WIREM® ). as well as data transmission to other computers and printers.uk The piping for district heating laid out underground. a great number of functions.PIPE2000 Ltd-For Information District Heating Control General system description WIREM 10. • Alarms.

Should the isolation resistance diminish. coloured green Principle of monitoring The physical principle for monitoring. embedded in the thermal insulation. FEP-Insulation. For the monitoring itself. CH . by a thermally stable PTFE sleeving.pipe they run parallel. The wire itself is protected against direct contacts to metal. Monitoring of the thermal insulation is performed by a special feeler wire (see figure). which can attain 1000 m in length and therefore is able to monitor 1000 m of piping.e.uk Position of the feeler cables The monitoring cables (feeler wire and return wire) are embendded in the insulating material between the inner and outer pipes. an FEP isolated. A defined voltage is applied between the feeler wire. i. which is that of the unloaded resistance bridge principle. Large pipe networks of several kilometers in length are divided into monitoring sections of under 1000 meters. NiCr conductor inner pipe and about half way through the insulation. 2 3 1 2 1 Structure of the return wire 1. return wire back (see figure).co. and the pipe (see figure). on eiter side of the Structure of the feeler conductor 1. from „dry“ with over 50M to „wet“ with under 10K insulation resistance. as well as for fault location.and CASAFLEX ®.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. Gaps in insulation at regular intervals for wet contact detection 2. while in the flexible system FLEXWELL ® -cable. PTFE-Insulation. A monitoring unit is installed at each section. they are wound around the inner pipe and run close to each other. is the resistance reference method (WIREM ®). Branches of piping are also followed by branches in feeler wires. This permits monitoring over the entire length of the feeler wire. The perforations allow an accurate evaluation of the wet spots regarding their intensity in the whole monitored spectrum.110 15. copper return wire is laid out parallel to the feeler wire. A contact between the naked NiCr wire and wet spots occurs in perforations along the PTFE sleeve. Principle of monitoring Feeler wire (red) Layout of the feeler loop Feeler wire (red) Return wire (green) S Loop Return wire (green) Pipe center line I Insulation Monitoring unit Feeler loop with branch-off The reference resistance determines the tolerance threshold and is adjustable. Copper core 2. coloured red 3.10. In the FERWAG ® .PIPE2000 Ltd-For Information District Heating Control Functional aspects WIREM 10. Both wires form a feeler loop (see figures). a voltage rise will be registered in the monitoring instrument and an alarm will be released. feeler wire out. as will happen when a wet spot occurs.

a voltage U is applied across the loop.co. as it is balanced out in the measurement concept. strict quality control and measurement checks during production are applied in general . At the end of the feeler loop.10. a part voltage U1 caused by the wet spot.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.7 /m and the return wire near zero . among others. U1 U = R1 R = x% 100% = L1 L U U1 R R1 x% L L1 = Applied voltage = Measured voltage = Total loop resistance = Part loop resistance = Part result = Total pipe length = Distance to fault The gravity of the insulation fault (insulation resistance) has no influence on the precision of location. To avoid subsequent faults and gaps in the feeler loop. They target. The result is expressed not in Volt but in % of the applied voltage.uk Determining the fault location To locate the wet spot or contact fault. A capacitance measurement can also be used.120 15. Since the feeler wire has a relatively high resistance of 5. but the location of the break has to be performed manually by other means. Determining the fault location 100 % Fault location unit x% Wet spot Feeler wire (red) U U1 Return wire (green) CH . The usual method used in such cases is the time delay measurement. the following relationship results: Locating a break in the feeler loop or in the monitoring circuit A breakage in the feeler loop will be immediately detected in automatic installations. the solidity of all wire connections.PIPE2000 Ltd-For Information District Heating Control Determining the fault location WIREM 10. is measured between the inner pipe and the feeler cable.

The whole installation is then divided into separate loops with a maximal length of 1000 to 1200 m per unit.8 mm Length 9m : armoured wire Wiring by an electrician Block 3 Monitoring terminals T-pieces (downward) Wiring between the terminals Brugg in the building. done by an electrician Block 4 T-pieces (downward) Block 2 Results of measurements Resistance / length (DR) R = 5.10.co. it is good practice to insert some spare cables beside the pipes. or U 72 0.PIPE2000 Ltd-For Information District Heating Control Design and Reference Drawings WIREM 10.5 mm2.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. Reference drawings (Wiring diagrams) Control units Feeler Return 1 2 U89A 1 3 1 2 U89A 2 3 Heating Plant Block 1 The monitoring system BRANDES CrNi wire (red) Cu wire (green) TT 1.200 15. All units can be placed centrally in one building. For future expansion of the network.uk Design The design of the control circuit is done parallel to the design of the piping.7 /m Forward 2219 Return 2220 Insulation resistance (IR) Grade BS-MH-2 Forward 0 = >50 M Return 0 = >50 M CH .

92 12.0 .0 5.0 6.50 Block 4 x0 .0 1.0 12.5 0.6 5.0 12.3 R7 -14 0 6.65x0.52 12.56x0.0 1.50x0.65 6.PIPE2000 Ltd-For Information District Heating Control Reference Drawings Welding plans Reference Drawing Welding plan View A WIREM 10.0 12.57 1.84 4.0 Bg 85° .0 12.75 5.0 Bg 90° . Welding plans have proved to be the best reference.0 12.0 12.1-160 FER 88.0 Bg 90° 12.92 .0 6.0 4.0 6.10.65x0.56 0.65 1.77 12.84 6. 0.65x0.1 -16 Bg 90 0 ° .0 6.0 4.0 5.210 15.6 6.65 Materials Pipe FER 60.uk Reference Drawings To find the exact location of the fault above earth.50x0.65x0.65 12.50 x0 k3 12.9 Bg 61° .0 5.5x0. 0.50 Bg 90° .05 Elbow 90° 0. The more precise these are.0 Bg 90° .0 T-pieces Blo ck 8.65 Venting Bg 86° 0.9-180 Stand.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. Heating Plant Block 1 0.65 Bg 90° .95 6.74 12.0 6. 0. it is very important to have access to reference drawings.65x0.3 1.65 .65x0.0 3.92 1.0 5.0 12.6 6. 0.23 6.45 2 8.82 12.0 12.0 6.0 1.3-140 FER 76. 0.65 6.co.65 1.0 Bg 90° .0 12.8 5.65 5. 1.0 6.0 4.0 7. 0.0 1.65x0.50x0. 0.0 Bl oc Bg FER FE 60.0 12.81 0.65x0. L Elbow [m] 6m 6m 12 m 0.0 12.9 Bg 86° . 0.0 Bg 76.95 1.50 Bg 90° .9 6.0 6.0 1. the easier and quicker the spot can be found.65 0.65x0.0 6.95x1.0 7. 0.0 6.50 6.65x0.8 Bg 90° .0 12.0 6.0 (downward) 4.0 85 ° . 0.55 Bg = Elbow Draining.0 6.65 1. 0.65 FER 88.0 1.05 A 0.9-180 Bg 61° .0 1.0 5.65x0.0 CH . DN 32 1.5° .65 6.

if there is a failure or earth leakage (shaft monitoring). At the same time the fault signal lamp lights up on the instrument or cabinet door as follows: Insulation moist Failure in monitoring loop Earth leakage.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. Surface mounting Button and 2 signal lamps are mounted on the instrument. a horn.g. Lamps green : operating red : fault Brugg Ro hrsystem AG 5200 Brugg Fitting in switch cabinet For operation. A break in the detector lead or earth leakage (<5 kOhm) is signalled simultaneously.10.uk Unit description Function The instrument monitors the electrical insulation resistance between the detector lead and pipe (earth).300 15.co. By connecting a level switch (e. lamp or central alarm system is triggered. Fault If the electrical insulation resistance is exceeded (moist insulation). shaft monitoring with float switch CH . EHS-JOLA 6M.PIPE2000 Ltd-For Information District Heating Control Unit description U89A technical data WIREM 10. Otto Fischer AG) between the direct lead return and pipe. The unit is suitable for fitting in a switch cabinet and for surface mounting. an additional button and 2 signal lamps must be fitted in the cabinet door. The earth leakage signalling can also be used as a shaft monitor.

The switch should be set to the required position during installation. Clamp in instrument.PIPE2000 Ltd-For Information District Heating Control Unit description U89A WIREM 10.uk Alarm output for external fault display The instrument has an alarm output to supply a horn.10. However. a check is made of all the electronics. 30 V DC 5 A (direct current) 6 paracril cable sleeves mounted on sides 2 break-through apertures in casing bottom Connection screws with terminal plates. Acknowledgement By pressing the double function button (instrument test + acknowledgment button). During the test.2 mm. By pressing the button a fault is simulated.co. During this. As a result. 107 75 View A CH .5 mm2 IP 40 -10° to +50° C 0 to 10 kOhm (0 . the alarm output is switched off. The fault lamp remains alight until the fault has been remedied.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.310 15. the alarm output can be blocked or connected through by means of the switch fitted on the printed circuit board. max. we recommend that you implement a monthly operating check.5 VA High-tension current contact max. the fault lamp must be alight. a lamp or a central alarm system. Technical data • Supply voltage • Voltage tolerance • Power consumption • Output • Breaking capacity • Cable inlet • • • • Connection type Protection system Ambient temperature Max.1200 m) Casing dimensions 150 A Break through for wall fastening ø 4.2 mm Break through for clamp fastening to 35 mm standard bar DIN 46277. 250 V AC 5 A (alternating current) max. loop length 220 V 50 Hz ± 10 % 1. Break through for wall fastening ø 4. 2 x 1. Instrument test The instrument is maintenance-free.

switch off the main switch Possible fault causes Fault 1.PIPE2000 Ltd-For Information District Heating Control Fault handling procedure WIREM 10. Connect terminal 1 + 2 3. Loop.uk Procedure in the event of a fault Caution Before opening the instrument.320 15.10. CH . connecting lines). Press button (instrument test) 4. Remove terminal 1 + 2 2.co. then the cause should be sought in the pipe system (sockets. Fault lamp (red) alight a) continuously b) flashes c) flashes intermittently • 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 ) Possible cause • no mains voltage • 50 mA fuse on pc board defective Equipment test without pipe system Procedure 1.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. 2 + 5 Fault lamp display must flash must go out must be alight must flash intermittently If all 4 states are OK. Connect terminals 1. Green lamp not alight 2.

Length 9 m: armoured wire Assembly limit BRUGG Wiring by electrician CH .Leitung Cu (green or blue) C Assembly limit BRUGG DH .Leitung DH .co. collective alarm fault insulation moist break loop short circuit shaft Supply for display PC board connectors • operating Be sure to connect earth.JOLA 6 M Otto Fischer AG Wiring for branched network. lamp.10.PIPE2000 Ltd-For Information District Heating Control Electrical circuit.Line DH .g.Line Cr Ni (red or brown) Assembly limit BRUGG TT 1.Line Cabinet C DH . wiring diagram WIREM 10.Line Cr Ni (red or brown) Assembly limit BRUGG TT 1.330 15. in special cases connect to pipe. level regulator EHS . Mains 220 V 1.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.Line C Connection pipe • terminal C or 1 Shaft monitoring with float switch * Fault Cabinet external Cr Ni (red or brown) Cu (green or blue) B DH .B no connection terminal 3 Weak current Breaking capacity maximum 250 V AC 5A. Not applicable for surface mounting Terminals on pc board Switch blocked free Alarm output for "Fault external" in instrument test Weak current max. or U 72 0.Line A Cr Ni (red or brown) Cu (green or blue) B FW .8 mm Length 9 m: armoured wire Wiring by electrician 4 5 6 7 8 9 10 11 12 13 14 15 N P red green Acknowledge instrument test Supply for fault external horn.8 mm . switch off main switch.5 mm 2 or U 72 0. 30 V DC 5A Contact load 250 V AC / 5 A Monitoring socket 1 2 3 Cu (green or blue) A DH .Line Monitoring socket 1 2 3 Terminals FW . example only Wiring principle: Always probe loop Wiring between the sockets by an electrician (by the owner) BRUGG C DH .5 mm 2 .5 VA 50 mA 16 * e.uk Caution: Before opening the instrument. 12 V Terminal 3 potential free With direct connection terminals A .

uk Version for remote control transmission e. "Ridat Rittmeyer" The U 89 instrument is also suitable for computer controlled remote transmission.co.PIPE2000 Ltd-For Information District Heating Control Option: Remote control transmission WIREM 10.10. Terminals 9 to 13 Logical states 13 R1 Everything OK R2 I 12 R1 Insulation moist I 0 0 11 Earth leakage in shaft monitoring with level switch Detector lead has short circuit to earth 1 0 10 R2 Break in loop 0 I 9 The functions of the network and fault lamp on the instrument.340 15. In this case.2003 Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000. there is no need for wiring the cabinet door.g. The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission. These outputs are wired as followed by a change on the PC board. CH . and also "Fault external" (terminals 6 to 8) remain unchanged.

uk .uk www.co. Essex SS7 4QB Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.PIPE2000 Ltd 3 Kelvin Road Manor Trading Estate Benfleet.pipe2000.co.

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