Pipes Full Data V11006 06jul09

TECHNICAL INFORMATION SHEETS
Pre-Insulated Pipes
PIPE2000 Ltd
3 Kelvin Road Manor Trading Estate Benfleet, Essex SS7 4QB
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk www.pipe2000.co.uk
TECHNICAL INFORMATION SHEETS P RE - INSULATED P IPES
CALPEX -
The Professional Solution for Engineers
PIPE2000 Ltd
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/exible), CALPEX plastic casing pipe House entry, screwed connector, shaft entry, xed point forces House connection, compression joint, shaft entry, xed 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
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CPX 1.100
System description
1. General CALPEX district heating pipe is the registered trade name for a exible pipe system from Brugg Pipe Systems, specically 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 exible rigid polyurethane foam with excellent insulation values. The bending capability of CALPEX district heating pipe means that it is generally possible to pass over or under existing supply pipes and obstacles can be easily bypassed. With CALPEX district heating pipe, users can choose the shortest pipe route without the restrictions required by the classical method of pipe construction. The exible CALPEX district heating pipe is delivered to the site continuously in coils or on a cable drum. Long delivery lengths enable pipes to be laid in the ground largely without joints. This means that the pipe trench can be considerably narrower. This in turn allows considerable savings on underground work, especially as regards DUO pipes. Taking account of the very short time required for installation, CALPEX district heating pipe is not only the technically ideal solution but also the key to saving time and expense when setting up district heating networks; less co-ordination is required on site and the pipes are laid simply and quickly. The physical properties of the PEXa pipe combined with the composite insulation mean that thermal expansion can be ignored when using this product. Installing the connecting pieces is very simple. The joints are tted quickly and reliably with conventional screwed connectors, compression joints or electro-fusion joints. The wide range of accessories ensures that solutions can be chosen for every possible situation. 2. Range of applications Heating, pipe series 5 (SDR 11): Max. temp. for continuous operation TBmax: 80 C Max. permitted operating temp. Tmax: 95 C (uctuating) Max. permitted operating pressure p: 6 bar
see sheet CPX 1.110
Sanitary, pipe series 3.2 (SDR 7.4): Max. temp. for continuous operation TBmax: 80 C Max. permitted operating temp. Tmax: 95 C (uctuating) Max. permitted operating pressure p: 10 bar
see sheet CPX 1.110

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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-modied, 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 coefcient Linear expansion coefcient 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
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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 conrmed by the competent organizations in various countries. A typical uctuating temperature distribution for the ow 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 uctuating operation. 1 year = 365 days = 8760 hours.
Temperature Flow T1 65C T2 70C T3 75C T4 80C T5 85C T6 90C T7 95C 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.

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CPX 1.115
CALPEX UNO/DUO range

Heating, 6 bar
CALPEX in coils: Dimensions: DN 20 - 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 1 1 1 2 2 3 4 4 5 6 20 25 32 40 50 65 80 100 100 125 150 PEX carrier pipe dxs mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 110 x 10.0 125 x 11.4 160 x 14.6 Outer casing D x s1 mm 78 x 2.0 78 x 2.0 93 x 2.2 113 x 2.4 128 x 2.7 143 x 3.0 163 x 3.2 163 x 3.2 183 x 3.3 183 x 3.3 250 x 3.9 Minimum bending radius m 0.7 0.7 0.8 0.9 1.0 1.1 1.2 1.2 1.4 1.4 Volume carrier pipe l/m 0.32 0.53 0.83 1.30 2.07 2.96 4.25 6.36 6.36 8.20 13.4 3 Weight kg/m 0.90 1.00 1.39 1.97 2.60 3.39 4.56 5.10 5.68 6.37 11.31 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 1 1 1 2 PEX carrier pipe dxs mm 2 x 25 x 2.3 2 x 32 x 2.9 2 x 40 x 3.7 2 x 50 x 4.6 2 x 63 x 5.8 Outer casing D x s1 mm 93 x 2.2 113 x 2.4 128 x 2.7 163 x 3.2 183 x 3.3 Minimum bending radius m 0.8 0.9 1.0 1.2 1.4 Volume carrier pipe l/m 2 x 0.32 2 x 0.53 2 x 0.83 2 x 1.30 2 x 2.07 Weight kg/m 1.34 1.87 2.48 3.96 5.28 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, 6 bar, 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, 6 bar, DUO

Type
25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182
- We will produce different dimensions or special items on request (> 500 m). - Larger or smaller delivery lengths can be supplied on drums if requested. - Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width) UK DISTRIBUTOR PIPE2000 Ltd 15.04.2009
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CPX 1.120
CALPEX UNO/DUO range

Sanitary, 10 bar
s1 UNO DUO PEXa carrier pipe PUR foam PE foil LLD-PE casing Heating strip channel (HBK) (see sheets CPX 1.225, 1.540) 18
CALPEX sanitary, 10 bar, UNO

Type DN Inches 8 1 1 1 2 1 1 1 PEX carrier pipe dxs mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 32 x 4.4 40 x 5.5 50 x 6.9 Outer casing D x s1 mm 78 x 2.0 78 x 2.0 78 x 2.0 93 x 2.2 113 x 2.4 128 x 2.7 113 x 2.4 128 x 2.7 128 x 2.7 Minimum bending radius m 0.7 0.7 0.7 0.8 0.9 1.0 0.9 1.0 1.0 Volume carrier pipe l/m 0.201 0.314 0.423 0.660 1.029 1.633 0.423 0.660 1.029 Weight kg/m 0.96 1.06 1.12 1.56 2.25 3.06 1.83 2.49 2.76 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
CALPEX sanitary, 10 bar, DUO

Type DN Inches + 58 1 + 58 1 + 1 + 1 PEX carrier pipe dxs mm 28 x 4.0 + 22 x 3.0 32 x 4.4 + 22 x 3.0 40 x 5.5 + 28 x 4.0 50 x 6.9 + 32 x 4.4 Outer casing D x s1 mm 93 x 2.2 113 x 2.4 128 x 2.7 128 x 2.7 Minimum bending radius m 0.8 0.9 1.0 1.0 Volume carrier pipe l/m 0.314 + 0.201 0.423 + 0.201 0.660 + 0.314 1.029 + 0.423 Weight kg/m 1.47 1.95 2.60 2.96 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
- We will produce different dimensions or special items on request (> 500 m). - Larger or smaller delivery lengths can be supplied on drums if requested. - Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width)
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CPX 1.125
CALPEX QUADRIGA range

Heating 6 bar, sanitary 10 bar
s1 d PEXa carrier pipe PUR foam PE foil LLD-PE casing
CALPEX , heating 6 bar, sanitary 10 bar, QUADRIGA

Type DN Inches Carrier pipe dxs mm 25 x 2.3 25 x 2.3 28 x 4.0 5 22 x 3.0 8 1 32 x 2.9 1 32 x 2.9 28 x 4.0 5 22 x 3.0 8 1 32 x 2.9 1 32 x 2.9 1 32 x 4.4 5 22 x 3.0 8 1 40 x 3.7 1 40 x 3.7 1 40 x 5.5 28 x 4.0 Outer casing D x s1 mm 143 x 3.0 Minimum bending radius m 1.1 Volume carrier pipe l/m 0.327 0.327 0.314 0.201 0.539 0.539 0.314 0.201 0.539 0.539 0.423 0.201 0.835 0.835 0.660 0.314 Weight kg/m 3.25 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
D 110
143 x 3.0
1.1
3.39
169
143 x 3.0
1.1
3.41
110
169
163 x 3.2
1.2
4.15
65
101
- We will produce different dimensions or special items on request (> 500 m). - Larger or smaller delivery lengths can be supplied on drums if requested. - Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width) Maxi coil outer diameter 2800 mm x 1200 mm (width)
UK DISTRIBUTOR PIPE2000 Ltd 15.04.2009

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CPX 1.200
Pressure loss chart

Heating, 6 bar
Water temperature 80 C Surface roughness = 0.007 mm (PEXa) (1 mmWS = 9.81 Pa) m = Q = T = Flow rate in kg/h Power requirement in kW Temperature difference VL (ow)/RL (return) in C
160/130.8 mm (DN 150, 6)
Q860 m T
Q [kW]
200000
125/102.2 mm (DN 125, 5) 110/90.0 mm (DN 100, 4)
ter Wa
5000
o vel
3000
city
3000
2000
100000
4.0 m/
70000
90/73.6 mm (DN 80, 3) 75/61.4 mm (DN 65, 2) 63/51.4 mm (DN 50, 2)
2000
Mass ow rate m [kg/h]
1000
500
20000
30000
40000
1000
60000
3.0 m/ s
50/40.8 mm (DN 40, 1)
500
2.0
300
m/
10000
1.5
40/32.6 mm (DN 32, 1)
300
200
m/ s
1.0
150
m/
200
150
100
4000
32/26.2 mm (DN 25, 1)
5000
0.7 5m /s
0.5
3000
75
m/
100
0.4 m/
50
2000
75
25/20.4 mm (DN 20, )
0.3 m/
40
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]
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2000
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CPX 1.205
Pressure loss chart

Sanitary, 10 bar
Water temperature 60 C Surface roughness = 0.007 mm (PEXa) (1 mmWS = 9.81 Pa) m = Q = T = Flow rate in kg/h Power requirement in kW Temperature difference VL (ow)/RL (return) in C Q860 m T
Q [kW] 1000
30000
40000
Mass ow rate m [kg/h]
500
20000
63/45.6 mm (DN 50, 2)
500
3.0
300
m/ s
300
200
10000
50/36.2 mm (DN 40, 1)
200
40/29.0 mm (DN 32, 1)
ter Wa o vel
4000 5000
city
100
2.0 m/
3000
32/23.2 mm (DN 25, 1) 28/20.0 mm (DN 20, )
1.5
100
m/ s
50
2000
1.0 m/ s
0.7
50
22/16.0 mm (DN 16, 58)
5m
30
/s
1000
0.5
30
20
m/
0.4 m/ s
0.3
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

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2000
CPX 1.210
Heat loss
Heating, 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 0.127 3.8 5.1 6.4 7.6 32/ 76 0.161 4.8 6.4 8.1 9.7 40/ 91 0.167 5.0 6.7 8.4 10.0 50/111 0.173 5.2 6.9 8.7 10.4 63/126 0.196 5.9 7.8 9.8 11.8 75/142 0.212 6.4 8.5 10.6 12.7 90/162 0.229 6.9 9.2 11.5 13.7 110/162 0.328 9.8 13.1 16.4 19.7 110/182 PLUS 0.262 7.9 10.5 13.1 15.7 125/182 0.337 10.1 13.5 16.9 20.2 160/250 0.318 9.6 12.8 15.9 19.1
80 8.9 11.3 11.7 12.1 13.7 14.8 16.0 23.0 18.3 23.6 22.3
90 10.2 12.9 13.4 13.8 15.7 17.0 18.3 26.2 21.0 27.0 25.5
a = 0.1 m
TE
CALPEX DUO
(ow and return in one pipe)

RL (return) 80 13.7 14.0 16.0 14.9 17.8 90 15.6 16.0 18.2 17.0 20.3 VL (ow)
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 0.195 5.9 7.8 9.8 11.7 32 + 32/111 0.200 6.0 8.0 10.0 12.0 40 + 40/126 0.228 6.8 9.1 11.4 13.7 50 + 50/162 0.213 6.4 8.5 10.7 12.8 63 + 63/182 0.254 7.6 10.2 12.7 15.2
TE
E
Type of installation, CPX UNO: Type of installation, CPX DUO: Pipe distance: Cover above pipe: Ground temperature: Soil conductivity: Conductivity of PUR foam: Conductivity of PEX pipe: Conductivity of PE pipe:
2-pipe, laid in the ground 1-pipe, laid in the ground a = 0.10 m H = 0.60 m TE = 10 C = 1.2 W/mK E PU = 0.0237 W/mK PEXa = 0.38 W/mK PE = 0.33 W/mK
Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefcient [W/mK] TB = Average operating temperature [C] TE = Average ground temperature [C] VL = Flow RL = Return

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H = 0.6m
H = 0.6m
CPX 1.215
Heat loss
Sanitary, 10 bar
CALPEX UNO
Heat losses q [W/m] for one UNO pipe CALPEX UNO U-value [W/mK] 22/ 76 0.153 28/ 76 0.187 32/ 76 0.213 40/ 91 0.230 50/111 0.234 63/126 0.266 32/111 HBK 0.154 40/126 HBK 0.166 50/126 HBK 0.204 Average operating temperature TB [C] 40 50 60 4.6 6.1 7.7 5.6 7.5 9.4 6.4 8.5 10.7 6.9 9.2 11.5 7.0 9.4 11.7 8.0 10.6 13.3 4.6 6.2 7.7 5.0 6.6 8.3 6.1 8.2 10.2
70 9.2 11.2 12.8 13.8 14.0 16.0 9.2 10.0 12.2
TE
CALPEX DUO
Heat losses q [W/m] for one DUO pipe CALPEX DUO U-value [W/mK] 28 + 22/ 91 0.284 32 + 22/111 0.236 40 + 28/126 0.261 50 + 32/126 0.347 Average operating temperature TB [C] 40 50 60 8.5 11.4 14.2 7.1 9.4 11.8 7.8 10.4 13.1 10.4 13.9 17.4
TE
E
Type of installation, CPX UNO: Type of installation, CPX DUO: Cover above pipe: Ground temperature: Soil conductivity: Conductivity of PUR foam: Conductivity of PEX pipe: Conductivity of PE pipe:
1-pipe, laid in the ground 1-pipe, laid in the ground H = 0.60 m TE = 10 C = 1.2 W/mK E PU = 0.032 W/mK PEXa = 0.38 W/mK PE = 0.33 W/mK
Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefcient [W/mK] TB = Average operating temperature [C] TE = Average ground temperature [C]

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H = 0.6m
70 17.0 14.2 15.7 20.8
H = 0.6m
CPX 1.220
Heat loss
Heating 6 bar, sanitary 10 bar, 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 0.246 H 32 + 32/S 28 + 22/142 0.288 H 32 + 32/S 32 + 22/142 0.302 H 40 + 40/S 40 + 28/162 0.335 Average operating temperature TB [C] 50 55 60 9.8 11.1 12.3 11.5 13.0 14.4 12.1 13.6 15.1 13.4 15.1 16.7
65 13.5 15.8 16.6 18.4 H = 0.6m 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, laid in the ground H = 0.60 m TE = 10 C = 1.2 W/mK E PU = 0.032 W/mK PEX = 0.38 W/mK PE = 0.33 W/mK
Heat loss during operation: q = U (TB -TE) [W/m] U = Heat transfer coefcient [W/mK] TB = Average operating temperature [C] TE = Average ground temperature [C]
CALPEX QUADRIGA - heat loss during operation Example of calculation for average operating temperature TB [C] Flow - heating: 70 C Return - heating: 40 C Flow - sanitary: 60 C Return - sanitary: 50 C 70 + 40 + 60 + 50 = 55 C 4
TB =

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CPX 1.225
Planning and connection technology

Heating strip, sanitary, 10 bar
1. Requirements for heating strip 1.1 Minimum power
In relation to a maintained temperature of: 40 C 50 C 5.8 W/m 7.8 W/m 6.3 W/m 8.3 W/m 7.3 W/m 10.3 W/m
Type CALPEX UNO 32/111 40/126 50/126
60 C 9.6 W/m 10.4 W/m 12.8 W/m
1.2 Recommendations for heating strip Hot water: HWAT-R from Raychem meets the requirement for 50/126, 60 C Automatic power adjustment with HWAT-ECO Frost protection: FS-B-2X from Raychem requires thermostat with temperature sensor, UTR15
Max. 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. Joint
L Lmax* Through connection Supply Through connection L Lmax* Separation of heating strip End closure Supply Supply
3. T-branch
Supply
End closure Through connection L Lmax*
Supply End closure
Through connection
L Lmax*
For the T-branch, note that the sum of two connected pipes must not be > Lmax*. T-switches cannot be supplied. * Lmax = max. permitted length for heating strip
The heating strip and the accessories are installed by the electrician!

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CPX 1.300
House entry bend, 90

Heating 6 bar, UNO and DUO
Bend, 90 DN 20 - DN 125 (PEXa) Bend, 90 DN 150 (St 37.0) With welded-on compression coupling
1114 1100 UNO DUO
1600
250
250
1114
Figures in mm
CALPEX UNO
Type DN Inches 1 1 1 2 2 3 4 4 5 6 PEX carrier pipe dxs mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 110 x 10.0 125 x 11.4 160 x 14.6 Outer casing D x s1 mm 75 x 2.9 75 x 2.9 90 x 3.5 110 x 4.3 125 x 4.9 140 x 4.4 160 x 5.0 160 x 5.0 180 x 5.6 180 x 5.6 250 x 6.2 Volume carrier pipe l/m 0.32 0.53 0.83 1.30 2.07 2.96 4.25 6.36 6.36 8.20 13.43 Weight kg/unit 2.30 2.50 3.47 4.92 6.50 8.47 11.40 14.23 16.19 17.20 13.96
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 2.3 2 x 32 x 2.9 2 x 40 x 3.7 2 x 50 x 4.6 2 x 63 x 5.8 Outer casing D x s1 mm 90 x 3.5 110 x 4.3 125 x 4.9 160 x 5.0 180 x 5.6 Volume carrier pipe l/m 2 x 0.32 2 x 0.53 2 x 0.83 2 x 1.30 2 x 2.07 Weight kg/unit 4.32 4.67 7.42 9.90 13.96
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
1 1 1 2

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CPX 1.305

Sanitary, 10 bar, UNO and DUO
Bend, 90 DN 16 - DN 50 (PEXa)
1100
UNO
DUO
1600
250
250
Figures in mm
CALPEX UNO
Type DN Inches 8 1 1 1 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 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7
Outer casing D x s1 mm 75 x 2.9 75 x 2.9 75 x 2.9 90 x 3.5 110 x 4.3 125 x 4.9
Volume carrier pipe l/m 0.20 0.31 0.42 0.66 1.02 1.63
Weight kg/unit 2.40 2.65 2.80 3.90 5.62 7.65
CALPEX DUO
Type DN Inches + 58 1 + 58 1 + 1 + 1 PEX carrier pipe dxs mm 28.0 x 4.0 + 22.0 x 3.0 32.0 x 4.4 + 22.0 x 3.0 40.0 x 5.5 + 28.0 x 4.0 50.0 x 6.9 + 32.0 x 4.4 Outer casing D x s1 mm 90 x 3.5 110 x 4.3 125 x 4.9 125 x 4.9 Volume carrier pipe l/m 0.31 + 0.20 0.42 + 0.20 0.66 + 0.31 1.02 + 0.42 Weight kg/unit 3.67 4.87 6.50 7.30
28 + 22/ 91 32 + 22/111 40 + 28/126 50 + 32/126
20 + 16 25 + 16 32 + 20 40 + 25

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CPX 1.310

Heating 6 bar, sanitary 10 bar, QUADRIGA
Bend, 90 DN 16 - DN 50 (PEXa)
1100
250
1600
250
Figures in mm
CALPEX QUADRIGA
Type DN Inches 5 8 1 1 5 8 1 1 1 5 8 1 1 1 PEX carrier pipe dxs mm 25 x 2.3 25 x 2.3 28 x 4.0 22 x 3.0 32 x 2.9 32 x 2.9 28 x 4.0 22 x 3.0 32 x 2.9 32 x 2.9 32 x 4.4 22 x 3.0 40 x 3.7 40 x 3.7 40 x 5.5 28 x 4.0 Outer casing D x s1 mm 140 x 4.4 Volume carrier pipe l/m 0.327 0.327 0.314 0.201 0.539 0.539 0.314 0.201 0.539 0.539 0.423 0.201 0.835 0.835 0.660 0.314 Weight kg/unit 8.12
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 4.4
8.47
140 x 4.4
8.52
160 x 5.0
10.37

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CPX 1.315
CALPEX L-shell
Dimensions DN 20 - DN 50 ( 76 - 126 mm)
d1
CALPEX
1 4 3 5 2 376
Figures in mm 376
CALPEX L-shell, UNO/DUO

Outer casing d1 76 91 111 126 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; see CPX 1.390 Sealing clamps (14 pcs.) Insulation material; see CPX 1.365 Glued surface Reduction ring or sealing ring
CALPEX shells are freely reducable from 126 mm to 76 mm CALPEX shells are not suitable for use with CALPEX QUADRIGA (distribution chamber: see CPX 1.350).

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CPX 1.316
CALPEX Big L-shell

d1
CALPEX
1 4 3 5 2 508
Figures in mm 508
CALPEX Big L-shell, UNO/DUO

Outer casing d1 76 91 111 126 142 162 182 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; see CPX 1.390 Sealing clamps (22 pcs.) Insulation material; see CPX 1.365 Glued surface Reduction ring or sealing ring
CALPEX Big-shells are freely reducable from 182 mm to 76 mm CALPEX shells are not suitable for use with CALPEX QUADRIGA (distribution chamber: see CPX 1.350).

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CPX 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; see sheet 1.390 Insulation material, PUR or PE; see sheet 1.365 Shrink sleeve pipe Shrink hose
Installation note:
Weld on 1
CALPEX
d2
CALPEX
CALPEX
Insulated steel pipe
2 Install
CALPEX-CALPEX
d2 76 76 x 91 111 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

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
d1 x x x x x x x
x x x x
x x x
x x x
x x x

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CPX 1.325
CALPEX I-shell
1 4 3 2 5 6
CALPEX d1
Figures in mm 578
CALPEX I-shell, UNO/DUO

Outer casing d1 76 91 111 126 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; see CPX 1.390 Sealing clamps (12 pcs.) Insulation material; see CPX 1.365 Glued surface Reduction ring or sealing ring
x x
CALPEX shells are not suitable for use with CALPEX QUADRIGA (distribution chamber: see CPX 1.350).

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d2
CALPEX
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CPX 1.326
CALPEX Big I-shell

1 4 3 2 5 6
CALPEX d1
Figures in mm 752
CALPEX BIG I-shell, UNO/DUO

Outer casing d1 76 91 111 126 142 162 182 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; see CPX 1.390 Sealing clamps (22 pcs.) Insulation material; see CPX 1.365 Glued surface Reduction ring or sealing ring
x x x
x x x
x x x
x x
CALPEX Big-shells are freely reducable from 182 mm to 76 mm CALPEX shells are not suitable for use with CALPEX QUADRIGA (distribution chamber: see CPX 1.350).

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d2
CALPEX
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CPX 1.330
CALPEX T-shell
d2
CALPEX
3 4 6 373 5
CALPEX d1
578
Figures in mm
CALPEX T-shell, UNO/DUO

Outer casing d1 - d3 76 - 76 91 - 91 91 - 76 111 - 111 111 - 91 111 - 76 126 - 126 126 - 111 126 - 91 126 - 76 Branch, 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; see CPX 1.395 Sealing clamps (16 pcs.) Insulation material; see CPX 1.365 Glued surface Reduction ring or sealing ring

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d3
CALPEX
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CPX 1.335
CALPEX Big T-shell

d2
CALPEX
3 2 4 6 CALPEX d1 508 d3 Figures in mm 5
CALPEX
752
CALPEX Big T-shell, UNO/DUO

Outer casing d1 - d3 142 - 142 142 - 126 142 - 111 142 - 91 142 - 76 162 - 162 162 - 142 162 - 126 162 - 111 162 - 91 162 - 76 182 - 182 182 - 162 182 - 142 182 - 126 182 - 111 182 - 91 182 - 76 Branch, 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; see CPX 1.395 Sealing clamps (27 pcs.) Insulation material; see CPX 1.365 5 Glued surface 6 Reduction ring or sealing ring

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CPX 1.340
T-joint
Dimension DN 150 ( 250 mm)
CALPEX
CALPEX
1 A 2
Structure of T-joint 1 2 3 4 5 6 T-piece, insulated steel pipe (St 37.0) Shrink-on hoop Shrink sleeve pipe In-situ PUR foam CALPEX connector CALPEX pipe
4 5
CALPEX
View A
CALPEX T-joint, DN 150

Outer casing d1 d3 160/250 - 160/250 Branch, 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

In
su
lat
ed
st
ee
lp
ip
45
CALPEX
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CPX 1.345
Y-pipe
Heating, 6 bar
View: A - A Note: With UNO pipe, in the direction of ow, the forward ow (VL) is always on the right and with DUO pipe, it is always at the bottom. CPX UNO A D CPX UNO C CPX DUO 250 400 300 2020 250 11 0/+1 Figures in mm VL (ow) (bottom) RL (return) RL (return) 300 VL (ow) (right) VL (ow) (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 D 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 C mm 90 110 125 160 180
View: A - A Note: With UNO pipe, in the direction of ow, the forward ow (VL) is always on the right and with DUO pipe, it is always at the bottom. steel pipe A D steel pipe C CPX DUO 250 400 300 2020 250 11 0/+1 Figures in mm VL (ow) (bottom) RL (return) 300 RL (return) VL (ow) (right) VL (ow) (right)
CALPEX DUO / 2 x pre-insulated steel pipe (St 37.0)

UNO pipes mm 26.9 - 110 33.7 - 110 42.4 - 125 48.3 - 125 60.3 - 140 DN 20 25 32 40 50 D mm 110 110 125 125 140 DUO steel pipe mm 26.9 + 26.9/110 33.7 + 33.7/110 42.4 + 42.4/125 48.3 + 48.3/160 60.3 + 60.3/180 DUO CPX pipe mm 25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182 C mm 110 110 125 160 180

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CPX 1.350
Distribution chamber
Distribution chamber for all joints (DN 20 - DN 125) The distribution chamber is used to cover and protect completed BRUGG pipe joints, shut-off valves or junction branches. The distribution chamber is a watertight structure made of polyethylene; its multi-functional design makes it possible to use one chamber type for all pipe dimensions (DN 20 - DN 125).
270
145
130
6 13
6 16
10
475
40
120 360 120
200 8
80
120
Wall thickness approx. 8 mm
Chamber exit Pipe dimensions (outer diameter) outer, 206 x 8 mm Leadthrough for outer 182, 162* outer, 166 x 8 mm Leadthrough for outer 142, 126* outer, 136 x 8 mm Leadthrough for outer 111, 91*, 76* * with additional centering ring

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Figures in mm
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CPX 1.355
Distribution chamber
Installation for dimensions DN 20 - DN 125
1 2
CAL P
EX
166 206
136
Two-part reduction ring
5 See CPX installation instructions
Flat seal 29 x 12 M10 x 35

166
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CPX 1.360
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 trafc and for low-depth installations. The maximum load per unit of area must not exceed q = 153 kN/m (SLW 60 to DIN 1055). Installation method Correct installation of the sand must be ensured so that the plate can perform its function as a load shield for the inspection chamber. A Proctor density of dpr = 96 % should be the target for compaction. For subsequent work on the inspection chamber, the cover plate has lifting eyes. After completing the work and relling the pit, make sure that the inll between the inspection chamber and concrete slabs is restored correctly. Filling/insulation material Some suggestions for lling and insulation materials that can be used are listed below: - Bulk polystyrene material - Armaex or Tubolit - Foam using BRAG PUR foam canister Note There is no need to use lling material in the distribution shaft. Likewise, it is not essential to insulate the pipes! The decision is up to the customer. Note The plate must be located so that it completely covers the chamber below (see illustration).
133 Inspection chamber 80 3 10/20 1 Q 221 bottom 2 Q 131 bottom 3 17 x 10/20 mm (L = 0.5 m) Total length 8.5 m 4 3 x 12 mm (L = 0.85 m) Total length 2.55 m 7.5 21 21.5 12 21 16 21 15
Sand, compacted
pla te Co ve r 20 o1
Insp
ectio
20
n ch amb er
Figures in cm
Armouring
GOK 50
10/20
21
bo
tto
3 17 x
2
4 3x
Q1
op 1t
12
110 120 5 ME.1 10 2 Q131 top
1 Q221 bottom
5 3.8 continuous meters 10
Figures in cm

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Q2
Sand, compacted
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CPX 1.365
Insulation material
PE foam (DN 20 - DN 125), PUR foam container(s) (DN 20 - DN 150)
Insulation material for shrink joints Polyethylene foam tube, (DN 20 - DN 125) Extruded pipe insulation made of closed-cell polyethylene, excellent for insulating CALPEX shrink joints (not for CALPEX shells). Various thicknesses of insulation are available for the most common pipe diameters. The insulation material (thickness and length) is supplied for the relevant joint types. The insulation must be tted precisely into the joints on site.
PE
PUR foam for shrink joints and CALPEX shells CFC-free, cyclopentane-blown PUR foam in plastic bottles The required quantity of CFC-free polyurethane foam is delivered in suitable container sizes for the various joints and T-pieces. The components are supplied separately in two bottles and are only mixed together when needed. Please note the safety regulations in the installation instructions supplied with the product.
Safety regulations Protective goggles and gloves must be worn when using this product.
Synthetic gloves
Protective goggles

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CPX 1.370
Screwed connectors
Outer thread, weld end
Connection with external thread
PEX 22-75 L Heating, 6 bar Material: brass PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 Sanitary, 10 bar Material: brass PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 Screwed connector mm 25 x 2.3- 32 x 2.9-1 40 x 3.7-1 50 x 4.6-1 63 x 5.7-2 75 x 6.8-2 90 x 8.2-3 110 x 10.0-4 L mm 53 63 67 71 80 92 92 102 Screwed connector mm 22 x 3.0- 28 x 4.0- 32 x 4.4-1 40 x 5.5-1 50 x 6.9-1 63 x 8.7-2 L mm 51 58 63 67 71 80
PEX 90-110
Connection with weld end

St 37.0 L
PEX 22-75
St 37.0
PEX 90-110
Heating, 6 bar Material: brass / St 37.0 PEX pipe Weld end mm mm 22 x 3.0 26.9 x 2.65 25 x 2.3 26.9 x 2.65 28 x 4.0 26.9 x 2.65 32 x 2.9 33.7 x 2.3 40 x 3.7 42.4 x 2.6 50 x 4.6 48.3 x 2.6 63 x 5.8 60.3 x 2.9 75 x 6.8 76.1 x 3.2 90 x 8.2 88.9 x 3.2 110 x 10.0 114.3 x 3.6
L mm 180 180 180 180 185 190 195 200 240 280

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CPX 1.375
Screwed connector
Coupling: equal, coupling: reduced
Coupling, equal
Heating, 6 bar Material: brass PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 Sanitary, 10 bar Material: brass PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 Coupling mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.7 75 x 6.8 90 x 8.2 110 x 10.0 L mm 60 67 71 75 81 89 130 130 Coupling mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 L mm 58 65 67 71 75 81
PEX 22-75 L
PEX 90-110
Coupling, reduced
PEX 22-75 L
PEX 90-110
Heating, 6 bar Material: brass PEX pipe mm 32 x 2.9 / 25 x 2.3 40 x 3.7 / 32 x 2.9 50 x 4.6 / 40 x 3.7 63 x 5.8 / 50 x 4.6 75 x 6.8 / 63 x 5.8 90 x 8.2 / 75 x 6.8 110 x 10.0 / 90 x 8.2
Coupling mm 32-1 / 25- 40-1/32-1 50-1/40-1 63-2 / 50-1 75-2/ 63-2 90-3 / 75-2 110-4 / 90-3
Sanitary, 10 bar Material: brass PEX pipe mm 32 x 4.4/28 x 4.0 40 x 5.5/32 x 4.4 50 x 6.9/40 x 5.5 63 x 8.7/50 x 6.9
Coupling mm 32-1 / 28- 40-1/ 32-1 50-1/ 40-1 63-2 / 50-1
L mm 58 87 96 110 140 175 315

15.04.2009
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CPX 1.380
Screwed connectors
T-piece
d2 d2
d1
d3
d1
PEX
22-75
PEX
90-110
Heating, 6 bar Material: brass

d1 d3 mm 22 x 3.0 - 22 x 3.0 25 x 2.3 - 25 x 2.3 28 x 4.0 - 28 x 4.0 32 x 2.9 - 32 x 2.9 32 x 2.9 - 28 x 4.0 32 x 2.9 - 25 x 2.3 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 6.8 110 x 10.0 - 110 x 10.0 110 x 10.0 - 90 x 8.2 Branch, d2 mm 22 x 3.0 25 x 2.3 x x x x x x x x x x x x x x x x x
28 x 4.0
32 x 2.9
40 x 3.7
50 x 4.6
63 x 5.8
75 x 6.8
90 x 8.2
110 x 10.0
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.

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d3
CPX 1.385
Compression connectors
Outer thread, weld end
Connector with external thread
Heating, 6 bar Material: brass PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4 160 x 14.6 Sanitary, 10 bar Material: brass PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 Screwed connector mm 25 x 2.3- 32 x 2.9-1 40 x 3.7-1 50 x 4.6-1 63 x 5.7-2 75 x 6.8-2 90 x 8.2-3 110 x 10.0-4 125 x 11.4-5 160 x 14.6-6 L mm 62 72 82 89 109 110 115 120 125 130 Screwed connector L mm mm 22 x 3.0- 58 28 x 4.0- 62 32 x 4.4-1 72 40 x 5.5-1 82 50 x 6.9-1 89 63 x 8.7-2 109
Connector with weld end

L2
St 37
L1
Heating, 6 bar Material: Steel PEX pipe mm 22 x 3.0 25 x 2.3 28 x 4.0 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4 160 x 14.6
Weld end mm 26.9 x 2.65 26.9 x 2.65 26.9 x 2.65 33.7 x 2.3 42.4 x 2.6 48.3 x 2.6 60.3 x 2.9 76.1 x 3.2 88.9 x 3.2 114.3 x 3.6 139.7 x 3.6 168.3 x 4.1
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

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CPX 1.390
Coupling: equal, coupling: reduced, angle piece: 90
Coupling
Heating, 6 bar Material: brass PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4 160 x 14.6 Sanitary, 10 bar Material: brass PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 Coupling mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.7 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4 160 x 14.6 L mm 69 82 90 104 122 127 127 127 133 143 Coupling mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7 L mm 58 70 82 90 104 122
Coupling, reduced
Heating, 6 bar Material: Brass/steel* PEX pipe mm 32 x 2.9/ 25 x 2.3 40 x 3.7/ 32 x 2.9 50 x 4.6/ 40 x 3.7 63 x 5.8/ 50 x 4.6 75 x 6.8/ 63 x 5.8 90 x 8.2/ 75 x 6.8 110 x 10.0/ 90 x 8.2 125 x 11.4/110 x 10.1* 160 x 14.6/125 x 11.4*
Coupling mm 32-1 / 25- 40-1/ 32-1 50-1/ 40-1 63-2 / 50-1 75-2/ 63-2 90-3 / 75-2 110-4 / 90-3 125-5 / 110-4 160-6 / 125-5
Sanitary, 10 bar Material: brass PEX pipe mm 32 x 4.4/28 x 4.0 40 x 5.5/32 x 4.4 50 x 6.9/40 x 5.5 63 x 8.7/50 x 6.9
Coupling mm 32-1 / 28- 40-1/ 32-1 50-1 / 40-1 63-2 / 50-1
L mm 76 86 97 113 124 127 127 228 262
Angle piece, 90
z
Heating, 6 bar Material: brass PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
a mm 54 64 74 87 106 117 127 137
z mm 32 37 42 48 60 67 76 87
Sanitary, 10 bar Material: brass PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.6
PEX pipe mm 22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.6
a mm 66 74 87 106
z mm 39 42 39 60

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CPX 1.395
T-piece
d2 d2
d1
d3
d1
Brass/CrNi
St. 37.0
Heating, 6 bar
d1 d3 mm 25 x 2.3 - 25 x 2.3 32 x 2.9 - 32 x 2.9 32 x 2.9 - 25 x 2.3 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 6.8 110 x 10.0 - 110 x 10.0 110 x 10.0 - 90 x 8.2 125 x 11.4 - 125 x 11.4 Branch, d2 mm 25 x 2.3 o/x o/x o/x o/x o/x o/x o/x o/x o/+ o/x o/+ o/+ o/+ o/+ o/+ o
32 x 2.9 o/x o/x o/x o/x o/x o/x o/x o/x o/x o/x o/+ o/x o/+ o
40 x 3.7
50 x 4.6
63 x 5.8
75 x 6.8
90 x 8.2
110 x 10.0
125 x 11.4
o/x o/x o/x 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, 10 bar
d1 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 4.0 4.0 4.4 4.4 5.5 5.5 5.5 6.9 6.9 6.9 6.9 8.7 8.7 8.7 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 3.0 4.0 3.0 4.4 4.0 5.5 3.0 4.0 6.9 5.5 4.4 4.0 8.7 6.9 5.5 Branch, d2 mm 22 x 3.0 x x x x x x x x x x x x
28 x 4.0 x x x x x x x x x x x x x
32 x 4.4 x x x x x x x x x x
40 x 5.5 x x x x x x x x x x x x x
50 x 6.9
63 x 8.7
x x x x x x x x x
x x
Soldered ttings - T-pieces made of steel can be supplied on request - Other T-pieces can be supplied on request. - Dimension DN 150 is supplied in prefabricated and pre-insulated form (see sheet CPX 1.340).
Material: x = Brass CuZn39Pb3 (DN 20 - DN 50), Gunmetal Rg7 (DN 65 - DN 100) o = St 37.0, welded + = CrNi 1.4404, 1.4432, 1.4435 (316L)

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d3
CPX 1.400
Electro-fusion joints
Coupling
Heating, 6 bar Material: cross-linked polyethylene PEX pipe PEX pipe mm mm 75 x 6.8 75 x 6.8 90 x 8.2 90 x 8.2 110 x 10.0 110 x 10.0 125 x 11.4 125 x 11.4 160 x 14.6 160 x 14.6
Transition sleeve/joint with thread (AG)
Can be supplied on request
Transition sleeve/joint, with ange
Can be supplied on request
Angle piece, 90
Heating, 6 bar Material: cross-linked polyethylene PEX pipe PEX pipe mm mm 75 x 6.8 75 x 6.8 90 x 8.2 90 x 8.2 110 x 10.0 110 x 10.0 125 x 11.4 125 x 11.4 160 x 14.6 160 x 14.6
Only trained personnel, using suitable fusion equipment, may install the electro-fusion joints for PEXa connections.

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CPX 1.405
End cap
Standard, shrinkable
Shrink-on end cap, UNO End cap, UNO (LD-PE) LD-PE end caps are tted on; suitable for dry rooms
Shrink-on end cap, DUO
End cap, DUO (LD-PE)
Shrink-on end cap, QUADRIGA
End cap, QUADRIGA (LD-PE)
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

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CPX 1.410
Wall sealing ring

for wall openings
for pipes up to O/D 182 mm for pipes over O/D 250 mm
Da
Da 50
Di
Di
50
Figures in mm
CALPEX UNO, DUO, QUADRIGA

Outer casing diameter mm 76 91 111 126 142 162 182 250 Neoprene wall sealing ring Di, inner mm 74 88 107 122 137 155 175 243 Da, outer mm 118 133 153 168 183 203 223 290
Building entry (see sheet CPX 1.415)

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CPX 1.415
Building entry
Wall opening
Wall leadthrough
PEX connection piece: see sheet 1.370 or sheet 1.390 80 mm approx. 80 mm
CALPEX D CALPEX pipe; see sheets 1.115, 1.120 End cap: see sheet 1.405 Wall seal: see sheet 1.410
Wall opening
Outer casing D 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
100 L
80

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CPX 1.420
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
Core bores Perfect bores are required for installation. As hairline cracks may be present in the concrete or result from drilling, it is advisable to seal the entire length of the borehole with suitable sealant (such as AQUAGARD). Tightness can only be guaranteed if this recommendation is followed. 1 CALPEX district heating pipe 2 Seal set, single-seal 1 x 40 mm, Shore hardness D 35 3 Seal set, double-seal* 2 x 40 mm, Shore hardness D 35 4 Liner pipe: made of bre cement or coated core bore * Suitable for pressure from water up to 0.5 bar
Outer pipe R mm 76 91 111 126 142 162 182 250
Liner pipe, core bore D mm 150 150 200 200 200 250 250 350
Seal set R1 inner mm 78 93 113 128 143 163 183 251
Seal set D1 outer mm 150 150 200 200 200 250 250 350
Building entry (see sheet CPX 1.425)

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CPX 1.425
Building entry
Core bores/cement pipe liners
Wall leadthrough
PEX connection piece: see sheet CPX 1.370 or CPX 1.390
80 mm
CALPEX pipe: see sheets CPX 1.115, 1.120
CALPEX D End cap: see sheet CPX 1.405 Wall seal: see sheet CPX 1.420
Core bores
min. 30
Outer casing D 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

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CPX 1.430
Pipe warning tape

CALPEX pipe warning tape
Pipe warning tape to be laid in the ground. Roll length: 250 m
CALPEX trench structure

1 2 3
1 Pipe warning tape 2 Excavated material 3 Washed sand

60 30
Installation depth; see sheet CPX 1.505

T

10
10
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CPX 1.500
Pipe routing
CALPEX Connection to insulated steel pipe
CALPEX B
CALPEX A Insulated steel pipe
CALPEX
Loop-in method
CALPEX CALPEX connection
CALPEX B D A C C
B D CALPEX E

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CPX 1.505
Trench dimensions
Trench prole, 2 CALPEX pipes UNO DUO, QUADRIGA
60
30
60 T
30
10
10 D
10
10 B
10
10 D
10
10
D B
10
T Figures in cm Minimum bending radius m 0.7 0.8 0.9 1.0 1.1 1.2 1.4 Casing pipe D 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 D 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 0.8 0.9 1.0 1.1 1.2 1.4
Trench prole, 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; see sheet CPX 1.430 2 Excavated material 3 Sand, washed, max. grain size 8 mm Installation depth: Max. installation depth: 2.6 m Our approval is required for installation at greater depths.
SLW 30 300 kN total load as per DIN 1072; if subject to higher trafc loads (e.g. SLW 60), a load-distributing superstructure as per RStO75 is required. With no trafc load, the minimum trench depth T can be reduced by 20 cm.

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CPX 1.510
Connection (rigid/exible)
CALPEX to insulated steel pipes
Installation instructions for transition from CALPEX to insulated steel pipe (KMR) 1. Junction with T-piece
min 1.0 DS 2.0 CALPEX I 2.0 I
2. Transition with xed point
Joint/sleeve CALPEX Rmin 2.0 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.
The thermal movement l of the insulated steel pipe cannot be compensated by the CALPEX pipes. A xed point must be installed.
3. Transition with Z-bend

1.0 DS 2.5
4. Transition with expansion bend

1.0 DS 2.5
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. 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, a xed anchor point must be installed. - Design of expansion components - Positioning of expansion pads as per the section on PREMANT

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CPX 1.515
House entry, screwed connector

Shaft entry, xed point forces
approx. 80 *A max. 100 *80 Figures in mm Heating, 6 bar PEX pipe A mm mm 25 x 2.3 210 32 x 2.9 220 40 x 3.7 220 50 x 4.6 220 63 x 5.8 230 75 x 6.8 235 90 x 8.2 260 110 x 10.0 270 Sanitary, 10 bar 22 x 3.0 210 28 x 4.0 210 32 x 4.4 220 40 x 5.5 220 50 x 6.9 220 63 x 8.7 230
Fixed point
PEX connecting piece with external thread: see sheet 1.370
End cap: see sheet 1.405
Wall sealing ring: see sheet 1.410
CALPEX pipe see sheets 1.115 and1.120

1 Weld on approx. 80 *B *80 2 Install Figures in mm
Heating, 6 bar PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
B mm 340 340 340 360 340 340 410 450
PEX connecting piece with weld end: see sheet 1.370
Fixed point End cap: see sheet 1.405
* Dimensions can be reduced by max. 60 mm if end cap is walled in.
Fixed point forces occurring CALPEX heating, 6 bar

Maximum xed point forces occurring per pipe for: TB = 90 C, 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, 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, 10 bar

Maximum xed point forces occurring per pipe for: TB = 60 C, pB = 10 bar Type DN Fmax [N] 22/ 76 16 820 28/ 76 20 1350 32/ 76 25 1730 40/ 91 32 2700 50/111 40 4230 63/126 50 6715
Fmax [N] 755 1225 1940 3015 4740 6720 9720 14480

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CPX 1.520
House entry, compression joint

Shaft entry, xed point forces
approx. 80 *A max. 100 *80 Figures in mm Heating, 6 bar PEX pipe A mm mm 25 x 2.3 260 32 x 2.9 260 40 x 3.7 270 50 x 4.6 270 63 x 5.8 320 75 x 6.8 320 90 x 8.2 330 110 x 10.0 340 125 x 11.4 340 160 x 14.6 340 Sanitary, 10 bar 22 x 3.0 260 28 x 4.0 260 32 x 4.4 260 40 x 5.5 270 50 x 6.9 270 63 x 8.7 320
Fixed point
PEX connecting piece with external thread: see sheet 1.385
Wall sealing ring: see sheet 1.410
CALPEX pipe: see sheets 1.115 and 1.120

1 Weld on approx. 80 *B 2 *80 Install Figures in mm Heating, 6 bar PEX pipe mm 25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4 160 x 14.6
PEX connecting piece with weld end: see sheet 1.370
Fixed point
B mm 250 250 260 270 310 310 310 310 310 310
* Dimensions can be reduced by max. 60 mm if end cap is walled in.
Fixed point forces occurring CALPEX heating, 6 bar

Maximum xed point forces occurring per pipe for: TB = 90 C, 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, 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, 10 bar

Maximum xed point forces occurring per pipe for: TB = 60 C, pB = 10 bar Type DN Fmax [N] 22/ 76 16 820 28/ 76 20 1350 32/ 76 25 1730 40/ 91 32 2700 50/111 40 4230 63/126 50 6715
Fmax [N] 755 1225 1940 3015 4740 6720 9720 14480 18745 30730

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CPX 1.525
Installation of house entry

3 UNO
CALPEX x
4 DUO
CALPEX
1 Align pipe and cut to length at right-angles.
2 Using pipe cutter or saw, cut through casing at distance X (UNO) or Z (DUO).
UNO screwed connector House connection: DN 16 - 65: X = 90 mm DN 80 - 100: X = 140 mm Joint/sleeve: DN 16 - 65: X = 70 mm DN 80 - 100: X = 140 mm DUO screwed connector House connection: DN 16 -40: Y = 80 mm DN 16 - 40: Z = 180 mm Joint/sleeve: DN 16 - 40: Y = 60 mm DN 16 - 40: Z = 160 mm
UNO compression joint House connection: DN 16 - 40: X = 140 mm DN 50 - 125: X = 180 mm Joint/sleeve: DN 16 - 40: X = 110 mm DN 50 - 100: X = 140 mm DN 125 - 150: X = 150 mm DUO compression joint House connection: DN 16 - 40: Y,Z = 140 mm DN 50 Y,Z = 160 mm Joint/sleeve: DN 16 - 40: Y,Z = 110 mm DN 50 Y,Z = 140 mm
5 Using a knife blade to a maximum depth of 5 mm, split the casing.
6 Peel off the casing.
7 Cut back/remove the insulation along length X, (Z) Important: Do not scrape or score the outer surface of the carrier pipe!
8 Fit the wall sealing ring. Tighten the clamps (if present).
9 Carefully shrink on the pipe end closure according to the Raychem DHEC installation instructions which are enclosed in the package.
10 Install the tting as per the enclosed installation instructions for BEULCO (screwed connector) or REHAU (compression joint).

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CPX 1.530
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.
Fit of connection piece
Cleaning products and cleaning cloths Pipe cutter for PEX pipe
Spanner wrench

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25 mm at bit for cutting ller hole
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CPX 1.535
Installation tools
for press t joints
Manual tool for PEX 22 - 40 mm (packed in one case)
Expander tool, up to 32 mm (basic tool)
Press tool, up to 40 mm Expander tool for 40 mm (basic tool)
Case with basic tool including head and yoke
Expander head, up to 32 mm
Expander head, over 40 mm
Press yoke, 22 - 40 mm
Hydraulic tool for PEX 50 - 110 mm (packed in two cases)
Hydraulic press and expander tool 50 - 110 mm including foot pump (basic tool)
Case with basic tool (without heads and yoke)
Expander head 50 - 110 mm
Press yoke 50, 63 mm
Reducer 75/90 mm for yoke, 110 mm
Case with expander heads and press yoke
Electro-hydraulic tool for PEX 125 - 160 mm (packed in two cases)
Hydraulic press and expander tool 125 - 160 mm including foot pump (basic tool)
Case with basic tool (without heads and yoke)
Expander head 125 - 160 mm
Press yoke 160 mm
Reducer 125 mm for yoke, 160 mm
Case with expander heads and press yoke

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CPX 1.540
Heating strip, sanitary, 10 bar

Drawing in, sensor, joint
1. Pulling through the heating strip
CALPEX Glass bre wire CALPEX Heating strip Detail A
1. Unroll the pipe so that it is straight, next to the trench (without bends). See also CPX 1.120. Shorten the casing and cut back the channel. From one end, push the glass bre wire ( 6.5 mm) through the channel. The heating strip can be pushed in for straight lengths of up to 30 m. 2. Connect the heating strip or pull cord to the wire (drill a hole in the strip) and pull through the heating strip.
2. Installation of the temperature sensor for frost protection The temperature sensor has to be installed on the carrier pipe, opposite the heating strip. It must be installed at the coldest point of the pipe (outside the building). For this purpose, cut open an area of the casing measuring 10 x 7 cm and peel it off, cut open 10 x 7 cm of foam, x the temperature sensor onto the carrier pipe with adhesive tape, ll the hole with the insulation material supplied, apply lling adhesive S1113 below and above the temperature sensor cable (see Detail B), and seal with the sealing set.
approx. 10 cm approx. 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, S 1113, 60 mm long Detail B
Shrink hose
3. Remove the insulation

CALPEX approx. 120 mm Detail D
Shorten the casing by 120 mm and cut off the exposed channel.
4. 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; FS-B-2X) Detail E
Heating strip joint (S-06 for HWAT-R and FS-B-2X)
Heating strip (HWAT-R; FS-B-2X)
Protect the heating strip against moisture * Lmax = max. permitted length for heating strip
The heating strip and the accessories are supplied and installed by the electrician!

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CASAFLEX
THE PROFESSIONAL SOLUTION FOR ENGINEERS
PIPE2000 Ltd
PIPE2000 Ltd UK Distributor
CASAFLEX - District heating pipe

Contents
CFL 5.0
03.6.05
Tel: 01268 759567 Fax: 01268 569932 email: pipe@pipe2000.co.uk
5.0 5.1 5.100 5.105 5.110 5.111
Contents System description System description Quality certicate CASAFLEX (CFL) - District heating pipe UNO Construction, Dimensions, Material, Weight and Delivery length CASAFLEX (CFL) - District heating pipe DUO Construction, Dimensions, Material, Weight and Delivery length
5.2 5.200 5.210 5.215 5.216 5.220 5.225 5.240
Engineering Method of laying Pressure loss diagram Heat loss CASAFLEX - UNO Heat loss CASAFLEX - DUO Combination CASAFLEX - plastic sheath pipe Transit T-Piece KMR Pit constructions, building entry
5.3 5.300 5.300.1 5.300.5 5.301.2 5.301.3 5.305 5.315 5.316 5.320
Components Connecting piece CASAFLEX - UNO Connecting piece CASAFLEX - UNO Typ 25 Connecting piece CASAFLEX - UNO DN 100 Connecting piece CASAFLEX - DUO Y-pipe CASAFLEX - DUO Connecting socket Wall sealing ring Wall duct Accessory equipment Connecting piece - Insulating material, Trench warning tape
Subject to technical change
5.5 5.500 5.505 5.505.1 5.505.2 5.505.5 5.515
Data for excavation, Installation Trench dimensions Building entry, Wall breakthrough Building entry, anchor forces Construction work Over ground laying Installation of house connection

System description
CFL 5.100
03.6.05
1. General Remarks
CASAFLEX district heating pipe system is the name given to a exible domestic connection system made by BRUGG Rohrsysteme. It is designed for use in small and medium-sized district and local heating networks, in industry and agriculture, in solar collector systems and swimming pools. The CASAFLEX district heating pipe system has a corrugated carrier pipe made of stainless steel (X5 CrNi 18/9). The corrugated pipe has been designed on uid dynamic lines. The heat insulation consists of a chlorouoro-carbonfree and exible polyurethane foam with outstanding heat insulating properties. Under the sheath pipe of PE-LD is a safety foil which prevents the diffusion of the gases. The exibility of the CASAFLEX district heating pipe allows it to follow the conditions of almost any route. Existing service pipes and other obstacles can be crossed over, below or bypassed easily. The pipes can be laid across existing pipework, either from above or below and routed easily around any obstacles. Regardless of the conventional structure of pipework, it is possible with the CASAFLEX district heating pipe system to select the shortest route. The CASAFLEX district heating pipe can be supplied to the site in the desired length, either in a single piece or in coils or on drums. It can be laid in earth largely without connection points, which means the trenches can be considerably narrower than usual. As a consequence, considerable time can be saved on excavation work. If you consider the short laying time, the CASAFLEX district heating pipe is not only the technically perfect solution, but because of the reduction in coordinating work and the fast and easy way it is laid, it is also the key to saving time and money when laying district heating pipe systems. The physical properties of the corrugated carrier pipe make it possible to lay it without having to take thermal expansion into account. Assembly of the connections is extremely user-friendly with simple screw connection enabling the joints to be assembled quickly and in complete safety.
2. Range of Application
Operating temperature up to 160 C Highest temperature up to 180 C Operating pressure PN 16 up to PN 25

Quality certicate ISO 9001
CFL 5.105
03.6.05

District heating pipe CASAFLEX - UNO
CFL 5.110
03.6.05
3 4
Pos Material 1 2 Corrugated stainless steel carrier pipe of nickel-chromium steel acc. to EN 10088 1.4301 / AISI 304 or 1.4571 / AISI 316Ti, or 1.4404 / AISI 316L Only DN 20 - DN 80 Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam), up to 160 C operating temperature (180 C peak), thermal conductivity = 0,025 W/mK at 50 C average temperature Only DN 100 Flexibel insulation of CFC-free polyurethane foam, usable up to 130 C, thermal conductivity = 0,0255 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, PE-LD black (VDE 0209) seamless extruded. Protection against mechanical inuence and moisture. Detection monitoring wires: (a) 1 x NiCr, (b) 1 x Cu insulated; (c) 1 x Cu ^ Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System
3 4 5 6
Type CASAFLEX
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. bending radius [m] 0.8 0.8 1.0 1.0 1.2 1.5 1.8 2.0
Capacity carrier pipe [l/m] 0.44 0.80 1.35 2.04 3.12 5.12 8.43 14.3
Weight
max. 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] 1.30 1.48 2.15 2.46 3.02 4.10 5.70 7.40
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 3000 x 1600 (large), type EX20 2) Dimension of coils 2800 x 800 (large) * on request

District heating system CASAFLEX - DUO
CFL 5.111
03.6.05
6 1
Pos Material 1 2 3 4 5 6 Corrugated stainless steel carrier pipe of nickel-chromium steel acc. to EN 10088 1.4301 / AISI 304 or 1.4571 / AISI 316Ti, or 1.4404 / AISI 316L Flexibel insulation of CFC-free polyisocyanurate foam (PIR foam), up to 160 C operating temperature (180 C oating), thermal conductivity = 0,025 W/mK at 50 C average temperature Expanded metal Multi-layer barrier foil Casing pipe from low density polyethylene, PE-LD black (VDE 0209) seamless extruded. Protection against mechanical inuence and moisture. Detection monitoring wires: (a) 1 x NiCr, (b) 1 x Cu insulated; (c) 1 x Cu ^ Conductors pairs: a + b (red + green) = WIREM/BRANDES System a + c (Cu-white + green) ^= North System
Type CASAFLEX
DN
Inch
["] 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. bending radius [m] 1.1 1.4 1.5 1.8
Capacity carrier pipe [l/m] 0.44 0.80 1.35 2.04
Weight
[kg/m] 2.5 3.1 3.7 4.2
D max. delivery length Drum1) Coil2) [m] 370 230 210 180 [m] 200/260* 160/190* 110/140* 90/125*
1) Dimension of drums 3000 x 1600 (large), type EX20 2) Dimension of coils 2800 x 800 (large) * on request

Method of laying
CFL 5.200
03.6.05
Connection CASAFLEX - plastic sheath pipe
CASAFLEX
plastic sheath pipe
CASAFLEX
CASAFLEX CASAFLEX
Looping-in method
Laying from building to building

Pressure loss (diagram)
CFL 5.210
03.6.05
Water, average temperature = 80 C
Flow quantity [kg/h]
s m/ 1.0 s m/ 0.9 s m/
0.8
m 0.7
0.6
0.5
0.4 s m/
0.3 m/ s
/s
s m/
s m/
0. 2 s 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/
[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 uid dynamics so that the specic pressure losses correspond approximately to those of the nominal connection sizes. The sizing ranges of this specication should be respected. In accordance with the rules of sound engineering practice, the ow velocity should not exceed 2 m/s when connecting via a heat exchanger or 1 m/s in the case of a direct connection.

Heat loss CASAFLEX - UNO
CFL 5.215
03.6.05
CASAFLEX, parallel laying of 2 single lines
TE = 10 C E = 1.2 W/mK
a = 0.1 m
H = 0.6 m
= 0.43 W/mK
PIR = 0.025 W/mK PUR = 0.0255 W/mK
Heat loss during operation: q = K (TB - TE) [W/m]
K = Specic heat losses [W/mK] TB = Average operating temperature [C] TE = Average earth temperature [C]
Heat loss q [W/m] for single line pipe, parallel laying Type CASAFLEX 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 DN K-value [W/mK] 0.113 0.143 0.153 0.197 0.217 0.266 0.335 0.591 average operating temperature TB [C] 40 50 60 70 80 7.9 10.0 10.7 13.8 15.2 18.6 23.5 41.3 90 100 110 120 130 9.0 11.4 12.2 15.8 17.4 21.3 26.8 47.2 10.2 12.6 13.8 17.7 19.5 23.9 30.2 53.2 11.3 14.3 15.3 19.7 21.7 26.6 33.5 59.1 12.4 15.7 16.8 21.7 23.9 29.2 36.9 65.0 13.5 17.2 18.4 23.6 26.0 31.9 40.2 70.9
20 25 32 40 50 65 80 100
3.4 4.5 5.7 6.8 4.3 5.7 7.1 8.6 4.6 6.1 7.6 9.2 5.9 7.9 9.8 11.8 6.5 8.7 10.8 13.0 8.0 10.6 13.3 15.9 10.1 13.4 16.8 20.1 17.7 23.6 29.5 35.4

Heat loss CASAFLEX - DUO
CFL 5.216
03.6.05
CASAFLEX DUO pipe
TE = 10 C E = 1.2 W/mK = 0.43 W/mK PIR = 0.025 W/mK
Heat loss during operation: q = K (TB - TE) [W/m]
H = 0.6 m
K = Specic heat losses [W/mK] TB = Average operating temperature [C] TE = Average earth temperature [C]
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] 0.156 0.181 0.224 0.251 average operating temperature TB [C] 40 4.7 5.4 6.7 50 6.2 7.2 60 7.8 70 80 90 100 110 120 130
20 25 32 40
9.4 10.9 12.5 14.0 15.6 17.2 18.7
9.0 10.9 12.7 14.5 16.3 18.1 19.9 21.7
8.9 11.2 13.4 15.7 17.9 20.2 22.4 24.6 26.9
7.5 10.0 12.5 15.0 17.6 20.1 22.6 25.1 27.6 30.1

Connecting instruction CASAFLEX - plastic sheath pipe
CFL 5.220
03.6.05
Laying instructions for combination CASAFLEX (CFL) on plastic sheath pip (KMR)
all dimensions in m 1 Transition from T-piece KMR
min. 1.0 CASAFLEX l CASAFLEX 2.0 l DS 2.0
1 Transition with xed point
DP CASAFLEX Rmin.
Pipe joint
KMR
2.0 Pipe joint
FP KMR
CASAFLEX l CASAFLEX Flex-T-piece Rmin. DP KMR
The lateral expansion l must only be sufcient for the expansion to be absorbed by the T-branch DS and by CASAFLEX district heating pipes.
The expansion l, owing to increase of temperature, does not need to be compensated by the CASAFLEX
1 Transition with Z elbow

1.0 DS 2.5
1 Transition with expansion elbow

1.0 DS 2.5
CASAFLEX DP Pipe joint KMR
CASAFLEX Pipe joint DP KMR FP l l L
Laying of Z elbow according to the expansion l, which must be compensated by section DS.
If pipe length L resp. l is > than permissible, a xed point should be included to allow exact checking of the expansion. Design of expansion elements Location of expansion pads according to the Chapter Plastic Sheath Pipe from the main catalogue.
DS = Expansion leg l = Expansion FP = Plastic sheath pipe - xed point DP = Expansion pads

Transition T-Piece KMR
CFL 5.225
03.6.05
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
45 CASAFLEX
KM
CFL

Pit construction Building entries
CFL 5.240
03.6.05
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. They must be constructed so as to be watertight, and any surface water which may get in must be removed as soon as possible in order to prevent damage to the pits and the heat insulation of the pipes feeding into them. The pipe entries, depending on the local conditions, must be furnished with a watertight seal. In the case of surface water which exerts no pressure, a simple labyrinth seal will be sufcient; where there is pressure from the ground water an adjustable packing seal is almost always needed. The pipe endings are mostly only equipped with a splash water guard. It is also possible to deliver them with protection against surface water, however, but any protracted ooding, especially at operating temperatures, should be avoided even then. Due to these requirements, the use of pit constructions has today largely been discontinued. In their place pre-insulated T-pieces and, where necessary, pre-insulated shut-off and evacuation/ventilation valves are tted. In this way it is possible to save costs for the construction and maintenance of pits, frequently quite considerable, while at the same time increasing operating safety.

Connecting piece CASAFLEX - UNO - Type 16
CFL 5.300
03.6.05
The CASAFLEX connecting piece is especially designed for the connection of CASAFLEX district heating pipes. It is designed for all installation of house connections and for connections in the dry shafts, as
3 5 2 1 6 4
well as transition with expansion elbow and as transition from T-pieces. The CASAFLEX connecting piece is intended for use with hot water pipes (PN 16).
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, two pieces CASAFLEX heating pipe Stretching tape
Execution
Type building dry T-Piece / Pipe joint Execution See design on the drawing Pos. 7, Protection cap is not necessary see CFL 5.240 + 5.300.1
Data Table
Type DN Inches ["] 3/4" 1" 11/4" 11/2" 2" Steel carrier pipe dxs mm 26.9 x 2.6 33.7 x 3.2 42.4 x 3.2 48.3 x 3.2 60.3 x 3.6
Shaft
22/91 30/91 39/111 48/111 60/126
20 25 32 40 50

Connection CASAFLEX - UNO - Type 25
CFL 5.300.1
03.6.05
In the connection Type 25 the rib mesh is integrated via a metal cap or clamping ring; this increases the mechanical stability of the assembly,
which is necessary when operating pressures exceed 16 bar. The connections are intended for use with hot water pipes.
10
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 - 100) rib mesh shrink sleeve
Type CASAFLEX
DN
Inches ["]
pipe connection dxs [mm] 26.9x2.6 33.7x3.2 42.4x3.2 48.3x3.2 60.3x3.6 76.1 x 3.6 88.9 x 4.0
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

Connection Unit DN 100 - Type 16
CFL 5.300.5
03.6.05
The CFL connection unit is a connection element specially designed for CASAFLEX district heating pipes. It is used to establish all connections to pipe
installations in buildings and shafts as well as for transition and T-connections. The connection units are intended for use with hot water pipes up to PN 16.
11
10
12
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] 114.3 x 4.5
127/182
100

Connection CASAFLEX - DUO - Type 16
CFL 5.301.2
03.6.05
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.
3 2 6 1 9
The connection units are intended for use with hot water pipes.
10
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 9,10
cone plate B allen bolts end cap (2 pieces) clamps
Inches ["]
pipe connection dxs [mm] 26,9 x 2,6 33,7 x 3,2 42,4 x 3,2 48,3 x 3,2
A [mm] 45,9 52,7 61,4 *
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

Y Pipe CASAFLEX - DUO
CFL 5.301.3
03.6.05
RL
D
300
View A
VL
C C
90
VL
RL
A
150
CFL - alarm wires
300
250
170
2150
Typ CASAFLEX
DN
Inches ["]
Pipe connection dxs [mm]
C [mm]
A [mm]
2 x single KMR steel pipe [mm]
D [mm]
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"
26.9 x 2.6 33.7 x 3.2 42.4 x 3.2 48.3 x 3.2
140 160 180 200
65 75 80 93
26.9 x 2.6 33.7 x 3.2 42.4 x 3.2 48.3 x 3.2
90 90 110 110

Connecting socket
CFL 5.305
03.6.05
CASAFLEX connecting socket

1 3 4 5
CASAFLEX CASAFLEX d2 carrier pipe equal
CASAFLEX - 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, see page CFL 5.300, position 3 Insulation material (PUR-foam hose), see page CFL 5.320 Shrinking socket Shrink sleeve CASAFLEX - 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
CASAFLEX - CASAFLEX d2 91 111 d1 126 142 162 182 91 111 126 142 162 X

Wall sealing ring
CFL 5.315
03.6.05
Da
50 mm
Data table Type CASAFLEX 22/91 30/91 39/111 48/111 60/126 75/142 98/162 127/182 Protective sheath D Da mm mm 93 93 113 113 128 144 164 183 133 133 153 153 168 183 203 218

Wall duct
CFL 5.316
03.6.05
Sealing set B, double sealing large 2 x 40 mm, hardness 35
Sealing set A, (centering) large 1 x 20 mm
Pipe liner made of bre cement or coated core drill hole
D internal
D external
For each pipe duct one sealing set C40 and one sealing set A is needed!
Pipeline diameter PE mm 91 111 126 142 162 182
Pipe liner core drill hole mm 150 200 200 250 250 300
casing tube DN 150 200 200 250 250 300
sealing set A/B D internal mm 93 113 128 144 163 183 D external mm 150 200 200 250 250 300
When ordering the sealing sets, please state the diamaters D internal and D external.
Core drill holes

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

Insulation material
CFL 5.320
03.6.05
T-piece sets and sockets

PUR - 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.
PUR - foam package Base: CO2-blown, 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 120C. Applications with higher operatings temperature (max. 160C) only on request.
Trench warning tape for laying under ground

Standard length 100 m Laying depth; see work sheet CFL 5.500

Trench dimensions
CFL 5.500
03.6.05
Trench section
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 D mm cm
Depth T cm
min. 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
1.0 1.0 1.0 1.0 1.2 1.5 1.8 2.0
Covering depth maximum covering depth: 2.6 m Higher covering only after consultation with us. SLW 30 ^ 50 kN wheel load, resp. 300 kN total load = according to DIN 1072. For bigger loads (i.e. SLW 60) a load distribution superstructure according to RStO75 is required. Without trafc load the minimum covering hight may be reduced by 20 cm. 1 Trench warning tape; see work sheet CFL 5.320 2 Excavated material 3 Sand washed, grain size 0-3/4 mm 4 CASAFLEX District heating pipe 5 Connecting piece; see work sheet CFL 5.300
Trench section by the connection of T-piece

max. 2 m max. 1 m
1.5 x B
2.5 m
Rmin
1.0 m

Building entry Wall breakthrough
CFL 5.505
03.6.05
Connection with weld-on end

Monitor leads Monitoring socket on the pipe ca. 80 Monitoring socket on the wall
all dimensions in mm
Wiring to the socket
min. 250
Fixed point; see text Connecting piece; see work sheet CFL 5.300
160
CASAFLEX district heating pipe; see work sheet CFL 5.110 Wall sealing ring; see work sheet CFL 5.315
End-cap
Fixed point
The connection and the CASAFLEX pipe are not suitable for absorbing the expansion of the continued pipe. For this reason a xing point clamp must be mounted. (see work sheet CFL 5.505.1)
Wall breakthrough
Casing pipe D mm 93 113 128 144 163 182 L min. mm 500 500 550 600 650 700 H mm 300 300 300 350 350 400
80
100 L min.
80
Breakthrough bored
30
Casing pipe D mm 93 113 128 144 163 182
D1 min. mm 200 220 240 260 280 300
A mm 230 250 270 290 310 330
D1 min.

Building work Anchor forces
CFL 5.505.1
03.6.05
CASAFLEX district heating pipe is a selfcompensating, statically neutral system i.e. the system takes up longitudinal heat expansion internally. Loads and deformation due to external inuences can however only be taken up by the system to a limited extent.
Connection to conventional systems should involve as little loading as possible. Depending on the selfcompensation and pressure inside the pipe, the following anchor forces per pipe should be observed.
Anchor forces per pipe Typ F (6 bar) (KN) 0.3 0.5 0.8 1.3 1.9 3.1 5.1 8.6 F (10 bar) (KN) 0.5 0.8 1.4 2.1 3.2 5.2 8.5 14.4 F (16 bar) (KN) 0.8 1.4 2.2 3.4 5.1 8.3 13.7 23.0 F (21 bar) (KN) 1.0 1.8 2.9 4.5 6.7 10.9 17.9 30.2 F (25 bar) (KN) 1.2 2.1 3.5 5.4 8.0 12.9 21.3 36.0
DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100

Building work
CFL 5.505.2
03.6.05
When carrying out building work on CASAFLEX district heating pipework, the alignment and position of the pipe must be secured. The following open trench lengths should not be exceeded. If greater lengths need to be laid bare, sand saddles can be placed at the prescibed intervals.
Dimensions of the saddles HS 2 x DA, BS 7 x DA, LS 4 x DA T-pieces must be secured by additional sand saddles. If trenches are excavated parallel to the CASAFLEX routing, the following separation distance must be observed:
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
0.5 0.5 0.5 0.5 0.5 0.6 0.6 0.6
Open trench length L
LS
Open trench length L
Sand saddle
BS

Laying in the open
CFL 5.505.5
03.6.05
When CASAFLEX piping is to be laid in the open, the following precautions must be taken: 1. Lay a continuous mounting rail (very economic: angled prole steel, galvanized) 2. Changes of direction should also be supported (wherever possible on a pre-bent angled prole) 3. Reinforced at prescribed intervals with clamp rings and pressure distribution plates, 3 clamps in a 90 curve. 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. Limit PN 10 5. Secure the ends with anchor points. 6. Make use of BRUGG's help when making project plans and laying the cable Support during planning and laying by BRUGG
Intervals between clamps 2m 2m 2m 2m 2m 2m 2m 2m
Min. bending radius 0.8 m 1.0 m 1.0 m 1.0 m 1.2 m 1.5 m 1.8 m 2.0 m

Installation house connection PN 16 CFL 22/91 - CFL 60/126
CFL 5.515
03.6.05
PIPE2000 Ltd
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk Web: www.pipe2000.co.uk
UK Distributor
Ausgabe: 05/1-01 DE
Technische nderungen vorbehalten/Subject to technical changes
Art.-Nr : 66356
CASAFLEX
Montageanleitung Installation instructions
DE
CH: D: A: B: I: PL: SK: SF:
BRUGG Rohrsystem AG, Industriestrasse 39, CH-5314 Kleindttingen, Tel. 056/ 268 78 78, Fax 056/ 268 78 79 BRUGG Rohrsysteme GmbH, Adolf-Oesterheld-Str. 31, D-31515 Wunstorf, Tel. 05031/170-0, Fax 05031/170 170 BRUGG Rohrsysteme Ges. mbH, Reischlgasse 5, A-4950 Altheim, Tel. 07723 / 439 620, Fax 07723 / 439 623 BRUGG Pipesystems N. V., Kampenhoutsebaan 16, B-1982 Elewijt (Zemst), Tel. 015/ 621 050, Fax 015/ 621 167 BRUGG Pipesystem srl, Via L. Bertolini 27, I-29100 Piacenza, Tel. 0523 / 590 431, Fax 0523 / 594 369 BRUGG Systemy Rurowe, Sp. z o. o. ,Ul. Lipowa 1, PL-05-860 Plochocin, Tel. 022/ 722 56 26, Fax 022/ 722 51 97 BRUGG Rohrsysteme, Beniakova 6, SK-84105 Bratislava, Tel. 07/ 716 443, Fax 07/ 716 443 BRUGG PEMA OY, P. O. Box 707, SF-60101 Seinjoki, Tel. 00358 400 560 719 , 00358 641 77 000
Ausgabe: 05 / 1-01 DE, Freigabe: 16.01.2001 RD
Montageanleitung CASAFLEX
deutsch/english
Art.-Nr. 66356 Seite: 1 von 7 Ausgabe: 05 / 1-01 DE

1. Inhaltsverzeichnis / Content D: Allgemeine Hinweise E: General instructions Dimensionen Transport, Empfang und Verlegung der Rohre Montage bei tiefen Temperaturen Verarbeiten des Rohres fr Verbindungen (Bild 1 - 12) Erstellung der Verbindung im Haus (Bild 13 - 17) 2. Allgemeines Diese neu berarbeitete Montageanleitung fr das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch, franzsisch, italienisch sowie englisch vor. Sie ersetzt alle frheren Ausgaben und ist Bestandteil jeder Materiallieferung. Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgnge fr Verlegung und Montage. Sie sind das Ergebnis umfangreicher Entwicklungsarbeiten und der praktischen Erfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. Bevor Sie mit der Arbeit beginnen, sollten Sie sorgfltig jede Phase dieser Montageanleitung durchlesen. Danach fhren Sie Schritt fr Schritt aus. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. Tragen Sie Handschuhe und Schutzbrille. Fr weitere Informationen wenden Sie sich bitte an Ihren rtlichen Verkaufsberater. 3. Rohrkonstruktion CASAFLEX Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr. 1.4301, DIN 17 441 Dmmung aus FCKW-freiem, 100 % CO2-geblasenem PUR-Schaum Schutzmantel aus Polythylen LDPE 4. Anwendungsbereich CASAFLEX-Fernwrmeleitung ist der Name fr eine biegbare Hausanschlussleitung der Brugg Rohrsysteme. Sie ist fr den Einsatz in kleinen und mittleren Fern- und Nahwrmenetzen, sowie in Industrie und Landwirtschaft, in Sonnenkollektoranlagen, und in der Schwimmbadtechnik gedacht. Das Rohrsystem CASAFLEX eignet sich fr den unter- und oberirdischen Transport von Heizungswasser bis max. 130 C und max. 16 bar Dauerdruck. Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht. Seite 1 Seite 2 Seite 3 Seite 3 Seite 4 Seite 5,6 Seite 7 Art.-Nr. 66356 Art.-Nr. 66356
Fr Schden und Betriebsstrungen, die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben, wird keine Haftung bernommen. Es gelten die allgemeinen Verkaufsbedingungen. Kopieren verboten.
Installation instruction CASAFLEX

english/deutsch
art.-no: 66356 page: 2 from 7 issue: 05 / 1-01 DE
Subject to technical changes/Technische nderungen vorbehalten

1. Content / Inhaltsverzeichnis D: Allgemeine Hinweise E: General instructions Dimensions Transport, reception and laying of pipes Installation at low temperatures Convert pipe for connections (picture 1 - 12) Installation of a house connection (picture 13 - 17) 2. General This completely revised installation instruction for the pipe-system CASAFLEX is held in english, german, french and italian. It replaces all earlier versions and is included in any material delivery. The following chapters describe all steps of laying and installing. They are a result of comprehensive development and practical experience of the producer Brugg Pipe Systems and its suppliers. Please study this installation instruction carefully before starting. Then follow it step-by-step. Adhere to the local security regulations for installation work. Carry gloves and safetyglasses. For further information please contact your local sales engineer. 3. Pipe construction CASAFLEX Service-pipe of nickel-chromium steel X5 CrNi 18/9, Wno. 1.4301, DIN 17 441. Insulation of CFC-free, 100 % CO2-blown polyurethane-foam Jacket-pipe of polyethylene LDPE 4. Application CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems. CASAFLEX is for the use of small and middle district heating systems as well as for industrial use, agriculture, solar energy and swimming pool technology. The pipe system CASAFLEX is designed for under- and above ground transport of heating water up to max. 130 C and up to max. 16 bar permanent pressure. The pipe-type and range of application is printed on the jacket. page 1 page 2 page 3 page 3 page 4 page 5,6 page 7 art.-no. 66356 art.-no. 66356
For damages and operating troubles, resulting from application of system components which are not recommended by our company or in case of not following the installation instruction, we do not undertake any liability. Our general terms and conditions are applicable. Copies are prohibited.
deutsch/english

Dimensionen/Dimensions
Baureihe Range Mediumrohr Service-pipe Mantel Jacket mm 78 93 113 113 128 113 128 128 143 Inhalt Volume Liter/m 0.44 0.80 0.80 1.35 1.35 2.04 2.04 3.12 3.12 Gewicht Weight kg/m 1.10 1.16 1.93 1.68 2.60 2.46 2.92 3.02 3.54 Biegeradius Bending radius R min m 0.8 0.8 1.0 1.0 1.2 1.0 1.2 1.2 1.3
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 22.0 x 0.3 30.4 x 0.3 30.4 x 0.3 39.4 x 0.4 39.4 x 0.4 48.2 x 0.5 48.2 x 0.5 60.4 x 0.5 60.4 x 0.5
D: Transport, Empfang und Verlegung der Rohre E: Transport, reception and laying of pipes
Sandschicht, Korngrsse 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. 60 C
Rmin
Rmin
10 0
8 0
8 0
A Mantelrohr
D mm
D1
min mm
A
mm
78 93 113 128 143
180 200 220 240 260
210 230 250 270 290
600 mm
D1
Montageanleitung Assembly Instructions deutsch CASAFLEX english
Verlegung und Montage von CASAFLEX-Rohren

1. Verlegung (Skizze) Spannbnder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen.
Laying and installation of CASAFLEX pipes

1. Laying (sketch) Cut fixing ribbons one after the other from outside to inside while unwinding the coil in the trench or adjacent.
Spannbnder fixing ribbons
2. Rohrende richten (Skizze) Aussenmantel auf ca. 60C wrmen (Oberflche glnzt) und im eingespannten Zustand abkhlen. Richtschiene vom Rohr lsen.
2. Direct pipe-end (sketch) Heat up outer jacket to approx. 60C (surface shines) and cool it down in a fixed situation. Disassemble directional tool.
ca. 60 C
3. Verlegung und Montage bei tiefen Aussentemperaturen (< 5C) Ring wenn mglich in einer geheizten Halle lagern oder mit Heizstrahlern Aussenmantel wrmen und dann sofort verlegen. Rohrende wie oben beschrieben richten.
3. Laying and installation with low outer temparature (<5C) Store coil, if possible, indoor or warm up the outer jacket with a heating appliance and lay immediately. Direct pipe-end as described above.
deutsch / english

D: Verarbeiten des Rohres fr Verbindungen. E: Convert pipes for connections. 1 2 3
5 4 3 2 1
max. 5 mm
200 mm
5
D: Bentigte Werkzeuge
Handsge, Markierungsstift, Zollstock, Messer, Edelstahlbrste, Feile (H2), Zange, Innensechskantschlssel*, Ratsche, Brenner E: Requested tool Saw, marking pen, folding role, knife, high grade steel brush, file (H2), pliers, allen spanner*, spanner, gas burner. *SW 6 DN 20 + 25 *SW 8 DN 32 + 40 30-100 mm *SW 10 DN 50 4 4.1
D: Einzelteile der Verbindung 1 Druckring 2 Sttzring 3 Graphit - Dichtring 4 Anschlussstck 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 Sge durchtrennen und lngs aufschneiden. Sge max. 5 mm tief einstecken. E: Separate with saw the jacket from the pipe end and open it longitudinally. The saw deeps into foam max. 5 mm.
22-39: 50-60 mm 48-60: 60-70 mm
4.2
D: Meldedern am Rohrende freilegen und herausziehen. E: Lay open the detector wires and pull them out.
D: Innenrohr auf Lnge rechtwinklig absgen. E: Cut the service pipe square to its axis.
D: Mantel entfernen. E: Remove coat. Fr Schden und Betriebsstrungen, die sich aus der Verwendung von nicht durch uns empfohlene Systemkomponeten oder die Nichtbeachtung der Montageanleitung ergeben, wird keine Haftung bernommen. Es gelten die allgemeinen Verkaufsbedingungen. Kopieren verboten.
deutsch / english

D: Verarbeiten des Rohres fr Verbindungen. E: Convert pipes for connections. 7 8 2239: 35 mm 4860: 45 mm 9
1 2
D: Rohrende mit Drahtbrste metallisch blank subern + entstauben. Achtung: Rohroberflche ist die Dichtflche. 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 Lnge absgen. E: Cut the service pipe with help of the pressure ring square to its axis.
D: Druckring (1) ganz nach hinten schrauben. Sttzring (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 l
0 mm
1
D: Anschlussstck (4) ohne Dichtring auf den Sttzring aufschieben und gegendrcken. Druckring (1) bis 0.5 mm gegen Anschlussstck 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
D: Schrauben len! Anschlussstck aufschieben, Schrauben anziehen bis Anschlussstck am Druckring anliegt. Gegen Verdrehen festhalten. E: Lubricate the screws! Tighten up the screws to the pressure ring. Hold it to avoid distort.
controlling 1-2 mm D: Dichtring (3) auf den Sttzring aufschieben, Druckring nicht mehr drehen. E: Move sealing ring (3) onto the supporting ring, do not turn the pressure ring.
deutsch / english

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: berflssige Meldeader zurck schneiden. WIREM/BRANDES: rot + grn; Nordisches System: Cu-weiss + grn. E: Cut the remain detection conductor WIREM/BRANDES: red + green North System: Cu-white + green
D: Schrumpfschluche ber die 2 Adern ziehen; mit weicher Flamme schrumpfen (max. 5-10 s). E: Push shrink sleeves above 2 detector wires; shrink with small flame (max. 5-10 s).
16
17
berwachungsdose an Wand Monitoring socket on the wall D: berwachungsdose am Rohr E: Monitoring socket on the pipe
ca. 80
160
Festpunkt; siehe Text Fixing point; see text
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. Thats why a fixing point clamp must be mounted.
min. 250

flexible solutions
75/142 + 98/162 PN 16
1. Inhaltsverzeichnis / Content
D: Allgemeine Hinweise Seite E: General instructions Seite Dimensionen Seite Transport, Empfang und Verlegung der Rohre Seite Montage bei tiefen Temperaturen Seite Verarbeiten des Rohres fr Verbindungen (Bild 1 - 12) Seite Erstellung der Verbindung im Haus (Bild 13 - 17) Seite 1 2 3 3 4 5,6 7 Art.-Nr. 66356 Art.-Nr. 66356
2. Allgemeines
Diese neu berarbeitete Montageanleitung fr das Rohrsystem CASAFLEX liegt nun in den Sprachen deutsch, franzsisch, italienisch sowie englisch vor. Sie ersetzt alle frheren Ausgaben und ist Bestandteil jeder Materiallieferung. Die nachfolgenden Kapitel der Montageanleitungen beschreiben die Arbeitsvorgnge fr Verlegung und Montage. Sie sind das Ergebnis umfangreicher Entwicklungsarbeiten und der praktischen Erfahrung des Herstellers Brugg Rohrsysteme und dessen Unterlieferanten. Bevor Sie mit der Arbeit beginnen, sollten Sie sorgfltig jede Phase dieser Montageanleitung durchlesen. Danach fhren Sie Schritt fr Schritt aus. Befolgen Sie die lokalen Montagesicherheitsbestimmungen. Tragen Sie Handschuhe und Schutzbrille. Fr weitere Informationen wenden Sie sich bitte an Ihren rtlichen Verkaufsberater.
3. Rohrkonstruktion CASAFLEX
Mediumrohr aus gewelltem Innenrohr aus Chromnickelstahl X5 CrNi 18/9 WNr. 1.4301, DIN 17441 Dmmung aus FCKW-freiem, 100 % CO2-geblasenem PUR-Schaum Schutzmantel aus Polythylen LDPE
4. Anwendungsbereich
CASAFLEX-Fernwrmeleitung ist der Name fr eine biegbare Hausanschlussleitung der Brugg Rohrsysteme. Sie ist fr den Einsatz in kleinen und mittleren Fern- und Nahwrmenetzen, sowie in Industrie und Landwirtschaft, in Sonnenkollektoranlagen, und in der Schwimmbadtechnik gedacht. Das Rohrsystem CASAFLEX eignet sich fr den unter- und oberirdischen Transport von Heizungswasser bis max. 130 C und max. 16 bar Dauerdruck. Rohrtyp und Einsatzbereich sind auf dem Mantel angebracht.
- Technische nderungen vorbehalten - Subject to technical change -

flexible solutions
75/142 + 98/162 PN 16
1. Inhaltsverzeichnis / Content
D: Allgemeine Hinweise Seite E: General instructions Seite Dimensionen Seite Transport, Empfang und Verlegung der Rohre Seite Montage bei tiefen Temperaturen Seite Verarbeiten des Rohres fr Verbindungen (Bild 1 - 12) Seite Erstellung der Verbindung im Haus (Bild 13 - 17) Seite 1 2 3 3 4 5,6 7 Art.-Nr. 66356 Art.-Nr. 66356
2. General
This completely revised installation instruction for the pipe-system CASAFLEX is held in english, german, french and italian. It replaces all earlier versions and is included in any material delivery. The following chapters describe all steps of laying and installing. They are a result of comprehensive development and practical experience of the producer Brugg Pipe Systems and its suppliers. Please study this installation instruction carefully before starting. Then follow it step-by-step. Adhere to the local security regulations for installation work. Carry gloves and safetyglasses. For further information please contact your local sales engineer.
3. Pipe construction CASAFLEX

Service-pipe of nickel-chromium steel X5 CrNi 18/9, Wno. 1.4301, DIN 17 441 Insulation of CFC-free, 100 % CO2-blown polyurethane-foam Jacket-pipe of polyethylene LDPE
4. Application
CASAFLEX district heating pipe is the name of a flexible house connection pipe from Brugg Pipe Systems. CASAFLEX is for the use of small and middle district heating systems as well as for industrial use, agriculture, solar energy and swimming pool technology. The pipe system CASAFLEX is designed for under- and above ground transport of heating water up to max. 130 C and up to max. 16 bar permanent pressure. The pipe-type and range of application is printed on the jacket.

flexible solutions
75/142 + 98/162 PN 16
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
2 3
76.1 x 3.6 88.9 x 4.0
142 162
5.12 8.43
4.10 5.70
1.50 1.80
D: Transport, Empfang und Verlegung der Rohre E: Transport, reception and laying of pipes
Alle Masse in mm Dimensions in mm
600 mm
30
80
600 mm
Rmin
100
80 D D 80
80
Rmin
A Manteau
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

flexible solutions
75/142 + 98/162 PN 16
Verlegung und Montage von CASAFLEX-Rohren

1. Verlegung (Skizze)
Spannbnder nacheinander von aussen nach innen durchtrennen und Ring im Graben (oder neben dem Graben) abrollen.
Laying and installation of CASAFLEX pipes

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

Aussenmantel auf ca. 60C wrmen (Oberflche glnzt) und im eingespannten Zustand abkhlen. Richtschiene vom Rohr lsen.
2. Direct pipe-end (sketch)

Heat up outer jacket to approx. 60C (surface shines) and cool it down in a fixed situation. Disassemble directional tool.
ca. 60 C
3. Verlegung und Montage bei tiefen Aussentemperaturen (< 5C)

Ring wenn mglich in einer geheizten Halle lagern oder mit Heizstrahlern Aussenmantel wrmen und dann sofort verlegen. Rohrende wie oben beschrieben richten.
3. Laying and installation with low outer temparature (<5C)

Store coil, if possible, indoor or warm up the outer jacket with a heating appliance and lay immediately. Direct pipe-end as described above.

flexible solutions
75/142 + 98/162 PN 16
D: Verarbeiten des Rohres fr Verbindungen. E: Convert pipes for connections. 1 2 3
5 4 3 2 1
max. 5 mm
5
D: Bentigte Werkzeuge Handsge, Markierungsstift, Zoll-stock, Messer, Edelstahlbrste, Feile (H2), Zange, Innensechs-kantschlssel*, Ratsche, Brenner E: Requested tool Saw, marking pen, folding role, knife, high grade steel brush, file (H2), pliers, allen spanner*, spanner, gas burner. D: Einzelteile der Verbindung 1 Druckring 2 Sttzring 3 Graphit - Dichtring 4 Anschlussstck 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 Sge durchtrennen und lngs aufschneiden. Sge max. 5 mm tief einstecken. E: Separate with saw the jacket from the pipe end and open it longitudinally. The saw deeps into foam max. 5 mm.
4 4.1
75-98: 100 mm
4.2
D: Meldedern am Rohrende freilegen und herausziehen. E: Lay open the detector wires and pull them out.
D: Innenrohr auf Lnge rechtwinklig absgen. E: Cut the service pipe square to its axis.
D: Mantel entfernen. E: Remove coat.

flexible solutions
75/142 + 98/162 PN 16
D: Verarbeiten des Rohres fr Verbindungen. E: Convert pipes for connections. 7 8

75: 70 mm 98: 80 mm
D: Rohrende mit Drahtbrste metallisch blank subern + entstauben. Achtung: Rohroberflche ist die Dichtflche. 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 Lnge absgen. E: Cut the service pipe with help of the pressure ring square to its axis.
D: Druckring (1) ganz nach hinten schrauben. Sttzring (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
l
4
1
D: Anschlussstck (4) ohne Dichtring auf den Sttzring aufschieben und gegendrcken. Druckring (1) bis 0.5 mm gegen Anschlussstck 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
D: Schrauben len! Anschlussstck aufschieben, Schrauben anziehen bis Anschlussstck am Druckring anliegt. Gegen Verdrehen festhalten. E: LUBRICATE THE SCREWS! Tighten up the screws to the pressure ring. Hold it to avoid distort.
controlling 75: 3 mm 98: 8 mm
D: Dichtring (3) auf den Sttzring aufschieben, Druckring nicht mehr drehen. E: Move sealing ring (3) onto the supporting ring, do not turn the pressure ring.

flexible solutions
75/142 + 98/162 PN 16
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: berflssige Meldeader zurck schneiden. WIREM/BRANDES: rot + grn; Nordisches System: Cu-weiss + grn. E: Cut the remain detection conductor WIREM/BRANDES: red + green North System: Cu-white + green
D: Schrumpfschluche ber 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: berwachungsdose an Wand E: Monitoring socket on the wall
D: berwachungsdose am Rohr E: Monitoring socket on the pipe
ca. 80
160
Festpunkt; siehe Text Fixing point; see text
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. Thats why a fixing point clamp must be mounted.
min. 250
CASAFLEX - Fernwrmeleitung 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 2 3 4 5 6 7 8 9 10 11
Sttzring Graphitdichtring Anschlussstck Druckring Innen-Sechskantschraube Meldeadern Schutzkappe und Aderherausfhrung 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 ber eine Blechkappe mit einbezogen; dies erhht die mechanische Stabilitt, was bei Betriebsdrcken oberhalb von 16 bar notwendig ist. Die Anschlussverbindungen sind fr 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.

CFL
2
07.05
Anschlussverbindung The connector assemply

Schelle Clip collar Klammersegmente Clamp segments Blechkappe Metal cap Schrauben Screws
Druckring Pressure ring
Sttzring Back-up ring
Graphit - Dichtring Graphite sealing ring
Anschlussstck Connector
Montage - Werkzeug Tools for installation

Persnliche Schutzausrstung: Schutzhandschuhe Achtung: Unfallverhtungsvorschriften beachten! Personal protective clothing: protective gloves Attention! Be careful to observe all safety regulations
Handsge Handsaw Markierungsstift Marker Zollstock / Ruler Messer / Knife Edelstahl - Drahtbrste Stainless steel wire brush Halbrund - Feile (Hieb 2) Half-round le (No. 2) Zange Pliers
Innensechskantschlssel Hexagonal socket head screwdriver Ratsche Ratchet

CFL
3
07.05
A
Achtung: Blechkappe ber das Rohr ziehen. Absetzma 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 Lngsrichtung aufschneiden. Cut open the jacket using the knife around the circumference and lengthwise.
B
PE-Mantel abschlen. Achtung: Blechkappe Peel off the PE jacket. Streckgitter mit Handsge am Umfang durchsgen. B = 80mm Saw through the rib mesh on the circumference with the handsaw. B = 80mm

CFL
4
07.05
Streckgitter mit Drahtbrste 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 Drahtbrste metallisch blank brsten! 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!
10
Druckring bis gegen den Schaum aufschrauben, Sgering gegen den Druckring schrauben. Screw the pressure ring up against the foam, Screw the saw collar up against the pressure ring.
Innenrohr am Sgering entlang absgen. Saw off the inner pipe along the line of the saw collar.

CFL
5
07.05
11
12
Sgering entfernen; Sgeschnitt mit Feile entgraten. Remove the saw collar; smooth off any ridges in the saw cut with the le.
Sttzring in das Innenrohr einschrauben. Gewindeende mu mit dem Wellrohrende abschlieen. Screw the back-up ring into the inner pipe. The end of the screw thread must form a close t with the end of the corrugated pipe. 14
13
Graphit-Dichtring auf den Sttzring aufschieben. Push the graphite sealing ring over the backup ring.
Anschlussstck aufsetzen. Place the connector over the assembly.

CFL
6
07.05
15
16
Schrauben einsetzen und schrittweise im Uhrzeigersinn festziehen. Druckring und Anschlussstck mssen auf Block liegen. Put in the screws and tighten them gradually clockwise. The pressure ring and the connector must be in alignment.
Streckgitter um den Druckring umformen. Mould the rib mesh around the pressure ring.
17
18
Blechhaube vorziehen, dabei berwachungsadern durch die Gewindehlse herausfhren. Pull the metal protective sheath forwards, taking care to lead out the monitor leads through the thread socket.
Mit Klammersegmenten die Blechhaube gegen den Druckring xieren. Secure the metal sheath with the clamp segments against the pressure ring.

CFL
7
07.05
19
20
Schelle aufsetzen und festschrauben. Slip the clip collar over the assembly and screw it tight.
berwachungsadern mit Siliconkabel verbinden. Connect the monitor leads with the silicon cable.
CASAFLEX - District heating pipe Installation instructions DN 100

11 10
CFL 5.311.6
page 1 25.02.03
1.0 Introduktion
114,3 x 4,5
3
Fig. 1
12
- 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 , M 1 2 x 5 0 O - 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 , M 1 2 x 7 0
3 2 4
Do not begin work until you have read the installation instruktions carefully.
6 11 5 Fig. 2 13

2.2 Stripping off the PE jacket
CFL 5.311.6
page 2 25.02.03
2.0 2.1
Preparing the pipe end tools
4 Fig. 3
10
11
Fig. 4 Make a mark at a length of 120 mm on the casing pipe.
1. gloves 2. clamp 110 x 30 3. wrench 4. hexagonal tool 5. ratchet 6. stainless steel brush 7. file 8. knife 9. saw 10. marker 11. yardstick 2.2
Aligning the pipe ends Straighten out a length of approx. 1 m of the pipe, using a bending device if necessary. Fix the piping securely in place before fitting the connector assembly (e.g. on an assembly stand). Always use pipe clamping jaws when fixing the pipe in the vice.
Fig. 5 Make a mark around the casing pipe using the protection cap as a guide.
CFL 5.311.6
page 3 25.02.03
Fig. 8 Remove the casing pipe.
Fig. 6 Cut radially using the saw. Warning: take care of the monitoring wires!
Fig. 9 Remove the foam using the knife.
Fig. 7 Cut the casing pipe longitudinally using the knife.
Fig. 10 Bend the monitoring wires backwards.
CFL 5.311.6
page 4 25.02.03
Fig. 11 Make a mark on the corrugated pipe 90mm far from the end of casing pipe.
Fig. 13 Saw through the corrugated pipe using the face of the clamp as a guide.
Fig. 14 and 15 Insert a cloth and remove ridges from the pipe end inside and outside.
Fig. 12 Fit the clamp at that mark and check the distance 3 times around the pipe.

3.0 Fitting the connector
CFL 5.311.6
page 5 25.02.03
Fig. 18 Screw the internal backing sleeve (1) up to 2/3 of its length into the corrugated pipe. Fig. 16 Clean the outer surface using a stainless steel brush:
Fig. 19
Screw the thrust collar (4) against the end of the corrugated pipe.
Fig. 17 Remove the cloth and all shavings.
CFL 5.311.6
page 6 25.02.03
1,5-2mm Fig. 20 Push the connecting piece (4) right up against the internal backing sleeve. The distance between the connecting piece (4) and the thrust collar must be 1,5-2mm. You can screw the internal backing sleeve in or out until you reach this setting.
Fig. 22 Push the connection piece (3) right up against the thrust collar using the preinstallation screws (13).
oil
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.
Fig. 23 Tighten the preinstallation screws (13) until the cylindrical screws can be used. Replace all preinstallation screws (13) with cylindrical screws. Tighten all cylindrcal screws clockwise. The connecting piece (4) and the thrust collar (1) must be screwed together face to face until seated snugly against each other. Use oil to grease all screws!
CFL 5.311.6
page 7 25.02.03
Fig. 26 0 mm Fig. 24 If required: fit the O-ring (6) . Grease the O-ring (6) . Fit the protective cap with a strong push til the beveled edge of the thrust collar.
Fig. 25 Push the connecting cable through its bore and connect it with the monitoring wires. Note seperate installation instruction
Fig. 27 Fix the protective cap with its screws (7) . Screw the connector for monitoring wires (11). If required: fit shrinking sleeve half to half on casing pipe and protective cap. Note seperate installation instruction.
CASAFLEX - District heating pipe Wall sealing ring
CFL 5.315
26.02.03
Wall sealing ring
Da
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
CASAFLEX - Fernwrmeleitung DUO Anschluverbindung

Montageanleitung Art.Nr.69727
CFL 5.560.1
24.02.05
2 4 1 6
1. Bauteile: 1-Druckplatte (Markierung "A"), 2-Druckring , 3-Sttzring, 4-Anschlustck, 5-Grapitdichtring, 6-Konusplatte (Markierung "B"), 7-Innensechskantschrauben Zustzlich: Endkappe, berwachungsader-Set
Parts: 1-pressure plate (marking "A"), 2-pressure ring , 3-core piece, 4-connection end, 5-graphite packing ring, 6-cone plate (marking "B") , 7-allen bolts In addition: end cap, connection set for monitoring wires
2. Markierung am Mantelrohrende = 50mm
Marking at casing pipe end = 50mm
50mm
3. Mantel entlang der Markierung einsgen. Sgetiefe = Sgeblatthhe. ACHTUNG: Innenrohre und berwachungsadern nicht beschdigen!
- Technische nderungen vorbehalten -
Saw casingpipe along marking. depth=depth of saw blade. Attention: do not damage service-pipes or monitoring wires!
4. Mantelrohr mit Messer axial einschneiden.
Cut casingpipe axial with knife.

Montageanleitung
5. Mantel und Streckgitter abschlen Achtung: Streckgitter ist scharfkantig! Innenrohre mit Messer freilegen berwachungsadern 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 5.560.2
24.02.05
6. Innenrohre mit Edelstahldrahtbrste sorgfltig metallisch blank brsten Achtung: Rohroberflche ist Dichtflche! 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 sorgfltig metallisch blank reinigen
Clean the outer surface of the servicepipes between the pipes using a drilled abrasive paper
8. Sgeschnitt mit Feile entgraten Remove burrs from pipe end inside and outside using a halfround file

Montageanleitung
CFL 5.560.3
24.02.05
9. die Druckplatte(1) ber die Innenrohre schieben, dabei die Rohre mit dem Holzkeil spreizen Die Aussparungen mssen zum Rohrende weisen. Pull pressure plate(1) over the servicepipes using the wooden wedge as a spread. The wards have to point to the pipe end.
10. Druckringe(2) auf die Innenrohre aufschrauben; der grere Durchmesser zeigt zur Druckplatte
Screw the pressure rings(2) up to the service pipes; the greater diameter points towards the pressure plate
11. die Sttzringe(3) in die Innenrohre einschrauben. Der zylindrische Ansatz mu mit dem Wellrohrende abschlieen.
Screw the core piece(3) into the servicepipe up to the end of the thread. The thread must end flush with the inner pipe.
0,5mm
12. Anschlustcke(4) ber die Sttzringe schieben; die Druckringe werden soweit verdreht, da zwischen Anschlustck und Druckring ein Spalt von 0,5 mm verbleibt.
Push the connecting end(4) right up against the core piece. The distance between the connecting end and the pressure ring must be approx. 0,5mm. Screw the pressure ring in or out until you reach this setting.

Montageanleitung
CFL 5.560.4
24.02.05
13. Anschlustcke wieder abnehmen. Die Druckringe in die Aussparungen der Preplatte drkken. Druckringe und Sttzringe hierbei nicht mehr verdrehen.
Remove connecting ends and push the pressure rings into the wards of the pressure plate. The core piece and the pressure ring must not be rotated doing this.
14. Grapitringe(5) auf die Rohrenden aufschieben
Place the graphite packing ring(5) onto the pipe end
15. Anschlustcke wieder aufsetzen
Refit the connecting ends

16. Konusplatte(6) ber die Anschlustcke schieben;

der grere Durchmesser zeigt dabei zum Rohr.
Push the cone plate(6) over the connecting ends; the greater diameter has to point towards the pipe

Montageanleitung
CFL 5.560.5
24.02.05
0mm
17.Schrauben(7) einsetzen und schrittweise umlaufend festziehen. Druckplatte und Konusplatte mssen auf Block liegen. Schrauben mit surefreiem l schmieren!
Fit the allen head bolts(7) and tighten them gradually in a clockwise pattern. Insert the bolts with a non acid based grease!
OIL
18. Falls erforderlich: berwachungsadern verbinden Endkappe aufsetzen und mit Schlauchschellen befestigen If required: Connect monitoring wires Fit end cap and fix it with clamps
0,5mm
19. Fertig!
Ready!
20. Werkzeug: Handsge, Markierungsstift, Zollstock, Messer, Edelstahldrahtbrste, Halbrundfeile (Hieb 2), Zange, Innensechskantschlssel, Ratsche Sonderwerkzeug: Holzkeil, Schleifleinen K 180 ( im Lieferumfang) Persnliche Schutzausrstung: Schutzhandschuhe Tools: saw, marker, yardstick, knife, stainless steel brush, half round file, pliers, allen key, ratchet Special tools: wooden wedge, abrasive paper K 180 (delivered) For safety: gloves
PIPE2000 Ltd-For Information
District Heating Control Table of contents
WIREM 10.0
15.10.2003
Tel: 01268 759567 Fax:01268 569932 email: pipe@pipe2000.co.uk
10.0 10.1
10.100 10.110 10.120
Table of contents General system description

System description Functional description Measuring description
10.2
10.200 10.210
Design and reference charts

Design and reference charts Welding plans
10.3
10.300 10.310 10.320 10.330 10.340
Control unit U89A

Unit description, technical data Unit description, page 2 Fault handling procedure Electrical circuit, wiring diagram Option: Remote control transmission
CH
District Heating Control General system description
WIREM 10.100
15.10.2003
The piping for district heating laid out underground, is nowadays mostly equipped with control equipment, to monitor its operation. The advantage of this lies in the early detection and quick location of damages. Feeler wires melted into the thermal insulation in the factory perform, together with the monitoring equipment, a great number of functions. The safety of the installation is improved and the costs of repairs reduced. The systems FLEXWELL -cable, FERWAGpipe and CASAFLEX -district heating pipe of BRUGG Pipe Systems are equipped ex-works with the Reference Resistance Measurement system (WIREM ). Other monitoring systems can be supplied if specified. The BRUGG STEEL PROTECTION PIPE is available as an option. WIREM and BRANDES are compatible systems. 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. Supply of data on the state of the insulation. Detection and identification of the feeler conductor making contact with the inner pipe, a breakage or damages anywhere in the circuit can be detected and identified.
An entry of humidity through e.g. a faulty welding seam, loose sleeve or external damage can be detected, monitored located and reported during operation. A display reports a failure or interference basing on early detection and self diagnostics. Feeler gauges connected to the control system and situated in wells, can produce an alarm in case of entry of water. Alarms, measurands, state of contacts and other data can be registered and transmitted to other systems. The network of monitoring, measuring and locating units can be built up at will depending on conditions of volume of data required and network size. 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, testing over dialog and storing of results, as well as data transmission to other computers and printers.
CH
District Heating Control Functional aspects
WIREM 10.110
15.10.2003
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. In the FERWAG - and CASAFLEX - pipe they run parallel, on eiter side of the Structure of the feeler conductor
1. Gaps in insulation at regular intervals for wet contact detection 2. PTFE-Insulation, coloured red 3. NiCr conductor
inner pipe and about half way through the insulation, while in the flexible system FLEXWELL -cable, they are wound around the inner pipe and run close to each other. 2 3
Structure of the return wire

1. Copper core 2. FEP-Insulation, coloured green
Principle of monitoring
The physical principle for monitoring, as well as for fault location, is the resistance reference method (WIREM ), which is that of the unloaded resistance bridge principle. A defined voltage is applied between the feeler wire, embedded in the thermal insulation, and the pipe (see figure). Should the isolation resistance diminish, as will happen when a wet spot occurs, a voltage rise will be registered in the monitoring instrument and an alarm will be released. The perforations allow an accurate evaluation of the wet spots regarding their intensity in the whole monitored spectrum, from dry with over 50M to wet with under 10K insulation resistance. For the monitoring itself, an FEP isolated, copper return wire is laid out parallel to the feeler wire. Both wires form a feeler loop (see figures), which can attain 1000 m in length and therefore is able to monitor 1000 m of piping. Branches of piping are also followed by branches in feeler wires, i.e. feeler wire out, return wire back (see figure).
Feeler wire (red)
Layout of the feeler loop

Feeler wire (red) Return wire (green)
S
Loop
Return wire (green)
Pipe center line
Insulation
Monitoring unit
Feeler loop with branch-off
The reference resistance determines the tolerance threshold and is adjustable. Monitoring of the thermal insulation is performed by a special feeler wire (see figure). The wire itself is protected against direct contacts to metal, by a thermally stable PTFE sleeving. A contact between the naked NiCr wire and wet spots occurs in perforations along the PTFE sleeve. This permits monitoring over the entire length of the feeler wire.
Large pipe networks of several kilometers in length are divided into monitoring sections of under 1000 meters. A monitoring unit is installed at each section.
CH
District Heating Control Determining the fault location
WIREM 10.120
15.10.2003
Determining the fault location

To locate the wet spot or contact fault, a voltage U is applied across the loop. At the end of the feeler loop, a part voltage U1 caused by the wet spot, is measured between the inner pipe and the feeler cable. The result is expressed not in Volt but in % of the applied voltage. Since the feeler wire has a relatively high resistance of 5.7 /m and the return wire near zero , 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, but the location of the break has to be performed manually by other means. The usual method used in such cases is the time delay measurement. A capacitance measurement can also be used. To avoid subsequent faults and gaps in the feeler loop, strict quality control and measurement checks during production are applied in general . They target, among others, the solidity of all wire connections.
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, as it is balanced out in the measurement concept.

100 %
Fault location unit
x%
Wet spot
Feeler wire (red)
U1
Return wire (green)
CH
District Heating Control Design and Reference Drawings
WIREM 10.200
15.10.2003
Design
The design of the control circuit is done parallel to the design of the piping. The whole installation is then divided into separate loops with a maximal length of 1000 to 1200 m per unit. All units can be placed centrally in one building. For future expansion of the network, it is good practice to insert some spare cables beside the pipes.
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 1,5 mm2, or U 72 0,8 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 = 5.7 /m Forward 2219 Return 2220 Insulation resistance (IR) Grade BS-MH-2 Forward 0 = >50 M Return 0 = >50 M
CH
District Heating Control Reference Drawings Welding plans

Reference Drawing Welding plan
View A
WIREM 10.210
15.10.2003
Reference Drawings
To find the exact location of the fault above earth, it is very important to have access to reference drawings. The more precise these are, the easier and quicker the spot can be found. Welding plans have proved to be the best reference.

0.95
1.05 Elbow 90 0.95x1.05
A
0.95 6.57 1.82 12.0 12.0 7.9 Bg 61 , 0.65x0.65
Materials
Pipe FER 60.3-140 FER 76.1-160 FER 88.9-180 Stand. L Elbow [m] 6m 6m 12 m 0.5x0.5 0.65x0.65 0.65x0.65
FER 88.9-180
Bg 61 , 0.65x0.65
Venting
Bg 86 0.65x0.65
1.0
1.0
7.9 Bg 86 , 0.65x0.65
1.0
1.0
12.0 12.0 12.0 Bg 90 , 0.65x0.65 Bg 90 , 1.56x0.92 12.0
12.0
12.0
12.0
Bl
oc
Bg
FER FE 60.3 R7 -14 0 6.1 -16 Bg 90 0 , 0

85 , 0
.50 x0
k3
12.0
12.0
12.0 4.6 5.6 6.0 6.0 6.0 Bg 90 , 0.65x0.65 6.0 5.8 5.8 Bg 90 , 0.50x0.50 Bg 90 , 0.50x0.50 Bg 90 , 0.50x0.50 6.0 6.0 4.3 1.0 6.0 6.0 4.92 1.9 6.0 3.75 5.0 1.0 6.0 6.0 1.77 12.0 1.0 Bg 76.5 , 0.65x0.65 12.0 Bg 90 12.0 12.0 6.74
12.0
6.52 12.0 1.56 0.92
.65
.50
Block 4
x0
.65
5.84 4.65
6.0 6.0
6.0 5.84
6.0
12.0
5.23
6.0
12.0
Bg 90 , 0.65x0.65
6.0
(downward)
4.6 6.0
1.0
5.0
Bg 85 , 0.65x0.65
1.0
6.0 5.81 0.55
Bg = Elbow
Draining, DN 32
1.0
T-pieces
Blo
ck
8.45
8.0
CH
District Heating Control Unit description U89A technical data
WIREM 10.300
15.10.2003
Unit description
Function
The instrument monitors the electrical insulation resistance between the detector lead and pipe (earth). A break in the detector lead or earth leakage (<5 kOhm) is signalled simultaneously. The earth leakage signalling can also be used as a shaft monitor. By connecting a level switch (e.g. EHS-JOLA 6M, Otto Fischer AG) between the direct lead return and pipe. The unit is suitable for fitting in a switch cabinet and for surface mounting.
Surface mounting
Button and 2 signal lamps are mounted on the instrument. Lamps green : operating red : fault
Brugg Ro hrsystem AG 5200 Brugg
Fitting in switch cabinet

For operation, an additional button and 2 signal lamps must be fitted in the cabinet door.
Fault
If the electrical insulation resistance is exceeded (moist insulation), if there is a failure or earth leakage (shaft monitoring), a horn, lamp or central alarm system is triggered. At the same time the fault signal lamp lights up on the instrument or cabinet door as follows:
Insulation moist Failure in monitoring loop Earth leakage, shaft monitoring with float switch
CH
District Heating Control Unit description U89A
WIREM 10.310
15.10.2003
Alarm output for external fault display The instrument has an alarm output to supply a horn, a lamp or a central alarm system. Acknowledgement By pressing the double function button (instrument test + acknowledgment button), the alarm output is switched off. The fault lamp remains alight until the fault has been remedied. Instrument test The instrument is maintenance-free. However, we recommend that you implement a monthly operating check. By pressing the button a fault is simulated. As a result, a check is made of all the electronics. During this, the fault lamp must be alight. During the test, the alarm output can be blocked or connected through by means of the switch fitted on the printed circuit board. The switch should be set to the required position during installation.
Technical data Supply voltage Voltage tolerance Power consumption Output Breaking capacity Cable inlet Connection type Protection system Ambient temperature Max. loop length
220 V 50 Hz 10 % 1.5 VA High-tension current contact max. 250 V AC 5 A (alternating current) max. 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, max. 2 x 1.5 mm2 IP 40 -10 to +50 C 0 to 10 kOhm (0 - 1200 m)
Casing dimensions
150
Break through for wall fastening 4.2 mm.
Break through for wall fastening 4.2 mm Break through for clamp fastening to 35 mm standard bar DIN 46277. Clamp in instrument.
107
75 View A
CH
District Heating Control Fault handling procedure
WIREM 10.320
15.10.2003
Procedure in the event of a fault
Caution Before opening the instrument, switch off the main switch
Possible fault causes

Fault 1. Green lamp not alight 2. 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. Loop. Remove terminal 1 + 2 2. Connect terminal 1 + 2 3. Press button (instrument test) 4. Connect terminals 1, 2 + 5 Fault lamp display must flash must go out must be alight must flash intermittently
If all 4 states are OK, then the cause should be sought in the pipe system (sockets, connecting lines).
CH
District Heating Control Electrical circuit, wiring diagram
WIREM 10.330
15.10.2003
Caution: Before opening the instrument, switch off main switch.
Not applicable for surface mounting

Terminals on pc board Switch blocked free Alarm output for "Fault external" in instrument test Weak current max. 12 V Terminal 3 potential free With direct connection terminals A - B no connection terminal 3 Weak current Breaking capacity maximum 250 V AC 5A, 30 V DC 5A
Contact load 250 V AC / 5 A
Monitoring socket
1 2 3
Cu (green or blue)
DH - Line
Connection pipe terminal C or 1 Shaft monitoring with float switch * Fault Cabinet external
Cr Ni (red or brown) Cu (green or blue)
DH - Line
Cr Ni (red or brown)
Assembly limit BRUGG TT 1,5 mm 2 , or U 72 0,8 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, lamp, collective alarm fault insulation moist break loop short circuit shaft Supply for display
PC board connectors
operating
Be sure to connect earth, in special cases connect to pipe. Mains 220 V 1.5 VA
50 mA
16
* e.g. level regulator EHS - JOLA 6 M

Otto Fischer AG
Wiring for branched network, example only

Wiring principle: Always probe loop
Wiring between the sockets by an electrician (by the owner) BRUGG
C
DH - Line
Cabinet C
DH - Line
Monitoring socket
1 2 3
Terminals
FW - Leitung
Cu (green or blue)
Assembly limit BRUGG

DH - Line
A
FW - Leitung DH - Line
DH - Line
TT 1,5 mm 2 or U 72 0,8 mm ,
CH
District Heating Control Option: Remote control transmission
WIREM 10.340
15.10.2003
Version for remote control transmission e.g. "Ridat Rittmeyer"

The U 89 instrument is also suitable for computer controlled remote transmission. In this case, there is no need for wiring the cabinet door. These outputs are wired as followed by a change on the PC board.
Terminals 9 to 13
Logical states
13 R1
Everything OK
R2 I
12 R1
Insulation moist
11
Earth leakage in shaft monitoring with level switch Detector lead has short circuit to earth
10 R2
Break in loop
The functions of the network and fault lamp on the instrument, and also "Fault external" (terminals 6 to 8) remain unchanged. The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission.
CH
PIPE2000 Ltd
COPPERFLEX
PIPE2000 Ltd
Copper Heating Piping Table of contents
CCO 9.0
4.7.2000
9.0 9.1
9.100 9.105 9.115
Table of contents System description

System description part 1 System description, part 2 Copper heating piping for local networks Structure, dimensions, materials, weights and supplied lengths
9.2
9.200 9.201 9.202 9.203 9.210 9.220
Planning, design engineering

Pipe routing Pipelaying instructions, part 1 Pipelaying instructions, part 2 Pipelaying instructions, part 3 Pressure losses Heat losses
9.3
9.320 9.340 9.345 9.355 9.365 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
9.5
9.500 9.505
Underground construction work, assembly

Trench dimensions Pipe entry into buildings
Copper Heating Piping System Description Part 1
CCO 9.100
4.7.2000
1. General
CCO Copper Heating Piping for Local Networks is a flexible pipe system suitable for temperatures of up to 120 C. This piping is intended for use in small and medium-sized local heating networks. CCO Copper Heating Piping for Local Networks has a medium pipe made of copper. Manual processing of this piping is very easy. The heat insulation consists of a flexible CFCfree hard polyurethane foam with outstanding heat insulation characteristics. The flexibility of the CCO Heating Piping for Local Networks means that it can be adapted to virtually any pipe conditions with no problems. Pipes can cross above or below existing supply lines, and obstacles can be easily bypassed. CCO Heating Piping for Local Networks makes it possible to choose the shortest pipe route, without taking classical pipe construction methods into consideration. CCO Heating Piping for Local Networks is supplied to the site as one piece in the desired length, in rings. By and large, the pipe can be laid in the ground without any connection points so that the pipe trenches can be considerably narrower, making substantial savings possible on the underground construction work. This is particularly true of DUO lines. Another feature: only a very short time is required to lay the pipe. All of these benefits mean that CCO Heating Piping for Local Networks is not only a technically perfect solution, but also that it offers the key to saving time and costs when constructing local heating networks - thanks to the reduced outlay on coordination at the site, and the fast and simple installation procedure.
2. Range of application
Heating: max. 120 C and max 16 bar operating pressure
CCO Heating Piping for Local Networks can be supplied with one or two inner pipes.
Copper Heating Piping System Description Part 2
CCO 9.105
4.7.2000
3. Medium pipe
Material: Soft copper, R220 to EN1057 Oxygen-free copper, 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 8.93 max. 140 220 to 270 40 to 70 125000 16.6 10 E-6
DIN 17671 DIN 17671 DIN 17671 -
4. Heat insulation
Material: PUR insulation Density Heat conductivity Closed cells Water absorption after 24 hours CFC-free, 100% CO2-driven polyurethane foam (PUR) Reference temperature C 50 Value > 60 0.032 90 < 10 kg/m W/mK % %
3
Examination norm DIN 53420 DIN 52612 EN 253
5. Protective casing
Material: Purpose: Polyethylene of low density, PE-LD, extruded seamless Protection against mechanical effects and moisture Reference temperature C Value 928-938 kg/m3 0.43 W/mK 105-110 C Examination norm DIN 53479 DIN 52612
PE-LD protective casing Density Heat conductivity Crystallite melting range
Copper Heating Piping Local heating and house connection piping

Heating, 120 C, 16 bar, UNO and DUO
CCO 9.115
4.7.2000
UNO
DUO
1 2
Pos 1 2 3 4
Material Medium pipe in soft copper, R220, to EN1057, SF-Cu F22 to DIN 1787/17671/1754 Flexible, CFC-free polyurethane foam, resistant up to 130 C Thermal conduction coefficient = 0.032 W/mK at 50 C average temperature PE-LD film Outer casing in black PE-LD polyethylene (VDE 0209), extruded seamless. Protection against mechanical effects and moisture.
CCO, 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. Bending Carrier pipe Cu sheath radius dxs D x s1min, mm m mm Capacity carrier pipe l/m Weight kg/m max. Delivery length
Ring without connections
15 x 1.0 15 x 1.0 18 x 1.0 18 x 1.0 22 x 1.0 22 x 1.0 28 x 1.2 35 x 1.5
63 x 1.8 75 x 2.0 63 x 1.8 75 x 2.0 63 x 1.8 75 x 2.0 75 x 2.0 90 x 2.2
0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.8
0.13 0.13 0.20 0.20 0.31 0.31 0.51 0.83
0.93 1.09 1.01 1.17 1.12 1.27 1.57 2.27
280 280 300 300 200 200 130 On request
Ring dimensions: 2800 x 800 mm (width) / pipe length without interrelated fittings CCO, 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. Bending sheath dxs radius D x s1min, mm m mm Capacity carrier pipe l/m Weight kg/m max. Delivery length
Ring without connections
15 x 1.0 18 x 1.0 22 x 1.0 15 x 1.0 22 x 1.0 28 x 1.2 15 x 1.2 28 x 1.2 22 x 1.0
90 x 2.2 90 x 2.2 90 x 2.2 90 x 2.2 90 x 2.2 90 x 2.2
0.8 0.8 0.8 0.8 0.8 0.8
2 x 0.13 2 x 0.20 1 x 0.31 1 x 0.13 2 x 0.31 1 x 0.51 1 x 0.13 1 x 0.51 1 x 0.31
1.35 1.50 1.51 1.72 1.92 2.03
280 300 200 200 130 130
Copper Heating Piping Examples of pipe routing
CCO 9.200
4.7.2000
Connection: copper local heating pipe plastic casing pipe

Copper local heating pipe
A C
Note expansion pad as shown on catalogue pages CCO 9.201, 9.202 and 9.203
Looping-in method
A
Copper-copper connection
B D C A
C D B E
Copper Heating Piping Pipelaying instructions Part 1
CCO 9.201
4.7.2000
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, amplitude: 10 x outer diameter of copper local heating pipe). Expansion pad Expansion pad for sinusoidal curves
10 x outer casing
Bild 3
2m
> 10 m
Special solder must be used to solder the pipes together (this must be resistant to galvanic or electrochemical corrosion). 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. This also includes rolling apart and rolling together.
10 m
Examples of pipe routes

Bild 3
Expansion pad for sinusoidal curves
<5m
> 10 m
Bild 3
B
Bild 3
5 - 10 m
CCO 9.202
4.7.2000
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. Expansion padding has to be applied to copper local heating junction pipes. The number of expansion pads required depends on the movement of the main pipe. 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.e. they are positioned on top). The first layer of expansion pad is positioned around the local copper heating pipe which branches off (the junction pipe). The second and third layers of expansion pad are only applied at the sides (i.e. they are placed adjacently). The foregoing illustrations assume that junction sleeves are used.
CCO or KMR
Illustration 2
Expansion pad 20 l 40 mm
2m
CCO oder KMR
CCO 9.203
4.7.2000
Straight transitions from plastic casing pipes to the copper local heating pipe
For transitions from plastic casing pipes to the copper local heating pipe, it should be noted that the copper local heating pipe can only absorb the heat expansion to a limited extent. The following examples show how this can be guaranteed:
KMR
CCO KMR
max. 5 m The length of the plastic casing pipe may exceed 20 m. Expansion padding is required. The maximum length of the plastic casing pipe is 5 m. Expansion padding is required. No sinusoidal curve is required on the copper pipe.
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. 10 m
CCO
1. If gunmetal reductions are used, no particular instructions need to be followed. 2. The following instructions refer to reductions with normal copper soldered sleeves
Reduction The maximum length of the plastic casing pipe is 10 m. Expansion padding is required.
CCO
CCO CCO, reduced
KMR
CCO
max. 5 m
max. 20 m
The heat expansion is absorbed by the sinusoidal curve (see page CCO 9.210) upstream of the T-junction. Expansion padding is required.
The maximum length of the plastic casing pipe is 20 m. Expansion padding is required.
Copper Heating Piping Pressure loss
CCO 9.210
4.7.2000
Water, average temperature 80 C

Roughness = 0.0015 mm (copper)
(1 mm water column = 9.81 Pa) Q 860 T m = flow in kg/h Q = power required in kW T = temperature difference forward and return flow in C
kg/h
4 5
10
20
30 40 50
100
1 mbar/m
200 300
500 700 1000

10 mbar/m
2000 3000
Pa/m
Pressure loss, p
Copper Heating Piping Heat loss

Heating, 120C, 16 bar, UNO and DUO
CCO 9.220
4.7.2000
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 7.8 7.2 9.0 7.8 10.8 9.0 11.4 12.0 80 9.1 8.4 10.5 9.1 12.6 10.5 13.3 14.0 90 10.4 9.6 12.0 10.4 14.4 12.0 15.2 16.0 100 11.7 10.8 13.5 11.7 16.2 13.5 17.1 18.0 110 13.0 12.0 15.0 13.0 18.0 15.0 19.0 20.0 120 14.3 13.2 16.5 14.3 19.8 16.5 20.9 22.0
E
0.13 0.12 0.15 0.13 0.18 0.15 0.19 0.20
. .. . . . . . . . . a=0.1m .. . .
.. ..
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 9.6 10.8 11.4 13.2 17.4 15.6 80 11.2 12.6 13.3 15.4 20.3 18.2 90 12.8 14.5 15.2 17.6 23.2 20.8 100 110 14.4 16.2 17.1 19.8 26.1 23.4 16.0 18.0 19.0 22.0 29.0 26.0 120 17.6 19.8 19.8 24.2 31.9 28.6
0.16 0.18 0.19 0.22 0.29 0.26
.. .. . .. . ... . . .
. .. . TE
Method of laying:
2 separate UNO pipes underground Covering height: H = 0.60 m Earth-temperature: TE = 10 C Conductivity of ground: E = 1.2 W/mK Conductivity of PUR-foam: PU = 0.032 W/mK Conductivity of PEX-pipe: PEX = 0.38 W/mK Conductivity of PE-casing: PE = 0.43 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]
Copper Heating Piping Connecting socket Tee Branch insulation kit
CCO 9.320
4.7.2000
Connecting socket
1 2 3 4
d2 d1 63 75 90
63 x
75 x
90
1 2 3 4
CCO joint, see sheet CCO 9.345 Insulation material, see sheet CCO 9.340 Shrinking socket Shrinking hose
Tee Branch insulation kit

d2 1 Copper T-piece, see sheet COO 9.345 2 GFK half-shells 3 Insulating material, see sheet COO 9.340 4 Reducer ring 5 Special sealing compound GFK fibreglass-shell tested by Fernwrme-Forschungsinstitut (FFI) of Hannover
2 3
CCO CCO
CCO
Dimensions of GFK shell external

d1 d3
63 - 63 63 - 75 63 - 90 75 - 63 75 - 75 75 - 90 90 - 63 90 - 75 90 - 90
Junction, 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
Copper Heating Piping Insulation material

PUR-foam pack, PE-foam hose
CCO 9.340
4.7.2000
T-piece sets and sockets PUR - foam bottle

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

Base: CO2 -blown, CFC-free PUR-foam
Security requirement for the foam insulation
Component A
plastic gloves
plastic gloves
Separating rail
eye protection
Component B
eye protection
Copper Heating Piping Soldering instructions Soldered fittings

Soldering instructions
CCO 9.345
4.7.2000
Soldered fittings
Brugg Pipe Systems recommends fittings The special BRUGG solder must be used to solder the fittings. from the Georg Fischer company (+GF+). All joints and T-pieces, etc. can be obtained in all dimensions from 18 to 35 Solder with high silver content mm.
Joint, equal
Type Euro standardisation ISO 3677
BRL 8.50.34 pr EN 1044 B Cu Ag Zn Sn 630-730 Zn 27 Sn 3 Si Cu 0.1-02 36
Article number 7270 +GF+
Composition Ag Guideline analysis (%) 34 Application
Joint, reduced
Capillary brazing joints soldering for steels, copper and copper alloys, nickel and nickel alloys. For solder points with operating temperatures up to 200 C. Suitable for Cu pipe installation to DVGW working sheet GW 2. Rods thinly covered with flux 710 C 630-730 C 360 N/mm2 480 N/mm2 9,0 g/cm3 > 12 % 14 Sm/mm2
Article number 7240 +GF+ Flux
Technical information Working temperature Melting range Tensile strength St 37 St 50 Specific gravity Elongation Electrical conductivity Heat sources
T-connection piece, equal, reduced
Acetylene/oxygen mixture The oxy-fuel gas flame must be set to neutral.
Caution! Solder sleeves with notches are available in the trade; under no circumstances must these be used!
Copper Heating Piping Connection of copper heating pipe to KMR
CCO 9.355
3.7.2000
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. The fitting would be welded on his steel end and would be connected with soldered fitting on his copper end.
Connecting joint Outer in mm St x Cu
L1
mm
L2
mm
St-Cu-Fitting
17.2 x 15 26.9 x 18 26.9 x 22 33.7 x 28 42.4 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, double internal and external sealed
KMR-Pipe Outer
90 mm
110 - 140 mm
160 - 200 mm
225 - 250 mm
280 - 315 mm
Branche line Outer mm 63 75 90
X X X
X X X
X X X
X X X
X X X
Copper Heating Piping End cap
CCO 9.365
4.7.2000
Shrinkdown end cap
The cap is shrunk onto the pipe end with a gas flame or hairdryer. 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
Copper Heating Piping Wall sealing ring Pipe warning tape
CCO 9.370
4.7.2000
Wall sealing ring

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 9.500
Copper Heating Piping Trench dimensions
CCO 9.500
4.7.2000
Trench profile, 2 copper local heating pipes UNO Normal trench cross-section in road area 1 2 3
. . .. .. . . . .. . . . .. . . . . . .. . . . . .. . .. . . . . .. . . . . . . .. . .. . . .. . . . . . .. . .. . . .. . . . . . . . . . .. . . . . . . .
DUO
all dimensions in cm 1 2 3
. . . . . . . .. . . . . . . . . . .. . . . . . . .. .. . . .
10 10 D 10 D 10 B Pipe casing D cm Width Depth Minimum radius of B T curvature, m cm cm Pipe casing D cm Width B cm
D B
10
Depth Minimum radius of T cm curvature, m
6.3 7.5 9.0
43 45 48
77 78 79
0.7 0.7 0.8
9.0
30
80
0.8
Trench profile, 4 copper local heating pipes (loop-in method)

1
. .. . . . . . . . . . . .. . . .
all dimensions in cm 1 2 3
. . . .. .. . .. . . . .. . .
2
.
3
. . ... . . . . . . . . . . . . . .. . . .. . . . . .. .
. . .. .. .. . . .. . . . . . . .
10 D
D 10 10 D B
B (4xD + 2x10)
10
1 Pipe warning tape 2 Excavated material 3 Washed sand, grain size 0-3/4 mm Laying depth: maximum laying depth: 2.6 m Our approval is required before laying at greater depths.
SLW 30 = 300 kN total load to DIN 1072; for exposure to higher operating loads (such as SLW 60), a loaddistributing superstructure to RStO75 is required. With no traffic load, the minimum trench depth T can be reduced by 20 cm.
When digging the pipe trench, make sure that the pipes lie in a sand bed (grain size: 0-8 mm) of at least 10 cm, and that there is coverage of the same thickness above.
Copper Heating Piping Entry into buildings
CCO 9.505
4.7.2000
Entry into buildings Wall openings

ca 80 mm
60 mm 80 mm
CCO
Copper connection piece; see sheet CCO 9.345
Pipe; see sheet CCO 9.115 Wall sealing ring; see sheet CCO 9.370
End cap; see sheet CCO 9.365
Wall opening
Outer casing
D mm
L min
mm
H
mm
63 75 90
400 450 500
250 250 250
80
100
80
L Dimensions in mm
Breakthrough bored
30
Outer casing
D mm
D1 min
mm
A
mm
63 78 93
160 180 200
190 210 230
A Dimensions in mm
PIPE2000 Ltd
EIGERFLEX
PIPE2000 Ltd
EIGERFLEX Table of contents
CPE 4.0
15.10.2003
4.0 4.1
4.100 4.110 4.115
Table of contents System description

System description DN 20 100, Carrier pipe 25 110 mm EIGERFLEX pipe DN 2040, Carrier pipe 25 50 mm EIGERFLEX pipe DN 50 100, Carrier pipe 63 110 mm Structure, dimensions, weights and supplied lengths
4.2
4.200 4.205 4.210 4.215 4.220
Planning, design engineering

Pressure loss Heat losses Connection to end of frost protection strip Sleeve joint - frost protection strip T-piece - frost protection strip
4.3
4.300 4.310 4.320 4.330 4.340 4.345
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)
4.5
4.500
Underground construction work, assembly

Trench dimensions Pipe entry into buildings Openings in walls
EIGERFLEX System description
CPE 4.100
15.10.2003
Flexible pipe system with frost protection strip
1. Medium pipe
Material: Life expectancy: Characteristics: PE medium pipe Polyethylene class PE with high density, to DIN EN ISO 12162 50 years at 20 C and 10 bar continuous load (30 C and 6.3 bar) Suitable for cold water and sewage/waste water pipes operating at up to 20 C/10 bar and 30 C/6.3 bar respectively Ref. Test standard Value temperature C 20 20 20 950 0.43 32 600-900 1.8 10 E-4 127 - 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. Frost protection strip

Material:
Outer casing Screened protective braiding Insulation Conductive heating element Copper conductor
Frost protection strip, self regulating
25 - 50 mm
63 - 110 mm
Power delivery 17 W/m Width 7.9 mm, Thickness 5.6 mm 20 mm 230 V AC Continuous operation 65 C, short periods 85 C, to -30 C 102 m / 16 A, (84 m / 13 A) 17 W/m
Power delivery 11 W/m Width 7.9 mm, Thickness 5.6 mm Dimensions 20 mm Minimum bending radius 230 V AC Operating voltage Max. permissible ambient temperature Continuous operation 65 C, short periods 85 C, to -30 C 128 m / 16 A, (118 m / 13 A) Maximum heating circuit length 11 W/m Power delivery (W/m at 5 C)
To protect people and equipment, we basically specify a 30 mA residual current-operated device (FI).
3. Heat insulation
Material: PUR-insulation Density Heat conductivity Closed cellular structure Water absorption after 24 hrs.
CFC-free, 100% CO 2-driven polyurethane foam (PUR) Ref. temperature C 50 Value > 60 0.032 90 10 kg/m W/mK % %
3
Test standard DIN 53420 DIN 52612 EN 253
4. Protective casing
Material: Purpose: PE-LD - protective casing Density Heat conductivity Crystallite melting range Polyethylene of low density, PE-LD, extruded seamless Protection against mechanical effects and moisture Ref. temperature C Value 928-938 kg/m3 0.43 W/mK 105-110 C Test standard DIN 53479 DIN 52612
EIGERFLEX EIGERFLEX - pipe 25 - 50 mm

with frost protection strip
CPE 4.110
15.10.2003
Aluminium foil, 50 mm wide
Frost protection strip Freezstop 11FSM2-CT
s1 EIGERFLEX
PE Medium pipe PUR-Foam PE-Foil PE-LD casing, corrugated
EIGERFLEX
Frost protection strip: Power delivery 11 W/m
EIGERFLEX pipe
Type
DN Inches Medium pipe PE Outher casing Min. 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. delivery length
Jumbo-Coil
s
Maxi-Coil
25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6
78 x 2.0 78 x 2.0 93 x 2.2 93 x 2.2
0.7 0.7 0.8 0.8
0.327 0.539 0.835 1.307
0.90 1.00 1.39 1.54
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. Delivery is on drums. On request, shorter lengths will be supplied on drums.
EIGERFLEX EIGERFLEX - pipe 63 - 110 mm

with frost protection strip
CPE 4.115
15.10.2003
Frost protection Frost strip Freezstop protection strip 17FSM2-CT channel
s1 EIGERFLEX
PE Medium pipe PUR-Foam PE-Foil PE-LD casing, corrugated
EIGERFLEX
18
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. bending dxs D x s1 radius mm mm m Medium pipe volume Weight kg/m max. delivery length
Jumbo-Coil Maxi-Coil
s
m
63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
128 x 2.7 128 x 2.7 163 x 3.2 163 x 3.2
1.0 1.0 1.2 1.2
2.091 2.961 4.254 6.362
2.60 2.75 4.56 5.69
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. Delivery is on drums. On request, shorter lengths will be supplied on drums.
EIGERFLEX Pressure loss

PE-Pipe
CPE 4.200
15.10.2003
Water, average temperature 20 C

Roughness = 0.01 mm (PE)
(1 mmWS = 9.81 Pa)
Water speed
20000 30000 40000
/90 ) 10N 100 1

(D
90
.6 /73 80) N
(D
1.45) 5/6DN 6 7 ( 1.4 3/5 0) 6 5

(DN
Flow in m [kg/h]
0.8 0/4 0) 5 4
(DN
3.0 m/
2.0
10000
m/
.6 /32 40N 32)

(D
1.5 m/ s
1.0
5000
6.2 2/2 5) 3 2
(DN
m/
0.7 5m
4000
/s
0.5
3000
m/
2000
0.4 5/2 0) 2 2
(DN
0.4 s m/ 0.3 s m/
30
300 20
500
1000
100
200
300
400
500
800
40
50
80
1000
2000
1200
1400
1600
1800
120
140
160
180
EIGERFLEX Heat losses
CPE 4.205
15.10.2003
Heat losses at different external temperatures or surface temperatures of the casing pipe. Medium temperature: 2 C
The frost protection strip can no longer compensate for a heat loss of more than 10 W/m, and there is a danger of freezing.
surface temperatures
Tmed = 2 C
If the pipes are laid underground (covered height H = 0.6 m), the heat losses are reduced by at least 20%.
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
0.6 0.8 1.0 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 4.9 5.1 5.3 5.5 5.7 5.9 6.1 6.3 6.5 6.7 6.8 7.0 7.2 7.4 7.6 7.8 8.0 0.7 1.0 1.2 1.4 1.7 1.9 2.2 2.4 2.6 2.9 3.1 3.4 3.6 3.8 4.1 4.3 4.6 4.8 5.0 5.3 5.5 5.8 6.0 6.2 6.5 6.7 7.0 7.2 7.4 7.7 7.9 8.2 8.4 8.6 8.9 9.1 9.4 9.6 9.8 10.1 0.8 1.0 1.3 1.6 1.8 2.1 2.3 2.6 2.9 3.1 3.4 3.6 3.9 4.2 4.4 4.7 4.9 5.2 5.5 5.7 6.0 6.2 6.5 6.8 7.0 7.3 7.5 7.8 8.1 8.3 8.6 8.8 9.1 9.4 9.6 9.9 10.1 10.4 10.7 10.9 1.1 1.4 1.8 2.2 2.5 2.9 3.2 3.6 4.0 4.3 4.7 5.0 5.4 5.8 6.1 6.5 6.8 7.2 7.6 7.9 8.3 8.6 9.0 9.4 9.7 10.1 10.4 10.8 11.2 11.5 11.9 12.2 12.6 13.0 13.3 13.7 14.0 14.4 14.8 15.1 0.9 1.2 1.6 1.9 2.2 2.5 2.8 3.1 3.4 3.7 4.0 4.3 4.7 5.0 5.3 5.6 5.9 6.2 6.5 6.8 7.1 7.4 7.8 8.1 8.4 8.7 9.0 9.3 9.6 9.9 10.2 10.5 10.9 11.2 11.5 11.8 12.1 12.4 12.7 13.0
Medium temperature: 2 C
1.2 1.6 2.0 2.5 2.9 3.3 3.7 4.1 4.5 4.9 5.3 5.7 6.1 6.6 7.0 7.4 7.8 8.2 8.6 9.0 9.4 9.8 10.2 10.7 11.1 11.5 11.9 12.3 12.7 13.1 13.5 13.9 14.3 14.8 15.2 15.6 16.0 16.4 16.8 17.2 1.1 1.4 1.8 2.2 2.5 2.9 3.2 3.6 4.0 4.3 4.7 5.0 5.4 5.8 6.1 6.5 6.8 7.2 7.6 7.9 8.3 8.6 9.0 9.4 9.7 10.1 10.4 10.8 11.2 11.5 11.9 12.2 12.6 13.0 13.3 13.7 14.0 14.4 14.8 15.1 1.7 2.2 2.8 3.4 3.9 4.5 5.0 5.6 6.2 6.7 7.3 7.8 8.4 9.0 9.5 10.1 10.6 11.2 11.8 12.3 12.9 13.4 14.0 14.6 15.1 15.7 16.2 16.8 17.4 17.9 18.5 19.0 19.6 20.2 20.7 21.3 21.8 22.4 23.0 23.5
EIGERFLEX Connection and end Frost protection strip
CPE 4.210
15.10.2003
1. Technical data
Heating strip type Max. heating circuit length based on switch-on temperature of 5 C: self regulating 16 A max. 100 m (13 A max. 80 m) Regulation: Thermostat UTR 15 adjustment range: 5 C to 15 C pipe contact thermostat or ambient thermostat
2. 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. Then shorten the inner pipe to length according to the fitting instructions.
3. Installation procedure
Electrical installation according to local regulations Only to be connected by an authorised electrical installer 30 mA residual current-operated device (FI) - required by regulations! Automatic fuse, C-characteristic
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; can be extended to a maximum of 100 m, with screened cable, 1.5 mm 2 Temperature sensor on pipe Temperature sensor in open air End closure EA-H
Connection heating strip / cold lead A-H/K

max. 100 m
4. Installing the temperature sensor on the pipe

The temperature sensor has to be installed on the medium pipe opposite the heating strip. It must be fitted at the coldest point on the pipe (outside the building). For this purpose, cut open a 10x7 cm area of the outer casing and peel back, cut out 10x7cm foam, and fix the temperature sensor on the inner pipe with adhesive tape. Fill the hole with the insulating material that is provided: apply filling adhesive S1113 below and above the temperature sensor cable (see sketch), seal with shrinkdown tube.
approx. 10 cm approx. 7 cm Filling adhesive S 1113, 60 mm long Shrinkdown tube Temperature sensor EIGERFLEX Temperature sensor cable Shrinkdown tube
EIGERFLEX Sleeve joint Frost protection strip
CPE 4.215
15.10.2003
1. Technical data
Heating strip type: Max. heating circuit length at switch on temperature of 5 C: self-regulating max. *100 m/16 A (max. 80 m/13 A) * for larger lengths see catalogue sheet CPE 4.100
2. 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. 100 m
max. 100 m
max. 100 m
3. 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. Then shorten the inner pipe to length as shown in illustration 2.
4. 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 + 4.310
Protect heating strip against moisture
EIGERFLEX T-piece Frost protection strip
CPE 4.220
15.10.2003
1. Technical data Frost protection strip

Heating strip type: Max. heating circuit length at switch on temperature of 5 C: self-regulating max. *100 m /16 A (max. 80 m /13 A) * for larger lenghts see catalogue sheet CPE 4.100 100 m.
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. Planning
At the T-junction, 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. Then shorten the inner pipe to length according to the fitting instructions.
4. Fitting T-piece with T-junction
Screwed T-piece or electro welded T
T-Piece Micro Uni Clip MUC
EIGERFLEX Joint sleeve Fitting the T-piece
CPE 4.300
15.10.2003
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, see sheet CPE 4.320 Insulation material, see sheet CPE 4.310 Shrinkdown sleeve pipe Shrinkdown tube
Fitting the T-piece

d2
d1
645 mm
Junction, d2 d1 d3
25/76 - 25/76 32/76 - 32/76 40/91 - 40/91 40/91 - 32/76 50/91 - 50/91 50/91 - 40/91 63/126 - 63/126 63/126 - 50/91 75/126 - 75/126 75/126 - 63/126 90/162 - 90/162 90/162 - 75/126 110/162-110/162 110/162- 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
1 2 3 4 5
PE T-piece, see sheet CPE 4.320 GFK half-shells Insulating material, see sheet CPE 4.310 Reducer ring Special sealing compound
d3
max. 490 mm
2 4
d2
EIGERFLEX Insulation material

PE-foam hose, PUR-foam pack
CPE 4.310
15.10.2003
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
EIGERFLEX Screwed PE joint Screwed PE T-piece
CPE 4.320
15.10.2003
Connection
coupling
75
L L
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
90
L
90
L
Screwed PE T-piece
d2
Junction, 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
d1
d3
75
d2
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
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
EIGERFLEX End cap
CPE 4.330
15.10.2003
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
EIGERFLEX Wall sealing ring Pipe warning tape
CPE 4.340
15.10.2003
Wall sealing ring
Data table
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 NW A R FE UN G
EIGERFLEX Wall duct DOYMA Core drilling
CPE 4.345
15.10.2003
Standard DOYMA C40 Cellar/shaft (Internal) External
DOYMA C40 with additional centering ring DOYMA A40 Cellar/shaft (Internal) 4
D external, mm 150 150 200 200 250 250 300
External
1 4
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 mm 76 91 111 126 142 162 182
D Pipe liner Core drill hole mm 150 150 200 200 250 250 300
Doyma Type C40 Doyma Type A40 D internal, mm 78 93 113 128 143 163 183
EIGERFLEX Trench dimensions Building entry
CPE 4.500
15.10.2003
Trench section, 1 CPE Leitung

all dimensions in cm . .. . . . . . .. . . . . . . . . .. . . . .. . . . . .. . . 10 D 10 30
1 2 3
min 60
Outher casing 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.
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 D mm
mm
Breakthrough bored
Outher casing D mm
D
mm
113 128
80 D 80
270 290 320

Dimensions in mm
78 93
240 250
78 93 113 128 163
180 200 220 240 280
A
Dimensions in mm
163
PIPE2000 Ltd
FLEXWELL
PIPE2000 Ltd
FLEXWELL heating cable Contents
FHK 3.0
28.02.98 07.03
3.0 3.1 3.110
Contents System description Technical specifications Design, dimensions, materials, weights and delivery lengths Planning, design Pressure loss diagram Heat loss diagram Loop-in method Laying method House connections (spacing and axial dimensions) Connectors Nominal widths, 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, installation Instructions for excavation works Technical codes, standards, 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
3.2 3.201 3.203 3.210
3.211
3.212 3.213 3.3 3.301 3.303 3.304 3.305
3.306 3.4 3.414 3.5 3.501
3.502 3.503 3.504 3.506 3.6 3.600 3.602
FLEXWELL heating cable System Description
FHK 3.1
28.02.98 07.03
FLEXWELL heating cable is the protected name for a flexible pipe system from BRUGG Rohrsysteme to transport district heating and warm tap water. This pipe, which is laid underground, has proven itself in practical applications under extreme and very different conditions for many years. FLEXWELL heating cable is equiped with a corrugated carrier pipe of special steel. This material is extremely corrosion resistant and therefore best suited to transport various media like heating water, warm tap water, drinking water, condensation and others. The corrugations of the carrier pipe not only give the district heating pipe its flexibility, but also compensate the temperature related length changes of the pipe. Elements to absorb the elongation (U-bends, L-limbs, fixed points) as required in rigid pipe systems are not necessary. 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. The continuous, outer multilayer corrosion protection provides incomparable safety in the ground during operation. The heat insulation of the FLEXWELL heating cable consists of flexible polyurethane hard foam (CFHC-free), which with operating temperatures of up to 150 oC withstands higher temperatures than conventional PUR-insulated pipes.
The flexibility of the FLEXWELL heating cable enables unproblematic adaptation to virtually all route conditions. Obstacles like existing supply lines present no problem because the pipe can simply be passed over, under or around them. Without regard to classical pipe construction, the shortest route can be selected with the FLEXWELL heating cable. The FLEXWELL heating cable is a safe solution especially in earth subsidence zones and in very wet ground (high groundwater level). It can be laid in water (under water) without problem. The pipe trenches for the FLEXWELL heating cable can be dimensioned considerably narrower than for rigid pipe systems. This makes significant savings in underground construction projects possible. Due to its flexibility, the FLEXWELL heating cable is especially well suited for the horizontal jet drilling method. This method is used wherever valuable surfaces have to be protected or difficult crossings made. If one also considers the very short laying time, the FLEXWELL heating cable is not only a technically perfect, 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.
FLEXWELL heating cable Design, Dimensions, Materials, Weights and Delivery Lengths
FHK 3.110
28.02.98
6 s2
s1
d1
D3
1 Corrugated carrier pipe of nickel-chromium steel X5 CrNi 18-10 (1.4301, EN 10088), (AISI 304) or X6 CrNiMoTi 17-12-2 (1.4571, EN 10088), (AISI 316Ti) or X2 CrNiMo 17-12-2 (1.4404, EN 10088), (AISI 316L) 2 Corrugated sheath pipe of steel Ast 4 LG, DIN 1624 3 Heat insulation of flexible polyurethane hard foam (CFHC-free), resistant up to 150 oC, thermal conductivity at 50 oC: 0.032 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, (b) 1 x Cu insulated, (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 - Dimensions, weights, delivery lengths
Type FHK 30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/22 147/22 [DN] d1 s1 Steel sheath pipe External diameter Carrier pipe volume Weight Max. delivery length*) Minimum bending radius Trench width D S2
3max
200/31 150 197.5 1.2 1.3 313 23.2 33.2 150 6 1
Comparable nominal width Special steel carrier pipe
25 30 0.3 0.6 94 0.81 3.9 1.000 1 0.5 30 0.3 0.6 121 0.81 5.4 640 1.2 0.55 38.9 0.4 0.6 121 1.35 5.7 640 1.2 0.55
32 38.9 0.4 0.6 156 1.35 8.6 590 1.5 0.6
50 60 0.5 0.7 156 3.12 9.1 590 1.5 0.6
65 75.8 0.6 0.8 178 5.12 12.2 480 2 0.65 98 0.8 0.8 178 8.43 12.8 480 2 0.65
80 98 0.8 0.9 233 8.43 19.3 270 4 0.75
100 127 0.9 0.9 233 14.3 19.8 270 4 0.75
125 147 1.0 0.9 233 17.3 20.3 250 4 0.75
[mm] [mm] [mm] [mm] [dm /m] [kg/m] [m] [m] [m]
3
*) according to maximum possible drum capacity and normal manufacturing length
FLEXWELL heating cable Pressure Loss Diagram
FHK 3.201
28.02.98 01.03.01
Average water temperature = 80C
300.000
200.000
[kg/h]
100.000 9 8 7 6 5
Flow rate
4 3
310 00/ K2 FH
0 /22 147 FHK 220 27/ K1 FH
10.000 9 8 7 6 5 4 3
m/s 1.0 s m/ 0.9 s m/ 0.8 s m/ 0.7
FHK
220 98/ HK F 171 98/
s m/ 0.6
s m/ 0.5
s m/ 0.4
171 75/ FHK

148 60/ FHK
s m/ 0.3
s m/ 0.2
1.000 9 8 7 6 5 4 3
116 39/ HK F
48 9/1 K3 FH
s m/ 0.1
91 30/ FHK
16 0/1 K3 FH
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]
0.1
0.5
1.0
10
50
100 [mmWS/m]
Pressure loss Example: Flow rate 7000 kg/h; FLEXWELL heating cable type 75/171 pressure loss 90 Pa/m
FLEXWELL heating cable Heat Loss Diagram
FHK 3.203
28.02.98
70
Heat loss [W/mK] 0.6 m
60
Heat loss [kcal/mh]
50 tE = 10 C 40 E = 1.2 W/mK
20 0/ 31 0
u. 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 . FH 1u 30/9 /148 FHK K 39 u. FH 16 30/1
20
10
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Carrier pipe temperature [C]

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 E = 1.2 W/mK tE = 10 C
FLEXWELL heating cable Loop-in Method Laying Method
FHK 3.210.1
28.02.98
Due to its flexible construction, the FLEXWELL heating cable is suitable for laying by the loop-in method from cable technology. The advantages are: - no underground branches or connections - reduction in risks - increase in safety - reduction in costs - possibility for inexpensive installation of fittings inside the building
Fig. 1 Conventional method of laying, connections and branches underground
Fig. 2 Loop-in method, connections in the building
FLEXWELL heating cable Loop-in Method House Connections
FHK 3.210.2
28.02.98 07.03
min. 350
1 3
Field-run pipes min. 350 2 Return
Flow
Flow
Return incoming pipes

1 2 3 4
FLEXWELL heating cable Connector Wall duct Wall opening (watertight sealing on site)
Depending on the altitude (high, low), a drain or vent possibility must be provided on construction side. For the size and arrangement of the wall openings see worksheets FHK 3.501.3 and FHK 3.501.4.
FLEXWELL heating cable Axial and Wall-Spacing Dimensions Connection Unions Type 30/91 to 75/171
FHK 3.211.1
28.02.98 07.03
Connector with graphite sealing ring type GR
l1 L1 4
min. 350
e1
min. 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 3.501.3 and FHK 3.501.4)
Nominal widths, pipe-connection, 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 60.3 x 2.9 240 145 280 75/171 DN 65 76.1 x 2.9 270 145 300
165 120 220
33.7 x 2.6 200 130 230
200 130 240
42.4 x 2.6 240 135 245
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 3.211.2
28.02.98 07.03
Connector type A
l1 3 D L1 6
L1
min. 350
1 2
min. 350
Connector type DE
l3 L1 5
Axial and wall-spacing dimensions

min. 350 e1
min. 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 3.501.3 and FHK 3.501.4)
Nominal widths, pipe-connection, wall and axial-spacing dimensions Type FHK Comparable nominal widths Dxs e1 L1 r l1 l2 l3 98/171 DN 80 88.9 x 3.2 270 235 122 385 385 400 98/220 127/220 DN 100 114.3 x 3.6 310 280 150 430 455 445
Dimensions in mm 147/220 DN 125 139.7 x 4.0 310 280 180 430 490 445
310 280
FLEXWELL heating cable Centre distances and wall clearances for welded connection Typ 30/91 to 200/310
FHK 3.211.3
28.02.98 07.03
Fig.1: Connection variant G, welded

l1 L1 3 1
2 4
Fig. 2: Wall clearances and centre distances

min. 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 3.501.3 and FHK 3.501.4)
min. 350 (550)1)
Nennweiten, Rohranschluss-, Wand- und Achsabstandsmasse Nominal bores, pipe connection, 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 60.3 x 2.9 240 230 383
75/171 DN 65 76.1 x 2.9 270 235 388
98/171
DN 25 33.7 x 2.6 165 215 377 200 215
DN 32 42.4 x 2.6 200 215 373 240 230
DN 80 88.9 x 3.2 270 235 385 310 280
114.3 x 3.6 139.7 x 4.0 168.3 x 4.5 310 280 426 310 280 426 410 210 (310)
1)
300 (400)1)
Dimensions in brackets apply when connection is installed on site, those without brackets for pipework assembled at our works.
FLEXWELL heating cable Laying through Protective Pipes
FHK 3.212.1
28.02.98
The following instructions must be followed when laying FLEXWELL heating cables (FHK) through protective pipes: 1. A protective pipe is basically needed for every FHK to guarantee sound guidance when pulling the FHK through the protective pipe. 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. 2. In the case of through-pressing it is not always possible to introduce two small protective pipes into the ground next to each other. A large protective pipe is then pressed in instead. In such cases it is necessary to contact us beforehand to arrange a constructive solution. 3. 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.
4. Bends in the route directly in front of and behind the protective pipes are to be avoided. If this cannot be guaranteed, the routing must be arranged with us beforehand. 5. In the case of protective pipes made of PVC, 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. The internal diameter of the protective pipes must be at least 20 mm larger than the external diameter of the FHK or runners (FHK 3.212.2, fig. 1 and 2).
FLEXWELL heating cable Laying through Protective Pipes
FHK 3.212.2
28.02.98 07.03
Fig. 1: Laying of district heating pipe through straight, well-aligned protective pipes without runners. Max. protective pipe length = 30 m1) Clearance min. 20 mm
Plug joint for
PVC sewer pipe PE sewer pipe AZ sewer pipe
PVC/PE/AZ sewer pipe
FHK
Fig. 2: Laying of district heating pipe through straight, well-aligned protective pipes with runners. Max. protective pipe length = 30 m1) Clearance min. 20 mm
FHK max. 1.0 mm runner distance L from end

Type FHK
Protective pipe of steel4) or concrete Plastic runner
30/91
30/116 39/116 121 2.00 160 x 3.6 32 168 x 9 150 29 219.1 x 4.5 210 4 S19 51
39/148 60/148
75/171 98/171
Max. FHK casing pipe Runner spacing L PVC sewer pipe acc. to DIN 19 534 2) Clearance between FHK and PVC pipe AZ sewer pipe acc. to DIN 19 850 2) Internal pipe Clearance between FHK and AZ pipe Steel pipe acc. to DIN 2458 3) 4) Internal pipe Runner (made by Frankenplastik) Clearance between FHK and pipe
[mm] [m] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
95 2.00 125 x 3 24 141 x 8 125 30 168.3 x 4 160 3 S19 27
315 x 7.7 67 328 x 14 300 67 323.9 x 5.6 313 3 F + 1 G25 30
400 x 9.8 67 436 x 18 400 87 406.4 x 6.3 394 4 F + 1 G25 31
1) Deviations only after consultation with BRUGG Rohrsysteme 2) Min. covering for SLW 60 = 0.80 m, for SLW 30 or under a road pavement 0.60 m 3) Min. covering = 0.60 m 4) Joints without root seam
156 178 2.50 3.00 without runners 200 x 4.5 250 x 6.1 35 60 220 x 10 274 x 12 200 250 44 72 with runners 219.1 x 4.5 273 x 5 210 263 4 T19 2 F + 1 G25 20 35
98/220 127/220 147/220 233 3.00
200/310
313 4.00
FLEXWELL heating cable Horizontal Jet Drilling Method
FHK 3.213
28.02.98 07.03
Due to its flexibility, the FLEXWELL heating cable is especially well suited for the horizontal jet drilling method described below. This method can be applied to the complete dimensional series from FHK 30/91 to FHK 200/310. The horizontal jet drilling method was developed for trenchless laying of supply lines. It is used wherever valuable surfaces (parks, nature reserves, pedestrian zones, paved paths, front gardens, etc.) have to be protected or where difficult crossings (water, canals, busy roads, railway lines, dams, buildings, etc.) have to be made. Short description of the method The drill consists of a single screwed hollow drill rod and a drill head equipped with nozzles. A water-bentonite mixture injected under high pressure and in small quantities cuts and loosens the ground and stabilises and lubricates the bore hole. The special shape of the drill head enables a controlled change in direction and exact control of drilling. At the end of the pilot hole the drill head is replaced with an expansion head equipped with nozzles and the FLEXWELL heating cable is coupled to it. At the same time as the drill rod is retracted the FLEXWELL heating cable is pulled into the bore hole expanded and supported by the water-bentonite suspension. Advantages of the system No trenches, earthworks only for assembly trenches Little damage to the surface No consequential damage, e.g. through subsidence of the ground or road surface Little obstruction/danger to stationary and moving traffic Protection of trees and plants Largely independent of the weather High working speed
FLEXWELL heating cable Connectors PN 25 Type 30/91 to 75/171 Version GR
FHK 3.301.1
28.02.98 07.03
The district heating pipe connectors with graphite sealing ring type GR (fig.1) is a connection element specially designed for FLEXWELL heating cables for heating and tap water pipes up to a size of DN 65. It is used to establish all connections to pipe installations in buildings and Fig. 1: Connector with graphite sealing ring type GR 4 3 7 1 12 11 10
shafts as well as for transition and T-connections. The electronic detection conductors are passed out of the connectors watertight. This connector can withstand a maximum temperature of 150 OC up to nominal pressure stage PN 161).
1 2 3 4 5 6 7 8 9 10 11
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
Detail X
15 14 13 10 Detector wire NiCr red insulation Nordic wire white insulation Copper wire green insulation
12
Version for tap water pipes

39/116 39/148 32 42.4 x 2.6 R 1 1/4 60/148 50 60.3 x 2.9 R2 75/171 65 76.1 x 2.9 R 2 1/2
Nominal widths, 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 33.7 x 2.6 R1
1) In pressure tests in partially filled trenches or with unfixed connectors max. permissible pressure = 0.5 bar
FLEXWELL heating cable Connectors PN 16 Type 98/171 to 147/220 Versions A, B and DE
FHK 3.301.2
28.02.98 07.03
The heating cable connector (fig.1) is a connection element specially designed for FLEXWELL heating cable. It is used to establish all connections to pipe installations in buildings and shafts as well as for straight through and T-connections (FHK 3.303 and FHK 3.304). The connector comes in three variants (fig. 2). On delivery the pipe ends are protected by plastic caps to protect the carrier pipe from dirt. The connectors type A and B (fig. 2) are intended for heating water pipes. The connector type DE also
comes in a special version for tap water pipes. It comes with an PTFE-surrounded IT seal. This PTFE sleeve may not be removed or damaged. The electronic detection conductors are passed out of the connector watertight. These connectors can withstand a maximum temperature of 150 OC up to nominal pressure stage PN 161).
Figure 1: Connection union (type A)

24 7 10 8 6 2 5 3 17 18 19 4 14 1 13 15 16
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, B, 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, pipe union dimensions

Type FHK Comparable nominal width Pipe union dimensions Figure 2: Connector versions [DN] [mm]
98/171 98/220 80 88.9 x 3.2
127/220 100 114.3 x 3.6
147/220 125 139.7 x 4.0
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. permissible pressure = 0.5 bar
FLEXWELL heating cable Connectors PN 25 Type 30/91 to 200/310 Version G, welded

2 11 10 4 5
FHK 3.301.3
28.02.98 07.03
6 7 3
FLEXWELL heating cable

Type FHK 30/91 - 147/220
WIG seam
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
4 7 5
13 10 11
Y
14
15
13
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
Nominal widths, pipe union dimensions

Type FHK Comparable nomina width Pipe union dimensions [DN] [mm] 30/91 30/116 15 33.7x2.6 39/116 39/148 32 42.4x2.6 60/148 50 60.3x2.9 75/171 65 76.1x2.9 98/171 98/220 80 88.9x3.2 127/220 100 147/220 125 200/310 150
114.3x3.6 139.7x4.9 168.3x4.5
Note: In pressure tests in partially filled trenches or with unfixed connectors max. permissible pressure = 0.5 bar.
FLEXWELL heating cable Straight through Connections PN 16 Type 30/91 to 147/220
FHK 3.303.1
28.02.98
Construction of the Straight through connection PN 16 7 4 3 6 2 4 5 1
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
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
FLEXWELL heating cable Straight through Connections PN 25 Type 30/91 to 200/310, Welded
4 3 2 7 5 1
FHK 3.303.2
28.02.98
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 - 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 - 39/116 39/148 - 60/148 75/171 98/171 98/220 - 127/220 - 147/220 200/310 L [mm] 800 800 800 850 850 850 900 Dmax (mm) 215 235 265 290 320 355 320
FLEXWELL heating cable T-Connection
FHK 3.304
28.02.98
Construction of the T-connection

~1400 1000 500
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
H D2
50 100
H = D1+D2 + 50 2
1000 ~1350
Depending on the pressure stage, the T-pieces are supplied with the standard or welded connector.
FLEXWELL heating cable Wall duct Watertight 0.3 bar
FHK 3.305.1
28.02.98
3 4
For dimensions see worksheets 3.501.3 and 3.501.4
1 2 3 4 5 6
Fastening ring Hexagon screw M6 x 20 Washer Cast ring Sealing ring FLEXWELL heating cable
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
FLEXWELL heating cable Doyma Wall Duct with Core Drill Hole or Asbestos Cement Pipe Lining Presswater-tight > 0.3 bar
FHK 3.305.2
28.02.98
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
Dinternal
Dexternal
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 (= Dexternal) must be specified when ordering the Doyma sealing set. The pipe may not be moved axially after mounting the Doyma sealing set.
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
FLEXWELL heating cable Doyma Wall duct with Steel pipe lining Presswater-tight 0.3 bar
FHK 3.305.3
28.02.98
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)
Dinternal Dexternal DH
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 98/220 127/220 147/220 200/310 168.3x4.5 219.1x6.3 219.1x6.3 244.5x6.3 244.5x6.3 273.0x6.3 273.0x6.3 323.9x7.1 323.9x7.1 323.9x7.1 406.4x6.3 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
The internal diameter of the steel pipe lining (= Dexternal) must be specified when ordering the Doyma sealing set. The pipe may not be moved axially after mounting the Doyma sealing set.
FLEXWELL heating cable Pipe Lining Connection Presswater-tight > 0.3 bar
FHK 3.305.4
28.02.98
min. 250 mm Shrink collar
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 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 D1 x s1 D2 x s2 l1 and l2 [mm] [mm] [mm] Da x s [mm] [mm] [mm] 94 DN 150 (168.3x4.5) 360 1 F + 1 G25 110x3.0 196x4.0 150 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 233 DN 300 (323.9x7.1) 500 2 M + 1 N36 250x4.9 340x6.0 150 200/310 310 DN 400 (406.4x6.3) 560 2 M + 2 N36 339x4.5 422x6.0 150 121 DN 150 (168.3x4.5) 360 2 C 15 137x2.8 196x4.0 150 156 DN 200 (219.1x5.9) 410 2 F + 1 G25 175x3.8 245x4.5 150 178 DN 250 (273.0x6.3) 460 2 M36 196x4.0 303x5.5 150
FLEXWELL heating cable House Connection Bend
FHK 3.306
28.02.98 07.03
7 6
D2
D1
700
1 FLEXWELL heating cable with connector (A, DE, G or GR) 2 Shrink collar 3 HP PE shrink joint 4 Shrink collar 5 Bend 90O preinsulated, 1.5 x 1.5, steel or special steel 6 Labyrinth gland 7 End cap
Type FHK
FHK external 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
FLEXWELL heating cable Laying without trenches
FHK 3.414
28.02.98 07.03
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. min. Empf. min. min. borehole radius min. borehole diam. Bohrlochradius Bohrlochdurchm.
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 Bohrungslnge [m] 121 112 110 141 190 167 201 224
drilling length (m) Bohrungslnge (m)
39/116
60/148
75/171
98/171
127/220
147/220
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. The maximum drilling length for the specific project must be determined taking into consideration the local conditions and permissible tractional forces in each case. FZ = permissible tractional force using waterjet drilling technique A special traction head must be used for this. The borehole should be widened to the recommended minimum borehole diameter before pulling in the FLEXWELL district heating cable..
200/310
30/91
FLEXWELL heating cable Instructions for Excavation Works Technical Codes, Standards, Guidelines for Construction
FHK 3.501.1
28.02.98
Technical codes, standards

At least the following standards, codes and directives must be followed for the underground works for FLEXWELL heating cable: DIN 1072 Road and Foot Bridges, Design Loads DIN 4033 Drainage Channels and Lines of Prefabricated Pipes, Guidelines for Construction DIN 4124 Building Trenches and Trenches, Embankments, Working Space Widths, Sheeting DIN 18300 VOB, Part C, General Technical Specifications; Earthworks DIN 18303 VOB, Part C, General Technical Specifications; Excavation Lining Works DIN 18304 VOB, Part C, General Technical Specifications; Piling DIN 18305 VOB, Part C, General Technical Specifications; De-watering Works DIN 18307 VOB, Part C, General Technical Specifications; Underground Gas and Water Piping Works DIN 18308 VOB, Part C, General Technical Specifications; Drainage Works DIN 18320 VOB, Part C, General Technical Specifications; Landscape Gardening Works DIN 18330 VOB, Part C, General Technical Specifications; Bricklaying Works DIN 18337 VOB, Part C, General Technical Specifications; Sealing against Non-pressing Water DIN 18354 VOB, Part C, General Technical Specifications; Asphalt Coating Works Instruction Sheet Protection of Pipe Trenches and Building Trenches1 Instruction Sheet on the Filling of Pipe Trenches2 Accident Prevention Regulations The trench widths B given in the table in worksheet FHK 3.501.2 are recommended values. They do 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 3.506 must be complied with. For trench-work specifications for straight through connections see worksheet FHK 3.502, for T-pieces FHK 3.503.
1 2
Employers Liability Insurance Association for the Building Trade Society for the Research into Roads, Work Group Underground, Maastrichter Str. 45, D-50672 Cologne
FLEXWELL heating cable Instructions for Excavation Works Trench Dimensions
FHK 3.501.2
28.02.98 07.03
Trench dimensions
Fig. 1: Trench plan Fig. 2: Trench sectional view A-A (dimensions in m)
1 A Rmin A
5 6
min. 0.6 0.3 0.1 d B LK 1 2 3 4 5 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; laying construction-side) 6 Sand filling (grain size 0 - 4 mm) 7 Filling material (reusable excavated material) x Tmin
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. 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 0.80 0.60 0.50 1.00 0.50 1.00 0.40 0.14 121 0.85 0.60 0.55 1.10 0.50 1.20 0.47 0.16 156 0.85 0.60 0.60 1.20 1.00 1.50 0.51 0.18 178 0.90 0.60 0.65 1.30 1.00 2.00 0.59 0.20 233 0.95 0.60 0.75 1.50 1.50 4.00 0.72 0.24
200/310 313 1.05 0.60 0.95 2.00 2.50 6.00 1.00 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
Trench and working space dimensions, excavation and sand-filling quantities The trench widths B are recommended values. Please pay attention to valid technical rules, directives and accident prevention regulations.
FLEXWELL heating cable Instructions for Excavation Works Wall Openings
FHK 3.501.3
28.02.98
Fig. 3: Wall opening FLEXWELL connector

a 2 3 4 h b
min. 0.35 m a
min. 0.35 m
Fig. 4: Wall opening for loop-in method

b
min. 2 x h h
min. 2 x b
a min. 0.35 m
min. 0.35 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).
1 2 3 4
FLEXWELL heating cable (FHK) Connector Wall duct Concrete (wall opening - watertight sealing on site) Dimensions in m 0.21 0.55 0.35 0.18 0.65 0.40 0.10 0.85 0.50
Dimensions wall opening, wall distances FHK a b h 30/91 0.26 0.35 0.20 0.24 0.45 0.25 0.22 0.50 0.30
30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310
FLEXWELL heating cable Core Drill Holes*)

*) only applies to standard wall duct
FHK 3.501.4
28.02.98
Top of trench ground
For core drill holes for Doyma seals see worksheet 3.305.2
D A B C D Axial spacing Core drill hole diameter Distance trench ground-pipe axis Diameter wall duct
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
410 460
400 450
120 155
298 378
FLEXWELL heating cable Instructions for Excavation Works Straight Through Connections
FHK 3.502
28.02.98
Fig. 1: Working space for straight through connections (side view) 4 2 3 1 0.1 1 2 3 4 FLEXWELL heating cable Straight through connection Sand filling (0 - 4 mm round grain) Filling material (reusable excavated material) 0.3
0.1
Fig. 2: Working space for straight through connections (ground plan)
0.1
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
A1
1.5
2.5
2.0
4.0
2.0
5.0
Trench width B 0.5 0.55 0.55 0.6 0.6 0.65 0.65 0.75 0.75 0.75 1.00
Min. trench width B1 1.5 1.55 1.55 1.6 1.6 1.65 1.65 1.75 1.75 1.75 2.00
In event of repair dimension A1 has to be increased by 2.5 m to bend out the FLEXWELL heating cable.
FLEXWELL heating cable Instructions for Excavation Works T-Piece Connections Branch downwards
FHK 3.503.1
28.02.98
Fig.1: T-piece connection, working space (ground plan) Dimensions apply to all FHK types
~1.3 m
1.8 m
0.9 m 0.25
1.8 m
0.9 m 0.25
~1.3 m
0.9 m
0.9 m
1.8 m
Fig. 2: T-piece connection, working space Branch downwards (sectional view)
4
Min. covering 0.6 mm
1 2 3 4
FLEXWELL heating cable (FHK) T-branch Sand filling (0 - 4 mm round grain) Filling material (reusable excavated material)
Trench ground main pipe H 0.1 0.3
Table 1 Branch downwards (fig. 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
30/91 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.19
30/116 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.20
39/116
39/148
60/148
75/171
98/171
98/220
127/220
147/220
200/310
0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.21
0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.22
0.28 0.28 0.28 0.28 0.28 0.28 0.24
0.30 0.30 0.30 0.30 0.30 0.26
0.32 0.32 0.32. 0.32 0.28
0.34 0.34 0.34 0.30
0.36 0.36 0.32
0.36 0.32
0.36
H = Difference in height between trench ground main pipe and trench ground branch pipe
FLEXWELL heating cable Instructions for Excavation Works T-Piece Connections Branch Upwards
FHK 3.503.2
28.02.98
Fig.1: T-piece connection, working space (ground plan) Dimensions apply to all FHK types
~1.3 m
1.8 m
0.9 m 0.25
1.8 m
0.9 m 0.25
~1.3 m
0.9 m
0.9 m
1.8 m
Fig. 2: T-piece connection, working space Branch upwards (sectional view)
1 2 3 4
FLEXWELL heating cable T-branch Sand filling (0 - 4 mm round grain) Filling material (reusable excavated material)
Min. covering 0.6 m
0.1 H Trench ground main pipe 0.3
Table 1 Branch upwards (fig. 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 0.23 0.24 0.25 0.26 0.28 0.30 0.32 0.34 0.36 0.36 0.40
30/116 0.24 0.25 0.26 0.28 0.30 0.32 0.34 0.36 0.36 0.40
39/116
39/148
60/148
75/171
98/171
98/220
127/220
147/220
200/310
0.25 0.27 0.28 0.30 0.32 0.34 0.36 0.36 0.40
0.27 0.28 0.30 0.31 0.34 0.36 0.36 0.40
0.28 0.30 0.31 0.34 0.36 0.36 0.40
0.30 0.32 0.34 0.36 0.36 0.40
0.33 0.35 0.38 0.38 0.40
0.35 0.38 0.37 0.40
0.36 0.36 0.40
0.36 0.40
0.36
H = Difference in height between trench ground main pipe and trench ground branch pipe
FLEXWELL heating cable Instructions for Excavation Works House Connection Bend
FHK 3.504
28.02.98
Fig.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 - 4 mm round grain) Filling material (reusable excavated material)
6 1 8 7 2 4 3 5 0.10
Tmax.
0.10 0.20
Fig.2: House connection bend Ground plan
1.50
a1 2xB B1) b
a2 h
Type FHK B Trench width a Side wall distance to centre of breakthrough 0.30 0.32 0.32 0.34 0.34 0.36 0.38 0.41 0.42 0.43 0.53
Minimum dimensions b h T max. a2 2) Wall distance Length Width Distance to centre of of the of the to bottom breakthrough breakthrough breakthrough of the foundation 0.15 0.16 0.16 0.16 0.16 0.17 0.18 0.20 0.20 0.21 0.26 0.49 0.52 0.53 0.56 0.57 0.62 0.66 0.72 0.74 0.77 0.95 0.20 0.25 0.25 0.30 0.30 0.35 0.35 0.40 0.40 0.40 0.50 1.00 1.00 1.00 0.98 0.98 0.98 0.97 0.96 0.95 0.93 0.92
30/91 30/116 39/116 39/148 60/148 75/171 98/171 98/220 127/220 147/220 200/310
0.50 0.55 0.55 0.60 0.60 0.65 0.65 0.75 0.75 0.75 0.95
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, etc.
FLEXWELL heating cable Distances to Other Supply Lines
FHK 3.506
28.02.98 07.03
The temperature of the earth in the immediate vicinity of underground heating cables is higher than normal. The transmission capacity of underground electric cables can be influenced by this. Reasonable minimum distances between the supply lines and heating cables are therefore necessary (see also VDE 0100 and VDE 0101).
Fig. 1: Crossing lines 2
1 1 Heating cable 2 Other supply lines 3 Distance lines
Fig. 2: Parallel lines 2
3 1
Table 1: Minimum distance to crossing lines

Table 2: Minimum distance to parallel lines Type of supply line Min. distance Parallel lines Length 5m >5m
Type of supply line
minimum distance
1-kV, signal, measuring cables 10-kV or one 30-kV cable Several 30-kV cables or cables above 60 kV Gas and water pipes
0.3 0.6 1.0 0.2 Dimensions in m
1-kV, signal, measuring cables 10-kV or one 30-kV cable Several 30-kV cables or cables above 60 kV Gas and water pipes
0.3 0.6 1.0 0.4
0.3 0.7 1.5 0.4
Dimensions in m
PIPE2000 Ltd
FLEXWELL FSR SAFETY PIPE
PIPE2000 Ltd
PIPE2000 Ltd
3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB
Tel No 01268 759567 Fax No 01268 569932 email pipe@pipe2000.co.uk
PIPE2000 Ltd
FLEXWELL Safety Pipe

Systems Description
FSR 3.101
12.04

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

FLEXWELL Safety Pipe System Product Range
FSR 3.102
12.04
The FLEXWELL Safety Pipe System is a family of pipework assemblies supplied in endless lengths, capable of leak-monitoring and suitable for the transport of water pollutant, ammable/non-ammable or otherwise hazardous uids and gases. The system is supplied with all components for installation of the piping and a complete range of leak detection equipment.
Consisting of a primary pipe, reinforcing bands, a corrugated outer containment pipe, a surveillance space, a double layer of BRUGG bitumen and a polyethylene jacket as external corrosion-proong. 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 3.201
FLEXWELL Safety Pipe DN 25 - DN 80 with corrugated copper primary pipe and corrugated steel outer containment pipe Worksheet FSR 3.201
FLEXWELL Safety Pipe DN 20 - DN 150 with thermoplastic primary pipe and corrugated steel outer containment pipe (only on request)
FLEXWELL Safety Pipe DN 25 - DN 50 - with corrugated stainless steel primary pipe and outer containment pipe and protective jacket Worksheet FSR-M 3.211 DN 25 - DN 100, except DN 40 with corrugated stainless steel primary pipe and corrugated steel outer containment pipe Worksheet FSR 3.202
Important data sheets for FLEXWELL Safety Pipes: head loss diagrams: Worksheets FSR 3.800 Details for underground installation: Worksheet FSR 3.800 ... Wall and manhole entry: Worksheets FSR 3.700 ...
Leak monitoring for FLEXWELL Safety Pipe Worksheets LDS 3.400 ...
FLEXWELL Safety Pipe Components f. i.: Connecting joints Worksheet FSR 3.300 ...
PIPE2000 Ltd

Product Description Flanged system ttings with monitored gasket seals
FSR 3.103
12.04
Flanged pipe tting with monitored gasket seals for the transport of hazardous substances
Solvents, i. e. tri/perchloroethylene, toluene, etc. petrol alcohols oils, emulsions lyes acids gases
The safe transport of hazardous substances makes continually growing demands on the constructors of fuel depots and industrial plants. In order to optimize the use of FLEXWELL safety piping, which already oers a high level of safety anyway due to its doublewalled construction, special anged pipe connections, elbows, T-pieces and through-connections with monitored gasket seals are available. They can be integrated into the leak monitoring system so that permanent, uninterrupted monitoring of the entire pipe system from the tank to the user becomes possible. These double-walled and monitored ttings must be located where they are clearly visible. It is not permitted to install anged ttings below ground. The principle of monitoring gasket seals consists in
having a radial groove extending full circle over the sealing surface of the anged tting that connects via a drilled port hole to the surveillance space of the safety pipe. The complete system comprises the double-walled, exible FLEXWELL Safety Pipe, the monitored pipe ttings and the leak monitoring system. Due to the exibility of the pipe, the use of elbow ttings is unnecessary within certain bending radii, and the entire pipe length can be laid in one piece.
PIPE2000 Ltd

FLEXWELL Safety Pipe with copper primary pipe Product Description
FSR 3.201
12.04
1. 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 1.5
corrosion-proong (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 0.2 0.12
bending radius cm 30
article No.
kg/m 1.0
821 003 90
2. FLEXWELL Safety Pipe with corrugated copper primary pipe
corrugated copper primary pipe
helically wrapped steel banding surveillance space
corrugated steel outer containment pipe
PE-HD jacket corrosion-proong (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.
type
DN
PN
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 2.5 3
internal volume primary surveillance pipe space l/m l/m 0.8 1.3 2 3 6 0,38 0.41 0.65 0.73 2
kg/m 1.9 2.3 3.8 4.8 9.2
PIPE2000 Ltd

FLEXWELL Safety Pipe with stainless steel primary pipe Product Description
FSR 3.202
12.04
3. FLEXWELL Safety Pipe with corrugated stainless steel primary pipe Material No. 1.4571 and 1.4539
corrugated stainless steel primary pipe
helically wrapped steel banding
surveillance space
corrugated steel outer containment pipe
PE-HD jacket corrosion-proong (bitumen)
Primary pipe: Material No. 1.4571

type DN PN d D wall of PE-HD jacket mm 2 2 2,5 3 4 internal volume primary surveillance pipe space l/m l/m 0,8 1,3 3 6 14 0,38 0,41 0,73 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.
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 2,4 4,8 9,2 18,4
Primary pipe: Material No. 1.4539

type DN PN d D wall of PE-HD jacket mm 2 2 2,5 internal volume primary surveillance pipe space l/m l/m 0,8 1,3 3 0,38 0,41 0,73 weight bending radius cm 50 60 70 821 105 95 821 106 95 821 107 95 article No.
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 1,8 2,4 4,8
Other materials for primary and outer containment pipe available on request.
PIPE2000 Ltd

FLEXWELL Safety Pipe with protective jacket type: FSR-M Product Description
FSR 3.211
12.04
1. 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 24,5
D1 mm 27
Volume inner pipe surveillance l/m space l/m 0,2 0,12
Weight kg/m 0,95
radius cm 30
ArticleNo. 821 013 90
FSR-M 16/30
15
25
16
2. FLEXWELL Safety Pipe with corrugated stainless steel inner pipe
D1 steel reinforcing bands surveillance space corrugated outer pipe material: 1.4301 oder 1.4404 protective jacket DN PN d mm D mm 43 53,5 76,5 D1 mm 46,2 57,1 80,5 Volume inner pipe surveillance l/m space l/m 0,8 1,3 3 0,38 0,41 0,73 Weight kg/m 1,3 2,1 3,6 radius cm 50 60 70 821 115 91 821 116 91 821 117 91 ArticleNo. 25 32 50 25 25 25 30 39 60 D1
D D
corrugated inner pipe material: 1.4404 oder 1.4571 Typ
FSR-M 30/48 FSR-M 39/60 FSR-M 60/83
PIPE2000 Ltd

Standard Connecting Joint with stub end, jointing of primary pipe: brazing
FSR 3.301
12.04
FLEXWELL safety pipe type FSR 16/30

screw plug, to be removed when connecting to leak detector
threaded sleeve
measuring branch for connection to leak detector see worksheet FSR 3.350 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. 100 26 60
overlap heat-shrink sleeve PE jacket min. 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. For installing the connection: see Installation Instructions FSR 3.920 ...
Subject to technical modifications
PIPE2000 Ltd

Standard Connecting Joint with collar and single or split collar flanges, jointing of primary pipe: brazing
FSR 3.302
12.04
FLEXWELL safety pipe type FSR 30/48 to FSR 83/120

measuring branch for connection to leak detector see worksheet FSR 3.350 threaded sleeve with collar flange as per DIN 2656 containment pipe brazed to threaded sleeve brazed banding screw plug, to be removed when connecting to leak detector
primary copper pipe brazed to sleeve
heat-shrink sleeve
d1
PE jacket removed from convoluted containment pipe A two set of split collar flanges see Worksheet FSR 3.340 B cutback length of casing pipe C
Material: Threaded sleeve made of steel R-St 37.0 acc. DIN 1629 Collar flange and split collar flanges made of steel USt 37-2acc. DIN 17100, hot-dipped galvanized
type
DN
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. DIN 2656 D k bolts* mm mm 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 1.5 1.5 1.5 1.5
B mm 55 54 51 49 54
C mm 80 80 80 100 100
article No. collar flange 829 829 829 829 829 355 356 354 357 359 90 90 90 90 90
article No. 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. to DIN 2635. For the double set of split flanges use bolts 10 mm longer. Bolts and nuts are not included in the set supplied. Warning: Only brazing materials approved by BRUGG may be used. For installing the connection: see Installation Instructions FSR 3.920 ...
PIPE2000 Ltd

Connecting Joint with threaded male end, jointing of primary pipe: brazing
FSR 3.303
12.04

measuring branch for connection to leak detector see worksheet FSR 3.350 screw plug, 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
cutback length of casing pipe A B
PE jacket removed from convoluted containment pipe C
Material: Threaded sleeve made of steel R-St 37.0 acc. 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.
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. For installing the connection: see Installation Instructions FSR 3.920 ...
PIPE2000 Ltd

Monitored connection with slide-on flange Part 1 Joined by: hard-soldering
FSR 3.308
12.04
Leak-monitored connection Type: Part 1

for connection to leak-monitored elbow Worksheet 3.502 and leak-monitored T-piece Worksheet 3.503
Measuring branch for the connection to leak detector see Worksheet 3.350 MeaScrew socket with slide-on flange acc. to DIN 2656 hard-soldering outer pipe Remove the locking screw when connecting to the leak detector.
hard-soldering copper inner pipe
hard-soldering reinforcing bands
shrink sleeve
d1
d2
Removing the PE jacket from the outer pipe A two-part slide-on flanges see Worksheet No.FSR 3.340 B Pulling off the outer pipe from the inner pipe C
Overlap shrink sleeve PE jacket min. 80
Material: Screw socket made of steel St 37.0 acc. to DIN 1629 slide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100, 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. to DIN 2656 A B D k bolts* mm mm Stck 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.-No. 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. for Measuring branch 829 335 00) * * The screw length given is intended for joining to a blank flange acc. to DIN 2635. For two-part flanges use screw
lengths 10mm longer. Screws and nuts are not included in the material delivered.
Only BRUGG solder Type 8.50.34 may be used!

Installation of the connection see installation instructions FSR 3.920 ...
PIPE2000 Ltd

Monitored connection with slide-on flange Part 2 Joined by: hard-soldering
FSR 3.309
12.04

Of Part 1 as leak-monitored through-connection acc. to Worksheet 3.501
Measuring branch for the connection to leak detector see Worksheet 3.350 MeaScrew socket with slide-on flange acc. to DIN 2656 hard-soldering outer pipe Remove the locking screw when connecting to the leak detector.
hard-soldering copper inner pipe
shrink sleeve
d1
d2
Removing the PE jacket from the outer pipe A two-part slide-on flanges see Worksheet No.FSR 3.340 B Pulling off the outer pipe from the inner pipe C
type
DN
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. to DIN 2656 A D k bolts* mm mm Stck 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 1,5 1,5 1,5 1,5 1,5
B mm 61,5 60,5 62,5 60,5 70,5
C mm 80 80 80 100 100
Art.-No. 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

Material: Screw socket made of steel St 37.0 acc. to DIN 1629 slide-on flange and two-part slide-on flange made of steel USt 37-2 acc. to DIN 17100, hotgalvanized O washer seal: Choice of material acc. to material to be transported Only to be supplied by BRUGG
PIPE2000 Ltd

Standard Connecting Joint with collar and single or split collar flanges,
jointing of primary/containment pipe: WIG welding/ brazing
FSR 3.310
12.04

measuring branch for connection to leak detector see worksheet FSR 3.350 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, to be removed when connecting to leak detector
heat-shrink sleeve
d1
PE jacket removed from convoluted containment pipe B two set of split collar flanges see Worksheet FSR 3.340 cutback length of casing pipe C
Material: DN 25, DN 32 and DN 50: Threaded sleeve made of Mat. No. 1.4571, 1.4539 acc. to DIN 17440. DN 80 and DN 100: Threaded sleeve of Mat. No. R-St 37.0 + 1.4571. Choice of material acc. to primary pipe material of the FLEXWELL Safety Pipe. Collar flange and split collar flanges made of steel USt 37-2acc. DIN 17100, hot-dipped galvanized.
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. DIN 2656 B C D k screws* mm mm 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. 1.4571 829 355 91 829 356 91 829 357 91 829 359 91 829 360 91
Article No. 1.4571 829 355 51 829 356 51 829 357 51 829 359 51 829 360 51
Article No. 1.4539 829 345 91 829 346 91 829 347 91
Article No. 1.4539

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. to DIN 2635. For the double set of split flanges use bolts 10 mm longer. Bolts and nuts are not included in the set supplied. Warning: Only brazing materials approved by BRUGG may be used. For installing the connection: see Installation Instructions FSR 3.920 ...
PIPE2000 Ltd

Connection with thread lug Joined by: WIG welding/hard-soldering
FSR 3.311
12.04
FLEXWELL-Safety Pipe Ttype FSR 30/48 bis FSR 60/83

Remove the locking screw when connecting to the leak detector.
WIG welding stainless steel inner pipe
Measuring branch for the connection to leak detector see Worksheet 3.350 hard-soldering outer pipe
shrink sleeve
Pulling off the outer pipe from the inner pipe B
Removing the PE jacket from the outer pipe C
* Material: 1.4539 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 63,5 85
B mm 71 72 82
C mm 80 80 100
Article-No. 1.4571 829 355 97 829 356 97 829 358 97
Article-No. 1.4539 829 345 41 829 346 41 829 347 41
FSR 30/48 FSR 39/60 FSR 60/83
25 32 50
Material: Screw socket stainless steel Material No.: 1.4571, 1.4539* acc. to DIN 17440 Choice of material depends on material of inner pipe of FLEXWELL Safety Pipe
PIPE2000 Ltd

Monitored connection with slide-on flange Part 1 Joined by: WIG welding/hard-soldering
FSR 3.318
12.04

for connection to leak-monitored elbow Worksheet 3.512 and leak-monitored T-piece Worksheet 3.513
WIG welding stainless steel inner pipe Measuring branch for the connection to leak detector see Worksheet 3.350 MeaScrew socket with slide-on flange acc. to DIN 2656 hard-soldering outer pipe shrink sleeve Remove the locking screw when connecting to the leak detector.
d1
d2
two-part slide-on flanges see Worksheet No.FSR 3.340
B Pulling off the outer pipe from the inner pipe
Material: DN 25, 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. 1.4571, 1.4539 acc. 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. to DIN 17100, 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. to DIN 2656 D k bolts* mm mm Stck. 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 2,5 2,5 2,5 2 2 B mm 60,5 59,5 59,5 90 87 C mm 80 80 100 100 130 Art.-No. without measuring branch 1.4571 1.4571 1.4539 1.4539
slide on flangetwo- 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

PIPE2000 Ltd

Monitored connection with slide-on flange Part 2 Joined by: WIG welding/hard-soldering
FSR 3.319
12.04

Of Part 1 as leak-monitored through-connection acc. to Worksheet 3.511
WIG welding stainless steel inner pipe Measuring branch for the connection to leak detector see Worksheet 3.350 MeaScrew socket with slide-on flange acc. to DIN 2656 hard-soldering reinforcing bands hard-soldering outer pipe shrink sleeve Remove the locking screw when connecting to the leak detector.
d1
d2
two-part slide-on flanges see Worksheet No.FSR 3.340
B Pulling off the outer pipe from the inner pipe
type
D N d d1 d2 DN m mm m m m
flange acc. to DIN 2656 A B C Art.-No. without measuring branch D k bolts* 1.4571 1.4571 1.4539 1.4539 mm mm Stck. mm mm mm slide on flangetwo- 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 0,5 129,5 100 0,5 139,5 130 829 481 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

Material: DN 25, 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. 1.4571, 1.4539 acc. 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. to DIN 17100, hotgalvanized
PIPE2000 Ltd

Two-part slide-on flange for standard connection
FSR 3.340
12.04
Pip ety af L-S EL XW FLE
4 segments arranged at 90 angles
2b
U-St 37-2 acc. to DIN 17100, hot-galvanized stainless steel acc. 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 d k D 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. to DIN 2635. Screws and nuts are not included in the material delivered.
PIPE2000 Ltd

Monitoring system Measuring branch
FSR 3.350
12.04
Measuring branch Type MA, long for connection with slide-on flange/two-part slide-on flange
Type I without flanged copper pipe Article No. 829 331 00 Type II with flanged copper pipe Article No. 829 332 00
straight screw-in inset, long, DN 4 intermediate thrust collar spacer with O clamping nut washers Cu seal Cu sleeve joint 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. 829 333 00 Type II with flanged copper pipe Article No. 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, galvanized, chromated On request: stainless steel
Installation instructions for - screwed flange connection see Worksheet No. ISI 8.60.01 - hand flanging tool, see Worksheet No. ISI 8.60.02
thrust collar straight screw-in inset, Cu DN 4 sleeve clamping nut intermediate joint 6 Cu seal spacer with O copper pipe washers 6 x 1 mm
PIPE2000 Ltd

Monitoring system Test valve
FSR 3.351
12.04
Test valve Type PV, long

for connection with slide-on flange with two-part slide-on flange Article No. 829 448 90
Test valve Type PV, short

for connection with external thread lug with soldered end Article No. 829 448 93
locking screw (cylindrical) G1/4 sealing washer (Cu) two-way stopcock
nipple G1/8, R1/4 copper seal
long nipple G1/8A, R1/4 copper seal
Material In series production: stopcock brass, nickel-plated long nipple - steel galvanized, chromated On request: stainless steel
Material In series production: stopcock brass, nickel-plated nipple steel galvanized, chromated
PIPE2000 Ltd

Monitoring system Test valve assembled
FSR 3.352
12.04
Test valve Type PV, 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. 829 448 70 Type II with flanged copper pipes Article No. 829 448 71
Test valve Type PV, short - assembled

with extended copper pipe for connection with soldered end with external thread lug Type I without flanged copper pipes Article No. 829 448 80 Type II with flanged copper pipes Article No. 829 448 81
Secure two-way stopcock (e.g. at edge of manhole) to ensure that joint is screwed tight to prevent leaks. locking screw (cylindrical) G1/4 sealing washer (Cu) two-way stopcock
Secure two-way stopcock (e.g. at edge of manhole) to ensure that joint is screwed tight to prevent leaks.
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, long G1/8A A copper pipe can be used when a hand flanging device is available. 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, chromated stopcock brass, nickel-plated
PIPE2000 Ltd
Leak Detection Systems

Leak detection for FLEXWELL safety pipe
System description
LDS 3.401
12.04
Leak monitoring
FLEXWELL safety piping is permanently monitored using pneumatic leak detection equipment/ leak detectors. These regulate the monitoring pressure in the surveillance space and register any changes of pressure which may occur. The surveillance space is filled with the leak detection medium (an inert gas) and prevents uncontrolled spillages of the transported product when leaks occur. 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. 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, (flammable and non-flammable) fluids are transported. The term leak detection equipment/leak detector includes all the equipment necessary for the detection of leaks. The main components are: the leak detector/leak detection equipment (LAZ) the connection between the surveillance space (UR) and leak detector (LAZ) double-walled piping the surveillance space (UR) a leak detection medium The use of this system complies with the most stringent European safety standards (Class 1). 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. 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. FLEXWELL Safety Pipe with a positive-pressure leak detector.
FLEXWELL Safety Pipe with pressured gas leak monitoring
FLEXWELL Safety Pipe with vacuum leak monitoring
PIPE2000 Ltd

System description
LDS 3.402
12.04
Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. 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. FLEXWELL Safety Pipe with leak monitoring is an approved leak detection equipment/leak detector system.
The advantages of the system Using double-walled FLEXWELL Safety Pipe with leak monitoring offers, besides a high degree of operative safety, substantial economic advantages: - the entire system can be easily and simply monitored at any time without interrupting operations - requirements such as e.g. pressure/volume measurements, pressure tests or route surveys can be dispensed with.
PIPE2000 Ltd

Leak detection systems on the vacuum principle
LDS 3.410
12.04

Leak detector on the vacuum principle are suitable for monitoring FLEXWELL Safety Pipes for the transport of: - water-hazardous, flammable substances - water-hazardous, flammable substances <=55C only in the Ex-variant - water-hazardous, non-flammable substances In every case in which the alarm is triggered, the vacuum pump is automatically switched off. It can only be switched on again by throwing the toggle switch mounted on the outside of the leak detector for this purpose. 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. 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. 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. The conditions set out in the approval for FLEXWELL safety piping and the leak detectors used must be complied with.
Leak detection on the vacuum principle Illustration
Principles of functioning The vacuum pump installed in the leak detector creates a partial vacuum. By monitoring this partial vacuum, leaks in the walls of the piping are automatically detected. 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 optical and acoustic alarm is triggered. Minimal, unavoidable permeability (not leaks) are regulated automatically by the leak detector, without triggering the alarm if they lie between the upper and lower values of the monitoring partial vacuum. Subsequent evacuation is carried out by the vacuum pump in the leak detector.
Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. 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. FLEXWELL safety pipe with leak monitoring is an approved leak detection equipment/leak detector system.
PIPE2000 Ltd

Leak monitoring on the positive pressure principle
LDS 3.450
12.04
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 : - water hazardous flammable substances - 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: - by topping up, regulated by pressure changes, from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space Operating mode S - from a mobile pressure reservoir which is only connected when the line is put into operation or during a function test. Operating mode M The surveillance space is connected with the leak detector by means of the connecting leads. The pressure which builds up is measured by the pressure sensor. If pressure drops to the value set previously for ALARM ON due to a leak, the optical and acoustic alarm will be triggered. 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.
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. 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. 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
PIPE2000 Ltd
FLEXWELL-Safety Pipe
Anchoring to buildings, pipe-supporting bridges etc.
FSR 3.710
12.04
1. Anchoring in buildings or on supporting structures

Installation example No. 1 Installation example No. 3
Anchoring the FSR to existing metal profile anchor rails recessed into the concrete (Jordahl No. 14 or equivalent strength) by means of saddle brackets.
N.B.: Commercially available brackets with suitable dimensions can be used for anchoring instead of the components shown in these drawings. The conditions on site should be taken account of. Anchoring on anchor rails or metal profil rods does, however, have the following advantages compared with anchoring to a fixed point 1. The FLEXWELL safety pipe can be provisionally secured during laying.
Installation example No. 2
Anchoring the FSR to existing anchor rails mounted on the wall surface (profile A8 or equivalent) by menas of saddle brackets.
2. The anchoring brackets only need to be loosened, pushed a little to one side and after aligning, to be tightened again.
2. Bending radius and distance between brackets

Type bending radius distance between brackets max. horizontal vertical brackets provided by the contractor must fit following pipe- mm 30 - 33 48 - 52 60 - 65 70 - 75 83 - 90 120 - 125 170 - 180
FSR 16/30 FSR 30/48 FSR 39/60 FSR 48/71 FSR 60/83 FSR 83/120 FSR 127/175
m 0,30 0,50 0,60 0,60 0,70 1,00 1,50
m 1,20 1,20 1,40 1,50 1,60 1,60 1,60
m 1,40 1,40 1,60 1,70 1,80 2,00 2,00
PIPE2000 Ltd
Wall Entry Seals Technical data
FSR 3.720
12.04
General Wall entry seals for FLEXWELL Safety Pipe are to be cast in concrete by the client. With correct installa-tion, the tightness between concrete and the wall duct as well as between the wall duct and the FSR is 0.2 bar against water, 0.1 bar against gas pressure.
Wall entry seals type MD for FSR 16/30 - FSR 60/83 The sealing element consists of a cross linked polyo-lefin heat-shrink sleeve, buttressed internally by a galvanized steel spiral. The outside of the convoluted surface has a special coating, which forms a longitu-dinally watertight bond with wet concrete or mortar. Both ends are coated inside with a plastic sealing compound. When heated using a gas flame the ends shrink and the sealing compound melts and is pressed into any grooves or irregularities. 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. 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, two wall sleeves can be pushed into each other to make up the extra length required.
A
set up measure = L
B max.
Wall entry seals type MD for FSR 83/120 and FSR 127/175 The sealing element consists of a cast iron sleeve, a sealing ring and a collar flange. 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. The FLEXWELL Safety Pipe is sealed with a sealing packing, which is pressed into the sleeve upon tightening of the bolts of the collar flange. 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. mm 186 829 395 90 243 829 396 90
D1
Warning! Slide wall sleeves over the pipe before assembling the connecting joint.
set up measure = L
PIPE2000 Ltd
Wall breakthroughs, boreholes
FSR 3.721
12.04
Wall breakthroughs for connections with slide-on flange acc. to DIN 2656 Type D screw socket 40 D 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. D + 100 mm
min. D + 100 mm
min. D + 150 mm
D flange
Boreholes for connections with slide-on flange acc. 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 D KD 40 100 115 120 140 150 150 170 165 180 200 220 270 290
KD borehole flange
D flange
Boreholes for connections with two-part slide-on flange TTake care to observe the external diameter of the wall entries. See worksheet No. FSR 3.720
Only applies to wall entries as per Worksheet FSR 3.720
PIPE2000 Ltd
Entry pipe sleeves for steel manholes and pipe wall sleeve for wall entries
FSR 3.722
12.04
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. For standard sizes refer to table below. The pipe sleeves must be supplied, set and sealed into the steel manhole or masonry wall by the client. Warning ! If FLEXWELL Safety Pipe connecting joints are to be fitted later, use split collar flanges. Standard collar flanges are larger in diameter than the pipe sleeves and wont fit.
steel manhole entry

split collar flanges 150 wall plate of steel manhole assembly pipe sleeve heat shrink sleeve
split spacer former masonry wall set up measure = L 150 pipe sleeve
jacket pipe wall entry
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. D. x wall mm 48,3 x 2,6 76,1 x 2,9 88,9 x 3,2 114,3 x 3,6 114,3 x 3,6 168,3 x 4,5 219,1 x 5,9
set up measure d mm 40 68 78 88 102 138 190 L mm 150 200 200 200 200 250 250
article No.
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.
PIPE2000 Ltd
Doyma wall entry with borehole or fibre-cement jacket pipe
Technical details
FSR 3.723
12.04
For screw sockets with a collar, two-part slide-on flanges must always be used, since they have an external diameter greater than the borehole or the internal diameter of the casing tube.
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
D2
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. The position of the pipe must not be axially changed after installing the Doyma sealing pack.
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
PIPE2000 Ltd
Firewall entry Fire-retardant seal
Technical details
FSR 3.730
12.04
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. P-3024/0148-MPA BS
Components
Fire-retardant pipe seal, gasproof, watertight under pressure, with fire-retardant sealing pack and noise insulation tested acc. to DIN 4109 Type: comprising:
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, to withstand temperatures from -40C to +140C (standard) special fibre cement
D mm 24,5 43 53,5 76,5
internal diameter of casing diameter of borehole
D1
D2
D1 mm 27 46,2 57,1 80,5
D2 mm 80 100 100 150
Please enclose a filled-in checklist with every order. 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. On top of that, 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. Checklist Worksheet No. 3.732
Fire-retardant pack R90 oder R120
PIPE2000 Ltd
Firewall entry Abschottung fr Leichtbauwnde F 90
Technical details
FSR 3.731
12.04
Piping non-flammable
Buchsenrohr Type 11.500 BSRN verkleben Abdichtung
Innendurchmesser Buchsenrohr
FLEXWELL-Sicherheitsrohr Typ: FSR-M
Buchsenrohr Type 12.500 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 _________ 11.500 BSRN
D mm 24,5 43 53,5 76,5
D2
D2 mm 42 61 61 106
Please enclose a filled-in checklist with every order. 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. On top of that, 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. Checklist Worksheet No. 3.732
Type:
FSR-M _________ 12.500 BSRN
bestehend aus: 1 Buchsenrohr, geteilt __________ mm lang 2 Steckrosetten, geteilt 1 sealing packs, geteilt 1 fire-retardant pack Buchsenrohr: Kunststoff Brandschutzpackung R90
bestehend aus:1 Buchsenrohr __________ mm lang 2 Steckrosetten 1 sealing packs 1 fire-retardant pack
PIPE2000 Ltd
Checklist Fire-retardant seal
FSR-M FSR 3.732

12.04
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 24,5 mm 27,0 mm FSR-M 30/48 43,0 mm 46,2 mm FSR-M 39/60 53,5 mm 57,1 mm FSR-M 60/83 76,5 mm 80,5 mm
Supply line
Medium: ____________________
Return line Medium: ____________________ With multiple entries, exact details of each individual pipe must be given.
Construction site data: Entry for Thickness of wall/ceiling (exact thickness) Material Wall 100 - 149 mm Ceiling 150 - 174 mm 175 - 300 mm > 300 mm
= _________mm = _________mm = _________mm = ________mm concrete stonework brickwork borehole casing pipe casing pipe casing pipe
ligtweight construction acc. to DIN 4102 T4 FSR-M without protective jacket other: __________________________________
Building: Description Town Client _________________________________________________ _________________________________________________ _________________________________________________
Please fax checklist to:
0049 (0) 50 31 - 170 145
PIPE2000 Ltd
PIPE2000 Ltd
3 Kelvin Road Manor Trading Estate Benfleet Essex SS7 4QB
FLEXWELL FSR LEAK DETECTION
PIPE2000 Ltd
PIPE2000 Ltd

System description
LDS 3.401
12.04
Leak monitoring
FLEXWELL safety piping is permanently monitored using pneumatic leak detection equipment/ leak detectors. These regulate the monitoring pressure in the surveillance space and register any changes of pressure which may occur. The surveillance space is filled with the leak detection medium (an inert gas) and prevents uncontrolled spillages of the transported product when leaks occur. 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. 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, (flammable and non-flammable) fluids are transported. The term leak detection equipment/leak detector includes all the equipment necessary for the detection of leaks. The main components are: the leak detector/leak detection equipment (LAZ) the connection between the surveillance space (UR) and leak detector (LAZ) double-walled piping the surveillance space (UR) a leak detection medium The use of this system complies with the most stringent European safety standards (Class 1). 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. 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. FLEXWELL Safety Pipe with a positive-pressure leak detector.
FLEXWELL Safety Pipe with pressured gas leak monitoring
FLEXWELL Safety Pipe with vacuum leak monitoring
PIPE2000 Ltd

System description
LDS 3.402
12.04
Approval/suitability All leak detection equipment/leak detectors in use must comply with the basic criteria laid down for construction and testing standards. All such preconditions which could have a bearing on the functional and operative safety of the system must therefore be observed. 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. FLEXWELL Safety Pipe with leak monitoring is an approved leak detection equipment/leak detector system.
The advantages of the system Using double-walled FLEXWELL Safety Pipe with leak monitoring offers, besides a high degree of operative safety, substantial economic advantages: - the entire system can be easily and simply monitored at any time without interrupting operations - requirements such as e.g. pressure/volume measurements, pressure tests or route surveys can be dispensed with.
PIPE2000 Ltd

LDS 3.410
12.04

Leak detector on the vacuum principle are suitable for monitoring FLEXWELL Safety Pipes for the transport of: - water-hazardous, flammable substances - water-hazardous, flammable substances <=55C only in the Ex-variant - water-hazardous, non-flammable substances In every case in which the alarm is triggered, the vacuum pump is automatically switched off. It can only be switched on again by throwing the toggle switch mounted on the outside of the leak detector for this purpose. 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. 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. 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. The conditions set out in the approval for FLEXWELL safety piping and the leak detectors used must be complied with.
Leak detection on the vacuum principle Illustration
Principles of functioning The vacuum pump installed in the leak detector creates a partial vacuum. By monitoring this partial vacuum, leaks in the walls of the piping are automatically detected. 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 optical and acoustic alarm is triggered. Minimal, unavoidable permeability (not leaks) are regulated automatically by the leak detector, without triggering the alarm if they lie between the upper and lower values of the monitoring partial vacuum. Subsequent evacuation is carried out by the vacuum pump in the leak detector.
PIPE2000 Ltd

Leak monitoring on the positive pressure principle
LDS 3.450
12.04
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 : - water hazardous flammable substances - 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: - by topping up, regulated by pressure changes, from a stationary nitrogen pressure reservoir which is constantly connected with the surveillance space Operating mode S - from a mobile pressure reservoir which is only connected when the line is put into operation or during a function test. Operating mode M The surveillance space is connected with the leak detector by means of the connecting leads. The pressure which builds up is measured by the pressure sensor. If pressure drops to the value set previously for ALARM ON due to a leak, the optical and acoustic alarm will be triggered. 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.
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. 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. 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
PIPE2000 Ltd
FERWAG -
The Professional Solution for Engineers
PIPE2000 Ltd
PIPE2000 Ltd
UK Distributor
Tel No 01268 759567 Fax No 01268 569932 email: pipe@pipe2000.co.uk
FERWAG -District heating pipe Contents
FER 7.0
15.10.2003
7.0 7.1
7.100 7.105
Contents System description

System description (general) System description (data)
7.2
7.200
Engineering
Laying Engineering, Contents
7.3
7.300 7.305 7.310 7.312 7.313 7.314 7.316 7.317 7.318 7.320 7.325 7.330 7.335 7.340 7.345 7.351 7.352 7.355 7.360
Components
FERWAG -District heating pipe, heating and sanitary Construction, Dimensions, Material, Weight and Delivery lengths Elbow, short-legged Elbow, 1.0 x 2.0 m T-pieces, branch-off, Insulation thickness 1 T-pieces, branch-off, Insulation thickness 2 T-pieces, branch-off, Insulation thickness 3 Parallel T-pieces with steel pipe, Insulation thickness 1 Parallel T-pieces with steel pipe, Insulation thickness 2 Parallel T-pieces with steel pipe, Insulation thickness 3 Anchors Preinsulated valves for underground laying, description, installation Shut-off valve, ball valve Fitting for shut-off valve, ball valve Pipe joints connection, shrink-on sleeve SMPE-2D Pipe joints connection, end sockets, shrink-on seal Pipe joints connection, EWELCON-Fusion Welded Joint, System description Pipe joints connection, EWELCON-Fusion Welded Joint, Technical specifications Wall sealing ring, Trench warning tape Wall duct (Doyma - for civil defence structures)
7.4
7.400
Transport and storage

Transport and storage
7.5
7.500 7.501 7.502 7.505 7.510 7.515 7.520 7.525 7.530 7.531 7.532
Data for excavation, Installation

Civil engineering works, laying pipes (trench profile) Civil engineering works, laying pipes Filling the pipe trenches House connection (wall penetration, core drilled holes) Assembly rules Concrete block for an anchor Draining and venting arrangements Underground installation for ballvalves Hot tapping, system description Hot tapping, dimensions and measurements Hot tapping, preparation weld seam and weld composition
7.6
Tendering text
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe System description
FER 7.100
15.10.2003
FERWAG district heating pipe is the registered name for a pre-insulated plastic casing pipe system used to transport district heat. The pipe system is designed to be laid directly in the earth, without ducts. It has proven its excellence over several decades and is nowadays acknowledged as the industrial standard in normal cases. Depending on the purpose for which it is used, FERWAG district heating pipe has a carrier pipe made either of steel (welded, seamless or galvanised), copper or special steel. This means that FERWAG district heating pipe is suitable for transporting heating water, hot water for industrial or domestic use, condensate and other fluids, but not for steam. The heat insulation of the FERWAG heating pipe is provided by a rigid polyurethane foam offering resistance up to 140 C. The outer protection is provided by an HDPE (high density polyurethane) casing pipe. All three components form a fixed unit, making this pipe system a member of the composite pipe family.
FERWAG district heating pipe is available in three categories of insulation thickness. Depending on the dimensions, the pipe construction units can be supplied in lengths of 6 + 12 (or 16) m. The construction units and all the associated moulded fittings such as elbows or bends, T-pieces, fixed points or anchors and so on, are prefabricated in the factory. This results in a modular kit system which is correspondingly simple to plan and assemble. All the components are connected on site, using circumferential seams. The weld seams and the end sockets are subsequently insulated with joint sleeves. Subsequent insulation work is usually carried out on our behalf by the system supplier or by qualified specialist companies. During the planning phase, we will assist system users on request by placing our experience with the system at their disposal free of charge, as part of our service.
PIPE2000 Ltd
UK Distributor
FERWAG- District heating pipe
FER
7.105 Description du matriel

26.8.2003 Sanitary
Materials supplied
FERWAG district heating pipe system for constant medium temperatures up to a maximum of 140 C, comprising: FERWAG district heating pipes FERWAG moulded fittings (elbows, Tpieces, fixed points, HDPE sleeves, etc.) FERWAG accessories (MDR, pipe underlay, line warning tape, etc.).
Pipes and moulded fittings

Threaded pipes: DIN 2440, longitudinally welded, galvanised to DIN 2444 Thread: DIN 2999 Part 1; over 2 1/2 ends without thread. Medium pipes made of other materials are available on request.
Casing pipe
HDPE, Hoechst, GM 5010 T2 or Unifos NCPE 3316 Standard: EN 253 Factory certificate:DIN 50.049-2.2 Material Dimensions of HDPE casing pipes External diameter Internal diameter Minimum wall thickness 90 2,2 85,6 110 2,5 104,0 125 2,5 118,8 140 3,0 133,0 160 3,0 152,0 180 3,0 172,0 200 3,2 192,0 225 3,5 216,2 250 3,9 240,2 280 4,4 269,0 315 4,9 302,6 355 5,6 341,0 400 6,3 384,4 450 7,0 432,4 500 7,8 480,4 560 8,8 538,0 630 9,8 605,2 710 11,1 682,0 800 12,5 768,6
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 to DIN 17120 DIN 2458/1626; EN 253 DIN 50.049-3.1 B 114.3, DIN 2559-22
Pipes for T-pieces and fixed points

T-pieces and fixed points with the same wall thicknesses as the pipes; end sockets of compensators and fittings with the same wall thicknesses as the welded pipes; material matches the straight welded pipes.
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. Material Standard: EN 448 Dimensions: Factory certificate: Acceptance test certificate: End sockets: Technical data: St 37.0 DIN 2605, DIN 2458/1626; Same as straight pipes DIN 50.049-2.2 or DIN 50.049-3.1 B 150-200 mm Same as for straight pipes. St 37.0 DIN 2448/1629; EN 448, DIN 2458/1626 Same as straight pipes DIN 50.049-2.2 or DIN 50.049-3.1 B
Heat insulation (EN 253)

Polyurethane foam (pentane blown) Polyurethane foam manufactured from 3 components: polyol, isocyanate and pentane Mixing and metering takes place in high-pressure systems. Core pipe density: Min. 60 kg/m3 Closed cell percentage: 96% Thermal conductivity coefficient: 0.0260 W/mK for an average temperature of the insulating layer of 50C
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.
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Laying Engineering Contents
FER 7.200
15.10.2003
7.20
7.201 7.202 7.203
Principles, theory
Layout of the line Laying length, Lmax Natural fixed point (maximum laying length)
7.21
7.210 7.211 7.212 7.214 7.215 7.216 7.217 7.218
Tables: max. covering, Lmax., thermal prestressing

Maximum permissible covering height Lmax, laying without prestressing, insulation thickness 1 Lmax, laying without prestressing, insulation thickness 2 and 3 Thermal prestressing (description) Laying with thermal prestressing, DN 20-300, insulation thickness 1 Laying with thermal prestressing, DN 20-300, insulation thickness 2 Laying with thermal prestressing, DN 350-500, insulation thickness 1 and 2 Laying with thermal prestressing, DN 20-200, insulation thickness 3
7.22
7.220 7.221 7.222 7.223
Expansion calculation
Restricted expansion Restricted expansion up tp 90 C, DN 20-125, insulation thickness 2 Restricted expansion up tp 90 C, DN 20-125, insulation thickness 3 Restricted expansion
7.23
7.230 7.231 7.232
Design of expansion elements

L-elbow, Z-elbow, U-elbow - sheet 1 Elbow < 90 (bend in the line) - sheet 2 Location of expansion pads
7.24
7.240 7.241 7.242 7.243
Dimensioning, heat loss

Pressure losses Heat loss, insulation thickness 1 Heat loss, insulation thickness 2 Heat loss, insulation thickness 3
7.25
7.250 7.251 7.252 7.253 7.254
Laying direction
Laying direction, sheet 1 Laying direction, sheet 2 Laying direction, pipe elbows, min. bending radius, small bends, sheet 3 Laying direction, changes of direction at 40-50 and 40-50 , sheet 4 Connecting instruction, transition flexible pipe to plastic sheath pipe
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Layout of the line
FER 7.201
15.10.2003
Layout of the line for FERWAG district heating pipes is not subject to any special requirements. With respect to the pipe, it should fundamentally be selected with consideration to possible expansion. For this purpose, changes of direction in the normal layout of the line using L elbows are an initial option. In addition there are Z elbows and U elbows, which are capable of taking up the expansion arising at precisely defined points. The angle sizes of the "expansion elbows" should not exceed 90 , since otherwise considerably longer expansion legs are needed. If possible a right angled line course should always be aimed for.
a
Fig. 4 Straight line layout between two buildings with expansion taken up within the line by U elbows.
Fig. 1 Straight line layout between two buildings. The expansion of the district heating pipes must be taken up in building A or B by pipe legs or similar.
a b
Fig. 2 Angled line layout, expansion taken up by natural change of direction in L elbow and building a.
a b
Fig. 5 Angled line layout between two buildings. Expansion taken up within the line by Z elbows.
a
Fig. 6 Straight line layout, expansion taken up within the line by U elbows.
Fig. 3 Straight line layout between two buildings with expansion taken up within the line by Z elbows.
3m
Building If no expansions are provided in the houses, then anchor must be fitted in the building wall or approx. 3 m before it.
FP
PIPE2000 Ltd
UK Distributor
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'
[m]
Friction force, Fr' [N/m]
Z elbow
FP Lmax Lmax
Fr'= [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
= 0.5
PIPE2000 Ltd
UK Distributor
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
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' = [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)
= 0.5
PIPE2000 Ltd
UK Distributor
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
0.15
Covering height, H [m] Friction force, Fr' [kN/m] Permissible stress, =185 N/mm2 Friction factor ground/PE, = 0,5 Specific gravity of ground, = 19 kN/m3 Pressure coefficient at rest, Kd = 0,463
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Laying without prestressing

Maximum permissible laying length, Lmax
FER 7.212
15.10.2003
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
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
0.15
Covering height, H [m] Friction force, Fr' [kN/m] Permissible stress, =185 N/mm2 Friction factor ground/PE, = 0,5 Specific gravity of ground, = 19 kN/m3 Pressure coefficient at rest, Kd = 0,463
PIPE2000 Ltd
UK Distributor
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 /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
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]
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Laying with thermal prestressing

DN 20-300, Insulation thickness 1
FER 7.215
15.10.2003
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
26,9 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 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 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 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
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 16 19 22 27 30 34 39 42 50 57 61 70,5 11 12 14,5 16,5 20 23 25,5 29,5 32 38,5 44 47 55 9 10 11,5 13 16 18,5 20,5 24 26 31 36 38,5 45 7,5 8 9,5 11 13,5 15,5 17,5 20 22 26 30 32,5 38 3,5 4 4,5 5 6,5 7 8 9 10 12 13,5 14,5 17 2,5 3 3,5 4 5 5,5 6 7 7,5 9 10,5 11 13 2 2,5 2,5 3 4 4,5 5 5,5 6 7,5 8,5 9 11 1,5 2 2,5 2,5 3 3,5 4 5 5 6 7 7,5 9 0,5 1 1 1 1,5 1,5 1,5 2 2,5 3 3 3,5 4,5 0,5 1 1 1 1 1,5 1,5 2 2 2,5 3 3 3,5 0,5 0,5 0,5 1 1 1 1 1 1,5 1,5 2 3 3,5 0,5 0,5 0,5 0,5 0,5 1 1 1 1,5 1,5 1.5 2,5 3 18 20,5 24 27 33,5 37,5 42,5 48,5 52,5 62,5 71.5 76 88 13,5 15,5 18 20,5 25,5 28,5 32 37 40 48 55 59 68,5 11 12,5 14,5 16,5 20,5 23 26 30 32,5 39 44,5 48 56 9 10,5 12 14 17 19,5 21,5 25 27,5 32,5 37,5 40,5 47,5 5,5 6 7 8 10 11 12,5 14,5 15,5 18,5 21 22,5 26 4 4,5 5,5 6 7,5 8,5 9,5 11 12 14 16,5 17,5 20 3 3,5 4,5 5 6 7 7,5 9 9,5 11,5 13,5 14,5 17 2,5 3 3,5 4 5 5,5 6,5 7,5 8 9,5 11 12 14 0,5 1 1 1 1,5 1,5 2 2,5 3 3 4 4 5 0,5 1 1 1 1,5 1,5 1,5 2,5 2,5 3 3,5 3,5 4,5 0,5 0,5 0,5 1 1 1 1 1,5 2 3 3 3,5 4 0,5 0,5 0,5 0,5 1 1 1 1 2 2 3 3 4 20 22,5 26 30 36,5 41,5 46,5 53,5 58 69 78,5 84 97 15 17 20 22,5 28 31,5 35,5 40,5 44 53 60,5 65 75,5 12 13,5 16 18 22,5 25,5 28,5 33 35,5 42,5 49 53 62 10 11,5 13,5 15 18,5 21 24 27,5 30 36 41,5 44,5 52 6,5 7,5 8,5 10 12 13,5 15 17,5 19 22,5 25,5 27,5 31,5 5 5,5 6,5 7,5 9 10,5 11,5 13,5 14,5 17 20 21 24,5 4 4,5 5 6 7,5 8,5 9,5 10,5 11,5 14 16 17,5 20 3 3,5 4,5 5 6 7 8 9 10 12 13,5 14,5 17 1 22 1 24.5 1 28,5 1 32,5 1,5 40 2 45,5 2 51 2,5 58,5 63 3 3,5 75 85,5 4 4,5 91,5 5,5 106 1 16,5 1 18,5 1 21,5 1 24,5 1,5 30,5 1,5 34,5 38,5 2 2,5 44,5 48 3 57,5 3 66 4 71 4 82 5 1 13 1 15 1 17,5 1 20 24,5 1 27,5 1 1,5 31 2,5 36 2,5 39 3 46,5 3 53,5 4 58 4,5 67 0,5 11 1 12,5 1 14,5 1 16,5 1 20,5 1 23 1,5 26 2 30 32,5 2 39 3 45 3 3,5 49 57 4 8 8,5 10 11.5 14,5 16 18 20,5 22,5 27 30,5 32,5 38 6 6,5 7,5 9 11 12 14 16 17 20,5 23,5 25 29,5 4,5 5,5 6 7 8,5 10 11 13 14 16,5 19 20,5 24 4 4,5 5 6 7 8 9,5 10,5 11,5 14 16 17,5 20 1 23,5 1 26,5 1 31 1 35,5 2 43,5 2 49 2,5 55 3 63 3,5 68,5 3,5 81,5 4,5 92,5 99 5 6 115 18 1 20 1 23,5 1 1,5 27 1,5 33 1,5 37 2 42 2,5 48 3 52 3,5 62,5 4 71,5 4,5 76,5 5,5 89 1 1 1 1 1 1,5 1,5 2,5 2,5 3 4 4 5 1 1 1 1 1 1 1,5 2,5 2,5 3 3 4 4,5 14,5 16 19 21,5 26,5 30 33,5 39 42 50,5 58 62,5 73 12 13,5 15,5 18 22 25 28 32,5 35,5 45,5 49 53 62 9 10 12 14 17 19 21,5 24,5 26,5 31,5 36 38,5 44 7 7,5 9 10,5 13 14,5 16 18,5 20 24 27,5 29,5 34,5 5,5 6 7 8,5 10 11,5 13 15 16,5 19,5 22,5 24 28 4,5 5 6 7 8,5 9,5 11 12,5 13,5 16,5 19 20,5 24 1 1 1 1,5 2,5 2,5 2,5 3 3,5 4 4,5 5,5 6,5 1 1 1,5 1,5 1,5 2 2,5 3 3,5 4 4,5 5 6 1 1 1 1 1,5 1,5 2 2,5 3 3 4 4,5 5,5 1 1 1 1 2 2 2 2,5 2,5 3 4 4 5
H = 1,2 m
H = 1,0 m
H = 0,8 m
H = 0,6 m
l DS
Lg FP
Operating temperature TB [ C] Preheating temperature Tv [ C] Laying temperature Tk=10 [ C], T = TvTk Sliding range when cooling Lg [m] Elastic recovery when cooling l [mm] Permissible stress = 190 N/mm2
Friction factor ground/ PE, =0,5 Specific gravity of ground, = 19 kN/m3 Coefficient of compression, Kd=0,463 Covering height H [m] Expansion leg DS [m]
PIPE2000 Ltd
UK Distributor

DN 20-300, Insulation thickness 2
FER 7.216
15.10.2003
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
26,9 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 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 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 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
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 16,5 19 24 26,5 30 34,5 37,5 44,5 50,5 54 63,5 9 10 12,5 14,5 18 20 23 26,6 29 34,5 39 42 49,5 7 8 10 11,5 14,5 16 18,5 21,5 23,5 28 31,5 34 40,5 6 6,5 8,5 9,5 12 13,5 15,5 18 19,5 23,5 26,5 29 34 3 3,5 4 4,5 5,5 6,5 7 8 9 10,5 12 13 15 2 2,5 3 3,5 4,5 4,5 5,5 6,5 7 8 9 10 12 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6,5 7,5 8 9,5 1,5 1,5 2 2,5 3 3.5 3.5 4 4,5 5,5 6,5 7 8 0,5 1 1 1 1 1,5 1,5 2 2,5 2,5 3 3,5 4 0,5 0,5 0,5 1 1 1 1 1,5 2 2 2,5 3 3,5 0,5 0,5 0,5 0,5 1 1 1 1 1 1,5 2 2 3 0,5 0,5 0,5 0,5 0,5 1 1 1 1 1 2 2,5 3 15 16,5 21 24 30 33 37,5 43 47,5 56 63,5 67,5 79 11 12,5 16 18 22,5 25 28,5 33 36 43 49 52,5 62 9 10 12,5 14,5 18 20 23 26,5 29 34,5 39,5 43 50,5 7,5 8,5 10,5 12 15 17 19,5 22,5 24,5 29 33,5 36 43 4,5 5 6 7 9 10 11 13 14 16,5 19 20 23,5 3,5 3,5 4,5 5,5 6,5 7,5 8,5 10 11 12,5 14,5 15,5 18,5 2,5 3 4 4,5 5,5 6 7 8 8,5 10,5 12 12,5 15 2 2,5 3 3,5 4,5 5 5,5 6,5 7,5 8,5 10 10,5 13 1 1 1 1,5 1,5 2 2 2,5 2,5 3 4 4 4,5 0,5 1 1 1 1 1,5 1,5 2,5 2,5 3 3,5 3,5 4,5 0,5 0,5 1 1 1 1 1,5 1,5 2 2,5 3 3 4 0,5 0,5 0,5 1 1 1 1 1 1,5 1,5 3 3 3,5 16,5 18,5 23 26,5 32,5 36,5 41,5 47,5 52 61,5 69,5 74,5 87 12,5 14 17,5 20 25 27,5 31,5 36 39,5 47 53,5 57,5 68 10 11 14 16 20 22 25,5 29 32 38 43,5 47 55,5 8 9,5 11,5 13,5 16,5 18,5 21 24,5 27 32 37 40 47 5,5 6 7,5 8,5 10,5 12 13,5 15,5 17 20 23 24,5 28,5 4 4,5 5,5 6,5 8 9 10 12 13 15,5 17,5 18,5 22 3 3,5 4,5 5 6,5 7 8,5 9,5 10,5 12,5 14,5 15,5 18 2,5 3 4 4,5 5,5 6 7 8 9 10,5 12 13 15,5 1 1 1 1,5 1,5 2 2,5 3 3 3,5 4 4,5 5 0,5 1 1 1 1,5 1,5 2 2,5 2,5 3 3,5 4 4,5 0,5 0,5 1 1 1 1 1,5 1,5 2,5 3 3,5 3,5 4,5 0,5 0,5 0,5 1 1 1 1 1,5 2 2,5 3 3,5 4 18 20 25 28,5 35,5 39,5 45 52 56,5 67 76 81 95 13,5 15 19 21,5 27 30 34,5 39,5 43,5 51,5 58,5 63 74 11 12 15 17,5 22 24 27,5 32 35 41,5 47,5 51,5 60,5 9 10 12,5 14,5 18 20 23 27 29,5 35 40 43,5 51,5 6,5 7 9 10 12,5 14 16 18,5 20 24 27 29 34 4,5 5,5 6,5 7,5 9,5 10,5 12 14 15,5 18,5 21 22,5 26,5 4 4,5 5,5 6 8 8,5 10 11,5 12,5 15 17 18,5 21,5 3 3,5 4,5 5 6,5 7 8,5 9,5 10,5 12,5 14,5 15,5 18,5 19,5 1 21,5 1 27 1,5 31 1,5 38,5 2 43 2,5 49 2,5 56 3 3,5 61,5 3,5 72,5 4,5 82,5 5 88 5,5 103 14,5 1 16,5 1 20,5 1 23,5 1 1,5 29,5 1,5 32,5 2 37 2,5 43 47 3 55,5 3 63,5 4 68 4,5 80,5 5 1 11,5 1 13 1 16,5 1 19 1 23,5 1,5 26 2 30 2,5 34,5 38 2,5 45 3 51,5 3,5 55,5 4 66 4,5 0,5 10 1 11 1 14 1 16 1 19,5 1 22 1 25 2,5 29 32 2,5 38 3 43,5 3 47 3,5 55,5 4,5 7,5 8,5 10,5 12 15 16,5 19 21,5 23,5 28 32 34 40 5,5 6,5 8 9 11,5 12,5 14,5 16,5 18 21,5 24,5 26,5 31 4,5 5 6,5 7,5 9 10 11,5 13,5 14,5 17,5 20 21,5 25,5 4 4 5,5 6 7,5 8,5 9,5 11 12,5 14,5 17 18 21,5 1 1,5 1,5 1,5 2 3 2,5 3 3,5 4 4,5 5,5 6 1 1 1 1,5 1,5 1,5 2 3 3 3,5 4 5 5,5 1 1 1 1 1,5 1,5 2 2,5 2,5 3 4 4 5 1 1 1 1 1 1,5 1,5 2,5 2,5 3 3,5 4 4,5
H = 1,2 m
H = 1,0 m
H = 0,8 m
H = 0,6 m
Lg FP
DS
PIPE2000 Ltd
UK Distributor

DN 350-500 Insulation thickness 1 + 2
FER 7.217
15.10.2003
H m
350 400 450 500 350 400 450 500 350 400 450 500 350 400 450 500
DN
Steel pipe dxs
mm
355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3
500 560 630 710 500 560 630 710 500 560 630 710 500 560 630 710 69 77,5 76 74 54 61 60 58 44 50 49,5 48 16,5 18,5 18 18 13 14 14 14 10,5 11,5 12 11,5 4,5 5 6 6 4 4,5 4,5 4,5 3,5 4 4,5 4,5 3,5 4 4 4,5 86 97 95 92 67 76 75 75 55 62 62 60,5 47 53 53 52 25,5 29 28 27,5 20 22,5 22 21,5 16,5 18,5 18,5 18 14 15,5 15,5 15,5 5,5 6 6,5 7 5 5,5 5,5 5,5 4,5 5 5,5 6 4 4,5 5 5,5 95 106 105 102 74 83 82,5 80,5 61 69 68 66,5 51,5 58 58 56,5 31 35 34,5 33 24 27 27 26 19,5 22,5 22,5 22 17 19 19 18,5 6 6,5 7,5 7,5 5,5 6 6,5 6,5 5 5,5 5,5 6 4,5 5 5,5 6 103 116 114 111 81 91 90 87,5 66 75 74 72 56 64 63 61,5 37 41,5 41 39,5 29 32,5 32 31 23,5 26,5 26,5 26 6,5 7 7,5 8,5 6 6,5 7 7,5 5,5 6 6 6,5 112 126 124 120 87 99 97,5 95 72 81 80,5 78,5 60,5 69 68,5 67 43 48,5 48 46,5 34 38 38 36,5 28 31,5 31 30,5 23,5 26,5 26,5 26 7 8 8,5 9,5 6,5 7 7,5 7,5 6 6,5 7 7,5 5,5 6 6,5 7
1,0 m
0,8 m
0,6 m
37,5 9 42,5 10 42 10 41 10
5 20 5,5 23 22,5 6 6,5 22
H m
350 400 450 500 350 400 450 500 350 400 450 500 350 400 450 500
1,2 m
DN
Steel pipe dxs
mm
355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3 355,6 x 5,6 406,4 x 6,3 457,2 x 6,3 508,0 x 6,3
560 630 710 800 560 630 710 800 560 630 710 800 560 630 710 800 61,5 69 67,5 65,5 48 54 53 52 14,5 16 16 15,5 11,5 13 12,5 12,5 4 4,5 5 5,5 3,5 4,5 4,5 4,5 3,5 4 4 4 3,5 4 4,5 4,5 77 86 84,5 82 60 67,5 66,5 65 49 55,5 55 53,5 41,5 47 47 46 23 25,5 25 24,5 18 20 20,5 19,5 14,5 16,5 16,5 16 12,5 14 14 13,5 5,5 6 6,5 7 4,5 5 5,5 6 4 4,5 4,5 5 4 4,5 5 5 84,5 94,5 93 90 66 74 73 71 54 61 60,5 59 46 51,5 51,5 50 27,5 31 30,5 29,5 21,5 24 24 23,5 17,5 20 20 19 15 17 17 16,5 6 6,5 7 7,5 5 5,5 6 6,5 4,5 5 5,5 6 4 5 5,5 6 92 103 101 98 72 81 80 78 59 66,5 66 64 50 56,5 56 55 33 37 36 35 25,5 29 28,5 28 21 23,5 23,5 23 17,5 20 20 19,5 6 7 7,5 8 5,5 6 6,5 7 5 5,5 6 6,5 4,5 5 5,5 5,5 100 112 110 107 78 87,5 86,5 84 64 72 71 69,5 54 61 61 59,5 38,5 43 42,5 41 38 34 33,5 32,5 24,5 27,5 27,5 27 21 23,5 23,5 23 6,5 7,5 8 8,5 6,5 6,5 7 7,5 5,5 6 6,5 7 5 5,5 6 7
0,8 m
0,6 m
39,5 9,5 44 10,5 44 10,5 43 10 33,5 37,5 37,5 36,5 8 9 9 9
1,2 m
1,0 m
Lg FP
DS
PIPE2000 Ltd
UK Distributor

DN 20-200 Insulation thickness 3
FER 7.218
15.10.2003
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
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 10,5 2,5 11,5 3 15 3,5 17 4 21 5 23,5 5,5 27 6,5 31 7,5 33,5 8 39,5 9,5 45 10,5 0,5 0,5 1 1 1 1 1,5 1,5 2 2,5 3 13 14,5 18 21,5 26 29,5 34 39,5 42 49,5 56 4 4,5 5,5 6,5 7,5 8,5 10 11,5 12,5 14,5 16,5 1 1 1 1 1,5 1,5 2 2,5 2,5 3 3,5 0,5 1 1 1 1 1 1,5 1,5 2 2,5 3 14,5 16 20,5 23,5 28,5 32 37 42,5 46,5 54,5 61,5 4,5 5,5 6,5 7,5 9,5 10,5 12 14 15 18 20 1 1 1 1,5 1,5 1,5 2 2,5 3 3 4 15,5 17,5 22,5 25,5 31 35 40,5 46,5 50,5 59,5 67,5 5,5 6,5 8 9 11 12,5 14,5 16,5 18 21 24 1 1 1 1,5 1,5 1,5 2,5 3 3 3,5 4 1 1 1 1 1 1,5 2 2,5 2,5 3 3,5 17 19 24 27,5 34 38 44 50,5 55 64,5 73 6,5 7,5 9,5 10,5 13 14,5 17 19,5 21 25 28 1 1 1,5 1,5 1,5 2 3 3 4 4 4,5 1 1 1 1 1,5 1,5 2 2,5 3 3,5 4
H = 0,6 m
20 25 32 40 50 65 80 100 125 150 200
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
125 125 140 140 160 180 200 250 280 315 400
8 9 11,5 13 15,5 17,5 20,5 23,5 25,5 30,5 34,5
2 2 2,5 3 3,5 4 5 5,5 6 7 8,5
0,5 0,5 0,5 1 1 1 1 1 1,5 1,5 2,5
10 3 11 3,5 14 4 16 5 19,5 6 22 6,5 25,5 7,5 29,5 8,5 9,5 32 11,5 38 43,5 13
11 12 15,5 17,5 21,5 24,5 28 32,5 35,5 42 47,5
3,5 4 5 6 7 8 9 10,5 11,5 13,5 15,5
0,5 1 1 1 1 1,5 1,5 2,5 2,5 3 3,5
12 13 17 19,5 23,5 26,5 31 35,5 38,5 45,5 52
4 4,5 6 7 8,5 9,5 11 12,5 14 16 18,5
13 14,5 18,5 21 25,5 29 33,5 38,5 42 49,5 56
5 5,5 7 8 10 11 13 15 16 19 21,5
H = 0,8 m
20 25 32 40 50 65 80 100 125 150 200
26,9 x 2,65 33,7 x 2,3 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
125 124 140 140 160 180 200 250 280 315 400
6,5 7 9 10,5 12,5 14,5 16,5 19 21 24,5 28,5
1,5 1,5 2 2,5 3 3,5 4 4,5 5 6 7
0,5 0,5 0,5 0,5 1 1 1 1 1 1,5 2,5
2,5 8 2,5 9 11,5 3 4 13 16 4,5 18 5,5 20,5 6 24 7 26 7,5 31 9 35,5 10,5
0,5 0,5 1 1 1 1 1 1,5 1,5 2,5 3
8,5 3 9,5 3 12,5 4 14,5 4,5 17,5 5,5 19,5 6,5 23 7,5 26 8,5 28,5 9,5 11 34 38,5 12,5
0,5 0,5 1 1 1 1 1,5 2 2,5 3 3
9,5 10,5 13,5 15,5 19 21,5 25 28,5 31,5 37 42
3,5 4 5 5,5 6,5 7,5 9 10 11 13 15
0,5 1 1 1 1 1,5 1,5 2,5 2,5 3 3,5
10,5 11,5 14,5 17 20,5 23,5 27 31 34 40 46
4 4,5 5,5 6,5 8 9 10,5 12 13 15,5 17,5
1 1 1 1 1,5 1,5 2 2,5 2,5 3 3,5
H = 1,0 m
20 25 32 40 50 65 80 100 125 150 200
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
125 125 140 140 160 180 200 250 280 315 400
5,5 6 7,5 8,5 10,5 12 14 16 17,5 20,5 24
1,5 1,5 2 2 2,5 3 3,5 4 4 5 5,5
0,5 0,5 0,5 0,5 1 1 1 1 1 1,5 2
6,5 7,5 9,5 11 13 15 17,5 20 22 26 29,5
2 2 3 3 4 4,5 5 6 6,5 7,5 9
0,5 0,5 0,5 1 1 1 1 1 1,5 2 3
7,5 2,5 8 2,5 10,5 3,5 12 4 14,5 4,5 16,5 5,5 19 6 22 7 24 8 28,5 9,5 32,5 10,5
0,5 0,5 0,5 1 1 1 1 1,5 1,5 2,5 3
8 3 9 3 11,5 4 13 4,5 16 5,5 18 6,5 21 7,5 24 8,5 9,5 26 11 31 35,5 12,5
0,5 1 1 1 1 1 1 2 2,5 3 3
8,5 9,5 12,5 14 17 19,5 22,5 26 28,5 33,5 38,5
3,5 3,5 4,5 5,5 6,5 7,5 8,5 10 11 13 15
1 1 1 1 1 1,5 1,5 2,5 2,5 3 3,5
H = 1,2 m
Lg FP
DS
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Restricted expansion
FER 7.220
15.10.2003
Expansion hindered by earth friction

Temperature difference T1) [K] 50 60 70 80 90 100 110 120 0.1 120 110 100
Lm
0.2 0.3 0.4 Ratio L/Lmax 0.5 0.6 0.7 0.8 0.9 1.0 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, welded inner pipe pipe length L2) = 30 m H 3) = 0,8 m T = 100 K Lmax = 56 m (from worksheet 7.212) L/Lmax = 0,53 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
PIPE2000 Ltd
UK Distributor

Expansion up to 90 C, DN 20-125 Insulation 2, permissible without prestressing
FER 7.221
15.10.2003
16
Expansion l [mm]
H=0.70 m DS 2 TB=65 C
( T=55 C)
Sliding area
Adhesion area 139.7-250 114.3-225 88.9-180 The maximum permissible laying length may be exceeded. Temperature stress at 90 max. 190 N/mm2. Maximum permissible coverage height: see sheet 7.210 Expansion members: see sheet 7.230. Coverage correction factor: H = 0.60 m l graph + 12% H = 0.80 m l graph 12%
14 12 10 8 6 4 2 10
76.1-160
48.3-125 60.3-140 42.4-125 26.9-110 33.7-110
15
20
25
30
35
40
45
50
55
60
65
25
Expansion l [mm]
H=0.70 m DS 2 TB=80 C
( T=70 C)
Laying length of pipe L [m] 139.7-250 114.3-225 88.9-180 76.1-160 60.3-140 48.3-125 42.4-125 33.7-110 26.9-110
70
Example (sheet 7.230):

Pipe 76.1-160 (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 = 2.4 m DS = 2.4 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 = 2.4 m
35
Expansion l [mm]
H=0.70 m DS 2 TB=90 C
( T=80 C)
70
139.7-250 114.3-225 88.9-180 76.1-160 60.3-140 48.3-125 42.4-125 33.7-110 26.9-110 TB [ C] L [m] H [m] l [mm] DS [m] Fr' [kN/m] =190 N/mm 2 =0,5 =19 kN/m 3 Kd=0,463 Operating temperature Laying length of pipe Coverage height Expansion Expansion leg Frictional force Permissible stress Friction factor, 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
l
DS
Adhesion area Sliding area
NFP
Lg L
Fr'[kN/m]
70
PIPE2000 Ltd
UK Distributor

Expansion up to 90 C, DN 20-125 Insulation 3, permissible without prestressing
Adhesion area
FER 7.222
15.10.2003
14
Expansion l [mm]
H=0.70 m DS 3 TB=65 C
( T=55 C)
Sliding area
139.7-280 The maximum permissible laying length may be exceeded. Temperature stress at 90 max. 190 N/mm 2. Maximum permissible coverage height: see sheet 7.210 Expansion members: see sheet 7.230. Coverage correction factor: H = 0.60 m l graph + 12% H = 0.80 m l graph 12%
12 10 8 6
114.3-250 88.9-200 76.1-180 60.3-160 48.3-140 42.4-140 33.7-125 26.9-125
4 2 10 15 20 25 30 35 40 45 50
55
60
65
25
Expansion l [mm]
H=0.70 m DS 3 TB=80 C
( T=70 C)
70
139.7-280 88.9-200 114.3-250
Example (sheet 7.230):

Pipe 76.1-180 (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 = 2.2 m DS = 2.2 m l = 15 mm l = 15 mm
20
76.1-180 60.3-160 48.3-140
15
10
33.7-125 42.4-140 26.9-125
5 10 15 20 25 30 35 40 45 50
DK
DS = 2.2 m
55
60
65
30
Expansion l [mm]
H=0.70 m DS 3 TB=90 C
( T=80 C)
Laying length of pipe L [m] 139.7-280 114.3-250 88.9-200
25 20 15 10 5 10
70
76.1-180 60.3-160 48.3-140 42.4-140 33.7-125 26.9-125 TB [ C] L [m] H [m] l [mm] DS [m] Fr' [kN/m] =190 N/mm 2 =0,5 =19 kN/m 3 Kd=0,463 Operating temperature Laying length of pipe Coverage height Expansion Expansion leg Frictional force Permissible stress Friction factor, 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
l
DS
Adhesion area Sliding area
NFP
Lg L
Fr'[kN/m]
70
PIPE2000 Ltd
UK Distributor
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Expansion elements

Sheet 1
FER 7.230
15.10.2003
Requisite minimum length of the expansion leg, DS

The length and location of the expansion pads may be seen from the tables and from worksheet 7.232. The maximum permissible expansion for expansion is 45 mm. Operating pressure 16 bar. Expansion leg DS in m
L elbow
Do not add l of both sides!
DN
Expansion l in mm
10 1,2 1,4 1,6 1,8 2,1 2,4 2,7 2,9 3,2 3,4 15 1,3 1,6 1,9 2,2 2,5 2,8 3,6 3,8 4 4,2 20 1,6 2 2,2 2,6 2,9 3,3 4,5 4,7 5,1 5,2 25 1,7 2,2 2,5 2,9 3,3 3,6 5 5,5 5,9 6,0 30 2 2,5 2,7 3,3 3,7 4 5,9 6,5 7 7,1 35 2,1 2,6 3 3,5 4 4,5 6,5 7 7,5 7,8 40 2,3 3 3,2 3,9 4,5 50 2,6 3 3,6 4,6 5 60 2,9 3,4 4 5 5,7
l
DK DS
20, 25 32, 40 50 65, 80 100 125 150 200 250 300*
DS
5 5,6 6,5 7 8 9 8 9 11 8,2 10 12 8,6 10,2 12,5
L elbow
A = DS/2 where DN is 20 - 125; A = DS where DN is 150 - 250
DN
Expansion l in mm
10 1 1,3 1,5 1,7 1,8 2,3 2,3 2,7 2,8 3,1 15 1,2 1,5 2 2,1 2,2 2,5 2,7 2,8 3,3 3,7 20 1,4 1,8 2,2 2,4 2,5 2,9 3,2 3,2 3,7 4,1 25 1,5 2 2,4 2,6 2,8 3,2 3,5 3,6 4 4,6 30 1,7 2,3 2,7 2,9 3,1 3,5 3,9 4 4,5 5,1 35 1,9 2,4 2,8 3,1 3,3 3,7 4,1 4,4 4,7 5,2 60 2,1 2,4 2,7 40 2,1 2,6 3 3,4 3,5 4 4,5 4,7 5 5,9 50 2,4 2,9 3,4 3,7 4 4,5 5 5,5 6 6,6 60 2,6 3,2 3,7 4 4,5 4,9 5,5 6 7 7,6
FP
x
DS
20, 25 32, 40 50 65 80 100 125 150 200 250, 300*
l
DK A
Z elbow
l = l1+ l2 B = DS/2 where DN is 20 - 125; B = DS where DN is 150 - 250
DN
20, 25 32, 40 50 65, 80 100, 125 150, 200 250 300*
Expansion l = l1 + l2 in mm
15 1 1,2 1,3 20 1,2 1,4 1,5 30 1,5 1,6 1,8 40 1,6 2 2,3 50 1,9 2,3 2,5 70 2,3 2,6 3 80 2,4 2,8 3,2 90 2,5 3 3,5 100 2,7 3,2 3,7
l2 DS
DK l1 B
1,6 2,2 2 2,3 2,4
1,8 2,4 2,4 2,6 2,8
2,3 2,6 3,1 3,5 3,7
2,6 3,2 4 4,2 4,5
3 3,7 4,5 5 5,3
3,4 4,1 5,2 5,7 6
3,6 4,5 5,9 6,3 6,7
4 5 6,3 7 7,3
4,4 5,4 7 7,6 8
4,6 5,8 7,6 8 8,5
U elbow
l = l1+ l2 C = 1 m where DN is 20 - 50; C = 2 m where DN is 65 - 250 l1 DS/2 DK = expansion pads FP = fixed point
DN
20, 25 32, 40 50 65 80 100 125 150*
Expansion l = l1 + l2 in mm
30 1 1 1 1,6 1,6 1,65 1,65 1,65 40 1 1 1 1,6 1,6 1,65 1,65 1,65 50 1 1 1,2 1,6 1,6 1,65 1,65 2,2 60 1 1,2 1,4 1,6 1,6 1,65 2 2,5 70 1 1,3 1,5 1,6 1,6 2 2 2,8 80 1,2 1,4 1,6 2 2 2 2,3 3,3 90 1,3 1,5 1,8 2 2 2,3 2,5 3,5 100 1,4 1,7 2 2 2,2 2,5 2,7 4
DK
l2
DS/2
DS
*for larger dimensions, values must be calculated
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Expansion elements

Elbow < 90 (bend in the line); sheet 2
FER 7.231
15.10.2003
In order to determine the expansion leg length (DS) and expansion pad location (DK) for elbows < 90 , the lateral displacement (deflection) Q is a determining factor. The lateral displacement Q may be a maximum of 45 mm where the line is being laid using expansion pads. Anchors may if necessary be arranged before bends in the line, or else the elbows should be mechanically or thermally prestressed, causing the values for Q to be halved. The total lateral displacement Q should be used in all cases for calculating the thickness of the expansion areas without thermal prestressing. Determining the features of expansion legs DS DN 20 - DN 100: by Q [mm] from table of expansion elements L elbow, sheet 7.230 DN 125 - DN 250: by Q [mm] x 1.1, from table of expansion elements L elbow, sheet 7.230 Determining the features of expansion pads DK, DN 20 - DN 250 Thickness of the pad: Q [mm] is a determining factor Length: expansion leg length Location: see worksheet 7.232, location of expansion pads
Calculation of lateral displacement, 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 5,5 6 6,5 7 8 9 9,5 11 12 14 16 18,5 22,5 28 38 10 10 11 12 13 14 16 17,5 19 21,5 24 27,5 32 37,5 45 15 15 16 18 19,5 21,5 23,5 26 29 32 36 41 47,5
l1 = l2 [mm] 20 20 22 24 26 28,5 31,5 34,5 38,5 43 25 25 27 30 33 36 39 43 30 30 33 36 39 43 35 35 38 41,5 45,5 40 40 43,5 47,5
Lateral displacement Q1 = Q2 [mm]
If
l1 = l2 => Q = l/sin
+ l/tan
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Location of expansion pads
FER 7.232
15.10.2003
Expansion pads are located in the area of expansion elbows, T pieces and reducing sockets, in order to allow the FERWAG pipe to move in the earth. 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. At least one expansion pad should be fitted in the incoming pipe leg in the area of the pipe elbow. If additional expansion pad has to be taken up in the pipe leg, accordingly more expansion, the pads must be fitted there, according to the length alteration.
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, 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 = 3,9 m 1st layer = 4 pads (metre) 2nd layer = 1/2 of 1st layer = 2 pads (m) l
DS / 2
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Pressure losses

Average water temperature 80 C
FER 7.240
15.10.2003
Average water temperature 80 C

m Q 860 T
m = Flow rate in kg/h Q = Power requirement in kW T= Temp. difference, 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.
mm 21,6 29,1 37,2 43,1 54,5 70,3 82,5 107,1 132,5 160,3 210,1 263,0 312,7 344,4 393,8 444,6 495,4
25
0
100
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
3.6 3.2
3 2
1 10 000
2.4
2.8
50
5 000 4 000 3 000
2.0
1.8 1.6
1.4
40 32
0.6 0.8
1.2
1.0
Flow quantity, m
2 000
25
0,5
.1 1 000
DN
20
0,3 0,2
500 400 5
0,15
50
.1 100
10
200 300 20 30
500 50
1 1000
100
2000 3000 200 300
5000
Pa/m
(1 mmWC = 9.81 Pa)
500 mmWC/m
Pressure loss, p
Surface roughness value = 0.045 mm
Flow quantity, m
0.5
0.4 m/ s 0.3
PIPE2000 Ltd
UK Distributor
FER
Heat loss
7.241
26.8.2003
Method of laying: Distance between pipes: Earth temperature: Covering height: Conductivity of ground: Conductivity of PU foam:
2 pipes laid a = 0,20 m TE = 10 C H = 0,6 m E = 1,2 W/mK PU= 0,0260 W/mK
Heat loss during operation: q = U (TB - TE) [W/m] U = Specific heat losses [W/mK] TB = Average operating temperature [ C] TE = Average ground temperature [ C]
E TE
Heat losses q [W/m] for a pipe Type FERWAG 26,9 - 90 33,7 - 90 42,4 - 110 48,3 - 110 60,3 - 125 76,1 - 140 88,9 - 160 114,3 - 200 139,7 - 225 168,3 - 250 219,1 - 315 273,0 - 400 323,9 - 450 355,6 - 500 406,4 - 560 457,2 - 630 508,0 - 710 U-value [W/mK] 0.132 0.161 0.165 0.190 0.212 0.250 0.257 0.268 0.311 0.370 0.403 0.388 0.446 0.433 0.460 0.457 0.441 Operating temperature TB [C] 50 5.3 6.5 6.6 7.6 8.5 10.0 10.3 10.7 12.5 14.8 16.1 15.5 17.8 17.3 18.4 18.3 17.6 60 6.6 8.1 8.2 9.5 10.6 12.5 12.9 13.4 15.6 18.5 20.1 19.4 22.3 21.7 23.0 22.9 22.0 70 7.9 9.7 9.9 11.4 12.7 15.0 15.4 16.10 18.70 22.2 24.2 23.3 26.8 26.0 27.6 27.4 26.5 80 9.2 90 10.56 100 11.9 14.5 14.8 17.1 19.1 22.5 23.1 24.2 28.0 33.3 36.2 34.9 40.1 39.0 41.4 41.2 39.7 110 13.2 16.1 16.5 19.0 21.2 25.0 25.7 26.8 31.1 37.0 40.3 38.8 44.6 43.3 46.0 45.7 44.1 120 14.5 17.8 18.1 20.9 23.3 27.5 28.3 29.5 34.3 40.7 44.3 42.7 49.0 47.7 50.6 50.3 48.5 130 15.8 19.4 19.8 22.8 25.4 30.0 30.9 32.2 37.4 44.4 48.3 46.6 53.5 52.0 55.2 54.9 52.9
11.30 12.91 11.5 13.3 14.8 17.5 18.0 18.8 21.8 25.9 28.2 27.2 31.2 30.3 32.2 32.0 30.9 13.18 15.18 16.95 19.97 20.57 21.47 24.91 29.58 32.22 31.06 35.67 34.67 36.80 36.58 35.27
PIPE2000 Ltd
UK Distributor
FER
Heat loss
7.242
26.8.2003
2 pipes laid = 0,20 m a TE = 10 C H = 0,6 m E = 1,2 W/mK PU= 0,0260 W/mK
E TE
Heat losses q [W/m] for a pipe Type FERWAG 26,9 - 110 33,7 - 110 42,4 - 125 48,3 - 125 60,3 - 140 76,1 - 160 88,9 - 180 114,3 - 225 139,7 - 250 168,3 - 280 219,1 - 355 273,0- 450 323,9 - 500 355,6 - 560 406,4 - 630 457,2 - 710 508,0 - 800 U-value [W/mK] 0.113 0.134 0.145 0.165 0.184 0.207 0.216 0.225 0.260 0.295 0.312 0.304 0.347 0.334 0.346 0.343 0.334 Operating temperature TB [C] 50 4.5 5.4 5.8 6.6 7.4 8.3 8.7 9.0 10.4 11.8 12.5 12.2 13.9 13.4 13.8 13.7 13.4 60 5.6 6.7 7.3 8.2 9.2 10.3 10.8 11.3 13.0 14.8 15.6 15.2 17.4 16.7 17.3 17.2 16.7 70 6.8 8.0 8.7 9.9 11.0 12.4 13.0 13.5 15.6 17.7 18.7 18.2 20.8 20.1 20.8 20.6 20.1 80 7.9 9.4 10.2 11.5 12.9 14.5 15.1 15.8 18.2 20.7 21.9 21.3 24.3 23.4 24.2 24.0 23.4 90 9.0 10.7 11.6 13.2 14.7 16.5 17.3 18.0 20.8 23.6 25.0 24.3 27.8 26.7 27.7 27.5 26.8 100 10.2 12.0 13.1 14.8 16.6 18.6 19.5 20.3 23.4 26.6 28.1 27.4 31.3 30.1 31.2 30.9 30.1 110 11.3 13.4 14.5 16.5 18.4 20.7 21.6 22.5 26.0 29.5 31.2 30.4 34.7 33.4 34.6 34.3 33.4 120 12.4 14.7 16.0 18.1 20.3 22.7 23.8 24.8 28.6 32.5 34.4 33.4 38.2 36.8 38.1 37.8 36.8 130 13.5 16.1 17.4 19.7 22.1 24.8 26.0 27.0 31.2 35.4 37.5 36.5 41.7 40.1 41.5 41.2 40.1
PIPE2000 Ltd
UK Distributor
FER
Heat loss
7.243
26.8.2003
2 pipes laid a = 0,20 m TE = 10 C H = 0,6 m E = 1,2 W/mK PU= 0,0260 W/mK
E TE
Heat losses q [W/m] for a pipe Type FERWAG U-value [W/mK] Operating temperature TB [C] 50 4.1 4.8 5.3 5.9 6.4 7.2 7.6 8.1 8.8 9.8 10.2 60 5.2 6.0 6.6 7.4 8.0 9.0 9.5 10.1 11.0 12.2 12.8 70 6.2 7.2 7.9 8.8 9.6 10.8 11.4 12.2 13.3 14.6 15.3 80 7.2 8.5 9.2 10.3 11.2 12.6 13.3 14.2 15.5 17.1 17.9 90 8.3 9.7 10.5 11.8 12.8 14.4 15.2 16.2 17.7 19.5 20.4 100 9.3 10.9 11.9 13.3 14.4 16.1 17.1 18.2 19.9 22.0 23.0 110 10.4 12.1 13.2 14.7 16.0 17.9 19.0 20.3 22.1 24.4 25.5 120 11.4 13.3 14.5 16.2 17.6 19.7 20.9 22.3 24.3 26.8 28.1 130 12.4 14.5 15.8 17.7 19.2 21.5 22.8 24.3 26.5 29.3 30.6
26,9 - 125 0.104 33,7 - 125 42,4 - 140 48,3 - 140 60,3 - 160 76,1 - 180 88,9 - 200 114,3 - 250 139,7 - 280 168,3 - 315 219,1 - 400 0.121 0.132 0.147 0.160 0.179 0.190 0.203 0.221 0.244 0.255
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Laying direction

sheet 1
FER 7.250
15.10.2003
Location of branches
When locating branches, e.g. house connection lines to the main line, the particular features of the plastic sleeve pipe system must be observed. Even short connection lines of small dimension are held by the surrounding earth, so that their movement is restricted. The natural fixed point is again created within the length of the connection line, so that restoring forces act on the main line. The differing movements and force conditions of main lines and the connection line must therefore be taken into account in all cases.
Fig. 1 Connection line 6m 1.1 Direct connection

Main line NFP DK
Building
max. 6m
Fig. 2 Connection line > 6m 2.1 With anchor

max. 3m Main line FP DK
Building
> 6m
2.2 With L-elbow adjacent to main line

Building DK Main line NFP a b l >6m
NFP = natural fixed point DK = expansion pad
PIPE2000 Ltd
UK Distributor

sheet 2
FER 7.251
15.10.2003
Fig. 3 3.1 With L-elbow above main line (special manufacture)
Main line Building
DK
NFP
b
l
DK
NFP
Main line
NFP = natural fixed point DK = expansion pad
The leg length a depends on length l. Length b is based on the possible movement of the main line. The total length a + b should be surrounded by expansion pads. Expansions of the main line are also possible on connections in the adhesion area, as a result of subsequent repair measures, so that expansion pads must be fitted as a precautionary measure. The thickness of the expansion pads then needed can be reduced if the connection lines remain free and are laid with low stress, where the main line is prestressed.
PIPE2000 Ltd
UK Distributor

sheet 3
FER 7.252
15.10.2003
Pipe elbows, minimum bending radius

If district heating pipes have to be laid along roads, it may be necessary to follow curves in the road by means of elbows or bends in the pipe. In such cases, the elbows may be composed of several straight lengths of pipe. If the angle is up to 3 , these elbows can be created with bevelled cuts, but for greater angles, they can only be created with moulded fittings. This curvature of the line creates bending stresses in the pipe, making it necessary to specify a minimum radius of bending in relation to the pipe dimensions. 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 26.9 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
Rmin m 27 34 42 48 61 77 90 115 141 170 221 275 327 359 410 461 513
h = R [1
Rzul S h da Es
1 (s/(2 R))2] [m]
Rzul
= 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. Adhesion area: bends of a maximum of 5 are permissible in bevelled cuts. The bends must be laid without expansion pads.
Reductions in the adhesion area

Depending on the different stress cross-sections, there is bound to be a shift in the progression of the axial pressure force in the reduction. The higher pressure force in the area of the larger dimension may lead to an overload in the smaller stress cross-section, as a reaction force. This may be excluded either by avoiding reductions in the adhesion area, or by positioning a fixed point on the larger dimension side.
Fixed point
Reductions in the adhesion area
d1
d2
PIPE2000 Ltd
UK Distributor

sheet 4
FER 7.253
15.10.2003
Changes of direction over long line lengths
At
40 - 50
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 - 50
FP 45
The second, newly formed angle is always larger in both cases, thus achieving more gradual compensation.
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Connecting instruction

Transition flexible pipe to plastic sheath pipe
FER 7.254
15.10.2003
Laying instruction for transition flexible pipes on plastic sheath pipe (KMR)
Transit from T-Piece KMR

min 1.0 DS 2.0*
Transition with fixed point
2.0*
DK Pipe joint KMR

Rmin 2.0 m
FP
Pipe joint KMR
l
flexible pipe
Rmin
GFK Shell DK KMR *FHK: 5 m possible

The expansion l, owing to increase of temperature, must not be compensated by the flexibles district heating pipes. Installation of a fixed point.
*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.
4 Transition with Z elbow

1.0 m DS 2.5*
Transition with expansion elbow

1.0 m DS 2.5*
Pipe joint
DK KMR
Pipe joint
DK KMR
*FHK: 5 m possible
FP
*FHK: 5 m possible
If pipe length L resp. l is > than permitted, a fixed point should be included to allow exact check of the expansions.
Laying of Z elbow according of the expansion l, which must be compensated by section DS.
DS l FP DK
= Expansion leg = Expansion = Plastic sheath pipe - fixed point = Expansion pads
Design of expansion elements Location of expansion pads according the Chapter Plastic sheath pipe from the main catalogue.
l L
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe District heating pipe

Heating, Sanitary
FER 7.300
15.10.2003
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 26,9 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
Standard Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 length
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 2,8 3,0 4,1 4,5 5,9 7,3 9,3 13,4 16,4 21,2 31,5 45,8 59,2 67,4 85,7 98,5 124,0 2,5 2,8 3,6 4,7 5,2 6,9 8,6 11,0 15,8
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 3,2 3,5 4,5 4,9 6,3 7,9 9,9 14,6 17,7 23,0 34,6 50,4 64,5 74,6 94,9 109,8 141,0 2,9 3,2 4,1 5,1 5,5 7,3 9,2 11,6 16,9
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 0,37 0,67 1,09 1,46 2,33 3,88 5,35 9,01 13,79 20,18 34,67 54,33 76,80 93,16 121,80 155,25 192,75
kg/m 3,6 3,9 4,9 5,3 6,9 8,5 10,7 15,9 19,5 25,3 37,3
Heating
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
Sanitary
49 46 43 46 43 47 48 51 63
3,3 3,6 4,4 5,5 5,9 7,9 9,8 12,4 18,3
0,20 0,37 0,58 1,01 1,37 2,21 3,72 5,13 8,71
D external diameter, t - insulation thickness
16 m exceeding DN 200 on request
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Elbows, short-legged
FER 7.305
15.10.2003
90
R
5 85
R
Steel pipe
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 26,9 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
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 3d 3d 3d 3,5d 3,5d 3,5d 3,5d 3,5d 2,5d
L
m 0.5 0.5 0.5 0.5 0.5 0.65 0.65 0.65 0.65 0.65 1.0 1.0 1.0 1.0 1.0 1.0 1.1 0.5 0.5 0.5 0.5 0.5 0.5 0.6 0.6 0.6
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 0.5 0.5 0.5 0.5 0.5 0.65 0.65 0.65 0.65 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.5 0.5 0.5 0.5 0.5 0.5 0.5 0.6 0.6 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 0.5 0.5 0.5 0.5 0.5 0.65 0.65 0.65 0.65 1.0 1.0
D mm 125 125 140 140 160 180 200 250 280 315 400
Heating
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"
Sanitary
0.5 0.5 0.5 0.5 0.5 0.5 0.6 0.6 0.6
125 125 125 140 140 160 180 200 250
D
t mm 46 43 46 43 47 48 52 63 65 68 83 49 46 43 46 43 47 48 51 63
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Elbows 90 , 1.0 x 2.0 m
FER 7.310
15.10.2003
1000
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
Sanitary
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe T pieces, branch-off at 45

Heating, Insulation thickness 1
FER 7.312
15.10.2003
45 H [mm]
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

FER 7.313
15.10.2003
45 H [mm]
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

FER 7.314
15.10.2003
45 H [mm]
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
FERWAG -District heating pipe Parallel T pieces with steel pipe

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
H [mm]
PIPE2000 Ltd
UK Distributor

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
H [mm]
PIPE2000 Ltd
UK Distributor

FER 7.318
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 1.0 275 1.0 275 1.0 285 1.0 285 1.0 295 1.0 305 1.0 315 1.0 340 1.0 355 1.0 370 1.0 275 1.0 285 1.0 285 1.0 295 1.0 305 1.0 315 1.0 340 1.0 355 1.0 370 1.0 415 1.0 290 1.0 290 1.0 300 1.0 310 1.0 320 1.0 345 1.0 360 1.0 380 1.0 420 1.0 290 1.0 300 1.0 310 1.0 320 1.0 345 1.0 360 1.0 380 1.0 420 1.0 310 1.0 320 1.0 330 1.0 355 1.0 370 1.0 390 1.0 430 1.0 330 1.0 340 1.0 365 1.0 380 1.0 400 1.0 440 1.0 350 1.0 375 1.0 390 1.0 410 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
1.3 400 1.3 415 1.3 435 1.3 475 1.3 430 1.3 450 1.3 490 1.5 515 1.5 560 1.5 650
d1
DN
H [mm]
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Anchors
FER 7.320
15.10.2003
Disc - anchor, 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
DN
20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500
dxD
mm 26,9 x 110 33,7 x 110 42,4 x 125 48,3 x 125 60,3 x 140 76,1 x 160 88,9 x 180 114,3 x 225 139,7 x 250 168,3 x 280 219,1 x 355 273,0 x 450 323,9 x 500 355,6 x 560 406,4 x 630 457,2 x 710 508,0 x 800
kN
39 47 60 69 97 123 160 231,5 285 382,5 610,6 778,5 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. load in kN Ds = external diameter of the steel disc in mm

For mass of the concrete block (foundation mass) and concrete quality; see catalogue page FER 7.515
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Preinsulated valves for underground laying

Description, installation and assembly
FER 7.325
15.10.2003
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, i.e.: A. where the test conditions to AGFW are met (Code of Practice 2.5/volume: Flat laying of KMR for district heating pipes) B. where no screwed connections are located in the insulation area Range of application to max. 140 C, to max. 25 bar operating pressure processed, fully desalinated, deoxigenated, clean pipe water unsuitable for installation in bends and expansion leg areas Material Body made of steel, forged and welded Welded ends in St 35.8 to DIN 17175 Ball and wedge sealing surfaces (VAG gate valve) in stainless steel Actuating spindle in stainless steel Seals reinforced with Teflon Ball seal spring-supported Spindle seal, multiple, top seal replaceable Leak monitoring wire foamed in Heat insulation in PUR hard foam HDPE casing Testing Type test to AGFW Code of Practice 2.5, volume 4, members' information no. 32, 23.7.84 Inspection certificate to DIN 50049.2.2 Pressure test on each fitting to DIN 3230, sheet 3: BA, BN or BO (BN/BO leakage rate 1) same test for spindle seal any equivalent test Delivery and storage Ball valves in the open position Slide valves in ready to close position (to protect sealing surfaces) Protective caps on both pipe ends Installation Ball valves should only be welded in in the open position, with body protected from overheating (max. 150 C) Slide valves should only be fitted in ready to close position and in prescribed flow direction Expansion pads should be fitted as prescribed in the dome area
Care should be taken particularly to ensure sufficient freedom of movement of the dome Upper uninsulated spindle section must not stand in groundwater/water First switching operation must not take place until the line has been flushed through (open slide valve first) If there is a risk of frost, uncovered fittings must be completely emptied Grease steel parts on dome well At a provisional line end, exposed pipe end must be welded shut Position indication (ball valve only) Milled notch on actuating spindle square and pointer. OPEN/CLOSED lettering below bell-shaped stop or notch on square protector Actuation Close by turning clockwise to stop (90 in the case of the ball valve) Operation Suitable socket wrenches are to be used for switching For ball valves, plug-in gears with appropriate retaining parts are available (recommended from DN 100) Do not use force on the switching shaft Do not overtighten end stops Intermediate positions in the case of ball valves are not permissible owing to possible wear on the ball seals The prepared pipe water must not exhibit any solid material particles, owing to damage to the sealing faces. Maintenance Steel parts on the dome should be periodically cleaned and well greased Operate at least every 3 months, moving from OPEN to CLOSED several times until moving freely Ensure freedom of movement of the dome at all times Check groundwater level and condition Important The above rules must be observed. We and the valve manufacturer can accept no liability for damage caused by incorrect assembly, handling and maintenance.
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Shut-off valve Ball valve BALLOMAX
FER 7.330
15.10.2003
DN 20 - DN 250, PN 25, insulation thickness 3, except DN 200 & 250, insulation thickness 2 Reduced bore, except in the case of DN 20
Standard design
D1
SW - 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
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 26,9 x 3,2 33,7 x 3,2 42,4 x 3,2 48,3 x 3,2 60,3 x 3,6 76,1 x 3,6 88,9 x 4,0 114,3 x 4,0 139,7 x 4,5 168,3 x 5,0 219,1 x 6,3 273,0 x 7,1
Rules for assembly, operation and maintenance as per sheet FER 7.325 Fittings, see sheet FER 7.335
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Fitting for shut-off valve Ball valve
FER 7.335
15.10.2003
6-square Wrench
6-square protector
6-square Wrench, 27/32
4-square, 27/32 4-square, 27/32 1100 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)
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Pipe joints

Sealed with shrink-on SMPE-2D
FER 7.340
15.10.2003
The joints (subsequent insulations) between the pipes and the moulded fittings must be foamed and sealed on the site. The FERWAG system includes various types of sleeves. The subsequent insulation is normally undertaken by our fitters. 1. HDPE shrink-on sleeve with internal and external seal, SMPE-2D SMPE = non-interconnected shrink-on sleeve, 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. Before welding, the shrink-on sleeve must be pushed on to the pipe. The seal (internal seal) is fitted, and then the shrink-on sleeve is pushed over the joint. Next, the shrink-on sleeve is shrunk on to the casing pipe with a gentle gas flame. Before shrinking 6 2 5 1 4 For additional double security (2D), the shrink-on sleeve is sealed externally with a seal (external seal). It is possible to carry out a tightness test before foaming. PUR installation foam is used to provide the heat insulation. The filling holes are welded with a conical HDPE plug.
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, the sleeve is foamed using 2-component PUR foam.
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 inside of the shrink-on seal consists of a special hot-melt adhesive. When it is heated with an open flame, the shrink-on seal shrinks on to the sleeve and the pipe.
Foaming cannot take place in heavy rain or snow, or in cold weather (temperatures below 0 C).
1.1 Fitting the joint (repair joint)

If, for any reason, it is not possible to push the sleeve on before welding (2 short elbows, etc.) the sleeve may be divided and one half can be pushed on to either side, or else the sleeve must be slit open by our fitter and longitudinally welded on site. L = 720 780
2. HDPE reduction joint

Reduction sleeves are required when the pipe cross-section changes (pipe reduction, Tpieces, fixed points). Fitting and sealing follow the same procedure as for the HDPE sleeve.
600
D1
D2
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Pipe joint connection

End sockets, Shrink-on seal
FER 7.345
15.10.2003
3. HDPE end sockets

End sockets are required at provisional line ends in the earth. An end socket must always be fittet to protect PUR and steel pipes. Sealing is as in the case of the HDPE socket.
400
400
Shrink-on seal
FERWAG shrink-on seals protect the PUR insulation on the front of the FERWAG pipes from sprayed water, in buildings and shafts. In the case of standing water (flooding), the shrink-on seal is not necessarly watertight. The shink-on seal also prevents the PUR insulation at the end of the pipe from escaping in gas form.
Indicator wires
Material: Heat shrinkable, cross-linked polyolefin. Coating with sealing adhesive.
Important assembly instruction The FERWAG shrink-on seals should be pushed onto the end of the FERWAG pipes before welding the inner pipes, and protected from the effects of heat during welding.
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
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
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
PIPE2000 Ltd
UK Distributor
FERWAG-District heating pipe EWELCON-Fusion Welded Joint System Description
FER 7.351
15.10.2003
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- and gas-tight joints between pipes of plastic material, particularly standard plastic cased pre-insulated pipes with a HDPE casing as used in underground district heating mains. The EWELCON Fusion Welded Joint is an entirely prefabricated HDPE sheet which is wrapped around the two pipe ends immediately prior to welding. This simplifies the process of installation and is decisively important in achieving uniform and high joint quality, even when installing pipes under difficult and cramped conditions. The weld seam area can be cleaned and dried easily. These features make the EWELCON system particularly suitable for repair and cleanup jobs in existing mains networks. The HDPE sheet of the EWELCON Fusion Welded Joint is fitted with a heating element and a temperature sensor on the inside surface. The heating element, a meander strip of copper wire, forms a heating coil about 27 mm wide. This coil is placed so as to enclose the entire inner area of the collar when the sheet is wrapped around. The material of the sheet and the pipe along the meander strip is plasticized (melted) during welding, and becomes fused into a homogenous mass due to the high dilation pressure of the melt. After the molten zone has cooled down, the annular space has effectively been sealed shut by a weld seam some 30 mm wide. 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. This mechanism is put effectively into practice in the EWELCON system. The required pressure holding the weld surfaces together is reliably applied by a specially developed clamping device. The welding process is controlled by a microprocessor-controlled welding set, which monitors and stores the temperature of the fusion weld zone and heating coil throughout the welding process. This guarantees that the temperature of the fusion welding zone is largely independent of external influences (e. g. weather conditions), and is uniform from one welding job to the next. Every completed weld collar joint is subjected to a close visual examination as well as to a leak test, and is afterwards foamed out and the filling and ventilation drill holes closed off with weld plugs.
PIPE2000 Ltd
UK Distributor
FERWAG-District heating pipe

EWELCON Fusion welded joint Technical specifications
Heating coil Temperature sensor
FER 7.352
15.10.2003
Heating coil connection lead
B Sheet thickness: s
Heating coil connection lead
L
Dimensions Weight
s [mm] W 700 [kg]
Packing unit
Casing -
W1) [mm]
L [mm]
W 850 W 700 W 850 [kg] [pc.] [pc.]
[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
1.2 1.3 1.5 1.7 1.9 2.1 2.3 2.4 2.5 2.7 3.0 3.3 3.7 4.2 7.0 7.7 8.7 13.2 14.7 16.5 18.0
1.5 1.6 1.8 2.1 2.3 2.6 2.8 2.9 3.0 3.2 3.6 4.0 4.5 5.0 8.5 9.5 10.5 16.0 17.8 20.0 22.0
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 - DIN EN 32 162 (PE-HD)
Other dimensions on request.
225 mm are delivered in rolls. Joints up to 1) Standard width: W=700; Repair width: W=850
PIPE2000 Ltd
UK Distributor
FERWAG District heating pipe
EWELCON-S
Electro-Welding-Coupling
FER 7.353
24.09.04
The EWELCON -S Electro-Welding Coupling Sleeve is an integral part of the EWELCON-Family. It is the ideal complement to the approved EWELCON Welding Coupling Sleeve for the sleeve technique in the dimensional range below. The EWELCON-S Electro-Welding Coupling, the shrink sleeve and the pre-constructed heating elements will be supplied in separate packing units. The shrink sleeve provided with sun protection foil will already be inserted over the inner pipe - casing pipe weld. The heating elements will be supplied in handy packing units that protect against soiling and are suitable for construction sites. The heating elements will rstly be directly laid over the weld on both the KMR-ends. The weld seam area can be lightly cleaned and dried. This substantially contributes to the high and constant quality of the joint, especially in complex and cramped assembly conditions. These characteristics make the EWELCON-S System particularly suitable for rewiring. Repairs and reconstruction of existing pipelines can be carried out using the EWELCON Welding Coupling Sleeve for the sleeve technique. For reasons of quality, only tters who have completed the basic training by our commissioned trainers, who have acquired the necessary qualications, assemble these joints. The EWELCON Electro-Welding Coupling Sleeve shrink sleeve is made from bimodal PE-HD thus ensuring optimal long-term capacity. The serpentine heating element with copper wire terminals is embedded into one of the PE-HD lead frames. Each set of
heating elements is tted with a temperature sensor. The heating elements are then xed to the previously prepared casing pipe, they conform to component tolerances. Thanks to the special construction at the connection ends, constant welding conditions are ensured all round the circumference of the pipe. It will be possible to conventionally shrink the shrink sleeve onto the casing pipe using a soft liqueed petroleum gas ame; thus the heating elements will be optimally adhered. 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. These facts are substantly app l i e d i n t h e E W E L C O N - S s y s t e m . The necessary contact pressure will be provided by a specially developed clamping tool. The weld procedure will be regulated by a microprocessor-controlled welding device. Thus the weld bath temperature and the heating element temperature are monitored and saved throughout the whole weld process. In this way the weld bath temperature is largely independent of external perturbations (e.g. atmospheric conditions) and can be compared between welds. The parameters for each weld procedure are saved in the welding computer and can be read and documented at a later stage. In addition, each sleeve joint provided will undergo visual and density tests, be packed with foam and the vent holes sealed with weld stoppers.
PIPE2000 Ltd
UK Distributor
FERWAG District heating pipe
EWELCON-S
Electro-Welding-Coupling
FER 7.354
24.09.04
casing pipe
D [mm] 90 110 125 140 160 180 200 225 250 280
PE-HD-Casing pipe (before shrinkage)

Outer- DM [mm] 107 129 143 156 178 198 224 255 278 306 Wall thickness at least [mm] 2,9 2,9 3,0 3,4 3,5 3,5 3,8 4,3 4,4 4,9 600 24,5 L [mm] dB [mm]
Weld stopper
dS [mm]
Heating element set

Length LSS Width BSS [mm] [mm] 310 370 420 460
28
520 580 650 730 810 900
100
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Wall sealing ring Trench warning tape
FER 7.355
15.10.2003
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
Trench warning tape

Trench warning tape for laying underground Lenght 250 m Laying depth; see page FER 7.500
G UN EIT ! G EL UN RM HT AC RNW FE
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Wall duct (DOYMA)

Watertight, for civil defence structures
FER 7.360
15.10.2003
DOYMA wall duct Type C 40 for HDPE sleeve pipe diameter 110 to 800 mm
1 FERWAG pipe 2 Sealing set C, double sealing 3 Pipe liner made of fibre cement or coated core drill hole Suitability against pressurised water (Up to diameter 180 mm is sufficient, for nonpressurised water, sealing set A) Sealing capacity Impermeable to gas Load-bearing capacity Axial movements External Internal
D R
DOYMA wall duct type F/ZS, civil defence tested for HDPE sleeve pipe diameter 110 to 800 mm
External Internal 1 FERWAG pipe 2 Sealing set F/ZS, double sealing 3 Pipe liner made of fibre cement or coated core drill hole Suitability Against pressurised water Civil defence tested, T 86-008 Sealing capacity Impermeable to gas Load-bearing capacity Axial movements
D R
2 1
R Pipeline diameter PE mm 90 110, 125 140, 160 180, 200 225, 250 280, 315 355 400 450 500
D Pipe liner Core drill hole mm 150 200 250 300 350 400 450 500 600 700
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). Assembly / Trench filling In order to avoid deformation at the sealing point, special care should be taken during assembly or filling of the trench that no sinking of the pipes can subsequently occur. We also recommend that the pipe should be supported or hung inside the building. We cannot guarantee a good seal if these recommendations are not observed.
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Transport and storage
FER 7.400
15.10.2003
Transport
Delivery of the pipes, mouldings and fittings is generally undertaken by lorry, free of charge to the site / dispatch address. Owing to transfer of the risk at the time of delivery, it is recommended that the customer should appoint and make available a responsible person to receive the goods. In order to avoid costly waiting times, the unloading areas should be prepared accordingly.
Unloading, handling
Unloading is the responsibility of the customer / consignee. With the exception of pipes up to approximately DN 80, which can still be unloaded manually, lifting gear should be used for unloading. In order to avoid damage, in paticular of the heat insulation, the mouldings and pipes must not be thrown or rolled.
Moving with textile straps, min 100 mm wide Diagonal ropes, sufficiently far away from the sleeve pipe, only attach hooks to the steel pipe
Fig. 1: Hanging appliances for safe, protective handling
levelled sand bed
Fig. 2: Intermediate storage on a levelled sand bed

min 0,06 m Up to DN 150 min. 0.20 m DN 150 min. 0.25 m 0,4 max. 1,90 m
even surface
Fig. 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. The ends of the heat insulation and the steel pipe ends are treated with a damp protection product by the factory, but this is only of limited effect and is not effective on a long term basis. Mouldings and fittings should be stored on planks or wooden pallets, if possible under cover and dry.
max. 2,0 m
ca. 0,15 m
max. 2,0 m
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Civil engineering works Laying pipes
FER 7.500
15.10.2003
Laying pipes
It is vital to ensure that the PE outer sleeve is not damaged. Before welding, the PE socket pipes must be pushed over one pipe end in each case. Subsequently they are pulled back over the connection points in order to protect the insulation. When laying pipes, the monitoring wires must always be on top. Care must be taken that sufficient space is left around the sockets to set up the secondary insulation (at least 15 or 20 cm respectively below and between the sockets).
Civil engineering works

When excavating the pipe trenches, general building regulations must be observed. In difficult ground conditions, subsidence etc., an assembly proposal should be requested from us. The pipe trench must be kept free of water during the entire assembly period. The FERWAG district heating pipes should be laid on foam material pipe bases (sand sacks) which are approximately 1 m from the welding points in each case. After assembly, the line must be backfilled on all sides to match the profile of the trench, with noncohesive, round-edged sand (grain size 0 - 3/4 mm). The trench should then be filled to 30 cm below ground level with excavated material and compacted. Lay BRUGG warning strip, fill trench completely and compact.
Trench profile
EWELCON see down!

Washed sand, grain size 0 - 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 0.70 0.70 0.75 0.80 0.90 0.95 1.00 1.05 1.10 1.20 1.30 1.35 1.45 1.55 1.70 1.80 1.90 2.10 2.30 0.28 0.30 0.36 0.37 0.44 0.49 0.54 0.59 0.66 0.76 0.87 0.97 1.12 1.29 1.52 1.74 1.99 2.40 2.75
Line warning strip
min 0.15
0.10
ca. 0.20
Polystirol pipe base BRUGG every 3 m
0.20
ca. 0.20
min 0.60
.. . . . . ... . . . . . . . .. . .. . . . .. . .. . . . ... .. . . . . . .. . ... . . . . . .
0.40
.. . .. . .
EWELCON Fusion Welded Joints:

The head holes should be provided at every pipe joint, between the pipes min. 23 cm (see sheet 7.501)
*Sand contents according trench dimensions +10%
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Civil engineering works Laying pipes
FER 7.501
15.10.2003
Trench preparation around expansion pads

The trench around the expansion pads must be widened on both sides and deeper by at least 10 cm.
0.10
10 cm deeper
0.10
expansion pad 2- 4 m
Trench profile with head hole

Head holes should be provided for larger sizes at each weld seam, and at least at elbows and T pieces, so that the steel pipes can easily be welded together and the socket connections cleanly executed. The width of the normal trench profile can thereby be reduced.
0.20
0.35
B + 0.40
1.80
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Filling the pipe trenches
FER 7.502
15.10.2003
Covering material (sand)

round-edged washed sand, maximum grain size 4 mm (0 - 3/4 mm) proportion of ultra-fine grains 0.25 mm: if possible, not above 8%. non-cohesive, or with the lowest possible proportion of loam. As an alternative, so-called cyclonic sand (sludge sand), grain size 0-1 mm, is permissible (the waste from washed sand). Broken glass is not permissible as a substitute for sand in the case of FERWAG pipes (it is permissible for FLEXWELL ).
Embedding the pipe in sand (as shown on the Trench Profile sheet)
We recommend that welding pits and trench fillings are first filled with lean concrete. Cover the pipe apex to a height of at least 10 cm. Compacting - very important! Between, underneath and next to the pipes, the sand must be tamped down or compacted by hand, layer by layer, using suitable implements (such as a shovel or pick stem). No cavities must be created. Important: do not damage the seals or the pipe!
Residual filling of the pipe trench

The rest of the trench must be filled up with compactable material, such as excavation material and/or fine sand, and it must be well compacted. The national and local regulations govern the use of excavation material and/or the minimum layer thickness of the fine sand. Compact the material using a vibrator with a maximum surface pressure of 100 kPa. Earliest compression is after the pipe apex is covered up to a height of 30 cm. Do not forget: fit line warning tape and any protective pipes (not over the pipes approx. 30 cm. above the pipe apex). Topmost layer: incorporate humus or HMT, depending on the regulations. If the coverage is insufficient (minimum of 60 cm), or for areas subject to heavy traffic loads, pressure distribution plates must be incorporated above the sand layer in order to relieve the stress on the pipes.
As a general rule, all construction and safety regulations must be followed!
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe House Connection

Wall penetration Neoprene rubber
FER 7.505
15.10.2003
Wall duct
Wall sealing ring made of profiled neoprene rubber; see sheet FER 7.355
Cellar / shaft
Monitoring socket
FERWAG
Shrink-on seal see sheet FER 7.345
60
50
min.120
Wall penetration
B
Core drilled holes*
80
80
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
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Assembly rules
FER 7.510
15.10.2003
6, 12 m
min 150 mm
min 750
min 120 mm
< 300 mm
min 300 mm
min 120 mm

min 170 mm

PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Concrete block for anchor

For maximum anchor forces
FER 7.515
15.10.2003
. . .
. .
. . .
. . . . . . . . .
. . . . . .. . . .. . . . . .. .. . . . . . . . . . . .. . . . . . .. . . . . . .
. .
. .
. . . .
. . . . .
. . . . . .
a
A1
L*
L* must not be any wider!
In the event of different fixed point forces and ground conditions, the foundation dimensions must be calculated. Steel pipe Fixed point force Concrete block dimensions Distance between pipes, 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 26,9 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
Fs max
kN 66,5 83,7 107,2 123,1 172,4 219,9 284,1 412,9 507,6 680,9 1000,6 1388,5 1847 2052 2592 2920 3240
B
m 0,8 0,8 0,8 0,9 1,1 1,2 1,3 1,6 1,8 2,0 2,5 2,9 3,7 3,8 4,4 5,3 5,5
A1
m 0,40 0,40 0,40 0,45 0,55 0,65 0,80 0,95 1,15 1,40 1,70 2,10 2,25 2,40 2,40 2,60 2,60
A
m 0,8 0,8 0,8 0,9 1,0 1,1 1,3 1,5 1,7 2,0 2,4 2,9 3,1 3,3 3,3 3,5 3,5
* L
m 0,8 0,8 0,8 0,8 1,0 1,0 1,0 1,0 1,0 1,3 1,3 1,3 1,3 1,3 1,3 1,3 1,3
Basis of calculation for concrete block size Max. shearing force for 2 pipes: Fs max = 2As T, [ T = 165 N/mm2, T = 70 K ] Covering height H = 0,8 m Foundation dimensions are based on an angle of friction of = 32,5 for non-cohesive ground (friction factor = 0,64 ) Piled density = 18 kN/m3 Concrete quality P 350 to DIN 1045, water impermeable, with reinforcement
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Draining and venting arrangements
FER 7.520
15.10.2003
. . . . . . .. . .. .. . .. . .. .. .. . .. . . 150 .
. ... ..
. . . . . . . .
min. 120 2 1 150
. . . . . .. .. . . . . . . . 3 .. . . . .. . .. . . . .. . . 4 ..
. . . .
500
5 L as specified
1 3 L as specified 2
min 100
. . . . . .. . . . .. . . . . . .. . . . . . . ..
1000
dimensions in mm
1 Valve, supplied by customer 2 Shrink-on seal, supplied separately 3 Expansion pad
4 Sand 5 Lean-mixed concrete 6 Gravel for drainage
PIPE2000 Ltd
UK Distributor
FERWAG -District heating pipe Underground installation for ball valves
FER 7.525
15.10.2003
Inspection wells with heavy duty cast-iron lids
D2
D2
. . . . .. . . . . .. .. . . . ... .. . .... . .. ... .. .. . . . . . . .. . . . . . . . .. .
. .. .... . .. .. ... .. ... . .. . .. .
. . . . . ... . . .. . . . . .. . . . . .. . . .. . . . .... .. . . . . ... . . .
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. 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
PIPE2000 Ltd
UK Distributor
FER
Hot tapping
System description
7.530
26.8.2003
The BRUGG-Ballomax hot tapping system is used to where branches are made from main lines while the district heating system is working. The today used tools and components are the result of a long term development process which combines experience and new technology. This hot tapping method saves costs thanks to an economic and a safe executable drillling process withour service interruption. The hot tapping tool for weldable connections on steel pipes is designed for branches in the dimensions DN 25 up to DN 100, a maximum pressure of 25 bar and a temperature up to 140 (180) C.
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. All hot tapping valves are designed with a reduced opening. They can be used in district heating networks or other process pipelines. The hot tapping method features the possibility to install belated branches on every place of the Network. Hot tapping for bigger dimensions of branches can be carried out on request by an other system .
PIPE2000 Ltd
UK Distributor
FER
Hot tapping
Dimensions and measurements
7.531
26.8.2003
Dimensions and measurements
Hex key
*Ball diameter is not reduced
A1
A2
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. diam. main line min. diam. PE casing (outflow)
DN 25* 25 24 26
DN 32 25 24 41
DN 40* 40 40 68
DN 50 40 40 112
DN 65 50 48 200
DN 80 65 65 380
DN 100 80 79 620
33,7x2,9 42,4x2,9 48,3x2,9 60,3x3,1 76,1x3,1 88,9x3,2 114,3x3,6 37,0x5,8 37,0x5,8 54,0x6,7 54,0x6,7 63,0x7,0 82,0x8,0 100,0x9,0 60,3 46,0 145,0 10 1,3 DN 32 110 60,3 46,0 145,0 10 1,2 DN 40 125 88,9 57,0 200,0 10 3,5 DN 50 125 88,9 57,0 200,0 10 3,4 DN 65 140 114,3 70,0 260,0 14 5,1 DN 80 160 133,0 80,0 265,0 14 6,7 DN 100 180 159,0 92,0 275,0 14 11,3 DN 125 225
bigger dimensions with other system on request
Application for branches without reduced diameter

Anschluss - Dimensionen Hot tapping valve Pipe diameter Steel-pipe reduction Diameter main line min. diam. 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
33,7x2,9 48,3x2,9 48,3x2,9 76,1x3,1 88,9x3,2 114,3x3,6
PIPE2000 Ltd
UK Distributor
FER
Hot tapping
Preparation weld seam and weld composition
7.532
26.8.2003
Preparation weld seam and weld composition

Welding end with weld seam preparation
Outer thread for hot tapping tool
Hex bolt - to be tighted (blocked in the ball) and welded together with the body (around) after placing in operation of the brach pipe.
Place the hot tapping valve without crack directly on the main line
Weld composition: Electric welding (2-3 layers) with Kb-electrodes, basic Type E5155B10 DIN 1913 2.5 mm
Take care that no welding material is getting into the hot tapping valve! Chamfering of the welding end according DIN 2559, 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
WIREM
PIPE2000 Ltd
District Heating Control Table of contents
WIREM 10.0
15.10.2003
10.0 10.1
10.100 10.110 10.120
Table of contents General system description

System description Functional description Measuring description
10.2
10.200 10.210
Design and reference charts

Design and reference charts Welding plans
10.3
10.300 10.310 10.320 10.330 10.340
Control unit U89A

Unit description, technical data Unit description, page 2 Fault handling procedure Electrical circuit, wiring diagram Option: Remote control transmission
CH
District Heating Control General system description
WIREM 10.100
15.10.2003
The piping for district heating laid out underground, is nowadays mostly equipped with control equipment, to monitor its operation. The advantage of this lies in the early detection and quick location of damages. Feeler wires melted into the thermal insulation in the factory perform, together with the monitoring equipment, a great number of functions. The safety of the installation is improved and the costs of repairs reduced. The systems FLEXWELL -cable, FERWAGpipe and CASAFLEX -district heating pipe of BRUGG Pipe Systems are equipped ex-works with the Reference Resistance Measurement system (WIREM ). Other monitoring systems can be supplied if specified. The BRUGG STEEL PROTECTION PIPE is available as an option. WIREM and BRANDES are compatible systems. 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. Supply of data on the state of the insulation. Detection and identification of the feeler conductor making contact with the inner pipe, a breakage or damages anywhere in the circuit can be detected and identified.
An entry of humidity through e.g. a faulty welding seam, loose sleeve or external damage can be detected, monitored located and reported during operation. A display reports a failure or interference basing on early detection and self diagnostics. Feeler gauges connected to the control system and situated in wells, can produce an alarm in case of entry of water. Alarms, measurands, state of contacts and other data can be registered and transmitted to other systems. The network of monitoring, measuring and locating units can be built up at will depending on conditions of volume of data required and network size. 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, testing over dialog and storing of results, as well as data transmission to other computers and printers.
CH
District Heating Control Functional aspects
WIREM 10.110
15.10.2003
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. In the FERWAG - and CASAFLEX - pipe they run parallel, on eiter side of the Structure of the feeler conductor
1. Gaps in insulation at regular intervals for wet contact detection 2. PTFE-Insulation, coloured red 3. NiCr conductor
inner pipe and about half way through the insulation, while in the flexible system FLEXWELL -cable, they are wound around the inner pipe and run close to each other. 2 3
Structure of the return wire

1. Copper core 2. FEP-Insulation, coloured green
The physical principle for monitoring, as well as for fault location, is the resistance reference method (WIREM ), which is that of the unloaded resistance bridge principle. A defined voltage is applied between the feeler wire, embedded in the thermal insulation, and the pipe (see figure). Should the isolation resistance diminish, as will happen when a wet spot occurs, a voltage rise will be registered in the monitoring instrument and an alarm will be released. The perforations allow an accurate evaluation of the wet spots regarding their intensity in the whole monitored spectrum, from dry with over 50M to wet with under 10K insulation resistance. For the monitoring itself, an FEP isolated, copper return wire is laid out parallel to the feeler wire. Both wires form a feeler loop (see figures), which can attain 1000 m in length and therefore is able to monitor 1000 m of piping. Branches of piping are also followed by branches in feeler wires, i.e. feeler wire out, return wire back (see figure).
Feeler wire (red)
Layout of the feeler loop

Feeler wire (red) Return wire (green)
S
Loop
Return wire (green)
Pipe center line
Insulation
Monitoring unit
Feeler loop with branch-off
The reference resistance determines the tolerance threshold and is adjustable. Monitoring of the thermal insulation is performed by a special feeler wire (see figure). The wire itself is protected against direct contacts to metal, by a thermally stable PTFE sleeving. A contact between the naked NiCr wire and wet spots occurs in perforations along the PTFE sleeve. This permits monitoring over the entire length of the feeler wire.
Large pipe networks of several kilometers in length are divided into monitoring sections of under 1000 meters. A monitoring unit is installed at each section.
CH
District Heating Control Determining the fault location
WIREM 10.120
15.10.2003

To locate the wet spot or contact fault, a voltage U is applied across the loop. At the end of the feeler loop, a part voltage U1 caused by the wet spot, is measured between the inner pipe and the feeler cable. The result is expressed not in Volt but in % of the applied voltage. Since the feeler wire has a relatively high resistance of 5.7 /m and the return wire near zero , 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, but the location of the break has to be performed manually by other means. The usual method used in such cases is the time delay measurement. A capacitance measurement can also be used. To avoid subsequent faults and gaps in the feeler loop, strict quality control and measurement checks during production are applied in general . They target, among others, the solidity of all wire connections.
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, as it is balanced out in the measurement concept.

100 %
Fault location unit
x%
Wet spot
Feeler wire (red)
U1
Return wire (green)
CH
District Heating Control Design and Reference Drawings
WIREM 10.200
15.10.2003
Design
The design of the control circuit is done parallel to the design of the piping. The whole installation is then divided into separate loops with a maximal length of 1000 to 1200 m per unit. All units can be placed centrally in one building. For future expansion of the network, it is good practice to insert some spare cables beside the pipes.
Reference drawings (Wiring diagrams)

Control units
Feeler Return 1 2 U89A 1 3 1 2 U89A 2 3
The monitoring system BRANDES

CrNi wire (red) Cu wire (green)
TT 1,5 mm2, or U 72 0,8 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 = 5.7 /m Forward 2219 Return 2220 Insulation resistance (IR) Grade BS-MH-2 Forward 0 = >50 M Return 0 = >50 M
CH
District Heating Control Reference Drawings Welding plans

Reference Drawing Welding plan
View A
WIREM 10.210
15.10.2003
Reference Drawings
To find the exact location of the fault above earth, it is very important to have access to reference drawings. The more precise these are, the easier and quicker the spot can be found. Welding plans have proved to be the best reference.

0.95
1.05 Elbow 90 0.95x1.05
A
0.95 6.57 1.82 12.0 12.0 7.9 Bg 61 , 0.65x0.65
Materials
Pipe FER 60.3-140 FER 76.1-160 FER 88.9-180 Stand. L Elbow [m] 6m 6m 12 m 0.5x0.5 0.65x0.65 0.65x0.65
FER 88.9-180
Bg 61 , 0.65x0.65
Venting
Bg 86 0.65x0.65
1.0
1.0
7.9 Bg 86 , 0.65x0.65
1.0
1.0
12.0 12.0 12.0 Bg 90 , 0.65x0.65 Bg 90 , 1.56x0.92 12.0
12.0
12.0
12.0
Bl
oc
Bg
FER FE 60.3 R7 -14 0 6.1 -16 Bg 90 0 ,0

85 ,0
.50 x0
k3
12.0
12.0
12.0 4.6 5.6 6.0 6.0 6.0 Bg 90 , 0.65x0.65 6.0 5.8 5.8 Bg 90 , 0.50x0.50 Bg 90 , 0.50x0.50 Bg 90 , 0.50x0.50 6.0 6.0 4.3 1.0 6.0 6.0 4.92 1.9 6.0 3.75 5.0 1.0 6.0 6.0 1.77 12.0 1.0 Bg 76.5 , 0.65x0.65 12.0 Bg 90 12.0 12.0 6.74
12.0
6.52 12.0 1.56 0.92
.65
.50
Block 4
x0
.65
5.84 4.65
6.0 6.0
6.0 5.84
6.0
12.0
5.23
6.0
12.0
Bg 90 , 0.65x0.65
6.0
(downward)
4.6 6.0
1.0
5.0
Bg 85 , 0.65x0.65
1.0
6.0 5.81 0.55
Bg = Elbow
Draining, DN 32
1.0
T-pieces
Blo
ck
8.45
8.0
CH
District Heating Control Unit description U89A technical data
WIREM 10.300
15.10.2003
Unit description
Function
The instrument monitors the electrical insulation resistance between the detector lead and pipe (earth). A break in the detector lead or earth leakage (<5 kOhm) is signalled simultaneously. The earth leakage signalling can also be used as a shaft monitor. By connecting a level switch (e.g. EHS-JOLA 6M, Otto Fischer AG) between the direct lead return and pipe. The unit is suitable for fitting in a switch cabinet and for surface mounting.
Surface mounting
Button and 2 signal lamps are mounted on the instrument. Lamps green : operating red : fault
Brugg Ro hrsystem AG 5200 Brugg
Fitting in switch cabinet

For operation, an additional button and 2 signal lamps must be fitted in the cabinet door.
Fault
If the electrical insulation resistance is exceeded (moist insulation), if there is a failure or earth leakage (shaft monitoring), a horn, lamp or central alarm system is triggered. At the same time the fault signal lamp lights up on the instrument or cabinet door as follows:
Insulation moist Failure in monitoring loop Earth leakage, shaft monitoring with float switch
CH
District Heating Control Unit description U89A
WIREM 10.310
15.10.2003
Alarm output for external fault display The instrument has an alarm output to supply a horn, a lamp or a central alarm system. Acknowledgement By pressing the double function button (instrument test + acknowledgment button), the alarm output is switched off. The fault lamp remains alight until the fault has been remedied. Instrument test The instrument is maintenance-free. However, we recommend that you implement a monthly operating check. By pressing the button a fault is simulated. As a result, a check is made of all the electronics. During this, the fault lamp must be alight. During the test, the alarm output can be blocked or connected through by means of the switch fitted on the printed circuit board. The switch should be set to the required position during installation.
Technical data Supply voltage Voltage tolerance Power consumption Output Breaking capacity Cable inlet Connection type Protection system Ambient temperature Max. loop length
220 V 50 Hz 10 % 1.5 VA High-tension current contact max. 250 V AC 5 A (alternating current) max. 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, max. 2 x 1.5 mm2 IP 40 -10 to +50 C 0 to 10 kOhm (0 - 1200 m)
Casing dimensions
150
Break through for wall fastening 4.2 mm.
Break through for wall fastening 4.2 mm Break through for clamp fastening to 35 mm standard bar DIN 46277. Clamp in instrument.
107
75 View A
CH
District Heating Control Fault handling procedure
WIREM 10.320
15.10.2003
Procedure in the event of a fault
Caution Before opening the instrument, switch off the main switch
Possible fault causes

Fault 1. Green lamp not alight 2. 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. Loop. Remove terminal 1 + 2 2. Connect terminal 1 + 2 3. Press button (instrument test) 4. Connect terminals 1, 2 + 5 Fault lamp display must flash must go out must be alight must flash intermittently
If all 4 states are OK, then the cause should be sought in the pipe system (sockets, connecting lines).
CH
District Heating Control Electrical circuit, wiring diagram
WIREM 10.330
15.10.2003
Caution: Before opening the instrument, switch off main switch.
Not applicable for surface mounting

Terminals on pc board Switch blocked free Alarm output for "Fault external" in instrument test Weak current max. 12 V Terminal 3 potential free With direct connection terminals A - B no connection terminal 3 Weak current Breaking capacity maximum 250 V AC 5A, 30 V DC 5A
Contact load 250 V AC / 5 A
Monitoring socket
1 2 3
Cu (green or blue)
DH - Line
Connection pipe terminal C or 1 Shaft monitoring with float switch * Fault Cabinet external
DH - Line
Assembly limit BRUGG TT 1,5 mm 2 , or U 72 0,8 mm

4 5 6 7 8 9 10 11 12 13 14 15 N P
red green
Acknowledge instrument test Supply for fault external horn, lamp, collective alarm fault insulation moist break loop short circuit shaft Supply for display
PC board connectors
operating
Be sure to connect earth, in special cases connect to pipe. Mains 220 V 1.5 VA
50 mA
16
* e.g. level regulator EHS - JOLA 6 M

Otto Fischer AG
Wiring for branched network, example only

Wiring principle: Always probe loop
Wiring between the sockets by an electrician (by the owner) BRUGG
C
DH - Line
Cabinet C
DH - Line
Monitoring socket
1 2 3
Terminals
FW - Leitung
Cu (green or blue)

DH - Line
A
FW - Leitung DH - Line
DH - Line
TT 1,5 mm 2 or U 72 0,8 mm ,
CH
District Heating Control Option: Remote control transmission
WIREM 10.340
15.10.2003
Version for remote control transmission e.g. "Ridat Rittmeyer"

The U 89 instrument is also suitable for computer controlled remote transmission. In this case, there is no need for wiring the cabinet door. These outputs are wired as followed by a change on the PC board.
Terminals 9 to 13
Logical states
13 R1
Everything OK
R2 I
12 R1
Insulation moist
11
Earth leakage in shaft monitoring with level switch Detector lead has short circuit to earth
10 R2
Break in loop
The functions of the network and fault lamp on the instrument, and also "Fault external" (terminals 6 to 8) remain unchanged. The instrument can be tested or the "Fault external" acknowledged by a relay contact in the remote control transmission.
CH
PIPE2000 Ltd

Pipes Full Data V11006 06jul09

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TECHNICAL INFORMATION SHEETS

TECHNICAL INFORMATION SHEETS P RE - INSULATED P IPES

The Professional Solution for Engineers

CALPEX district heating pipe

1.2 1.200 1.205 1.210 1.215 1.220 1.225

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

3. Protective casing Materials: Purpose:

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

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

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

CALPEX UNO/DUO range

CALPEX in straight lengths: Dimensions: DN 150

CALPEX heating, 6 bar, UNO

CALPEX heating, 6 bar, DUO

25 + 25/ 91 32 + 32/111 40 + 40/126 50 + 50/162 63 + 63/182

CALPEX district heating pipe

CALPEX UNO/DUO range

CALPEX sanitary, 10 bar, UNO

CALPEX sanitary, 10 bar, DUO

28 + 22/ 91 32 + 22/111 40 + 28/126 50 + 32/126

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

CALPEX QUADRIGA range

s1 d PEXa carrier pipe PUR foam PE foil LLD-PE casing

CALPEX , heating 6 bar, sanitary 10 bar, QUADRIGA

H25 + 25/S28 + 22/142

H32 + 32/S28 + 22/142

H32 + 32/S32 + 22/142

H40 + 40/S40 + 28/162

UK DISTRIBUTOR PIPE2000 Ltd 15.04.2009

CALPEX district heating pipe

Pressure loss chart

125/102.2 mm (DN 125, 5) 110/90.0 mm (DN 100, 4)

90/73.6 mm (DN 80, 3) 75/61.4 mm (DN 65, 2) 63/51.4 mm (DN 50, 2)

Mass ow rate m [kg/h]

40/32.6 mm (DN 32, 1)

32/26.2 mm (DN 25, 1)

25/20.4 mm (DN 20, )

1200 1400 1600

Pressure loss p [Pa/m]

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

Pressure loss chart

Mass ow rate m [kg/h]

63/45.6 mm (DN 50, 2)

50/36.2 mm (DN 40, 1)

40/29.0 mm (DN 32, 1)

32/23.2 mm (DN 25, 1) 28/20.0 mm (DN 20, )

22/16.0 mm (DN 16, 58)

Pressure loss p [Pa/m]

UK DISTRIBUTOR PIPE2000 Ltd

CALPEX district heating pipe

(ow and return in one pipe)

UK DISTRIBUTOR PIPE2000 Ltd 15.04.2009

CALPEX district heating pipe

70 9.2 11.2 12.8 13.8 14.0 16.0 9.2 10.0 12.2

UK DISTRIBUTOR PIPE2000 Ltd 15.04.2009

70 17.0 14.2 15.7 20.8