SEALS SEALS E.1. E.1.1

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1 SEALS E.1. Though "elastomer" is synonymous with "rubber", it is more formally a polymer that can be modified to a state exhibiting little plastic flow and quick or nearly complete recovery from an extending force, and upon immediate release of the stress, will return to approximately its own shape. According to the definition of the American Society for Testing and Materials (ASTM) for the term "elastomer" it is essential that: An elastomer part must not break when stretched approximately 100%. After being stretched 100%, held for 5 minutes and then released, it must retract to within 10% of its original length within 5 minutes after release. SEALS Resistance to the media As used throughout this manual, the term "media" denotes the substance retained by the seal like liquids, gasses, or a mixture of both, powders or solids. The chemical effect of the media on the seal is of prime importance. It must not alter the operational characteristics or reduce the life expectancy of the seal. Excessive deterioration of the seal must be avoided. It is easy, however, to be misled on this point. A significant amount of volume shrinkage usually results in premature leakage of any seal, whether static or dynamic. On the other hand, a compound that swells excessively, or develops a large increase or decrease in hardness, tensile strength, or elongation, will often continue to serve well for a long time as a static seal, in spite of undesirable test results on elastomer compounds. The first step in selecting the correct material is to select an elastomer that is compatible with the chemical environment. Compound A compound is a mixture of base polymer(s) and other chemicals which form a finished rubber material. More precisely, the term 'compound' refers to a specific blend of ingredients tailored for particular characteristics required to optimize performance in some specific service. The basis of compound design is selection of the polymer type. To the elastomer, the compounder may add reinforcing agents, such as carbon black, coloured pigments, curing or vulcanizing agents, activators, plasticizers, accelerators, anti-oxidants or anti-radiation addiditives. There may be hundreds of such combinations. The physics of rubber Rubber is composed of long chains of randomly oriented molecules. These long chains are subject to entanglement and cross-linking. The entanglement has a significant impact on the viscoelastic properties such as stress relaxation. When a rubber is exposed to stress or strain energy, internal rearrangements such as rotation and extension of the polymer chains occur. These changes occur as a function of the energy applied or the duration and rate of application, as well as the temperature at which the energy is applied. ISO 1629 identifies approximately 25 elastomeric types. E.1.1

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3 SEAL MATERIALS E.1. NBR / Acrylonitrile butadiene Nitrile, chemically, is a copolymer of butadiene and acrylonitrile. Acrylonitrile content varies in commercial products from 18% to 50%. As the nitrile content increases, resistance to petroleum base oils and hydrocarbon fuels increases, but low temperature flexibility decreases. Due to its excellent resistance to petroleum products, and its ability to be compounded for service over a temperature range of -30 C / -22 F to 120 C / 248 F nitrile is the most widely used elastomer in the seal industry today. Also many military rubber specifications for fuel and oil resistant seals require nitrile based compounds. It should be mentioned that to obtain good resistance to low temperature, it is often necessary to sacrifice some high temperature resistance. Nitrile compounds are superior to most elastomers with regard to compression set, tear, and abrasion resistance. Nitrile compounds do not possess good resistance to ozone, sunlight, or weather. They should not be stored near electric motors or other ozone generating equipment. They should be kept from direct sunlight. However, this can be improved through compounding. NBR is the standard material for hydraulics and pneumatics. NBR resists oil-based hydraulic fluids, fats, animal and vegetable oils, flame retardant liquids (HFA, HFB, HFC), grease, water and air. SEALS EPDM - EPM / Ethylene Propylene, and Ethylene Propylene Diene rubber Ethylene propylene rubber is an elastomer prepared from ethylene and propylene monomers (ethylene propylene copolymer) and at times with an amount of a third monomer (ethylene propylene terpolymers). Ethylene propylene rubber has a temperature range of -40 C / -40 F to 145 C / 293 F, depending on the curing system. It has a great acceptance in the sealing world because of its excellent resistance to heat, water and steam, alkali, mild acidic and oxygenated solvents, ozone, and sunlight. These compounds also withstand the affect of brake fluids and other phosphate ester-based hydraulic fluids. EPDM compounds are not recommended for gasoline, petroleum oil and grease, and hydrocarbon environments. Special EPDM compounds have good resistance to steam. FPM - FKM / Fluorocarbon rubber Fluorocarbon elastomers have grown to major importance in the seal industry. Due to its wide range of chemical compatibility, temperature range, low compression set, and excellent aging characteristics, fluorocarbon rubber is the most significant single elastomer developed in recent history. Fluorocarbon elastomers are highly fluorinated carbon-based polymers used in applications to resist harsh chemical and ozone attack. The working temperature range is considered to be -30 C / -22 F to +200 C / 392 F. But for short working periods it will take even higher temperatures. Special compounds having improved chemical resistance are also available with new types always being developed. Generally speaking, with increasing fluorine content, resistance to chemical attack is improved while low temperature characteristics are diminished. There are, however, specialty grade fluorocarbons that can provide high fluorine content with low temperature properties. FPM resists mineral oils and greases, aliphatic, aromatic and also special chlorinated hydrocarbons, petrol, diesel fuels, silicone oils and greases. It is suitable for high vacuum applications. Many fluorocarbon compounds have a higher than normal mould shrinkage rate, molds for fluorocarbon products are often different from molds for Nitrile. AU - EU / Polyurethane rubber (PU) Polyurethanes (Polyester-urethane AU and Polyether-urethane EU) exhibit outstanding mechanical and physical properties in comparison with other elastomers. Urethanes provide outstanding resistance to abrasion and tear and have the highest available tensile strength among all elastomers while providing good elongation characteristics. Ether based urethanes (EU) are directed toward low temperature flexibility applications. The ester based urethanes (AU) provide improved abrasion, heat, and oil swell resistance. Over a temperature range of -40 C / -40 F up to 82 C / 180 F, resistance to petroleum based oils, hydrocarbon fuels, oxygen, ozone and weathering is good. However, polyurethanes quickly deteriorate when exposed to acids, ketones and chlorinated hydrocarbons. Certain types of polyester-urethanes (AU) are also sensitive to water and humidity. Polyether-urethanes (EU) offer better resistance to water and humidity. The inherent toughness and abrasion resistance of polyurethane (EU) seals is particularly desirable in hydraulic systems where high pressures, shock loads, wide metal tolerances, or abrasive contamination is anticipated. E.1.3

4 SEAL MATERIALS CSM / Chlorosulfonated polyethylene CSM show excellent resistance to weathering and give good service in many media. It is inherent ozone resistant and shows a very low erosion rate in rain and hail, regardless of colour. CSM provides good oil, acid, and flame resistance. The temperature range is -40 C / -40 F to 140 C / 284 F FEP / Fluorinated ethylene propylene FEP is a copolymer of tetrafluorethylene and hexafluorpropylene. FEP has a lower melting point than PTFE making it suitable for injection moulding. FEP is used for encapsulation with for example Silicone square seals. FEP has a wide spectrum of chemical compatibility and temperature range and excellent aging characteristics. The temperature range for Silicone - FEP encapsulated seals is -60 C / -76 F to 205 C / 401 F. PTFE / Poly tetrafluorethylene Poly TetraFluoroEthylene is a fluorocarbon-based polymer and is commonly abbreviated PTFE. PTFE's mechanical properties are low compared to other plastics, but its properties remain at a useful level over a wide temperature range of -30 C / -22 F to 300 C / 572 F. Mechanical properties are often enhanced by adding fillers. It has excellent thermal and electrical insulation properties and a low coefficient of friction. PTFE is very dense and cannot be melt processed - it must be compressed and sintered to form useful shapes. PTFE + 15% graphite / Poly tetrafluorethylene + 15% graphite PTFE seals filled with 15% graphite have a low coefficient of friction compared to other filled PTFE materials. Compared to unmodified PTFE they show a higher flexural modulus and surface hardness up to 97 Shore A, a lower notched impact strength, tensile strength, elongation at break and electrical characteristics compared with unmodified PTFE. VMQ / MVQ / Silicone rubber Silicones are a group of elastomeric materials made from silicone, oxygen, hydrogen, and carbon. Extreme temperature range and low temperature flexibility are characteristics of silicone compounds. As a group, silicones have poor tensile strength, tear resistance, and abrasion resistance. Special compounds have been developed with exceptional heat and compression set resistance. High strength compounds have also been made, but their strength does not compare to conventional rubber. Silicones possess excellent resistance to extreme temperatures -55 C / -67 F to 230 C / 446 F. Some special compounds resist even higher temperatures. Retention of properties of silicone at high temperature is superior to most other elastic materials. Silicone compounds are very clean and are used in many food and medical applications because they do not impart odour or taste. Silicone compounds are not recommended for dynamic sealing applications due to relatively low tear strength and high coefficient of friction. Silicone is resistant to hot air, ozone, UV radiation, engine and transmission oils, animal and vegetable fats and oils, and brake fluids. VMQ also has low resistance to mineral oils. Silicone can be compounded to be electrically resistant, conductive, or flame retardant. Silicones are also fungous resistant, odorless, tasteless and non-toxic but are not resistant to petrol oils. SBR / Styrene Butadiene Rubber This material is similar to natural rubber. SBR still finds service in brake fluid applications, although the high temperature range is inferior to that of ethylene propylene compounds. Service range for this material is -50 C / -58 F to +110 C / +230 F. E.1.4

5 SEAL MATERIALS E.1. novatec PREMIUM II novatec PREMIUM II offers flange seals for raised face and flat face applications. Raised face flange seals are used in circumstances where the seal is directly placed on the contact face of the flange, between the flange holes. Flat face flange seals are placed over the full flange surface, including the flange holes. novatec PREMIUM II is a flange seal used in a wide range of industries. Due to the combination of graphite and aramide fibres (KEVLAR ) and a low percentage of binder the flange seal is very good temperature resistance and therefore resistant to 80% of all common media in the chemical industry. novatec PREMIUM II seals show good stress relaxation, high temperature resistant, good ductility, anti stick coating, excellent torque retention, high tensile strength and a temperature range of +320 C / +608 F. SEALS novatec PREMIUM II is a registered trademark of Frenzelit KEVLAR is a registered trademark of Dupont Dow Elastomers GORE Universal Pipe Seal (UPG) Style 800 GORE Universal Pipe Seal (UPG) Style 800 is composed out of 100% expanded PTFE. They are offered for flat face and raised face applications. Due to his multidirectional fibre structure and his unique profile (envelope type) GORE UPG Style 800 seals are used for a wide range of applications in the chemical industry. Following features are to be mentioned: chemically inert and temperature resistant (-210 C / -346 F up to +260 C / 500 F), seals at low bolt load, high dimensional stability, high resistance against creep and cold flow, resistant to all media in the 0-14 ph range with exception for alkali metals and element fluorine. GORE is a registered trademark of W.L. Gore & Associates, Inc. BIO-PRO As the process conditions in pharmaceutical installations are getting more and more severe (temperature - CIP - SIP -aseptic), the need of a universal applicable product is relevant. GYLON BIO-PRO is a perfect combination between virgin PTFE and glass based microspheres. Due to its inorganic microspheres, GYLON BIO-PRO is highly compressible and can be used in a wide range of applications. The mix of PTFE with microspheres permits GYLON BIO-PRO to resist to a universal range of liquids, and combines a high temperature resistance (from -210 C / -346 F to 260 C / 500 F) with an exceptional good mechanical stability. Indeed, cold-flow, usually recognised as one of the major problems with virgin PTFE-seals, is completely eliminated when using a modified PTFE-seal such as GYLON BIO-PRO. GYLON BIO-PRO can be used in low- stress-applications, which means that this material can be used in plastic, glass as well as in stainless steel couplings like triclamp couplings. GYLON BIO-PRO is a registered trademark of Garlock Sealing Technologies E.1.5

6 CHEMICAL TERMS Chemical term ASTM 1418 ISO 1629 Polymer trade name Registered trade mark of Acrylonitrile Butadiene NBR NBR Perbunan N, Buna N Bayer Corporation Highly Saturated Nitrile HNBR HNR Therban Bayer Corporation Carboxylated Nitrile XNBR XNBR Nipol Zeon Chemicals Inc. Fluorocarbon FKM FPM Viton DuPont Dow Elastomers Ethylene Propylene EPDM EPDM Nordel DuPont Dow Elastomers Styrene Butadiene SBR SBR Stereon Dow Corning Corp. Poly Tetrafluorethylene PTFE PTFE Teflon DuPont Dow Elastomers Polychloroprene CR CR Neoprene DuPont Dow Elastomers lsobutylene lsoprene IIR IIR Butyl ExxonMobil Chemical Silicone VMQ MVQ Silastic Dow Corning Corp. Fluorosilicone FVMQ MFQ FSE General Electric Co. Chlorosulfonaled Polyethylene CSM CSM Hypalon DuPont Dow Elastomers Polyisoprene NR / IR NR / IR SMR Goodyear Rubber Products * Natural * Synthetic Natsyn Copr. Polyurethane (Polyester or Polyether) AU or EU AU or EU Vulkolan Bayer Corporation Perfluoroelastomer FFPM FFPM Kalrez DuPont Dow Elastomers Fluorinated etylene propylene FEP FEP - - E.1.6

7 CAM & GROOVE COUPLINGS E.1. Cam & groove couplings in compliance with FEDERAL Mil A-A-59326A / EN / DIN 2828 Coupler seal Square seal SEALS Form: Square Seal place: Coupling side coupler part Material: NBR, EPDM, FPM, CSM, Reference: NBR: VLXB... EPDM: VLXE... FPM: VLXV... CSM: VLXH... Temperature range: NBR: -30 C / -22 F to 120 C / 248 F EPDM: -40 C / -40 F to 145 C / 293 F FPM: -30 C / -22 F to 200 C / 392 F CSM: -40 C / -40 F to 140 C / 284 F Colour: NBR: black EPDM: black yellow striped FPM: green CSM: black green striped Hardness: NBR: 60 +/- 5 Shore A EPDM: 70 +/- 5 Shore A FPM: 70 +/- 5 Shore A CSM: 70 +/- 5 Shore A Dimensions ND Inch OD Ø +/- 0.3 mm ID Ø +/- 0.2 mm Height +/- 0.2 mm 15 1/ / / / / E.1.7

8 CAM & GROOVE COUPLINGS Closed seal Form: Square + closed Seal place: Coupling side coupler part Material: FEP outside, Silicone inside Reference: VLXPSG... Temperature range: -60 C / -76 F to 204 C / 399 F Colour: Transparent outside, red inside Hardness: 60 +/- 5 Shore D Dimensions ND Inch OD Ø +/- 0.3 mm ID Ø +/- 0.2 mm Height +/- 0.2 mm 15 1/2" /4" " /4" /2" " /2" " Open envelope seal Form: Open envelope Seal place: Coupler side Material: PTFE outside, EPDM or FPM inside Reference: PTFE - EPDM : VLXP... PTFE - FPM : VLXP... V Temperature range: PTFE - EPDM : -25 C / -13 F to 100 C / 212 F PTFE - FPM : -10 C / 14 F to 200 C / 392 F Colour: PTFE: white outside EPDM: black inside FPM: black grey striped inside Hardness: PTFE - EPDM: 85 +/- 5 Shore D FPM - FPM: 85 +/- 5 Shore D Dimensions ND Inch OD Ø +/- 0.3 mm ID Ø +/- 0.2 mm Height +/- 0.2 mm 15 1/2" /4" " /4" /2" " /2" " " E.1.8

9 CAM & GROOVE COUPLINGS E.1. Closed envelope seal Form: Closed envelope Seal place: Coupler side Material: PTFE outside, FPM core inside Reference: VLXPG... Temperature range: -15 C / -26 F to 200 C / 392 F Colour: PTFE: white outside FPM: black inside Hardness: PTFE - FPM: 74 +/- 5 Shore D SEALS Dimensions ND Inch OD Ø +/- 0.3 mm ID Ø +/- 0.2 mm Height +/- 0.2 mm 15 1/2" /4" " /4" /2" " /2" " " Thread seal Form: Square + flat Seal place: Female thread side for adaptor / coupler part Material: PTFE or PU Reference: PTFE: X2RP... PU: X2RV... Temperature range: PTFE: -30 C / -22 F to 300 C / 572 F PU: -40 C / -40 F to 82 C / 180 F Colour: PTFE: white PU: brown Hardness: PTFE: 90 +/- 5 Shore A PU: 65 +/- 5 Shore A Dimensions ND Inch OD Ø +/- 0.3 mm ID Ø +/- 0.2 mm Height +/- 0.2 mm 20 3/ / / / E.1.9

10 GUILLEMIN COUPLINGS Guillemin couplings in compliance with EN / NF E Square seal for coupling part Dimensions Form: Square Seal place: Coupling side Material: NBR, FPM, EPDM, PTFE Reference: NBR: GXB... FPM: GXV... EPDM: GXE... PTFE: GXP... Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F EPDM: -40 C / -40 F to 145 C / 293 F PTFE: -30 C / -22 F to 300 C / 572 F Colour: NBR: black FPM: green EPDM: white PTFE: white Hardness: NBR: 60 +/- 5 Shore A FPM: 75 +/- 5 Shore A EPDM: 60 +/- 5 Shore A PTFE: 95 +/- 5 Shore A ND Inch Ø OD mm Ø ID mm Height mm / / Flat seal for plug Dimensions Form: Flat Seal place: Male plug without locking ring Material: NBR, EPDM Reference: GXB... GP GXE... GP Temperature range: NBR: -30 C / -22 F to 120 C / 248 F EPDM: -40 C / -40 F to 145 C / 293 F Colour: NBR: beige Hardness: NBR: 60 +/-5 Shore A EPDM: 60 +/- 5 Shore A ND Inch Ø OD mm Ø ID mm Height mm / E.1.10

11 GUILLEMIN COUPLINGS E.1. Crimping seal for helical coupling and composite hoses Form: Profiled Seal place: Composite swage ferrule Material: NBR Reference: CX... Temperature range: NBR: -30 C / -22 F to 120 C / 248 F Colour: Black Hardness: 65 +/- 5 Shore A SEALS Dimensions ND Inch OD Ø +/- 2 mm ID mm / E.1.11

12 DSP COUPLINGS DSP-couplings in compliance with NF S / NF S Profiled seal for coupling part ND ND 100 Form: Profiled Seal place: Coupling side Material: NBR Reference: DXB... Temperature range: -30 C / -22 F to 120 C / 248 F Colour: Black Dimensions ND Inch Ø OD mm Ø ID mm Height mm DSP DSP / AR E.1.12

13 TW COUPLINGS E.1. TW couplings in compliance with EN / DIN Profiled crown seal Form: Profiled Seal place: Coupling side crown part ND Material: NBR, FPM, CSM Reference: NBR: GSDB... FPM: GSDV... CSM: GSDH... Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F CSM: -40 C / -40 F to 140 C / 293 F Colour: NBR: black FPM: black CSM: green SEALS Dimensions ND Inch Ø OD mm Ø ID mm Height mm Dimension ND 100 is only available in o-ring version. O-ring Form: O-ring Seal place: Coupling side crown part ND 100, Female dust cap ND 100 Material: NBR, FPM, CSM Reference: NBR: TWFB100 FPM: TWFV100 CSM: TWFH100 Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F CSM: -40 C / -40 F to 145 C / 293 F Colour: NBR: black FPM: black CSM: green Hardness: 70 / 80 +/- 5 Shore A Dimensions ND Inch Ø OD +/- 0.8 mm Ø ID +/- 0.8 mm Height +/- 0.3 mm E.1.13

14 TW COUPLINGS Square seal Dimensions Form: Square Seal place: Female cap ND 50 and ND 80 Material: NBR, FPM, CSM Reference: NBR: TWFB... FPM: TWFV... CSM: TWFH... PTFE: TWFP... Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F CSM: -40 C / -40 F to 140 C / 293 F PTFE: -30 C / -22 F to 300 C / 572 F Colour: NBR: black FPM: black CSM: green PTFE: white Hardness: 70 / 80 +/- 5 Shore A PTFE: 90 +/- 5 Shore A ND Inch Ø OD mm Ø ID mm Height mm Dimension ND 100 is only available in o-ring version. Thread seal in compliance with EN / DIN 2817 Form: Square + flat Seal place: Female thread side for EN / DIN 2828 Material: PTFE or PU Reference: PTFE: X2RP... PU: X2RV... Temperature range: PTFE: -30 C / -22 F to 300 C / 572 F PU: -40 C / -40 F to 82 C / 180 F Colour: PTFE: white PU: brown Hardness: PTFE: 90 +/- 5 Shore A PU: 65 +/- 5 Shore A ND Inch Ø OD mm Ø ID +/- 1 mm Height mm E.1.14

15 GK COUPLINGS E.1. Profiled seal Form: Profiled Seal place: Coupling side Material: NBR, FPM Reference: NBR: GKX FPM: GKXV Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F Colour: NBR: black FPM: green SEALS Dimensions Ø OD mm Ø ID mm Height mm E.1.15

16 EXPRESS COUPLINGS Express couplings in compliance with NF E Profiled seal Form: Profiled Seal place: Coupling side Material: NBR Reference: EXX Temperature range: -30 C / -22 F to 120 C / 248 F Colour: Black Dimensions Ø OD mm Ø ID mm Height +0.5mm E.1.16

17 EUROPEAN AIR COUPLING E.1. European air coupling in compliance with DIN 3489 Profiled seal Form: Profiled Seal place: Coupling side Material: NBR Reference: EAX Temperature range: -30 C / -22 F to 120 C / 248 F Colour: Black SEALS Dimensions Ø OD mm Ø ID mm Height mm +0.1 / / E.1.17

18 TRICLAMP COUPLINGS Triclamp couplings in compliance with DIN Profiled seal Dimensions Form: Profiled Seal place: Flange side Material: NBR, FPM, EPDM, PTFE, Silicone Reference: TRIX... P Temperature range: NBR: -30 C / -22 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F EPDM: -40 C / -40 F to 145 C / 293 F PTFE: -30 C / -22 F to 300 C / 572 F Silicone: -55 C/ -67 F to 230 C / 440 F Colour: NBR: black FPM: green EPDM: black PTFE: white Silicone: red ND For flange mm Ø ID mm Triclamp couplings in compliance with INCH Non-profiled seal Form: Non-profiled Seal place: Flange side Material: NBR, FPM, EPDM, PTFE Reference: TRIX... Temperature range: NBR: -35 C / -30 F to 120 C / 248 F FPM: -30 C / -22 F to 200 C / 392 F EPDM: -40 C / -40 F to 145 C / 293 F PTFE: -30 C / -22 F to 300 C / 572 F Colour: NBR: black red dotted FPM: green EPDM: black green dotted PTFE: white Dimensions ND For flange mm Ø ID mm 1" /2" " /2" " " E.1.18

19 TRICLAMP COUPLINGS E.1. Triclamp couplings in compliance with ISO 1127 Profiled seal Form: Profiled Seal place: Flange side Material: Silicone, EPDM, FPM, BIO-PRO Reference: TRIX... P Temperature range: Silicone: -55 C / -67 F to 230 C / 440 F EPDM: -40 C / -40 F to 140 C / 284 F FPM: -30 C / -22 F to 200 C / 392 F BIO-PRO: -210 C / +346 F to 260 C / 500 F Colour: Silicone: translucent EPDM: black FPM: white or black BIO-PRO :blue SEALS Dimensions ND For flange mm Ø ID mm Triclamp couplings in compliance with IMPERIAL Non-profiled seal Form: Non-profiled Seal place: Flange side Material: NBR, FPM, EPDM, PTFE Reference: TRIX... Temperature range: NBR: -35 C / -30 F to 120 C / 250 F FPM: -30 C / -22 F to 200 C / 392 F EPDM: -40 C / -40 F to 145 C / 293 F PTFE: -30 C / -22 F to 300 C / 572 F Colour: NBR: black FPM: green EPDM: black PTFE: white ND For flange mm Ø ID mm 1" /2" " /2" " " E.1.19

20 CARDAN COUPLINGS O-ring seal Form: O-ring Seal place: Coupling side female part Material: SBR Reference: KX... Temperature range: -50 C / -58 F to 110 C / 230 F Colour: Black Hardness: 50 +/- 5 Shore A Dimensions ND Ø OD mm Ø ID mm Height mm E.1.20

21 SCREW HOSE COUPLINGS E.1. Screw hose couplings in compliance with EN / DIN 2817 Thread seal Form: Seal place: Material: Reference: Square + flat Coupling side female part PU PTFE X2RV... X2RP... Temperature range: PTFE: -30 C / -22 F to 300 C / 572 F PU: -40 C / -40 F to 82 C / 180 F Colour: PTFE: white PU: brown SEALS Dimensions ND Inch Ø OD mm Ø ID mm Height mm +/ / / / / / E.1.21

22 NIPPLES Thread seal Form: Square + flat Seal place: Female thread Material: PU Reference: PU: X2RV... for brass coupling Temperature range: PU: -40 C / -40 F to 82 C / 180 F Colour: PU: brown Hardness: PU: 65 +/- 5 Shore A Dimensions ND Inch Ø OD mm Ø ID mm Height mm +/ / / / / / E.1.22

23 FOOD COUPLINGS - DIN E.1. Food couplings in compliance with DIN U-shape seal Form: Semi-rounded Seal place: Coupling side male threaded part Material: NBR Reference: DIN Temperature range: -30 C / -22 F to 120 C / 248 F Colour: Blue Hardness: Shore A SEALS Dimensions ND Inch Ø OD mm Ø ID mm Height mm 15 1/2" /4" " /4" /2" " /2" " " " Seal disk Form: Squared + flat Seal place: Blind nut Material: NBR Reference: DIN Temperature range: -30 C / -22 F to 120 C / 248 F Colour: Beige Hardness: 60 +/- 5 Shore A Dimensions ND Ø OD mm Ø ID mm Height mm 15 1/2" /4" " /4" /2" " /2" " " " E.1.23

24 FOOD COUPLINGS - SMS Food couplings in compliance with SMS Square seal Form: Square Seal place: Couplings side male threaded part Material: EPDM Reference: DIN Temperature range: -40 C / -40 F to 145 C / 293 F Colour: Black Hardness: Shore A Dimensions ND Inch Ø OD mm Ø ID mm Height mm 25 1" /4" /2" " /2" " " E.1.24

25 STEAM COUPLINGS E.1. Steam couplings in compliance with EN / DIN 2826 Thread seal Form: Flat Seal place: Female thread side for EN / DIN 2826 version Material: PTFE or novatec PREMIUM II with KEVLAR Reference: PTFE: X2RP... novatec : XRVSN... Temperature range: PTFE: -30 C / -22 F to 300 C / 572 F novatec PREMIUM II with KEVLAR : 320 C / 608 F Colour: PTFE: White novatec PREMIUM II with KEVLAR : blue Hardness: PTFE: 90 +/- 5 Shore A novatec PREMIUM II with KEVLAR : 95 +/- 5 Shore A novatec PREMIUM II is a registered trademark of Frenzelit KEVLAR is a registered trademark of Dupont Dow Elastomers SEALS Dimensions for PTFE thread seal ND Inch Ø OD mm Ø ID mm Height mm +0 / -0.5 mm +/ /2" /4" " /4" /2" " Dimensions for PTFE thread seal novatec PREMIUM II ND Inch Ø OD mm Ø ID mm Height mm +0 / -0.5 mm +/ /2" /4" " /4" /2" " E.1.25

26 DINBO STEAM COUPLINGS Profiled seal Form: Profiled Seal place: DINBO female spud male thread side Material: PTFE + 15% graphite Reference: BOFXP... Temperature range: 180 C / 356 F Colour: Carbon black Hardness: 97 +/- 2 Shore A Dimensions ND Inch Ø OD mm Ø ID mm Height mm 15 1/ / E.1.26

27 PETROL HOSE COUPLINGS E.1. Petrol hose couplings in compliance with EN Thread seal Form: Square + flat Seal place: Coupling side swivel nut Material: PU Reference: X2RV... Temperature range: -40 C / -40 F to 82 C / 180 F Colour: Brown Hardness: 65+/- 5 Shore A SEALS Dimensions ND Inch Ø OD mm Ø ID mm Height mm +/- 1 +/ /2" /4" " /4" /2" E.1.27

28 FLANGE COUPLINGS Flange couplings in compliance with EN / DIN and ASTM Raised face flange gasket Form: Flat Seal place: Raised face Working pressure: DIN: PN ASTM: ASA 150 lbs Material: GORE UPG Style 800 novatec PREMIUM II Reference: EN / DIN: FXG... DIN ASTM: FXN... A1 Temperature range: GORE UPG Style 800: -210 C / -346 F to 260 C / 500 F novatec PREMIUM II: 320 C / 608 F Colour: GORE UPG Style 800: white novatec PREMIUM II: blue Dimensions for DIN flanges ND EN / DIN Ø OD mm Ø ID mm Height mm 15 PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ PN10/ Dimensions for ANSI flanges INCH ANSI Ø OD mm Ø ID mm Height mm 1/2" ASA 150lbs /4" ASA 150lbs " ASA 150lbs /4" ASA 150lbs /2" ASA 150lbs " ASA 150lbs /2" ASA 150lbs " ASA 150lbs " ASA 150lbs " ASA 150lbs " ASA 150lbs " ASA 150lbs E.1.28

29 INSPECTION DOCUMENTS E.2. Inspection documents Where materials, fabricated parts and assemblies are manufactured, the manufacturer produces documents including declarations and test reports to confirm the nature of the manufacturing, inspection and testing processes applied. Types of inspection document 2.1. Declaration of order compliance Inspection documents drawn up on the basis of inspections and tests conducted by production personnel authorised by the manufacturer. INSPECTION DOCUMENTS 2.2 Test report Inspection documents drawn up on the basis of inspections and tests carried out or supervised by authorised independent personnel and based on non-specific testing. The results are reported to the customer. 3.1 Inspection document 3.1 These documents are marked as 3.1 and are drawn up on the basis of inspections and tests carried out or supervised by the manufacturer's authorised representative independent of the manufacturing and based on specific testing. The former certificate with designation 3.1 B is replaced by the new 3.1 certificate. 3.2 Inspection document 3.2 This certificate is drawn up on the basis of inspections and tests carried out by the manufacturer's authorised representative independent of the manufacturing department and either the purchaser's authorised representative or the inspector designated by the official regulations. The former certificates 3.1 A, 3.1 C and 3.2 are replaced by the new 3.2 certificate. Inspection documents are validated by the person(s) responsible by signing or marking in an appropriate way. Where certificates are prepared by computer, the signature may be replaced by the name and job title of the person responsible for validating the document. E.2.1

30 INSPECTION DOCUMENTS EN DOCUMENT CONTROL DOCUMENT CONDITIONS DOCUMENT REFERENCE METHOD CONTENT OF ISSUE VALIDATED BY 2.1 Declaration of Non-specific Test results In accordance with The manufacturer order not included the requirements compliance contained in the order. 2.2 Test report Non-specific Includes the results In accordance with The manufacturer of tests conducted the requirements using a non-specific inspection and testing method. contained in the order and, where required, in accordance with official regulations and the corresponding technical rules. 3.1 Inspection document 3.1 The manufacturer's authorised representative independent of the manufacturing department. 3.2 Inspection Specific document 3.2 Statement of compliance with the order including test results conducted using a specific inspection and testing method. In accordance with official regulations and the corresponding technical rules. The manufacturer's authorised representative independent of the manufacturing department and either the purchaser's authorised representative or the inspector designated by the official regulations. E.2.2

31 PRODUCTION METHODS PRODUCTION METHODS E.3. Investment or lost wax casting LMC-Couplings stainless steel cam & groove couplings and stainless steel cam & groove handles are produced using the investment casting process. The basic concept of investment casting is the creation of a sacrificial wax or plastic mould, which is then coated with refractory material to form the casting mould years ago, the sacrificial mould was carved painstakingly from wax. Sprues and risers would be added to the wax mould to create a completely wax pattern, which would then be covered with clay or plaster, allowed to set, and baked. The baking process would melt the wax, leaving a one-time pattern in the plaster mould. Modern investment casting involves one more step. Skilled model makers create metal dies containing the primary patterns. Wax or plastic is then injected into these dies to create the wax pattern. Typically, the wax pattern contains many different patterns gated together by sprues and risers. The wax pattern is then covered with a refractory material by dipping in ceramic slurry, or coating with refractory moulding material. The mould is then baked, and the wax or plastic allowed to drain out or vaporize. Molten metal is then poured into the mould. Removing the cast metal from the mould is more difficult with investment casting than with other casting methods, because the mould material (typically refractory) is often resistant to removal. Chemicals, high-pressure water jet washing and sand blasting are some of the methods used to remove moulds. PRODUCTION METHODS Die casting The basis of the method is to force molten metal into a reusable mould under high pressure. The metal then cools (often assisted by water cooling of the die), opened and the casting ejected. Moulds for die-casting are quite complex, and are usually made from steel alloy in two sections (the cover and ejector). The die must be able to withstand high temperatures and pressures, and so is typically made from steel alloys containing chromium or tungsten. To increase die life and improve throughput, dies are normally cooled using water, air or nitrogen. There are two major types of die-casting machines. Hot chamber die-casting machines are used for low melting point materials. Aluminium, magnesium, brass and bronze die-castings are all produced using cold chamber machines. In cold chamber die-casting, the metal is fed from the holding furnace into a chamber, from where a plunger forces it into the die. Cold chamber machines are typically rather slower than hot chamber machines Materials best-suited for die casting are zinc, aluminium, magnesium, copper, lead and tin. High pressure die-casting is generally limited to non-ferrous metals, due to the difficulty of making refractory moulds capable of withstanding the high temperatures and pressures involved. E.3.1

32 PRODUCTION METHODS Sand casting Sand casting is used to produce brass, bronze and aluminium cam & groove couplings. Sand casting is one of the most widely-used industrial casting processes, and is the technique used to produce over 90% of all metal castings. The process begins with the fabrication of a pattern of the finished component, which is often in two pieces due to the mould construction method. The pattern can be made from virtually any material, including wood, foam, clay and plastic. The mould containing the sand is called a flask, and is in two pieces: the top (or cope) and the bottom (or drag) which is separated by the centre line. Holes called sprues are used to feed the molten metal into the flask, whilst holes called risers allow any air bubbles to escape. To begin the casting process, the flask is divided into its two parts. The pattern is then inserted, and the flask reassembled. Sand is then packed very tightly around the pattern, the flask opened and the pattern removed. The sand imprint is checked carefully, and any additional risers and sprues added where necessary (if not included in the original pattern). The flask is then closed and molten metal poured into the sprues until it emerges from the risers. Once the metal has cooled, the flask is broken open and the casting removed. The sand is cleaned and recycled for future casting operations. The sprues and risers are removed and the part is cleaned. Either green sand (actually black in colour) or dry sand is used for the casting process. In green sand casting, the sand binder is kept moist with water, and the component is cast as quickly as possible after the pattern is removed. In dry sand casting, the binder is organic, and the mould is baked after the pattern is removed. Green sand casting is cheaper, but dry sand casting can achieve closer dimensional tolerances. A baked sand core is inserted into the mould after the pattern has been removed in order to create a hollow casting. The core is then destroyed and removed after casting to leave a hollow component. Drop forging A heated work piece is formed by the rapid closing of a punch and die, forcing the work piece to conform to a die cavity. A work piece may be forged by a series of punch and die operations (or by several cavities in the same die) which gradually change its shape. The structure of the basic material remains intact, which means that drop-forged components retain excellent mechanical properties, like LMC-Couplings TW couplings in brass. Forged components are highly elastic, ductile and very strong. As a result, components are not brittle and, when subject to sudden overload do not break, but reduce maximum tension through plastic flow off without imposing unreasonable loads. These already-excellent mechanical properties can be further improved by heat treatment. This production method creates components that are very well-suited to subsequent machining operations. E.3.2

33 MATERIALS MATERIALS E STEEL ALLOYED STEEL - STAINLESS STEEL AISI 304 / This is the most common Cr-Ni 18/8 quality and is used widely in the food processing and pharmaceutical industries for piping and storage units. AISI 304 is also used to manufacture all kinds of equipment for the brewing industry, margarine factories and abattoirs, as well as in the chemical industry to manufacture equipment for processes involved in the production of materials such as nitric acid, nitrates, nitrate fertilizers and explosives. MATERIALS AISI 304L / Stainless steel is more highly-resistant to nitric acid at high concentrations and temperatures than This alloy is used primarily in the chemical, food processing, pharmaceutical and other industries for reactor vessels, storage tanks and other equipment. Stainless steel AISI 304L / is used chiefly in applications where the metal is deformed or subjected to thermal loads over extended periods. Use of this material is particularly recommended where temperatures of between 500 C / 932 F and 900 C/ 1652 F are likely to be encountered. AISI 316 / Grade AISI 316 is the standard molybdenum-bearing grade, second only in importance to AISI 304 amongst the austenitic stainless steels. The molybdenum gives AISI 316 better overall corrosion-resistance properties than Grade AISI 304, and particularly higher resistance to pitting and crevice corrosion in chloride environments. It is readily brake-formed or roll-formed into a variety of components for industrial, construction and transport applications. AISI 316 offers excellent corrosion resistance in a range of atmospheric environments and many corrosive media (generally more resistant than AISI 304). This material is subject to pitting and crevice corrosion in warm chloride environments, and to stress corrosion cracking above approximately 60 C/140 F. It can be considered as resistant to potable water containing a maximum chloride content of approximately 1000mg/L at ambient temperature, reducing to around 500mg/L at 60 C. Grade AISI 316 is usually regarded as the standard marine grade stainless steel, but it is not resistant to warm sea water. In many marine environments, AISI 316 does exhibit surface corrosion, usually in the form of brown staining, particularly in association with crevices and rough surface finishes. E.4.1

34 MATERIALS AISI 316L / Grade AISI 316L is the low-carbon version of AISI 316 and is immune from sensitisation (grain boundary carbide precipitation). AISI 316L is used extensively in heavy gauge welded components (over about 6mm). Use of this material is particularly recommended where temperatures of between 500 C/932 F and 900 C/1652 F are likely to be encountered. AISI 316Ti / Compared to AISI 304, AISI 316Ti is characterised by its properties in niric acid and in orgnic cooled acid soluions. Optimal processing properties are achieved by means of het treatment in the temperature range of +/ C followed by rapid cooling in air or water Cr 8-10 Ni 0.15 C Increasing Cr and Ni improves the oxidation and corrosion resistance ,5-18,5 Cr 10,5-13,5 Ni 2-2,5 Mo 0.10 C Addition of Mo improves the resistance against pitting and the tear strength at high temperatures Cr 8,5-10,5 Ni 0.08 C Low C-grade improves welding capacities L 16,5-18,5 Cr Ti 16,5-19,5 Cr Cr Cr Cr L Cr Ni 10,5-13,5 Ni Ni 9-12 Ni 9-12 Ni 10-12,5 Ni 2-2,5 Mo 2-2,5 Mo 3-4 Mo No Ti 0.08 C Low C-grade improves welding capacities Ti Addition of Ti minimizes chromium Mo addition improves pitting resistance Addition of Nb improves welding capacities Addition of Ni improves welding capacities Low C-grade improves welding capacities E.4.2

35 MATERIALS E.4. International material comparison - stainless steel Germany USA SWEDEN FRANCE UK ITALY SPAIN JAPAN RUSSIA W.-Nr. AISI UNS SS AFNOR BS UNI UNE JIS GOST S Z 6 CN S 15 X 5 CrNi F.3504-X 5 CrNi SUS Ch18N S Z 10 CNF S L S Z 2 CN S 12 X 3 CrNi18.11 F.3503-X 2 CrNi SUS 304L 03Ch18N S Z12Cn S SUS S Z 6 CND S 16 X 5 CrNiMo F,3534-X 5 CrNiMo SUS L S Z 2 CND S 14 X 2 CrNiMo F.3533-X 2 CrNiMo SUS 316L S Z 6 CNT S 31 X 6 CrNiTi F.3523-X 6 CrNiTi SUS Ch18N10T Ti S Z 6 CNDT S 31 X 6 CrNiMoTi F.3535-X 6 CrNiMoTi SUS 316Ti 10Ch17N13M2T MATERIALS UNALLOYED STEEL STEEL The wide range of grades available allows steel to be used in a wide range of applications, including the automotive, construction and packaging industries. The excellent shape retention and strength characteristics of steel have made it one of the most important products created by man. Steel has a huge range of properties, including: 1. Weldability 2. Fatigue resistance 3. Electrical conductivity / thermal conductivity 4. Corrosion resistance when galvanized 5. Mouldability 6. Reusability 7. Mechanical strenght International material comparison - steel EN Material number EN (former) Germany France UK S235JR S235JR St 37-2 E S355J S355J0 St 52-3 U E C S355JR S355J2G3 St 52-3 N - 50 D GALVANIZED STEEL For example, steel flange couplings are galvanized to improve their corrosion resistance. The galvanizing process involves the adding of a zinc layer to the coupling surface. Zinc coatings prevent oxidation of the protected metal by forming a barrier and acting as a sacrificial anode if this barrier becomes damaged. Galvanized steel can be welded, but this is not recommended. Galvanized steel is suitable for high-temperature applications of up to 200 C / 392 F. Use at temperatures above this level will result in the zinc layer peeling off at the intermetallic layer. E.4.3

36 MATERIALS NON FERROUS ALLOYS BRASS Brass is an alloy of copper and zinc, which becomes mutually soluble when melted and therefore lose their individual identities. On cooling, the combination becomes brass. Small amounts of other elements can be added to brass to deliver specific effects and thereby add useful properties and desirable characteristics to the parent alloy. 1) Tin Additions of around 1% are usual, giving a small increase in tensile strength and improved corrosion resistance under marine conditions. 2) Lead Virtually insoluble in brass, it can be introduced to form discrete particles finely distributed throughout the alloy. These particles act as "chip breakers" in machining operations and enable higher-speed machining, finer swarf and reduced tool wear. The actual amount of lead added depend on end-user requirements, but normally range from 1.5% to 4.5%. 3) Iron The addition of small amounts of iron (around 0.5%) increases tensile strength, but higher amounts can result in excessive tool wear and machining problems. 4) Aluminium Use of this element increases hardness and tensile strength, but only at the expense of some reduction in ductility. 0.5% - 1.0% is normal, but some brass alloys may contain as much as 6% aluminium. These alloys offer high corrosion resistance in marine applications. 5) Manganese The addition of %, usually in association with iron, increases tensile strength and hardness with only a slight reduction in ductility. 6) Nickel Occasionally added in concentrations of 1-2%, nickel delivers some improvement in tensile strength with no reduction in ductility. 7) Arsenic Arsenic in concentrations of % delivers high resistance to 'dezincification', a specific form of corrosion. International material comparison - Brass EN US Germany France UK International CuZN39Pb3 CW614N B455 C MS 58 CuZn40Pb3 CZ 121 CuZN39Pb3 CuZn40Pb2 CW617N B455 C MS 58 CuZn39Pb2 CZ 122 CuZn40Pb2 E.4.4

37 MATERIALS E.4. BRONZE Bronze is a copper alloy made from natural ores alloyed with tin or other elements to create a metal which does not exist in nature. When such ore is refined, the metal looks like copper, but is harder and more useful for making tools, weapons and sculptures. Bronze is now widely used in tool and machinery manufacture, as well as in the minting of coins. The bronze solidification process is quite unique. When molten bronze is poured into a mould, it expands as it cools and fills every detail of the mould. As it cools further and solidifies, it shrinks slightly, so that the final result does not stick to the mould. Over time, bronze takes on a range of colours caused by surface oxidation. This effect is referred to as patina. MATERIALS Traditionally, bronze was defined as a copper alloy containing tin (not exceeding 10%). Tin increases hardness, making bronze more wear-resistant than copper. Bronzes with a tin content of 10% or more are harder, stronger and more corrosion-resistant than brass. Today s bronzes may vary quite significantly, and are typically copper alloys which may contain silicon (Si), manganese (Mn), aluminium (Al), zinc (Zn), lead (Pb), iron (Fe) and other elements, either with or without tin (Sn). The variations in bronze (both in proportion and elemental composition) can significantly affect its characteristics, whether by improving wear-resistance and/or machine-ability, or reducing corrosion in water, etc. International material comparison - Bronze EN US Germany France UK International CuSn5Zn5Pb5-C CC491K C83600 G-CuSn5ZnPb CuSn5Pbn5Zn5LG2 CuPb5SnZn5 ALUMINIUM Aluminium is easily formed, machined and cast. Alloys containing small amounts of copper, magnesium, silicon, manganese, and other elements have very useful properties. One of the key properties of aluminium is its low density, being only one-third as heavy as steel. Aluminium and most of its alloys are highly resistant to most forms of corrosion. The metal's natural coating of aluminium oxide provides a highly-effective barrier to the ravages of air, temperature, moisture and chemical attack. Aluminium is also a very good conductor of electricity, which, in combination with its other intrinsic qualities, has ensured its use as a replacement for copper in many applications. Aluminium is non-magnetic and non-combustible; properties invaluable in advanced industries like electronics and offshore engineering. Aluminium is non-toxic and impervious; qualities that quickly established it as a preferred material in the food and packaging industries. Other valuable properties include high reflectivity, heat barrier properties and heat conduction. The metal is malleable and easily worked using all the usual manufacturing and shaping processes. International material comparison - Aluminium Europe Germany USA FRANCE UK ITALY EN W.-Nr. AISI AFNOR BS UNI EN AW-6082 AlMg Si EN AC G-AlSi 7CMG A375.0 A-S7G03 2L99 - E.4.5

38 MATERIALS THERMOPLASTICS POLYPROPYLENE Polypropylene is an economical material that offers a combination of outstanding physical, chemical, mechanical, thermal and electrical properties not found in any other thermoplastic. Compared with low- and high-density polyethylene, it has lower impact strength, but superior working temperature and tensile strength. Polypropylene offers excellent resistance to organic solvents, degreasing agents and electrolytic attack. It is light in weight, stain-resistant and has a low moisture absorption rate. Polypropylene is a tough, heat-resistant, semi-rigid material, ideal for the transfer of hot liquids or gases. It is recommended for vacuum systems and wherever high temperatures and pressures are likely to be encountered. It offers excellent resistance to acids and alkalies, but performs poorly with aromatic, aliphatic and chlorinated solvents. HIGH DENSITY POLYETHYLENE (HDPE) A linear polymer, High Density Polyethylene (HDPE) is prepared from ethylene by a catalytic process. The absence of branching results in a more closely packed structure with a higher density and somewhat higher chemical resistance than LDPE. HDPE is also somewhat harder and more opaque and it can withstand rather higher temperatures 120 C / 248 F for short periods and 110 C / 230 F continuously. High density polyethylene lends itself particularly well to blow molding, e.g. for bottles, cutting boards, dipping baskets, dippers, trays and containers. Dynalab Corp's plastic fabrication shop fabricates thousands of catalog and custom acrylic products. HDPE is excellent resistance (no attack) to dilute and concentrated acids, alcohols and bases. It shows good resistance (minor attack) to aldehydes, esters, aliphatic and aromatic hydrocarbons, ketones and mineral and vegetable oils. NYLON (POLYAMIDE) Nylon (Polyamide), is considered to be the first engineering thermoplastic. It is one of many heterochain thermoplastics which has atoms other than C in the chain. Nylon is created when a condensation reaction occurs between amino acids, dibasic acids and diamines. Commercially Nylon is commonly used in the production of tire cords, rope, belts, filter cloths, sports equipment and bristles. It is particularly useful when machined into bearings, gears, rollers and thread guides. Polyamide is excellent resistance (no attack) to oils and bases. It has a good resistance (no attack) to solvents, formaldehyde and alcohols. It s resistance is limited (moderate attack and suitable for short term use only) to dilute acids. Polyamide has poor resistance (not recommended for use with) to phenols E.4.6

39 MATERIALS E Surface treatments Stainless steel surface cleanliness and smoothness Microbiological cleanliness and particle control is of greatest importance and necessity in industrial applications like semiconductor manufacturing, pharmacy and biotechnology. The demand for process cleanliness in respect of analysis of process gases, water, chemicals and products in the pharmacy and biotechnology industries also plays a major role. Stainless steel is a common and obvious choice of material where sanitary and cleanliness is required. It looks clean and is easily handled, welded, bent and formed. Under normal conditions it does not rust. Stainless steel is available in cold-rolled or hot-rolled sheets, seamless tubes, welded tubes, bars and many other forms. Surface roughness requirements have become increasingly common in the food and beverage industries in order to avoid contamination, particle build-up or the growth of impurities in gases and liquids. There is also a need to avoid fouling and surface contamination in pipelines and vessels. These demanding and highly-specified requirements for stainless steel surfaces have resulted in the development of electro-polishing, which is now accepted as a standard industrial method of meeting the highest demands of surface roughness and surface cleanliness for stainless steel products and components. MATERIALS Ra value Stainless steel surfaces vary depending on the manufacturing method used (cold-rolled, hot-rolled, extruded, drawn or welded). Mechanical treatments like grinding will also affect the surface of stainless steel. Surface roughness measurement (Ra, R max) is the most common way of evaluating surface quality. However, this method reveals nothing about metallurgical cleanliness, characteristics or the material s ability to resist surface contamination, since all it shows is an average vertical deviation from a straight line. So surface roughness figures are just a small part of evaluating surface quality. Microscopic examination of the surface provides valuable information about its microstructure and character. E.4.7

40 MATERIALS The following methods are used in order to obtain surfaces with a fine and low Ra values: 1. Grinding/mechanical polishing 2. Blasting 3. Electro-polishing 1. Grinding/mechanical polishing is a very useful way of removing scratches or other mechanical defects. The surface acquires a uniform appearance, and very low Ra values can be achieved by repeated polishing. However, the outer surface layer and grain boundaries are contaminated with oxides, material from the grinding belt and lubricants (where used). The austenitic structure is also damaged, and the surface loses the properties of the underlying material. This defective surface layer is well-defined and is known as the Beilby layer. Its negative effects are poor corrosion resistance and risk of contamination between surface and medium. 2. Blasting has similar negative effects to grinding. Blasting should not be used as a preparation for electropolishing. Blasting gives an even appearance and is used primarily for surfaces not intended to come into contact with media. 3. Electro-polishing is an electrochemical method which removes a surface layer approximately 20µm thick, most of which comes from the peaks of the micro-profile. The austenitic structure appears very clean, the surface has a bright, shiny appearance, and even the outer surface has the same properties as the underlying material. The technical advantages of electro-polishing are: * Metallurgical cleanliness * Reduced friction * Improved corrosion resistance * Reduced surface area * Easy cleaning The electro-polishing process may improve a surface finish by up to 50%, and removes material at the same time as reducing surface roughness. Since material is removed, process runtimes are often limited to maintain dimensional tolerances, thus delivering actual surface roughness improvements of between 10% and 35%. Electro-polishing improves surfaces at the microscopic level, so if the material has a surface texture or scratching, electro-polishing will only produce a shiny texture or shiny scratch. Mechanical polishing should be used to remove macroscopic texture or blemishes. The life span of electro-polished surfaces Electro-polishing is a surface treatment, not a surface coating, so polished surfaces can be physically damaged or degraded in the same way as the underlying material. An electro-polished AISI 316 stainless steel surface has the same strength and hardness as those published for AISI 316 material. It should however be noted that electro-polishing can produce such a shiny finish that even the finest surface scratch may be visible. Electro-polished surfaces are more resistant to corrosion, and are therefore more resilient in many corrosive environments. The difference between electro-polishing and mechanical polishing Electro-polishing is an electrochemical process, whereas mechanical polishing is a mechanical process. Electro-polishing is a surface treatment that can improve surface finish, since it dissolves material from the surface. Mechanical polishing, like machining, alters a surface by cutting material from it. Electro-polishing improves surface finish at the microscopic level, whilst mechanical polishing improves it at the macroscopic level. E.4.8

41 MATERIALS E.4. Roughness certificate When considering roughness measurements, measuring instruments work within a specific spatial bandwidth, which means that some features are too wide (or far apart) to be detected, whilst some are too narrow (or close together). These limits are commonly expressed in terms of spatial frequency (i.e., the inverse of maximum or minimum widths). The degree of roughness measured (RMS or Ra) does not include features outside this range. For comparisons between measurements (or instruments) to be valid, the spatial bandwidths must be identical. There are also limits of operation for measuring the amplitude of surface features. When expressing roughness, it is important to specify not only bandwidth, but also to state the specific range of surface amplitudes covered by the instrument used. MATERIALS LMC-Couplings triclamp couplings can be supplied with roughness certificates on request. This certificate demonstrates that the requested roughness average is achieved. The roughness certificate contains several reference measurements: 1. Ra 2. Ry 3. Rz 4. Rq Ra Arithmetical Roughness average Ra is the arithmetic average of the absolute values of profile height deviations from the mean line, recorded within the evaluation length. Simply put, Ra is the average of a set of individual measurements of the peaks and valleys of a surface within the scanning path. Ra is the preferred method for evaluating gradual surface changes. The calculation formula used means that the numerical value measured for Ra is always smaller than that for Rz for the same roughness profile. L = evaluation length Z(x) = the profile height function The digital approximation is: E.4.9

42 MATERIALS Ry Maximum height A portion stretching over a reference length in the direction in which the average line extends is cut out from the roughness curve. The gap between the peak line and the trough line is measured in microns (µm) in the direction of the magnitude axis. Rz Determined roughness The determined roughness depth Rz is the mathematical average of the largest individual roughness depths Zn from a number of individual measurement paths l5 = c. Averaging the largest roughness depths of measurement paths directly adjacent to each other reduces the influence exerted by individual peaks and ridges. The complete path L is the sum of the individual measurement paths. Rz = Z1 + Z2 + Z3 + Z4 + Z5 5 RMS (Rq) Root mean square average RMS is the root mean square average of the profile height deviations from the mean line, recorded within the evaluation length. L= evaluation length Z(x) = the profile height function The digital approximation is: E.4.10

43 MATERIALS E.4. Difference between Ra and RMS Ra and RMS both represent surface roughness, but are calculated differently. Ra is the Roughness Average of the measured microscopic peaks and valleys of a surface. RMS is the Root Mean Square of the measured microscopic peaks and valleys of a surface. Each value uses the same individual height measurements of surface peaks and valleys, but in different formula. The formulas are shown above. It can be seen that a single large peak or flaw within the microscopic surface texture will affect (raise) the RMS value more than the Ra value. MATERIALS Equivalent Ra values for surface finish grade numbers Roughness values Ra Roughness values Ra Roughness micrometres micro inches Grade Numbers N N N N N N N N N N N N1 E.4.11

44 MATERIALS MATERIAL DESCRIPTION W.-nr GERMANY - DIN USA - AISI/SAE FRANCE - AFNOR UK - BS MECHANICAL PROPERTIES RP0.2 Rm A5 Z Av HRC N/mm2 N/mm2 % % Stainless steel Steel Aluminium Brass Bronze X 5 CrNi Z6CN S X 10 CrNiS Z10CNF S X 2 CrNi L Z2CN S X 5 CrNiMo Z6CND S X 2 CrNiMo L Z2CND S X 6 CrNiTi Z6CN S X 6 CrNiMoTi Ti Z6CNDT S17 2, Hastelloy C Monel Alloy Fe 360 D 1 (St37-3) A E 24-U C Fe 510 D 1 (St52-3) SAE 1518 E B S20 SAE MF M SMnPb36k 12L14 S300Pb Ck35 SAE 1035 XC A Ck45 SAE 1045 XC M 46 1, MnV AlMgSiPb 6012 A SgPb AlCuMgPb 2007 A-U4PB AlMgSi A-SGM 0,7 H AlMgSi 0, A-GS H AlMg A-G3M CuZn 39 Pb3 (Ms58) ASTM 360 UZ39PB2 CZ121Pb CuZn 37 (Ms63) ASTM 272 UZ36 CZ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~758 30~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~310 12~ ~ ~ CHEMICAL PROPERTIES W.-nr C Si Mn P S Cr Mo Ni Others % % % % % % % % % Stainless steel Steel Aluminium Brass Bronze , , ,070 1,000 2,000 0,045 0,030 17,000~19,000-8,500~10,500-12,000 1,000 2,000 0,060 0,150~0,350 17,000~19,000-8,000~10,000-0,030 1,000 2,000 0,045 0,030 18,000~20,000-10,000~12,500-0,070 1,000 2,000 0,045 0,030 16,500~18,500 2,000~2,500 10,500~13,500-0,030 1,000 2,000 0,045 0,025 17,000~18,500 2,500~3,000 12,500~15,000-0,080 1,000 2,000 0,045 0,030 17,000~19,000-9,000~12,000 Ti (5x%C) 0,800 0,080 1,000 2,000 0,045 0,030 16,500~18,500 2,000~2,500 10,500~13,500 Ti (5x%C) 0,800 0,010 0,080 0, ,000 13,000 55,560 Co2.5/W3/Fe3/V ,500 2,000-0, ,500 Fe 2.5 / Cu 31 0,170-1,400 0,045 0, ,200 0,550 1,600 0,045 0, ,42~0,50-0,700~1,100 0,060 0,180~0, ,150 0,050 1,100~1,500 0,100 0,340~0, Pb: 0,150~0,350 0,320~0,39 0,400-0,035 0,030 0,400 0,100 0, ,400 0,500~0,800 0,035 0,030 0,400 0,100 0,400-0,220 0, ~1,700 0,040 0, V: ,60~1,40 0,50 0,10 0,40~1,00 0,60~1,20 0,30 0,30 0,20-0,80 0,80 3,30~4,60 0,50~1,00 0,40~1,80 0,10 0,80 0,20-0,70~1,30 0,50 0,10 0,40~1,00 0,60~1,20 0,25 0,20 0,10-0,30~0,60 0,10~0,30 0,10 0,10 0,35~0,60 0,05 0,15 0,10-0,40 0,40 0,10 0,50 2,60~3,60 0,30 0,20 0,15-57,0~59,0 2,5~3,5 35,5~38,5 0,10 0,50 0,50 0,30 0,40-62,0~64,0 0,10 35,2~37,2 0,03 0,10 0,30 0,05 0,10-0,05 4,0~6,0 4,0~6,0-0,30 2,50-4,00~6,00 Cu 81~85 / Sb 0.3 E.4.12

45 MATERIALS TECHNICAL INFORMATION: PROPERTIES OF ELASTOMERS ASTM 1418 NR SBR NBR EPDM IIR CR AU CSM VMQ FVMQ FKM ISO code 1629 NR SBR NBR EPDM IIR CR AU CSM MVQ MFQ FPM Shoreness (Shore A) Pull strength (p.s.i.) Tear strenght E V G G V V E F N N G Wear strength E E G G G G V V N N G Inflammable N N N V V F N N G V F to E hydr. liquids Lubricants N N G N N F V F F E E Fuel oils N N G N N F V F R E E Hydraulic oils N N U N N G V U G E E Vegetable oils N F U F U G V G G E E Animal fats N F U F U G V G G E E Trade gasoline N N V N N F V F F E E Gasoline high octane N N G N N N V N N E E Kerosene N N V N N F V F F E E Aromatic N N F N N N G R N E E hydrocarbons Alifatic N N V N N G V G F E E hydrocarbons Water (< 80 C F) G V V E E F Fto N E E E E Water (> 80 C F) N F F E G N N E E E G Alcohols G G V E E E F V E E E Ketones N N N G V N N F G N N Concentrated N N N F F N N V F F V acids Diluted acids F F F G E G N E G V E Alkalis? G G F V E G N E G F G Chlorated N N F N N N F N N E E solvents Ozone / obselence light F F F U U E E U U U U Max. C /F continue 70 C/155 F 110 C/230 F 120 C/248 F 145 C/293 F 120 C/248 F 105 C/220 F 70 C/155 F 140 C/284 F 230 C/446 F 205 C/400 F 200 C/392 F Electr. properties U E N U U E G G U U U Flame extinguishing No No No No No Yes No Yes No No Yes E= Excellent V= Very good G= Good F= Fair N= Not recomended E.4.13

46

47 THREADS E.5. E.1. Generally three types of threads are used for low pressure couplings: BSP BSPT NPT THREADS SEALS NPSM DIN In Europe, BSP and BSPT threads are more commonly used than NPT threads. NPT threads are typically American threads. Since many American industrial machines and products are exported to European markets, couplings with NPT threads are a regular requirement. The main difference between the three types referred to above is the seal method used. BSP threads are sealed using a thread seal or o-ring. BSPT and NPT threads are sealed by their conical thread. For food couplings, like food couplings complying with DIN and SMS, a round thread is used. Due to the round thread these couplings are easy to assemble, disassemble and to clean. NPSM, or the National Standard Free-fitting Straight Mechanical Pipe Thread, is an American thread type used for DINBO steam couplings. Due to the mechanical sealing of DINBO couplings and the steam application, a straight pipe thread NPSM is used. The connection of petrol hose couplings is made by screwing the ISO Metric fine thread DIN 13, of the male or female coupling into the ferrule. The ISO MF is an exception in thread type used for other low pressure couplings used in this catalogue. E.5.1

48

49 THREADS E.5. Female thread D Pitch Threads Metric BSP NPT NPSM DIN (inch) 8, /8 8, /8 8,701 1 M10X1 9,025 1,5 M10X1,5 9, /8 10,052 1,5 M12X1,5 11, /4 11, /4 11,888 1/4 12,052 1,5 M14X1,5 14,052 1,5 M16X1,5 14, , /8 14, /8 15,317 3/8 16,052 1,5 M18X1,5 18,052 1,5 M20X1,5 18, /2 18, /2 18,974 1/2 20,052 1,5 M22X1,5 20, /8 22,052 1,5 M24X1,5 23, /4 24,052 1,5 M26X1,5 24, /4 24,334 3/4 24,402 2 M27X2 24,50 8 NW10(Rd28x1/8 ) 27,402 2 M30X2 28,052 1,5 M30X1,5 29, /2 1 30, ,402 2 M33X2 30, ,600 8 NW15(Rd34x1/8 ) 33,402 2 M36X2 36,052 1,5 M38X1,5 38, /2 1 1/4 38, /4 39, /4 39,402 2 M42X2 40,50 8 NW20(Rd44X1/6 ) Female thread D Pitch Threads Metrisch BSP NPT NPSM DIN (inch) 42,402 2 M45X2 43,052 1,5 M45X1,5 44, /2 1 1/2 44, /2 45, /2 45,402 2 M48X2 48,90 6 NW25(Rd52x1/6 ) 49,402 2 M52X2 50,052 1,5 M52X1,5 50, /4 54,80 6 NW32(RD58X1/6 ) 56, /2 2 56, , ,60 6 NW65(Rd65X1/6 ) 62,402 2 M65X2 66, /2 68,75 3 M72X3 2 1/2 69,84 2 M72X2 72, /2 74,70 6 NW50(Rd78x1/6 ) 75,67 2 M80X4 77,83 4 M80X2 82, , , ,40 2 M90X4 88,70 4 M90X2 91,80 6 NW65(Rd95X1/6 ) 97,40 2 M100X4 3 1/2 98,70 4 M100X2 104,30 4 NW80(Rd110X1/4 ) 107,40 4 M110X4 108, , ,40 4 M125X4 124,30 4 NW100(Rd130X1/4 ) 135, , ,40 4 M140X ,82 4 NW125(Rd160X1/4 ) 156,10 6 M160X6 160, , , ,30 4 NW150(Rd160X1/4 ) THREADS E.5.3

50 THREADS Male thread D Pitch Threads Metric BSP NPT NPSM DIN (inch) 9, /8 9,910 1/8 10,00 1 M10X1 10,00 1,5 M10X1,5 10, /8 12,00 1,5 M12X1,5 13, /4 1/4 13, /4 14,00 1,5 M14X1,5 16,00 1,5 M16X1,5 16, /8 3/8 17, /8 18,00 1,5 M18X1,5 20,00 1,5 M20X1,5 20,904 1/2 20, /2 21, /2 22,00 1,5 M22X1,5 22, /8 24,00 1,5 M24X1,5 26,00 1,5 M26X1,5 26,263 3/4 26, /4 26, /4 27,00 2 M27X2.0 28,00 8 NW10(Rd28x1/8 ) 30, M30X1.5 30,00 2 M30X2.0 32, ,00 2 M33X2.0 33, , /2 1 34,00 8 NW15(Rd34x1/8 ) 36,00 2 M36X2.0 38,00 1,5 M38X1,5 41, /4 41, /4 42,00 2 M42X2.0 42, /2 1 1/4 Male thread D Pitch Threads Metric BSP NPT NPSM DIN (inch) 44,00 6 NW20(Rd44x1/6 ) 45,00 1,5 M45X1,5 45,00 2 M45X2 47, /2 47, /2 48,00 2 M48X2 48, /2 1 1/2 52,00 2 M52X2 52,00 1,5 M52X1,5 52,00 6 NW25(Rd52x1/6 ) 53, /4 58,00 6 NW32(Rd58x1/6 ) 59, , , /2 2 65,00 2 M65X2 65,00 6 NW40(Rd65x1/6 ) 72,00 3 M72X3 2 1/2 72,00 2 M72X2 73, /2 75, /2 78,00 6 NW50(Rd78x1/6 ) 80,00 4 M80X4 80,00 2 M80X2 87, , ,00 4 M90X4 90,00 2 M90X2 95,00 6 NW65(Rd95x1/6 ) 100,00 4 M100X4 3 1/2 100,00 2 M100X2 110,00 M110X4 NW80(Rd110x1/4 ) 113, , ,00 4 M125X4 130,00 4 NW100(Rd130x1/4 ) 138, ,00 4 M140X4 140, , ,00 6 M160X6 160,00 4 NW125(Rd160x1/4 ) 163, , ,00 4 NW150(Rd190x1/4 ) E.5.4

51 FLANGES E.6. For flange couplings standardized flanges are used complying with EN / DIN or ASTM. The flange coupling can be swivel or fixed. A flange-to-hose connection should preferably be fitted with at least one swivel flange. During assembly, the connection with the fixed flange is fitted to the pipe system first, followed by the swivel flange. FLANGES The swivel flange prevents twisting of the hose during assembly. For flange couplings, flanges complying with EN / DIN 2673 and ASTM A 182 ANSI B16.5 are used. Always connect flanges of the same standard EN/DIN or ASTM and pressure range. Due to difference in overall dimensions ASTM and EN / DIN flanges can not be connected. In the next table you ll find an overview of flange types with their corresponding pressure classes. E.6.1

52

53 FLANGE TYPES E.6. WELDING NECK FLANGE EN / Type 11 PN 6 = DIN2631 PN 10 = DIN2632 PN 16 = DIN2633 THREADED FLANGE EN / Type 13 PN 10/16 = DIN2566 FLANGES PN 25 = DIN2634 PN 40 = DIN2635 BLIND FLANGE EN / Type 5 SLIP-ON FLANGE EN / Type 4 PN 10/16 = DIN2527 PN 6 = DIN2641 PN 10 = DIN2642 PN 25 = DIN2655 PN 40 = DIN2656 WELDING NECK FLANGE ASTM THREADED FLANGE ASTM RF 150 lbs RF 150 lbs RF 300 lbs RF 600 lbs BLIND FLANGE ASTM LAP-JOINT FLANGE ASTM RF 150 lbs RF 150 lbs RF 300 lbs RF 300 lbs RF 600 lbs E.6.3

54 FLANGE DIMENSIONS EN-DIN PN 6 ND D K N D2 1/ / / / / EN-DIN PN 10 ND D K N D / N= number of bolts D2 K D EN-DIN PN 16 ND D K N D2 1/ / / / / EN-DIN PN 25 ND D K N D EN-DIN PN 40 ND D K N D ASTM 150 lbs D K N D2 1/ / / / / ASTM 300 lbs D K N D2 1/ / / / / ASTM 600 lbs D K N D2 1/ / / / / E.6.4

55 HOSE ASSEMBLIES E.7. The way how low pressure hoses and couplings are assembled depends on many factors like hose type, hose tail of the coupling, working pressure of the hose and coupling, temperature range, application, etc. For low pressure couplings following hose assemblies are often used. Safety clamps Worm drive clamps HOSE ASSEMBLIES Two bolt saddle clamps Wire Binding Buckling Swaging E.7.1

56 HOSE ASSEMBLIES Assembly instructions for coupling hoses using safety clamps Choose a hose that is designed for assembly using safety clamps. Assembly is easier if you use a work bench for safety and stability. To achieve effective electrical conductivity, hoses incorporating copper strands should be brushed with contact paste. Insert the hose tail into the hose-end by hand and press it in as far as the safety collar. A rubber hammer can be used to tap larger diameter hose tails into place. Locate the clamp shells around the collar of the inserted coupling and screw the safety clamps together temporarily using hardened steel bolts. E.7.2

57 HOSE ASSEMBLIES E.7. Assembly instructions for coupling hoses using safety clamps HOSE ASSEMBLIES Always tighten the hardened steel bolts diagonally. Replace them later with stainless steel nuts and bolts. Avoid using silicone sealants, since these are not always permitted for use in industrial plants. Once the clamps have been fitted, examine the hose assembly closely. Check that the safety clamps are parallel. In correctly-dimensioned joints, there will always be a space between the clamp shells. E.7.3

58 HOSE ASSEMBLIES Safety clamps One of the safest ways to assemble hoses is to use safety clamps. Safety clamps consist of two clamp shells, and are clamped around the hose end by means of nuts and bolts. In order to assemble hoses using safety clamps, you must use either a smooth hose shank complying with EN / DIN 2817 or a serrated hose shank with safety collar complying with EN / DIN The safety clamp collar is located behind the coupling collar to achieve a safe, secure assembly. Always check the wall thickness of hoses first, and select the recommended safety clamp accordingly. Safety clamps and couplings can be used in all applications. For not standardized thin wall hoses LMC-Couplings offers not standardized safety clamps. The assembly methods of these safety clamps are similar to the standardized once. Worm drive clamps Worm drive clamps are often used with industrial couplings in smalle dimensions. The worm drive clamp is placed over the hose end, and closed simply by turning a screw. This fast, easy assembly method is recommended for aspiration hoses, suction hoses and (small diameter) low pressure hoses. Worm drive clamps are NOT recommended for use in assembling high pressure Buckling Buckling assemblies involve the use of a stainless steel band and stainless steel buckling clip. Using a tensioning tool, the stainless steel band is tightened around the hose and secured by closing the buckling rings. This fast, easy assembly method is recommended for aspiration hoses, suction hoses and (small diameter) low pressure hoses. Wire binding Hose binding involves pulling a fine steel wire tightly around the hose using a hose binding machine. This assembly is recommended for use with flexible thin wall hoses, like fire hoses. Swaging Swaging is a metal forming technique in which the metal is formed to shape under high pressure. Swaging differs from forging in that the metal is worked cold. To swage rubber hoses HRRK swage ferrules are recommended. The internal surface of HHRK swage ferrules is similar to grooved internal surface of RK-safety clamps. For PTFE hoses HRP swage ferrules are used. The internal surface of HRP swage ferrules is smooth to avoid hose damage when swaging. Composite hoses are swaged using CHR swage ferrules in combination with a CX crimping seal. E.7.4