9.0. Table of contents. CALCOPPER - District heating pipe CCO. 9.0 Table of contents. 9.1 System description

Transcription

1 Table of contents Table of contents 91 System description 9100 System description (general) 9105 System description (data) 9115 CALCOPPER - Local and house connection pipe Construction, dimensions, materials, weights and delivery lengths 92 Planning, design engineering 9200 Pipe routing 9201 Pipelaying instructions, part Pipelaying instructions, part Pipelaying instructions, part Pressure losses 9210 Heat losses 93 Components 9320 Joint sleeve / Fitting the T-piece 9340 Insulating material 9345 Copper fittings / brazing instructions 9355 Connection of copper heating pipe to KMR 9365 End cap 9370 Wall sealing ring / Pipe warning tape 95 Underground construction work, assembly 9500 Trench dimensions 9505 Pipe entry into buildings

2 System Description General General CALCOPPER is a fleible pipe system suitable for temperatures of up to 120 C This piping is intended for use in small and medium-sized local heating networks CALCOPPER has a medium pipe made of copper Manual processing of this piping is very easy The heat insulation consists of a fleible CFCfree hard polyurethane foam with outstanding heat insulation characteristics The fleibility of the CALCOPPER piping means that it can be adapted to virtually any pipe conditions with no problems Pipes can cross above or below eisting supply lines, and obstacles can be easily bypassed CALCOPPER 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 CALCOPPER 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 CALCOPPER makes it possible to choose the shortest pipe route, without taking classical pipe construction methods into consideration 2 Range of application Heating: Ma continuous operating temperature TBma: 120 C Ma operating pressure p: 16 bar

3 System Description Data Carrier pipe Material: Soft copper, R220 to EN1057 Oygen-free copper, deoidised with phosphorus SF-Cu F22 to DIN17671 Characteristics: Meets the requirements specified by EN 1057 (mechanical values in the delivered state) Cu medium pipe Density Proof stress Ultimate tensile strength Hardness Modulus of elasticity Linear epansion coefficient Heat conductivity Reference temperature C Value 893 ma to to E W/mK kg/dm 3 N/ 2 N/ 2 N/ 2 1/K Eamination norm DIN DIN DIN Heat insulation Material: CFC-free, 100% pentane-blown polyurethane foam (PUR) PUR insulation Density Heat conductivity Closed cells Water absorption after 24 hours Reference temperature C 50 Value > kg/m 3 W/mK % % Eamination norm DIN DIN EN Protective casing Material: Purpose: Polyethylene of low density, PE-LD, etruded seamless Protection against mechanical effects and moisture PE-LD protective casing Density Heat conductivity Crystallite melting range Reference temperature C Value kg/m W/mK C Eamination norm DIN DIN 52612

4 Local heating and house connection piping Heating, 16 bar, UNO and DUO s d D s1 UNO DUO Pos Material Medium pipe in soft copper, R220, to EN1057, SF-Cu F22 to DIN 1787/17671/1754 Fleible, semi fleible pentane-blown polyurethane foam, resistant up to 130 C Thermal conduction coefficient λ = W/mK at 50 C average temperature PE-LD film Outer casing in black PE-LD polyethylene (VDE 0209), etruded seamless Protection against mechanical effects and moisture CALCOPPER, UNO Type 15/76 18/76 22/76 22/91 28/76 28/91 35/91 DN Carrier pipe Cu d s Casing D s Min Bending radius m Capacity carrier pipe l/m Weight l/m ma Delivery length Ring without connection m On request Ring dimensions: Ø (width) CALCOPPER, DUO Type DN 18+18/ / / / /91 25 Carrier pipe Cu d s Casing D s Min Bending radius m Capacity carrier pipe l/m Weight kg/m ma Delivery length Ring without connection m

5 Eamples of pipe routing Connection: copper local heating pipe - plastic casing pipe Copper local heating pipe B A Copper local heating pipe Plastic sheath pipe C Copper local heating pipe Looping-in method Connection CALPEX-CALPEX Connection: Copper - Copper A B D A C C D B E Note epansion pad as shown on catalogue pages 9201, 9202 and 9203

6 Instructions for pipe laying Part Instructions for pipe laying If the lengths of pipe to be laid eceed 5 m, the copper junction pipes must first be bent into a sinusoidal shape (curve length: L = 2 m, amplitude: 10 outer diameter of copper local heating pipe) Epansion pad 2 m 10 Ø outer casing Copper local heating pipe Epansion pad for sinusoidal curves Copper local heating pipe > 10 m Method of laying 10 m > 10 m Copper local heating pipe Copper local heating pipe Epansion pad for sinusoidal curves 1-5 m Copper local heating pipe Copper local heating pipe Epansion pad for sinusoidal curves > 5 m Copper local heating pipe Copper local heating pipe < 5 m Copper local heating pipe Epansion pad for sinusoidal curves Copper local heating pipe 5-10 m - Special brazing must be used to solder the pipes together (this must be resistant to galvanic or electrochemical corrosion) - The brazing instructions / manufacturer's instructions for the copper fittings 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

7 Instructions for pipe laying Part Pipe junctions from copper or steel / Main pipes on copper The copper local heating pipe can only accoodate forces and deformations from connected eternal pipes to a limited etent Epansion padding has to be applied to copper local heating junction pipes The number of epansion pads required depends on the movement of the main pipe The 3 illustrations shown below provide the basic rules: Illustration 1 Copper local heating pipe Epansion pad l 20 1 m Illustration 3 Epansion pad 40 l 60 Copper local heating pipe 3 m or KMR or PLASTIC CASING PIPE Illustration 2 Epansion pad 20 l 40 Copper local heating pipe 2 m oder KMR Thickness of epansion pads: 40 The epansion pads must be applied as far as the casing of the main pipe (ie they are positioned on top) The first layer of epansion pad is positioned around the local copper heating pipe which branches off (the junction pipe) The second and third layers of epansion pad are only applied at the sides (ie they are placed adjacently) The foregoing illustrations assume that junction sleeves are used

8 Instructions for pipe laying Part 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 epansion to a limited etent The following eamples show how this can be guaranteed: KMR KMR KMR KMR ma 5 m Über 20 m The maimum length of the plastic casing pipe is 5 m Epansion padding is required No sinusoidal curve is required on the copper pipe The length of the plastic casing pipe may eceed 20 m Epansion padding is required KMR KMR KMR KMR ma 10 m ma 20 m The maimum length of the plastic casing pipe is 10 m Epansion padding is required The maimum length of the plastic casing pipe is 20 m Epansion padding is required Reduction General instructions for reducing the medium pipe The following rules must be followed for a reduction of the medium pipes: ma 5 m, reduziert 1 If gunmetal reductions are used, no particular instructions need to be followed 2 The following instructions refer to reductions with normal copper fittings The heat epansion is absorbed by the sinusoidal curve (see page 9210) upstream of the T-junction Epansion padding is required

9 Pressure loss Heating, 16 bar Water, average temperature 80 C Roughness ε = 0015 (copper) (1 water column = 981 Pa) Q 860 m = T m = Flow rate in kg/h Q = Power requirement in kw T = Temperature difference forward/return flow in C Flow quantity, m [kg/h] Water-velocity v [m/s] 18 m/s 14 m/s 12 m/s 10 m/s 08 m/s 06 m/s 05 m/s 04 m/s 03 m/s 02 m/s 015 m/s 25 m/s (DN 32) (DN 25) (DN 20) (DN 15) (DN 10) Pressure loss, p [Pa/m] 1mbar/m 10 mbar/m

10 Heat loss Heating, 120 C, 16 bar, UNO and DUO Copper heating pipe Heat loss q [W/m] for single-line pipe UNO Type U-Value average operating temperature TB [ C] UNO [W/mk] / / / / a=01m H=06m 22/91 0, / TE E 35/ Copper heating pipe (Forward and return flow in the same protective sheath) Heating loss q [W/m] for twin-line pipe DUO Type U-Value average operating temperature TB [ C] DUO [W/mk] / / / / H=06m 28+28/ TE E Method of laying: Covering height: Earth-temperature: Conductivity of ground: Conductivity of PUR-foam: Conductivity of CU-pipe: Conductivity of PE-casing: 2 separate UNO pipes underground H = 060 m TE = 10 C λe = 12 W/mK λpu = W/mK λcu = 0305 W/mK λpe = 043 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 earth temperature [ C]

11 Connecting socket Tee Branch insulation kit Connecting socket d1 d2 1 Copper fitting, see sheet Insulation material, see sheet Shrinking socket 4 Shrinking hose d1 d Tee Branch insulation kit GFK fibreglass-shell tested by Fernwärme-Forschungsinstitut (FFI) of Hannover d2 d d3 ma Copper T-piece, see sheet COO GFK half-shells 3 Insulating material, see sheet COO Reducer ring 5 Special sealing compound Ø eternal d1 d Junction, d

12 CALCOPPER - District heating pipe Insulation material PUR-foam package Insulation material for T-piece sets and sockets PUR - foam package The required volume of polyurethane foam is supplied in the appropriate foam size for the various sockets and T-pieces The clip (splitting the components) must be removed by pulling it away The two components are mied together by shaking PUR - foam package Base: CFC-free PUR-foam Security requirement for the foam insulation plastic gloves eye protection

13 Soldering instructions Soldered fittings Copper fittings Brugg Pipe Systems recoends fittings from the Georg Fischer company (+GF+) All joints and T-pieces, etc can be obtained in all dimensions from 18 to 35 Brazing instructions The special BRUGG brazing must be used to solder the fittings Joint, equal Brazing (high argentiferous ) Type BRL Euro standardisation pr EN 1044 ISO 3677 B Cu Ag Zn Sn Art-No GF+ Composition Ag Zn Sn Si Cu Guideline analysis (%) Joint, reduced Application Capillary brazing joints brazing for steels, copper and copper alloys, nickel and nickel alloys For brazing points with operating temperatures up to 200 C Suitable for Cu pipe installation to DVGW working sheet GW 2 Art-No GF+ Connection with eternal thread Flu Rods thinly covered with flu Technical information Working temperature 710 C Melting range C Tensile strength St N/ 2 St N/ 2 Specific gravity 90 g/cm 3 Elongation > 12% Electrical conductivity 14 Sm/ 2 Art-No GF+ Heat sources Acetylene/oygen miture The oy-fuel gas flame must be set to neutral T-connection piece, equal, reduced Art-No GF+ Caution! Copper fittings with notches are available in the trade; under no circumstances must these be used!

14 Connection of copper heating pipe to KMR St-Cu-Fitting L1 L2 45 St-Cu-Fitting Cu 70 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 copper fitting on his copper end Connecting joint Outer ø in St Cu L L Fle-T-Socket KMR-Pipe Outer ø Branche line Outer ø The branche line would be insulated by the shrinking socket, double internal and eternal sealed

15 End cap 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 15/76 18/76 22/76 28/76 22/91 28/91 35/ / / / / /91 Shrinkdown end cap DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2000 DHEC 2100 DHEC 3200 DHEC 3200 DHEC 3250 P604 DHEC 3250 P604 DHEC 3250 P604

16 Wall sealing ring Pipe warning tape Wall sealing ring Copper heating pipe Da D 50 Type 15/76 18/76 22/76 22/91 28/76 28/91 35/ / / / / /91 Wall sealing ring Outer pipe casing D Da Pipe warning tape To be laid in the ground Standard roll length: 250 m Laying depth: see sheet 9500 ACHTUNG! FERNWÄRMELEITUNG

17 Trench dimensions Trench profile, 2 copper local heating pipes UNO DUO all dimensions in cm D T D T 10 D 10 D 10 B 10 D B 10 Pipe casing Ø D cm Width B cm Depth T cm Minimum radius of curvature, m Pipe casing Ø D cm Width B cm Depth T cm Minimum radius of curvature, m Trench profile, 4 copper local heating pipes (loop-in method) D D 10 D D D T 10 T D D D D D 10 B(4D + 210) 10 D D 10 B 1 Pipe warning tape 2 Ecavated material 3 Washed sand, grain size 0-3/4 Laying depth: maimum laying depth: 26 m Our approval is required before laying at greater depths SLW 30 = 300 kn total load to DIN 1072; for eposure to higher operating loads (such as SLW 60), a load-distributing 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 ) of at least 10 cm, and that there is coverage of the same thickness above

18 Entry into buildings Entry into buildings Copper connection piece; see sheet ca 80 D Var 1 Var 2 Pipe; see sheet 9115 Wall sealing ring; see sheet 9370 Fipoint End cap; see sheet 9365 Due to the epansion of the CALCOPPER piping fipoints must be installed Wall opening Outer casing Ø D L min H H D 100 D 80 L Breakthrough bored 30 Outer casing Ø D D1 min A D A