Pre-Insulated Piping Systems

Transcription

1 Uniclass L71161:N352:P7108 CI/SfB PIPPG5 In6 (M2) June 2012 Pre-Insulated Piping Systems Product Guide and Trade Price List June 2012

2 Polypipe Building Products Polypipe is the UK s leading and fastest growing manufacturer of plastic plumbing products for hot and cold plumbing and heating systems. Our products serve the domestic market, providing installers and end users with easy to install, reliable products. At Polypipe we have a coitment to delivering products that meet every conceivable need within our chosen market sectors, with each range designed to provide outstanding innovation, performance and value. About Polypipe With an enviable reputation for a broad product range, reliability and value, Polypipe is one of Europe s largest and most innovative manufacturers of plastic piping systems for residential, coercial and infrastructure sectors. People trust Polypipe to deliver tried and tested, cost effective system solutions across the spectrum of construction projects and market sectors. Operating 17 manufacturing and operations sites, Polypipe manufactures over 16,000 items across multiple product sectors for the residential, coercial and infrastructure markets - the widest range available in its market sector. Polypipe meets, and strives to exceed, the changing regulations governing our operations and products. We are proud of our record in introducing new product systems to meet changing environmental and regulatory issues. Polypipe at a glance 2000 employees across UK, Europe and the Middle East 17 manufacturing and operational sites 30 principal brands 16,000 products 100 worldwide patents and designs 550 trademarks registered or pending 40 UK and European product approvals 20 sustainable product systems CONTENTS Unique Assets of Polypipe Pre-Insulated Pipe Product Range & Pricing 4-5 Installation Instructions 6-7 Trench Details 7 Connection Instructions 8 Insulation 9 Heat Loss Table 10 Pressure Testing

3 Pre-Insulated Pipe The unique assets of Polypipe Pre-Insulated Pipe: flexibility, durability and availability Suitable for single plot applications such as remote boilers and heat pumps Available - Standard coil lengths available off the shelf Flexible - Durable - Reliable - Flexibility Quick and easy to install with flow and return in one lay Inner PEX barrier pipe and corrugated HDPE outer casing Brass mechanical clamp fittings require no special tools or equipment Fast installation even in the event of bends, obstacles and wall feed-throughs. No compensators needed thanks to the piping system s self-compensatory behaviour No skilled welders needed for connections Limited weight facilitates easy installation Simple and safe to operate modular system of connections, including couplings and accessories Fast installation and accelerated assembly cut installation costs significantly No special tools needed Durability High-grade raw materials ensure a very long product life Unique double wall outside casing in HDPE provides extra protection to the carrier pipes Sophisticated geometry of outside casing ensures unparalleled flexibility and high resistance to impacts and pressure Very elastic thermal foam insulation in PE-X with closed cell structure excellent long-term insulation qualities and high μ factor Corrosion-free carrier pipes in PE-Xa, unique chemical resistance, very long life even under high pressures and temperatures, maximum resistance to cracks caused by ageing System pipes are highly resistant to external influences, such as stress, micro organisms and temperature swings Insulating centrepiece guarantees an effective separation of inlet and outlet pipes Polypipes Pre-Insulated Pipes are suitable for central heating applications only. They are not suitable for hot and cold water services, gas, oil or any other fuel or compressed air. Single plot applications are single residential properties only. 3

4 Pre-Insulated Pipes Double flexible pre-insulated, self-compensating, underground pipe. Suitable for heating water. Not suitable for hot and cold water supply. Corrosion-resistant transport pipe in cross-linked PE-Xa in accordance with DIN 16892/16893, with yellow oxygen barrier in accordance with DIN Thermal, elastic, CFC-free foam insulation made from cross-linked PE-X with closed microcellular structure. Minimal water absorption capacity of < 1% in accordance with DIN Insulating PE-X centrepiece guarantees an effective separation of flow and return pipes. Corrugated outside casing in HDPE, made in accordance with the closed chamber principle to provide highgrade protection to the piping system. PIPES - Flow & Return distinguished by single or double dashed line on pipe. Description PE-Xa OD / w/t PE-Xa ID Outside casing OD Weight Bending radius (1) Code Number Price Flow Return DN kg/m m Per Roll 25 x 10mtr Htg Twin Pipe Coil 2 x 25/ INS HTG x 15mtr Htg Twin Pipe Coil 2 x 25/ INS HTG x 20mtr Htg Twin Pipe Coil 2 x 25/ INS HTG x 10mtr Htg Twin Pipe Coil 2 x 32/ INS HTG x 15mtr Htg Twin Pipe Coil 2 x 32/ INS HTG x 20mtr Htg Twin Pipe Coil 2 x 32/ INS HTG (1) Applicable practical values without risk of pipe distortion or damage. Max operating pressure: 6 bar Max fluid temperature: + 95 C PE-Xa pipes: SDR 11 Carrier pipes are individually identified as flow and return DUST CAP Description Code Number Price each HEAT SHRINK CAP Description Code Number Price each 160 x 25 Dust Caps INS DC Heat Shrink Cap INS HSC x 32 Dust Caps INS DC 9.43 INSULATION KIT Description To fit outside casing OD L Insulation kit OD Weight Code Number Price kg each 160 Insulation Kit for Coupler ,0 INS160IKC Guarantees complete insulation and sealing of straight connections in pipes. Kit comprises a smooth black HDPE pipe, rock wool insulation, 2 shrink sleeves, adhesive tape and assembly instructions. Heat shrinkable caps to be ordered separately (see installation instructions on page 9) 4

5 Pre-Insulated Pipes MALE COUPLINGS Description To fit PEX pipe OD / w/t Thread Code Number Price inch each 25 Male Couplings 25/ M INS25MC-HTG Male Couplings 32/2.9 1 M INS32MC-HTG Max operating pressure: 10 bar Max fluid temperature: +95 C PE-Xa pipes: SDR 11 The coupling has a supporting spigot, a cylindrical outside compression sleeve and a clamping ring with stainless steel bolt. The included remote plate makes it easier to fit the coupling. FEMALE COUPLINGS Description Thread Code Number Price each inch 25 Female Coupler 3 4 FF INS25FC-HTG Female Coupler 1 FF INS32FC-HTG 6.42 FIX POINTS Description Thread Code Number Price each inch 25 Fix Point 3 4 FF INS25FP-HTG Fix Point 1 FF INS32FP-HTG Fix points must be installed to absorb the possible effects of thermal expansion / shrinkage of the PE-Xa transport pipes. The nonapplication of fix points may result in serious damage to pipes, joints and buildings. 5

6 Installation Instructions 1.1 Transport and storage of Pre-Insulated Pipe Pipes are supplied in coils with a maximum length of 20 metres. Pipe ends are sealed with protective end covers to prevent the entry of pollutants. In storage, care must be taken to ensure that the PE- Xa carrier pipe is protected from sunlight and that no undesirable deformation of the coil is occuring. Pipes must be transported and stored in such a way that sharp objects, like stones and tree roots cannot damage them. Pipes must not be dragged along the ground. Only nylon or tectile straps should be used for fastening the coils during transport. 1.2 Utility trench profile Up to a trench depth of 120cm, we recoend digging a vertical trench; deeper than 120cm we recoend a V-shaped trench. Excavation works must be carried out in the approved manner, according to the rules and regulations of local authorities. Prior permission is often required and care should be taken to identify existing underground services prior to installation. A land register plan might be useful to eliminate possible conflicts with existing or future utilities and structures. After completion of the pipe-laying process, the route must be marked with a warning tape. Entry in the land register is also recoended. 1.3 Groundwork Pipes are laid in trenches in the ground. It is most practical to lay the excavated ground alongside the trench. The following steps are a suary of the basic pipe installation procedure: - Position the coil alongside the trench - Remove the packaging - Place the end of the pipe in position - Cut the outermost straps - Roll the pipe alongside or straight into the trench - Cut the middle straps - Roll out further - Cut the innermost straps - Roll out completely - Apply the dust caps or shrink caps - Connect your pipes with couplings - Conduct the pressure test fill in the report - Fill the trench with a first layer - Apply the warning tape - Fill up the trench ATTENTION: Minimum laying temperature for Pre-Insulated Pipes: -5 o C. The following guidelines should be followed during pipe installation: - Lay the pipes in a bed of sand - Avoid damaging the casing, remove sharp objects from the ground - Always grasp the transport pipe and not the outer tube - Keep to the stated bending radii - Lay the pipe with a slight curve bending from one side of the trench to the other - Sketch how and where the pipe network runs on a plan, which you should keep 6

7 R A jacket A 1.4 Trench dimensions Particular attention must be paid to ground frost depth. Values in brackets refer to an authorised axle load of 5T. B C D (650) b width t* depth (1060) Excavation m 3 /m approx Sandfill m 3 /m approx Securing the Pipe In a trench: Care must be taken to ensure that a slightly curved line is maintained. In order to keep the pipes in the desired position, the trench may be backfilled with sand at regular intervals. In buildings: Fixed points must be installed at entry of buildings. They are necessary to anchor pipes at each end of the pipe run to account for expansion and contraction. If the installation includes an externally mounted heat pump provision must also be made anchoring to avoid damage to the heat pump. 2 D 1 t* C B R A A R A b A 1. Backfill 2. Route warning tape 3. Sand fill 4. Sandbed 5. Pre-Insulated Pipe ATTENTION: The use of fixed points is mandatory. Where pipes are to be installed in any situation other than un-trafficked or up to 5 tonne axle load please contact our technical services department for further guidance. 7

8 Installation Instructions 1.6 PE-X terminal connections Polypipe Pre-Insulated Pipe connections are mechanical fittings. They are available in straight versions with a male thread which can be used with female couplers to create straight connections in pipes and fix points to create anchor points. 6 Push the pipe COMPLETELY over the coupling. 1 Cut the PE-X pipe squarely with a suitable pipe cutter. 7 Slide the clamping ring back to completely cover the fitting. 2 Deburr the pipe with an appropriate tool, ensuring a clean smooth pipe end free from dirt and debris 8 Remove the bolt and steel plate. 3/4 The clamping ring is loosely attached to the coupling with a nut that clamps open the clamping ring in a steel plate. This clamping ring can be removed freely. 9/10 Assemble the bolt, washer and nut provided and tighten the clamping nut in accordance with the following force: 5 Slide the clamping ring over the pipe. NB! Do NOT rotate the clamping ring. Ensure that the notch on the inside of the clamping ring is facing the fitting. ø S M 25 M 8 8 Nm 32 M 8 8 Nm Note: Please make sure to lubricate the threads on bolt and nut, as well as the washer(s). 8

9 1.7 Insulation Kit Each kit comprises a smooth black HDPE pipe, rock wool insulation, two heat shrink sleeves, adhesive tape and assembly instructions. 1 Slide the rigid sleeve over the Pre-Insulated pipe. 5 Slide the rigid sleeve back so as to enclose the connections. 2 The use of heat shrinkable sleeves is mandatory on the pipe ends and should be ordered separately. 6 Use a heat gun or mini torch with soft yellow flame (do NOT use a blue flame!) to gently shrink both sleeves half onto the rigid sleeve and half onto the jacket of the Pre-Insulated pipe. 3 Secure the terminal conections. L1 L1 L2 L2L3 L1 L1 4 Wrap the insulating blanket around the carrier pipe so that the connections are properly covered. Tie with the supplied tape. L1 L3 L1 L2 Code Number L1 L2 L3 L3 INS160IKC

10 Heat Loss Tables The use of PE-X pipes has proved successful for years in many installations worldwide. Data in the tables reflect principal standards and directives that have been established for cross-linked PE-X pipes by competent national and international authorities. The values used in calculating the heat loss charge are: λ Insulation: W/m.K Heat losses in W/m x 32 2 x 25 jacket λ Ground: 1.2 W/m.K Δ T λ PE-Xa pipe: 0.35 W/m.K Depth of cover over top of pipe: 50 cm With the ΔT being calculated, the heat loss per metre of piping can easily be read along the corresponding line of the table. Heating capacity in Watts calculated at a T of 20 C Pipe rugosity: Water density: g/cm 3 Water temperature: 80 0 c PE-Xa pipe 25 x x 2.9 ΔT = (T v +T r ) - T o 2 T v : Flow temperature T r : Return temperature T o : Ground temperature l/s Δt : 20 C Watts v m/s R Pa/m v m/s R Pa/m , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,

11 Pre-Insulated Pipes Pressure test according to DIN The pressure test procedure is mandatory before backfilling over any pipes Prior to concealing, fill the finished pipework with water, taking care to avoid air locks. The pressure test must be conducted in three parts, starting with the preliminary test, followed by the main test. 1. Preliminary test. The preliminary test involves applying a test pressure equal to 1.5 times the admissible operating pressure. This pressure must be regenerated twice within the space of 30 minutes at intervals of 10 minutes. Following a test period of another 30 minutes, the test pressure must not have fallen by more than 0,6 bar. Leakages must not occur at any points in the system being tested. 2. Main test. The main test has to be conducted iediately after the preliminary test. The test takes 2 hours. At the end of this period, the test pressure recorded after the preliminary test must not have fallen by more than 0.2 bar. Leakages must not occur at any point in the system being tested. 3. Heat test. Finally To ensure that the underground network is completely watertight, we advise you to heat the system at 85 C for one hour, regularly checking that the connections are secure. Let the system cool down to 20 C before conducting a final check of all pipe connections. Leakage testing - DIN bar Top up pressure 1.5 x operating pressure P <0.6 bar 1 P <0.2 bar Preliminary Test Main Test Heat Test min Test the finished pipe-work before concealing! The state-of-the-art execution and documentation of the pressure test for the entire piping system is a warranty requirement! 1 Preliminary test bar / psi 2 Main test bar / psi 3 Heat test bar / psi 1.1 Operating pressure x Beginning o c 1.2 After 10 min (restore 2.1) End 3.2 After 1 hour 1.3 After 20 min (restore 2.1) 2.2 Test pressure o c 1.4 After 30 min 2.3 After 120 min 3.4 Final check 1.5 After 60 min admissible pressure drop < 0.6 bar 2.4 Remarks admissible pressure drop < 0.2 bar 11

12 Pre-Insulated Piping Systems Polypipe Ulster Dromore Road Lurgan, Craigavon Co. Armagh BT66 7HL United Kingdom Tel: +44 (0) Fax: +44 (0) Polypipe Building Products 2410 London Road Mount Vernon Glasgow G32 8XZ United Kingdom Tel: +44 (0) Fax: +44 (0) Polypipe Building Products Broomhouse Lane Edlington Doncaster DN12 1ES United Kingdom Tel: +44 (0) Fax: +44 (0)