RAUPEX Industrial Piping System

Subject to technical modifications
Technical information 876.600 E
RAUPEX Industrial Piping System
Table of contents
1.
Programme components
3
2.
2.1
2.1.1
2.1.2
2.1.3
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
Pipe
RAU-PE-XA Material
Material properties
PE-Xa property values
Chemical stability
Long-term rupture strength
Types of pipe
RAUPEX-A
RAUPEX-K
RAUPEX-0
RAUPEX-UV
RAUTHERM-FW
3
3
3
3
3.
3.1
3.2
3.3
3.4
3.5
3.6
Compression sleeve joint
Description
Fittings material
Jointing tools
Fitting a compression sleeve joint (16 mm to 40 mm)
Fitting a compression sleeve joint (40 mm to 110 mm)
Separating a compression sleeve joint
5
5
5
6
7
8
9
4.
4.1
4.2
4.3
4.4
4.5
4.6
Electrofusion couplers
9
Material
9
Application limits
9
Assembly equipment
9
Joining
10
Fitting tapping saddles
Notes on welding electrofusion couplers and tapping
saddles
14
5.
5.1
5.2
5.3
4
5
5
5
5
5
5.5.6
5.5.7
6.
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Cooling water
General aspects
Configuration
Form to determine the pressure loss
Example for calculating the pressure loss
Cooling water SDR 11
Cooling water SDR 7,4
Form for calculating the pressure loss
5.4.2
5.4.3
5.4.4
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
2
Transport of solids
Hydraulic transport of solids
Pneumatic transport of solids
27
27
27
8.
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.2
8.3
8.4
27
27
27
27
27
27
28
28
28
8.6.1
8.6.2
Assembly and laying
Underground installation
Earthwork
Checking the pipes
Special features in laying coiled pipes
Minimum bending radii for underground laying
Filling the pipe trench
Positioning within existing pipework
Positioning in ductwork
Positioning in combination with the cable carrier
system (cable ladder)
Using the cable carrier system for positioning
Positioning underneath or at the side of the cable
carrier system
Uncovered positioning with supporting clip channel
Deflection leg assembly with supporting clip channel
Calculation of the deflection leg
Example calculation
Calculating the deflection leg by diagram
Uncovered positioning without supporting
clip channel
Positioning a deflection leg
Pre-stressed positioning
9.
9.1
9.2
REHAU pipe clamp
REHAU pipe clamps with and without clip bow
REHAU wall clamps
35
35
36
10.
10.1
10.2
Fire protection
Fire risk
Fire protection sleeves
37
37
37
11.
11.1
11.2
Marking of pipe systems
Marking colours
REHAU adhesive labels
37
37
38
12.
Practical examples
38
Notes
39
8.4.1
8.4.2
Compressed air
16
General aspects
16
Energy costs of compressed air
16
Advantages of RAUPEX industrial pipe system
in compressed air engineering
16
Quality of compressed air
17
Quality class for maximum particle size and
maximum concentration
17
Quality class for water content
17
Quality class for oil content
17
Example for the quality description of compressed air 17
Configuration
18
Determination of the operating pressure
18
Determination of the volume current
18
Determination of the pipe length
18
Determination of the pressure drop
19
Determination of the pipe diameter by means of a
nomogram
19
Compressed air - pipe dimensions SDR 11
20
Compressed air - pipe dimensions SDR 7.4
21
5.4
5.4.1
7.
7.1
7.2
22
22
22
22
23
24
25
26
8.5
8.5.1
8.5.1.1
8.5.1.2
8.5.1.3
8.6
28
28
28
29
29
29
29
29
32
29
34
1. Product range
2.1 RAU-PE-Xa material
2.1.2 PE-Xa property values
In more and more branches of industry,
such as the automotive industry, chemical
industry and the power supply industry, the
RAUPEX industrial pipe system is used for
various applications. The fast and safe
installation, the anti-corrosion properties, the
light pipe material, and the favourable installation costs show that RAUPEX combines
many advantages in one system.
The RAUPEX industrial pipe system meets
the requirements of the industry for safe and
complete system solutions. It offers an
extensive assortment of differently coloured
pipes, fittings, tools, and other accessories
which will be explained and described in
greater detail in this technical information
manual.
The pipes in the industrial RAUPEX pipe
range consist of the RAU-PE-Xa material, a
cross-linked polyethylene which has been
produced according to the REHAU process.
The polyethylene is cross-linked at high
pressure and high temperature under addition of peroxide. In this process, links are
produced between the macro molecules in
such a way that they link up to a network.
Density
0,94 g/cm3
Average coefficient of
thermal elongation in a
temperature range of
0 to 70° Celsius
1.5 10-4 K-1
Caloric conductibility
0.41 W/Km
Modulus of elasticity
600 N/mm2
Surface resistance
>1012 Ω
Building material class
B2 (normal
inflammability)
Pipe accuracy
0.007 mm
2. Pipe
RAUPEX pipes consist of a basic pipe made
of cross-linked polyethylene (PE-Xa) in compliance with German standard DIN
16892/93 and a coloured coating. RAUPEX
pipes are offered for two pressure stages
with different wall thicknesses (SDR 11 and
SDR 7.4). The abbreviation stands for
”standard dimension ratio” and describes
the ratio between external diameter and wall
thickness of the pipe.
d
SDR =
s
d: external diameter of the pipe [mm]
s: wall thickness [mm]
This formula reveals that the SDR 7.4 pipes
have a thicker wall than the SDR 11 pipes.
For this reason, SDR 7.4 pipes can be loaded with a higher internal pressure than
SDR 11 pipes. On account of the lower
internal diameter, however, the flow rate of
the SDR 7.4 pipes drops to approx. 60 per
cent of the values of SDR 11 pipes. For this
reason, it is important to take into consideration the pressure conditions, the throughflow ratio as well as the temperature conditions in selecting the ideal pipe in order to
obtain an overall economic solution.
The characteristic feature for high-pressure
cross-linkage is the linkage in the melt
above the crystallite melting point. The
cross-linking reaction occurs during the pipe
formation in the extrusion tool. Even in the
case of thick-walled pipes, this process
ensures a regular cross-linkage across the
whole wall thickness. Pipes cross-linked by
high pressure can be heated to beyond the
recrystallation temperature without a loss of
quality, which permits durable deformation
or return of the pipe into the original condition by heat treatment.
2.1.1 Material properties
Cross-linking the PE dramatically improves
the material properties.
■
■
■
■
■
■
■
■
■
Tab. 1: Property values of PE-Xa
2.1.3 Chemical stability
RAUPEX pipes have an excellent chemical
stability. Safety factors and temperature
resistance depend on the media, which in
parts differ to the values for water and air. If
RAUPEX pipes are to be used for the transport of chemicals, REHAU technical department can offer assistance.
Corrosion resistance
Favourable ageing behaviour
Creep resistance
Recoverability
Temperature resistance
Low sound transmission
Pressure resistance
Toxicologically and physiologically safe
Excellent notched bar impact value
3
2.2 Long-time rupture strength
The long-time rupture strength of RAUPEX
pipes depends on a combination of pressure, temperature, and time. Each combination produces a maximum permissible pressure for specific temperatures and operating
life.
Temperature
[° Celsius]
Operating years
Permissible operating pressure p [bar]
SDR 11
SDR 7.4
10
1
5
10
25
50
100
17.9
17.5
17.4
17.2
17.1
17.0
28.3
27.8
27.6
27.3
27.1
26.9
20
1
5
10
25
50
100
15.8
15.5
15.4
15.2
15.1
15.0
25.1
24.6
24.4
24.2
24.0
23.8
30
1
5
10
25
50
100
14.0
13.8
13.7
13.5
13.4
13.3
22.3
21.9
21.7
21.4
21.3
21.1
40
1
5
10
25
50
100
12.5
12.2
12.1
12.0
11.9
11.8
19.8
19.4
19.3
19.1
18.9
18.7
50
1
5
10
25
50
100
11.1
10.9
10.8
10.7
10.6
10.5
17.7
17.3
17.2
17.0
16.8
16.7
60
1
5
10
25
50
9.9
9.7
9.7
9.5
9.5
15.8
15.5
15.3
15.2
15.0
70
1
5
10
25
50
8.9
8.7
8.6
8.5
8.5
14.1
13.8
13.7
13.6
13.4
80
1
5
10
25
8.0
7.8
7.7
7.6
12.7
12.4
12.3
12.1
90
1
5
10
15
7.2
7.0
6.9
6.9
11.4
11.1
11.0
11.0
95
1
5
6.8
6.6
10.8
10.6
Medium: air and water Safety factor: 1.25
Tab. 2: Long-time internal rupture strength of RAUPEX pipes
4
2.3 Types of pipe
German standard DIN 2403 defines certain
pipe colours for different media. The colours
of RAUPEX pipes are based on this definition.
2.3.1 RAUPEX-A
The RAUPEX-A pipe consists of an UV stabilised basic pipe made of RAU-PE-Xa in
compliance with German standard DIN
16892/93 and a coating made of PE 80 in
silver grey (RAL 7001). In compliance with
German standard DIN 2403 the silver grey
colour is the marking colour for the medium
of air. The use as a fresh air pipe, scavenging air pipe, supply air pipe and compressed air pipe is permissible.
2.3.2 RAUPEX-K
The RAUPEX-K pipe consists of an UV stabilised basic pipe made of RAU-PE-Xa in
compliance with German standard DIN
16892/93 and a coating made of PE 80 in
green (RAL 6018). In compliance with
German standard DIN 2403 the green
colour is the marking colour for water-conducting pipes. For this reason, these pipes
are suitable for raw water pipes, waste
water pipes, condensate pipes, sealing
water pipes and cooling water pipes.
Fig. 1: Compression sleeve joint in sectional view.
2.3.3 RAUPEX-O
3. Compression sleeve joint
3.2
The RAUPEX-O pipe consists of an UV stabilised basic pipe made of RAU-PE-Xa in
compliance with German standard DIN
16892/93 and a coating made of PE 80 in
blue (RAL 5015). These pipes are suitable
for all industrial applications, for which a
blue pipe is requested. Apart from the range
of application in compliance with German
standard DIN 2403, blue is frequently the
marking colour for compressed air.
3.1 Description
The fittings of the compression sleeve joint
are made of special non-dezincifying brass
in compliance with European standard DIN
EN 1254/3 (E), class A, or gunmetal. The
compression sleeves are made of unstressed standard brass CuZn39Pb3 / F43 in
compliance with German standard 17671 or
gunmetal.
2.3.4 RAUPEX-UV
The RAUPEX-UV pipe consists of an UV
stabilised basic pipe made of RAU-PE-Xa in
compliance with German standard DIN
16892/93 and a coating made of PE 80 in
black (RAL 9005). In compliance with
German standard DIN 2403 the black colour
is the marking colour for non-combustible
gases and non-combustible liquids. These
pipes are especially suited for outdoor use
and for applications, in which increased UV
radiation values may occur. When using
these pipes, it is important to observe that
insulation may increase the temperature of
pipes considerably, which has to be taken
into consideration for the pressure applied.
The compression sleeve joint developed and
patented by REHAU is a coupling for fast,
safe, and durably tight connection of RAUPEX pipes. It consists of a fitting and a compression sleeve. As the pipe acts as a seal,
no additional ‘O’ ring seals are required.
Four sealing ribs ensure the absolute safety
of the connection, which withstands the
tough application conditions on building
sites. Special ribs on the external sleeve
prevent the connection coming loose in
operation.
Fittings material
To complete a compression sleeve joint, a
REHAU compression sleeve tool has to be
used, permitting a fast, easy, and safe
installation.
2.3.5 RAUTHERM-FW
The RAUTHERM-FW pipe consists of a
basic pipe made of RAU-PE-Xa in compliance with German standard DIN 16892/93
and an oxygen diffusion barrier in compliance with DIN 4726 and DIN 4729. On
account of the oxygen diffusion barrier the
RAUTHERM-FW pipe is especially suited for
closed circuits, in which oxygen transfer into
the system is to be prevented.
5
3.3 Installation tools
REHAU offers several tools for the application of compression sleeve joints. The various
tool options enable the installer to choose
the ideal tool for the respective range of
application.
All REHAU tools for compression sleeve
joints have been designed in such a way
that they meet the requirements of building
sites. The installer has to decide which tool
offers the best solution for the particular
application.
Fig: 2 RAUTOOL M1
Fig. 3: RAUTOOL H1
RAUTOOL M1:
Manual tool with double clamping jaws for
two dimensions each. Field of application
from 16 to 40 mm in dimension.
RAUTOOL H1:
Mechanical hydraulic tool with double clamping jaws for two dimensions each. The tool
is driven by a foot/hand pump. Field of
application from 16 to 40 mm in dimension.
Fig. 4: RAUTOOL E2
Fig. 5: RAUTOOL A1
RAUTOOL E2:
Electro hydraulic compression sleeve joint
tool with double clamping jaws for two
dimensions each. The tool is driven by an
electro-hydraulic unit which is connected to
the tool cylinder by an electro-hydraulic
hose. Field of application from 16 to 40 mm
in dimension.
RAUTOOL A1:
Electro-hydraulic tool with battery pack drive
and double clamping jaws. The tool is driven
by a hydraulic tool operated on a battery
pack, which is fitted directly to the tool cylinder. Field of application from 16 to 40 mm in
dimension.
The hydraulic tools RAUTOOL H1, RAUTOOL E2, and RAUTOOL A1 are compatible and are fitted with the same kits.
Expanding pliers and the expander heads of
the REHAU expanding system RO are compatible with all tools up to a diameter of
32 mm.
Fig. 6: RAUTOOL G1
RAUTOOL G1:
Tool for the dimensions of 50 mm and
63 mm as well as the dimensions of 40 mm
and 75 to 110 mm to order. The tool cylinder is used for widening and pushing. The
tool is driven by an electro-hydraulic unit. If
required, the tool can be fitted with a foot
pump.
6
3.4 Fitting a compression sleeve joint (16 mm to 40 mm)
Fig. 7:
1. Cut the tube to the requested size.
Fig. 8:
2. Push the compression sleeve over the
tube. The inside chamfer has to point to the
end of the tube.
Fig. 9:
3. Use the expander bit to widen the tube
by 30° twice, ..
Fig. 10:
4. … or use an expander.
Fig. 11:
5. Push the fitting into the tube. After a short
period of time the fitting has a tight fit in the
tube.
Fig. 12:
6. Apply the tool to the joint. Do not jam.
Fig. 13:
7. Push the compression sleeve right up to
the fitting collar.
Fig. 14:
8. Directly after completion, the joint can be
subjected to pressure and temperature.
7
3.5 Fitting a compression sleeve joint (40 mm to 110 mm)
Fig. 15:
1. Cut the pipe to the requested size.
Fig. 16:
2. Push the compression sleeve over the
pipe. The inside chamfer has to point to the
pipe end.
Fig. 17:
3. Use the expanding unit of RAUTOOL G1
to widen the pipe by 30° twice.
Fig. 18:
4. Push the fitting into the pipe. After a short
period of time the fitting has a tight fit in the
pipe.
Fig. 19:
5. Remove the expanding unit from the tool.
Fig. 20:
6. Push the jaws onto the cylinder.
Fig. 21:
7. Apply the tool to the joint. Do not jam.
Fig. 22:
8. Push the compression sleeve right up to
the fitting collar.
Fig. 23:
9. Directly after completion, the joint can be
subjected to pressure and temperature.
8
3.6 Separating a compression
sleeve joint
Given the following procedure, the compression sleeve joint fitting can be used
again after separation:
1.
2.
3.
4.
4.
Cut the fitting with the compression
sleeve from the pipe retaining a piece
of pipe as short as possible.
Heat the entire fitting to more than 130°
Celsius.
Use pliers to pull the compression
sleeve off, removing the piece of
RAUPEX pipe – Warning – Danger of
getting burnt !
Reuse the compression sleeve fittings
after they have cooled down; discard
the compression sleeve.
Electrofusion couplers
REHAU electrofusion fittings are fittings with
an integrated resistance wire. By means of
electric current, this wire is heated to the
required fusion temperature, at which the
fusion is carried out. Each fitting has an integrated recognition resistor, which ensures
the automatic setting of the welding parameters in the REHAU welding apparatus
(article No. 244 762 001). The barcode on
all REHAU electrofusion fittings permits the
use of all commercially available welding
apparatus with a bar code reader.
By means of a weld sprew indicator which
protrudes during the welding process, each
fitting gives a visual check. In the case of
pipes made of polymer materials, oxidation
caused by environmental influences may
occur in the margin areas of the walls. For
this reason, the external layer has to be
scrapped or peeled off directly before the
welding process can begin.
4.1 Material
4.3 Assembly tools
REHAUS electrofusion couplers are made of
black UV stabilised polyethylene (PE 100).
■ Density: > 0.93 g cm3 (in compliance
with German standard DIN 53479,
process A)
■ Melting index 005 (MFI 190/5): 0.4 to
0.7 g/10 min. in compliance with
German standard DIN 53735
REHAU welding apparatus operates fully
automatically. It has a stable housing and
has a display which is illuminated in the
background. With two differently coloured
welding cables (black and red) the welding
apparatus is connected to the fitting. For
this purpose, the red cable is plugged into
the red contact on the fitting. The resistor
mounted in the REHAU fitting is used to
automatically set the welding parameters in
the welding apparatus. An automatic monitoring system controls the welding process
based on the electrical current. In case of a
fault, the operator is informed by a warning
signal indication on the display.
4.2 Application limits
Temperature [°C]
Maximum
Operating
operating pressure years
[bar]
[a]
20
16
50
30
12.8
50
40
9.6
50
50
6.4
15
Safety factor: 1.25 Medium: air and water
Tab 3: Limits of application for electrofusion
couplers
Input voltage (AC)
230 V (185 - 300 V)
Input frequency
50 Hz (40 - 65 Hz)
Current intensity - input
16 A
Output voltage
40 V
Current intensity - output
max. 60 A
Output
2600 VA / 80% ED
Temperature range
-10° Celsius to +50° Celsius
Unit safety
CE, IP 54
Weight
approx. 18 kg
Length of power cable
4.5 m
Length of welding cable
4.7 m
Display
2 x 20 characters - background illuminated
Dimensions
440 x 380 x 320 mm
Parameter input
automatic
Electrical monitoring of input
voltage / current intensity / frequency
Electrical monitoring of output
voltage, contact, resistance, short circuit, current
intensity curve, welding time,
working temperature, system check
Error message
continuous warning signal, data on display
Tab. 4: Technical data for REHAU welding apparatus for electrofusion couplers
Fig. 24: REHAU-ESM sleeve in sectional
view.
Fig. 25: Integrated welding wires.
Fig. 26: REHAU welding device.
9
4.4 Jointing
Fig. 27:
1. Cut the pipe to the requested size.
Fig. 28:
2. Mark the shaving area (refer to table 5).
Dimension
Shaving area
20
30 mm
25
30 mm
32
35 mm
40
39 mm
50
44 mm
63
53 mm
75
56 mm
90
66 mm
110
75 mm
125
80 mm
160
81 mm
Tab. 5: Shaving areas on electrofusion
couplers
Fig. 29:
3. Use a manual scraper to remove the coating. Do not scrape beyond the marking.
Fig. 30:
4. When using special scraping tool, marking is not required.
Fig. 31
5. The welding area has to be free from
grease and dust - if necessary use Tangit
cleaning agent to clean.
Fig. 32:
6. Remove the electrofusion coupler from
the PE bag.
Fig. 33:
7. Push the electrofusion coupler on to the
pipe end.
Fig. 34:
8. Push the second pipe end into the coupler. The scraped area has to disappear into
the coupler completely.
10
Fig. 35:
9. Connect the welding apparatus - red
cable to red contact.
Fig. 36:
10. Press the start button of the welding
apparatus.
Fig. 37:
11. Check the alignment and the insertion
depth. If the scraped area is visible, check
the insertion depth.
Dimension
Cooling-down time
20 - 63
20 min.
75 - 110
30 min.
125
45 min.
160
70 min.
Tab. 6: Cooling-down times for electrofusion
couplers
Fig. 38:
12. Press the start button again.
Fig. 39:
13. An acoustic signal will be sounded after
the welding process has been completed.
The plugs can be removed.
14. The complete operating pressure may
be applied only after the cooling times have
run down.
11
4.5 Fitting the tapping saddle
Tapping saddles permit the extension of the
pipe system under pressure without loss of
the medium. The welding zone is a ring
around the outlet hole. For this reason the
joining process by means of a tapping
saddle differs from the welding process of a
compression sleeve joint.
12
Fig. 40:
1. Place the lower part of the tapping saddle
where required, and mark.
Fig. 41:
2. Remove the coating on half the circumference of the base pipe between the two
markings.
Fig. 42:
3. If and when necessary, use Tangit cleaning agent to clean the welding area on the
pipe and the tapping saddle.
Fig. 43:
4. Attach the tapping saddle.
Fig. 44:
5. Connect the welding apparatus - red
cable to red contact.
Fig. 45:
6. Press the start button to start the welding
process.
Fig. 46:
7. An acoustic signal will be sounded after
the welding process has been completed.
The plugs can be removed.
Fig. 47:
8. After a cooling period of 20 minutes,
finish the branch of the pipe. Subsequently
subject the entire pipe to a pressure test at
the branch.
Fig. 48:
9. After the pressure test, use a 12 mm
Allan key to screw the hollow punch into the
main pipe.
Fig. 49:
10. After breaking through the pipe, turn the
hollow punch anti-clockwise up to the stop.
Fig. 50:
11. Remove the slide-in aid.
Fig. 51:
12. Open the cap until the reverse lock
engages.
Fig. 52:
Tapping saddle in sectional view.
13
4.6 Notes on welding electrofusion couplers and tapping saddles
Fig. 53:
Use a PE pen in a contrasting colour to
mark the pipe.
Fig. 54:
Do not use the coupler for marking.
Fig. 55:
Do not use the upper part of the tapping
saddle to mark the pipe.
Fig. 56:
Do not scrape beyond the marking.
Fig. 57:
If a scraper tool is used, apply it once only.
Any remains of the coating on the pipe do
not disturb the welding process, provided
the upper layer has been removed.
Fig. 58:
RAUTHERM pipes with an EVAL coating
must not be used in combination with the
electrofusion technique.
Fig. 59:
Do not touch the welding area.
Fig. 60:
Do not touch the inside of the electrofusion
coupler.
Fig. 61:
The welding area must not be wet or soiled.
14
Fig. 62:
Do not use a used cloth for cleaning. Use
watertight and unused cellulose cloths only.
Fig. 63:
Do not weld any pipes which not have been
entirely inserted.
Fig. 64:
If the coupler is to be used as a sleeve coupler, the stop nipples have to be removed.
Fig. 65:
The master switch of the welding apparatus
is located on the rear side.
Fig. 66:
In case of welded electrofusion couplers,
the indicating nipples are raised on either
pipe end.
Fig. 67:
There is only one indicating nipple on tapping saddles.
■ The welds have to be carried out on supported pipes, with no longitudinal tension. If and when necessary, rounding
clamps and holding devices have to be
used. After the cooling period on the fittings has elapsed the supports can be
removed.
■ Do not move the pipes during the welding process.
■ Do not remove the mains plug during the
welding process.
■ If a fault message is released by the welding apparatus, the electrofusion couplers have to be removed and thrown
away.
15
5. Compressed air
5.1 General aspects
Hole diameter
[mm]
1
The whole industry from small workshops to
large production operations use compressed air as a source of energy. Modern production processes use compressed air for
driving tools and machines, controlling and
cleaning.
5.2 Energy costs of compressed air
A big disadvantage of compressed air is its
high energy costs. The leakage in pipe
systems contribute significantly to the energy costs. The reason for the frequent loss of
energy are leaking screw connections, poorly sealed joints, holes caused by corrosion,
seals destroyed by compressor oil and faulty adhesive points. For this reason, the elimination of leakage has to be sought in the
selection of pipe systems. The RAUPEX
industrial pipe system has been designed to
meet the requirements of compressed air
systems. Due to the complete freedom from
leakage, RAUPEX is the solution to energy
cost problems.
Pressur loss at 6 bar
[l/s]
1.238
Loss of energy
[kWh]
Costs*
[e/a]
0.3
210.–
3
11.14
3.1
2170,–
5
30.95
8.3
5810,–
33.0
23100,–
10
123.8
* Cost calculation: kWh x 0.08 e/kWh x 8,750 operating hours/a
Tab. 7: cost of leakage from a defined hole size
5.3 Advantages of the RAUPEX
industrial pipe system in
compressed air engineering
The combination of RAUPEX pipes, compression sleeves and electrofusion couplers
makes the RAUPEX industrial pipe system
suited for use in compressed air lines. The
operator has the following advantages:
■ No leakage in the pipe system, no loss of
energy and lower operating costs.
■ No corrosion, thus longer service life of
the pipe system and lower investment
costs.
■ Continuous quality of compressed air;
impurities from corrosion products are
impossible, which makes the use of
additional filters (loss of pressure) superfluous.
16
■ Pipes in standard colour, no painting of
the pipes required.
■ Faster installation reduces costs and
helps meet deadlines.
■ Easy-to-learn assembly technique, no
specially trained technical staff required.
■ Light-weight pipe material, easy overhead laying and less outlay for suspension than for steel pipes.
■ To be used as flexible or rigid pipe
systems.
■ Underground laying or laying in buildings
possible.
■ Pipes available in cut lengths or coils.
■ Extensions are possible during operation
(tapping saddle).
■ Suitable for renovation and new construction.
■ Good resistance to compressor oils.
■ Economic overall installation.
5.4 Compressed air quality
Different applications of compressed air
require different qualities of compressed air.
The continuous quality at every point in the
network is important. RAUPEX industrial
pipesystem guarantees a stable air quality in
the entire pipe system from the generator to
the consumer.
The quality of compressed air is described
by the following three factors in standard
ISO 8573: content of solids, content of
water, and content of oil in the air. As certain applications have different requirements
on each of the three factors, they are described by a classification. The following three
figures are used to describe the quality of
the compressed air.
5.4.1 Quality class for maximum
particle size and maximum
concentration
On account of impurities in the air, solids are
also found in compressed air. Filters can be
used to reduce the particle size and the particle concentration as required by the application.
Class
Maximum particle Maximum part.
size
concentration
[µm]
[mg/m3]
1
0.1
0.1
2
1
1
3
5
5
4
15
8
5
40
10
Tab. 8: Quality classes for solids
5.4.2 Quality class for the content
of water
Due to the compression of atmospheric air,
the content of water increases considerably
in the compressed air. As a rule, the air is
dried during the preparation process of the
compressed air so that no condensate
occurs in the plant. In order to be able to
qualify and classify the content of water in
the compressed air, the pressure dew point
is used as a guideline value. The pressure
dew point describes the temperature at
which the water contained in the compressed air starts to condensate.
Class
Pressure dew point
1
2
3
4
5
6
7
- 70° C
- 40° C
- 20° C
+ 3° C
+ 7° C
+10° C
Not specified
5.4.3 Quality class for the content
of oil
Some compressors need lubricating oil for
the working process. Depending on the
quality of the compressed air, this oil has to
be extracted again during the treatment process. Several processes are employed for
this purpose. The oil concentration is important for the user of the compressed air. The
highest quality is obtained with the lowest
concentration of oil (field of application: photographic engineering).
In some machines and tools, a certain minimum concentration of oil is required. In individual cases corresponding service units are
used to oil the air in addition.
Class
Maximum oil concentration
[mg/m3]
1
2
3
4
5
0.01
0.1
1
5
25
Tab. 10: Quality classes for oil
5.4.4 Example for the quality
description of compressed air
Compressed air of quality class 2.4.3
In this case compressed air is described
which contains a maximum of 1mg/m3 of
solids at a maximum particle size of 1 µm,
which has a pressure dew point of +3°
Celsius, and which contains a maximum of
1mg/m3 of oil.
Tab. 9: Quality classes for water
17
5.5 Configuration
Nomograms are suitable for approximate
configuration of individual pipe sections. The
following values have to be available for
configuration by nomogram:
■
■
■
■
operating pressure
volume current
pipe length
pressure drop
5.5.1 Determination of the operating
pressure
For the maximum operating pressure, please refer to the data of the manufacturer of
the compressor. The maximum pressure
required by the consumer is also important
for the operating pressure. The operating
pressure should be 1 bar above the highest
pressure required by the consumer.
Note: If there are several users with different requirements on the pressure, it is frequently more economical to operate several
networks in different pressure stages.
5.5.2 Determination of the air
volume
5.5.3 Determination of the pipe
length
In order to determine the air volume (standard volume) of the pipe section, the consumer values of all users have to be included
in the calculation. Machine and tool manufacturers can render information in this case,
although in some cases these values are not
available explicitly. Please use the table
below to determine approximate values for
compressed air operated tools.
In addition to the loss of pressure over the
length of the pipe, the increased loss of
pressure of the fittings has to be taken into
consideration. Spare lengths are added to
the real length of the pipe in this case.
Tool
Air consumption
[l/s]
Air operated blow gun
Spray gun
Abrasive grinder
Vibrating grinder
Sheet nibbler
Drilling machine
Rotating screw driver
Impact screw driver
Grinding machine
2-5
2-7
3 - 14
4-7
8 - 11
9 - 30
2 - 11
2 - 35
5 - 20
As the pipe dimension are required to determine the spare length, the pipe diameter
without fitting has to be estimated roughly
first of all. Subsequently check the result
under consideration of the spare length,
which has to be corrected, if and when
necessary.
Tab. 11: Consumption figures for air operated tools
Replacement lengths for SDR 11 fittings
Fitting
20 x 1.9
25 x 2.3
32 x 2.9
40 x 3.7
50 x 4.6
63 x 5.8
75 x 6.8
90 x 8.2
110 x 10
160 x 14.6
90° angle
0.8 m
1.0 m
1.2 m
1.5 m
2.4 m
3.0 m
3.7 m
4.5 m
6.0 m
8.0 m
45° angle
0.3 m
0.3 m
0.4 m
0.5 m
0.6 m
0.8 m
1.0 m
1.3 m
1.6 m
2.0 m
T piece
passage
0.1 m
0.2 m
0.2 m
0.3 m
0.4 m
0.5 m
0.7 m
0.8 m
1.0 m
1.3 m
T piece
outlet
0.8 m
1.0 m
1.2 m
1.5 m
2.4 m
3.0 m
3.9 m
4.8 m
6.0 m
8.0 m
Reduction
0.2 m
0.3 m
0.4 m
0.5 m
0.7 m
1.0 m
1.5 m
2.0 m
2.5 m
3.0 m
Tab. 12: Replacement lengths for SDR 11 fittings
Replacement lengths for SDR 7.4 fittings
Fitting
16 x 2.2
20 x 2.8
25 x 3.5
32 x 4.4
40 x 5.5
50 x 6.9
63 x 8.7
90° angle
0.8 m
0.8 m
1.0 m
1.2 m
1.5 m
2.4 m
3.0 m
45° angle
0.3 m
0.3 m
0.3 m
0.4 m
0.5 m
0.6 m
0.8 m
T piece
passage
0.1 m
0.1 m
0.2 m
0.2 m
0.3 m
0.4 m
0.5 m
T piece
outlet
0.6 m
0.8 m
1.0 m
1.2 m
1.5 m
2.4 m
3.0 m
Reduction
0.2 m
0.2 m
0.3 m
0.4 m
0.5 m
0.7 m
1.0 m
Tab. 13: Replacement lengths for SDR 7.4 fittings
18
5.5.4 Determination of the pressure
drop
The pressure drop should not exceed 0.1
bar at full load in the entire pipe system. In
order to facilitate the determination of the
pipe diameter, the entire length of a pipe
system is divided into three sections. In
these pipe sections, the following maximum
pressure drops should not be exceeded:
Example:
Operating pressure:
Volume current:
Pipe length:
Pressure drop:
Results in a pipe:
8 bar
50 l/s
400 m
0.03 bar
RAUPEX-A 90 x 8.2
Pipe length [m]
Rohrlänge [m]
1
2
3
5
7
10
20
30
50 70 100
200 300 500 700 1000 2000
10
1
main pipe
ring or distribution pipe
branch pipe
0.04 bar
0.03 bar
0.03 bar
4
5
RAUPEX
20 x 1,9
6
7
2
8
9
10
5.5.5 Determination of the pipe
diameter by means of a
nomogram
3
RAUPEX
25 x 2,3
4
5
20
20
6
The nomogram permits the graphical determination of the pipe diameter. A coloured
pen and a ruler are required.
7
RAUPEX
32 x 2,9
8
9
10
30
40
RAUPEX
40 x 3,7
50
30
60
Procedure:
70
20
30
40
40
RAUPEX
83 x 5,8
50
60
70
RAUPEX
75 x 6,8
RAUPEX
90 x 8,2
RAUPEX
110 x 10
RAUPEX
160 x 14,6
80
90
100
60
90
100
200
3
Volume
flow rate[m
[m
/h]
3 /h]
Volumenstrom
The operating pressure is drawn in the form
of a line from the X axis upwards. The volume current is drawn from the Y axis on the
right-hand side of the nomogram to the left
up to a line of 2,000 m. From the intersection of the lines of the volume current and of
the operating pressure, continue up to the
2,000 m line parallel to the available diagonal. From this point draw a horizontal line up
to the value of the pipe length. From this
intersection continue diagonally to the top
right or bottom left to the line of the pressure drop. Drawing a line to the left from this
intersection will produce the value of the
required internal diameter.
Volumenstrom
[l/s]
Volume
flow rate [l/s]
80
RAUPEX
50 x 4,6
300
400
500
70
600
200
700
800
900
1000
80
90
300
100
400
500
2000
600
All values refer to the standard volume.
[mm]
Note:
Pipe internal diameter
Rohrinnendurchmesser
[mm]
700
800
900
1000
3000
4000
150
5000
6000
2000
0,001 0,002
0,005
0,01
0,02
0,05
0,1
0,2
Druckabfall
der Rohrleitung
Pipe
systeminpressure
loss [bar][bar]
0,5
1
2
3
5
7000
8000
9000
8 10 16
Operating
pressure
Betriebsdruck
[bar] [bar]
19
5.5.6 Compressed air – pipe dimensions SDR 11
Operating pressure:
bar
Volume current:
l/s
Pipe length:
m
Pressure drop:
bar
➡ RAUPEX-A
x
Pipe length [m]
Rohrlänge [m]
1
2
3
5
7
10
20
30
50 70 100
200 300 500 700 1000 2000
10
1
4
5
RAUPEX
20 x 1,9
6
7
2
8
9
10
3
RAUPEX
25 x 2,3
4
5
20
20
6
7
RAUPEX
32 x 2,9
8
9
10
30
40
50
30
60
70
RAUPEX
50 x 4,6
30
40
40
RAUPEX
63 x 5,8
50
60
Volume
flow rate [l/s] [l/s]
Volumenstrom
20
80
90
100
200
70
RAUPEX
75 x 6,8
RAUPEX
90 x 8,2
RAUPEX
110 x 10
RAUPEX
160 x 14,6
80
90
100
60
300
400
500
70
600
200
700
800
900
1000
80
90
300
100
400
500
2000
600
Pipe internal diameter [mm]
Rohrinnendurchmesser
[mm]
700
800
900
1000
4000
150
5000
6000
2000
0,001 0,002
20
3000
0,005 0,01 0,02
0,05
0,1
0,2
Pipe
system pressure
loss Rohrleitung
[bar]
Druckabfall
in der
[bar]
0,5
1
2
3
5
8 10 16
Operating pressure [bar]
Betriebsdruck [bar]
7000
8000
9000
Volume
flow rate [m3/h]
Volumenstrom
[m3 /h]
RAUPEX
40 x 3,7
5.5.7 Compressed air – pipe dimensions SDR 7.4
Operating pressure:
bar
Volume current:
l/s
Pipe length:
m
Pressure drop:
bar
➡ RAUPEX-A
x
Pipe length [m]
Rohrlänge [m]
1
2
3
5
7
10
20
30
50 70 100
200 300
500 700 1000
2000
10
RAUPEX-A
16 x 2,2
1
4
5
RAUPEX-A
20 x 2,8
6
7
2
8
9
10
RAUPEX-A
25 x 3,5
3
4
5
RAUPEX-A
32 x 4,4
9
10
20
30
40
50
60
70
Volume
flow rate [m3/h][m3 /h]
Volumenstrom
8
Volumenstrom [l/s]
Pipe internal diameter [mm]
7
Volume flow rate [l/s]
RAUPEX-A
50 x 6,9
20
6
Rohrinnendurchmesser
[mm]
RAUPEX-A
40 x 5,5
20
80
90
100
30
RAUPEX-A
63 x 8,7
40
40
50
200
60
70
80
90
100
60
300
400
500
600
200
0,001
0,002
0,005
0,01
0,02
0,05
0,1
Pipe
system pressure
loss [bar]
Druckabfall
in der
Rohrleitung
0,2
[bar]
0,5
1
2
700
3
5
8 10
20
Operating
pressure [bar]
Betriebsdruck
[bar]
21
6. Cooling water
Designation
Bezeichnung
Symbol
Symbol
value
ζ
y-Wert
6.1 General aspects
90° angle
Winkel 90°
1,3
45°
angle
Winkel
45°
0,5
6.2 Configuration
T
piece branch
T-Stück
Abzweig
1,3
The following procedure is required to determine the configuration of the cooling water
pipes:
T
piece passage
T-Stück
Durchgang
0,3
T
piece distribution
T-Stück
Verteilung
1,5
T
piece combination
T-Stück
Vereinigung
1,3
Reduction
Reduzierung
0,4
Gate
valve
Absperrschieber
0,5
Ball
cock
Kugelhahn
0,1
Cooling water is required wherever heat has
to be dissipated. Often these pipes are configured as a circuit.
At the beginning the required dimension of
the pipe is estimated. For this purpose, the
two diagrams in chapters 6.2.3 or 6.2.4 can
be used as a basis. Subsequently the pressure loss in the pipe is calculated. If the
pressure loss is outside of the requested
value, the pipe system has to be calculated
with another pipe diameter.
Pressure:
Pressure loss:
Pressure loss gradient:
Volume current:
Pipe length:
Coefficient of resistance:
Number of pieces:
Media speed:
.
p [Pa]
∆ p [Pa]
R [Pa/m]
V [l/s]
l [m]
ζ
n
v [m/s]
Tab. 14: ζ values for fittings
The pressure loss is calculated from a pipe
length dependent and a fitting dependent
pressure loss, which is calculated according
to equation 6.1.
The pressure loss of an individual fitting can
be calculated by means of equation 6.4.
The ζ-values required can be found in
Table 6.1.
∆p = ∆p tube + ∆p mouldings Equation 6.1
ρ
∆p mouldings1 = ζ mouldings1 · – · v2
2
Equation 6.4
∆p tube = R · I
Equation 6.2
For the pipe frictional pressure loss gradient
R, please refer to the diagram in chapter
6.2.4 for SDR 7.4 or the diagram in chapter
6.2.3 for SDR 11. These diagrams have
been set up for cooling water with a temperature of 15° Celsius. The pipe .dimensions
and the volume current V are required to
determine the frictional pressure loss
gradient R.
The additional pressure loss ∆p moulding,
which is produced by the fittings, is
calculated from the sum of the individual
pressure losses of the fittings according to
equation 6.3.
∆p mouldings = n mouldings1 · ∆p mouldings1 +
n mouldings2 · ∆p mouldings2 + n mouldings3
·∆p mouldings +...
Equation 6.3
22
The value for speed v can be determined
graphically in the diagrams rendered in
chapters 6.2.3 or 6.2.4. This value then has
to be raised to the power v2. For the
ζ-values, please refer to Table 14.
The results of equation 6.4 are entered in
equation 6.3. Subsequently, the results of
equation 6.3 and equation 6.2 can be used
in equation 6.1. If the value of equation 6.1
is below ∆p rendered available, the pipe has
been configured correctly. If this is not the
case, the pipe system has to be recalculated with a larger pipe diameter until the
required values for ∆p are made.
6.2.1 Form to determine the
pressure loss
In order to determine the pressure loss easily, use the REHAU form for the determination of the pressure loss.
Enter the pipe dimension in line 1 and the
volume current in line 2. Use the diagrams
rendered in chapters 6.2.3 or 6.2.4 to determine the pipe frictional pressure loss
gradient, and enter this into line 3. By
means of the pipe length, which is entered
in line 4, the pressure drop ∆p pipe can be
calculated by multiplication. The diagram is
used to determine the speed v, which is
entered in line 5, and the squared value is
entered in line 6. This value is then entered
in lines 7 to 15.
For the calculation of ∆p fittings, the corresponding number of pieces are entered in
the lines 7 to 15. By multiplication, the pressure losses of the individual fittings are
obtained. By addition, ∆p fitting is determined, which is entered in line 16. The overall
pressure loss ∆p is then finally calculated in
line 17.
6.2.2 Example for calculating the pressure loss
Determine the
pressure loss
Ermittlung
Druckverlust
in the pipe
für Rohrstrang
dimension:
1 Pipe
Rohrdimension:
V =
3,6
l/s
3 Pipe
Rohrreibungsgefälle:
frictional pressure loss:
R =
250
Pa/m
4 Rohrlänge:
Pipe length:
l =
60
m
5 Velocity:
Geschwindigkeit:
v =
1,2
m/s
6
v2 =
1,44
m2/s2
From
the diagram
aus Diagramm
∆p
∆ppipeline
Rohrleitung = R x l =
15000
Pa
From
the diagram
aus Diagramm
∆p
∆pMouldings
Formteile
= Number
Anzahl x Value-ζ
y-Wert
elbow90°
7 90°
Winkel
∆p
∆p90°
elbow90°
Winkel
=
10
x
1,3
x
500 x
1,44
=
9360
Pa
elbow45°
8 45°
Winkel
∆p
∆p45°
elbow45°
Winkel
=
2
x
0,5
x
500 x
1,44
=
720
Pa
piece branch
9 TT-Stück
Abzweig
∆p
∆pTT-Stück
piece branch
Abzweig
=
–
x
1,3
x
500 x
–
=
piece connector
10 TT-Stück
Durchgang
∆p
∆pTT-Stück
piece connector
Durchgang
=
4
x
0,3
x
500 x
1,44
=
864
Pa
piece splitter
11 TT-Stück
Verteilung
∆p
∆pT T-Stük
piece splitter
Verteilung
=
–
x
1,5
x
500 x
–
=
–
Pa
piece combiner
12 TT-Stück
Vereinigung
∆p
∆pTT-Stück
piece combiner
Vereinigung
=
–
x
1,3
x
500 x
–
=
–
Pa
13 Reducer
Reduzierung
∆p
∆pReducer
Reduzierung
=
–
x
0,4
x
500 x
–
=
–
Pa
valve
14 Gate
Absperrschieber
∆p
∆pGate
valve
Absperrschieber
=
2
x
0,5
x
500 x
1,44
=
valve
15 Ball
Kugelhahn
∆p
∆pBall
valve
Kugelhahn
=
–
x
0,1
x
500 x
–
=
Description
Bezeichnung
Symbol
Symbol
x
v2
/2 x
=
–
Pa
720
Pa
–
Pa
∆p
∆pMouldings
∆p90°
elbow90° + ∆p..... + ∆p..... =
Formteile = ∆p
Winkel
11664
Pa
line 7 -615
∑ Zeile
– 14
17
∆ppipeline
∆p = ∆p
∆pMouldings
Rohrleitung + ∆p
Formteile =
26664
Pa
line 4 +4 16
∑ Zeile
+ 15
,8
6
90 ,8
x8
,2
11
0x
10
,6
6
14
,
16
0x
75
x
x5
63
x4
50
40
x3
,7
,9
,3
x2
32
x2
25
x1
,9
16
20
Pipe frictional pressure loss gradient R [Pa/m]
75x6,8
2 Flow
Volumenstrom:
rate:
7,0
6, m/s
5,0 0 m/s
m/
4,
3, 0 m/ s
3,0 5 m/s s
m/
2,
2,0 5 m/s s
m
/s
1,
1,2 5 m/s
1,0 m/s
m/s
0,7
m/s
0,5
0,4 m/s
m/s
0,3
m/s
0,2
m/s
250 Pa/m
0,1
m
/s 3,6 l/s
Flow rate [l/s]
23
0,2
m
/s
,9
,3
x1
,9
x2
20
7
x2
25
3,
,6
x
32
,8 8
x4
40
,
2
x5
6
,
50
63 5 x x 8 x 10
,6
7
0
0
14
9
11
0x
16
7,0
6, m/s
5, 0 m/
4, 0 m/ s
3, 0 m/ s
3, 5 m/ s
2,5 0 m/s s
2,0 m/s
m/
1,5
m/s s
1
,
0
m/s
0,7
m/s
0,5
0,4 m/s
m/s
0,3
m/s
/s
24
0,1
m
Volumenstrom [l/s]
Flow rate [l/s]
6.2.3 Cooling water SDR 11
Pipe
Rohrreibungsgefälle
frictional pressure
R [Pa/m]
loss R [Pa/m]
0,1
m/s
Flow rate [l/s]
20
25
,8
2
x
,5
3
x
32
,4
4
x
,5
5
x
,9
6
x
40
50
7
8,
x
63
7,0
6,0 m/s
5,0 m/s
4,0 m/s
m/s
3,0
2,5 m/s
2,0 m/s
m/s
1,5
m/s
1,0 m
/s
0,7
m/s
0,5
0,4 m/s
m/s
0,3
m/s
0,2
m/s
16
,2
2
x
6.2.4 Cooling water SDR 7.4
Pipe frictional pressure loss R [Pa/m]
25
6.2.5 Form for calculating the pressure loss
l/s
Determine the pressure loss
Ermittlung
Druckverlust
in the
pipe
für Rohrstrang
V =
dimension:
1 Pipe
Rohrdimension:
2 Flow
Volumenstrom:
rate:
=Rxl=
From
diagram
austhe
Diagramm
∆p
∆ppipeline
Rohrleitung
v2
Pa
Pa/m
/2 x
=
Pa
R =
x
500 x
=
Pa
frictional pressure loss:
3 Pipe
Rohrreibungsgefälle:
= Number
Anzahl x Value-ζ
y-Wert
x
500 x
=
Pa
line 7-156 – 14
∑ Zeile
Pa
1,3
x
500 x
=
Pa
m
x
0,5
x
500 x
=
Pa
l =
∆p
∆p
Mouldings
Formteile
=
x
1,3
x
500 x
=
Pa
length:
4 Pipe
Rohrlänge:
∆p
∆p
90°Winkel
elbow
90°
=
x
0,3
x
500 x
=
Pa
Pa
line 4 + 4
16+ 15
∑ Zeile
From the
diagram
aus
Diagramm
elbow 90°
7 90°
Winkel
∆p
∆p
45°Winkel
elbow
45°
=
x
1,5
x
500 x
=
Pa
m/s
elbow 45°
8 45°
Winkel
∆p
∆p
T piece
branch Abzweig
T-Stück
=
x
1,3
x
500 x
=
v =
piece branch
9 TT-Stück
Abzweig
∆p
∆p
T piece
connector
T-Stück
Durchgang
=
x
0,4
x
500 x
5 Velocity:
Geschwindigkeit:
piece connector
10 TT-Stück
Durchgang
∆p
T piece
splitterVerteilung
∆p
T-Stük
=
x
0,5
x
m2/s2
piece splitter
11 TT-Stück
Verteilung
∆p
∆p
T piece
combiner
T-Stück
Vereinigung
=
x
0,1
v2 =
piece combiner
12 TT-Stück
Vereinigung
∆p
∆p
Reducer
Reduzierung
=
x
∆pMouldings = ∆p
∆p
∆p90°
elbow 90° + ∆p..... + ∆p..... =
Formteile
Winkel
Pa
=
13 Reducer
Reduzierung
∆p
Gate
valve
∆p
Absperrschieber
=
6
Symbol
Symbol
valve
14 Gate
Absperrschieber
∆p
∆p
BallKugelhahn
valve
16
∆pMouldings
∆p = ∆p
∆ppipeline
Rohrleitung + ∆p
Formteile =
Description
Bezeichnung
valve
15 Ball
Kugelhahn
17
26
7.
Transport of solids
RAUPEX pipes are ideal for the transport of
solid matter (for exceptions, please refer to
chapters 7.1 and 7.2). On account of the
high resistance of the RAU-PE-Xa material
to abrasive media, RAUPEX pipes achieve
considerably better service life values than
steel or even PE. However, please observe
that changes of direction by bent RAUPEX
pipes have to be designed as the highest
abrasive values occur in the area of the
bend. We recommend electrofusion couplers for connection.
7.1 Hydraulic transport of solids
RAUPEX pipes are ideal for the transport of
suspended solids. If other carrier fluids are
used apart from water, the specific resistance of the fluid must not exceed the
value of 106 W/cm as otherwise electrostatic charging may occur.
8.
Assembly and laying
RAUPEX pipes can be laid concealed or
unconcealed, in cable ducts or in cable
carrier systems in buildings. The pipes can
also be laid underground in ducts or protective pipes.
8.1 Underground installation
RAUPEX pipes supplied in cut lengths or
coils can be laid underground, whereby the
use of rolled pipes will be more economical
for longer distances. On account of their
material properties, RAUPEX pipes are ideal
for underground installations. Trenchless
laying techniques in particular or laying without sand bed increase the demands on the
pipe material with respect to notching,
cracking and fast crack extension. RAUPEX
pipes meet these requirements as well.
8.1.1 Earthwork
7.2 Pneumatic transport of solids
RAUPEX pipes are suitable for pneumatic
transport of solids to a limited extent only,
as RAUPEX pipes do not conduct electricity.
Due to this fact, electrostatic charging may
occur during transport of the air/solids mixture. In case of some materials, this may
cause a danger of explosion. Charging is
avoided during the transport of the air/solids
mixture, if the relative humidity is less or
equal than 65 per cent. In this case a pneumatic transport of solids is permissible (please refer to the guidelines on the Prevention
of Dangers by Electrostatic Charging issued
by the Employers’ Third Party Insurance
Association of the Chemical Industry,
Chemie GmbH publishing house, D-69469
Weinheim, Germany).
The requirements set forth in German standard DIN 4033 have to be observed in all
earthwork and laying as a matter of principle. The dimensions of the trench have an
influence on the volume and the distribution
of the earth and traffic loads, and thus on
the load on the pipe system. The width of
the trench bottom depends on the external
diameter of the pipe, and on whether an
accessible working space is required to lay
the pipes (minimum working spaces in compliance with German standard DIN 4124).
The trench bottom has to be produced in
the width and depth rendered in such a way
that the pipe comes to rest on the entire
length. In case of rocky and stony ground,
the trench has to be excavated at least 0.1
m deeper, and a stone-free layer has to be
placed. In case of a non-load-bearing trench
bottom with a lot of water as well as in case
of changing ground layers of different loadbearing capacity, the pipes have to be secure by means of suitable building measures,
such as fill of fine gravel. In case of gradients, cross bars have to be set to prevent
the top layer being swept away. If and when
necessary, a drainage has to be included.
8.1.2 Checking the pipes
8.1.3 Special features in laying
coiled pipes
Safety instructions:
In unwinding the coiled pipes, please
keep in mind that the pipe end may
whip away when the tie is removed.
As considerable forces are released,
in large diameters in particular, caution is advised (danger of accident).
The coiled pipes can be unwound in several
ways. As a rule, pipes up to an external diameter of 63 mm are unrolled with the coil
upright. In case of larger pipe diameters, the
use of unwinding equipment is advised. The
coiled pipes then may be placed on the
turnstile, and can be unwound by hand or
by a vehicle driving slowly. Please make
sure that the pipe length unrolled is not twisted because kinks may be caused.
On request Rehau offers the service of tying
the coiled pipe together in different layers.
Thus it is possible to unwind the outer layers
while the inner ones remain tied up.
The reduction of flexibility at low temperatures will cause a less easy unwinding and laying operation in case of laying temperatures
of around zero degrees. In this case, it is
advisable to store the coiled pipes in a heated hall or a heated tent for some hours
prior to laying. Alternatively, the pipes may
be heated by passing through hot air or
steam at a maximum of 80° Celsius.
8.1.4 Minimum bending radii in
case of underground laying
The following minimum bending radii dependent on the laying temperature have to be
observed when laying the RAUPEX pipes
underground:
Laying
temperature
Minimum bending
radius R
PE-Xa
20°C
10 × d
10°C
15 × d
0°C
25 × d
d = external pipe diameter
Tab. 15: Minimum bending radius in case of
underground laying
Before laying the pipes in the trenches, they
have to be checked for transport and storage damage. Pipes and pipe section must
not be fitted if they have been damaged by
sharp edges. Scratches may have a depth
of a maximum of 20 per cent of the wall
thickness.
27
8.1.5 Filling the pipe trench
8.3 Laying in a duct
If due to insulation the temperature of the
pipe is considerably over the temperature of
the pipe trench, the pipe has to be slightly
covered prior to filling the trench to ensure a
tension-free laying.
On account of their flexibility RAUPEX pipes
are suitable for laying in ducts. REHAU pipe
clamps have to be used to attach the T pieces, the inlet and outlet as well as the fitting.
One pipe clamp each is required to attach
the front and back of the fitting.
Contrary to German standard DIN 4033, the
excavated material can be used to refill the
pipe trench when using RAU-PE-Xa, provided the following conditions are adhered to:
■ The excavated earth has to be well
compacted.
■ The maximum grain size should not
exceed 63 mm.
Rubble, recycled rubble, and ground slag
can also be used in the area of the pipe.
The remaining trench in the area of the street body has to be filled in compliance with
the German guidelines ZTV A-StB 97
(”Additional Technical Contractual
Conditions and Guidelines for Excavation
Work in Traffic Areas”). Machines may be
used, if the permissible fill height is observed.
8.4.2 Laying underneath or at the
side of the cable carrier system
8.4 Laying in combination with the
cable carrier system
(cable ladder)
REHAU pipe clamps have to be used to lay
RAUPEX pipes underneath or at the side of
a cable carrier system. The spacing between pipe clamps as rendered in Table 17
has to be observed. In order to prevent
collisions with holders, REHAU spacers
have to be used.
In order to avoid suspension, RAUPEX pipes
can be laid by means of the cable carrier
system (KTS). On account of the light weight
and the flexibility of the RAUPEX pipes, the
following types of laying are possible with
the cable carrier systems.
8.4.1 Using the cable carrier system
for laying
The pipes are placed in the cable carrier
system. T pieces, fittings and outputs have
to be attached on both sides with REHAU
pipe clamps in order to ensure a safe
attachment. In-between attachment is required only when deemed necessary.
Fig. 70: RAUPEX laid underneath or at the
side of cable carrier system.
8.5 Uncovered laying with
supporting clip channel
8.2 Laying in existing pipework
If existing pipes already available, the
RAUPEX pipes can be laid inside.
Depending on the local conditions, cut
lengths or coiled pipes can be used. Limits
are set by the inside diameter of the pipe
and the outside diameter of the connecting
pieces. Upon request, coiled pipes of the
required lengths can be supplied.
In case of uncovered laying, the use of
REHAU supporting clip channel is recommended, which is simply clipped onto the
RAUPEX pipe, thus turning a flexible RAUPEX pipe into a rigid pipe that can be laid
uncovered. The side-effect is that the coefficient of length expansion is reduced in the
supporting clip channels of the 16 to 63 mm
dimensions. The maximum space between
pipe clamps is 2.5 m in case of laying in 5 m
supporting clip channels. By using the clip
channels of the dimensions 75 mm, 90 mm,
110 mm, and 160 mm, the co-efficient of
linear expansion is not reduced. Contrary to
the 16 mm to 63 mm supporting clip channels, adhesive tape has to be used to attach
the pipe in addition to the pipe clamps.
If temperature variations are expected in the
pipe laid, fixed points have to be placed on
the outlet points of the RAUPEX pipe.
Fig. 68: RAUPEX pipes laid in cable carrier
system.
Length of pipe L
Change of length ∆l
Fixed point
Length of deflection leg Ls
Fig. 71: Supporting clip channel
8.5.1 Deflection leg assembly with
supporting clip channel
Fig. 69: Deflection leg.
28
Changes in length due to temperature can
be compensated by deflection legs.
However, the minimum length of deflection
legs has to be observed depending on the
maximum change in temperature.
Ls = C × √Da × ∆I
8.5.1.1 Calculation of the deflection
leg
Ls:
Da:
∆l:
C:
In order to determine the length of the
deflection leg, the temperature-related
change in length has to be calculated:
8.5.1.3 Calculating the deflection
leg by diagram
length of the deflection leg [mm]
external pipe diameter [mm]
change in length [mm]
constant (RAUPEX: C = 12)
Complicated calculations can be replaced
by graphical determination.
Use the diagrams in chapters 73 and 74 for
RAUPEX pipes with dimensions of 16 mm
to 63 mm.
∆l = α × L × ∆T
8.5.1.2 Example calculation
∆l:
α:
L:
∆T:
change in length [mm]
co-efficient of expansion [mm/mK]
length of the pipe [m]
temperature difference [K]
Pipe:
Pipe length:
∆T:
RAUPEX-A 40 x 3.7 (laid with
supporting clip channels)
50 m
20 K
Dimension
[mm]
Coefficient of
expansion α
[mm/mK]
∆l = 0,04 mm/mK × 50 m × 20 K = 40 mm
16 - 40
0.04
Ls = 12 × √40 mm × 40 mm = 480 mm =
0,5 m
50 - 63
0.1
75 - 160
0.15
Fig. 75 is applicable for RAUPEX pipes with
dimensions of 75 mm to 160 mm:
Calculation of the deflection leg 16 mm to
160 mm without supporting clip channel. In
these dimensions the use of supporting clip
channels does not cause a reduction of the
length expansion.
The pipe section requires a deflection leg of
0.5 m in length.
Tab. 16: Coefficient of linear expansion with
supporting clip channel
The value of the change in length is used to
calculate the length of the deflection leg.
Determination ofBiegeschenkelermittlung
the deflection leg for RAUPEX
with supporting
clip channel 16 – 40 (α = 0,04 mm
für RAUPEX
mit Chiphalbschale
mK )
Temperature
[K]
Temperaturdifferenzdifference
[K]
External pipe
diameter [mm] [mm]
Rohraussendurchmesser
10 000
80 K
60 K
50 K
40 K
30 K
5 000
2 000
16
20
25
32
40
20 K
Longitudinal
change
Längenänderung
[mm] [mm]
1 000
10 K
500
200
100
50
20
10
5
2
1
1
2
5
10
20
50
100
Pipe
length[m]
[m]
Rohrlänge
200
500
1 000
2 000
50
100
200
480
500
1 000
2 000
5 000
Length
of deflection[mm]
leg [mm]
Länge Biegeschenkel
Fig. 72: Deflection leg.
29
Fig. 73: Determination of the deflection leg 16 to 40 mm with supporting clip channel
10 000
5 000
2 000
1 000
500
200
100
50
20
10
5
2
1
2
5
10
20
50
100
200
500
2 000
50
10 K
20 K
80 K
60 K
50 K
40 K
30 K
Temperature
difference
Temperaturdifferenz
[K][K]
1 000
100
200
[mm]
1 000
2 000
16
20
25
32
40
5 000
External pipe diameter [mm]
Rohraussendurchmesser
[mm]
mm
– 40 (α = 0,04 mK
)
500
Longitudinal
change [mm]
Länge Biegeschenkel
Determination
of the deflection leg for RAUPEX
with supporting
clip channel 16
Biegeschenkelermittlung
für RAUPEX
mit Chiphalbschale
1
Rohrlänge [m]
Pipe length [m]
30
[mm]
External
pipe diameter [mm]
Längenänderung
Length of deflection [mm]
Längenänderung [mm]
1
2
5
10
20
50
100
200
500
1 000
2 000
5 000
10 000
1
2
5
10
50
Longitud
tubería [m][m]
Rohrlänge
20
100
200
Temperature
difference [K]
Temperaturdifferenz
[K]
500
1 000
10 K
20 K
50 K
40 K
30 K
2 000 100
80 K 60 K
500
1 000
2 000
5 000
External
pipe diameter [mm]
Rohraussendurchmesser
[mm]
50 – 63 (α = 0,1 mm
mK )
Länge Biegeschenkel [mm]
Longitudinal change [mm]
200
Determination
of the deflection legfür
for RAUPEX
withmit
supporting
clip channel
Biegeschenkelermittlung
RAUPEX
Chiphalbschale
10 000
50 63
Fig. 74: Determination of the deflection leg 50 to 63 mm with supporting clip channel
31
8.6 Uncovered laying without
supporting clip channel
Uncovered laying is the standard method of
laying pipes in a building. Apart from laying
pipes in supporting clip channels, pipes can
also be laid without supporting clip channels. The pipe clamp spacing has to be
observed depending on the temperature.
The use of REHAU pipe clamps has proved
to be especially advantageous as they permit a fast and uncomplicated installation. It
is important to lay the pipes in such a way
that a temperature-related length expansion
can take place. The deflection legs have to
be taken into consideration here. Table 17
renders the permissible support widths.
■ In case of vertical installation of the
pipes, the support width can be increased by 30 per cent.
■ The support width can be increased by
30 per cent for air pipes.
8.6.1 Laying a deflection leg
In order to determine the number of deflection legs, a calculation in analogy to the calculation in chapter 8.5.1.1 can be carried
out, whereby the length expansion factor
has to be set at α = 1.5 mm/mK in general.
In addition, the graphical determination can
be used.
32
Dimension
Span [m]
at 20°C
at 40°C
at 60°C
at 80°C
16
0,55
0,45
0,40
0,35
20
0,60
0,55
0,45
0,40
25
0,65
0,60
0,50
0,45
32
0,75
0,65
0,60
0,50
40
0,85
0,75
0,65
0,55
50
0,95
0,85
0,75
0,65
63
1,05
0,95
0,85
0,70
75
1,15
1,05
0,90
0,75
90
1,25
1,10
1,05
0,85
110
1,40
1,25
1,10
0,95
160
1,70
1,40
1,30
1,10
Maximum density 1 kg/dm3; maximum bending 4 mm
Tab. 17: Span for RAUPEX pipes without supporting clip channel
Length of deflection leg [mm]
Längenänderung [mm]
1
2
5
10
20
50
100
200
500
1 000
2 000
5 000
10 000
20 000
1
2
5
10
50
100
Pipe
length [m] [m]
Rohrlänge
20
200
500
Temperature
difference [K] [K]
Temperaturdifferenz
1 000
10 K
20 K
60 K
50 K
40 K
30 K
2 000 50
80 K
100
Determination of the deflection
leg for RAUPEX without supporting
channel
Biegeschenkelermittlung
für clip
RAUPEX
200
[mm]
1 000
Longitudinal
change [mm]
Länge Biegeschenkel
500
2 000
5 000
External pipe diameter [mm]
Rohraussendurchmesser
[mm]
16 – 160 (α = 0,15 mm
mK )
16
20
160
20 000
32 50 75
40 63 90 110
10 000
25
Fig. 75: Determination of the deflection leg 16 to 160 mm without supporting clip channel.
33
8.6.2 Pre-stressed laying
RAUPEX pipes can be laid without deflection legs and without supporting clip channels. Pre-stressed laying is very popular.
The RAUPEX pipe is heated to maximum
temperature and is attached to the fixed
points in this condition. The forces occurring
during the cooling process have to be taken
up by the fixed points. Tables 18 and 19
can be used to determine the values of the
forces occurring.
∆T
10 K
20 K
30 K
40 K
50 K
60 K
70 K
80 K
90 K
100 K
Dimension [mm]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
20
× 1.9
117
233
350
467
583
700
817
933
1050
1167
25
× 2.3
177
354
531
709
886
1063
1240
1417
1594
1771
32
× 2.9
286
573
859
1145
1432
1718
2004
2291
2577
2863
40
× 3.7
456
911
1367
1823
2279
2734
3190
3646
4101
4557
50
× 4.6
709
1417
2126
2834
3543
4251
4960
5669
6377
7086
63
× 5.8
1126
2251
3377
4503
5628
6754
7879
9005
10131
11256
75
× 6.8
1574
3147
4721
6294
7868
9441
11015
12588
14162
15735
90
× 8.2
2276
4552
6828
9103
11379
13655
15931
18207
20483
22758
110 × 10
3393
6786
10179
13572
16965
20358
23750
27143
30536
33929
160 × 14.6
7203
14405
21608
28811
36013
43216
50418
57621
64824
72026
Safety factor 1.2
Tab. 18: Fixed point forces RAUPEX SDR 11
∆T
10 K
20 K
30 K
40 K
50 K
60 K
70 K
80 K
90 K
100 K
Dimension [mm]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
F [N]
16
× 2.2
103
206
309
412
515
618
721
824
927
1030
20
× 2.8
163
327
490
654
817
980
1144
1307
1471
1634
25
× 3.5
255
511
766
1021
1277
1532
1787
2043
2298
2553
32
× 4.4
412
824
1236
1648
2060
2472
2884
3296
3708
4120
40
× 5.5
644
1288
1931
2575
3219
3863
4507
5150
5794
6438
50
× 6.9
1009
2018
3027
4036
5045
6054
7063
8072
9081
10090
63
× 8.7
1603
3206
4809
6411
8014
9617
11220
12823
14426
16028
Safety factor 1.2
Tab. 19: Fixed point forces RAUPEX SDR 7.4
34
9. REHAU pipe clamp
REHAU pipe clamps can be used to fasten
RAUPEX pipes without supporting clip
channels.
Dimension
Pipe
weight
Volume
Pipe
weight
filled with
water
Dimension
Pipe
weight
Volume
Pipe
weight
filled with
water
[mm]
[kg/m]
[l/m]
[kg/m]
20 × 1.9
0.111
0.196
0.307
[mm]
[kg/m]
[l/m]
[kg/m]
16 × 2.2
0.098
0.097
0.195
25 × 2.3
0.169
0.311
32 × 2.9
0.268
0.519
0.480
20 × 2.8
0.153
0.152
0.304
0.787
25 × 3.5
0.238
0.238
0.476
40 × 3.7
0.425
50 × 4.6
0.659
0.804
1.229
32 × 4.4
0.382
0.398
0.780
1.263
1.921
40 × 5.5
0.594
0.625
1.219
63 × 5.8
75 × 6.8
1.040
2.011
3.051
50 × 6.9
0.898
0.979
1.877
1.451
2.875
4.325
63 × 8.7
1.468
1.555
3.024
Tab. 21: RAUPEX pipe weights SDR 7.4
90 × 8.2
2.099
4.128
6.228
110 × 10
3.112
6.193
9.305
160 × 14.6
6.595
13.090
19.685
Tab. 20: RAUPEX pipe weights SDR 11
9.1 REHAU pipe clamps with and
without clip bow
Up to 32 mm, REHAU pipe clamps are supplied without clip bows. The pipe is simply
clipped into the pipe clamp and when required can be pulled out again (Figs. 76 and
77).
By using spacers the distance of the pipe
axis to the attachment level can be changed
(Figs. 78 and 79).
By combining the pipe clamp and the spacer, holders for several parallel pipes can be
set up (Fig. 80).
Fig. 76
Fig. 77
Fig. 78
Fig. 79
Fig. 80
35
As from 40 mm, REHAU pipe clamps are
supplied with clip bows (Figs. 81 and 82). If
the REHAU pipe clamps are suspended, the
maximum holding forces must not be
exceeded (Tab. 22).
Fig. 81
Fig. 82
Article number
Designation
Maximum holding force [N]
247356
REHAU pipe clamp REHAU 16
18.50
243633
REHAU pipe clamp REHAU 20
19.25
243643
REHAU pipe clamp REHAU 25
20.00
243653
REHAU pipe clamp REHAU 32
21.50
243663
REHAU pipe clamp REHAU 40
359.50
243673
REHAU pipe clamp REHAU 50
338.50
243683
REHAU pipe clamp REHAU 63
377.25
243693
REHAU pipe clamp REHAU 75
507.50
243703
REHAU pipe clamp REHAU 90
458.00
243713
REHAU pipe clamp REHAU 110
423.00
243723
REHAU pipe clamp REHAU 160
752.00
Holding force at a 90° angle to the pipe axis
Tab. 22: Maximum holding force of the REHAU pipe clamps
9.2 REHAU wall clamps
In order to attach the pipes directly to the
wall, the REHAU wall clamps can be used.
Fig. 83 Wall pipe clamp.
36
10. Fire protection
Dimension
Weight
[kg/m]
Fire risk
[kWh/m]
Fire risk
[MJ/m]
20
×
1.9
0.111
1.35
4.88
25
×
2.3
0.167
2.04
7.33
32
×
2.9
0.269
3.28
11.81
40
×
3.7
0.425
5.19
18.67
50
×
4.6
0.658
8.03
28.90
63
×
5.8
1.04
12.69
45.68
75
×
6.8
1.45
17.69
63.68
90
×
8.2
10.1 Fire risk
RAUPEX pipes have the fire risks listed in
Tables 23 and 24.
10.2 Fire protection sleeves
In order to fit pipe sections in hazardous
areas, approved fire protection sleeves can
be used.
2.10
25.62
92.23
110 × 10
3.11
37.94
136.59
160 × 14.6
6.59
80.40
289.43
Tab. 23: Fire risk of RAUPEX pipe SDR 11
Dimension
Weight
[kg/m]
Fire risk
[kWh/m]
Fire risk
[MJ/m]
16
×
2.2
0.098
1.20
14.59
20
×
2.8
0.153
1.87
22.77
25
×
3.5
0.238
2.90
35.42
32
×
4.4
0.382
4.66
56.86
40
×
5.5
0.594
7.25
88.41
50
×
6.9
0.926
11.30
137.83
63
×
8.6
1.45
17.69
215.82
Tab. 24: Fire risk of RAUPEX pipe SDR 7.4
11. Marking of pipe systems
11.1 Marking colours
A clear marking of the pipes according to
the media flowing is in the interest of safety
and correct maintenance, and it is imperative for fire protection. The marking is intended to point out to hazards in order to prevent accidents and to observe general
health and safety requirements. This applies
in particular in industrial plant construction
where several media lines are laid next to
each other.
The marking can be effected by coloured
signs or labels, colour rings or by coloured
pipes. If signs, labels or colour rings are
used, they have to be affixed to all important
operating points, such as at the beginning
and end, at branches, wall and ceiling
break-throughs as well as fittings. It is considerably easier to colour-code the entire pipe
system. German standard DIN 2403 defines
colour for certain groups of fluids. This
colour coding is not applicable for underground installation of pipes.
Flow media
Group
Colour
Colour sample
Water
1
green
RAL 6018
Water vapour
2
red
RAL 3000
Air
3
grey
RAL 7001
Combustible gases
4
yellow or yellow
RAL 1021
with red
RAL 1021 + RAL 3000
Non-combustible gases
5
black or yellow
RAL 9005
with black
RAL1021 + RAL 9005
Acids
6
orange
RAL 2003
Lyes
7
violet
RAL 4001
Combustible liquids
8
Non-combustible liquids
9
Oxygen
0
brown or brown
RAL 8001
with red
RAL 8001 + RAL 3000
black or brown
RAL 9005
with black
RAL 8001 + RAL 9005
blue
RAL 5015
Tab. 25: Colour allocation for pipes in buildings in compliance with German standard
DIN 2403
37
11.2 Adhesive labels of REHAU
Adhesive labels of REHAU (Fig. 84) can be
used to mark pipes according to the medium and the direction of flow. The labels
stick to RAUPEX pipes and have arrows in
both directions. Perforated arrow tips can
be removed from the centre part with ease.
Fig. 84: REHAU adhesive labels.
12. Practical examples
Fig. 85: Motorcar industry.
Fig. 87: Manufacturing halls made of timber.
38
Fig. 86: Railway construction.
Notes
39
Our verbal and written advice relating to technical
applications is based on experience and is to the best
of our knowledge correct but is given without obligation.
The use of REHAU products in conditions that are
beyond our control or for applications other than those
specified releases us from any obligation in regard
to claims made in respect of the products.
We recommend that the suitability of any REHAU
product for the intended application should be
checked. Utilization and processing of our products are
beyond our control and are therefore exclusively your
responsibility. In the event that a liability is nevertheless
considered, any compensation will be limited to the
value of the goods supplied by us and used by you.
Our warranty assumes consistent quality of our
products in accordance with our specification
and in accordance with our general conditions of sale.
The REHAU Academy:
Our seminars help you achieve your
goals.
REHAU not only offers its partners innovative products that meet today's requirements
with up to date designs. Through the
REHAU Academy we are able to share
valuable expertise and first hand experience. Our seminars are for everyone, regardless of whether you are a craftsman, planner, or architect, an engineer, distributor or
in sales, from a large or small company.
They enable you to acquire the greater
expertise needed for more success in the
market.
Contact your local REHAU sales office for
more information.
ACADEMY
www.REHAU.com
[email protected]
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Erlangen/Germany, Tel.: +49 (0) 91 31 92 50, [email protected]
876.600 E 12.01