RAUVITHERM Technical Manual

RAUVITHERM Technical Manual
ENERGY
EFFICIENCY
RAUVITHERM
PRE-INSULATED DISTRICT HEATING PIPE
TECHNICAL AND INSTALLATION MANUAL 463600 EN
www.rehau.co.uk
Valed from October 2011
Subject to Technical Alterations
Building Solutions
Automotive
Industry
CONTENTS
1........
1.1. . . . . . .
1.2. . . . . . .
1.3. . . . . . .
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
2........
2.1. . . . . . .
2.2. . . . . . .
2.2.1 . . . . .
2.2.2 . . . . .
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAUVITHERM Pipe (fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
REHAU Jointing Technique . . . . . . . . . . . . . . . . . . . . . . . . . . .
REHAU Compression Sleeve Joint (fig. 2) . . . . . . . . . . . . . . . .
REHAU T-shrouds and I-shrouds (fig. 3) . . . . . . . . . . . . . . . . .
4
4
4
4
4
3........
3.1. . . . . . .
3.1.1 . . . . .
3.1.2 . . . . .
3.1.3 . . . . .
3.2. . . . . . .
3.2.1 . . . . .
3.3. . . . . . .
3.4. . . . . . .
3.5. . . . . . .
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAUVITHERM pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrier Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAUVITHERM Outer Pipe Jacket . . . . . . . . . . . . . . . . . . . . . . .
Jointing Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAUVITHERM Insulating Sleeve System. . . . . . . . . . . . . . . . . .
RAUVITHERM Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAUVITHERM Pipe Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
6
6
6
7
8
8
4........
4.1. . . . . . .
4.1.2 . . . . .
4.1.3 . . . . .
4.1.4 . . . . .
4.2. . . . . . .
4.3. . . . . . .
4.4. . . . . . .
4.4.1 . . . . .
4.5. . . . . . .
4.5.1 . . . . .
4.6. . . . . . .
4.6.1 . . . . .
4.6.2 . . . . .
4.6.3 . . . . .
4.7. . . . . . .
4.7.1 . . . . .
4.7.2 . . . . .
4.7.3 . . . . .
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Branch Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Building-to-building ("Dasiy Chain") Layout . . . . . . . . . . . . . . . 9
Branching off a Plastic Jacketed Main Line . . . . . . . . . . . . . . . 9
Design Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Loss Caculation for SDR 11 Pipe . . . . . . . . . . . . . . 10
Heat Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat Losses in RAUVITHERM Pipes. . . . . . . . . . . . . . . . . . . . 13
Pipe Laying Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Open-cut Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pull-through Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ploughing-in Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pipe Trenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Trench Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Proximity to Other Services . . . . . . . . . . . . . . . . . . . . . . . . . 18
Protecting the Pipes in Special Installation Situations . . . . . . . 18
5........
5.1. . . . . . .
5.1.1 . . . . .
5.1.2 . . . . .
5.1.3 . . . . .
5.1.4 . . . . .
5.1.5 . . . . .
5.2. . . . . . .
5.3. . . . . . .
5.4. . . . . . .
5.4.1 . . . . .
5.4.2 . . . . .
5.4.3 . . . . .
5.4.4 . . . . .
5.5. . . . . . .
5.5.1 . . . . .
RAUVITHERM Installation Instructions . . . . . . . . . . . . . . .
Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting with a Digger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting with a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Laying Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jointing Pipes with the Compression Sleeve Technique . . . . .
Service Connection Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . .
Connceting through the Basement . . . . . . . . . . . . . . . . . . . .
Prefabricated Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prefabricated Y-pipe RAUVITHERM . . . . . . . . . . . . . . . . . . . .
Exposed Lengths with End Caps . . . . . . . . . . . . . . . . . . . . . .
Linear Thermal Expansion during Installation. . . . . . . . . . . . .
Linear Thermal Expansion in Trenches . . . . . . . . . . . . . . . . .
2
19
19
19
19
20
20
20
20
22
27
27
27
28
29
29
29
5.5.2 . . . . .
5.6. . . . . . .
5.6.1 . . . . .
5.6.2 . . . . .
5.6.3 . . . . .
Linear Thermal Expansion when Connecting to Buildings . . . .
Installation Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe in Sleeve System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing During Land Development Phase . . . . . . . . . . . . . .
Tapping into Existing Lines . . . . . . . . . . . . . . . . . . . . . . . . . .
29
30
30
30
30
6........
6.1. . . . . . .
6.2. . . . . . .
6.3. . . . . . .
Commissioning / Standards and Guidelines . . . . . . . . . . .
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Applicable Standards and Guidelines . . . . . . . . . . . . . .
Pressure Test Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
32
1
RAUVITHERM
INTRODUCTION
In view of the increasing need to minimise CO2 emissions as much as
possible, local and district heating supply technology is becoming ever more
important. With the number of new supply stations being set up, the requirements for a flexible and efficient local and district heating pipe system are also
increasing. Pioneering technologies, combining optimum functionality with low
energy losses, form the basis for the insulated pipe system RAUVITHERM from
REHAU.
1.1
System Advantages
- Flexible pipe system ensures cost-effective heat distribution
- High operating safety because the RAUVITHERM pipes are made of
corrosion-resistant material
- Full range of system components for all applications
- Longitudinal water tightness
Biogas plant
1.2
Scope
This Technical Information applies to the planning/design, installation and
use of the flexible RAUVITHERM pre-insulated heating pipe system, the
REHAU compression sleeve joints and the REHAU insulating sleeve systems,
T-couplings and jointing sleeves.
1.3
Applications
RAUVITHERM is a pre-insulated pipe system used predominantly for below
ground.
- District Heating
- Swimming Pool Technology
- Cooling Technology
- Biogas and Biomass Applications
- Connection of External Surface Heating
- Heat Pump Applications
- Remote boiler/CHP units
Connection to wood chip burner
Biomass plant
Pay attention when you see this symbol!
Important information for the safe and correct handling of this product
Abbreviations used in this RAUVITHERM Technical Manual:
PE-Xa = high pressure cross linked polyethylene
PE-LD = Polyethylene - low density
PE-HD = Polyethylene - high density
EVOH = Ethylen-Vinyl-Alcohol-Copolymer
PU = Polyurethane
3
2
RAUVITHERM
MAIN COMPONENTS
2.1
RAUVITHERM Pipe (Fig. 1)
RAUVITHERM district heating pipes consist of carrier pipes (PE-Xa) with a
primer and oxygen diffusion barrier (EVOH), insulation made from cross-linked,
closed-cell PE foam sheet (λ = 0.043 W/mK) and a PE foamed corrugated outer jacket to increase the ring stiffness and flexibility. In the case of DUO pipes,
the location of the two carrer pipes in relation to each other is determined by
extruded foam made of PE.
Advantages
- High flexibility
- Quick installation
- Small bending radius
- Very good thermal insulation properties
Fig. 1
RAUVITHERM pipe
Fig 2
RAUVITHERM compression sleeve joint
Fig. 3
4
RAUVITHERM shroud system
2.2
REHAU Jointing Technique
2.2.1
REHAU Compression Sleeve Joint (Fig. 2)
The jointing technique for a compression sleeve is a method developed and
patented by REHAU for quick, safe and permanently leakproof connections
between PE-Xa pipes. It comprises simply a fitting and the compression
sleeve.
Additional sealing elements are not required, as the pipe itself acts as a
seal. Four sealing ribs guarantee a completely secure connection, which also
withstands the tough application conditions on construction sites. Specially
designed ribs on the compression sleeves prevent the connection coming
loose during operation.
Advantages
- Secure, permanently leakproof connection
- Practically no bore reduction, as carrier pipes are expanded to make the
connection. The resulting pressure loss is negligible and there is no cavitation
- Quick installation
- Can be pressurised immediately
- Works under any weather conditions
2.2.2
REHAU T- shrouds and I-shrouds, (Fig. 3)
Connecting points in the ground, for example sockets or T-couplings, are to be
insulated and sealed to an insulation quality equivalent to that of RAUVITHERM
pipes. The insulating sleeve system Generation I, which was specially developed
for this application, comprises a plastic component with stepped ends for
adjustment to the relevant outer jacket diameter. For sealing, two heat-shrink
sleeves are used for the I-Shroud or three heat-shrink sleeves for the T-shroud.
For insulation, high-quality dual-component PU foam (RAUVITHERM
coupler foam) is supplied in bottles.
Advantages
- Quick and easy assembly
- Reliable sealing
- Extremely good thermal insulation properties
- Universal sleeve: only 4 products for branches and joints in all dimensions
3
RAUVITHERM
PROPERTIES
3.1
RAUVITHERM Pipe
The RAUVITHERM pipes are made of the following main components
- carrier pipe (1)
- pipe insulation (2)
- pipe jacket (3)
These sub-areas are explained in detail below.
- Creep resistance
- Shape rentention
- Temperature resistance
- Poor transmission of sound
- Pressure resistance
- Toxicologically and physiologically harmless
- Excellent notched impact strength
3
Properties of PE-Xa Carrier Pipe
2
1
Fig. 4
RAUVITHERM pipe with main components
3.1.1
Carrier Pipes
The carrier pipe is made of high-pressure cross linked polyethylene PE-Xa
(produced in accordance with DIN 16892 and DIN 16893). The carrier pipes
are cross linked via the addition of peroxide under high pressure and at a high
temperature. This process bonds the macromolecules so that they form a
network.
Density
0,94 g/cm3
Average thermal longitudinal
expansion coefficient in temperature
range of 0 °C to 70 °C
1,5 10-4 K-1
Thermal conductivity
0,38 W/mK
Modulus of elasticity
600 N/mm2
Surface resistance
1012 Ω
Construction material class (DIN
4102)
B2 (normal flammability)
Surface friction coefficient
0,007 mm
Table 1
Properties of PE-Xa carrier pipe
Chemical Resistance
The RAUVITHERM PE-Xa carrier pipe demonstrates excellent resistance
to chemicals. The safety factors and temperature resistances are dependent
on the medium. The resistances mentioned in DIN 8075, Supplement 1, generally also apply to PE-Xa. Often, because of its cross linking, PE-Xa is more
resistant than non-cross linked PE.
Pressure and Temperature Limits
The following temperature and pressure limits apply in accordance with DIN
16892/93 at continuous operating temperatures for RAUVITHERM pipes.
(Application: water; safety factor 1,25)
Fig. 5
Carrier pipes SDR 11
RAUVITHERM, SDR 11
40 °C
50 °C
60 °C
70 °C
80 °C
90 °C
95 °C
11,9 bar
10,6 bar
9,5 bar
8,5 bar
7,6 bar
6,9 bar
6,6 bar
RAUVITHERM Carrier Pipes SDR 11
The RAUVITHERM SDR 11 pipes are predominantly used in heating and
cooling circulation systems. For this reason, they have an additional oxygen
diffusion barrier made of EVOH in accordance with DIN 4726. The colour of
these pipes is orange.
Table 2
Advantages of PE-Xa Carrier Pipes
- Excellent chemical resistance
- Extremely low friction coefficient (e = 0.007 mm at 60 °C)
- No incrustation
- Permanently low pressure loss over entire service life
- SDR 11 pipes with special, orange-coloured EVOH oxygen diffusion barrier
- Corrosion-resistance
- Good aging behaviour
Approvals for RAUVITHERM pipe
- WRAS Approved (up to 110mm UNO and DUO
50 years
50 years
50 years
50 years
25 years
15 years
10 years
Pressure and temperature limits SDR 11
For varying pressures and temperatures, the expected service life can be
determined according to DIN 13760 “Miner’s rule”. The carrier pipes are
designed for maximum operating temperatures of 95 °C, but can tolerate
excess temperatures of up to 110 °C for short periods.
5
3.1.2
Pipe Insulation
The insulation of the RAUVITHERM pipe SDR 11 consists of crosslinked PE
foam sheets and in the case of DUO pipes an additional foamed PE moulding
("bones").
3.2
Jointing Technique
In the case of below ground pipe joints, the system operator must be able to
rely on the jointing technique. Permanent watertightness of the pipe joints can
only be ensured if the pipe joints are carried out using the REHAU compression sleeve jointing technique. Processing of the compression sleeve joint must
be carried out using RAUTOOL tools.
Fig. 8
Fig. 6
Compression sleeve joint
3.2.1
Compression Sleeve
The compression sleeve fittings are made of dezincification-resistant special
brass in accordance with DIN EN 1254/3 (E) Class A, gunmetal or ST 37.0.
Compression sleeves are made of annealed standard brass CuZn39Pb3 / F43
in accordance with DIN 17671 or gunmetal.
Exposed pipe layers
Advantages
- Very fine pores (closed cell up to 95 %)
- High water resistance, thereby no water infiltration during operation
- Low thermal conductivity
RAUTOOL Tools
To process the REHAU compression sleeve, there are various manual, hydraulic and electro-hydraulic tools available:
Properties of PU Pipe Insulation
Heat conductivity
≤ 0,043 W/mK
3
3
Density
≥ 30 kg/m (Knochen bis 45 kg/m )
Compression grade
0,073 N/mm2
Water absorption
< 1 % Vol (DIN 53428)
Long-term temperature resistance
+95 °C
Table 3
RAUTOOL M1
Manual tool with double clamping jaw for 2 dimensions. Area of use is dimensions 16 mm – 40 mm. The M1 clamping jaws must only be used with the
RAUTOOL M1. (Fig. 9)
Properties of PU pipe insulation
3.1.3
RAUVITHERM Outer Pipe Jacket
RAUVITHERM pipes feature a corrugated outer pipe jacket. Primarily with the
larger pipe jacket diameters > 200 mm the corrugation increases the static
properties and the flexibility of the pipe. This makes the outer jacket highly
robust thanks to its solid wall pipe design.
Fig. 9
RAUTOOL M1
RAUTOOL A3
Electric hydraulic tool with battery operated and clampling jaws for 2 Dimensions. The operation is carried out through a battery operated hydraulic power
unit which is found directly on the tool cylinder. For dimensions 16 – 40. (Fig.
10)
Fig. 7
Outer jacket
Advantages
- Seamless extruded around the PEX-foam
- Ideal for the connection between pipe (sleeve sealing technique)
- High robustness due to its construction
Fig. 10
6
RAUTOOL A3
RAUTOOL G2
Tool for the dimensions 50mm – 110mm (optionally also available
for dimension 40 mm). It is driven via a hydraulic foot pump or via an
electrohydraulic unit. (Fig. 11)
- Installation instructions
Fig. 14
Fig. 11
RAUVITHERM I-shroud
RAUTOOL G2
3.3
RAUVITHERM Insulating Sleeve System
The sleeve is made of extremely robust and impact-resistant PE-HD. In addition, for high-quality insulating sleeve production, there is also abrasive strip,
temperature gauges and Forstner bits available to create the foam hole.
Properties of Sleeve Set System
High-density polyethylene (PE-HD):
Thermal conductivity
0,43 W/mK
Crystallite melting range
105-110 °C
Density
0,93 N/mm2
Modulus of elasticity
600 N/mm2
Construction material class (DIN
4102)
B2 (normal flammability)
Table 4
Properties of sleeve system
Heat-shrink Sleeves for Shroud Set
The heat-shrink sleeving is coated inside with a hot melt adhesive to seal the
sleeve to the RAUVITHERM pipe.
Material Properties of Heat-shrink Sleeve
Fig. 12
Shroud system
The sleeve system Generation I is available in two different configurations as a
T-coupling or as a jointing sleeve.
The T-Shroud set comprises of
- 1 T-shroud, large or small
- 3 heat-shrink sleeves
- 11 screws for T-shroud large
- 1 Vent plug
- Installation instructions
Fig. 13
Tensile strength
14 MPa
Max. expansion
300 %
Density
1,1 g/cm3
Water absorption
< 0,1 %
Adhesive softening temperature
80-90 °C
Construction material class (DIN
4102)
B2 (normal flammability)
Table 5
Material properties of heat-shrink sleeve
RAUVITHERM T-Shroud
RAUVITHERM I-Shroud
The RAUVITHERM jointing sleeve is used to insulate couplings and end caps.
The I-shroud set contains:
- 1 jointing sleeve, large or small
- 2 heat-shrink sleeves
- 1 Vent plug
7
3.4
RAUVITHERM Foam
RAUVITHERM sleeve insulation is made of dual-component PU foam.
The foam is supplied with the set and comprises of:
- 2 bottles
- 1 filler attachment
- Installation instructions
Technical Data Component A, Colour: brown
Flashpoint
> 200 °C
Vapour pressure (20 °C)
1 hPa
Density (20 °C)
1,23 g/cm3
Table 6
Technical data component A
Technical Data Component B, Colour: yellowish
Flashpoint
-5 °C
Vapour pressure (20 °C)
345 hPa
Density (20 °C)
1,06 g/cm3
Table 7
Technical data component B
Technical Data for Foam [measurement temperature 20 °C]
Fig. 15
Foam set
Mix ratio for weight (A:B)
146:100
Mix ratio for volume (A:B)
130:100
Start time
54 seconds
Thread time
335 seconds
Raw density (unrestricted foaming)
42 kg/m3
Raw density (core)
>60 kg/m3
Closed-cell factor
>88 %
Table 8
Before using the foam products, the safety data sheets and the installation
instructions supplied with the products must be read through carefully.
Foam technical data
Technical Data Component A, Colour: brown
Temperature
Mixing/shaking time
Processing time
25 °C
20 s
30 s
20 °C
25 s
40 s
15 °C
40 s
50 s
Table 9
3.5
RAUVITHERM Pipe Sizes
Processing of foam components
RAUVITHERM Dimensions
Dimension
Max. ring Coil Length (m)
2.8 x 0.8m
2.8 x 1.2m
Volume
(l/m)
Weight
(kg/m)
0.33
207
207
207
138
138
95
95
87
59
300
300
300
240
140
140
110
110
100
138
138
138
84
59
240
240
240
140
100
UNO
25
32
40
50
63
75
90
110
125
0.83
1.3
2.07
2.96
4.25
6.36
8.20
0.98
1.07
1.22
1.75
2.08
2.99
3.64
4.60
6.10
25
32
40
50
63
2 x 0.33
2 x 0.54
2 x 0.83
2 x 1.31
2 x 2.07
1.66
1.87
2.24
3.31
4.77
0.54
DUO
Table 10 RAUVITHERM Dimensions
Fig. 16
8
RAUVITHERM outline diagram
4
DESIGN
4.1
General Information
With the flexible RAUVITHERM pipes, both district heating networks and connecting lines between two buildings can be achieved cost effectively. There are
three different laying alternatives. Combinations are possible.
4.1.2
Branch Layout
With this method, buildings are connected via branches from a main line.
Advantages
- Flexible in design
- Easy installation even before buildings are constructed
- Branches can be connected to the main line at a later stage
Fig. 17
Branch piping
Fig. 18
Building-to-building ("Daisy Chain") piping
Fig. 19
Branching off a plastic jacketed main line
4.1.3
Building-to-building ("Daisy Chain") layout
In many cases, the availability of long delivery lengths of RAUVITHERM pipes
allows for the complete elimination of belowground connections or branches
by laying the RAUVITHERM pipes from one building to the next and back.
Advantages
- No connections below ground
4.1.4
Branching off a plastic jacketed main line
Existing district heating networks can either be extended or tapped into for
connctions to future developmetn of properties as long as the network can
accomodate the increased load.
Advantages
- If the operating temperatures of the main line are too high, a secondary
network with RAUVITHERM pipes can be created via a network decoupling
9
4.2
Design Tips
From the heat demands plotted over one year, it is clear that full heat carrying
capacity is only required on a few days a year. Investment and running costs
(due to higher energy losses) of district heating networks rise proportionally
with the nominal pipe diameter. Therefore, the smallest possible pipe diameters should be designed for the pipe network. The low additional costs required to compensate for the increased pressure loss at full capacity are more
than outweighed by the savings mentioned above. It may also be practical to
use a second pump, which starts automatically when the primary pump is at
full capacity and which otherwise serves as a back-up.
In connecting lines in particular, it may be a good idea to split the lines
into three (two flow pipes and one return pipe) or into four pipes (two
flow pipes and two return pipes). If the second lines are only switched
on when the capacity of the first is exceeded, the network can indeed
be operated with minimal energy losses for most of the year.
4.4
Pressure Loss
4.4.1
Pressure Loss Calculation for SDR 11 Pipes
To estimate pressure loss in a pipe section, the pipe routing must be known in
order to determine the necessary section and therefore pipe length. The flow
rate [l/s] or the heat-carrying capacity [kW] together with the design temperature drop [K] can be used for system design.
Calculation method using flow rate [l/s]: taking SDR 11 pipes as an
example:
Flow Rate:
0,65 l/s
Section Length:
100 m
= Total Pipe Length: 200 m
Selecting a Pipe Size
First, start at 0.65 l/s and draw a straight line vertically upwards (red line).
Where the straight line crosses the lines for each pipe size (circles), draw another horizontal straight line to the left axis Pressure loss drop (green line). This
shows the relevant pressure loss drop [Pa/m] for the corresponding pipe size.
Selecting the Flow Speed
From the intersections (circles), draw a line diagonally upwards and left
(blue line) to find the flow speed in the pipe.
Calculation using Heat-carrying Capacity [kW]
If the values for design temperature drop in K and heat-carrying capacity in
kW are available, the capacity on the axis with the relevant temperature drop
is used as a starting point.
Fig. 20
Annual time curve
4.3
Pipe Sizing
The hydraulic performance of RAUVITHERM pipes is considerably greater than
that of steel pipes due to the lower pipe friction coefficient with the same
inner diameter. For this reason, pressure loss tables for steel pipes cannot
be used for the pressure-loss calculation of RAUVITHERM pipes. When sizing
RAUVITHERM pipes, we recommend comparing the energy losses and pump
capacities.
Since full pump capacity is usually only required on a few days of the year,
reducing the pipe dimensions can lead to considerable savings in terms of
energy loss and material used.
For sizing, the maximum carrying capacities must be calculated for the
heating supply network. The charts on the following pages can be used for
estimating pressure loss. Tables, diagrams (Fig. 21) and example calculations
(pg 13) are available for the pressure loss calculation.
10
Example:
Temperature drop:
Heat-carrying capacity:
Length:
30 K
80 kW
100 m
Selection
Starting at the 80 kW mark on the bottom axis (temperature drop 30 K), draw
a line upwards (yellow line). All subsequent steps follow the same sequence
as the previous process using the flow rate.
Circle 1
Circle 2
Circle 3
Fig. 21
Pressure loss diagram SDR 11
Alternatives
32 x 2,9
Circle 1 pipe size:
Green Line
Pressure loss:
550 Pa/m
Total pressure loss:
550 Pa/m x 200 m
-------------------------------------------------------------------------= 110.000 Pa
= 1,1 bar
Circle 3 pipe size:
50 x 5,7
Green Line
Pressure loss:
65 Pa/m
Total pressure loss:
65 Pa/m x 200 m
-------------------------------------------------------------------------= 13.000 Pa
= 0,13 bar
Blue Line
Flow speed:
Blue Line
Flow speed:
1,3 m/s
0,5 m/s
Circle 2 pipe size:
40 x 3,7
Green Line
Pressure loss:
200 Pa/m
Total pressure loss:
200 Pa/m x 200 m
-------------------------------------------------------------------------= 40.000 Pa
= 0,4 bar
Blue Line
Flow speed:
0,8 m/s
Detailed pressure loss table available on request.
11
Fig. 22 Pressure loss diagram for SDR 11
12
4.5
Heat Losses
4.5.1
Heat Losses in RAUVITHERM Pipes
With a soil temperature of 10 °C, soil conductivity of 1.2 W/mK, depth of 0.6
m from the surface and (when using two UNO pipes) pipe spacing of 0.1 m,
the following heat losses per metre of pipe can be expected at the average
water supply temperature. The indicated heat losses apply to 1 m of trench
considering flow and return pipe (2 Uno or 1 Duo).
Assumptions
UNO pipe: 2 pipes in trench below ground
DUO pipe: 1 pipe in trench below ground
For UNO pipes:
Depth from surface:
Ambient soil temperature:
Soil conductivity:
Cond. of PE-Xa-foams:
Cond. of PE-Xa-pipes:
Cond. of PE-pipe jacket:
a = 0,1 m
h = 0,6 m
E = 10 °C
E = 1,2 W/mK
PU = 0,043 W/mK
PE-Xa = 0,38 W/mK
PE= 0,09 W/mK
FIg. 23
RAUVITHERM UNO SDR 11
Fig. 24
RAUVITHERM DUO SDR 11
Heat Losses During Operation
Q = U (B - E) [W/m]
U = thermal heat transfer coefficient [W/mK]
B = average water supply temperature [ °C]
E = ambient soil temperature [ °C]
Heat losses UNO pipe SDR 11 (Flow and Return)
Fig. 25
Heat losses UNO pipe
13
Heat losses DUO pipe SDR 11 (Flow and Return)
Fig. 26
Heat losses DUO pipe
Heat Load
kW
5K
10K
15K
25K
30K
10
0.48
0.24
0.16
0.10
0.08
20
0.96
0.48
0.32
0.19
0.16
30
1.44
0.72
0.48
0.29
0.24
40
1.91
0.96
0.64
0.38
0.32
50
2.39
1.20
0.80
0.48
0.40
60
2.87
1.44
0.96
0.57
0.48
70
3.35
1.67
1.12
0.67
0.56
80
3.83
1.91
1.28
0.77
0.64
90
4.31
2.15
1.44
0.86
0.72
100
4.78
2.39
1.59
0.96
0.80
200
9.57
4.78
3.19
1.91
1.59
300
14.35
7.18
4.78
2.87
2.39
400
19.14
9.57
6.38
3.83
3.19
500
23.92
11.96
7.97
4.78
3.99
600
28.71
14.35
9.57
5.74
4.78
700
16.75
11.16
6.70
5.58
800
19.14
12.76
7.66
6.38

900
21.53
14.35
8.61
7.18
1000
23.92
15.95
9.57
7.97
1100
26.32
17.54
10.53
8.77
1200
28.71
19.14
11.48
9.57
1300
20.73
12.44
10.37
1400
22.33
13.40
11.16
1500
23.92
14.35
11.96
Table 11
14
Temperature Drop (T)
Flow rates for various heat loads and varying temperature drop (T), Flow rate in l/sec
Instructions for Using Pipe Sizing and Energy Loss Tables
a) Pipe Sizing
- Using the heat load (kW) and temperature drop (T) obtain flow in
l/sec from table 10
- Use the flow rate in Table 11 to select a suitable pipe size
b) Energy Loss and Temperature Drop
- Using the selcted pipe size and the mean water temperature, obtain
the energy loss and temperature drop over 100m pipe lengths
using Table 13 & 14
Pressure losses are based on a mean temperature of 70oC
Flow rate
(L/sec)
25 x 2.3
Pa/m
m/sec
0.1
64
0.31
0.2
218
0.61
32 x 2.9
Pa/m
m/sec
65
0.37
0.3
135
0.56
0.4
227
0.74
40 x 2.9
Pa/m
m/sec
79
0.48
0.5
118
0.60
0.6
164
0.72
0.7
216
0.8
276
50 x 2.9
Pa/m
m/sec
0.84
73
0.5
0.96
93
0.6
115
0.7
1.0
139
0.8
1.5
291
1.1

0.9
2.5
Flow rate
(L/sec)
75 x 6.8
Pa/m
m/sec
3
141
1.0
3.5
187
1.2
4
240
1.4
4.5
298
1.5
90 x 8.2
Pa/m
m/sec
123
1.06
5
149
1.18
5.5
178
1.29
6
209
1.41
6.5
242
1.53
7
277
1.65
110 x 10
Pa/m
m/sec
104
1.10
7.5
118
1.18
8
133
1.26
8.5
148
1.34
9
165
1.41
9.5
182
10
200
125 x 11.4
1.49
98
1.16
1.57
107
1.22
228
1.83
m/sec
95
0.72
241
1.20
160 x 14.6
m/sec
20
116
1.49
25
175
1.86
30
247
2.23
Table 12
m/sec
Pa/m
Pa/m
15
Pa/m
63 x 2.9
Pipe sizing and pressure loss table
15
Pipe Size
(mm)
Mean Water Temperature (oC) and Temperature Drop (T)
40oC
T
50oC
T
60oC
T
70oC
T
80oC
T
90oC
T
25 x 2.3
0.49 kW 0.6 °C
0.66 kW 0.8 °C 0.82 kW
1.0 °C
0.98 kW 1.2 °C 1.15 kW
1.4 °C
1.31 kW
1.6 °C
32 x 2.9
0.57 kW 0.4 °C
0.77 kW 0.5 °C 0.96 kW
0.6 °C
1.15 kW 0.7 °C 1.34 kW
0.8 °C
1.53 kW
0.9 °C
40 x 3.7
0.67 kW 0.2 °C
0.89 kW 0.3 °C 1.12 kW
0.4 °C
1.34 kW 0.5 °C 1.56 kW
0.5 °C
1.79 kW
0.6 °C
50 x 4.6
0.68 kW 0.1 °C
0.90 kW 0.2 °C 1.13 kW
0.2 °C
1.35 kW 0.2 °C 1.58 kW
0.3 °C
1.80 kW
0.3 °C
63 x 5.8
0.83 kW 0.1 °C
1.11 kW 0.1 °C 1.39 kW
0.1 °C
1.66 kW 0.2 °C 1.94 kW
0.2 °C
2.22 kW
0.2 °C
75 x 6.8
0.85 kW 0.1 °C
1.14 kW 0.1 °C 1.42 kW
0.1 °C
1.71 kW 0.1 °C 1.99 kW
0.1 °C
2.27 kW
0.2 °C
90 x 8.2
1.02 kW 0.0 °C
1.36 kW 0.1 °C 1.69 kW
0.1 °C
2.03 kW 0.1 °C 2.37 kW
0.1 °C
2.71 kW
0.1 °C
110 x 10
1.23 kW 0.0 °C
1.63 kW 0.0 °C 2.04 kW
0.1 °C
2.45 kW 0.1 °C 2.86 kW
0.1 °C
3.26 kW
0.1 °C
1.27kW
1.69kW
0.0 °C
2.54kW
0.1 °C
3.39kW
0.1 °C
125 x 11.4
Table 13
0.0 °C
0.0 °C 2.12kW
2.96kW
RAUVITHERM UNO Energy Loss and Temperature Drop for 100m pipe length
Pipe Size
(mm)
0.0 °C
Mean Water Temperature (oC) and Temperature Drop (T)
40oC
T
50oC
T
60oC
T
70oC
T
80oC
T
90oC
T
25 x 2.3
0.73 kW 0.9 °C
0.98 kW 1.2 °C 1.22 kW
1.5 °C
1.47 kW 1.8 °C 1.71 kW
2.0 °C
1.96 kW
2.3 °C
32 x 2.9
0.78 kW 0.5 °C
1.04 kW 0.6 °C 1.30 kW
0.8 °C
1.56 kW 1.0 °C 1.82 kW
1.1 °C
2.08 kW
1.3 °C
40 x 3.7
0.96 kW 0.3 °C
1.28 kW 0.4 °C 1.61 kW
0.6 °C
1.93 kW 0.7 °C 2.25 kW
0.8 °C
2.57 kW
0.9 °C
50 x 4.6
1.01 kW 0.2 °C
1.34 kW 0.2 °C 1.68 kW
0.3 °C
2.01 kW 0.4 °C 2.35 kW
0.4 °C
2.69 kW
0.5 °C
63 x 5.8
1.15 kW 0.1 °C
1.54 kW 0.2 °C 1.92 kW
0.2 °C
2.31 kW 0.2 °C 2.69 kW
0.3 °C
3.07 kW
0.3 °C
Table 14
16
RAUVITHERM DUO Energy Loss and Temperature Drop for 100m pipe length
4.6
Pipe Laying Techniques
Thanks to the flexibility of RAUVITHERM pipes, various pipe laying techniques
can be used. The pipe laying technique must be adapted to suit the local
conditions.
4.6.1
Open-cut Technique
This is the most common laying method.
RAUVITHERM pipe trenches can be very narrow. Sufficient working space only
has to be available at joints.
Advantages
- Flexible laying without special tools
- Simple and cost-effective
- Additional connections can be made at any time
Fig. 27
4.7
Pipe Trenches
The dimensions of the pipe trench influence the level and distribution of the
soil and traffic loads and therefore the load-bearing capacity of the pipeline.
The width at the bottom of the trench depends on the outer diameter of the
pipe and also whether or not additional accessible working space is required
to lay the pipes. Sections underneath roads must comply with loading
classifications SWL 30 or SWL 60 in accordance with DIN 1072. For loads
greater than SLW 30 (e.g. SLW 60), a load-distributing surface structure in
accordance with RStO 75 is necessary.
For RAUVITHERM pipes, accessible working space is only required in jointing
areas, as stipulated in DIN 4124. The minimum pipe cover for RAUVITHERM
pipes is 60 cm. The maximum cover is 2.6 m. More or less cover must be
confirmed by means of a static load calculation. The trench bottom is to be
constructed in such a way that it fulfils the width and depth specifications and
the pipeline is in contact with it over its entire length.
Open-cut technique
4.6.2 Pull-through Technique
With the pull-through method, RAUVITHERM pipes can be installed in disused
channels, already laid pipes or in plastic pipe jackets requiring renovation.
Advantages
- Defective pipelines can be renovated easily
- Cost-effective laying through empty pipes that already exist or have been
installed using horizontal directional drilling.
Fig. 28
Pull-through technique
4.6.3
Ploughing-in Technique
In the ploughing-in technique, the pipes are laid quickly and without any great
effort. The ploughing-in method can be used for soils that are free of stones
or when the ploughing-in method can guarantee that the pipe will be laid in a
bed of sand.
Advantages
- No need for pipe trenches
- High installation efficiency
Fig. 29
Fig. 30
Ground worls
The trench bottom should not be aerated. Before the pipes are laid, any
aerated, cohesive soil is to be removed down to where the aerated soil begins
and this is to be replaced with non-cohesive soil or a special pipe support.
Aerated, non-cohesive soil is to be packed again.
Ploughing-in technique
The REHAU technical department is to be contacted in the case of installing
RAUVITHERM using the ploughing in technique and installations in groundwater.
Fig. 31
Trench base
17
4.7.1
Trench Widths
The diagrams below show the required trench widths. Only sand of grade 0/4
is to be used around the pipes and must be compacted manually in layers.
Fig. 32
DUO pipe trenches
4.7.2
Proximity to Other Services
Minimum distances from other services must be observed (see Table 14).
Drinking-water services adjacent to district heating pipes are to be separated
by the minimum distance to prevent them from warming up above the temperature specified by the applicable standards. If this cannot be guaranteed by
the distance, the drinking-water lines are to be insulated.
Other service
Parallel line <5 m
or crossover
Parallel
line>5 m
1-kV-, signal/measuring cables
0,3 m
0,3 m
10-kV- or 30-kV-cable
0,6 m
0,7 m
more than 1 x 30-kV-cable or
cable over 60 kV
1,0 m
1,5 m
Gas and water
connections
0,2 m
0,4 m
Table 15
Distances from other services
4.7.3
Protecting the Pipes in Special Installation Situations
Boggy Conditions and Marshland
If pipes are laid in boggy soil or marshland with a varying water table or
underneath roads, solid obstructions that can affect the pipe support must
be removed to a sufficient depth under the pipes. In cases where the bottom
of the trench is unstable or the soil is highly saturated, or where there are
different soil layers of varying levels of stability, the pipes have to be secured
through adequate construction measures, e.g. using non-woven fabric.
Fig. 33
Pipe system with UNO pipe
Fig.36
Fig. 34
Pipe system with UNO pipes laid above one another
Earthworks
Sloped Trenches
On slopes, cross brackets are required to prevent the bedding from beingwashed away. In some cases, drainage may be needed.
Fig. 35
Pipe system with UNO pipes laid next to one another
Fig. 37
18
Ground work
5
RAUVITHERM
INSTALLATION INSTRUCTIONS
Fig. 38
RAUVITHERM pipe
5.1
Transport and Storage
Incorrect transportation or storage can result in damage to RAUVITHERM
pipes, accessories and fittings, which could affect the operational safety,
particularly the excellent thermal insulation properties. Pipes and pipework
components should be checked for any transportation and/or storage damage
before being placed in the trench. Damaged pipes and pipework components
must not be installed..
5.1.1
Storage Time
To protect the pipes from dirt and the carrier pipe from UV radiation, the
ends of the RAUVITHERM pipes must be kept clean. Contact with potentially
damaging substances (see Supplement 1 to DIN 8075) should be avoided.
RAUVITHERM pipes with a pipe jacket made of PE-HD can only be stored in
direct sunlight for a limited time. Experience has shown that, in Central Europe, pipes can be stored outside for up to 2 years after manufacture without
this affecting the
strength of the pipes. For prolonged periods of external storage or in areas
with intense solar radiation, e.g. sea, in southern countries, or at altitudes
over 1500 m, the pipes must be protected from direct sunlight. When
covering with tarps, the UV resistance of the pipes must be taken into account
and good ventilation of the pipes must be ensured to prevent any build-up of
heat. Unlimited storage is possible if the pipes are protected from any light.
5.1.2
Transport
Pipe coils are to be transported horizontally, lying completely flat on a load
area, and must be secured to prevent shifting. The load area must be cleaned
before loading up the pipe coils.
Fig. 39
Transportation
19
5.1.3
Lifting with a Digger
When lifting a pipe coil, ensure that the lower part of the coil, which is still
touching the ground and carrying part of the total weight, is not dragged
across the ground or load area. Take extra care when putting down the pipe
coils: do not use ropes for lifting, only transport straps at least 50 mm wide.
5.2
Laying Pipes
Cutting the Straps
RAUVITHERM pipes are supplied in coils with an outer diameter of up to 210
mm. When undoing the coil bindings, it is important to note that pipe ends
can spring out.
Fig. 43
Fig. 40
Lifting with a digger
5.1.4
Lifting with a Forklift
When using a forklift, ensure that the forks are covered with a soft material
(cardboard or plastic pipes). Note: When using plastic pipes, make sure they
are secured properly to prevent them from slipping off.
Fig. 44
Cutting the coil straps
When opening the bundled coil bindings, pipe ends can spring out! Always
open bindings layer by layer.
Do not stand in the danger zone!
Fig. 41
Lifting with a forklift
5.1.5
Storage
We recommend storing pipe coils horizontally on wooden planks. This will
largely avoid any pipe damage and allow easy lifting of the pipe coils when
moved at a later stage. Under no circumstances are pipe coils to be stored on
top of sharp-edged objects. Pipe coils should not be stored upright due to the
risk of them falling.
Attention: Injury Risk!
The small contact area between the ground and the coil would also allow
objects to easily penetrate the outer jacket.
Unwind Coils Layer by Layer
Ensure that the uncoiled pipe section does not twist, as otherwise kinks may
form. Another reason for cutting the straps layer by layer.
Fig. 45
Fig. 42
20
Storage
Opening the coil layer by layer
Uncoiling
For pipes with an outer diameter of up to 150 mm, the coils are usually
uncoiled in an upright position. For larger pipe sizes, we recommend using
a mechanical pipe unwinder. The coils can then, for example, be positioned
horizontally on the pipe unwinder and uncoiled by hand or with a slow-moving
vehicle.
In view of the reduced pipe flexibility at low temperatures around freezing, the
coil can be warmed up for a few hours in a heated building or a heated tent to
facilitate installation.
In the case of Duo pipes, install the flow and return pipes on top of one
another, so that branches cas easily be added to the side connections.
Fig. 48
RAUVITHERM pipes
Backfilling with Sand
Fill pipe trench up to 100 mm over the top of the pipes using sand of grade
0/4 and compact it by hand.
Fig. 46
Uncoiling
Bend Radius
The high flexibility of the RAUVITHERM pipes allows easy and quick laying.
Obstacles can be bypassed and changes of direction in trenches are possible
without the need for fittings. However, based on the pipe temperature, the
minimum bending radius specified in the following table must be observed.
Fig. 49
Fig. 47
Laying a bend area
Bending RadiI
If the bending radius has to be achieved at lower pipe jacket temperatures,
the bend area should be pre-heated with a low burner flame. For installation in
frost conditions, the bend area of the pipe must always be pre-heated!
Table 16
RAUVITHERM
outer diameter D
Minimum bending radius at 10 °C
pipe jacket temperature
120 mm
0,9 m
150 mm
1,0 m
175 mm
1,1 m
190 mm
1,2 m
210 mm
1,4 m
Backfilling trenches with sand
Identification Tape
For better identification during future excavation work, identification tape
should be laid 40 cm above the pipes. The identification tape should be labelled “Caution – District Heating Pipeline”. For easier location of the installed
pipeline, identification tape with metallic strips can be used.
Minimum bending radius for RAUVITHERM
Fig. 50
Identification tape
21
5.3
Jointing Pipes with the Compression Sleeve Technique
1 Cut pipe.
RAUVITHERM pipe could spring back!
2 Expose lengths according to outer diameter of carrier pipe
1
2
Carrier Pipe Outer Diameter
If the end of the pipe is not square, an extra 2-4cm (approx.) should also be
stripped so that the carrier pipe can be cut (see point 5).
Table 17
Exposed Length L
20 - 40 mm
120 mm + 40
50
140 mm + 40
63 - 125 mm
160 mm + 40
Exposing lengths
3 Cut the pipe jacket all the way round with a saw or pipe cutter and peel it
off.
Take care not to damage the carrier pipe!
4 Remove the foam
3
4
Take care not to damage the oxygen diffusion barrier!
5 Cut the carrier pipe square, if required (see point 2).
5
Please note: When installing a sleeve, slide a shrink hose over each end of the
carrier pipe, before connecting the carrier pipe! (see 5.3.1).
6 Slide compression sleeve on the pipe. Ensure that the outer milled ring
faces towards the insulation of the pipe and the chamfered end faces towards
the pipe end.
7 Expand pipe twice, offset by approx. 30°.
Do not use expander in the area of the compression sleeve. Slide the compression sleeve right back to the insulation.
22
6
7
8 Next, insert the fitting (REHAU T-piece for T-coupling or REHAU coupler
for V-coupling). Position the clamping jaws over the tool and clamp on to the
joint. Note: For diameters above 63 mm, use REHAU lubricant on the carrier
pipe in the area of the compression sleeve.
Before using the tool, read the operating instructions supplied with the tool
very carefully!!
8a
If required for additional compression sleeve connection, cut out a recess to
make room for the clamping tool. The insulation should then be removed as
specified in the table. Please ensure shrink sleeves are in position before
aking the joint!
8b
Carrier PipeOuter Diameter
20 - 40 mm
l
Tool A1 or M1
170 mm
l
Tool G1
------
40 - 110 mm
--------
270 mm
Table 18 Cutting a recess for too;
9 If required cut out recess for tool.
10 Slide shrink hose over pipe ends.
11 saw off shroud sides at the markeings according to the OD of the outer
pipe (see OD marking on shell).
10
12 Slide the top of the T-Shroud over RAUVITHERM Pipe.
13 Repeat the procedure with the other pipes according to steps 1-10.
12
13
23
14 Slide the RAUVITHERM Shroud downward over the two other connection
pipes.
14
15 Align the shroud sides over each other.
Remove sealing tape cover on one side and position the tape between the two
shroud sides.
Sealing tape needs to be positioned in such a manner that approx. 2mm of
the tape overlap outside of the shell.
15
16 Remove sealing tape cover completely and push both shroud sides
together. Puncture sealing tape in preparation for the screw connection.
Ensure that the shroud sides are aligned.
16
24
17 Seal the bottom of the shroud using the screws (part of the package).
Use an electric drill.
Press overlapping sealing tape remains, tight against the shroud.
18 Drill at the highest position at one of the three marked places a
ventilation hole in the shroud. Us a centre bit (d=25mm)
17
18
19
20
19 Clean the surface of the shell from dirt and grease
20 Gently heat shrink the sleeves over the two lower ends of the T-Shroud
(only one shrink sleeve for I-Shroud) with a soft flame.
Watch for the marking on the shell.
Start with shrinking the hose over the shell area. Let the area cool down and
continue by shrinking the remaining hose over the pipe surface
21 Seal the gap between the shroud and RAUVITHERM pipe at the higher
side of the T-Shroud with a wider tape.
21
22 Mix foam components.
Attention: Observe safety instructions to the foam set. See page 26.
23 Shake sealed bottle well (see instruction in the foam set)
24 Fill content of foam bottle into the plug hole.
22
23
25 Remove foam residuals. Push plug halfway in using a hammer.
26 Shrink the remaining shrink hose ove rthe upper end of T-shroud (see
step 20)
27 Installation finished.
25
25
Caution: The RAUVITHERM coupler foam is to be handled in
accordance with the instructions for use.
°C
35
30
25
20
recommended
max.
18–23 °C min.
15
10
5
Temperature
25 °C
20 °C
15 °C
Table 19
b
26
Shaking time
20 s
25 s
40 s
Processing times for foam
Processing time
50 s
40 s
50 s
5.4
Service Connection Pipes
5.4.1
Connecting through the basement
The RAUVITHERM pipes should be routed in straight lines. If the RAUVITHERM
pipeline runs parallel to the building, the bend for entry into the building must
have a bending radius of at least 2.5 x the value specified in Table 15. This
protects the pipe from unnecessary stress where it penetrates the wall. If the
spatial proportions are too small, prefabricated bends may also be used as
a fall-back option.
In order to realise the connection inside the building, the pipes must project
into the building by the amount specified in Table 20 (Page 29)
5.4.2
Prefabricated bends
The pre-fabricated RAUVITHERM bends are used where the possible bending
radius for routing into the building is smaller than required under Table 15.
This is usually the case when installing pipes going into a building without a
basement.
Installation
- Install wall seal and position pre-fabricated bend in the foundations
- The vertical end must be secured before the ground plate/foundations are
laid
Do not remove the protective end caps until the final connections have been
made. If there is a danger of the unprotected carrier pipe ends becoming dirty
or damaged by UV radiation, they must be protected with UV-resistant plastic
film/tape.
Fig. 51
Fig. 52
Prefabricated bends for UNO and DUO pipes
Installing a prefabricated bend
27
5.4.3 Pre-fabricated Y- Pipe RAUVITHERM
The prefabricated Y-Pipe is used to transition from UNO to DUO,
available for dimensions upto 63mm.
Installation
Fig. 53a Transition from UNO to DUO pipe using prefabricated Y-pipe
Fig. 53b Transition from UNO to DUO pipe using prefabricated Y-pipe
28
5.4.4
Exposed lengths with end caps
End caps are used to close off the pipes where they penetrate the building
wall. If the end cap should be installed inside a wall, the pipe jacket must be
stripped back before the RAUVITHERM pipes are positioned in the trench. In
this case, heat-shrink end caps must also be placed on the pipe ends beforehand. Otherwise, the pipes can be routed in first and stripped afterwards.
To carry out a compression sleeve joint with end caps, depending
on the type of cap (heat-shrink end caps or push-on end caps), the
exposed lengths shown in table 19 are required.
5.5
Linear thermal expansion during installation
5.5.1
Linear thermal expansion in trenches
No expansion bellows or compensators are required for RAUVITHERM pipes
when installed in trenches. As in the case of RAUVITHERM this concerns a slip
pipe system, fixed points are to be set after all house connections (see table
19).
5.5.2
Linear thermal expansion when connecting to buildings
To keep the thermal expansion within acceptable limits when connecting to a
building, RAUVITHERM pipes should not extend more than the distances specified in Table 19 beyond the inner building wall into the building itself. If the
push-on or heat-shrink end caps are inside the wall or extend into the core
drill hole, the dimensions x can be reduced by 60 mm. The carrier pipe requires fixing brackets suitable for the forces listed in the table. Fixing brackets
may be attached to the fitting body, but not to the compression sleeve.
RAUVITHERM UNO
RAUVITHERM DUO
Fig. 54
Exposed lengths
Installing a heat-shrink end cap
- Expose RAUVITHERM pipe in accordance with Table 18
- Rough up the heat-shrink area with an abrasive cloth and preheat it to over
60 °C with a soft flame. Use temperature indicator strips to check the preheating temperature!
- Slide on heat-shrink end cap and shrink on using a soft flame
- Then complete the compression sleeve joint
Heat-shrink end cap dimensions
Dimensions
RAUVITHERM UNO Carrier Pipe OD
A
25 to 40 mm
50 to 110 mm
125 mm
150 mm
175 mm
200 mm
RAUVITHERM DUO Carrier Pipe OD
B
20 to 40 mm
50 and 63 mm
150 mm
175 mm
Table 20
Exposed lengths, heat-shrink end caps (A, B)
Fig. 56
Carrier Pipe
OD x s [mm]
25 x 2,3
32 x 2,9
40 x 3,7
50 x 4,6
63 x 5,7
75 x 6,8
90 x 8,2
110 x 10
20 x 2,8
25 x 3,5
32 x 4,4
40 x 5,5
50 x 6,9
63 x 8,7
Fig. 57
Max. distance to wall from
- to x [mm]*
220 - 270
220 - 270
220 - 270
220 - 270
260 - 300
260 - 300
260 - 300
260 - 300
220 - 270
220 - 270
220 - 270
220 - 270
220 - 270
260 - 300
Max. anchor forces
per pipe [kN]
0,93
1,50
2,40
3,70
5,80
8,20
11,90
17,70
1,00
1,70
2,10
3,30
5,20
8,20
Table 21
Fixed points: distance to the wall and occurring forces
* To enable a fitting to be pressed in
Fig. 55
Heat-shrink end caps for UNO and DUO pipes
29
5.6
Installation techniques
5.6.1
Pipe in sleeve system
For crossing underneath buildings or for areas with difficult access, a pipein-sleeve installation is possible with RAUVITHERM. The inner diameter of
the sleeve pipe must be at least 2 cm bigger than the outer diameter of the
RAUVITHERM pipe jacket. The RAUVITHERM pipe can be pulled in using a
winching cable and towing sock, ensuring the maximum winching forces are
not exceeded. A lubricant applied to the RAUVITHERM pipe jacket minimises
the pipe friction. Changes in direction should only be made with the open-cut
installation technique.
5.6.2
Installing during land development phase
To develop plots for connection to a heating network where buildings will be
erected at a later date, dead legs can be laid and closed off with isolating
valves (available on request). The ball valves can be insulated with the REHAU
insulation kit for end caps.
5.6.3
Tapping into existing lines
The flexibility of the RAUVITHERM pipes allows the subsequent installation of
T-joints. The network section must be taken offline for this and the heating
water must be cooled to 30 °C.
30
6
COMMISSIONING / STANDARDS & GUIDELINES
6.1
Commissioning
General Information
The RAUVITHERM pipes and joints must be pressure-tested before they are
insulated or the trench is backfilled. The pressure test can be carried out
immediately after completing the compression sleeve joints.
Pressure test with water
Test Procedure
- Visually imspect the Districy Heating pipe work to ensure that there is no
post installation damage
- Flush the district heating circuit and allow for water to run clear of bubbles
and any dirt/chippings that may have got into the pipeline
- Pressurise the system to test pressure of 6 bar (or) 1.5 x operating pressure, whichever is greater. Close the isolation valve on the inlet and outlet.
Ensure there are no leaks from the connections
- The above step may need to be repeated several times before the pressure
within the system stabilises at the test pressure. This is due to the inherent
flexible properties of PE-Xa.
- When the pressure is stabilised in accordance to the graph below, remove
the pressure pump and the pressure test is successful.
Plans for public supplies, for water engineering and for transmission lines;
plans for pipe-systems for distant-heating
- DIN EN 15632: 2009
- District Heating pipes - Faactory insulated flexible pipe systems
- DIN 16892: 2000
Cross linked polyethylene (PE-X) pipes)
- General requirements, testing
- DIN 16893: 2000
Cross linked polyethylene (PE-X) pipe
- Dimensions
- DIN 13760 Miner’s Rule
- DIN 4726
Warm water floor heating systems and radiator pipe connecting – Piping of
plastic materials
- General requirements
- DIN 4729
Cross linked polyethylene pipes for warm water floor heating system
- General requirements
-
- DVGW Worksheet W531
- Manufacture, quality assurance and testing of pipes made of PE-Xa for
drinking-water installation
DVGW Worksheet W534
Compression joints for pipes made of PE-Xa
Fig 58
Pressure test diagram in accordance with DIN 1988
1 - Repumping
A - Pressure drop due to expansion of the pipe
B - Main Test
As-installed drawings
The actually installed pipe lengths are to be recorded and entered into an asinstalled drawing as per DIN 2425-2.
- DVGW Worksheet W534(E)
Pipe connectors and pipe connections
- VDI 2035 Prevention of damage in water heating installations
- WRAS Approved up to 110mm for UNO and DUO pipe
Corrosion Inhibitors
Note: When using corrosion inhibitors or flow conditioners, confirmation of
their compatibility with PE-Xa and the fitting materials used is to be obtained
from the manufacturer. The requirements of VDI 2035 relating to the quality
and treatment of the feed water should also be observed.
6.2.
Other applicable standards and guidelines
- DIN 2424 Part 2
31
6.3 Pressure Test Certificate
1.
Project Name
2.
Installation Date
................................................................................................................
Max. Operating Pressure
Max. Operating Temperature
Test Pressure:
Ambient Temperature:
3.
Pressure Test
a)
b)
c)
d)
e)
4.
...................................................................................
...................................................................................
...................................................................................
...................................................................................
Completed
Flush and fill the circuit
Pressureise to 6 bar (or) 1.5 times operating
pressure whichever is greater
Pressure several times again in accordance
with the pressure test diagram
(Pipe expansion causes initial pressure loss)
Test Period for 3 hours
Pressure test is succesful, if-there are no leaks
within the circuits - pressure has not fallen by
more than 0.1 bar per hour
Confirmation
The Pressure Teststing was carried out in accordance with the above recommendations.
No leaks were deducted and no component showed a permanent deformation.
Location:
..........................................................................
Date:
..........................................................................
M & E Contractor/
Installer:
..........................................................................
32
.......................
.......................
.......................
.......................
.......................
FURTHER REHAU PRODUCT RANGES
RAUTHERMEX pre-insulated pipe
RAUGEO PE-Xa Ground-source Probes
REHAU Underfloor Heating
RAUTOOLS
RAUBIO Fermenter Heating
RAUBIO Gas Condensation Chamber
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 obligations 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, then this will be based exclusively on our conditions of sale, which can be seen
under www.rehau.de/LZB. This also applies to any warranty claims, whereby the warranty assumes consistent quality of our products in accordance with our specification.
This document is protected by copyright. The rights conferred therein, particularly those relating to translation, reprinting, extraction of figures, electronic transmission, reproduction by photomechanical or similar means and storage
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UK & IRELAND SALES OFFICES
London, REHAU Ltd, The Building Centre, 25 Store Street, London WC1E 7BT Slough, Units 5 J & K, Langley Business Centre, Station Road, Langley, Slough SL3 8DS Phone:
01753 588500 Fax: 01753 588501 Manchester, Brinell Drive, Irlam, Manchester M44 5BL Phone: 0161 777 7400 Fax: 0161 777 7401 Glasgow, Phoenix House, Phoenix
Crescent, Strathclyde Business Park, Bellshill, North Lanarkshire ML4 3NJ Phone: 01698 503700 Fax: 01698 503701 Dublin, 9 St. Johns Court, Business Park, Swords Road,
Santry, Dublin 9 Phone: 00353 (0)1 8165020 Fax: 00353 (0)1 8165021
www.rehau.co.uk
463600EN
11.2011
Shenyang
Xi’an
Chengdu
Qingdao
Taipei
Pune
Bangalore
Effektive Vernetzung REHAU AG + Co
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.
This document is protected by copyright. All rights based
on this are reserved. No part of this publication may be
translated, reproduced or transmitted in any form or by
any similar means, electronic or mechanical, photocopying,
recording or otherwise, or stored in a data retrieval system.
www.rehau.com
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SINGAPORE - Regional Office for Asia/Australia
1 King George’s Avenue, REHAU Building, Singapore 208557 Tel: +65 6392-6006 Fax: +65 6392-6116
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