DISTRICT HEATING Sealing solutions pre-insulated pipes Raych
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Sealing solutions pre-insulated pipes
DISTRICT HEATING
Sealing solutions pre-insulated pipes
Raychem, global expert District Heating Developments joint technology pre-insulated pipes
III. principle heat-shrinking, technical explanation Benefits Raychem's sealing technology
Standards Tests
Jointing technology
Product selection guide RayJoint DualSeal IPPS/106 TPSM/138
VII. Foaming hole closure plugs
WEPS FOPS
VIII. caps
DHEC CCS-DHEC
Anchor plates
APPM
Equipment
Industrial applications pre-insulated pipes XII. Related products
ATUM DuraSeal Gelsnap TDUX
XIII. Raychem,
Call Raychem sales offices
Content
Raychem, global expert District Heating
Raychem heat-shrinkable products play role district heating installations around world. comprehensive product range answers every application need.
RayJoint Korea
RayJoint Sweden
RayJoint Germany
Raychem, global expert District Heating
RayJoint Germany
DualSeal Korea
DHEC
District Heating
Raychem, global expert District Heating
WPC100M IPEC
Pre-insulated pipe transmission pipeline
HTLP80 Canada
Pre-insulated pipe transmission pipeline
Raychem, global expert District Heating
Developments joint technology pre-insulated pipes
more than years Raychem been leading company heat-shrink technology. 1969 paths Raychem district heating first crossed.
1968
Development insulated pipes carrying water. insulated pipe consists steel carrier pipe, polyurethane insulation outer casing. Pre-insulated pipes designed buried applications. jointing outer casing carried using various techniques: with cold applied tape, with bitumen tape, even without extra sealing. believed that polyurethane foam itself watertight. Failures field prove otherwise.
Good sealing jointing technology required
1969
technology sealing pre-insulated pipe joints established Raychem's newly introduced ,,heat-shrink technology". Polyethylene sleeves crosslinked electron beams hot-expanded. After heating with torch they return their original shape.
1970
Raychem designs District Heating DHEC provide sealing between service pipe outer casing pipe.
Improved joint design required
Raychem introduces crosslinked heat-shrinkable sleeves coated with hotmelt adhesive, TDBM. Hotmelt adhesives provide excellent shear resistance.
1973 1975 1982
discovery that relative movements between pipe joint casing during construction period require flexible sealing zone causes Raychem introduce hotmelt coated tubular TDBM with separately installed flexible strip step-down area. Raychem introduces single-coated "wraparound" sleeves. single-coated materials with separately installed sealing strips leads good results. Now, only friction forces dealt with, while pipe operation, also relative movement forces during construction.
sealing product with integrated functions required
Raychem introduces DualSeal product, wraparound sleeve with different adhesive coatings. idea "double seal" born into practice elastic mastic coating middle DualSeal hotmelt coatings either side. mastic coating acts initial seal transition casing pipe hotmelt acts additional seal, providing mechanical strength keep sleeve place.
1983 1986
First trials weld casings joints casing pipe. Raychem develops Jointek 1000, high-performance, electrically installed product, based Raychem's shrink technology. flexible zone centre avoids transfer stress during installation. wide welding zone provides excellent soil resistance. Jointek 1000 independent individual systems. Several other systems introduced into market. Market circumstances require combination material price, cost installation high quality. Shrinkable non-crosslinked casings combination with different sealing sleeves introduced. Raychem introduces RayJoint "all one" crosslinked heat-shrinkable casing. RayJoint provides highest soil water resistance with economical installation acceptable material price. Several large diameter projects installed with RayJoint products. high quality DualSeal introduced offering high performance combination with easy installation.
1993 1996 1998 1999 2000
future, Raychem will continue provide solutions pre-insulated pipe market.
Developments joint technology pre-insulated pipes
principle heat-shrinking, technical explanation
Thermoplastic materials composed extremely long molecular chains random arrangement. Their strength depends upon distance between molecules crystalline nature molecular structure. fact, crystalline zone that contributes most strength.
thermoplastic heated above crystalline melting point (125°C), crystalline zones disappear. molecules then easily slip past each other, material flows. During investigation atomic energy, important discovery made that exposure some plastic materials high-energy penetrating radiation cause permanent crosslinking (intermolecular joining) adjacent molecules well known crosslinking.
This linking results chemical bonding plastic structure into three-dimensional matrix. Once material been crosslinked, will melt flow temperature. When heated, crystalline zones disappear before, flow shape change occurs because crosslinks ties between molecules. However, structure remains elastic when crystalline zones melted, material behaves like rubber.
Products that have been radiation-crosslinked exhibit perfect elastic memory. They supplied deformed expanded condition. When heated, they shrink example, tightly enclose object over which they have been placed. This makes them ideal covering variety pipes pipe fittings, well wires, lugs, terminals, connectors other electrical electronic components.
principle heat-shrinking, technical explanation
Legend
Raychem fabricates compounds into their final form then subjects them high energy radiation, thus permanently "freezing" them into desired shape. following illustrations demonstrate what happens molecular structure crosslinked tubing during subsequent stages manufacture during application. Next each illustration cross-section piece heat-shrinkable tubing.
cross-section tubing
crystalline zone
crosslinks
Figure enlarged schematic view very small crosslinked section extremely long molecules.
Once tubing been crosslinked, next step imparting elastic memory heat compound above crystalline melting point. molecules then tied together only crosslinks.
While hot, tubing deformed applying pressure, thus stretching crosslinked molecule.
While this deformed shape, tubing cooled. crystalline zones then reappear, thereby locking structure together indefinitely expanded form. This form which material supplied customers.
user reheats product, melting crystalline zones. crosslinks allow material return original shape. This perfect elastic memory crosslinked material.
After cooling, crystalline zones reform tubing locked recovered form. Upon subsequent reheating, further change shape will take place, unless mechanical force applied.
principle heat-shrinking, technical explanation
Benefits Raychem's sealing technology
Unique materials
outer backing layer made from irradiated crosslinked high-density polyethylene (HDPE). expanded during production phase. Heating with torch during installation returns original dimension.
Backing
HDPE backing provides high shrink force, resulting high hoop stress, high mechanical resistance. crosslinks, backing heated over melting point without damage. This results safe fast installation. Even after several years installation, backing will creep (loose recovery force). This results long-term, high-quality performance.
Adhesive
special stocking requirements necessary. shelf life limitation. Since products expanded elevated temperatures, they will recover when lying during construction.
adhesives (hotmelts mastics) developed produced Raychem. They specifically designed each application. combination backing adhesive guarantees quality total sealing system. difference between shrink temperature high crystalline melting point (125°C) Raychem backings lower softening points adhesive ensures that irregularities joint area ideally filled with adhesive.
Raychem expert
more than years Raychem been developing producing crosslinked heat-shrinkable systems. Raychem employees active members various committees creation norms standards. Their experience will help create clear requirements testing District Heating joints 489). long experience guarantee good quality joints. Raychem sites over world have been qualified 9001.
Benefits Raychem's sealing technology
Raychem complete range
Raychem total solution provider jointing sealing techniques District Heating. product range includes: joints (wraparound tubular), foaming hole closure systems, caps anchor protection sleeves. Additional equipment like torches, scrapers, heating shields, etc. part Raychem product assortment. addition, Raychem also designed products based modern polymer technology transmission pipelines water utilities. Millions pre-insulated pipe joints have been sealed with Raychem products. Raychem your expert sealing applications.
Training service
Raychem field service people help train installers specifics jointing technology. Trained installers receive Raychem certificate after successful training. Upon request Raychem field service people carry controls jointed sleeves field.
International sales support network
Raychem technical sales support representatives around world help customers understand solve technical engineering problems, provide hands-on field training expert applications assistance. Through this sales support network, through alliances with other leading technology manufacturing companies, work anticipate customers needs changing competitive environment.
Benefits Raychem's sealing technology
Test
Raychem products intensively tested. tests pre-insulated pipe joints specifically designed Raychem tests performed laboratories, well laboratories independent institutes.
Standards tests
Purpose
European standard "Pre-insulated bonded pipe systems underground water networks Joint assembly steel service pipes, polyurethane thermal insulation outer casing high density polyethylene".
Soil stress resistance
district heating pipe system subjected axial pipe joint movements temperature variations during operation. test method created distinguish different joints comparable way. Example period years represents about full action/temperature cycles.
Relative outer casing movement Raychem internal test method
ambient temperature fluctuations during construction phase, generated day/night cooling heating-up from pipe jacket, casing pipe will expand contract. This movement creates relative movement between pipe casing. When joint sealing element flexible enough accept this movement will lose function joint seal. Either sealing element (adhesive) doesn't adhere proper backing material break.
temperature impact test Raychem internal test method
When backfilling material stones from sliding trench wall jacket pipe sealing joint, they damage this sealing system especially temperatures.
Impact brittleness
During construction phase district heating pipe system subjected bending impacts temperatures. joint sealing element should resist these forces impacts.
Ultimate elongation test R527
material test determine quality material used. This test method determines maximum elongation break sustained test specimen backing material during tensile test.
Standards Tests
Test
Tensile strength R527
Purpose
This material test determines quality material used. determines maximum tensile stress sustained test specimen backing material during tensile test.
Thermal ageing followed ultimate elongation
check that joint will continue perform well many years after been installed, ageing test done. backing material sealing joint conditioned elevated temperatures change ultimate elongation measured.
External water pressure test DS2182
primary function joint sealing seal joint against water ingress during lifetime. Raychem products tested resist ground water level minimum metres.
Internal pressure test Raychem internal test method
Some residual gassing foam entrapped under oversized casing will expand during preheating installation will generate internal pressure underneath sealing system. sealing joint must able resist this internal pressure. This internal pressure simulated applying pressure inside empty non-foamed casing.
Peel strength sealing elements 30672
sealing layer used joint sealing system must have good adhesion strength product perform well. value measured used compare sealing element product with another.
Shear strength sealing elements 4587
Soil forces sealing joint mostly shear mode. sealing element used joint sealing system must have sufficient shear resistance. shear strength sealing joint plays role other tests such soil stress resistance relative outer casing movement.
Standards Tests
RayJoint
DualSeal
TPSM/138
IPPS
following criteria play important role when selecting right joint your installation: (mm)
Outside diameter casing pipe
Jointing technology
Overview
(°C)
Maximum temperature casing pipe during operation. higher expansion cushions used allow expansion pipes soil).
(bar)
pressure test done after installation. test: pressure maximum (7.25 psi) withstood during minutes without pressure drop.
Consult table below product selection. rough guideline, please consider detailed design data final selection. also contact your Raychem sales representative help with selecting right product.
PRODUCT
Type joint Oversized casing Heat-shrinkable casing All-in-one joint
RayJoint
DualSeal
90-800
IPPS/106
90-800
TPSM/138
90-500
90-1200
90-800
90-500
90/1200
Metal sheet casing Soil stress resistance 8,0% sand humidity
1000 50°C (60°C) tubular
90-1200 1000 50°C (60°C) wraparound
90-630 1000 50°C (50°C) wraparound
50°C (50°C) tubular
Maximum operating temperature (under expansion cushions)* Tubular wraparound Pressure testing after installation Product recommended main lines distribution service lines
PRODUCT
RayJoint
DualSeal
IPPS/106
TPSM/138
accordance with special cases (under expansion cushions) applicable
Jointing technology
RayJoint
RayJoint casing Fibre reinforced elastomeric sealant strip WEPS welded closure plug
Fully crosslinked heat-shrinkable casing All-in-one joint
Product features benefits
thick wall HDPE backing providing: high shrink force high mechanical resistance elastomeric sealant strips: superior performance against water ingress fibre reinforced controlled adhesive thickness during installation extra-wide internally protected risk contamination before installation soil stress resistance performance: 1,000 cycles (1.5%, sand humidity) additional outside seals required installation prior foaming foam loss pressure testable before foaming easy installation using standard gas-powered blow torches standard available casing pipe diameters from 1200 thickness adapted corresponding casing pipe thickness storage transportation, even high temperatures smart economics: superior performance installed cost shelf life limitation tested independent institutes: Finland accordance 489) Hannover
Product description
RayJoint crosslinked, heat-shrinkable, tubular, all-in-one joint with superior performance. RayJoint complete system offering both casing pipe continuation permanent sealing joint area. RayJoint system consists crosslinked tubular heat-shrinkable casing specially designed fibre-reinforced sealant strips specially designed welded foaming hole closure plugs RayJoint standard available common pipe diameters. During installation, RayJoint ends shrunk down. adhesive underneath melts fills surface irregularities pipe. firm bond formed between RayJoint casing pipe.
Technical properties
MATERIAL PROPERTIES Test method R527 R527 R527 ASD3111 4587 30672 Conditions 23°C, mm/min -40°C, mm/min 23°C, mm/min -40°C, mm/min Unnotched -40°C 150°C 23°C, mm/min mandrel 23°C, mm/min 23°C, mm/min Typical value 660% 400% pass 590% -20°C N/cm2 N/cm
Backing Tensile strength
Ultimate elongation Impact brittleness Thermal ageing followed ultimate elongation
Elastomeric adhesive temperature flexibility Shear strength Peel strength
SYSTEM PROPERTIES Soil stress resistance: 1,5% sand humidity 8,0% sand humidity Internal pressure test External pressure test Casing temperature temperature impact Relative outer casing movement Premature shrinkage Temperature cycling
2182 2182 489/EN 6097* 6097* 6097* Internal
1000 cycles 1000 cycles 40°C, bar, pass 23°C, bar, pass 50°C (60°C under expansion cushion) -25°C, height, pass cycles stroke pass month 90°C pass -30°C 70°C, days pass
Raychem Technical Specification
Jointing technology, RayJoint
Ordering information
RAYJOINT-XXX RAYJOINT-500 nominal diameter casing pipe fibre-reinforced mastic roll Note: Quantity ordered: Application table foaming hole closure plug RayJoint) foam spacer with adhesive tape center RayJoint (4pc/ RayJoint>800
S1113-120x1.6x25000-RI WEPS-25 EQ-RJ-SPACE
Equipment
EQ-HEAT-SHIELDS-150x3x25M EQ-WP-BOX-T6 EQ-WP-SADDLE-T4 EQ-WP-SADDLE-800-T1 EQ-WEPS-SCRAPER EQ-WP-DRILL-25 EQ-REUSABLE-PLUG Heat protection shields prevent overheating casing pipe Power supply (including pieces EQ-WP-SADDLE-T4) Saddle casing pipe diameter 90-800 Saddle casing pipe diameter Scraper surface preparation conical drill Plug close foaming holes during foaming page page page page page page page
Application table
Selection RayJoint depending casing pipe diameter.
max.
Casing pipe
RayJoint
Casing pipe nominal diameter RayJoint (mm) 1000 1050 1100 1150 1200
Inner diameter (ID) RayJoint supplied fully recovered min. (mm) max. (mm) 1040 1090 1141 1194 1242
Thickness RayJoint supplied fully recovered (mm) (mm) 10.6 11.2 11.2 12.0 12.0
Length sealant strip S1113-RI required RayJoint (mm) 1105 1237 1369 1584 1748 1946 2177 2491 2788 3117 3447 3843 4304 4568 4832 5425 5755 6085 6414 6744 7074 7403 7733 8063
Jointing technology, RayJoint
complete installation, please consult corresponding installation instruction.
RayJoint
Installation overview
Preparation Before welding service pipe, slide RayJoint over casing pipe. casing pipe RayJoint should free foreign materials. Mark centre RayJoint over joint area. Abrade installation area.
Sealing strips sealing strips. pipe ends gently with torch (30°C-40°C). Apply sealing strips pipe ends next marks, sealing strip will completely covered with RayJoint. diameters spacers centre Rayjoint pipe.
Slide RayJoint over sealing strips centre over joint. Drill foaming holes. Remove release plastic from both sealing strips. Wrap heatshields around casing pipe RayJoint.
Shrinking soft flame give heat sufficient time penetrate RayJoint. Start heating RayJoint, moving flame around circumference. Continue about minutes. Move other carry same procedure, alternate repeatedly, shrink until both RayJoint ends contact with casing pipe.
Inspection Pressure test foam RayJoint. Close foaming holes temporary, after curing remove plugs install Raychem WEPS foaming hole closure system. good installation defined foam leakage sealant area, full circumferential contact shrunk edges with casing pipe WEPS used foaming hole closure system.
Jointing technology, RayJoint
DualSeal
DualSeal seal
DualSeal backing Closure patch FOPS Joint casing
High performance wraparound sleeve Joint sealing oversized casing, heat-shrinkable casing, metal sheet casing half shells
Product features benefits
HDPE backing providing: high shrink force high mechanical resistance high performance sealing system consisting sealing zones: viscoelastic sealant: flexibility against stresses outer casing expansion relative outer casing movements barrier against moisture penetration easy install with excellent flow fill high surface tackiness reliable seal thermoplastic adhesive: increased temperature performance high shear resistance against circumferential axial soil forces additional sealing soil stress resistance performance: 1000 cycles sand humidity) wraparound product resulting easier logistics (delivery site time installation) special applications: test hole repair, repair casing, repair pipe DualSeal offers fast installation: closure patch pre-attached length specific pipe diameter corners tested independent institute: Hannover accordance with 489)
Thermoplastic adhesive Uncoated zone Viscoelastic sealant Thermoplastic adhesive
Product description
DualSeal high performance heat-shrinkable, wraparound sleeve. HDPE crosslinked backing precoated with sealing zones: viscoelastic sealant middle primary seal high-shear-strength thermoplastic adhesive layer each side secondary sealing anchoring DualSeal includes extra features: uncoated zone between sealing zones easy installation without slippage which results reduced installation time. embossed backing. profiled backing gives extra visual indication during installation. When heat applied, profiles disappear. smooth surface installation indicates homogeneous heat dissipation around circumference. Further visual indication given thermo-indicating paint backing position thermoplastic adhesive. disappearance paint during installation indicates that heat been applied homogeneously around circumference. fibre-reinforced closure patch coated with excellent shearresistant adhesive closes wraparound sleeve. DualSeal pre-attached closure patch. DualSeal UNI, cut-to-length sleeve with pre-attached closure patch, available faster more convenient installation. DualSeal installed after foaming.
DualSeal casing pipe continuation
DualSeal backing Closure patch Metal casing
Viscoelastic sealant strip Thermoplastic adhesive
Jointing technology, DualSeal
Technical properties
MATERIAL PROPERTIES Test method R527 R527 R527 4587 30672 ASD2671 4587 30672 Conditions 23°C, mm/min -40°C, mm/min 23°C, mm/min -40°C, mm/min unnotched -40°C 150°C 23°C, mm/min 23°C, mm/min 23°C, mm/min Method 23°C, mm/min 23°C, mm/min Typical value 750% 470% pass 750% N/cm2 N/cm -35°C N/cm2 N/cm
Backing Tensile strength
Ultimate elongation Impact brittleness Thermal ageing followed ultimate elongation
Thermoplastic adhesive Shear strength Peel strength temperature flexibility Viscoelastic sealant Shear strength Peel strength
SYSTEM PROPERTIES Soil stress resistance: 8,0% sand humidity Operating temperature casing External pressure test temperature impact Relative outer casing movement Temperature cycling test
489/EN 2182 6100* 6100*
1000 cycles 50°C (60°C under expansion cushion) 23°C, bar, pass -25°C, height, pass cycles 23°C, pass min.
Raychem Technical Specification
Ordering information
Roll Sheet-roll
DUALSEAL-III-XXXxYYM roll length (Sl) width (Sw)
Dualseal-III-190, 255, 320, 430, 770,
WPCP-IV-XXxYYY
Closure Patch
patch length (190, 255, 320, 430, 638, 768, function width DualSeal (Pl) patch width (100 (Pw) casing pipe diameters casing pipe diameters DUALSEAL-III-XXX-DIA casing pipe outer diameter sleeve width (190, 255, 320, 430, 640, 770, (Uw)
Unisleeve
Jointing technology, DualSeal
Application table
DualSeal types application seal jacket continuation
Seal
DualSeal length
Casing pipe 225-500
Sleeve length circumference casing circumference casing circumference casing
DualSeal width depending casing pipe diameter Recommended application Possible application
DualSeal combination with SHRINKABLE CASING gap)
Casing Pipe
1000 1200
DualSeal width
DualSeal combination with SHRINKABLE CASING (gap)
Casing Pipe
1000 1200
DualSeal width
Note: distance between casing pipe and, inside oversized casing when fully lifted. Maximum times oversized casing thickness. Casing must bevelled.
DualSeal-III-640/-770/-900: Casing pipe continuation
DualSeal length
Casing pipe 225-500
Sleeve length circumference casing circumference casing circumference casing
DualSeal width depending length metal sheet casing, length half-shells. length cover between between between between between between DualSeal width: S1113 mastic strip stepdown pipe edges DualSeal width: DualSeal width: S1113 mastic strip stepdown pipe edges DualSeal width: DualSeal width: S1113 mastic strip stepdown pipe edges DualSeal width:
Note: strip S1113 mastic must centred over metal sheet casing half-shell. width, thick)
Jointing technology, DualSeal
complete installation, please consult corresponding installation instruction.
DualSeal
Installation overview
Preparation After joint been foamed, excess foam needs removed using scraper. pipe casing areas should free foreign materials installation area abraded.
Preheating Preheat casing pipe areas minimum 60°C. soft flame. This operation absolutely necessary obtain good bond shortens installation time. Raychem district heating thermo-indicator stick check surface temperature.
Remove release plastic. Centre viscoelastic sealant sleeve over casing with uncoated zone positioned onto casing. sleeve should overlap itself Centre heat closure patch over sleeve overlap press down with gloved hand. soft flame.
Shrink sleeve First shrink sleeve casing side. Continue shrinking over step-down towards sleeve. Postheat sleeve until green paint becomes black. make sure hotmelt become liquid, push sleeve gently. small wrinkle will disappear form smooth surface again.
Inspection sleeve must smooth without upstanding edges, dimples cold spots. adhesive should exude around circumference sleeve edges.
Jointing technology, DualSeal
IPPS/106
IPPS/106 seal
IPPS/106 backing Closure patch FOPS Joint casing
Medium performance wraparound sleeve Joint sealing oversized casing, heat-shrinkable casing, metal sheet casing half shells
Product features benefits
HDPE backing providing: high shrink force high mechanical resistance soil stress resistance performance: 1000 cycles sand humidity) adhesive with high shear strength high mechanical resistance wraparound resulting easier logistics (delivery site time installation) unisleeve offers fast installation: closure patch pre-attached length specific pipe diameter corners tested independent institutes: Finland accordance with 489) Hannover
Thermoplastic adhesive
Product description
heavy wall crosslinked backing precoated with semi-crystalline adhesive providing sealing mechanical anchoring. fibre-reinforced closure patch coated with excellent shearresistant adhesive closes wraparound sleeve. IPPS/106 UNI, cut-to-length sleeve with pre-attached closure patch, available faster more convenient installation.
IPPS/106 backing Closure patch Metal casing
Note: IPPS/106 installed after foaming.
IPPS/106 casing pipe continuation
Thermoplastic adhesive
Technical properties
MATERIAL PROPERTIES Test method R527 R527 R527 ASE-28 2671 4587 30672 Conditions 23°C, mm/min 23°C, mm/min 150°C 23°C, mm/min Typical value >500% >450% 103°C -35°C N/cm2 N/cm2
Backing Tensile strength Ultimate elongation Thermal ageing followed ultimate elongation Adhesive Softening point temperature flexibility Shear strength Peel strength
SYSTEM PROPERTIES Soil stress resistance: 8,0% sand humidity Operating temperature External pressure test temperature impact
method 23°C, mm/min 23°C, mm/min
489/EN253 Finn. L1/1985 Internal
23°C, bar, hour -25°C, height,
1000 cycles 50°C pass pass
Jointing technology, IPPS/106
Ordering information
Roll
Sheet-roll
IPPS- XXXxYYM/106 coating code roll length (Sl) width (Sw)
IPPS-150, 220, 285, 30m/106 770, 20m/106
Closure Patch
WPCP-IV-XXX-YYY patch length (153, 218, 283, 638, 768, (Pl) patch width (100 (Pw)
Unisleeve
IPPS-XXX-DIA YYY/106 casing pipe outer diameter sleeve width (150, 220, (Uw)
Application table IPPS
Selection IPPS width depending casing pipe diameter. Recommended application Possible application
seal
Casing Pipe
1000 1200
IPPS width
Casing pipe continuation
Casing Pipe
1000 1200
IPPS width
IPPS length
Casing pipe 225-500
Sleeve length circumference casing circumference casing circumference casing
Jointing technology, IPPS/106
complete installation, please consult corresponding installation instruction.
IPPS/106
Installation overview
Preparation After joint been foamed, excess foam needs removed using scraper. pipe casing areas should free foreign materials installation area abraded.
Preheating Preheat casing pipe areas minimum 60°C. soft flame. This operation absolutely necessary obtain good bond shortens installation time. Raychem district heating thermo-indicator stick check surface temperature.
Remove release plastic while applying (40%/60%) sleeve over casing end. sleeve should overlap itself Centre heat closure patch over sleeve overlap press down with gloved hand. soft flame.
Shrink sleeve First shrink sleeve casing side. Continue shrinking over step-down towards sleeve. ambient temperature more than 20°C first shrink casing side both sleeves, then pipe side both sleeves. Roll overlap patch closure area. make sure adhesive become liquid, push sleeve gently. small wrinkle will disappear form smooth surface again.
Inspection sleeve must smooth without upstanding edges cold spots. adhesive should exude around circumference sleeve edges.
Jointing technology, IPPS/106
TPSM/138
Tubular product Joint sealing oversized casing heat-shrinkable casing
Viscoelastic sealant TPSM/138 backing FOPS Joint casing
Product features benefits
HDPE backing providing: high shrink force high mechanical resistance soil stress resistance performance: cycles (1.5% sand humidity) available complete casing pipe diameter range from easy installation individually packed polybag avoid contamination cost-effective solution tested independent institute: Hannover
Product description
HDPE crosslinked backing precoated with viscoelastic sealant. During shrinkage adhesive melts ensures firm bond between casing pipe oversized casing. generally used additional outside seal small medium diameter heat-shrinkable casings.
Technical properties
MATERIAL PROPERTIES Test method R527 R527 30672 R527 Conditions 23°C, mm/min -40°C, mm/min 23°C, mm/min -40°C, mm/min unnotched -70°C days, 100°C 23°C, mm/min Typical value >500% 280% pass loss elongation
Backing Tensile strength
Ultimate elongation Impact brittleness Thermal ageing followed ultimate elongation
Viscoelastic sealant Softening point temperature flexibility Shear strength Peel strength: after immersion ground water weeks 23°C
SYSTEM PROPERTIES Soil stress resistance: 1,5% sand humidity 8,0% sand humidity External pressure test temperature impact Relative outer casing movement
ASE-28 3111 4587 30672
mandrel 23°C, mm/min 23°C, mm/min
120°C -20°C N/cm2 N/cm
2182 6024* 6024*
23°C, bar, -25°C, height, cycles 23°C, mm/min
cycles cycles pass pass pass
Raychem Technical Specification
Jointing technology, TPSM/138
Ordering information
TPSM-XXX YYY-AAA coating code width (150 application table) max. recovered diameter min. expanded diameter TPSM-80/55-150/138
Application table
Selection depending casing pipe outside diameter
TPSM Casing pipe nominal (mm)
Sleeve width (mm)
80/55 92/67 112/81 135/93 150/104 165/127 196/153 215/150 230/170
Jointing technology, TPSM/138
complete installation, please consult corresponding installation instruction.
TPSM/138
Installation overview
Preparation Before welding service pipe, slide sleeve over casing pipe. After joint been foamed, excess foam needs removed using scraper. pipe casing areas should free foreign materials installation area abraded. Remove plastic from sleeve. remove inside release plastic yet.
Preheating Preheat casing pipe areas minimum 60°C. soft flame. This operation absolutely necessary obtain good bond shortens installation time. thermo-indicator stick check surface temperature.
Shrink sleeve Remove inner release plastic while centring sleeve over casing end. Using steady yellow flame, shrink sleeve centre, starting working downwards. Apply heat evenly around sleeve, moving flame constantly. Work towards casing until material fully recovered adhesive exudes sleeve edges.
Repeat shrinking process working towards opposite end. Installation finished when sleeve completely smooth adhesive exudes sleeve edges. Repeat sequence other sleeve.
Inspection Sleeve must smooth without upstanding edges, dimples cold spots. Adhesive exudation will evident along total circumference sleeves.
Jointing technology, TPSM/138
EQ-WP-SADDLE
Foaming hole closure plugs
WEPS system
Electrically installed closure system sealing foaming holes
Product features benefits
HDPE backing Melt flow indicator (MFI) UHMWPE fusion element HDPE welding layer HDPE centering disk
Product description
WEPS (welding plug system) electrofusion closure plug specifically designed sealing foaming holes oversized heat-shrinkable casings. construction WEPS consists thick High Density Polyethylene (HDPE) backing with melt flow indicators (MFIs) positioned each corner electrically conductive Ultra High Molecular Weight Polyethylene (UHMWPE) fusion element allows even heating without embedded resistance wires HDPE welding layer HDPE centering disk, sized foam injection openings reusable clamping tool, saddle, connects WEPS with power supply. same time, saddle ensures continuous correct pressure enable good bonding. Once power applied WEPS, conductive polymer layer brings welding layer above melt temperature, resulting fusion bond between WEPS applied surface (casing pipe).
large fusion area Soil stress resistance performance: >1000 cycles high reproducibility installation visual inspection good installation possible: evidence scraping filled Melt Flow Indicators (MFI) works equally well crosslinked RayJoint casings non-crosslinked regular casings used repair inspection openings casing pipe tested independent institutes: Hannover Finland safe installation: design power supply European safety regulations (KEMA) saddle prevents accidental touching WEPS during installation
Technical properties
MATERIAL PROPERTIES Test method R527 R527 R527 R527 Hannover Hannover Conditions 23°C, mm/min 23°C, mm/min 23°C, mm/min 23°C, mm/min 1000 cycles 1000 cycles Requirement minimum 500% minimum minimum 350% minimum leakage leakage Typical value >800% 375% pass pass
HDPE closure plug Tensile strength Ultimate elongation Fusion element (UHMWPE) Tensile strength Ultimate elongation System requirements Soil stress resistance: 1,5% sand humidity 8,0% sand humidity
Ordering information
WEPS-25
Equipment:
EQ-WP-BOX-T6 EQ-WP-SADDLE-T4 EQ-WP-SADDLE-800-T1 EQ-WEPS-SCRAPER EQ-WP-DRILL-25 EQ-REUSABLE-PLUG Power supply (including pieces EQ-WP-SADDLE-T4) Saddle casing pipe diameter 90-800 Saddle casing pipe diameter Scraper surface preparation conical drill Plug close foaming holes during foaming page page page page page page
Foaming hole closure plugs, WEPS
complete installation, please consult corresponding installation instruction.
WEPS system
Installation overview
Preparation When foam cured, drill foaming hole diameter Scrape (not abrade) installation area around foaming hole. Remove scraping particles with rag.
WEPS positioning Insert center WEPS foaming hole. Clamp saddle WEPS means strap keep buckle side. Tighten strap, that WEPS close contact with casing surface.
Electrical powering Connect WEPS power supply generator mains supply pull emergency stop button. Attach power leads WEPS saddle. timer recommended installation time depending approximate casing surface temperature.
Welding Start power cycle pushing "start" button, buzzer will sound. WEPS power supply will automatically shut after pre-set time elapsed. Power leads removed. most cases clamping tool removed after minutes' cooling.
Inspection Visually inspect that casing scraped (not abraded). Verify that melt flow indicators show complete melt flow completely filled. Additional melt flow must visible both edges that line with pipe axis.
Foaming hole closure plugs, WEPS
FOPS
FOPS mastic
Flame installed closure system Sealing foaming holes
Product features benefits
Thermoplastic adhesive FOPS backing
thermoplastic adhesive with high shear-resistance against soil forces easy install tested independent institute: Hannover
Product description
FOPS round heat-resistant patch used sealing foaming holes oversized heat-shrinkable casings. provides watertight mechanically strong seal foaming hole. patch made from crosslinked HDPE backing precoated with high shear-resistant thermoplastic adhesive. backing provided with thermo-indicating paint. This gives positive indication installers that heat been applied make adhesive flow. product used together with mastic fill foaming hole. FOPS often installed over standard welding plug.
Technical properties
MATERIAL PROPERTIES Test method R527 R527 R527 Conditions 23°C, mm/min -40°C, mm/min 23°C, mm/min -40°C, mm/min unnotched -70°C days 150°C 23°C mm/min) Typical value 650% 280% pass >500%
Backing Tensile strength
Ultimate elongation Impact brittleness Thermal ageing followed ultimate elongation
Adhesive Softening point Shear strength Peel strength
SYSTEM PROPERTIES Soil stress resistance: 1,5% sand humidity Operating temperature External water pressure
ASE-28 4587 30672
23°C, mm/min 23°C, mm/min
94°C N/cm2 N/cm
2182 23°C, bar,
cycles 50°C (60°C under expansion cushion) pass
Ordering information
FOPS-100 FOPS-MASTIC-2 FOPS closure patch FOPS filler
Equipment:
EQ-PRESS-FOPS Tool press down FOPS during installation
Foaming hole closure plugs, FOPS
complete installation, please consult corresponding installation instruction.
FOPS
Installation overview
Preparation Foam casing. When foam cured, remove temporary foaming hole plug. necessary, remove excess foam. installation area should free foreign materials abraded. Remove abrasion dust carefully.
Preliminary sealing Fill hole with mastic putty that level with surface.
Preheating Preheat surface around hole minimum 60°C. soft flame with sufficient heat allow penetrate into Raychem district heating thermo-indicating sensor check temperature. Only immediate colour change upon contact indicates that sufficient heat been applied.
Installation Slightly preheat adhesive side FOPS until it's tacky. Press FOPS place centered over foaming hole. Heat FOPS backing until temperature-sensitive paint changes color thermoplastic adhesive becomes liquid.
Inspection FOPS should completely contact with surface. There should bubbles upstanding edges. adhesive should exude around FOPS edge.
Foaming hole closure plugs, FOPS
VIII
Casing pipe Service pipe
caps
DHEC
District Heating sealing pipe ends
Product features benefits
HDPE backing providing: high shrink force high mechanical resistance viscoelastic sealant strip with high performance against water ingress high shrink ratio: product covering several different pipe sizes accommodates easy pipe ovality covering several combinations service casing pipe factory pre-installed, protection pipe insulation during transport storage case leakage, limits insulation degradation pipe length resulting reduced repair costs flexible pipe systems barrier exchange between foam (blowing agent) easy installation
Viscoelastic sealant strip DHEC backing
Product description
District Heating heat-shrinkable, molded product. DHEC installed pipe ends where prevents water ingress pipe insulation between casing service pipe. used pre-insulated pipes carrying fluids continuous operating temperature 130°C. DHEC Single designed pre-insulated pipes having service pipe. DHEC Twin designed pre-insulated pipes with service pipes. DHEC coated with elastomeric adhesive specially designed performance high temperature conditions. Uncoated edges prevent product from slipping casing pipe during installation.
Ordering information
DHEC-2XXX size code openings service outlet casing outlet) e.g. DHEC-2600
DHEC-3XXX size code openings service, casing) e.g. DHEC-3300
caps, DHEC
Application table
DHEC Single
Service pipe (mm) Casing pipe (mm) 2000 2000 2100 2060 2200 2340 2300
2400
2500
2600 2630 2700 2800 2900 3000
DHEC Twin
Service pipe (mm) 32(35) 42(40)
Casing pipe (mm)
3200
3250 3350-P604 3250 3250-P604 3280 3250-P604 3350-01 3300 3350-02 3280 3300 3350-02 3280 3350-03 3350-01
32(35)
42(40)
3350-03 3280 3360-01 3350-03
caps, DHEC
complete installation, please consult corresponding installation instruction.
DHEC
Installation overview
Preparation casing pipe service pipe must free foreign materials. Abrade casing pipe service pipe covered cap.
Preheating Preheat casing pipe service pipe 60°C minimum. Check temperature casing pipe service pipe with Raychem District Heating temperature indicator stick. Only immediate colour change upon contact indicates that sufficient heat been applied.
Alarm wires positioning alarm wire access necessary, wire brought outside cap, squeezed between pieces S1113 mastic. alarm wire protected shrink tubing. Position possible over pipe end.
Installation Start heating over casing pipe first. Move flame circular motion around pipe, until fully recovered. Shrink over step-down onto carrier pipe. necessary, squeeze together carrier pipe relieve entrapments. determine whether adhesive melted properly carefully pushing short distance along service pipe. small wrinkles which form should pull themselves immediately flat again.
Inspection There should entrapments, burn-holes upstanding edges.
caps, DHEC
VIII
CCS-DHEC
Wraparound seal District Heating
Casing pipe Closure patch with zipper underneath
Product features benefits
elastomeric sealant strip with high performance against water ingress high shrink ratio: product covering several different pipe sizes accommodates easy dimensional variations pipe ovality available pipe sizes from 1200 casing pipe diameter wraparound installation after welding service pipes
Service pipe Viscoelastic sealant strip CCS-DHEC backing
Product description
CCS-District Heating wraparound heat-shrinkable sleeve, closed with zipper. CCS-DHEC installed pipe ends where prevents water ingress pipe insulation between casing service pipe. used pre-insulated pipes carrying fluids continuous operating temperature 110°C. crosslinked backing consists fibre-reinforced structure with high expansion ratio accommodate several diameters both casing pipe service pipe. Near edges underneath zipper, product coated with elastomeric adhesive specially designed high temperature performance.
Ordering information
CCS-DHEC-XXX-YYY minimum service pipe maximum casing pipe CCS-DHEC-710-355
caps, CCS-DHEC
Application table
Selection CCS-DHEC depending diameters service pipe casing pipe
Casing pipe (mm) Service pipe (mm)
110/26*
128/48
163/60 186/70 200/
225/
250/ 280/133
Conical type
Casing pipe (mm) Service pipe (mm) 1016 1000 1200
315/168 400/219 560/273 710/355 900/457 1200/610
caps, CCS-DHEC
complete installation, please consult corresponding installation instruction.
CCS-DHEC
Installation overview
Preparation casing service pipe must free foreign materials. Abrade casing pipe service pipe covered cap.
Preheating Preheat service pipe casing pipe 60°C minimum. Check temperature casing pipe service pipes with Raychem district heating temperature indicator stick. Only immediate colour change upon contact indicates that sufficient heat been applied.
Alarm wires positioning alarm wire access necessary, wire brought outside cap, squeezed between pieces S1113 mastic. alarm wire protected shrink tubing. Position casing pipe close zipper. Heat zipper protection patch push down against zipper.
Installation Start heating over casing pipe first. Move flame circular motion around pipe, until fully recovered. Shrink over step-down onto carrier pipe. Push closure area place with gloved hand blunt tool. necessary, squeeze together carrier pipe relieve entrapments. determine whether adhesive melted properly carefully pushing short distance along service pipe. small wrinkles which form should pull themselves immediately flat again.
Inspection There should entrapments, burn-holes upstanding edges.
caps, CCS-DHEC
casing pipe APPM backing
Anchor plates
APPM
Tubular sleeve Corrosion protection round anchor plates
Product features benefits
HDPE backing providing: high shrink force high mechanical resistance high shrink ratio thick backing providing high impact penetration-resistance viscoelastic sealant with high flow fill properties homogeneous protection need primer easy install
Product description
APPM thick-wall, heat-shrinkable, tubular product. This product used district heating pipeline segments which require anchoring network. APPM shrunk over metal anchor protect this against corrosion. APPM backing HDPE-crosslinked, thick-wall backing with high shrink ratio (45%). completely coated with visco-elastic sealant prevent moisture penetration width
Ordering information
APPM-XXX/YY minimum service pipe maximum anchor plate APPM-710-355
Application table
APPM sizes selected depending anchor plate diameter.
Anchor plate diameter (mm) max. Casing pipe diameter (mm) min. APPM sizes XXX/YY 230/80 230/80 230/80 260/135 275/150 295/160 320/175 380/205 410/225 440/240 530/290 580/315 630/340 690/375 900/510
Anchor plates, APPM
APPM
Installation overview
Preparation Before welding service pipe, slide tubing about meter away from anchor plate. installation area should free contaminating foreign materials. Preheat anchor plate installation area minimum 60°C.
Positioning Position APPM middle anchor plate remove inside release plastic.
Shrink sleeve Using soft flame, start shrinking tubing centre. Apply heat evenly around tubing, moving flame constantly.
Then shrink tubing both sides anchor plate onto casing pipe. Installation finished when tubing completely smooth adhesive exudes tubing edges.
Inspection APPM must smooth without upstanding edges cold spots. adhesive should exude from both ends.
Anchor plates, APPM
EQ-TO-NOZZLE-BN60
Equipment
Propane torches
EQ-TO-NOZZLE-BN40
EQ-TO-NOZZLE-BN25
EQ-TO-HANDLE-PILOT-3488
EQ-TO-HOSE-4M-701291 hose
EQ-TO-HAN-701291 coupling hose
EQ-TO-REGU-US-3084-01 only EQ-TO-REGU-IT-3084-04 Italy only EQ-TO-REGU-EU-3084-05 Europe
Equipment
Installation equipment
Working gloves
Order Description:
EQ-GLOVES-PAI
Silicone roller
Order Description:
EQ-ROLLER-SILICON-RUBBE
Temperature-indicating stick
Order Description
RM-TEMP-DH-STICK
Heatshields
Order Description
EQ-HEAT-SHIELDS-150x3x25M
Heatshields prevent from overheating
Equipment
WEPS FOPS installation equipment
Power
Order Description:
EQ-WP-BOX-T6
This equipment controls total power delivered proper installation WEPS patches
Saddles
Order Description:
EQ-WP-SADDLE-T4 EQ-WP-SADDLE-800-T1
EQ-WP-SADDLE-T4: Saddle casing pipe diameter 90-800 EQ-WP-SADDLE-800-T1: Saddle casing pipe diameter
Drill
Order Description:
EQ-WP-DRILL-25
Tool drill hole needed WEPS installation conical drill
Scraper
Order Description:
Scraper remove contaminated EQ-WEPS-SCRAPE
Reusable plug
Order Description:
EQ-REUSABLE-PLUG
Plug close foaming holes during foaming
Press
Order Description:
EQ-PRESS-FOPS
Tool press down FOPS during installation
Mastic
Order Description:
FOPS-MASTIC-2
Filler mastic foaming hole must used combination with FOPS
Equipment
Industrial applications pre-insulated pipes
Raychem specific products sealing joints transmission lines.
Raychem supplies variety products pre-insulated pipelines transmission network where heated fluid transported. transmission pipe lines different from District Heating networks mainly because their operating temperatures significantly lower. example, transported 50°C, whereas water transported 120°C district heating network. Another difference that these pipelines subject less soil stress. Typical District Heating norms standards (e.g. 489) therefore used pipeline world.
Sealing sleeve Corrosion protection sleeve Closure patch
IPEC sealing strip IPEC backing
IPEC heat-shrinkable, pre-shaped product. IPEC installed pipe ends where prevents water ingress pipe insulation between casing pipe service pipe. case leakage pipe, limits insulation degradation pipe length resulting reduced repair costs. IPEC same function DHEC product range covers bigger diameter range delivered uncoated. thick sealant strip supplied with product needs wrapped around casing pipe service pipe before product installation. service pipes 5.563 inch (139 larger diameter double wrap sealing strip recommended.
more information check IPEC datasheet
Industrial applications pre-insulated pipes
CORROSION PROTECTION SLEEVES
corrosion protection service pipe
Raychem offers wide range corrosion protection shrink sleeves made combination HDPE backing with variety high-performance adhesives. following sleeves used steel service pipe slit width length depending application: 100M service pipe operating temp 100°C under insulation half shell HTLP service pipe operating temp 80°C under insulation half shell service pipe operating temp 120°C under insulation half shell
More detailed information about these sleeves selection criteria found catalogue: "Corrosion protection pipelines".
SEALING SLEEVES
sealing casing pipe
Shrink sleeves used seal insulation material against moisture ingress into weld joint area. ease application, three sleeves commonly used: coated with elastomeric sealant (mastic) general coated with high shear strength thermoplastic adhesive (hotmelt) general environments below 10°C
Note:
Insulation: Pre-shaped half shells commonly used. These products supplied Raychem.
Industrial applications pre-insulated pipes
Related products
ATUM
High-shrink-ratio, adhesive-lined polyolefin tubing
Product description
Environmentally seals protects wide variety electrical applications. High expansion ratio makes possible repair most damaged cable jackets without removing connectors. ATUM used district heating applications protection leak detection wires.
Product features benefits
shrink ratios Tubing environmentally seals protects components interconnections Medium wall provides increased mechanical protection ATUM adhesive bonds wide variety plastics, rubbers, metals, including polyethylene, aluminium, steel, copper.
DuraSeal
Heat-shrinkable, environmentally sealed, nylon-insulated crimp terminals disconnects
Product description
Marine electronics Fleet maintenance Commercial wiring (pumps/pools/spas) DuraSeal used district heating applications connection leak detection wires.
Product features benefits
Protects terminations from water, condensation, salt, corrosion Provides strain relief Protects against vibration rugged environment Completely insulates protects electrical terminations adhesive lining protection that more reliable than conventional splices listed
Related products
Gelsnap
Splice closure
Product description
Prevents water ingress non-flowing under permanent compression. Available three sizes. Gelsnap used district heating applications protection measuring points leak detection systems.
Product features benefits
Quick, easy special tools required install Robust reliable under wide variety environmental conditions Many connector types accommodated Butt, in-line branch configurations possible Easy, clean re-entry
TDUX
Product description
TDUX unique inflatable wraparound duct seal system permanently sealing cable ducts. been developed conjunction with plastic, concrete steel ducting wall feedthrough systems. suitable with polyethylene lead-jacketed cables.
Product features benefits
fast easy install very flexible reliable wraparound sealing system independent duct cable ovality wide application cable range with size seals vacant ducts ducts with more cables
Related products
XIII
Raychem,
world solutions technically sophisticated problems
customers seeking solutions technically sophisticated problems demanding markets, Raychem right choice. draw expertise materials science technologies, electronics, product design, process engineering serve many world's largest, most influential commercial industrial organizations. Raychem products deliver competitive advantage meeting stringent requirements performance reliability, even severe environments. Thousands innovative Raychem components systems used applications every electronics, transportation, telecommunications, infrastructure, energy networks.
Raychem expanded from strong base copper outside plant network products high-growth telecommunications markets, such fibre optics.
Resettable fuses protect automotive motors, electronic modules, wires, switches from overcurrents electrical burnout.
Heat-shrinkable tubing provides insulation strain relief thousands electronics applications.
Self-regulating heating cables used frost protection temperature maintenance pipes tanks industrial applications.
Raychem's cold-applied technology allows easy, tool-free installation medium-voltage cable terminations.
Raychem,
Call Raychem sales offices
America
Argentina Buenos Aires Redwood City (54) 5150 (800) 1929
Asia
China Shanghai India Delhi Korea Seoul (86) 64853288 (91) 9863 (82) 3468 1300
Europe
Belgium Kessel-Lo France Paris Germany Castrop-Rauxel United Kingdom (32) (33) 202122 (49) 2305 923410 (44) 2638
Middle East
Saudi Arabia Dammam (966) 8122044
Call Raychem sales offices
above information, including illustrations, believed reliable. Users however, should independently evaluate suitability each product their application. Raychem makes warranties accuracy completeness information disclaims liability regarding use. Raychem's only obligations those Standard Terms Conditions Sale this product case will Raychem liable incidental, indirect consequential damages arising from sale, resale, misuse product. Raychem Specifications subject change without notice. addition Raychem reserves right make changes materials processing, without notification Buyer, which affect compliance with applicable specification. ATUM, DualSeal, DuraSeal, RayJoint, TDUX trademarks Raychem.
District Heating
Raychem Diestsesteenweg 3010 Kessel-Lo Belgium Tel. (32) (32) Raychem Constitution Drive 110/2A Menlo Park, 94025-1164 Tel. (800) 241-1929 650-361-4900 (650) 361-5579
www.raychem.com
1999 Raychem Printed Belgium DH-095/CAT/1-11/99 021640-000
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