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HYDRA® GSINSTALLATIONMANUALUnitedKingdomandIreland
Witzenmann UK Ltd
Head Office
2EarnAvenue
RigheadIndustrialEstate
Bellshill,Scotland,ML43LW
Phone+441698749660
Fax+441698740774
[email protected]
www.witzenmann.co.uk
Unit4
WhitfieldBusinessPark
ManseLane
Knaresborough
NorthYorkshire,HG58BS
Phone+441423868586
Fax+441423865783
[email protected]
OfficeSuite9
CwmCynonBusinessCentre
CwmCynonIndustrialPark
MountainAsh
MidGlamorgan,CF454ER
Phone+441443471000
Fax+441443479638
[email protected]
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CONTENTS
1. Scope of application and general notes 41.1. Validity 41.2. Theproduct 41.3. Definition 41.3.1. Systemdefinition 41.3.2. FlexiblecorrugatedhosesPLT(pliabletube) 41.4. Specifications 51.5. Standardsandcodesofpractice 61.6. Systemconformity 71.7. Fieldsofapplication 71.8. Operatingconditions 7 2. HYDRA GS installation system and system components 8 HYDRAGSstainlesssteelcorrugatedpipesandpipedimensions 92.1. HYDRAGSPress 10 HYDRAGSPress-Threadednipple 10 HYDRAGSPress–Swivelconnection 10 HYDRAGSPress–Adaption 11 HYDRAGSPress–T-piece 11 HYDRAGSPress–Reducer 12 HYDRAGSPress–Conicalnipple 12 HYDRAGSPress–Presscase 13 HYDRAGSPress–Pipecutter 13 HYDRAGSPress–Expansionhead 142.2. HYDRAGSClick 15 HYDRAGSClick–ThreadedBSPfixedtapermale 15 HYDRAGSClick–ThreadedBSPparafixedfemale 15 HYDRAGSClick–T-piece 16 HYDRAGSClick–Soldersocket 17 HYDRAGSClick–ConnectionBS746female 17 HYDRAGSClick–Coppercompressionfitting 18 HYDRAGSClick–StraightCoupling 182.3. HYDRAGSPressundHYDRAGSClick 19 HYDRAGSBISMAT-Flashpipeclamp 19 HYDRAGSCaddyclip 19 HYDRAGSStripearthband 20 HYDRAGSCoroplastadhesivetape 20
3. Dimensioning the pipeline system 213.1. Basisfordimensions 213.2. Preliminarydimensioningusingtable 213.3. Pressurelossesinthecorrugatedpipeline 223.3.1. NaturalgasL 223.3.2. NaturalgasH 233.3.3. Propanegas 243.4. Examplecalculation 253.5. Pressurelosscalculationwithsoftwaretool 26 4. Assembly HYDRA GS Press 304.1. Assemblyprocedure 30 5. Assembly HYDRA GS Click 365.1. Assemblyprocedure 36 6. Assembly on parts outside the HYDRA GS gas installation system 386.1. ValidforHYDRAGSPressandClick Tighteningtorques 386.2. ValidforHYDRAGSPressandClick Minimumbendingradii 38 7. General notes on installation 397.1. Generalinstructions 397.2. HYDRAGSfirebehaviour 407.3. Potentialequalisation 407.4. Fasteningandfasteningdistances 41 8. Protection against corrosion or damage 43 9. Recommendations for storing gaskets 4310. Repair methods 4410.1. DamagetoHYDRAGSstainlesssteelcorrugatedpipes 44
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1. SCOPE OF APPLICATION AND GENERAL NOTES
1.1.Validity
ThisinstallationinstructionisvalidforthegasinstallationsystemHYDRAGSmadebyWitzen-mannGmbH,Germany.Itisintendedtoguidethegaspipeinstallerinthedesign,installationandfinaltestingstages.Allspecificationsinthismanualmustbecompliedwithduringworkandinstallation.NodeviationsfromtheinstallationspecificationsinthismanualarepermittedwithoutpriorconsultationwithWitzenmannGmbH.
1.2.Theproduct
TheWitzenmanngasinstallationsystemHYDRAGScompliestoandistestedaccordingtotherequirementsofBSEN15266:2007(Stainlesssteelpliablecorrugatedtubingkitsinbuildingsforgaswithanoperatingpressureupto0.5bar).ThegasinstallationsystemHYDRAGShasbeengrantedKitemarkLicenceNumberKM594313byBritishStandardsInstitution,coveringsizesDN15,DN22,DN28andDN32andassociatedfittings.Thecertificationalsoincludesresistancetohightemperatures(HTB)accordingtoBSEN1775.HYDRAGScanbeinstalledindomestic,industrialandcommercialbuildings.HYDRAGSissuitablefornaturalgasandliquifiedpetrolgas(2ndand3rdfamilygas).
1.3.Definition
1.3.1. System definitionHYDRAGSisaflexiblegasinstallationsystemforcarryinggasinthebuildingtechnology.HY-DRAGSisofferedinthefournominaldiametersDN15,DN22,DN28andDN32.HYDRAGSconsistsofflexiblecorrugatedhosesandHYDRAGSPressfittingsorHYDRAGSClickfittings,specialfasteningelements,abattery-operatedaxialpressingtoolforexpandingtheHYDRAGSPressfittingsandconfigurationsoftwarefordeterminingthesizeofthepipelines.
1.3.2. Flexible corrugated hoses PLT (pliable tube)Corrugated,sheathedpipewhichcanbebentbyhandeasilyforalimitednumberoftimes.
1.4.Specifications
GasinstallersshallbeinpossessionofavalidcertificateofcompetenceforactivitiesnecessarytoinstallandtestthegasinstallationsystemHYDRAGS,seeBS6891section4.ThevalidcertificatemusthavebeenissuedundereithertheApprovedCodeofPractise(ACoP)ortheNationalAccreditedCertificationScheme(ACS)forindividualgasinstallersoranequivalentqualification.
AllbusinessesandindividualsundertakinggasworkoninstallationssuppliedwithnaturalgasorLPGmustberegisteredwithabodyapprovedbytheHealthandSafetyExecutive(HSE).(InGreatBritainitisTheGasSafeRegister.InNorthernIreland,theCannelIslandsandtheIsleofMan,consulttherelevantauthoritiesforup-to-dateguidance.)AllgasappliancesandothergasfittingsmustbeinstalledinaccordancewithTheGasSafety(InstallationandUse)Regulations1998,buildingregulationsandmanufacturers'installationinstructions.InstallationsshouldalsocomplywithBritishStandards.(OurDesignandInstallationGuiderevisionswillfollowanyamendmentstotheRegulationsorBritishStandardsatalaterdate,andthusintheeventofanyconflicttheRegulationsand/orBritishStandardswilltakeprecedenceoverthisDesignandInstallationGuide).
Fordetailedinformationaboutconnection/disconnectionofpipes,installationindifferentmaterials(e.g.woodenjoistfloors;walls;cavitieswalls;etc.)seeBS5482-1sections12.3ffandBS6891section8.6ff.Note:thesestandardsarecurrentlyunderrevisionwiththeaimtocondensethedesignandinstallationspecificationsforalldomesticfuelgaspipeworksystemsintoonestandard.InstallationforindustrialandcommercialpremisesshallfollowIGEM/UP/2LatestEdition(forsizesaboveDN32andworkingpressureabove21mbar)andIGE/UP/1Lat-estEdition(strengthandtightnesstestingandpurging).Additionallocalregulationsshallalsobefollowed.Pleasecontactlocalauthoritiesfornecessaryinformation.
Thisinstallationguidecannotcoverallpossiblevariationsinconstructionstyle,buildingconfig-uration,appliancerequirementsorlocalrestrictions.IftheinstallerisunsureabouttheproperapplicationofHYDRAGS,werecommendyoucontactusoralocalrepresentative.
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1.5.Standardsandcodesofpractice
Aswellastheplanningandinstallationinstructionsgiveninthisinstallationmanual,itisalsonecessarytocomplywiththecurrenteditionsofthefollowingcodesofpracticewhenplanningandinstallingtheentiregassupplysysteminthebuilding:BSEN15266:2007 Stainlesssteelpliablecorrugatedtubingkitsinbuildingsforgas
withanoperatingpressureupto0.5barBSEN549 Rubbermaterialsforsealsanddiaphragmsforgasappliances
andgasequipmentBSEN10226-1:2004-09 Pipethreadswherepressuretightjointsaremadeonthethreads
–Part1:Taperexternalthreadsandparallelinternalthreads–Dimensions,tolerancesanddesignation
BSEN14291:2005-4 FoamproducingsolutionsforleakdetectionongasinstallationsBSEN837-1:1997-02 Pressuregauges–Part1:Bourdontubepressuregauges;
Dimensions,metrology,requirementsandtestingBSEN681-1:2003-8 Elastomericseals–Materialrequirementsforpipejointsealsused
inwateranddrainageapplications–Part1:VulcanizedrubberBS6891 Installationoflowpressuregaspipeworkofupto35mm(R11/4)
indomesticpremises(2ndfamilygas)-SpecificationBS5482-1 Codeofpracticefordomesticbutane-andpropane-gas-burning
installations. Part1:Installationsatpermanentdwellings,residentialparkhomes
andcommercialpremises,withinstallationpipeworksizesnotexceedingDN25forsteelandDN28forcorrugatedstainlesssteelorcopper
IGE/UP/1(Edition2) Strengthtesting,tightnesstestinganddirectpurgingofindustrialandcommercialgasinstallations.
IGEM/UP/2(Edition3) Installationpipeworkonindustrialandcommercialpremises.BSEN437 Testgases–Testpressures–Appliancecategories
Important Note:Crossreferencestoregulations,standardsandcodesofpracticerefertothecurrentstatusatthetimewhenthisinstallationmanualwaspublished.Intheeventofupdates,theuserisresponsibleforapplyingthecurrentregulations,standardsandcodesofpracticeapplicableatthegiventime.Thegenerallyacceptedengineeringstandardsmustalwaysbecompliedwith.
1.6.Systemconformity
OnlycomponentsfromtheHYDRAGSsystemmaybeusedforinstallation.The HYDRA GS installation system made from Witzenmann corrugated pipes is not compatible with the corrugated pipe kits for gas installations from other manufacturers. WitzenmannGmbHdoesnotacceptanyliabilityformalfunctionsthatarecausedbymixingwithsystemcomponentsfromothermanufacturers.Forinstallationofallgasappli-ancesandothergasfittings,itisnecessarytocomplywiththeinstallationinstructionsofthemanufacturer,theapplicablesafetyguidelinesaswellasthecorrespondingbuildingregula-tionsandstandards.
1.7.Areasofapplication
TheHYDRAGSmadefromflexiblestainlesssteelcorrugatedpipescanbeusedforpNewinstallationsofpipelinesystemspRenewingexistingpipelinesystemspExtendingexistingpipelinesystems
1.8.Operatingconditions
pMax.operatingpressure500mbarpTemperaturerange-40°Cto+60°CpNaturalgas/liquefiedgas
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HYDRA®GScorrugatedpipesandpipedimensionsTheHYDRAGSsystemofferstheinstallereasyandsafeinstallationofgaspipelines.Theflexiblegaspipeiseasytotransportandlay;theconnectingtechnologyissimpleandunprob-lematic,bothindesignandinhandling.The system is available in 2 designs:As a Click System for easy assembly with no hydraulic tool.Forthissystem,thefittingsareconnectedusingasimpleplugconnection.Thefittingisself-lockingandonlyneedstobescrewedtightusingaspannerorwrenchafterwards.Informationonallcomponentscanbefoundinchapter2.1.Asanalternative,thereisthePressSystemwithahydraulictoolforquickandeffectiveassem-blyoverlongdistances.Forthissystem,thefittingsareconnectedusingaspecialhydraulictool.Itislight,easytouseandisergonomicallyshaped.Thismakesitpossibletoworklongerwithouttiring.Informationonallcomponentscanbefoundinchapter2.2.
Country-specificapprovalsensurethatHYDRAGSsystemsfulfilallrequirementsforalongandsafeservice.
2. HYDRA® GS INSTALLATION SYSTEM AND THE SYSTEM COMPONENTS
StainlesssteelcorrugatedpipeforgasinstallationpPipematerial:1.4404(stainlesssteel)pSheathingmaterial:PE(polyethylene)
DNPipedimensions Corrugated
pipelength
d1+PE d2 d3 ondrummm mm mm m
15 22.1 21.2 16.5 15/30/7522 27.3 26.4 20.5 15/30/7528 32.6 31.7 25.7 15/30/7532 41.5 40.6 35.5 15/30/75
HYDRA® GS
Themanual"QuickSystem" Thesystemusingahydraulictool
HYDRA® GS CLICK HYDRA® GS PRESS
HYDRA Corrugated Hose
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2.1.HYDRA®GSPress
Threadednipple–HYDRA®GSPress
Adapter–HYDRA®GSPress
Threadednippleswithmalethreadacc.toDINEN10226-1areusedforconnectingthepliableHYDRAGSstainlesssteelcorrugatedpipestothefemalethreadconnectionsofvalves,fittingsorgassockets.pMaterial:brasspSealring:HNBR
Theadaptershaveapipethreadacc.toDINEN10226-1anda24°conewithmalethread.Togetherwiththero-tatingconnection,theyformaconicallysealingthreadedconnectionwithaswivelconnectionforconnectingthepliableHYDRAGSstainlesssteelcorrugatedpipestothefemalethreadedconnectionsofvalves,fittingsorgassockets.pMaterial:brass
Swivelconnection–HYDRA®GSPress T-piece–HYDRA®GSPress
Therotatingconnectionhasa24°coneandisusedforconnectingthepliableHYDRAGSstainlesssteelcorrugatedpipestovalvesorfittingswithanmalethreadanda24°cone.pMaterial:brasspSealring:HNBRpO-ring:HNBR
TheT-pieceshavea24°conewithmalethreadateachend.Theyareusedasconnectionelementstootherlinesandthusmakeitpossibletoconnectadditionalconsumers.pMaterial:brass
Dimensions[Nominaldiameterxthread]
DN
Articlenumber Weight
kg15/22xM30x2 1198222 0.196
28xM36x2 1198224 0.25832xM48x2 1198226 0.552
Dimensions[Nominaldiameterxconexunionnutthread]
DN
Articlenumber Weight
kg
15x24°xM30x2 1198215 0.11222x24°xM30x2 1198216 0.13128x24°xM36x2 1198217 0.17832x24°xM48x2 1198221 0.333
Connectiontofitting[Nominaldiameterxthreadacc.to
EN10226-1]DN
Connectiontonipplewithunionnut
[Nominaldiameterxconexthread]
DN
Articlenumber Weight
kg
15xR½ 15x24°xM30x2 1198227 0.07722xR¾ 22x24°xM30x2 1198228 0.09528xR1 28x24°xM36x2 1198229 0.166
32xR1¼ 32x24°xM48x2 1198230 0.254
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg
15xR½ 1198211 0.06422xR¾ 1198212 0.12028xR1 1198213 0.175
32xR1¼ 1198214 0.248
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Reducer–HYDRA®GSPress
Presscase–HYDRA®GSPress
Tool case Case content
1Charger 4Adhesivetape2Expansionhead 54Pressheads:DN15/DN22/DN28/DN323Axialpressingtool 6Pipecutter
Conicalnipple–HYDRA®GSPress Pipecutter–HYDRA®GSPress
Reducershavealarge24°conewitharotatableunionnutandasmaller24°conewithmalethread.Theyareusedforreducingthediameterofbranchestotheexistingconnection.Thismeansitispossibletomakeconnectionstoadditionallinesusingsmallernominaldiameters.ThereductionfromDN20toDN16ismadedirectlywiththerotatableconnections,sincethesearecompatibleindiam-eterandthread.pMaterial:brasspO-ring:HNBR
Theconenippleshavea24°conewithmalethreadandareconnectedusingaswivelconnectioninordertocon-necttwoHYDRAGSstainlesssteelcorrugatedpipesofthesamediametertogether.pMaterial:brasspSealring:HNBR
6 54
2
3
Thecorrugatedpipecutterisusedforcuttingthecorruga-tedtubetotherequiredlength.
Dimensions[Nominaldiameter]
DN
Articlenumber
15to32 1158149
Dimensions[Nominaldiameterxconexthread]
DN
Articlenumber Weight
kg15x24°xM30x2 1198233 0.08322x24°xM30x2 1198234 0.09628x24°xM36x2 1198235 0.13032x24°xM48x2 1198236 0.233
Connectiontohose[Nominaldiameterxthread]
DN
ConnectiontoT-piece[Nominaldiameterxconexunionnut
thread]DN
Articlenumber
Weight
kg22xM30x2 25x24°xM36x2 1198231 0.19028xM36x2 32x24°xM48x2 1198232 0.397
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Expansionhead–HYDRA®GSPress
Theexpansiontoolisusedforcorrectingthedeformationofthecutedgecreatedwhencuttingthecorrugatedpipeandforexpandingthecorrugatedpipetothediameterre-quiredforassemblywiththefitting.Theexpanderheadiscompatiblewithcommerciallyavailableexpansiontongsorelectrohydraulicgunswith18°cones.
Dimensions[Nominaldiameter]
DN
Articlenumber
Expansionhead 15to32 1060722Expansiontool 15to32 1078856
2.2.HYDRA®GSClick
ThreadedBSPfixedtapermale–HYDRA®GSClick
ThreadedBSPparafixedfemale–HYDRA®GSClick
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg153/8 1197725 0.181151/2 1197726 0.191223/4 1197727 0.322281 1197728 0.331
321¼ 1197729 0.440
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg151/2 1197731 0.20221/2 1197732 0.33281/2 1197733 0.316223/4 1197734 0.302283/4 1197735 0.286323/4 1197736 0.420
ThreadedBSPfixedtapermaleacc.toDINEN10226-1areusedforconnectingthepliableHYDRAGSstainlesssteelcorrugatedpipestothefemalethreadconnectionsofvalves,fittingsorgassockets.pMaterial:brasspSealring:HNBR
ThreadedBSPparafixedfemaleacc.toDINEN10226-1areusedforconnectingthepliableHYDRAGSstainlesssteelcorrugatedpipestothemalethreadconnectionsofvalves,fittingsorgassockets.pMaterial:brasspSealring:HNBR
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T-piece–HYDRA®GSClick
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg15 1197740 0.51722 1197739 0.91828 1197742 0.84932 1197748 1.54
22x22x15 1197738 0.86322x15x15 1197741 0.78328x28x15 1197744 0.79828x22x22 1197746 0.86528x22x15 1197747 0.81332x28x22 1197749 1.44632x28x15 1197751 1.342
TheT-piecesareusedasconnectionelementstootherlinesandthusmakeitpossibletoconnectadditionalconsumers.pMaterial:brasspSealring:HNBR
Soldersocket–HYDRA®GSClick
ConnectionBS746female–HYDRA®GSClick
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kgDN15Ø15 1197771 0.267DN22Ø15 1197772 0.282DN22Ø22 1197766 0.287DN28Ø22 1197767 0.267DN28Ø28 1197768 0.268DN32Ø22 1197769 0.344DN32Ø28 1197770 0.349
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg22 1197763 0.37428 1197764 0.37032 1197765 0.462
ConnectionpartwithsolderlugsforconnectingpliableHYDRAGSstainlesssteelcorrugatedpipeswithcopperlines.pMaterial:brasspSealring:HNBR
Connectionpartforconnectingtogasmeterwith1"threadacc.toBS746pMaterial:brasspSealring:HNBR
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StraightCoupling–HYDRA®GSClick
Coppercompressionfitting–HYDRA®GSClick
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kg15 1197752 0.30722 1197753 0.51728 1197754 0.44932 1197755 0.581
Dimensions[Nominaldiameterxthreadacc.toEN10226-1]
DN
Articlenumber Weight
kgDN15Ø15 1197756 0.203DN22Ø15 1197757 0.316DN22Ø22 1197758 0.342DN28Ø22 1197759 0.313DN28Ø28 1197761 0.335DN32Ø22 1197760 0.416DN32Ø35 1197762 0.462
ConnectionparttoconnecttwoHYDRAGSstainlesssteelcorrugatedpipeofsamediameter.pMaterial:brasspSealring:HNBR
CompressionfittingforconnectingpliableHYDRAGSstainlesssteelcorrugatedpipewithcopperlines.pMaterial:brasspSealring:HNBR
2.3.HYDRA®GSPressundHYDRA®GSClick
BISMAT®-Flashpipeclamp–HYDRA®GS
TheBISMAT®-Flashpipeclampisusedforfasteningthecorrugatedpipestobuildingstructuresorsupportingstructures.pMaterial:galvanisedsteelpSealring:EPDM(black)
DN D D G B H h bxs Articlenumber
mm Inch mm mm mm mm15 20-23 ½" M8 54 39 23 r20x1.25 105254922 25-28 ¾" M8 59 44 26 r20x1.25 105255628 32-35 1" M8 65 51 30 r20x1.25 105256032 40-43 1¼" M8 74 60 34 r20x1.25 1052562
Caddyclip–HYDRA®GS
TheholdingloopisanalternativetotheBISMAT-Flashpipeclampandisalsousedforfasteningthecorrugatedpipestothebuildingstructureorsupportingstructures.pMaterial:galvanisedsteel
DN d d B A Articlenumber
mm Inch mm mm22 26.9 ¾" 60.3 31.8 105252128 33.7 1" 68.3 36.5 105252732 42.2 1¼" 77.8 41.3 1052528
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3. DIMENSIONING THE PIPELINE SYSTEM
3.1.Basisfordimensions
Thedesignandinstallationoflow-pressuregaspipeworkindomesticpremisesisspecifiedinBS6891(2ndfamilygas)andBS5482-1(3rdfamilygases),whilstpipeworkwithlargerboresizesandhigheroperatingpressureiscoveredinIGEM/UP/2LatestEdition.Strengthtesting,tightnesstestinganddirectpurgingofinstallationpipeworkarecoveredintheIGE/UP/1standards.
NaturalgasL NaturalgasH Propane
Operatingtemperature t °C 15 15 25Operatingpressure,absolute p Pa 103300 103300 106300
Netcalorificvalue HI,B kWh/m³ 8.6 10.6 26.8
Dimensioning with the software tool allows a free choice of entries.
3.2.Preliminarydimensioningusingtable
Whenusingthetable,thepressurelossesofthecomponentsarereadinrelationtotheload.Thepressurelossoftheentirepipelinesystemiscalculatedbyaddingupthepressurelossesalongthecourseofthepipeline.Asarule,thetablesapplytoindividuallines.Whenthereareseveralconsumers,calculatebackwardsfromthem.Fromthebranchonwards,calculatebytakingthetotaloftheindividualloadings,wherebyitisalsopossibletotakeintoaccountasimultaneityfactorforreducingtheoverallload.Thepressurelossesofthestraightcorrugatedpipesarespecifiedbelowpermetre.Bendsandconnectionpartsinherentinthesystemaretakenintoaccountasadditionalpipelength.pR=R·(lR+lz) linm
Forallothercomponents(flowmonitor,gasmeter,applianceconnectionfitting,etc.),usetheinformationfromthemanufacturers.(pGS,pZG,pGA)Theheightdifferencebetweenthestartofthepipelineatthegaspressurecontrolinstallationandtheinstallationconnectionistakenintoaccountacc.tothefollowingformula.pH=(-4)·H Hinm
Thepressurelossinthepipelineis:p=pR+pGS+pZG+pGA+pH
Stripearthband-HYDRA®GS
Thestripearthingclipisusedforpotentialequalisationforthebuildinginstallation.pMaterial:stainlesssteel(V2A)
Type forcorrugatedpipediameterDN
Articlenumber
9271 15to32 1051809
Coroplastadhesivetape–HYDRA®GS
Type Lengthxwidth Articlenumber
PVC302 10mx25mm 1147254
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3.3.Pressurelossesinthecorrugatedpipelinedepending on the nominal load
3.3.1. Natural gas LPressurelossincorrugatedpipelinesfornaturalgasL(15°C,20mbar,8.6kW/m³)
RPa/m
DN[mm]15 22 28 32
0.4 2 4 8 200.6 5 10 250.8 3 6 11 291.0 7 13 331.2 4 14 361.4 8 16 391.6 9 17 421.8 5 18 452.0 10 19 482.5 6 12 21 543.0 7 13 24 603.5 14 26 654.0 8 15 28 705 9 17 31 796 10 19 34 877 11 20 37 958 12 22 40 1029 13 23 43 10810 14 24 45 11512 15 27 50 12714 16 29 54 13816 17 31 58 14820 20 35 66 167
Pressurelossesoftheconnectionparts,additionallengthslZtotheoverallpipelengthforsystemcomponents
DN Pressurelossesinmetres
90°bends Hoseconnection Tstraight Tbranch
16 0.15 0.2 0.4 0.520 0.2 0.3 0.6 0.925 0.25 0.2 0.4 0.832 0.3 0.2 0.4 1.3
3.3.2. Natural gas HPressurelossincorrugatedpipelinesfornaturalgasH(15°C,20mbar,10.6kW/m³)
RPa/m
DN[mm]15 22 28 32
0.4 3 5 10 240.6 6 12 300.8 4 8 14 361.0 9 16 401.2 5 18 441.4 10 19 481.6 6 11 21 521.8 12 22 552.0 7 13 23 592.5 8 14 26 663.0 9 16 29 733.5 17 32 804.0 10 18 34 865 12 21 38 976 13 23 42 1077 14 25 46 1168 15 27 49 1259 16 28 53 13310 17 30 56 14112 18 33 61 15614 20 36 67 16916 21 39 72 18220 24 43 81 205
QN
Bv
alue
sin
kW
QN
Bv
alue
sin
kW
0 5 10 15 20
20
40
60
80
100
120
140
160
180
200
Pa/m
DN15 DN28DN22 DN32
0 5 10 15 20
20
40
60
80
100
120
140
160
180
200
Pa/m
DN15 DN28DN22 DN32
Pressurelossesoftheconnectionparts,additionallengthslZtotheoverallpipelengthforsystemcomponents
DN Pressurelossesinmetres
90°bends Hoseconnection Tstraight Tbranch
16 0.15 0.2 0.4 0.520 0.2 0.3 0.6 0.925 0.25 0.2 0.4 0.832 0.3 0.2 0.4 1.3
QN
B/k
W
QN
B/k
W
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3.3.3. Propane gasPressurelossincorrugatedpipelinesforpropane(25°C,50mbar,26.8kW/m³)
RPa/m
DN[mm]15 22 28 32
0.4 5 9 17 430.6 6 12 21 540.8 7 13 25 631.0 8 15 28 711.2 9 17 31 791.4 10 18 34 851.6 11 20 36 921.8 21 39 982.0 12 22 41 1042.5 14 25 46 1173.0 15 27 51 1293.5 16 30 55 1414.0 18 32 60 1515 20 36 67 1716 22 40 74 1887 24 43 80 2058 25 46 86 2209 27 49 92 23510 29 52 97 24912 31 57 107 27414 34 62 116 29816 36 67 125 32120 41 75 141 362
3.4.Examplecalculation
pCombinationwaterheater,result:pressureloss<300PapNominalload:18kWpApplianceconnectionfitting,straightpattern:20PapHeightdifference:8.9m-35PapSelectedcrosssection:DN2266PapPiperesistance:6Pa/m(Table1naturalgasL)pPipelength:9.9mpStraightT-piece:(Tab.14lZ)0.6mpThreadedconnectionreduced:0.3mp90°bend:0.2m
QN
Bv
alue
sin
kW
0.6
2.4
0.4
3.0
0.6
0.6
1.2
0.3
0.4
3.2
2.8
7.1
Line12
Line21
Line20
Line10
GS 4 36 Pa
KWH 260 Pa18 kW15D 20Pa+8.9m -35PaDN22 66Pa6Pa/m9.9+0.6+0.3+0.2=11.0m
H 155 Pa9 kW15E 10Pa+5.4m -21PaDN15 38Pa5Pa/m6.4+0.5+0.2+0.45=7.55m
33 kW 128 PaDN28 9Pa6Pa/m1.0+0.25+0.2=1.45m
GDS 224 Pa6 kWGSD 15Pa+2.5m -10PaDN15 10Pa2.5Pa/m3.9+0,5+0,2+0,45=3.25
24 kW 209 PaDN22 81Pa10Pa/m7.0+0.9+0.2=8.1m
33 kW 54 PaDN28 18Pa6Pa/m2.1+0.5+0.4=3.0m
Line11
Line30
0 5 10 15 20
20
40
60
80
100
120
140
160
180
200
Pa/m
DN15 DN28DN22 DN32
QN
B/k
W
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3.5.PressurelosscalculationwithsoftwaretoolFirst,openthe"HydraGS.xlt"filewithadouble-click.Important:Macrosmustbeactivated.Tofillintheemptydialoguebox,clickoneofthetwobuttons"Createnewproject"or"Editproject".Adialogueboxappearswhichhasthesamestructure.Ifadialogueboxiscalledupwhichhasalreadybeenfilledin(*.xls)thenthe"Createnewproject"buttondeletesallpreviousentries.
Selectionofthegastypeusingthedrop-downmenuandtheoperatingconditionsintheheadofthetable.Theproposedvaluesforgastemperature,connectionpressure,permissiblepressurelossandnetcalorificvaluecanbeoverwritten.
pEntryofthepipelineroutingstartingfromthehouseconnectionincolumn2.Select"Continue"ifsubdividingintoseveralsections.Select"Branch"ifabranchfollows.Ifthelineendsattheconsumer,enter"End"andthenominalload(column5).Thelinesarenumberedautomatically(columns1,3,4).Entriesareonlypossibleinthewhitefields.
pIncolumn6,enterthedifferenceinheightbetweeneachconsumerandthehouseconnection.
7
2
8
3
9
4
5
6
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pEnterthenominaldiameterincolumn7.Thesubsequentlineshouldonlybeonenominaldiametersmallerthanthepreviousone.
pAftera"branch"isenteredincolumn2,twosubsequentlinesaredisplayed.Incolumn8forthefirstfollow-online,nowselectwhethertheflowthroughtheT-pieceisstraightorasaT-branch.Thesecondfollow-onlineisalwaysaT-branch.Adiameterreductionofthefollow-onlineisautomaticallytakenintoaccount.
pColumn9containstheextendedpipelengthoftheline.pThenumberof90°bendsisenteredincolumn10.However,itisalsopossibletoenterfrac-
tions(e.g.30°=0.33).p"Connections"incolumn11referstoallstartingorfinishingpiecesonthehose,irrespective
ofwhethertheyarethreadedorconeconnections.Inthecaseofreducers,theconnectormustalwaysbeenteredinthelinewiththesmallernominaldiameter.2connectionsmustbecountedforahoseextensionbyaconescrewconnection.
pThepressurelossesanddescriptionsofcomponentsfromothermanufacturerscanbeen-teredincolumns12and13.
pColumn14showsthepressurelossoftheindividuallineandcolumn15showsthetotalfortheparticularconsumer.Iftheresultincolumn15islargerthanthepermissiblepressurelossthentheresultisshowninred.Inthiscase,itisnecessarytoincreasethenominaldiameterincolumn7from16to20forline2-1.Alternatively,however,changingthetypeandnumberofinstalledpartscanproduceasuccessfulresult.
Oncethedialogueboxhasbeenclosed(cross),thedialogueboxallowingsavingandprintingwithnormalWindowsfunctionsisactivatedagain.Theentriescanbeeditedagainusingthe"Editproject"button.
Advantagesofthesoftwaretoolcomparedtousingthetable:pThepressurelossvaluesofthelinesareonlyroundedoffattheendofthecalculation.This
makestheresultmoreaccurate.pThepipelinecrosssectionscanbeoptimisedveryquickly.Theresultisdisplayedimmediately
aftereachentryiscompleted.pDialogueboxesthathavealreadybeencreatedcanbemodifiedforsimilarprojects.pItispossibletoenterthenetcalorificvalueasrequired,thusallowingoptimumadaptationto
theparticulargassupply.Thesameappliestotheoperatingconditionofthegas.
7
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4.1.Assemblyprocedure
4. ASSEMBLY HYDRA® GS PRESS
Step 1: Prepare the hose
Step 3: Expand the corrugated pipe
Theinitialpieceoftherolled-upHYDRAGScorrugatedpipemustalwaysbecutoffwithacleancutpriortouse.Measurethesuitablepipelength.
Nowtheendofthecut-to-lengthpipemustbeexpandedinordertoallowtheconnectionpartstobefitted.
Todothis,theexpansionheadfromthetoolcaseisscrewedontostandardexpandertongs
Step 2: Cut the corrugated pipe to length
Usethecorrugatedpipecuttertocutthesheathedpipetolength.Thecutmustbelo-catedinthegrooveofacorrugation.Turnthepipecutterinonedirectionandslowlytightenthepressurerolleraftereachturn.Important:Tighteningtoomuchleadstoirregularcutsanddeformations.Avoidkinkingandtearingthecorrugatedpipeafteranincompletecut.
Theclosedtoolispushedintotheendofthecorrugatedpipeuptothecollar.Theexpandertongisopenatthisstage.
Operate(close)thetongonceuptothestoppoint.Removetheexpansionhead.
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Step 5: Carry out visual inspection.
Theexpandedcorrugatedpipeispushedovertheconnectionpart.
Thenecessaryinsertiondepthhasbeenrea-chedwhentheyellowPEsheathingcanbeseenintheroundviewingholesofthecon-nectionpart.
Thecorrugatedpipethenmakesfirmmetal-on-metalcontactwiththeconnectionpart.
Right:Theviewingwindowiscompletelyfil-ledbythecorrugatedpipe.
Wrong:Inadequateinsertiondepth!
Thecutedgeofthecorrugatedpipemustneverbevisibleintheviewingwindow.
Step 4: Fit the connection part onto the press head; lock the pull rod with the bayonet socket
Selecttheappropriatepressheadfromthetoolcasetomatchthediameterofthefitting.Pushthepressheadfromthefrontintotheconnectionfittingwiththethreadedpartfore-most.
Pushthepressheadasfaraspossibleintothefitting.
Theninsertthepressheadasfaraspossibleintotheaxialpressingtool.Turn90°clock-wiseinthechuckoftheaxialpressingtooltolockthepresshead(bayonetsocket).
Brieflyoperatetheaxialpressingtooltosecuretheconnectionpartonthecentringpieceoftheaxialpressing
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Step 8: Remove the press head
Step 9: Seal the connection part
Removethepressheadbypressingtheunlockingmechanismontheendandbyturningit90°anticlockwise
Step 6: Install the connection part
Step 7: Trigger the return stroke
Thebattery-operatedaxialpressingtoolisstartedatthepushofabutton
Toremovethepresshead,releasetheslideontherearofthetool
Thepressheadthenmovesbacktoitsorigi-nalposition
Afteramaximumof8seconds,thepressheadwillhaveexpandedtheconnectionpart.Theaxialpressingtoolthenswitchesoffautomatically,anditcansimplybepulledoutofthecorrugatedpipe.
Wrapwithadhesivetape,beginningonthehoseandworkingtowardsthefitting.
Overlapthelayersbyapprox.0.5cm.Makesuretherearenocreases.
Wraptwolayersoftapearoundthehoseandthefittinguptothenut.
28 mm
5 mm
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5. ASSEMBLY HYDRA® GS CLICK
5.1.Assemblyprocedure
Step 1: Prepare the hose
Step 3: Assemble the connection part
Theinitialpieceoftherolled-upHYDRAGScorrugatedpipemustalwaysbecutoffwithacleancutpriortouse.Measurethesuitablepipelength.
Removesheathfromthefirst6corrugations,seesketch.
Step 2: Cut the corrugated pipe to lengthUsethecorrugatedpipecuttertocutthesheathedpipetolength.Thecutmustbelo-catedinthegrooveofacorrugation.Turnthepipecutterinonedirectionandslowlytightenthepressurerolleraftereachturn.Important:Tighteningtoomuchleadstoirregularcutsanddeformations.Avoidkinkingandtearingthecorrugatedpipeafteranincompletecut.
Loosenscrewfittinglightlybyhand.
Pushtheendofthehosefirmlyintothefitting.Therewillbeanpositiveclick.
Tightenthefittingusingawrench.Thedis-tancebetweenthebrasspartsofthefitting(aftertightening)shouldbe0.5mmmax.
Wrapwithadhesivetape,beginningonthehoseandworkingtowardsthefitting.
Overlapthelayersbyapprox.0.5cm.Makesuretherearenocreases.
Wraptwolayersoftapearoundthehoseandthefittinguptothenut.
28 mm
5 mm6 corrugations
Step 4: Seal the connection part
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6.1.ValidforHYDRA®GSPressandHYDRA®GSClick
Externalsystemsandfittingsmayonlybeconnectedtogetherusingscrewfittingswithstandardisedthreadora24°cone.
TighteningtorqueforHYDRA®GSPress
ScrewconnectionsforHYDRAGSPressshouldbetightenedwiththetoleratedtorquesasspecifiedinthefollowingtable.
NominaldiameterofcorrugatedpipeDN
Tighteningtorqueforunionscrewconnection
[Nm]
15 30±1022 30±1028 35±1032 50±10
6.2.ValidforHYDRA®GSPressandHYDRA®GSClick
Minimumbendingradii
Whenbendingcorrugatedpipes,makesurethebendingradiiarenotlessthantheminimumbendingradiispecifiedinthefollowingtable.
NominaldiameterofcorrugatedpipeDN
Minimumbendingradius
mm15 2522 3028 4532 60
7. GENERAL NOTES ON INSTALLATION
7.1.Generalinstructions
pStoreallHYDRAGSPresscomponentsintheiroriginalpackinginadryplace.pMakesurethatthecomponentsarestoredatroomtemperaturedirectlybeforebeinglaid.pIftheHYDRAGSstainlesssteelcorrugatedpipesweresubjectedtolowtemperatures,store
thematroomtemperatureuntiltheythemselveshaveroomtemperature.pBeforefitting,makesurethatsufficientHYDRAGSsystemcomponentsareavailableforthe
requiredlengthanddiameters.pInstallHYDRAGSstainlesssteelcorrugatedpipesinsuchawaythattheyareprotectedfrom
mechanicaldamage.pDuringfitting,avoidkinking,crimping,over-bending,over-stretchingortwistingtheHYDRAGS
stainlesssteelcorrugatedpipe.Alsoavoidcontactwithsharpobjects.Renewdamagedparts.pAvoidimpairingthefreeflowcross-sectionofHYDRAGSstainlesssteelcorrugatedpipes.pMakesurethatnoforeignbodiesenterthecorrugatedpipe.pHYDRAGSstainlesssteelcorrugatedpipesmaynot,underanycircumstances,beusedas
flexibleconnectionsforapparatus(forexample,insteadofgashoses).pPriortotakingacompletedinstallationintooperation,theentireinstallation
mustbecheckedinaccordancewiththetechnicalcodesofpractice.pFittingsandcomponentsmustbearrangedandsupportedsothattheycannottransmitany
impermissibleforcesanddeformationsontothepipesystem.pCorrugatedpipelinesdonotprovideasufficientlyrigidconnection.pThesealingsurfacesofconnectionpartsmustremainundamagedduringlayingpConnectionpartsmustbeinstalledwheretheyareeasilyaccessiblepThenumberofconnectionpartsmustbereducedtotheminimumnecessarypInnerpipesmustbelaidinaccordancewiththeapplicablecodesofpractice.pChargethebatterypriortoinitialusepPressheadsshouldnotbegreased
6. ASSEMBLY ON PARTS OUTSIDE THE HYDRA® GS GAS INSTALLATION SYSTEM
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7.2.HYDRA®GSFirebehaviour
HYDRAGSstainlesssteelcorrugatedpipeshavebeentestedfortheirfirebehaviourinaccor-dancewithEN13501-1andhavebeenclassifiedasB-S1-D2.ThePE-sheathingdoesnotconstituteaninsulatinglayerasdefinedbyBS4102.
7.3.Potentialequalisation
Gaspipelinesmaynotbeused(fullyorinpart)asprotectiveoroperationalearthsorasprotec-tiveearthconductorsinelectricalsystems.Gaspipelinesmaynotbeusedasalightningcon-ductorsorearthingsinlightningprotectionsystems.Themetalinnerpipingofeachbuildingmustbeconnectedtotherelevantequipotentialequalisationsystem.PleaseobservealsoBS6891,8.6andBS5482-1,12.3.3.
1Stripearthingcliponhexagonprofile2 HYDRAGScorrugatedpipe3 HYDRAGSthreadednipple
1Stripearthingcliponhexagonprofile2 HYDRAGScorrugatedpipe3 HYDRAGSunionnutnipplewithadapter
2
3 3
2
7.4.Fasteningandfasteningdistances
Gaspipelinesmaynotbeattachedtootherpipelines,normaytheybeusedassupportsforotherpipelinesandloads.Theymustbearrangedsothatdripsandcondensationfromotherpipelinescannothaveanyeffectonthem.
Dependingonthemechanicalstrength(tensilestrength)oftheirpipeconnections,theymustbeattachedtocomponentswithanadequatestructuralstrengthbymeansofpipebrackets.Thesupportingpartsofthepipebrackets(e.g.pipeclamps/clips,bolts)mustbemadefromnon-flammablematerials.Thefollowingtableprovidesguidancevaluesforfasteningdistancesoflaidpipelines.
Itisessentialtocomplywiththerecommendedfasteningdistances:
NominaldiameterDN
Recommendedfasteningdistance
horizontal vertical Bendm m m
15 1.00 2.50 0.2522 1.25 2.50 0.3028 1.50 2.50 0.4032 1.75 2.50 0.45
Plasticplugscanbeusedifthemechanicalstrengthofthepipelinewillnotbeimpairedincaseoffireattemperaturesupto650°C.Inpipelineswithpipeconnectionswhichnolongerguaranteetherequiredmechanicalstrength(tensilestrength)whenexposedtotemperaturesupto650°C,itisnecessaryfortheplugsusedtobeabletowithstandthesetemperatures(e.g.metalplugs).Furthermore,solidorcomparablestructuralcomponentsarerequiredinthebuildingforthefasteningpoints.
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8. PROTECTION AGAINST CORROSION OR DAMAGE
OnlyHYDRAGSBISMAT®-FlashpipeclampsandHYDRAGSCaddyholdingloopscertifiedinaccordancewithBSEN15266maybeusedtofastentheHYDRAGSstainlesssteelcorrugatedhosesystem.
Thepipeclampsandholdingloopsarepartoftheoverallapprovedsystem.HYDRAGSstain-lesssteelcorrugatedpipesmaynotbeinstalledusingotherpipeclamps.BISMATFlashisascrew-inpipeclampmadefromelectrolyticallygalvanisedsteelwithanacousticinsulationinsertmadefromblackEPDMrubberandaquickfastener.Themaximumpermittedloadiscertifiedacc.toRAL-GZ655/Aandis260N.
Inordertoguaranteeanoptimumdurationoffireresistance,useplugsandthreadedrodswhosefire-resistancepropertieshavebeentested(dimension≥M8orM10,strengthclass≥4.6).
Avoidanycontactbetweenthegaspipelinesandacids,alkalis,saltsorothercorrosivesub-stances.Inaddition,alsoavoidcontactbetweenthegaspipelinesandaggressivechemicalcompoundswhichcanleadtocorrosionofstainlesssteel.
Shouldcontactoccurnevertheless,removethechemicalresiduesthoroughlywithoutdelay.CheckthePEsheathingofthegaspipelinefordamage.IfthePEsheathingisundamaged,itwillprotectthestainlesssteelcorrugatedpipeagainstcorrosion.Ifthereisdamage,renewtheaffectedsection.
Avoidusingcompoundscontainingchloride,e.g.fordetectingleaks.Contactwithsuchcom-poundscancausetheHYDRAGSstainlesssteelcorrugatedpipestocorrode.
Atallintermediatestagesbetweenmanufactureanduse,storethegasketsinaccordancewiththerecommendationsofISO22301.
Comply with the following points:a)Thestoragetemperatureshouldbebelow25°C,preferablybelow15°C.b)Thegasketsshouldbeprotectedagainstlight,inparticularagainststrongsunlightandartifi-
ciallightwithahighultravioletproportion.c)Thegasketsshouldnotbestoredinaroomcontainingsystemsthatcan
generateozone,e.g.mercuryarclampsordeviceswithhigh-voltageelectricitywhichcancausesparkinganddarkelectricaldischarges.
d)Thegasketsshouldbestoredwithoutstress,i.e.withouttension,pressureorotherdeforma-tions;forexample,theyshouldnotbehungup.
e)Thegasketsshouldbekeptclean.
Insertthepipe. Pushtheclampclosedbyhand.
Done!
9. RECOMMENDATIONS FOR STORING THE GASKETS
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10. REPAIR METHODS
10.1.DamagetotheHYDRA®GSstainlesssteelcorrugatedpipes
The flexible corrugated pipes must be renewed without fail if:pthereisvisibledamagetothePEsheathing.pthecorrugatedpipehasbeenbenttootightly,leavingakink.pthecorrugatedpipehasbeendamagedbyasharporpointedobject.pthecorrugatedpipehasbeensignificantlycompressed.pthereisapressurelossinthehoseassembly
Renewaloftheentirecorrugatedpipelengthisrecommendedforsafetyreasons,inordertoavoidhavingscrewconnectionsincavities.Inaddition,inmostcasesthisprocedureismoreeconomicalthanrepairingonlypartofasection.Ifasectionistoberepaired,itispossible,dependingonthelengthofthepipelineremaining,toremovethedamagedpartandconnectthepartsleftusingHYDRAGSscrewconnections.Iftheremaininglengthsareshort,itispossibletouseapipelinesectionwithtwoHYDRAGSscrewconnectionsbetweenthetworemainingsections.Note:Aleaktestmustalwaysbecarriedoutaftereachrepair.
