CALCOPPER - District heating pipe CCO 9.0 Table of contents · 2020-05-20 · CALCOPPER - District heating pipe System Description General CCO 9.100 7.11.2005 1. General CALCOPPER

CALCOPPER - District heating pipe

Table of contents

CCO

9.0

7.11.2005

9.0 Table of contents

9.1 System description

9.100 System description (general)9.105 System description (data)9.115 CALCOPPER - Local and house connection pipe

Construction, dimensions, materials, weights and deliverylengths

9.2 Planning, design engineering

9.200 Pipe routing9.201 Pipelaying instructions, part 19.202 Pipelaying instructions, part 29.203 Pipelaying instructions, part 39.205 Pressure losses9.210 Heat losses

9.3 Components

9.320 Joint sleeve / Fitting the T-piece9.340 Insulating material9.345 Copper fittings / brazing instructions9.355 Connection of copper heating pipe to KMR9.365 End cap9.370 Wall sealing ring / Pipe warning tape

9.5 Underground construction work, assembly

9.500 Trench dimensions9.505 Pipe entry into buildings


System DescriptionGeneral

CCO

9.100

7.11.2005

1. General

CALCOPPER is a flexible pipe system suitablefor temperatures of up to 120 °C. This pipingis intended for use in small and medium-sizedlocal heating networks.

CALCOPPER has a medium pipe made of cop-per. Manual processing of this piping is veryeasy.

The heat insulation consists of a flexible CFC-free hard polyurethane foam with outstandingheat insulation characteristics.

The flexibility of the CALCOPPER piping means that it can be adapted to virtually anypipe conditions with no problems. Pipes cancross above or below existing supply lines,and obstacles can be easily bypassed.

CALCOPPER makes it possible to choose theshortest pipe route, without taking classicalpipe construction methods into considera-tion.

CALCOPPER is supplied to the site as onepiece in the desired length, in rings. By andlarge, the pipe can be laid in the groundwithout any connection points so that thepipe trenches can be considerably narrower,making substantial savings possible on theunderground construction work. This is par-ticularly true of DUO lines.

Another feature: only a very short time is re-quired to lay the pipe. All of these benefitsmean that CALCOPPER is not only a techni-cally perfect solution, but also that it offersthe key to saving time and costs when con-structing local heating networks - thanks tothe reduced outlay on coordination at thesite, and the fast and simple installation pro-cedure.

2. Range of application

Heating:

Max. continuous operating temperature TBmax: 120 °C Max. operating pressure p: 16 bar


System DescriptionData

CCO

9.105

7.11.2005

3. Carrier pipe

Material: Soft copper, R220 to EN1057Oxygen-free copper, deoxidised with phosphorusSF-Cu F22 to DIN17671

Characteristics: Meets the requirements specified by EN 1057(mechanical values in the delivered state)

4. Heat insulation

Material: CFC-free, 100% pentane-blown polyurethane foam (PUR)

Cu medium pipeDensityProof stressUltimate tensile strengthHardnessModulus of elasticityLinear expansion coefficientHeat conductivity

Reference temperature °C–

–––––

Value8.93

max. 140220 to 270

40 to 70125‘000

16.6 · 10 E-6305 W/mK

kg/dm3

N/mm2

N/mm2

N/mm2

1/K

Examination norm–

DIN 17671DIN 17671DIN 17671

–––

PUR insulationDensityHeat conductivityClosed cellsWater absorption after 24 hours

Reference temperature °C–

50––

Value> 60

≤ 0.0255≥ 90≤ 10

kg/m3

W/mK%%

Examination normDIN 53420DIN 52612

–EN 253

5. Protective casing

Material: Polyethylene of low density, PE-LD, extruded seamless Purpose: Protection against mechanical effects and moisture

PE-LD protective casingDensityHeat conductivityCrystallite melting range

Reference temperature °C–––

Value928-938

0.43105-110

kg/mW/mK°C

Examination normDIN 53479DIN 52612

–


Local heating and house connection piping

Heating, 16 bar, UNO and DUO

CCO

9.115

7.11.2005

s1

d D

s

DUOUNO

4321

Pos

1

2

3

4

Material

Medium pipe in soft copper, R220, to EN1057, SF-Cu F22 to DIN 1787/17671/1754

Flexible, semi flexible pentane-blown polyurethane foam, resistant up to 130 °CThermal conduction coefficient λ = ≤ 0.0255 W/mK at 50 °C average temperature

PE-LD film

Outer casing in black PE-LD polyethylene (VDE 0209), extruded seamless.Protection against mechanical effects and moisture.

Type

15/7618/7622/7622/9128/7628/9135/91

DN

10152020252532

Carrier pipe Cud x smm

15 x 1.018 x 1.022 x 1.022 x 1.028 x 1.228 x 1.235 x 1.5

CasingD x s1

mm76 x 2.076 x 2.076 x 2.093 x 2.276 x 2.093 x 2.293 x 2.2

Min. Bendingradius

m0.70.70.70.80.70.80.8

Capacitycarrier pipe

l/m0.130.200.310.310.510.510.83

Weight

l/m1.091.171.271.611.571.902.27

max. Delivery lengthRing without connection

m280300200200130200

On request

Type

18+18/9118+18/11122+22/9122+22/11128+28/91

DN

1515202025

Carrier pipe Cud x smm

18 x 1.018 x 1.022 x 1.015 x 1.028 x 1.2

CasingD x s1

mm91 x 2.2

113 x 2.491 x 2.2

113 x 2.491 x 2.2

Min. Bendingradius

m0.80.80.80.80.8

Capacitycarrier pipe

l/m2 x 0.202 x 0.202 x 0.312 x 0.312 x 0.51

Weight

kg/m1.502.271.722.212.10

max. Delivery lengthRing without connection

m300200200200200

CALCOPPER, DUO

CALCOPPER, UNO

Ring dimensions: Ø 2800 x 800 mm (width)


Examples of pipe routing

CCO

9.200

7.11.2005

A

B

C

D

Connection CALPEX-CALPEX

A

B

C

D

E

Looping-in method

Connection: copper local heating pipe - plastic casing pipe

Connection: Copper - Copper

Note expansion pad as shown on catalogue pages CCO 9.201, 9.202 and 9.203

Copper local heating pipe



Pla

sti

csh

ea

thp

ipe

A

B

C

Instructions for pipe laying

If the lengths of pipe to be laid exceed 5 m, the copper junction pipes must first be bent intoa sinusoidal shape (curve length: L = 2 m, amplitude: 10 x outer diameter of copper localheating pipe).


Instructionsfor pipe laying

Part 1

CCO

9.201

7.11.2005

2 m

10 x Ø outer casing

Expansion pad


Copperlo

calh

eating

pip

e

5 - 10 m

Expansion pad for sinusoidal curves


Copperlo

calh

eating

pip

e

< 5 m


Copperlo

calh

eating

pip

e


> 10 m

>5

m


Copperlo

calh

eating

pip

e


10 m

1-5

m

≤


Copperlo

calh

eating

pip

e Expansion pad for sinusoidal curves

> 10 m

Method of laying

- Special brazing must be used to solder the pipes together (this must be resistant togalvanic or electrochemical corrosion).

- The brazing instructions / manufacturer's instructions for the copper fittings must befollowed without fail.

- The shape of the copper piping should not be bent more than three times. This alsoincludes rolling apart and rolling together.



Part 2

CCO

9.202

7.11.2005

Pipe junctions from copper or steel / Main pipes on copper

The copper local heating pipe can only accommodate forces and deformations from connec-ted external pipes to a limited extent.

Expansion padding has to be applied to copper local heating junction pipes. The number of ex-pansion pads required depends on the movement of the main pipe. The 3 illustrations shownbelow provide the basic rules:

Thickness of expansion pads: 40 mm

The expansion pads must be applied as far as the casing of the main pipe (i.e. they are posi-tioned on top).

The first layer of expansion pad is positioned around the local copper heating pipe which bran-ches off (the junction pipe).The second and third layers of expansion pad are only applied at the sides (i.e. they areplaced adjacently). The foregoing illustrations assume that junction sleeves are used.

CC

OC

opperlo

cal

heating

pip

e

2 m

CCO oder KMR

Illustration 2

Expansion pad 20 ≤ ∆ l ≤ 40 mm

CC

OC

opperlo

calheating

pip

e

Expansion pad1 m

CCO or KMR

Illustration 1

l ≤ 1 m∆ 20 mm 1 m1 m

CCO or PLASTIC CASING PIPE

CC

OC

opperlo

cal

heating

pip

e

Illustration 3

3 m

Expansion pad 40 ≤ ∆ l ≤ 60 mm

CALCOPPER - District heating pipe CCO

9.203

3.10.2005


Part 3

Straight transitions from plastic casing pipes to the copper local heatingpipe

For transitions from plastic casing pipes to the copper local heating pipe, it should be notedthat the copper local heating pipe can only absorb the heat expansion to a limited extent. Thefollowing examples show how this can be guaranteed:

General instructions for reducingthe medium pipe

The following rules must be followed for a re-duction of the medium pipes:

1. If gunmetal reductions are used, no parti-cular instructions need to be followed.

2. The following instructions refer to reduc-tions with normal copper fittings.

The maximum length of the plastic casing pipeis 5 m. Expansion padding is required. No si-nusoidal curve is required on the copper pipe.

KM

R

KMRCCO

max. 5 m

The maximum length of the plastic casing pipeis 10 m. Expansion padding is required.

KM

R

KMRCCO

max. 10 m

The maximum length of the plastic casing pi-pe is 20 m. Expansion padding is required.

KM

R

KMR CCO

max. 20 m

The length of the plastic casing pipe may ex-ceed 20 m. Expansion padding is required.

KM

R KMR

Über 20 m

CCO

The heat expansion is absorbed by thesinusoidal curve (see page CCO 9.210)upstream of the T-junction. Expansionpadding is required.

Reduction

CCO

CCO,

reduziert

CCO

max. 5 m

CC

O


Pressure lossHeating, 16 bar

CCO

9.205

7.11.2005

35x

1.5

(DN

32)

28x

1.2

(DN

25)

22x

1.0

(DN

20)

18x

1.0

(DN

15)

15x

1.0

(DN

10)

0.1

5m

/s

0.2

m/s

0.3

m/s

0.4

m/s

0.5

m/s

0.6

m/s

0.8

m/s

1.0

m/s

1.2

m/s

1.4

m/s

1.8

m/s

2.5

m/s

Water-velocity v [m/s]

Flo

wquantity

,m

[kg/h

]

•

Pressure loss, ∆p [Pa/m]

50

70

100

200

300

500

700

1000

1500

2000

3000

5000

7000

10000

15000

1200

025

0012

0040

025

015

090

8060

3 4 5 7 20 30 4050 200 300 500 7001000

10mbar/m

1mbar/m

2000 300010010

Water, average temperature 80 °C

Roughness ε = 0.015 mm (copper)(1 mm water column = 9.81 Pa)

m = Flow rate in kg/hQ = Power requirement in kW

∆T = Temperature difference

forward/return flow in °C

Q · 860m• = ––––––––––∆T

Type

CCO UNO

15/76

18/76

22/76

28/76

22/91

28/91

35/91

U-Value

[W/mk]

0.095

0.107

0.123

0.151

0,111

0.133

0.161

70°

5.7

6.42

7.38

9.06

6.66

7.98

9.66

Heat loss q [W/m] for single-line pipe UNO average operating temperature TB [°C]

80°

6.65

7.49

8.61

10.57

7.77

9.31

11.27

90°

7.6

8.56

9.84

12.08

8.88

10.64

12.88

100°

8.55

9.63

11.07

13.59

9.99

11.97

14.49

110°

9.5

10.7

12.3

15.1

11.1

13.3

16.1

120°

10.45

11.77

13.53

16.61

12.21

14.63

17.71


Heat lossHeating, 120°C, 16 bar, UNO and DUO

CCO

9.210

7.11.2005

H=0

.6m

a=0.1m

TE E

H=0

.6m

TE

E

Copper heating pipe

Copper heating pipe (Forward and return flow in the same protective sheath)

Method of laying:

Covering height:Earth-temperature:Conductivity of ground:Conductivity of PUR-foam:Conductivity of CU-pipe: Conductivity of PE-casing:

2 separate UNO pipesundergroundH = 0.60 mTE = 10 °CλE = 1.2 W/mKλPU = 0.0255 W/mKλCU = 0.305 W/mKλPE = 0.43 W/mK

Heat loss during operation: q = U (TB -TE) [W/m] U = Specific heat losses [W/mK]TB = Average operating temperature [°C]TE = Average earth temperature [°C]

Type

CCO DUO

18+18/91

18+18/111

22+22/91

22+22/111

28+28/91

U-Value

[W/mk]

0.151

0.122

0.187

0.141

0.229

70°

9.10

7.32

11.22

8.46

13.74

Heating loss q [W/m] for twin-line pipe DUO average operating temperature TB [°C]

80°

10.62

8.54

13.09

9.87

16.03

90°

12.14

9.76

14.96

11.28

18.32

100°

13.66

10.98

16.83

12.69

20.61

110°

15.18

12.22

18.7

14.11

22.90

120°

16.69

13.42

20.57

15.51

25.19


Connecting socketTee Branch insulation kit

CCO

9.320

7.11.2005

Connecting socket

d2

1 2 3 4

d1

Tee Branch insulation kit

d3

12

3

4

d2

max.490

mm

d1

5

645 mm

1 Copper T-piece, see sheet COO 9.345

2 GFK half-shells3 Insulating material,

see sheet COO 9.3404 Reducer ring5 Special sealing compound

GFK fibreglass-shell tested byFernwärme-Forschungsinstitut

(FFI) of Hannover

d1d27590

111

75x

90

x

111

x

1 Copper fitting, see sheet CCO 9.3452 Insulation material, see sheet CCO 9.3403 Shrinking socket4 Shrinking hose

Ø externald1 d376 - 76 76 - 9191 - 7691 - 91

111 - 111

75xxxxx

Junction, d2

111

x

90xxxxx

CALCOPPER - District heating pipe CCO

3.10.2005

Insulation materialPUR-foam package

9.340

Insulation material for T-piece sets and sockets

PUR - foam package

The required volume of polyurethane foam is supplied in the appropriate foam sizefor the various sockets and T-pieces. The clip (splitting the components) must be re-moved by pulling it away. The two components are mixed together by shaking.

PUR - foam packageBase: CFC-free PUR-foam

Security requirement forthe foam insulation

plastic gloves

eye protection


Soldering instructionsSoldered fittings

CCO

9.345

7.11.2005

Copper fittingsBrugg Pipe Systems recommends fittings from the Georg Fischer company (+GF+).All joints and T-pieces, etc. can be obtained in all dimensions from 18 to 35 mm.

Caution!Copper fittings with notches are available in the trade; under no circumstances must these be used!

Type BRL 8.50.34

Euro standardisation pr EN 1044

ISO 3677 B Cu Ag Zn Sn 630-730

Composition Ag Zn Sn Si CuGuideline analysis (%) 34 27 3 0.1-02 36

Application Capillary brazing joints brazing forsteels, copper and copper alloys,nickel and nickel alloys. For brazingpoints with operating temperaturesup to 200 °C. Suitable for Cu pipeinstallation to DVGW working sheetGW 2.

Flux Rods thinly covered with flux

Technical information Working temperature 710 °CMelting range 630-730 °CTensile strength St 37 360 N/mm2

St 50 480 N/mm2

Specific gravity 9.0 g/cm3

Elongation > 12%Electrical conductivity 14

Sm/mm2

Heat sources Acetylene/oxygen mixtureThe oxy-fuel gas flame must be setto neutral.

Art-No. 7270 +GF+

Joint, equal

Art-No. 7240 +GF+

Joint, reduced

Art-No. 7271 +GF+

Connection with externalthread

Art-No. 7130 +GF+

T-connection piece, equal,reduced

Brazing instructionsThe special BRUGG brazing must be used to solder the fittings.

Brazing (high argentiferous )


Connection of copperheating pipe to KMR

CCO

9.355

7.11.2005

St-Cu-Fitting

Flex-T-Socket

Cu

70

St-Cu-Fitting

L1

L2

45°

Connecting jointOuter ø in mm

St x Cu17.2 x 1526.9 x 1826.9 x 2233.7 x 2842.4 x 35

L 1mm

215215215215225

L 2mm

185185 185 185 145

The branche line of the Copper Hea-ting pipe to KMR (plastic sheath pipe)would be connected using prefacto-red St-Cu-fitting. The fitting would bewelded on his steel end and would beconnected with copper fitting on hiscopper end.

The branche line would be insulated by the shrinkingsocket, double internal and external sealed

7691

111

xxx

xxx

110 -140 mm

90mm

160 -200 mm

225 -250 mm

280 -315 mm

xxx

xxx

xxx

Branche lineOuter ø mm

KMR-PipeOuter ø mm


End cap

CCO

9.365

7.11.2005

Shrinkdown end cap

The cap is shrunk onto the pipe end with a gas flame or hairdryer. Suitable formoist rooms and introduction into shafts.

Data table

Copper heating pipe

Type CCO15/7618/7622/7628/7622/9128/9135/91

18+18/9118+18/11122+22/9122+22/11128+28/91

Shrinkdown end cap

DHEC 2000DHEC 2000DHEC 2000DHEC 2000DHEC 2000DHEC 2000DHEC 2100DHEC 3200DHEC 3200

DHEC 3250 P604DHEC 3250 P604DHEC 3250 P604


Wall sealing ringPipe warning tape

CCO

9.370

7.11.2005

50

DDa

ACHTUNG!

FERNWÄRM

ELEITUNG

Wall sealing ring

Pipe warning tape

To be laid in the ground

Standard roll length: 250 m

Laying depth: see sheet CCO 9.500

Type CCO

15/7618/7622/7622/9128/7628/9135/91

18+18/9118+18/11122+22/9122+22/11128+28/91

Copper heating pipe

Da

118118118133118133133133153133153133

Wall sealing ringOuter pipe casing D

7878789378939393

11393

11393


Trench dimensions

CCO

9.500

7.11.2005

Trench profile, 2 copper local heating pipes

.

..

.

.

.

.

... .

.

.

.

.

.. .

.

.

.

.. ..

...

..

..

.

.

.

.

.... ..

.

.

..

.. .

.

.

.

....

..

.

...

......

... ... ..

.... .. .

.. .. .

10 1010 D D

60

B

21 3

D10

10

30

T

Trench profile, 4 copper local heating pipes (loop-in method)

.

. .. .

..

. ..

..

.

. . .

.

.

..

.

...

..

.

.

..

. ..

.

.

.

...

. .. ..

.

.

.

.. .

..

.

. ..

..

..

.. .

.

.

.. .

.

. .

.

.

..

.

..

.. .. .

.

.

.

30

10 10

D10

60

10

B

30

T

D

D D

21 3

DDD

D

(4xD + 2x10)

60

10

B

T

10 D 10

21 3

DD D

10

. ..

.

.

.

.

.. . .

.

.

...

.

..

.

.

.

...

.

.

.. . .

..

21 3

D10

10 D

60

10

B

30

10

T

UNO

Pipe casingØ D cm

7691

Minimumradius of

curvature, m0.70.8

DepthT

cm7879

WidthB

cm4548

DUO

Pipe casingØ D cm

91111

Minimumradius of

curvature, m0.80.9

DepthT

cm8085

WidthB

cm3030

all dimensions in cm

1 Pipe warning tape2 Excavated material3 Washed sand, grain size 0-3/4 mm

When digging the pipe trench, make sure that the pipes lie in a sand bed (grain size: 0-8mm) of at least 10 cm, and that there is coverage of the same thickness above.

SLW 30 = 300 kN total load to DIN 1072;for exposure to higher operating loads(such as SLW 60), a load-distributingsuperstructure to RStO75 is required.

With no traffic load, the minimum trenchdepth T can be reduced by 20 cm.

Laying depth:maximum laying depth: 2.6 mOur approval is required before laying atgreater depths.


Entry into buildings

CCO

9.505

7.11.2005

Entry into buildings

Wall opening

CCO

End cap; see sheet CCO 9.365

80 mm

Pipe; see sheet CCO 9.115

Wall sealing ring; see sheet CCO 9.370

Copper connection piece;see sheet CCO 9.345 ca 80 mm

60 mm

Fixpoint

Var. 1 Var. 2

D

80 80100D D

L

H

Outer casingØ D mm

7691

L minmm

450500

Hmm

250250

Breakthrough bored

A

D1

30

Outer casingØ D mm

7691

111

D1 minmm

180200220

Amm

210230250

Due to the expansion of the CALCOPPER piping fixpoints must be installed

Documents

CALCOPPER - District heating pipe CCO 9.0 Table of contents · 2020-05-20 · CALCOPPER - District heating pipe System Description General CCO 9.100 7.11.2005 1. General CALCOPPER