THOMAS. G-Flex Install Couplings. Couplings & Flange Adaptors Non Restrained Products PIPE PRODUCTS. Fully Rubber Lined Flexible Couplings

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1 THOMAS Couplings & Flange Adaptors Non Restrained Products PIPE PRODUCTS G-Flex Install Couplings Fully Rubber Lined Flexible Couplings E1

Project CLIENT Department of Water Affairs

2 COUPLINGS & FLANGE ADAPTORS - NON RESTRAINED VAAL DAM - Gauteng - South Africa DN1400 G-FLEX DN1400 G-FLEX DN1400 G-FLEX PROJECT Vaal River Eastern Sub-System Augmentation Project CLIENT Department of Water Affairs DN1400 G-FLEX PRODUCTS G-Flex Install Couplings DN1000 G-FLEX E2

G-Flex Install Application High performance full Stainless Steel flexible connections for all pipe materials.

Superior Design G-Flex Couplings are manufactured from stainless steel offering superior corrosion protection.

The lip seals are designed to resist the internal pressure in the pipes. As the pressure increases, the lips seals are pressed more tightly against the pipe surface.

3 G-Flex Install Application High performance full Stainless Steel flexible connections for all pipe materials. Flexibility G-Flex Install Couplings are high performance couplings allowing pipe angular deflection, expansion and contraction. Superior Design G-Flex Couplings are manufactured from stainless steel offering superior corrosion protection. The entire internal surface of the coupling is rubber lined, enabling these products to be used for harsh pipeline contents. EPDM, NBR or specialized rubber compounds are available. The couplings have a slim profile and can therefore be used in confined spaces where pipes run parallel in close proximity to one another. G-Flex Couplings utilise a self-energizing rubber seal, the sealing lips of the rubber seal press against the pipe surface and form lip seals. The lip seals are designed to resist the internal pressure in the pipes. As the pressure increases, the lips seals are pressed more tightly against the pipe surface. This makes the G-Flex the best possible means of connecting GRP pipe material that may be compromised by the over tightening of compression type VJ mechanical couplings. Easy to Install By simply positioning two pipes end to end and joining with a G-Flex Coupling, space, weight, time and cost savings are achieved with every installation. G-Flex Couplings have only 2 to 6 tightening bolts allowing the coupling to be installed rapidly. Lower torque ratings are required than mechanical VJ type couplings. The Range G-Flex couplings are available in Stainless Steel from DN15mm - DN3000mm for virtually any pipe material. FBE coated mild steel G-Flex couplings are available from DN350 - DN3000mm Coupling widths up to 310mm are standard. Wider couplings are available on request. Size Range - DN15mm - DN3000mm Industries - Water - Gas - Industrial Pipe Materials - Ductile Iron - Cast Iron - Steel - Stainless Steel - PVC - HDPE - Clay - GRP - Concrete - AC E3

4 Specifications Sealing The G-Flex coupling incorporates a self energising seal. Similar to that used in a PVC bell and spigot pipe. As the pressure rises, the sealing capacity is increased proportionately. The coupling adapts automatically to internal pressure changes ACTIVE SYSTEM PRESSURE SEALING 1 - G-Flex Coupling Casing 2 - G-Flex Self-Energizing Rubber Seal 3 - Pipeline Internal Hydrostatic Pressure Pipe End Preparation Pipe end preparation refers to the distance back from the end of the pipe that must be prepared to enable an effective coupling seal. The pipe surface is to be round, smooth, clean, free of grooves, weld beads, bumps, score marks or other irregularities. In order to maintain specified coupling pressure ratings, pipe end tolerance should be within ± 0.75% of pipe outside diameter. There are limits to the performance of all engineering designs; in the case of flexible couplings there are also limits in terms of the operating range of the product for pipe outside diameter, pressure rating and conveyance fluid chemical composition. With regard to the pipe end preparation it is always good engineering practice to ensure that the pipe is clean, round and free of grooves and weld beads. Working Tolerance The G-Flex coupling has a working tolerance but can NOT be used as a step coupling within that range. From DN80-450mm Working Tolerance = 6mm From DN500 upwards Working Tolerance = 8mm. Angular Deflection G-Flex Couplings allow certain amount of angular deflection between pipe ends. The maximum admissible angular deflection permitted by a G-Flex coupling depends on the pipe O.D being joined. For Pipe O.D. < 1500mm Max. Deflection = 2 For Pipe O.D. > 1500mm Max. Deflection = 1 Pipe End Misalignment It is good engineering practice to align pipes correctly before joining them with a mechanical coupling. G-Flex Couplings can accommodate a small degree of pipe end misalignment. For Pipe O.D < 300mm Maximum misalignment = 1% of pipe O.D. For Pipe O.D. > 300mm Maximum misalignment = 3mm of pipe O.D. Pipe Expansion & Contraction G-Flex Couplings provide a simple solution for problems resulting from thermal expansion and contraction of pipeline components. By means of gasket deformation as apposed to a sliding action over the pipe surface. G-Flex Couplings can accommodate a significant amount of pipe movement. The selfenergising gasket allows for a maximum of 15 mm of pipe movement per coupling. Pipe End Setting Gap G-FLEX Couplings must be installed without exceeding the maximum distance between the pipe ends being joined. For Standard Couplings with coupling widths up to 200mm maximum pipe setting gap = 20mm. Bolt Torque Rating G-FLEX s with an M12 Cap Screw - Torque 30-40Nm. G-FLEX s with an M16 Cap Screw - Torque 70-80Nm. E4

5 Specifications How To Specify a G-Flex Install Coupling The G-Flex Coupling shall exhibit construction and design characteristics as follows: º All rubber joints shall be hot vulcanised. Glued rubber joints are not permitted. º Coupling rubber seal shall be manufactured from Ethylene Propylene Diere Monomer (EPDM) or Nitrile (NBR) - depending on the application. º A maximum number of one vulcanised joint shall be permitted per rubber seal for OD < 1200mm. º A maximum number of two vulcanised joints permitted per rubber seal for OD > 1200mm. º Rubber internal profile shall include self-energizing circumferential sealing lips. º The coupling casing must be manufactured from stainless steel grade 304 or grade 316L unless otherwise specified. º The coupling shall include a stainless steel grade 304 or grade 316 armour plate suitably located to prevent the rubber seal from blowing out beneath the bolting mechanism. º The armour plate shall include a series of raised ribs in the stainless steel critical for the rigidity and strength of the armour plate. º The bolting method shall be a cap screw and threaded bar configuration. º All bolting components shall be manufactured from stainless steel grade 304 or grade 316. º All bolting threads shall be coated with a dry film lubricant of Molybdenum Disulfide. º The clamp width shall be a minimum of 200mm for pipe OD > 250mm. How To Order a G-Flex Install Coupling Explanation of codes, how to make your own code and order accordingly. Customers can specify any size or material by simply altering the purchase code as per their requirement. For example, to order a 310mm wide coupling to join a steel pipe with 406mm Pipe OD, the code would read as follows: GFI1-0406X E. Alternative materials are available on request. GFI x E THOMAS PRODUCT GROUP: GFI - G-Flex Install Coupling NUMBER OF CLAMP PARTS: 1-1 Part 2-2 Parts PIPE DIAMETER TO JOIN: In this example 406mm. Available up to DN3000mm COUPLING WIDTH: In this example 310mm. Available up to 710mm 6 Material Specification Coupling Material Grade must be specified as products are available in: - Stainless Steel Grade Stainless Steel Grade 316L - Mild Steel Fusion Bonded Epoxy Coated Standard material of construction is given below. Casing Stainless Steel Grade 304 / 316L Bolts Stainless Steel Grade 304 / 316 Bolting Bars Stainless Steel Grade 304 / 316 Armour Plate Stainless Steel Grade 304 / 316L Rubber Seal EPDM SANS974 Related ISO4633 Other rubber compounds such as Nitrile (NBR) and Viton are available on request E5

6 Specifications NOM. PIPE PIPE WORKING ORDER STANDARD COUPLING WEIGHT BOLTS BOLT BORE O.D. MATERIAL PRESSURE CODE WIDTH O.D. TORQUE STANDARD WIDTH W D (mm) (mm) (bar) (mm) (mm) (kg) (mm) (Nm) STEEL 20,0 GFI1-0022X E 57,0 37 0,2 2 x M STEEL 20,0 GFI1-0027X E 57,0 46 0,2 2 x M STEEL 20,0 GFI1-0034X E 57,0 51 0,2 2 x M STEEL 20,0 GFI1-0042X E 57,0 62 0,3 2 x M STEEL 20,0 GFI1-0048X E 57,0 66 0,4 2 x M STEEL 18,0 GFI1-0060X E 80,0 81 0,7 2 x M STEEL 18,0 GFI1-0076X E 80, ,8 2 x M STEEL 16,0 GFI1-0089X E 107, ,5 2 x M STEEL 16,0 GFI1-0114X E 107, ,7 2 x M STEEL 14,0 GFI1-0139X E 107, ,6 2 x M STEEL 14,0 GFI1-0165X E 107, ,9 2 x M STEEL 12,0 GFI1-0219X E 155, ,4 2 x M STEEL 12,0 GFI1-0273X E 155, ,9 2 x M GRP 10,0 GFI1-0318X E 155, ,6 2 x M STEEL 10,0 GFI1-0324X E 155, ,7 2 x M NOM. PIPE PIPE WORKING ORDER LONGER COUPLING WEIGHT BOLTS BOLT BORE O.D. MATERIAL PRESSURE CODE WIDTH O.D. TORQUE LONGER WIDTH W D (mm) (mm) (bar) (mm) (mm) (kg) (mm) (Nm) STEEL 20,0 GFI1-0034X E 100,0 51 0,2 2 x M STEEL 20,0 GFI1-0042X E 100,0 62 0,3 2 x M STEEL 20,0 GFI1-0048X E 100,0 66 0,4 2 x M STEEL 18,0 GFI1-0060X E 139,0 81 0,7 2 x M STEEL 18,0 GFI1-0076X E 139, ,8 2 x M STEEL 16,0 GFI1-0089X E 203, ,5 2 x M STEEL 16,0 GFI1-0114X E 203, ,7 2 x M STEEL 14,0 GFI1-0139X E 204, ,6 2 x M STEEL 14,0 GFI1-0165X E 204, ,9 2 x M STEEL 12,0 GFI1-0219X E 255, ,4 2 x M STEEL 12,0 GFI1-0273X E 255, ,9 2 x M GRP 10,0 GFI1-0318X E 255, ,6 2 x M STEEL 10,0 GFI1-0324X E 255, ,7 2 x M E6

7 Specifications NOM. BORE (mm) MILD STEEL FBE ORDER CODE WIDTH (mm) 210 ORDER CODE WIDTH (mm) 210 ORDER CODE WIDTH (mm) STEEL 21,8 GFI1-0356X E GFI1-0356X E GFI1-0356X E 361 VECTUS GRP 21,5 GFI1-0361X E GFI1-0361X E GFI1-0361X E 379 FLOWTITE GRP 20,6 GFI1-0379X E GFI1-0379X E GFI1-0379X E 406 STEEL 19,2 GFI1-0406X E GFI1-0406X E GFI1-0406X E 413 FLOWTITE GRP 18,9 GFI1-0413X E GFI1-0413X E GFI1-0413X E 413 VECTUS GRP 18,9 GFI1-0413X E GFI1-0413X E GFI1-0413X E 457 STEEL 17,2 GFI1-0457X E GFI1-0457X E GFI1-0457X E 464 FLOWTITE GRP 16,9 GFI1-0464X E GFI1-0464X E GFI1-0464X E 464 VECTUS GRP 16,9 GFI1-0464X E GFI1-0464X E GFI1-0464X E 508 STEEL 15,5 GFI1-0508X E GFI1-0508X E GFI1-0508X E 515 FLOWTITE GRP 15,3 GFI1-0515X E GFI1-0515X E GFI1-0515X E 516 VECTUS GRP 15,3 GFI1-0516X E GFI1-0516X E GFI1-0516X E STEEL 14,2 GFI1-0559X E GFI1-0559X E GFI1-0559X E STEEL 13,0 GFI1-0610X E GFI1-0610X E GFI1-0610X E 617 FLOWTITE GRP 12,9 GFI1-0617X E GFI1-0617X E GFI1-0617X E 619 VECTUS GRP 12,8 GFI1-0619X E GFI1-0619X E GFI1-0619X E STEEL 12,1 GFI1-0660X E GFI1-0660X E GFI1-0660X E STEEL 11,2 GFI1-0711X E GFI1-0711X E GFI1-0711X E 719 FLOWTITE GRP 11,1 GFI1-0719X E GFI1-0719X E GFI1-0719X E 721 VECTUS GRP 11,1 GFI1-0721X E GFI1-0721X E GFI1-0721X E STEEL 10,5 GFI2-0762X E GFI2-0762X E GFI2-0762X E STEEL 9,8 GFI2-0813X E GFI2-0813X E GFI2-0813X E 821 FLOWTITE GRP 9,8 GFI2-0821X E GFI2-0821X E GFI2-0821X E 823 VECTUS GRP 9,7 GFI2-0823X E GFI2-0823X E GFI2-0823X E 914 STEEL 8,8 GFI2-0914X E GFI2-0914X E GFI2-0914X E 923 FLOWTITE GRP 8,7 GFI2-0923X E GFI2-0923X E GFI2-0923X E 925 VECTUS GRP 8,7 GFI2-0925X E GFI2-0925X E GFI2-0925X E 1016 STEEL 7,9 GFI2-1016X E GFI2-1016X E GFI2-1016X E 1025 FLOWTITE GRP 7,8 GFI2-1025X E GFI2-1025X E GFI2-1025X E 1028 VECTUS GRP 7,8 GFI2-1028X E GFI2-1028X E GFI2-1028X E 1118 STEEL 7,2 GFI2-1118X E GFI2-1118X E GFI2-1118X E 1127 FLOWTITE GRP 7,1 GFI2-1127X E GFI2-1127X E GFI2-1127X E 1220 STEEL 6,6 GFI2-1219X E GFI2-1219X E GFI2-1219X E 1229 FLOWTITE GRP 6,6 GFI2-1229X E GFI2-1229X E GFI2-1229X E FLOWTITE GRP 6,1 GFI2-1331X E GFI2-1331X E GFI2-1331X E 1400 PIPE O.D. (mm) PIPE MATERIAL WP (bar) SS STEEL 5,7 GFI2-1420X E GFI2-1420X E GFI2-1420X E 1433 FLOWTITE GRP 5,6 GFI2-1433X E GFI2-1433X E GFI2-1433X E STEEL 5,3 GFI3-1520X E GFI3-1520X E GFI3-1520X E STEEL 5,0 GFI3-1620X E GFI3-1620X E GFI3-1620X E STEEL 4,5 GFI3-1820X E GFI3-1820X E GFI3-1820X E STEEL 4,0 GFI3-2020X E GFI3-2020X E GFI3-2020X E STEEL 3,8 GFI3-2120X E GFI3-2120X E GFI3-2120X E STEEL 3,7 GFI3-2220X E GFI3-2220X E GFI3-2220X E STEEL 3,4 GFI3-2420X E GFI3-2420X E GFI3-2420X E STEEL 3,2 GFI3-2520X E GFI3-2520X E GFI3-2520X E E7

8 Dimensions PIPE DN D WIDTH W & MATERIAL (mm) MS300WA SS304L SS316L MS300WA SS304L SS316L mm mm CASING CASING CASING CASING CASING CASING 350 PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD PIPE OD+36 E8

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