COOLSAFE Pre-Insulated PE Piping System Pipe Fittings Valves Installation
COOLSAFE PE piping system provides a cost effective way for installing insulated piping for a broad range of industries. Pipe and fittings are pre-insulated at the factory, saving additional labor on-site. COOLSAFE pre-insulated piping system installs easily using conventional butt or electrofusion welding methods. Components are molded and insulated to strict tolerances to ensure easy installation and long-term insulation of chilled media. Ideal Applications: Secondary cooling of food production, brewery and winery chilling, cold storage facilities and commercial refrigeration. Features and Benefits Supply Range Thermal conductivity better than 0.026 W/m-K (0.015 Btu-ft/h-ft2-F) @ 25 o C No gluing or dangerous open flames required during installation Easy and fast installation by simultaneous butt fusion or electrofusion UV and corrosion resistant Pipe and Fittings: Valves: Standard sizes up to 250mm (10") Any size possible with minimum order Materials: PP body with PE end connector Type-21 ball valves: 32mm - 110mm (1" - 4") Type-57 butterfly valve: 63mm - 250mm (2" - 10") Short Specifications Material Pipe Production Fitting Production Welding: Butt, electrofusion Pipe: ASTM D3350 cell classification PE346544C or better. Insulation: High density polyurethane foam Resin shall comply with FDA Code of Federal Regulators (CFR), Title 21, Chapter 1: Section 177.1520 determining suitability for contact with foodstuff. Dimensions and tolerances shall exceed ISO 15494 requirement. Dimensions and tolerances shall exceed ISO 15494 requirement. Pressure Rating Joining Components shall be pressure rated in accordance with ASTM D2837 and DIN 8077 for hydrostatic design basis. Components shall be manufactured to standard dimensional ratio (SDR) 17. Based on continuous service life of 50 years at 68 o F (20 o C). SDR17: 150psi (PN10) PN = Nominal pressure in bar. Available methods shall be according to the schedule below DVS 2207-1 Contact Butt: 1" (32mm) through max product size DVS 2207-1 Electrofusion: 1" (32mm) through max product size COOLSAFE pipe and fittings are manufactured by our business partner AGRU of Austria to the most stringent quality and manufacturing standards. Asahi/America s headquarters in Lawrence, MA domestically manufacturers the custom COOLSAFE fittings and valves, and maintains an extensive inventory of finished components. Asahi/America maintains an extensive fleet of welding equipment to support large projects across the Americas. Asahi/America and AGRU have been business partners since 1981 and actively provide unmatched customer service, technical expertise and product quality. 2
Technical Information Pressure Rating Polyethylene is an excellent choice for low temperature applications. Thermoplastics used in chemical systems require additional safety factors when compared to thermoplastics used in water systems. COOLSAFE PE pre-insulated piping system is designed to be used with chilled water applications using a glycol water mix. To account for additional safety, a reduced pressure chart is provided, which is an example application. For further information regarding chemical compatibility or applications with low temperature, please consult Asahi/America, Inc. Water Glycol PE Pressure Pipe PE Jacket PUR Insulation 3
Installation Pipe and fittings are supplied with extended carrier pipe to allow for easy alignment. Tip: Alignment of internal pipe shall not be of more than 10% off wall thickness Insulation should not be planed. Ensure 1/4-1/2 space for weld bead to form. Remove insulation from cut pipe Follow welding parameters for COOLSAFE. Removal of insulation is necessary prior to welding cut pipe. Asahi s mandrel plugs the ID and uses a blade to remove the insulation. Make sure weld surface is clean prior to welding. Design COOLSAFE provides unlimited options for design, including machined reducers to quickly reduce from large to small diameters or inline Dogbones with threaded connections, valves or other instrumentation connections. Please consult Asahi/America with your special connection requirements. Loop design with machined reducer to drop multiple sizes quickly. Dogbone with union and metal threaded end. 4
Polyethylene Welding Parameters carrier pipe diameter nominal [inch] pipe diameter ID x OD [mm] pipe wall (s) [mm] SDR (Carrier and Jacket) bead-up force* circular bead min. [mm] heatup time [s] max. changeover time [s] time to reach welding pressure [s] welding force* [lbs] cooldown time [min] Manual Machines lbs 1 32 x 90 2.9 x 5.4 11 x 17 56 1 50 5 5 56 8 2 63 x 125 3.8 x 3.9 17 x 33 72 1 50 5 5 72 8 3 90 x 160 5.4 x 4.9 17 x 33 125 1 55 5 5 125 8 4 110 x 200 6.6 x 6.2 17 x 33 193 1 65 6 6 193 9 Field 6 Hydraulic W4400 bar 2 63 x 125 3.8 x 3.9 17 x 33 13 1 50 5 5 13 8 3 90 x 160 5.4 x 4.9 17 x 33 23 1 55 5 5 23 8 Field 12 W4900/ Field 14 W4911-Hydraulic 3 90 x 160 5.4 x 4.9 17 x 33 11 1 55 5 5 11 8 4 110 x 200 6.6 x 6.2 17 x 33 15 1 65 6 6 15 9 6 160 x 280 9.5 x 8.6 17 x 33 30 1.5 95 7 7 30 13 8 200 x 315 11.9 x 9.7 17 x 33 42 1.5 120 7 7 42 16 10 250 x 355 14.8 x 10.9 17 x 33 58 1.5 150 8 8 58 20 Hydraulic Shop 12/ 14 W4001/W4002 3 90 x 160 5.4 x 4.9 17 x 33 25 1 55 5 5 25 8 4 110 x 200 6.6 x 6.2 17 x 33 40 1 65 6 6 40 9 6 160 x 280 9.5 x 8.6 17 x 33 78 1.5 95 7 7 78 13 8 200 x 315 11.9 x 9.7 17 x 33 107 1.5 120 7 7 107 16 10 250 x 355 14.8 x 10.9 17 x 33 150 1.5 150 8 8 150 20 Welding Temperature PE 420-446 o F (215-230 o C) *The drag force of the pipe must be added to the welding pressure indicated above. 5
Technical Information COOLSAFE Properties Size Weight / Ft (lb) Support Spacing (ft) ft2 -F-hr/btu R-Value (m2 -K/W) 1 1.09 5.1 38.2 6.71 2 2.14 5.7 26.1 4.58 3 3.61 6.7 22.5 3.95 4 5.61 7.2 21.0 3.68 6 11.07 9.0 16.6 2.91 8 14.47 10.0 12.3 2.16 10 18.85 10.8 12.6 2.21 COOLSAFE Velocities and Pressure Drops Flow rate (GPM) 1 2 3 4 6 8 10 V P V P V P V P V P V P V P 5 1.9 0.58 - - - - - - - - - - - - 7 2.7 1.14 - - - - - - - - - - - - 10 3.8 2.33 - - - - - - - - - - - - 15 5.8 5.23 1.3 0.12 - - - - - - - - - - 20 7.7 9.30 1.7 0.22 - - - - - - - - - - 40 - - 3.4 0.86 1.7 0.14 1.1 0.05 - - - - - - 60 - - 5.1 1.94 2.5 0.33 1.7 0.12 - - - - - - 80 - - 6.8 3.45 3.3 0.58 2.2 0.21 1.1 0.03 - - - - 100 - - 8.5 5.39 4.2 0.91 2.8 0.33 1.3 0.05 - - - - 150 - - - - 6.3 2.04 4.2 0.75 2.0 0.11 1.3 0.04 - - 200 - - - - 8.4 3.62 5.6 1.33 2.6 0.20 1.7 0.07 1.1 0.02 300 - - - - - - 8.4 2.99 4.0 0.46 2.5 0.15 1.6 0.05 400 - - - - - - - - 5.3 0.82 3.4 0.27 2.2 0.09 500 - - - - - - - - 6.6 1.28 4.2 0.42 2.7 0.14 600 - - - - - - - - 7.9 1.84 5.1 0.60 3.3 0.20 800 - - - - - - - - - - 6.8 1.07 4.3 0.35 1000 - - - - - - - - - - 8.5 1.67 5.4 0.55 1500 - - - - - - - - - - - - 8.1 1.23 V = Velocity of water in ft/s; P = Pressure drop in psi/100 ft of pipe COOLSAFE Equiv. Length Fitting Size 45 90 Tee 1 1.3 2.8 6.0 2 2.5 5.5 12.0 3 3.8 8.0 17.0 4 5.0 11.0 21.0 6 7.5 16.0 34.0 8 10.0 20.0 44.0 10 15.0 25.0 55.0 Length in feet 6
Technical Information 100 COOLSAFE Coolsafe Pressure Loss Pressure Loss (psi/100ft) 10 1 0.1 1" 2" 3" 4" 6" 8" 10" 0.01 1 10 100 1000 Flow Rate (GPM) Velocity (ft/s) 10 9 8 7 6 5 4 3 2 1 COOLSAFE Coolsafe Velocity 1" 2" 3" 4" 6" 8" 10" 0 1 10 100 1000 Flow Rate (GPM) 7
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