Download - 4-Raupex Pipes 0509
ConstructionAutomotive
Industry
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RAUPEX® PIPES: PEXaPROVEN PERFORMANCE
© REHAU 27-Apr-09 - Page 2
RAUPEX PIPES
- What is PEX?- What is PEXa?- RAUPEX Non-Barrier and
RAUPEX O2 Barrier pipes- RAUPEX UV Shield pipes- RAUPEX capabilities and limits- Markings and certifications- PEXa extrusion process- PEXa: The Green Choice
OUTLINE
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“RAUPEX” PIPES
- RAUPEX Non-Barrier, RAUPEX O2 Barrier, RAUPEX UV Shield- Similar pipes, same pressure ratings, special capabilities- RAUPEX O2 Barrier has special coating to block oxygen (O2) diffusion- RAUPEX UV Shield has special coating to block sunlight
REHAU’s TRADENAME FOR PEXa CROSS-LINKED (X) POLYETHYLENE
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POLYETHYLENE CROSS-LINKED (X), OR P-E-X
- “Poly Ethylene” means “many ethylene molecules”- Ethylene gas is the building block for
polyethylene (PE)- Polyethylene is used for thousands of engineering
applications, construction products and household goods
- Cold water pipes, gas pipes, milk jugs, auto parts, toys, etc.
- PE is not suitable for high-temperature applications- Susceptible to “creep”- Pressure resistance declines over time
- Polyethylene is the building block for PEX
PolyEthylene Molecule
Ethylene Hydro-carbon
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CROSS-LINKED POLYETHYLENE
- PEX is Poly Ethylene that has been chemically or physically modified – cross-linked (X) -to cause the molecules to link together, permanently
- Once PE is cross-linked into PEX, it becomes a thermo-set plastic, meaning that it cannot be melted and reshaped
- Compared to standard PE pipes, PEX has desirable high temperature strength, reduced sensitivity to notching, improved chemical resistance, and high flexibility
- There are 3 commercial processes or methods:- PEXa: High-pressure peroxide (“Engel”) – PEXb: Silane (“moisture cure”) – PEXc: Radiation (“electron beam” or “nuclear”)
- PEXa was pioneered by REHAU
ENHANCED POLYETHYLENE
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REHAU PEXa
History: - Dr. Thomas Engel, German Inventor
- Originally known as “Engel Method”- REHAU licensed the patent for the special
PEXa process in 1967- Started development work in 1968- Began series production in 1972 for PEXa
radiant heating pipes- Now known as “High-pressure peroxide”
cross-linking, or simply, PEXa
“CROSS-LINKED (X) POLYETHYLENE”
Signatures from original contract
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REHAU PEXa
REHAU process: PEXa - Cross-linking takes place in special
extruders designed for high pressure- Typical result is 85% cross-
linking, which is the highestavailable
- REHAU is a worldwide leader in PEXa technology
“CROSS-LINKED (X) POLYETHYLENE”
PEXa “molecule”
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RAUPEX PIPES
- RAUPEX Non-Barrier (Natural Opaque) - Solid wall of PEXa- Oxygen can pass through the pipe
wall (diffuse) and be absorbed into the heating system water
- This may cause corrosion of iron or steel components
- All RAUPEX pipes have the same temperature and pressure capabilities
NON-BARRIER: THE ORIGINAL PIPE
PEXa “molecule”
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RAUPEX PIPES
- RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier
is the outer layer, held on by special adhesive (red)
- Prevents oxygen diffusion through the pipe wall
- Meets requirements of DIN 4726, German standard for oxygen diffusion protection
- All RAUPEX pipes have the same temperature and pressure capabilities
Adhesive (Red)RAUPEX
EVAL O2 Barrier
O2 BARRIER: THE “HEATING” PIPE
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RAUPEX PIPES
- RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier
is the outer layer, held on by special adhesive (red)
- Prevents oxygen diffusion through the pipe wall
- Protects iron and steel (ferrous) components from corrosion caused by oxygen in the water
- All RAUPEX pipes have the same temperature and pressure capabilities
O2 BARRIER: THE “HEATING” PIPE
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RAUPEX PIPES
- RAUPEX UV Shield- (Red, White, Blue)- Colored HDPE shield is the
outer layer- Superior UV protection- Plumbing and non-ferrous
heating applications - 1/2”, 3/4” and 1”, coils, straight
lengths - No oxygen barrier
- All RAUPEX pipes have the same temperature and pressure capabilities
UV SHIELD: SUPERIOR UV PROTECTION
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RAUPEX PIPE LABELS1/2” RAUPEX NON-BARRIER1/2” RAUPEX O2 BARRIER
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RAUPEX PIPE LABELS1/2” RAUPEX UV SHIELD BLUE1/2” RAUPEX UV SHIELD RED
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RAUPEX PIPE CAPABILITIES
Flexibility- Bending radius of 5 times the pipe OD; the tightest of all PEX pipes- Pipes are less likely to kink when bending quickly or too tightly- Flexible to below -100°F; will not become brittle or break at cold temperatures
Freeze resistance- With room to expand evenly along its length, RAUPEX pipe will expand when frozen and
not break; pipe will return when thawed- This helps a pipe installed in a wall, but Not when inside a floor- Pipes inside a concrete floor are likely to break if allowed to freeze
Kink Resistance- PEXa resists kinking, even well below freezing temperatures- If kinked, PEXa can be field-repaired without cutting
- See instructions- Be sure to let pipe cool before moving it or applying any stress
CAPABILITIES AND LIMITSFLEXIBILITY, FREEZE RESISTANCE, KINK RESISTANCE
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If RAUPEX pipe becomes kinked… …it may be heated to 265°F (130°C) with hot air to remove the kink.
Non-Barrier pipe turns clear when fully Stop when the kink is gone!heated; coated pipes simply re-round Do not overheat the pipe!
RAUPEX PIPE CAPABILITIESCAPABILITIES AND LIMITSTHERMAL MEMORY: ONLY PEXa ALLOWS THIS!
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RAUPEX PIPE CAPABILITIES – THERMAL MEMORY
Do not use a torch and do not overheat the pipe!
CAPABILITIES AND LIMITSNEVER USE A TORCH
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RAUPEX PIPE CAPABILITIES
RAUGEO PEXa pipes are made according to national standards which establish the capabilities and application limits:
- Pipes are CTS (copper tube size), SDR9, with tight tolerances on dimensions
- Pipes have long-term pressure ratings* of:- 160 psi @ 73.4°F, 130 psi @ 120°F, 100 psi @ 180°F, 80 psi @ 200°F- These certifications are based on a 50-year extrapolation according to D 2837- Temperature/pressure ratings are marked on the pipes - Pipes will withstand short-term exposure over 230°F
- Pipes have minimum quick-burst capability (short-term) per ASTM F 876:- 475 psi @ at 73.4°F, 210 psi @ 180°F, 180 psi @ 200°F
CAPABILITIES AND LIMITSTEMPERATURE / PRESSURE CAPABILITY
*Temperature/Pressure ratings are based on an extrapolated time-to-failure prediction as defined in ASTM D 2837,with 2:1 Safety Factor on pressure
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RAUPEX PIPE CAPABILITIES
- RAUPEX Coefficient of longitudinal thermal expansion:9.3 x 10-4 in/ft x °F (0.14 mm/m x °C)
- Rule of thumb:1 inch of expansion/contraction per 10°F temperature change per 100 ft. length
Example:- 100 foot length of pipe heated from 70°F to 100°F - Thermal expansion = almost 3 inches for an unrestrained pipe
CAPABILITIES AND LIMITSTHERMAL EXPANSION
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RAUPEX PIPE CAPABILITIES
Chemical resistance (see REHAU TB120R2)- RAUPEX pipes are resistant to glycols, latex paints, silicone, urethane foam, most acids
and bases- RAUPEX Non-Barrier pipes are sensitive to certain adhesives at elevated temperatures- Do not apply adhesive tape to RAUPEX Non-Barrier pipes- If in doubt, check with REHAU
Chlorine and Chloramines potable water disinfectants (see REHAU TB135R2)- RAUPEX meets the strict requirements of ASTM F 876 and ASTM F 2023 for chlorine
resistance; pipe is tested also in accordance with NSF P171 - RAUPEX is chlorine resistant- Tested with free chlorine (Cl2) at 4.0 ppm, pH 6.8, 80 psi, 140°F - Chloramines (another water disinfectant) are not as aggressive as free chlorine
CAPABILITIES AND LIMITSENVIRONMENTAL RESISTANCE
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RAUPEX PIPE CAPABILITIES
UV Resistance (see REHAU TB218)- RAUPEX pipes are tested in the desert
near Phoenix, AZ for natural exposure to prove the capabilities, following ASTM F 2657 test procedure
- Then the pipes are subjected to the chlorine resistance test and must show retention of chlorine resistance
Results:- RAUPEX Non-Barrier -15 days- RAUPEX O2 Barrier - 30 days- RAUPEX UV Shield White – up to 3 months- RAUPEX UV Shield Red & Blue – up to 1 year
CAPABILITIES AND LIMITSENVIRONMENTAL RESISTANCE
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RAUPEX PIPE CAPABILITIESCAPABILITIES AND LIMITSSEE PRODUCT SUBMITTALS FOR FURTHER DETAILS
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PEX PIPE EXTRUSION
Basic Extrusion Process:1. Polymer compound is blended 2. Melted to temperature3. Compressed in extrusion chamber4. Forced through extrusion die that controls shape and dimensions
PEXa: cross-linking takes place in a special extruder, right at the die
HOW IS PEXa MADE?
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PEX PIPE EXTRUSION
1
34
Hopper (materials fed in)
Heating chamber (melts materials)
Compression chamber
Die (forms the shape)
REHAU PVC extruder: 1948
1
2
3
4
2
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REHAU PEXa EXTRUSION: RAUPEX NON-BARRIER (PEXa)
REHAU - R....
High Density Polyethylene
(HDPE) Heat Stabilizers
ExtruderWater Bath
Ink Jet
Inspection DevicesCoiler
Anti-Oxidants
UV Stabilizers
Liquid Peroxide
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REHAU PEXa EXTRUSION: RAUPEX O2 BARRIER (PEXa)
REHAU - R....
High Density Polyethylene
(HDPE)Heat
Stabilizers
Liquid Peroxide
ExtruderWater Bath
Co-ExtruderEVAL Adhesive
Ink Jet
Inspection Devices
Coiler
Anti-Oxidants
UV Stabilizers
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REHAU PEXa EXTRUSION: RAUPEX UV SHIELD (PEXa)
High Density Polyethylene
(HDPE)
Extruder
Liquid Peroxide
Water BathCoiler
Heat Stabilizers
Ink Jet
Inspection Devices
Anti-Oxidants
UV Stabilizers
Co-ExtruderPE Shield
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PEX EXTRUSION METHODS
REHAU High-pressure peroxide method (PEXa)
- Compounding: HDPE and stabilizers mixed, then liquid peroxide is carefully added- Compound fed into special extruder, melted at high pressure and precise temperature- Cross-linking occurs as the pipe is extruded, consistently throughout the pipe wall
- Degree of cross-linking is closely controlled- Carbon-Carbon bonds are unbreakable- QA inspection devices are in-line- No secondary process
- Typical degree of cross-linking is 80 - 89% (85% target for REHAU)
REHAU PEXa SUMMARY
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PEX EXTRUSION METHODS
Silane method (PEXb)
- HDPE modified with Silane (Silicone) by a custom compounder- Modified compound is mixed with catalyst in the plant and fed into extruder- Partially cross-linked pipe is extruded fast and wound onto large coils- Coils are subjected to steam (sauna) or hot water to cause cross-linking over time- Pipes may be unwound and rewound onto smaller coils for packaging- Typical degree of cross-linking: 65 - 70%
PEXb METHOD
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PEX EXTRUSION METHODS
E-Beam method (PEXc)
- Non cross-linked HDPE pipe is extruded from a normal extruder- Non-cross-linked pipe is wound onto large coils after cooling- Pipe is uncoiled and passed under an electron beam and dosed with radiation; several
passes are required to get even cross-linking- Pipes are unwound and rewound onto smaller coils for packaging- Typical degree of cross-linking: 65 - 70%.
PEXc METHOD
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SUMMARY OF PEX EXTRUSION METHODS
PEXa - Peroxide: Controlled cross-linking occurs in the extruder - 80-89% cross-linking is typical (REHAU ~ 85%)- Stronger and more flexible
PEXb - Silane: uses secondary moisture-cure process- 65-70% cross-linking is typical
PEXc - E-beam: uses secondary radiation process- 65-70% cross-linking is typical
INDUSTRY SNAPSHOT
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PEXa method
- REHAU- Uponor- Golan (HeatLink)- LK Pex (“Mr. Pex”)- Pex-Cor
PEXb Silane method
- Bow - CB Supplies- Genova Plastics- IPEX- JM Eagle- Viega- Watts Industries/Radiant- Zurn/Qest (formerly US
Brass)
PEXc E-Beam method
- Golan (HeatLink, ComfortPro)
- Hewing (Burnham)- Mercury- NIBCO- Roth - Viega
PEX EXTRUSION METHODSINDUSTRY SNAPSHOT: PEX “MANUFACTURERS”
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ALTERNATIVE METHODS - COMPOSITES
PEX-AL-PEX (PEXb)- Multi-layer pipe with aluminum- Unicore, Weil-McLain, Uponor
PERT-AL-PERT (PERT = polyethylene Raised Temperature)- IPEX “XPA” (replaced “Kitec”)
- Multi-layer pipe with aluminum- Not a PEX; only PERT
‘Rubber Hose’- Watts Radiant ONIX
INDUSTRY SNAPSHOT
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REHAU PEXa AS PART OF SUSTAINABLE DESIGN
- Lower cost to the environment for production- No mining operations for the ore, PE is abundant, created by refining operations- Low energy cost to produce compared with copper- No chlorine is used in production of PEXa
- Reduced heat loss and condensation through pipes- Saves energy, faster delivery of hot water
- Smooth wall, excellent flow characteristics- Reduces pumping costs
- Proven long life and durability- Provides value: Performance vs. environmental cost
PEXa IS GREEN
- Light weight of PEX reduces transportation costs- Light weight also reduces the necessary equipment to install pipes
- Quiet operation - Dampens water hammer, reduces pressure spikes that may harm equipment
- Protects health and safety- Does not add minerals to drinking water or to the public water system
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RAUPEX PIPES
- Higher strength- Greater flexibility- Proven longevity 35+ years- Chlorine resistance - UV resistance- Widest range of sizes and colors- The “Green” choice- Backed by:
- REHAU PEXa Limited Warranty- 35+ years of experience- Stringent quality control- ISO 9001 factories in Europe and USA- National and international certifications- REHAU ‘Know-How’
SUMMARY: PROVEN PERFORMANCE
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Industry
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RAUPEX PIPES: PEXaPROVEN PERFORMANCE