TECHNICAL SPECIFICATION

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1 THOMAS - G-FLEX GFLEX TECH SPEC CONNECTING INNOVATION JOHANNESBURG TEL: CAPE TOWN TEL: POLOKWANE TEL: DESIGNER, MANUFACTURER AND DISTRIBUTOR OF PIPE CONNECTION, REPAIR AND FLOW CONTROL SOLUTIONS THOMAS

2 G-FLEX FLEXIBLE COUPLING SERIES The Thomas G-FLEX Series of flexible pipe couplings represents the latest in flexible pipe connection technology. G-FLEX products are designed to accommodate smooth pipes of similar outside diameters. The couplings incorporate a self-energizing seal that ensures a watertight seal on rigid and flexible pipes. The coupling is most notably suitable for all pipes including Glass Reinforced Polyester (GRP) and HDPE where competitive products such as Viking Johnson type mechanical couplings are not suitable. USE G-FLEX Couplings are designed for use on air, water and sewer pipelines. The couplings are medium tolerance product and fit all popular standard pipe sizes. The couplings are suitable for steel, PVC, ductile iron, asbestos cement, GRP, cast iron and concrete pipes. Suitable for water treatment and distribution, industry, shipbuilding, construction and power stations. AVAILABLE RANGE From DN250mm - DN2500mm. ADVANTAGES OF THE G-FLEX COUPLING ADVANTAGES SIMPLICITY OF INSTALLATION FLEXIBILITY Complete unit. Angular deflections. Ready for use. Axial movements. Low weight. Radial deformations. Only one locking point. Rough surfaces. Quick assembly. Absorbs vibrations. Minimum space required. Economic solution. 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 seal 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 Pg. 1

3 G-FLEX FLEXIBLE COUPLING SERIES The Thomas G-FLEX is available as both a straight coupling and a repair coupling. G-FLEX couplings are available in two forms: 1. G-FLEX INSTALL 2. G-FLEX REPAIR G-FLEX INSTALL G-FLEX INSTALL is a straight coupling used when connecting pipes of a new installation. Or these couplings can be used in pairs to replace a section of damaged pipe. The coupling can not be opened up and wrapped around a pipe. G-FLEX INSTALL couplings are laid in sequence with the pipes which they are used to join. G-FLEX REPAIR G-FLEX REPAIR is a repair coupling used to repair holes in damaged pipes. The coupling can be split in half and wrapped around a damaged pipe on site. There is no requirement to cut the pipe. The coupling is simply split in half, the rubber seal is then wrapped around the pipe over the damaged area. The two halves of the coupling are then assembled around the rubber seal holding it in place. G-FLEX REPAIR couplings can be used to effect high pressure repairs on small and large diameter pipes. Pg. 2

4 PRESSURE RATING Bar = Standard Working Pressure (WP) Test Pressure = 1.5 x WP The table below represents standard product. HIGHER PRESSURE RATINGS ARE AVAILABLE ON REQUEST. SPECIAL STEELS ARE AVAILABLE ON REQUEST FOR HIGHER PRESSURE RATINGS NOMINAL WIDTH 200mm PIPE OD MS300WA SS304 MIN. MAX. CASING CASING mm mm Bar Bar MAXIMUM WORKING TOLERANCE When joining pipes of the same O.D., G-FLEX Coupling maximum admissible tolerances are as follows: WORKING TOLERANCE COUPLING OUTSIDE MAXIMUM WIDTH DIAMETER DIFFERENCE (mm) (mm) (mm) > Pg. 3

5 ANGULAR DEFLECTION The maximum allowable angular deflection between two pipes joined by a Thomas G-FLEX Coupling. G-FLEX Couplings allow certain amount of angular deflection between pipe ends. The maximum admissible tolerance permitted by G-FLEX couplings depends on the O.D. of pipe joined (see table below). ANGULAR DEFLECTION Outside Maximum Diameter Deflection * (mm) ß < > * Contact us for greater angles 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. It is important to note the following regarding the pipe end upon which a coupling gasket seals : => 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. It must be noted that the preparation of pipe ends is to ensure the coupling seal performs optimally on the pipe end. 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. The list can go on and on taking note of temperature, incline etc. 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. PIPE END PREPARATION PIPE DN LENGTH MIN. mm mm DN250 - DN 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 self-energising gasket allows for a maximum of 15 mm of pipe movement per coupling. EXPANSION & CONTRACTION CLAMP WIDTH PIPE MOVEMENT mm mm TORQUE AND ALLEN KEY SIZES G-FLEX s with an M12 Cap Screw - use a 10mm Allen Key - Torque 30-40Nm. G-FLEX s with an M16 Cap Screw - use a 14mm Allen Key - Torque 70-80Nm. Pg. 4

6 MISALIGNMENT Misaligned pipes can be joined using the G-FLEX Coupling. MISALIGNMENT OUTSIDE MAXIMUM DIAMETER DIFFERENCE (mm) <300 1% 300 3mm PIPE SETTING GAP G-FLEX Couplings must be installed without exceeding the maximum distance between the pipe ends being joined. PIPE SETTING GAP COUPLING MAXIMUM WIDTH SETTING GAP (mm) (mm) G-FLEX Couplings are not designed to support the pipe or to prevent axial movements. Therefore, the pipe must be properly supported and anchored. Couplings applied on vacuum lines or with vacuum risk require an internal band unless gaps between pipes can be avoided. Please consult us in this situation. MATERIAL OF CONSTRUCTION G-FLEX couplings are manufactured from a variety of materials each exhibiting different performance characteristics as required for different applications. 1. Casing - Stainless Steel (SS) Grade 201 / 304 / 316 or Mild Steel (MS) to SANS 1431 Grade 300WA MS Coating - Fusion Bonded Epoxy to SANS 1217 minimum thickness 250 microns 2. Bolting Bars - Stainless Steel (SS) Grade 304 / 316 or Mild Steel (MS) to SANS 1431 Grade 300WA MS Coating - Fusion Bonded Epoxy to SANS 1217 minimum thickness 250 microns 3. Bolts - Stainless Steel (SS) Grade 304 / 316 or Mild Steel (MS) to BS970 Grade 070M20 MS Bolt coating - Dacromet Galvanised 4. Armour Plate - Stainless Steel (SS) Grade 304 / Rubber - E.P.D.M.Grade E to BS Type W&D or NBR Pg. 5

7 HOW TO SPECIFY A G-FLEX COUPLING The G-FLEX Coupling shall exhibit construction and design characteristics as follows: 1. All rubber joints shall be hot vulcanised. Glued rubber joints are not permitted. 2. The Coupling rubber seal shall be manufactured from Ethylene Propylene Diere Monomer (EPDM) or Nitrile (NBR) - depending on the application. 3. The Coupling shell must be manufactured from a minimum of 3mm thick steel. A thinner material will not withstand the internal pipe pressure requirements. 4. 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. 5. The armour plate shall include a minimum of six raised ribs in the stainless steel critical for the rigidity and strength of the armour plate. 6. The Coupling shell must be manufactured from stainless steel grade 304 or grade 316 unless otherwise specified. 7. Rubber internal profile shall include self-energizing circumferential sealing lips. 8. A maximum number of one vulcanised joint shall be permitted per rubber seal for OD < 1200mm. 9. A maximum number of two vulcanised joints permitted per rubber seal for OD > 1200mm. 10. The bolting method shall be a cap screw and threaded bar configuration. 11. All bolting threads shall be coated with a dry film lubricant of Molybdenum Disulfide. 12. The clamp width shall be a minimum of 200mm for pipe OD > 250mm. HOW TO ORDER A G-FLEX COUPLING Explanation of codes, how to make your own code vs stock items. GFI /E THOMAS PRODUCT GROUP: GFI - INSTALL Coupling GFR - REPAIR Coupling QTY OF BOLT SETS: 1-1 Part Clamp 2-2 Part Clamp PIPE SIZE TO CONNECT: 406mm Outside Diameter Standard or custom sizes RUBBER SEAL MATERIAL: E - EPDM N - NBR (NITRILE) METALLIC SHELL: SS Grade CS FBE Coated MS Gr300WA AISI SS Grade AISI SS Grade 316 Standard products are produced with a SS Gr 304 or 316 shell, EPDM rubber seal, all bolts and lugs are supplied as standard in SS Gr 304. Standard sizes are available for all popular pipe materials. Customers can specify any size or material by simply altering the purchase code as per their requirement. Example, when ordering a complete SS Gr 304 G-Flex Install coupling with Nitrile rubber to join a DN610 STEEL pipe, the code would read as follows: GFI /N Alternative materials for the metallic shell and elastomeric rubber seal are available on request. Pg. 6

8 THOMAS - G-FLEX THOMAS UNIFIT UNIFIT SERIES PIPE AND ADAPTERS BUFFALO SADDLES UNDER PRESSURE DRILLS EASI TEES BUFFALO SERIES UNDER PRESSURE DRILLS & SADDLES LP SPECIALIZED FOR LOW PRESSURE APPLICATIONS ULTRA CLAMP ULTRA CLAMP STAINLESS STEEL REPAIR CLAMPS GFLEX FLEXIBLE FOR GRP & STEEL STAINLESS STEEL FLEXIBLE REPAIR COLLAR POLY GRIP SERIES POLY GRIP SERIES GRIPPER & ADAPTERS V-LOC VALVES SMALL BORE VALVES JUNIOR V-LOC SERIES BALL & GATE VALVES THOMAS STEEL FITTINGS FABRICATED STEEL FITTINGS LP COUPLING LOW PRESSURE COUPLING FOR SWP REPAIR COLLAR BELL & SPIGOT PIPE REPAIR SYSTEM STEEL FITTINGS FABRICATED STEEL FITTINGS TECH SPEC CONNECTING INNOVATION JOHANNESBURG TEL: CAPE TOWN TEL: POLOKWANE TEL: DESIGNER, MANUFACTURER AND DISTRIBUTOR OF PIPE CONNECTION, REPAIR AND FLOW CONTROL SOLUTIONS THOMAS

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