FlexLock. Couplings & Flange Adaptors. Unrivalled. For Ductile Iron or Steel Pipes
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1 Unrivalled FlexLock Couplings & Flange Adaptors For Ductile Iron or Steel Pipes pipe CONNECTIONS, repair & flow control products for the utilities industry
2 FlexLock Overview Unique, Patented & Self Anchoring Joints for Ductile Iron or Steel Pipes The FlexLock system provides a self-anchoring method of joining ductile iron or steel pipes and offers a cost effective, quick and simple alternative to traditional anchoring systems such as site welding, harnessing or thrust blocks. Above Ground or Buried Application FlexLock is a unique pipe jointing system that is fully end load bearing. Gaskets have embedded stainless steel teeth that grip the outer surface of the pipe, yet still allow for angular deflection of pipes in service. This prevents pipes from separating under pressure loads, making FlexLock ideal for above ground and buried applications, soft ground conditions or temporary pipe work. End Load Restraint Available as flange adaptors and couplings, FlexLock works on the same compression joint principle as standard Viking Johnson products but as the compression bolts are tightened, the stainless steel teeth grip around the outside diameter of the pipe, providing a fully end load restraint joint. Internal pressure in the pipe causes the assembly to lock firmly providing a leak proof joint. The FlexLock range consists of couplings and flange adaptors with nominal sizes from DN50 (2 ) up to DN300 (12 ) and are suitable for use on cold potable water pipelines with a maximum operating temperature of 40 C. FlexLock Flange Adaptors Pipe Materials FlexLock Coupling 2 Viking Johnson FlexLock Telephone: +44 (0)
3 FlexLock Couplings & Flange Adaptors Product Design Benefits Suitable for Water & Gas A FlexLock is supplied as standard with EPDM gaskets for water applications to EN 681. However it is also available with Nitrile gaskets to EN 682 suitable for natural gas, petroleum products, low aromatic fuels, sewage and drainage. Excellent Corrosion Protection Metal components are coated with Rilsan Nylon 11 which is WRAS approved for use with potable water. The nuts and bolts are Sheraplex coated to WIS , offering long term protection against corrosion, impact and abrasion to ensure continued reliable performance. Unique Load Bearing Teeth Couplings & Flange Adaptors Dedicated Customer Benefits As the compression bolts are tightened, unique load bearing stainless steel teeth, that are moulded into the gasket grip around the outside diameter of the pipe, providing a fully end load restraint joint. FlexLock permits angular deflection between pipes, allowing for normal pipeline movement such as ground settlement. Long radius curves can also be accommodated, reducing the need for special fittings. FlexLock couplings allow for a total angular deflection of ±6 (±3 for flange adaptors). Cost effective FlexLock can provide significant cost savings compared to non-locking couplings with a harnessing system. Restrains pressure thrusts without thrust blocks at bends. Working Pressure of 16bar on water up to and including DN200 and 10bar for DN250 & DN300. For gas applications a working pressure of 6 bar can be achieved. The ability to provide angular deflection in ANY plane is a particular advantage - a harness assembly can provide angular deflection only in ONE plane. Convert cut lengths of pipe into flanged pipes - allows use of pipe offcuts. Viking Johnson FlexLock 3
4 FlexLock Unique Sealing System How FlexLock Works FlexLock flange adaptors and couplings work on the same compression joint principle as standard Viking Johnson products. As the compression bolts are tightened, unique load bearing stainless steel teeth (moulded into the gasket) grip around the outside diameter of the pipe, providing a fully end load resistant joint. Internal pressure in the pipe causes the assembly to lock even more firmly. Step 1 Step 2 Step 3 Tightening the bolts compresses the gaskets between the end rings and the centre sleeve, pressing the gasket on to the pipe and driving the edges of the steel teeth to grip on the pipe surface. Progressive tightening of the bolts drive the teeth into their correct locked position. When the bolts are tightened to their correct torque, the FlexLock coupling or flange adaptor is securely locked in position providing a leak proof joint whilst at the same time allowing the joint to compensate for angular movement within the pipeline. 4 Viking Johnson FlexLock Telephone: +44 (0)
5 United Kingdom - Chesterfield Yorkshire Water FlexLock Flange Adaptors - DN250 Couplings & Flange Adaptors Dedicated Project FlexLock installed on ductile iron pipe. Client Yorkshire Water Contractor Black & Veatch Viking Johnson FlexLock 5
6 FlexLock Coupling Specifications L 1) Sleeve 2) End Ring 3) Gasket 4) Gripper Teeth 5) Bolt S A FlexLock Couplings Setting Gap Maximum Gap Pipe Nom Pipe OD (mm) Pipe Material Bolt Size No.-Dia x Length Overall Length (L) End Ring OD (A) Sleeve Length x Thickness (mm) (S) Setting Gap Min Max Working Pressure (bar) Gasket Mould Coupling Weight (kg) DN50/2" 60.3 steel 2-M12 x x DN65/2.5" 76.1/77 steel 2-M12 x x DN80/3" 88.9 steel 4-M12 x x DN80/3" 98.0 ductile iron 4-M12 x x DN100/4" steel 4-M12 x x DN100/4" 118 ductile iron 4-M12 x x DN150/6" steel 6-M12 x x DN150/6" steel 6-M12 x x DN150/6" 170 ductile iron 6-M12 x x DN200/8" steel 8-M12 x x DN200/8" 222 ductile iron 6-M16 x x DN250/10" steel 12-M16 x x DN250/10" 274 ductile iron 12-M16 x x DN300/12" steel 12-M16 x x / DN300/12" 326 ductile iron 12-M16 x x / Materials & Relevant Standards FlexLock bolt torques: M12 = 55-65Nm M16 = Nm Centre Sleeve/End Rings SG. Iron to BS 1563:1997:Symbol EN-GJS or Rolled Steel to: BS EN 10025:2004:Grade S275. Coupling Body Ductile Iron to BS EN 1563 EN-GJS or Mild Steel to: BS EN 10025:2004:Grade S275. Bolts/Nuts/Washers Bolts - Cold Forged Steel Fasteners to: BS EN ISO898-1: 2001 Property Class 8.8 Nuts - Steel BS EN :1994 Property Class 8 Washers - BS 4320 Form B Stainless Steel BS 1449:PT2:1983 Grade 304 S15 Coatings Body, Centre Sleeve, End Rings are coated in Rilsan Nylon 11 to WIS Part 1. Bolts, studs and nuts are Sheraplex coated to WIS Gaskets EPDM compound Grade E to BS EN WRAS listed. Suitable for: water, sewage, many strong and oxidising chemicals and food applications. Nitrile compound Grade G to BS EN Suitable for: natural gas, petroleum products, low aromatic fuels, compressed air, sewage and drainage. Stainless Steel teeth in gaskets BS 3146:1975:Part 2 Grade ANC2. Approvals/Standards Designed and manufactured under quality management systems to BS EN ISO They have been tested in accordance with the requirements of WRc Water Bye-laws Scheme and conform to the American Water Works Associations standard AWWA/ANSI C.219 for bolted couplings. Note: For coated steel pipe the maximum permitted coating thickness is 500μ DFT. This is to ensure the stainless steel teeth properly grip onto the pipe surface to mobilize the end load capability of the products. Due to the surface characteristics of stainless steel pipe, FlexLock grippers are unable to achieve a guaranteed grip on the pipe surface. FlexLock is suitable for use on cold potable water pipelines and has a maximum operating temperature of 40 C. Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice. 6 Viking Johnson FlexLock Telephone: +44 (0)
7 FlexLock Flange Adaptor Specifications 1) Flange Adaptor 2) End Ring 3) Gasket 4) Gripper Teeth 5) Stud L S Setting Gap Maximum Gap 4 F FlexLock Flange Adaptors Pipe Nom Pipe OD (mm) Pipe Material Bolt Size No.-Dia x Length Flange OD (A) Materials & Relevant Standards Overall Length (L) Flange Thickness (mm) (F) Sleeve Length (mm) (S) Flange Nominal Drilling BS EN Working Pressure (bar) Setting Gap DN50/2" 60.3 steel 2-M12 x PN10/ DN65/2.5" 76.1 steel 2-M12 x /65 PN10/ DN80/3" 88.9 steel 4-M12 x PN10/16 90 PN DN80/3" 98 ductile iron 4-M12 x PN10/16 90 PN DN100/4" steel 4-M12 x PN10/ PN DN100/4" 118 ductile iron 4-M12 x PN10/ DN150/6" steel 8-M12 x PN10/16 6 E 6 ANSI DN150/6" steel 8-M12 x PN10/ DN150/6" 170 ductile iron 8-M12 x PN10/ DN200/8" steel 8-M12 x PN DN200/8" steel 8-M12 x PN DN200/8" 222 ductile iron 6-M16 x PN DN200/8" 222 ductile iron 8-M16 x PN10 8 E DN250/10" steel 12-M16 x PN10/16* DN250/10" 274 ductile iron 12-M16 x PN10/16* DN300/12" steel 12-M16 x PN10/16* / DN300/12" 326 ductile iron 12-M16 x PN10/16* / A Min Max Gasket Mould FA Weight (kg) FlexLock bolt torques: M12 = 55-65Nm M16 = Nm * Working pressure rating is less than flange rating. Couplings & Flange Adaptors Dedicated Centre Sleeve/End Rings SG. Iron to BS 1563:1997:Symbol EN-GJS or Rolled Steel to: BS EN 10025:2004:Grade S275. Flange Adaptor Body Ductile Iron to BS EN 1563 EN-GJS or Mild Steel to: BS EN 10025:2004:Grade S275. Studs - Bolts/Nuts/Washers Studs/Bolts - Cold Forged Steel Fasteners to: BS EN ISO898-1: 2001 Property Class 8.8 Nuts - Steel BS EN :1994 Property Class 8 Washers - BS 4320 Form B Stainless Steel BS 1449:PT2:1983 Grade 304 S15 Coating Body, Centre Sleeve, End Rings are coated in Rilsan Nylon 11 to WIS Part 1. Bolts, studs and nuts are Sheraplex coated to WIS Gaskets EPDM compound Grade E to BS EN WRAS listed. Suitable for: water, sewage, many strong and oxidising chemicals and food applications. Nitrile compound Grade G to BS EN Suitable for: natural gas, petroleum products, low aromatic fuels, compressed air, sewage and drainage. Stainless Steel teeth in gaskets BS 3146:1975:Part 2 Grade ANC2. Approvals/Standards Designed and manufactured under quality management systems to BS EN ISO They have been tested in accordance with the requirements of WRc Water Bye-laws Scheme and conform to the American Water Works Associations standard AWWA/ANSI C.219 for bolted couplings. Note: For coated steel pipe the maximum permitted coating thickness is 500μ DFT. This is to ensure the stainless steel teeth properly grip onto the pipe surface to mobilize the end load capability of the products. Due to the surface characteristics of stainless steel pipe, FlexLock grippers are unable to achieve a guaranteed grip on the pipe surface. FlexLock is suitable for use on cold potable water pipelines and has a maximum operating temperature of 40 C. Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice. Viking Johnson FlexLock 7
8 United Kingdom - Liverpool West East Link Main FlexLock - DN150 & Large Diameter - DN800 Project West East link transmission main. The 53km pipeline runs from Prescot near Liverpool to Bury, near Manchester. Client United Utilities Contractor Murphys 8 Viking Johnson FlexLock Telephone: +44 (0)
9 To visit our Video Library go to: WILBURY WAY HITCHIN, HERTFORDSHIRE SG4 0UD. UNITED KINGDOM TELEPHONE: +44 (0) fax: +44 (0) ISO EMS ISO 9001 FM Visit to order your copy of the New Technical Paper 410. Designed and manufactured under quality management systems in accordance with BS EN ISO Environmental Management System accredited to ISO For full terms and conditions, please visit our website. Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice. DR6433_09_2012
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