TECHNICAL SPECIFICATION

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CONNECTING INNOVATION

TECHNICAL SPECIFICATION

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COUPLINGS

DESIGNER, MANUFACTURER AND DISTRIBUTOR OF PIPE CONNECTION, REPAIR AND FLOW CONTROL SOLUTIONS JOHANNESBURG TEL: +27 11 794 7594

THOMAS

G-FLEX FLEXIBLE COUPLING SERIES

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.

AVAILABLE RANGE

From DN250mm - DN2500mm.

SEALING

1. G-FLEX Coupling Casing

2. G-FLEX Self Energizing Rubber Seal 3. Pipeline Internal Hydrostatic Pressure

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.

Suitable for water treatment and distribution, industry, shipbuilding, construction and power stations.

ADVANTAGES OF THE G-FLEX COUPLING

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.

G-FLEX SERIES

TECHNICAL SPECIFICATION

G

FLEX

COUPLINGS

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.

ADVANTAGES

1 2 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

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

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.

INSTALL

REPAIR

G-FLEX SERIES

TECHNICAL SPECIFICATION

G

FLEX

Bar = Standard Working Pressure (WP) Test Pressure = 1.5 x WP

The table below represents standard product.

HIGHER PRESSURE RATINGS ARE AVAILABLE ON REQUEST.

MAXIMUM WORKING TOLERANCE PRESSURE RATING

When joining pipes of the same O.D., G-FLEX Coupling maximum admissible tolerances are as follows:

MS300WA SS304

MIN. MAX. CASING CASING

mm mm Bar Bar 250 399 29 20 400 499 23 16 500 559 21 14 600 649 18 12 650 699 17 11 700 749 16 11 750 799 15 10 800 849 14 9 850 899 13 9 900 949 12 8 950 999 12 8 1000 1049 11 8 1050 1099 11 7 1100 1149 10 7 1150 1199 10 7 1200 1249 9 6 1250 1299 9 6 1300 1349 9 6 1350 1399 8 6 1400 1449 8 6 1450 1499 8 5 1500 1549 8 5 1550 1599 7 5 1600 1699 7 5 1700 1799 7 5 1800 1899 6 4 1900 1999 6 4 2000 2099 6 4 2100 2199 5 4 2200 2299 5 4 2300 2399 5 3 2400 2499 5 3 2500 2599 5 3 NOMINAL WIDTH 200mm PIPE OD

COUPLING OUTSIDE MAXIMUM

WIDTH DIAMETER DIFFERENCE

(mm) (mm) (mm) 200 250 - 499 6 200 > 499 8 WORKING TOLERANCE

G-FLEX SERIES

TECHNICAL SPECIFICATION

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The maximum allowable angular deflection between two pipes joined by a Thomas G-FLEX Coupling.

PIPE END PREPARATION

EXPANSION & CONTRACTION

TORQUE AND ALLEN KEY SIZES ANGULAR DEFLECTION

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).

* Contact us for greater angles

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.

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.

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.

Outside Maximum Diameter Deflection * (mm) ß < 1500 2° > 1500 1° ANGULAR DEFLECTION

PIPE DN LENGTH MIN.

mm mm

DN250 - DN2500 220

PIPE END PREPARATION

CLAMP WIDTH PIPE MOVEMENT

mm mm

200 15

EXPANSION & CONTRACTION

G-FLEX SERIES

TECHNICAL SPECIFICATION

G

FLEX

MISALIGNMENT

Misaligned pipes can be joined using the G-FLEX Coupling.

PIPE SETTING GAP

G-FLEX Couplings must be installed without exceeding the maximum distance between the pipe ends being

joined.

MATERIAL OF CONSTRUCTION

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 / 316

5. Rubber - E.P.D.M.Grade E to BS2494 1990 Type W&D or NBR

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.

OUTSIDE MAXIMUM DIAMETER DIFFERENCE (mm) <300 1% ≥300 3mm MISALIGNMENT COUPLING MAXIMUM

WIDTH SETTING GAP

(mm) (mm)

200 15

PIPE SETTING GAP

1 2 3 4 5

G-FLEX SERIES

TECHNICAL SPECIFICATION

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G-FLEX couplings are manufactured from a variety of materials each exhibiting different performance characteristics as required for different applications.

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.

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:

GFI1-0610-304/N

Alternative materials for the metallic shell and elastomeric rubber seal are available on request.

G-FLEX SERIES

TECHNICAL SPECIFICATION

G

FLEX

COUPLINGS

RUBBER SEAL MATERIAL:

E - EPDM

N - NBR (NITRILE)

METALLIC SHELL:

201 - SS Grade CS201

300 - FBE Coated MS Gr300WA

304 - AISI SS Grade 304

316 - AISI SS Grade 316

THOMAS PRODUCT

GROUP:

GFI -

Coupling

GFR -

Coupling

INSTALL

REPAIR

QTY OF BOLT SETS:

1 - 1 Part Clamp

2 - 2 Part Clamp

GFI 1 - 0406 - 304/E

PIPE SIZE TO CONNECT:

406mm Outside Diameter

Standard or custom sizes

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STEEL FITTINGS

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STEEL FITTINGS

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REPAIR

COLLAR

REPAIR COLLAR

BELL & SPIGOT PIPE REPAIR SYSTEM

DESIGNER, MANUFACTURER AND DISTRIBUTOR OF PIPE CONNECTION, REPAIR AND FLOW CONTROL SOLUTIONS JOHANNESBURG TEL: +27 11 794 7594

THOMAS