Gulf Cool Therm


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Gulf Cool Therm PRE-INSULATED PIPES AND FITTINGS
FOR DISTRICT COOLING / UNDERGROUND CHILLED WATER PIPING

The Quality Insulation Products for Many Diverse
Application

TEL: 00971 6 5257776, FAX: 00971 6 5257774 P.O. BOX: 22069, SHARJAH - UNITED ARAB EMIRATES Email-1: [email protected] Email-2: [email protected] Email-3: [email protected]
www.gulfcooltherm.com

ABOUT US
We are pleased to introduce ourselves as a factory established in 1993, Sharjah – United Arab Emirates. Gulf Cool Therm Factory LLC is an ISO 9001:2008 Certi ed Company with Quality System certi ed by UKAS of United Kingdom. Gulf Cool Therm Factory LLC, is a leading manufacturers and suppliers of high quality: Thermal Insulation Materials
Pre-insulated Pipes and Fittings for District Cooling Application Polyisocyanurate Pipe, Duct, Slab and Vessel/Equipment Insulation Polyurethane Pipe, Slab and Vessel/Equipment Insulation Class ‘O’ CFC & HCFC Free Phenolic Foam Pipe, Duct, Wall and Roof Insulation Continuous PIR/PUR Foam Block Production Cold Insulation Materials for LNG, Oil and Gas Industries Foam Glass Insulation Phenolic Foam / Polyisocyanurate Pre-insulated Air Duct Panels Roof and Wall Insulation Polyurethane Spray Applied Foam High Density Thermal Support Inserts for piping and Ducting Heat Exchanger Insulated Box and Tray Field Joint Insulation and Application
With many CNC Foam cutting machineries and production process units in the eld with quality material available, highly quali ed technical and commercial sta . We are con dent that our product will comply with all international standard and de nitely will meet your requirements.
In order to facilitate our client with best service and respect to quality, prompt delivery, respective elements of production and marketing were provided and enhanced under a tight quality control.
www.gulfcooltherm.com

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GENERAL DESCRIPTION
Gulf Cool Therm Pre-insulated Piping systems for Underground chilled water pipeline, District Cooling and other energy related applications. The product consists of a carrier pipe, insulation and jacket pipe. The insulation are available in di erent thickness as well as di erent densities.
The Pre-insulated Pipes and Fittings are manufacture in accordance with BS EN 253 Standard.
CORE PIPES
Seamless black steel pipes conforming to ASTM A53 / API 5L Grade B, with schedule 40 wall thickness, and beveled ends for welded joints.
ERW black steel pipes conforming to ASTM A53 / API 5L Grade B, standard weight wall thickness, and beveled ends for welded joints.
HDPE Pipe PE 100, SDR 11-PN16 or HDPE PE 100, SDR 17-PN10
GRP PIPES- PL/PL, SN 10,000N/M2 (Dual Helical Filament Winding Process) Plain Ends to be joined by lamination (PL/PL)
Copper Pipe

SURFACE FINISH
The steel core pipe external surface will be cleaned and coated with red-oxide or the core pipe external surface will be grit-blasted to SA 2½ near white metal nish, then coated by airless spray with self-priming Polyamide/Polyamine epoxy to total DFT of 125 microns nominal 50 mm shall be kept bare (uncoated) from both pipe ends for joint welding as speci ed.

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INSULATION
The thermal insulation will be rigid cellular 100% CFC-free Polyurethane or Polyisocyanurate foam, as per EN 253factory injected between core pipe and outer casing/protective Jacket, having a density of 35Kg/m3 (2.2lbs/ft3), 48Kg/m3 (3 lbs/ft3) or 60Kg/m3 (3.75 lbs/ft3) and thermal conductivity of 0.023 W/m.K (0.16Btu-in/hr ft2 oF) maximum, at mean temperature of 10 oC Typical operating temperature is between -17 to +120°C (0 to 250°F).

OUTER CASING PROTECTIVE JACKET
The outer casing/protective jacket will be made of extruded High Density Polyethylene (HDPE PE 100) pipe, black UV-resistant, having a density of 950 kg/m³ and a long-term mechanical property with tensile stress of 4.0 MPa (580 psi) at 80 °C. OR GRP Pipe with continuous lament winding process (Drostholm) plain ends to be joined by lamination (Butt & Wrap)
FITTINGS
All ttings will be factory insulated with similar insulation and thickness, 150 mm-200 mm long beveled end extension factory welded to each end. All fabrication joints will be 100% pressure tested prior to insulation.

END SEAL
Each Pre-insulated pipe and tting will have a factory applied protective coating or end seal applied to the exposed ends of the insulation for protection against moisture ingress.

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FIELD INSULATION
When a Underground piping is constructed,

the 6/12 meters long

pipes/ ttings are jointed together after they are laid down and the pressure

test is completed. Start by placing the jacketing in position, Check space

After successful completion of foam lling the stainless wire/belt shall be removed. Then a Raychem heat shrinkable sleeve with a closure path is applied and heat shrunk over the tting to nish the joint. The eld joint can be air leak tested at 0.2 Bar

around and in between the pipes to see that adequate space is available for quick and easy installation without use force.

FIELD JOINT INSULATION

A 0.7 mm or 0.9 mm G.I sheet roll up around the joint and riveted (Use stainless wire/belt to avoid any bulging during foaming) Then the Polyurethane foam or Polyisocyanurate foam Chemical is poured through the drilled holes into the G.I sheets.

POURING OF THE FOAM CHEMICALS
Polyurethane/Polyisocynaurate foam consists of two components: Polyol and Isocyanurate (ISO/MDI) for the eld joint insulation.

The chemicals temperature should always be maintained at 20° - 25°C.
After the GI casing is installed, weight the exact amount of chemicals, Polyol & Isocyanate (ISO/MDI), in separate cups. Please note that Polyol with a pale-to-dark yellow colour and ISO is colored black. Both chemicals should not be exposed to air-moisture or heat for long hours. Make sure the chemicals containers are closed tightly after usage.

First, pour the Polyol (weighed in a cup) into mixing cup/bucket. When ready to mix, pour the ISO (weighed in a cup) into mixing cup/bucket with Polyol and using electric drill with mixer blade attached, mix the two chemicals for 10-15 seconds. Make sure the chemicals are thoroughly mixed. When the colour of the mixture changes (from dark to pale yellow) pour immediately (as quickly as possible) the mixture through the pouring hole on the top of jacket. Allow few minutes for the foam to rise, then, plug the pouring hole to refrain rising foam from coming out of the hole.

Strictly follow the foam manufacturers instructions for a proper ll.

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LEAKE DETECTION SYSTEM
GENERAL INFORMATION
Preinsulated pipe systems usually entail a large investment. A leak from the supply pipe or penetration of water into the pipe insulation should be discovered and localized as quickly as possible. This in turn, demands a monitoring system that functions even after long periods of inactivity. A typical monitoring system consists of Two (1.5mm) uninsulated copper wires which are embedded in the insulation surrounding the pipe and connected to an alarm unit. When moisture is present in the insulation the resistance between the alarm wire and the supply pipe decreases causing an alarm is activated in the central unit.
Localizing the position of a fault is carried out with the help of a measuring instrument which sends an electric pulse through the system. When the pulse detects a fault a re ection is sent back to the measuring instrument. As the velocity of the pulse is known the position of the fault can be calculated.
In order to ensure the greatest accuracy possible in positioning a fault in a pipeline, the alarm wire must be positioned the same distance possible from the pipe, pipe parts and joints. Furthermore, the higher the total resistance was before the fault occurred the more accurate the positioning of the fault.
The leak detection are using to ensure that a pre-insulated piping system gives a long end satisfactory service life, it is essential that the insulation is kept dry preventing corrosion to the steel service pipe.

Service Pipe

Crimping Joint Un-insulated Copper Wire

HDPE Outer Jacket Pipe

PUR / PIR Foam

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Properties Nominal Density: Kg/m3 Thermal Conductivity @ 10 oC (W/m.K)
Average Compressive Strength @ 10% Relative Deformation: kPa
Tensile Strength: kPa Shear Strength Closed Cell Content (%) Water vapor Transmission (perm-inch) Water absorption w/v (%) Dimensional stability (% Linear Change)
- 24 hours @ -15 oC - 24 hours @ +110 oC - 24 hours @ +70 oC, 100% RH Upper Temperature Limit (OC) Linear Coe cient of Expansion per OC Fire Resistance (small scale test) Surface spread of ame Extend of burn (mm) Flammability-weight retained Light Obscuration

Test Method ASTM D-1622 ASTM C 518/91 ASTM D-1621 BS EN 826:1996 ASTM D 1623 ASTM D 1622 ASTM D 2856 ASTM E 96-00 ASTM C 209 : 1996
ASTM D 2126 BS EN 1604 : 1997
BS 4370 BS 476 Part 5 BS 476 part 7 ASTM D 3014-74 ASTM D 2843-70 BS 5111 : Part 1

INSULATION TECHNICAL SPECIFICATION

Value

Value

Value

Value

35

50

60

80

0.023

0.023

0.024

0.028

170

350

450

750

220

385

480

630

138

195

230

310

>90

>90

>90

>90

1.5

1.5

0.5

0.4

2.5

2

1.5

1.3

Negligible 1.5 2 140
40-80 x 10-6 Class P Class 1 5 90% 30%

Negligible 1.5 2 140
40-80 x 10-6 Class P Class 1 5 90% 30%

Negligible 1 1.5
140 40-80 x 10-6
Class P Class 1
5 90% 30%

Negligible <1 <1 140
40-80 x 10-6 Class P Class 1 5 90% 30%

TEL: 00971 6 525 777 6, FAX: 00971 6 525 777 4, POST BOX: 22069, SHARJAH – UNITED ARAB EMIRATES Email 1: [email protected], Email 2: [email protected], Email 3: [email protected]
Website: www.gulfcooltherm.com
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Physical Properties Density Density Melt Flow Rate MFR2 Melt Flow Rate MFR5 Tensile Strength at yield Elongation at Break Vicat Softening Temperature Brittleness Temperature ESCR Charpy Impact, Notched Crystalline Melting Range Linear Expansion Hardness, Shore D Carbon Black Content Thermal Conductivity Thermal Stability

(Base resin) (Compound) (190oC/2.16 Kg) (190oC/5.0 Kg) (50mm/min)
(10% lgepal), F50 (O oC) (20-90 oC
(20 oC) (210 oC)

POLYETHYLENE (PE 100) TECHNICAL SPECIFICATION

Test Method

Value

Unit

ISO 1183 D/ISO 1872-2B

950

Kg/m3

ISO 1183 D/ISO 1872-2B

961

Kg/m3

ISO 1133

<0.1

g/10 min

ISO 1133

0.25

g/10 min

ISO 527-2

25

Mpa

ISO 527-2

>600

%

ISO 306 A-50

119

oC

ASTM D 746

< -70

oC

ASTM D 1693-A

>1000

H

ISO 179/1eA

16

kJ/m2

DSC

128-132

oC

0.2

Mm/m. oC

ISO 868

60

-

ASTM D 1603

> 2

%

DIN 52612

0.4

W/m.K

EN 728

>15

Min

TEL: 00971 6 525 777 6, FAX: 00971 6 525 777 4, POST BOX: 22069, SHARJAH – UNITED ARAB EMIRATES Email 1: [email protected], Email 2: [email protected], Email 3: [email protected]
Website: www.gulfcooltherm.com
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STEEL CORE PIPE DIMENSION

Nominal Diameter (MM) DN

Outside Diameter DS (MM)

Minimum Nominal Wall Thickness
T (MM)

20

26.9

2.0

25

33.7

2.3

32

42.2

2.6

40

48.3

2.6

50

60.3

2.9

65

73.0

2.9

80

88.9

3.2

100

114.3

3.6

125

141.3

3.6

150

168.3

4.0

200

219.1

4.5

250

273.0

5.0

300

323.9

5.6

350

355.6

9.5

400

406.4

9.5

450

457.2

9.5

500

508.0

9.5

550

558.8

9.5

600

609.6

9.5

650

660.4

9.5

700

711.2

9.5

750

762.0

9.5

800

812.8

9.5

850

863.6

9.5

900

914.4

9.5

950

965.2

9.5

1000

1016.00

9.5

HDPE JACKET PIPE DIMENSION

Minimum Outside Diameter
DC (MM)

Minimum Wall Thickness
e min (MM)

125

2.50

140

3.00

140

3.00

160

3.00

180

3.00

180

3.00

200

3.20

225

3.50

250

3.90

280

4.40

355

5.60

400

6.30

450

7.00

500

7.80

560

8.80

630

9.80

630

9.80

710

11.10

800

12.50

800

12.50

900

12.90

900

12.90

1000

13.30

1000

13.30

1100

13.80

1100

13.80

1200

14.60

INSULATION
Insulation Thickness (MM)
46.55 50.15 45.90 52.85 56.85 50.50 52.35 51.85 50.45 51.45 62.35 57.20 56.05 64.40 68.00 76.60 51.20 64.50 82.70 57.30 81.50 56.10 80.30 54.90 79.00 53.60 77.40

TEL: 00971 6 525 777 6, FAX: 00971 6 525 777 4, POST BOX: 22069, SHARJAH – UNITED ARAB EMIRATES Email 1: [email protected], Email 2: [email protected], Email 3: [email protected]
Website: www.gulfcooltherm.com
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HDPE CORE PIPE (PE 100) ISO 4427

OD (MM)

Wall Thickness (MM)

PN 10 (SDR-17)

PN 16 (SDR-11)

20

-

25

-

32

-

3.00

40

-

3.70

50

-

4.60

63

-

5.80

75

4.50

6.80

90

5.40

8.20

110

6.60

10.00

125

7.40

11.40

160

9.50

14.60

180

10.70

16.40

200

11.90

18.20

225

13.40

20.50

250

14.80

22.70

280

16.60

25.40

315

18.70

28.60

355

21.10

32.20

400

23.70

36.30

450

26.70

40.90

500

29.70

45.40

560

33.20

50.80

630

37.40

57.20

710

42.10

-

800

47.40

-

HDPE JACKET PIPE

INSUATION

OD (MM)

Wall Thickness (MM)

Insulation Thickness (MM)

75.00 90.00 90.00 110.00 125.00 160.00 180.00 200.00 225.00 250.00 280.00 300.00 315.00 355.00 400.00 400.00 450.00 500.00 560.00 630.00 630.00 710.00 800.00 900.00 1000.00

2.10 2.30 2.30 2.40 2.50 3.00 3.00 3.20 3.50 3.90 4.40 4.90 5.20 5.60 6.30 6.30 7.00 7.80 8.80 9.80 9.80 11.10 12.50 12.50 13.30

25.40 30.20 26.70 32.60 35.00 45.50 49.50 51.80 54.00 58.60 55.60 55.10 52.30 59.40 68.70 53.70 60.50 64.70 71.20 80.20 55.20 63.90 72.50 82.50 86.70

TEL: 00971 6 525 777 6, FAX: 00971 6 525 777 4, POST BOX: 22069, SHARJAH – UNITED ARAB EMIRATES Email 1: [email protected], Email 2: [email protected], Email 3: [email protected]
Website: www.gulfcooltherm.com
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