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RAUPEX PIPES
OUTLINE
- 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
RAUPEX PIPES
REHAUs TRADENAME FOR PEXa CROSS-LINKED (X) POLYETHYLENE
- 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
- 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
Ethylene Hydro-carbon
PolyEthylene Molecule
REHAU 27-Apr-09 - Page 4
CROSS-LINKED POLYETHYLENE
ENHANCED 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
REHAU PEXa
CROSS-LINKED (X) POLYETHYLENE
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
REHAU PEXa
CROSS-LINKED (X) POLYETHYLENE
REHAU process: PEXa - Cross-linking takes place in special extruders designed for high pressure - Typical result is 85% crosslinking, which is the highest available - REHAU is a worldwide leader in PEXa technology
PEXa molecule
RAUPEX PIPES
NON-BARRIER: THE ORIGINAL PIPE
- 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 PEXa molecule
REHAU 27-Apr-09 - Page 8
RAUPEX PIPES
O2 BARRIER: THE HEATING PIPE - 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
RAUPEX - All RAUPEX pipes have the same temperature and pressure capabilities
Adhesive (Red)
EVAL O2 Barrier
RAUPEX PIPES
O2 BARRIER: THE HEATING PIPE - 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
RAUPEX PIPES
UV SHIELD: SUPERIOR UV PROTECTION
- 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
Non-Barrier pipe turns clear when fully heated; coated pipes simply re-round
REHAU 27-Apr-09 - Page 15
*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
REHAU 27-Apr-09 - Page 17
Example: - 100 foot length of pipe heated from 70F to 100F - Thermal expansion = almost 3 inches for an unrestrained pipe
Basic Extrusion Process: 1. Polymer compound is blended 2. Melted to temperature 3. Compressed in extrusion chamber 4. Forced through extrusion die that controls shape and dimensions PEXa: cross-linking takes place in a special extruder, right at the die
Hopper (materials fed in) Heating chamber (melts materials) Compression chamber Die (forms the shape)
1
Coiler
Inspection Devices
REHAU - R....
Water Bath
Extruder
Ink Jet
High Density Polyethylene (HDPE) AntiHeat UV Stabilizers Oxidants Stabilizers Liquid Peroxide
Extruder
Ink Jet
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)
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%
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%.
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
PEXa method
Bow CB Supplies Genova Plastics IPEX JM Eagle Viega Watts Industries/Radiant Zurn/Qest (formerly US Brass)
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
- 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 - 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
RAUPEX PIPES
SUMMARY: PROVEN PERFORMANCE
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
www.rehau.com