HYGIENIC. Bioflex SMOOTHBORE, FLEXIBLE PTFE HOSE

Transcription

1 C H E M I C A L R E S I S T A N T S E L F C L E A N I N G F L E X I B L E HYGIENIC Bioflex SMOOTHBORE, FLEXIBLE PTFE HOSE

2 Contents PTFE The Optimum Choice For Hose Linings Page 1 An Introduction to Aflex Hose and Bioflex Page 2 Bioflex. Characteristics & Properties Pages & 4 The Bioflex Test Programme Page 5 How to order Bioflex Page 6 Bioflex Temperatures, Pressures & Flow Rates Page 7 Quality Assurance, Certification, Testing & Identification Page 8 Bioflex Size Range & Pages 9 & 10 Bioflex Hose Liners Page 11 Bioflex Hose Braids Page 12 Bioflex Rubber Covers Page 1 Bioflex External Protection Systems Page 14 Bioflex End s Pages 15 to 26 Standard Flange s Page 15 DIN 151 s Page 16 Saflok Cam Action s & Connectors Page 17 Standard Cam Action s Page Triclover s (Not PTFE Lined) Page 19 Triclover s (PTFE Lined) Page PTFE Beaded Triclover s Page 21 SMS & RJT s Page Elbow s Page 2 Bioflex ILine s Page 24 Dip Pipes Page 25 NonLined s Page 26 Bioflex Steam Heated Assemblies (CH Grade) Page 27 Bioflex Electrically Trace Heated Assemblies (ETH Grade) Page 28 Hose Configurations and Length Calculations Pages 29 to 1 Conditions Of Sale Page 2 Aflex Distributors Back Cover Bioflex... The World s Leading PTFELined Flexible Hose.

3 PTFE The Optimum Choice For Hose Linings Aflex Hose The World s Leading Manufacturer of PTFE Flexible Hose Aflex Hose, founded in 197, pioneered the concept of PTFE lined flexible hose for the transfer of process fluids more than 0 years ago. Section from a PTFE Molecule, 16 Angstrom Units long. PTFE, or Polytetrafluoroethylene, comprises longchain molecules of carbon atoms, each linked to two fluorine atoms. The fluorine atoms provide a helical spiral which surrounds the carbon chain and protects it. It is this structure which creates the unique properties for which PTFE is wellknown. Excellent Chemical Resistance Corroflon convoluted PTFE hose and other types of PTFE hose, manufactured and supplied by Aflex, are used by major Chemical, Pharmaceutical and Food companies worldwide. Over the years, hundreds of thousands of custombuilt hoses have been designed and built to cope with the most difficult of operating conditions, and Aflex have continuously developed and expanded their product range having pioneered and introduced Antistatic hose, Polypropylene Braided hose and many other innovations in response to customer demands. PTFE is renowned as the most chemically resistant material known. Only a very few, very unusual substances and In 1998, Aflex fulfilled the most stringent demand yet. Conventional Convoluted PTFE Liner conditions can affect it, like Fluorine gas at high temperature and pressure and liquid, boiling sodium metal. Customers, worldwide, had always asked for the ultimate PTFE lined flexible hose... one product which incorporates the = Fluorine Atom = Carbon Atom PTFE lined hoses can therefore be used for a wider variety of chemicals than any other hose type, making it the ideal choice for very corrosive chemical applications and multiproduct applications. NonStick Surface The use of PTFE as a surface for cookware products has demonstrated to the world how easily cleanable PTFE surfaces are. This means that PTFE lined hoses can be purged 100% clean more quickly, easily and reliably than any other type of hose. Excellent Temperature Range advantages of both convoluted and smoothbore designs. A product which is sufficiently flexible, like convoluted, yet which retains the advantages offered by smoothbore, like fast flow rate and cleanability. After years of painstaking research and development, Aflex launched such a hose... Bioflex. Bioflex is a smoothbore, highly flexible, PTFE lined hose. Its design overcomes the disadvantages of conventional smoothbore and convoluted PTFE flexible hose designs, dramatically improving on many of their individual technical performance parameters. The key feature of Bioflex PTFE hose is the PTFE liner design, which comprises integral rib sections which support the tube Rib Section The cookware application also demonstrates another of PTFE s many attributes temperature resistance. PTFE itself can be used as a hose liner at temperatures from 150 C up against kinking, vacuum and pressure, and highly compressed web sections which give a smoothbore inner surface and excellent flexibility. Web Section to +2 C, dependent upon the hose design and the application conditions. Another feature is the integral PTFE lined and flared end fitting design (see next page) which is available for all the standard This is the widest temperature range of any rubber or plastic hose lining material. end fittings on Bioflex Hose Assemblies. This provides clean, fullbore flow through the end fitting Bioflex PTFE Liner Hose The only issue with PTFE as a hose lining material is the best way it can be integrated in to the hose design. This is where Aflex Hose have a proven record of success over the last 0 years. without any entrapment points unlike conventional fittings, which introduce a bore restriction, also a crevice at the end of the fitting tail. This PTFE lining also protects the end fitting from any corrosive media passing through the hose bore. Today, Bioflex has become the established standard in process fluids applications all over the world, and continues to be introduced into new applications every day. Page 1 Page 2

4 Bioflex. The World s Leading PTFE Lined Flexible Hose Comparison with Silicone Rubber Hose Hygienic Cleanability much better, due to highly polished inner surface finish. Chemical Resistance considerably improved, particularly to strong oxidising acids and bases. Temperature & Pressure Ratings much higher temperature and pressure capability. Steam Resistance permanently resistant to steam sterilising (unlike silicone hose, which has a limited life). Comparison with Convoluted PTFE Hose Hygienic Cleanability vastly improved, due to smooth bore and hygienically polished surface finish. Fully Self Draining unlike conventional convoluted hose, which pools fluid in the convolutions when at an angle. Flow Rates more than 100% higher. Pressure Ratings more than 50% higher. Gas Permeation Resistance more than 150% higher. Flex Life at Temperature and Pressure more than 50 times the life, dependent upon test conditions. Stainless Steel Wire Braid Stainless Steel Spigot Ferrule, crimped to secure braid to spigot Swivelling Flange PTFE liner tube extended through the end fitting, then flared out to form the sealing face Bioflex PTFE liner tube: externally convoluted smooth bore, with slight ripples internal surface finish is mirror smooth, generated by hot polishing during manufacture Page Page 4

5 The Bioflex Test Programme How to Order Bioflex Bioflex has been designed to fulfil the most demanding of customer expectations and, as such, has been subjected to a highly complex and rigorous Proof Testing Programme, parts of which are described here. Test No. 1. The FlipFlop Test. Bioflex Hose Assemblies Bioflex is always custom built to individual order and is supplied in the form of finished hose assemblies, after the length, liner, braid, cover and end fittings have been decided upon. Selecting the Hose Grade Selecting the End s Bioflex is available with a range of standard end fittings (described on pages 1522), normally supplied hygienically PTFE lined and flared. End The Flip Flop test was invented by Aflex Hose to combine the extremes of flexing, temperature and pressure simultaneously. The hose is flexed to its Minimum Bend Radius in two opposing directions through a 2 o arc. It is cycled through this flexing profile times per minute, while pressurised to its Maximum Working Pressure, inside an oven heated to 0 0 C. Results Bioflex consistently achieves more than 50 times the life of standard convoluted hose. Typically, a 1 Bioflex hose is still intact tested at 50 Bar for 100,000 cycles, whilst a 1 convoluted hose tested at 0 Bar fails due to the inner tube bursting after 1,00 cycles. Similar results were also achieved when tested without pressure, at room temperature. Test No. 2. The Permeability Test. Fixed lengths of Bioflex were pressurised to 0 Bar with Helium Gas, and compared with samples of standard convoluted PTFE hose. Results Bioflex has more than 2.5 x the permeation resistance of standard convoluted hose. Millilitres of Helium which permeated hose, per metre, per hour: 1 Bioflex = 1 Convoluted = 71 Test No.. The Flow Rate Test. The test apparatus illustrated below was used to measure the flow rate of Bioflex, both in a straight configuration and coiled to its Minimum Bend Radius. The test medium was water. Results Comparisons were made with samples of standard convoluted hose with the same diameter on the inside of the convolutions as the Bioflex inside diameter. These show that Bioflex is capable of delivering 2 times the flow rate of convoluted hose. Additional tests have shown that the flow rate through a Bioflex hose is actually greater than that of a convoluted hose which is one size larger. For example, 1 1 /2 Bioflex has a higher flow rate than 2 convoluted hose. It is therefore possible to use a smaller Bioflex hose, fitted with full size end fittings, to replace a convoluted hose more effectively, and more economically! This remarkable improvement is due to the fact that the turbulent flow created by the convolutions in the standard product is virtually eliminated by the much smoother bore of Bioflex. There are two types of PTFE liner available, natural (GP) and antistatic (AS) and four types of braid, Grade 04 stainless steel () polypropylene (), Hastelloy (HB), PVDF or Kynar (). These are described on pages 11 and 12. Rubber covering and other external protection systems are also available, described on pages 1 and 14. A hose grade is specified by using the abbreviations given. For example, Bioflex AS, would describe a hose with an antistatic PTFE liner and a polypropylene braid. Stepup End s The very high flow rates of Bioflex hose relative to convoluted hose make it possible to use a smaller bore size Bioflex hose assembly with Stepup size end fittings, where the end fitting size is one size larger than the hose size. Thus, a lighter weight, more flexible hose can be used without compromising the flow rate! Selecting the Hose Length Bioflex hose assemblies are made up to the specific lengths required. The hose length is taken as the length from the sealing face at one end of the hose to the same at the other end. The length tolerance is normally +5%0%. Closer tolerances are available to special order. Nominal Size of Hose All hose end fitting spigots are supplied made from Grade 16, and all ferrules, swivelling nuts and flanges are from Grade 04, or Grade 16 if Grade 04 is not available. Grade 16 and Grade 04, depending upon the method of manufacture, will be to one of the following specifications: Maximum Hose Assembly Length in mm in mm in mm mtrs / / / /2 1 / / / / / / Grade *Bioflex Hose Assembly Length British Standard American Standard German/Euro Standard S1 AI S11 AI 16L C16 CF8M S15 AI S11 AI 04L C15 CF8 1.8 Minimum Hose Assembly Length* Used Straight Flexed Thru 90 * Listed lengths are for, or Braided Hose Assemblies fitted with PTFE lined fittings only. For all other specifications including rubber covered grades and nonlined ends, add 100mm up to 1 Bore, 150mm above 1 bore. Page 5 Page 6

6 Bioflex. Temperatures, Pressures & Flow Rates Temperature vs Pressure Due to its extremely strong construction, Bioflex has outstanding resistance to temperature and pressure, much higher than that of conventional convoluted PTFE lined hose. Temperature & MWP Graph for Bioflex GP, and AS, Bioflex Quality Assurance, Certification, Testing and Identification Maximum Working Pressure (MWP) Variation with Temperature: Hose with Braid as per Graph. Hose with Braid, pressure as listed (Page 10) from 0 C to +80 C and 50% less from 80 C to 100 C. Hose with RC, FP and grades as per Graph, BUT only within the temperature range for the particular grade of rubber cover, as given below. Maximum Operating Temperatures (Internal Fluid Only):,RC &, FP, Flow Rates In practice, flow rates will vary with hose flexing, fluid viscosity, end fitting design and other parameters, but Bioflex hose flow rates are always around 2 times better than convoluted PTFE hose, when comparing hose assemblies with PTFE lined (non borerestricted) end fittings. Bioflex Hose Flow Rate Calculation If it is required to determine the flow rate of a particular hose assembly, or if it is required to determine the pressure required to generate a certain flow rate, then this can sometimes be approximately calculated by the Bioflex supplier. It should be noted that calculations can only be made for fluids with a viscosity equal to water, and for hose assemblies with PTFE lined end fittings (no bore restrictions at the ends of the hose). The following information should be given to the supplier: To calculate the Flow Rate in Cubic Metres per Hour: Pressure in Bars at the Entry into the Hose Assembly (Subtracted to calculate Pressure Drop over the Hose Length) Pressure in Bars at the Exit from the Hose Assembly The hose configuration (roughly straight, or % Bends, or 66% Bends, or 100% Tightly Coiled) OR To Calculate the Pressure Drop in bars over the length of the Hose Assembly: Required Flow Rate in Cubic Metres per Hour The hose configuration (roughly straight, or % Bends. or 66% Bends, or 100% Tightly Coiled) NonWhistling 70 C to +2 C 0 C to +100 C C to + C C to +0 C C to +1 C (Subtract C from the above maximum temperature limits if the temperature is external to the hose). Temperature vs Vacuum All sizes of Bioflex GP, and AS, are usable at full vacuum up to 10 C. Above this, the vacuum resistance should be reduced 1% for every degree above 10 C. Rubber covered grades the same, BUT ONLY within the temperature limits for the type of rubber. The whistling noise created by turbulent flow when steam or other gases are passed through a convoluted hose is completely eliminated when using Bioflex. Quality Assurance Registrations Bioflex Hose and Hose Assemblies are manufactured and supplied by Aflex Hose Ltd, which is independently certified, audited and registered to BS EN ISO 9001:00. Aflex Hose Ltd has also been assessed in compliance with the European Pressure Equipment Directive 97/2/EC Module D1, for the CE marking of all applicable hose products. Aflex Hose has also been independently audited, and/or approved as a Hose Supplier to nearly all of the major Pharmaceutical Manufacturing Companies worldwide. Certification CE Marking All CE marked hose assemblies (European supply only) are always accompanied by a Hose Usage Data Sheet and a CE Declaration of Conformity. Other Certificates which can be supplied for an extra charge if requested, include: Material Certificates,.1B certification to EN104, including materials certificate copies from the original material suppliers. Pressure Test Certificates and Certificates of Conformity, which confirm the fact that the hose assembly has been pressure tested to 1.5 times the maximum rated working pressure. Certificates of Conformity also, certify that the hose assembly conforms to the specified requirements. Certificates of Conformity In accordance with EN45014:1998 FDA, Copies of letters from the PTFE raw material supplier, confirming compliance with FDA requirement 21 CFR USP Class VI Representative samples of both natural (GP) and antistatic (AS) PTFE Hose Liner materials have been test in accordance with USP Protocols and conform to the requirements of USP ClassVI (Chapter88) and the Elution Test (Chapter 87), and are considered non cytotoxic. Samples of the Silicone rubber cover, and the Blue EPDM rubber cover have also been tested, and conform to USP Class VI. Certificates of Conformity for FDA Approved. Both for PTFE as above, but also for antistatic PTFE Lined Bioflex Hose which includes Carbon Black, in accordance with FDA requirement CFR ATEX Attestations of Conformity and Labelling Available for the Bioflex range of hose and hose assemblies and include the following designation:.. II 2 G D c CERT. NO: RA 06ATEX64U for components intended for use in Gas:Zones 1 & 2 and Dust: Zones 21 & 22 Potentially Explosive Atmospheres Directive 94/9/EC. Testing of Bioflex Hose In addition to the other rigorous quality control testing procedures which are carried out at each manufacturing stage, all Bioflex hose is tested to 15 bar Helium after braiding and before assembly, to ensure total quality validation. Identification AURANCE AURANCE AURANCE QUALITY LIMITED LIMITED LIMITED NATIONAL NATIONAL NATIONAL Each hose assembly is supplied with a stainless steel identification tag or ring which includes the Manufacturer s Name (Aflex Hose Ltd), the hose description, working and test pressures, date of manufacture, and a unique serial number for traceability purposes. Page 7 Page 8

7 Nominal Hose Bore Size Actual Bore Size O/D of Tube Bioflex Size Range Braid Type O/D of Braid or Rubber Minimum Bend Radius & Usage MWP of Hose* Minimum Burst Pressure Maximum Continuous Hose Length Weight per Unit Length SPECIAL CONDITIONS PTFE Hose Use with Halogens When PTFE lined hose is used with the halogens Chlorine and Fluorine, or any corrosive halogen compounds which diffuse easily and are gaseous for example phosgene, then trace quantities may diffuse through the PTFE liner to the outside. Page 9 in mm in mm mm mm mm Bar Bar Mtrs Kg/Mtr /8 10 / / /8 16 /4 7 / /4 2 1 / /2 1 7 / / / / / /4 2 1 / / / TO RC TO,RC/FP 19. TO,RC/FP 2. TO,RC/FP TO,RC/FP 1.00 TO,RC/FP 7.0 TO,RC/FP 41. TO,RC/FP TO,RC/FP 55. TO,RC/FP TO,RC/FP *MWP: the Maximum Working Pressure of a hose assembly is limited to the lowest of the MWPs of either of the two end fittings, as given for each end fitting design on pages 1522, or of the hose itself as listed above. Only trace quantities are required, mixed with atmospheric moisture, to create a serious corrosion condition with stainless steel wire braid in particular. Also, if any Halogen compounds are present in the environment external to the hose (for example, salt in a sea water spray), and if the temperature of the hose exceeds 50 C, there is a serious risk of Chloride Stress Corrosion of the stainless steel wire braid on the hose. For such applications, always use the alternative braid materials, either HB or (for fluorine & chlorine) or (for external chlorides). Penetrating Fluids and Gases Like other plastics and rubbers, in certain special circumstances PTFE is sometimes subject to diffusion through the tube wall, dependant upon the nature of the chemical, and the pressure and temperature of operation. As mentioned above, Halogens represent a specific problem. Automotive fuels, on the other hand, diffuse much less through PTFE than through other plastics, like nylon. Some other types of penetrating fluids can also diffuse through PTFE to varying degrees, which may or may not present a problem. Known examples are sulphur trioxide, glacial acetic acid and methyl methacrylate. Consult with Aflex Hose if these, or any other gases or fluids which are known to be penetrating are to be used. Gas/Fluid Cycling There are some applications where the fluid passing through the hose turns into a gas, then back into a fluid, then into a gas etc., in a cyclic sequence. This is normally associated with changes in temperature and/or pressure. For complex reasons these conditions are extremely damaging to the hose liner, whatever material it is made from. For example, hoses are sometimes used to pass steam, water, steam etc into rubber moulding presses, in order to heat the mould, then rapidly cool it before reheating in the next cycle. Hoses of all types fail rapidly in such an application, and PTFE lined hose is no exception. Consult Aflex Hose for further information if these conditions apply. Connecting Assemblies for use in Applications When being connected for use in applications, the end fittings on hose assemblies must be connected to correct mating parts in the correct way, using the correct tools spanners, clamps, nuts and bolts etc. The connections must be sufficiently tightened to ensure that the joint is leakfree, but must not be overtightened as this can damage the sealing surfaces. In applications involving the transfer through the hose of expensive or dangerous fluids or gases, the connections must be pressure tested first before being put in to service. This should be done with some harmless media, like water or compressed air, to 1 1 /2 times the maximum working pressure of the hose assembly, as defined in this brochure. If in doubt, consult Aflex Hose for advice. Page 10

8 Bioflex Hose Liners Bioflex Hose Braids GP General Liner AS AntiStatic PTFE Liner Stainless Steel Braid TO Tube Only (no braid) Bioflex GP is the General grade, for use in all applications where fluids or gases are being conveyed which do not generate a risk of static charge development (see AS ). & Approvals Bioflex GP is a virgin PTFE liner, manufactured from hose grade PTFE which conforms to the requirements of: FDA 21 CFR Bioflex GP hose liner tube has also been tested, and complies with: USP Class 6 : Systemic Injection Test Intracutaneous Test Intramuscular Test USP L929 MEM Elution Test (Cytotoxicity) EC ELECTRICAL CONTINUITY When EC grade is requested, whether the hose liner is GP grade or AS grade, it requires that the hose assembly supplied is electrically continuous, or conductive, between metal end fittings at each end of the hose. The requirements for this are specified in the German Document BRG12, and the Specification EN ISO 12115, tested to EN ISO 801 Clause.7, which requires that for hose assemblies with a resistance between fittings of <10 2 ohms, a letter M can be applied, or <10 6 ohms, a letter Ω can be applied. Braided Bioflex Hose Assemblies all meet the requirements of both M and Ω, but are not stamped unless requested. Bioflex AS is an essential requirement in applications where there is the risk of an electrostatic charge buildup on the inside surface of the PTFE tube which may then discharge through the tube wall. Media passing through which create such a risk are fluids which have a Conductance of less than 10 8 S/m (Siemens per Metre), or 10 4 ps/m such as fuels, solvents, freons, some WFI (ultrapure Water for Injection ) and nonpolar organics which are being transferred at a medium to high flow velocity. All twin or multi phase media, and any nonmixing media, such as powder in air, or water droplets in steam, in gases or in oil, also colloidal fluids constitute a particular hazard for static charge generation, and always require grade AS. If in doubt, consult Aflex Hose. & Approval Bioflex AS is an antistatic PTFE liner manufactured from FDA approved PTFE, and less than 2.5% of high purity Carbon Black material to FDA requirement 21 CFR The carbon is encapsulated by the PTFE, and in normal, nonabrasive applications will not come loose to contaminate any fluid passing through. Bioflex AS also conforms to: USP Class 6 : Systemic Injection Test Intracutaneous Test Intramuscular Test USP L929 MEM Elution Test (Cytotoxicity) When AS (Antistatic) grade hose is specified, then the hose supplied will be in accordance with the requirements of BS5958 Part 2, 1991 Clause 19., when tested in accordance with EN ISO 801 Clause.1, which requires that the resistance between a plug inserted 25mm into the bore at the end of the hose assembly, and one of the metallic end fittings Polypropylene Braid should be less than 10 8 ohms. The only exception is for assemblies without braid. Grade AS, TO (Antistatic, Tube Only) meets the requirements of Ω, <10 6 NOTE: When in service, at least one end fitting must be ohms, but Grade GP, TO (Natural, Tube Only) does not meet either connected to earth, to permit dissipation of the static charge Kynar Braid is used for the same reasons as HB above, but M or Ω. from the end fitting. only in applications where the reduced pressure and temperature ratings of are acceptable. Page 11 Page 12 Stainless Steel braided hose is the general purpose product, and can be used in applications involving high temperatures and working pressures. High tensile AI 04 stainless steel wire is used, to give maximum pressure resistance and external protection to the hose. Polypropylene braided hose is often preferred to in applications involving frequent handling and movement of the hose, and where temperatures are within the range 0 C and +100 C. braid is lighter in weight, and any broken strands will not cut the operator s hands. In addition, braid is not prone to chloride stress corrosion, and has generally good chemical resistance. NOTE: Prolonged exposure to sunlight eventually results in UV degradation of braid. Kynar Braid (Polyvinylidene Fluoride Monofilament) TO grade hose (available in both GP and AS) is a lightweight hose, used in applications where working pressures are low and where there is no need for the physical protection offered by an external braid. TO grade is not vacuumproof. TO grade tube is not normally helium tested. HB Hastelloy Braid (C276 grade) Hastelloy Wire Braid is used instead of where severe chemical corrosion conditions exist around the outside of the hose. One way in which this can happen is when Chlorine or Fluorine are being transferred. Diffusion of trace quantities of such gases through the PTFE liner can lead to atmospherically wetted fluorine or chlorine attacking the braid material, in which case the Hastelloy Braid would be resistant. Same as for on Pages 9 and 10, except the Burst Pressures and the Maximum Working Pressures are both reduced to 25% of the pressures listed. Also, the sizes range is restricted, from 1 /2 up to 2 bore only.

9 Bioflex Rubber Covers Bioflex External Protection Systems RC Rubber Covered FP Fireproof Rubber Covered KR Kink Resistant SR Scuff Rings For the most rugged applications where the hose may be subjected to rough treatment and severe external abrasion. Also for hygienic applications, where the external smoothness As for RC hose, but where the hose is also required to resist failure in the event of fire, in accordance with Specification BS517 Section 10.1 (Fireproof). This specification calls for For applications where there is a risk that the hose might be severely flexed anywhere along its length, and possibly kinked as a result. For medium duty applications where the hose requires some protection against abrasion when dragged over the ground, but where a full rubber cover would be too heavy and and cleanability of the hose is of prime importance. An braided hose assembly has a smooth finish, blue EPDM external rubber cover vulcanised directly onto the braid. EPDM has excellent chemical resistance, and is temperature resistant up to 1 C (external) C (internal). Black antistatic EPDM, and alternative colours of rubber, and strips with alternative text titles are available to special order. an 1100 C flame to be applied to the hose at minimum bend radius, maximum operating pressure (water), and one end fitting under vibration. The hose must withstand at least 15 minutes without leakage. As for RC hose, but the red EPDM rubber is specially compounded to be fire resistant. Black, antistatic EPDM Fireproof rubber is also available as an option to special KR is only available on hoses which also have a wire braid and a rubber cover (RC, FP or ). An reinforcement wire is helically wound on to the wire braid, then the rubber cover is applied on top of the helical wire. Only available for sizes /4 and above. cumbersome. Also for and braided hose, which cannot be Rubber Covered. Specially moulded abrasion resistant rubber scuff rings are placed every half metre along the hose. Available for hose sizes 1 (25mm) to 2 (50mm) only. The The EPDM rubber cover has been tested and conforms to the requirements of USP Class VI. RC00 Rubber Covered 00mm at End As per the Rubber Covered hose grade, except that the standard RC Grade rubber has a supersmooth finish which is not possible on the KR hose grade. operating temperature should not exceed C (internal). PC Protection Coil Silicone Rubber Cover In applications where excessive flexing of the hose at the end fitting occurs, it is sometimes necessary to stiffen the hose in this area, to prevent kinking. For applications where the hose requires protection against abrasion when dragged over the ground, but where any rubber reinforcement is not permissible due to temperature, A layer of rubber is applied and vulcanised directly to the chemicals etc. ferrule, and 00mm along the hose from the fitting. This can be done either on an braided hose (RC00) or on a rubber As for RC hose, but where the hose may be required to covered hose as a 00mm long double layer of rubber at the A stainless steel wire helix is wound onto the braid and welded withstand temperatures up to 0 C. grade hose is semitransparent, allowing visual monitoring of the braid. end (DRC00). to the ferrules at each end. The rubber used is normally Blue EPDM, but if the hose is FP, or covered, then the same type and colour of rubber would An braided hose assembly has an external smooth finish be used (DFP00 or D00). Only available on,, HB or in sizes of /4 and silicone rubber cover vulcanised directly onto the braid. above. Cannot be applied to or braided hose. If required consult Aflex Hose for an alternative EPR system. (EPR As for the Braided Hose Grade. The Silicone rubber cover has been tested and conforms to includes a 00mm length of loose rubber hose jubilee clipped the requirements of USP Class VI. to the ferrule). Page 1 Page 14

10 Bioflex Standard Flange s Bioflex DIN 151 s Flange s Swivel flange fitting, integral PTFE lined and flared. Flanges to ASA 150 (ASME B16.5 Class 150), DIN PN10 or PN16, and BS10 Table E. Other flange ratings to these specifications are also available, and other types of flanges can be supplied. Standard Flange DIN 151 s (Male & Female) DIN 151 male and female fittings, integral PTFE lined and flared. The PTFE sealing face is hot moulded into the correct shape, designed to achieve the optimum pressure seal. Specification Generally to German DIN 151 specifications. Spigots in Grade 16 nuts and ferrules in Grade 04. Maximum Working Pressures (MWP) Braided, /4 to 1 1 /4 MWP = Bar. 1 1 /2 and 2 MWP = 25 Bar. Braided, MWP as for hose. Test Pressure = 1.5 x MWP. Grade 16 Spigot, Grade 04 Flange and Ferrule, except 1, 1 1 /2 and 2 PN10 Flanges are Grade 16. Alternative options include grade 16 flanges, polypropylene flanges mounted on spigots, zinc or nickel plated mild steel flanges, and other materials to special order. Length of NB: The PTFE lined male fitting is designed to be used without a rubber seal. Please note that when connecting to a PTFE Lined DIN151 Male, extra spanner tightening of the nut is sometimes required in order to provide a leak free connection. Maximum Working Pressures Nominal Size Flared Diameter These are defined by the flange specification. For standard PN10 and PN etc. the Maximum Working Pressures are 10 Bar and Bar respectively. For ASA 150 the Maximum Working Pressure is psi or 16 Bar. Test Pressures are 1.5 times the MWP of the fitting. (Exceptions: when the hose MWP is less than the fitting MWP). Ferrule Swivelling Flange Internally threaded Spigot Hose Size Nominal Size of Recommended Bolt Weight/ Length Flange Flared Diameter Tightening Torques ASA 150 DIN PN10 in mm in mm in mm ft.lbs mtr. kgs kg in mm in mm 1 1 /2 15 / / / / DIN151 Male DIN151 Female / / / / / / /2 1 1 /2 1 7 / /8 7 1 / / / *2 50 * / Length of Hotformed Sealing Face No rubber seal required Length of Internally threaded Spigot These are not the correct flared diameters, but they are the maximum diameter to which the PTFE can be flared out for that flange size. If the full size flare diameter is required, consult Aflex Hose for a solution. * StepUp Flange s on 2 Hose (see list) Because the 2 Bioflex Hose has better flow rates than both 2 1 /2 and Convoluted PTFE hose, it represents a superior alternative when fitted with the larger flanges. It is, however, necessary to also StepUp the PTFElined bore, to ensure an diameter match with the mating connector. This is best achieved using a solid PTFE Adaptor Plate, as shown in the drawing. Other sizes scan also be Stepped Up if required, for example 1 Hose to 2 Flange. 2 to ASA150 Flange Joint PTFE Lined Pipe ASA150 Flanges Solid PTFE Adaptor Plate A = Pipe Inlet Diameter B = Hose Inlet Diameter 2 Bore Hose Hose in Nominal Size DN Length (Male) (non rubber covered grades only) Length (Female) (non rubber covered grades only) Weight of Male Female in mm in mm kg kg 1 / / / / / / / /4 2 2 / /2 2 1 / / / / Ferrule Swivelling Nut Page 15 Page 16

11 Bioflex Saflok Cam Action s (Fixed or Swivel) Bioflex Standard Cam Action s Saflok Cam Action Coupler s PTFE Lined Fixed or Swivelling AutoLocking Arm Cam Action Quick Release. The lock is released by pulling a wire ring horizontally away from the fitting, then using the ring to pull the arm open. The lock is designed as a safety feature, to prevent accidental opening of the connection resulting from vibration or tugging. Generally to MilC27487 and DIN2828. (Fully interchangeable with other makes of Cam Action type quickrelease fittings to these specifications). Saflok Cam Action Ring Pull Trigger Lock Cam Action Adaptor (Male) s PTFE Lined Cam Action Adaptor (Male) s are also available. Specification, materials and size range as for Female (Coupler) s. Generally to MilC27487 and DIN2828. (Fully interchangeable with other makes of Cam Action type quickrelease fittings to these specifications). Cam Action Coupler (Male) Spigot Ferrule Cam Action spigot in Grade 16, ferrule in Grade 04, standard gasket in buna N nitrile rubber, with alternatives available. Cam Action spigot in Grade 16, ferrule in Grade 04. Maximum Working Pressures Alternative Gasket FEPencapsulated Silicone Rubber Gasket. (Rubber fully encapsulated inside an FEP outer). Usable at temperatures up to 1 C. (Note: this type of gasket requires higher clamping forces than normal to ensure a positive seal. Normally supplied with an aluminium or polypropylene male adaptor clamped in, to preset the gasket for easier use). NOTE: If customers want to use their own gaskets, which are not supplied by Aflex, they must supply these gaskets with their order, so that Aflex can fit these gaskets, then test the hose assemblies before despatch. Usable at temperatures up to 100 C, but higher temperature use is possible, dependent upon the gasket materials. Mating Connectors A wide variety of matingconnectors is available,, including BSP female threaded adaptors and PTFE lined flange adaptors. Maximum Working Pressures All sizes 10 Bar (Test Pressure = 15 Bar). Higher Working Pressures up to Bar are available to special order. Nominal Size Length of (non rubber covered grades only) Weight of in mm in mm kg /4 2 1 / / /2 2 / / Other sizes available to special order. All sizes 10 Bar (Test Pressure = 15 Bar) Higher working pressures up to Bar are available to special order. Cam Action Adaptor to Flange Connectors & Cam Action Adaptor (male) to Flange Connector, PTFE lined right through the connector. Construction & The Cam Action Adaptor and Flange components are welded together, and include a thick wall PTFE liner, either GP or AS grade, flared at both ends. Cam Action Flange Size & Adaptor Size Specification Flare Dia. on Flange Length Minimum Through Bore in mm in mm in mm in mm ASA / Cam Action Adaptor to Flange Connector 1 25 DN25/PN / /2 1 1 /2 ASA / /2 DN/PN / ASA / Through Bore Flare Diameter on Flange 2 50 DN50/PN / Length Page 17 Page

12 Triclover s Bioflex Triclover s Not PTFE Lined Triclover fitting, not PTFE lined. Hygienic design spigot, all internal (wetted) surfaces polished to <0.75µm (<15µ in) and Electropolished. Generally in accordance with BS4825: Pt or DIN 2676, also others. Maximum Working Pressures and Temperatures All sizes 16 Bar (Test Pressure = 24 Bar). Only up to the temperature limit of the rubber seal. Spigot in Grade 16 S11 (AI 16L, or 1.44), Ferrule in Grade 04. Size of Triclover s When ordering, it is necessary to determine: (a) What standard of internal polish is required? (b) What Triclover Flange Diameter is required? (c) What is the Hose Size required? (d) Is the Outlet Diameter for the hose fitting the same as the I/D of the Pipe to which it will be connected? See the List for the Sizes & Outlet Diameters. If the requirement is not on this list, then please specify the alternative dimensions required. If in doubt, request a Triclover Enquiry Form from Aflex Hose, to be filled in and returned. Unpolished, NonLined Triclover s In applications where polishing is not required, but the most economical price is required, unpolished and/or purgewelded end fittings to special order can sometimes provide a solution. Consult Aflex for details. NonLined Triclover Length of Internal Surfaces polished Outlet Triclover Diameter Flange Diameter Standard Hose and Pipe Sizes, and Outlet Diameters Nominal Pipe Pipe I/D Standard Size (inches Nominal Equal to Length of Triclover = BS4825, Hose Size Flange Dia. DN = DIN Outlet 2676) in mm mm mm 1/ ( /8 ) 1/2 & DN / ( 5 /8 ) /4 8.0 / ( 5 /8 ) / / ( 5 /8 ) DN ( 7 /8 ) (1 ) DN / (1 1 /4 ) DN / / / (1 1 /2 ) DN DN / DN DN DN = Standard, stocked fittings the other sizes are available to special order. Bioflex Triclover s PTFE Lined Triclover s Triclover fitting integral PTFE lined and hot formed. patented in Europe by Aflex Hose Ltd. Generally in accordance with BS4825: Pt, or DIN Maximum Working Pressures and Temperatures All sizes 16 Bar. (Test Pressure = 24 Bar). Only up to the temperature limit of the rubber seal. Spigots Grade 16. Ferrules Grade 04. Size of Triclover s When ordering, it is necessary to determine: (a) What Flange Diameter is required? (b) What is the Hose Size required? (c) Is the Outlet Diameter for the hose fitting the same as the I/D of the Pipe to which it will be connected? See the List for the Standard Sizes & Outlet Diameters. If the requirement is not on this list, then please specify the alternative dimensions required. If in doubt, request a Triclover Enquiry Form from Aflex Hose, to be filled in and returned. Standard Hose and Pipe Sizes, and Outlet Diameters Nominal Hose Size Standard Triclover Flange Dia. Pipe I/D Equal to Outlet Diameter * Step Up PTFE Lined Triclover s Because the 2 Bioflex Hose has better flow rates than either 2 1 /2 or convoluted PTFE hose, it represents a superior alternative when fitted with larger Triclover fittings. It is, however, necessary to Step Up the PTFE lined bore, to ensure a diameter match between the Outlet Diameter and the Pipe I/D, as shown in the drawing. Nominal Pipe Size (inches = BS4825, DN = DIN 2676) PTFE Lined Triclover Length of Specs & Sizes with pipe I/D which are larger than the largest O/D possible with a lined end from the hose size shown. Set against the nearest option Length of 15 Step Up Outlet Diameter PTFE Flared Face hot formed to correct shape for Rubber Seal Flange Diameter Length of (non rubber covered grades only) in mm mm mm mm / ( /8 ) 1/2 5.0 / DN / ( 5 /8 ) DN / ( 7 /8 ) (1 ) DN / (1 1 /4 ) DN / (1 /8 ) 1 1 /2 DN (8mm Pipe I/D) / (1 7 /8 ) 2 DN50 (50mm Pipe I/D) 58.0 * *. (2 /8 ) 2 1 / * *66.0 DN * *7.0 (2 7 /8 ) 87.0 * *81.0 DN Note: The /8, 5 /8, 7 /8,1 /8 and 1 7 /8 hose sizes can only be supplied as assemblies with lined triclovers (or ILined fittings) at BOTH ends, because other types of fittings (flanges, camlocks etc.) are not available for these hose sizes. Outlet Dia. * Step Up PTFE Lined Triclover Triclover Flange Diameter Page 19 Page

13 Bioflex PTFE Beaded Triclover s In this new (patent pending) design, the PTFE hose liner tube is extended through the Triclover end fitting, and is flared over the sealing face. It is then hotformed to conform to the shape of the rubber seal, and therefore replaces the rubber seal. Bioflex SMS & RJT s SMS Female s SMS female fitting, integral PTFE lined. Flared Face Hotformed into correct shape for seal. This includes the bead shape, which is used for concentric location of the seal to the mating component when a joint is made, as shown in the sketch opposite. Specification Generally to Swedish SMS 1148 specification. SMS Female Advantages of the Bioflex PTFE Beaded End After connection, the PTFE does not bulge into the bore in the same way that a rubber seal would. This rubber bulge interferes with the flow path, and can cause material entrapment, but these problems are eliminated by using this new design. The need to ensure the compatibility of the rubber seal with the media passing through is no longer a problem, due to the allptfe sealing system. Bioflex PTFE Beaded Triclover End (Shown in a joint with a Triclover Pipe Connection) Length of The moulded square edge gives a crevicefree joint with no bulge into bore Integral moulded PTFE Bead replaces rubber seal Spigot Grade 16, Ferrule & Nut Grade 04. Maximum Working Pressures All sizes 10 Bar. (Test Pressure = 15 Bar). Nominal Size Length of (non rubber covered grades only) Weight of in mm in mm kg / / / /2 2 / Ferrule Length of Internally threaded spigot Swivelling Nut The joint includes only one sealing face, not 2 as with the / rubber seal. The internal section of the moulded PTFE seal, which is squared off to provide a closed sealing edge in the joint, ensures no crevices in which materials entrapment might occur. RJT Female s RJT female fitting, integral PTFE lined. REPAIR NOTE If the PTFE sealing face is damaged by being dented, but is not actually cut open, then it can be repaired, by reheating and reforming the sealing face. This can be done by Aflex Hose for a small charge. Standard Hose and Pipe Sizes, and Outlet Diameters Nominal Hose Size Standard Triclover Dia. Pipe I/D Equal to Outlet Dia. Nominal Pipe Size (inches = BS4825, DN = DIN 2676) Length of (non rubber covered grades Flared Face Hotformed into correct shape for seal. Specification Generally to BS4825: Pt 5. If hoses are required to be joined together, then the Bioflex PTFE Beaded Triclover End can be connected to a standard Bioflex Triclover (see page 19) to provide an allptfe lined joint between the hoses. in mm mm mm / / DN / DN / / / Spigot Grade 16, Ferrule & Nut Grade 04. Maximum Working Pressures All sizes 10 Bar. (Test Pressure = 15 Bar). RJT Female Length of Internally threaded Spigot Generally in accordance with BS4825:Pt or DIN 2676, also others to special order. Nominal Size Length Weight of in mm in mm kg Spigot in Grade 16. Ferrules in Grade / /2 2 / / Ferrule Swivelling Nut Maximum Working Pressures All sizes 16 Bar (Test Pressure 24 Bar). Only up to 10 C. Page 21 Page 22

14 Bioflex 90 Elbow s Bioflex ILine s Introduction In applications where the hose is normally used at 90 to an end fitting, for example when a hose length is hanging vertically downwards from a horizontal connection, to pipework, then a 90 elbow can be used to take the strain. PTFE Lined 90 Elbow End Length 90 elbowed S/S tube enclosing S/S braided hose PTFE Lined ILine s ILine fittings, Integral PTFE Lined and Flared. ed to be used together with the standard clamps and Gaskets (EPDM, Nitrile, Viton, PTFE). PTFE Lined 90 Elbow End s As with most end fittings for Process Fluid applications, it is usually preferred that elbows are PTFE lined, for cleanliness, and to avoid internal bacteria traps. Aflex have developed a new design of PTFE lined 90 elbow. This design includes a normal PTFE lined straight fitting, attached to the end of the hose. The hose behind the fitting is passed through a 90 elbow stainless steel tube, which is welded to the back of the ferrule, as shown opposite. Size Range & Specification Triclover s: Hose Sizes 7 /8, 1, 1 /8, 1 7 /8 & 2 only. With all Other s: Hose Sizes 1, 1 1 /2 & 2 only. are generally the same as for the hose and straight end fittings. OffSet 1 Hose = 85mm 1 1 /2 & 2 Hose = 0mm DogLegs Length for straight fitting (see brochure) Hose Bore Sizes OffSet Length mm mm 7 /8 or /8, 1 1 / /8 & Elbow welded to ferrule Standard, straight (triclover) end Maximum Working Pressures All sizes up to Bar (Test Pressure = 27 Bar). Spigots Grade 16, Ferrule Grade 04. Nominal Hose Size ILine Size Sleeve Diameter in mm in mm in mm 7/ / / /2 1 / / /4 57. Length Like PTFELined Triclovers, ILine fittings are used on 7 /8, 1 /8 and 1 7 /8 hose sizes, with only the possibility of ILine or Triclover fittings at the other end. ILine Female Length Sleeve Diameter Elbows for Stainless Steel Braid and Rubber Covered Grades are available, but not for & Braids. Minimum Hose Lengths with 1 x Elbow s: 7/8 & 1 = 00mm 1 /8, 1 1 /2, 1 7 /8 & 2 = 500mm. (Double for 2 elbow fittings) Adaptors PTFELined and Flared FlangetoILine adaptors are also available, to special order. ILine Male Length DogLegs Elbow pieces can also be used to create doglegs in hoses, to shape the hose in applications where this may be an advantage, to special order. Sleeve Diameter (Only available for the hose sizes as above, but not for the rubber covered grades, and not for and grades). NonLined 90 Elbow NonLined 90 Elbow End s Length of A 90 elbow attached to the hose can be supplied nonptfe lined, as shown, for any size of hose or type of fittings, to special order. Elbow welded to stub end Elbow welded to spigot Swivelling Flange Page 2 Page 24

15 Bioflex Dip Pipes Bioflex Non Lined End s Fixed Dip Pipes Fixed Male s Fixed Male Fixed Dip Pipes are rigid tubes, either straight or 90 elbowed, which Fixed male fitting, BSP taper male thread. Length of are directly crimped to the end of Bioflex hoses. They are designed for insertion into drums, tanks and reaction vessels in order to suction drain (or inject) process fluids transferred through the hose. Threads to BS21. Spigot Standard dip pipes are in antistatic (AS) PTFE. Also available in 16, polypropylene, virgin PTFE (GP) and other materials to special order. How to order All components are either zinc plated mild steel or Grade 16 with a Grade 04 ferrule. Alternatives (to special order) Nominal Size Ferrule Length Weight of (steel) in mm in mm kg Specify the size and material of the dip pipe, whether it is straight or 90 elbowed. Give the length of the straight leg of the dip pipe and the length of the rest of the hose assembly separately. Maximum Working Pressures Dip Pipes are normally only tested to 4 Bar Pressure, and are not suitable for use at pressures higher than Bar. They are usable at negative pressure up to full vacuum. If higher pressure ratings are required, consult Aflex Hose. Nominal Hose Bore Size Inside Diameter in mm in mm in mm 1 / / / Fixed Dip Pipe NPT, JIC, metric or BSP parallel screwthreads with flat face or internal cone. Polypropylene males available to special order. Polypropylene Fixed Male s are only usable between 10 C and +50 C, and the Maximum Working Pressure is 80% less. / / / /4 2 1 / / /4 2 1 / / / Lengths Dip Pipes are supplied as standard in 1 metre lengths, but can be supplied in any length to individual requirements. Length of Dip Pipe Maximum Working Pressures (MWP) As given for the hose. (Test Pressures = MWP x 1.5). I/D O/D Cone Seat Female s Cone Seat Female Detachable Dip Pipes As Fixed Dip Pipes above, but connected to the hose through an end Detachable Dip Pipe Overall length of dip pipe cone seat female union fitting, BSP parallel thread nonlined. Length of Spigot fitting, not by crimping direct to the hose. Generally to BS50 and ISO A straight, or 90 elbowed antistatic PTFE Dip Pipe, fitted with (any) PTFE Lined & Flared end fitting. The most usual end fitting is a Cam Male (as shown), so the dip pipe can then be connected to a hose with a Cam Female end fitting. As above for Fixed Dip Pipes. All components are either zinc plated mild steel or Grade 16 with an Grade 04 Ferrule. Alternatives (to special order) These fittings may be supplied with a flat seat or with a metric or NPSM thread. Lug Nut female union (and male) fittings are also available in gun metal or stainless steel. JIC Females can also be supplied. 45 and 90 elbowed fittings also possible. Maximum Working Pressures As given for the hose. (Test Pressures = MWP x 1.5). Nominal Size Ferrule Swivelling Nut Length Weight of in mm in mm kg / / /4 2 / / / / /2 2 1 / / Page 25 Page 26

16 Bioflex Steam Heated Hose Assemblies. (CH Grade) Bioflex Electrically Trace Heated Hose Assemblies. (ETH Grade) CH Hose Assembly Inlet/Outlet for Steam Connection Small diameter PTFE heating hose, coiled along hose Silicone foam rubber thermal insulation Outer braid, or other protective cover For use in applications where the temperature of the process fluid must be maintained as it passes through the hose. This is usually required to prevent solidification or an increase in fluid viscosity. Steam heating is preferred to electrical heating in some applications for reasons of availability or safety, but is less controllable. The heating element comprises a small diameter PTFE heating hose, 6mm or 9.5mm bore size, with a single wire braid. This is spirally wrapped around the hose, with inlet and outlet ports attached, either both at one end or at opposite ends of the hose assembly. In the case of hose assemblies longer than metres, it is usual to have several heating hoses with inlet ports at opposite ends and along the hose. This reduces the effects of temperature loss over the length of the Hose Assembly. The thermal insulation is usually closedcell silicone foam rubber. The outer cover is a wire braid with a rubber cover if necessary. Each hose is custom designed and built to suit the requirements of the particular application. The following information is therefore required: Fluid in Hose Assembly Maintained Temperature of Fluid in Hose Temperature of Steam or Fluid in the Heating Hose For use in applications where the temperature of the process fluid must be maintained as it passes through the hose. In some applications, an additional melt out facility may also be required. The heating element comprises either a resistance or selfregulating element spirally wrapped around the hose assembly. Resistance element heated hoses usually also require a temperature sensor to be built in to the construction. The power leads and (if applicable) temperature sensor leads emerge from the hose assembly at one end, through glands and conduits. The thermal insulation is foam rubber, silicone foam rubber for temperatures above 80 C. The outer cover may be a polypropylene yarn or wire braid with a rubber cover if necessary, or a ribbed PVC waterproof sleeve. Each hose is custom designed and built. Application details must be supplied by filling in an ETH Hose Questionnaire, available from Aflex Hose. Generally, for Hazardous Areas, particularly ZONE 1, the Self Regulating type of heating element is employed, with or without a temperature sensor and control, and flameproof glands and conduit are also required. The watts per metre of the heating element, the pitch of the spiral on the hose, and the thickness of the thermal insulation are all calculated in accordance with established formulae to give the required maintained temperature. ETH Hose Assembly Flexible conduit for heating element connection Silicone foam rubber thermal insulation Flexible conduit for temperature sensor connection Temperature sensor Heating element coiled along hose Min/Max Ambient Temperature Pressure/Vacuum Applied to Fluid External Conditions of Abrasion etc As for Bioflex GP, on pages 9 and 10, except that the Minimum Bend Radius is tripled and the outside diameter and weight are significantly increased in line with the particular design. Maximum ETH Hose Assembly Lengths are as Bioflex GP,. Outer braid, or other protective cover As for Bioflex GP, on pages 9 and 10, except that the minimum bend radius is tripled, and the outside diameter and weight are significantly increased in line with the particular design. 1 PTFE lined PN10 flange spigots on heated hoses can only have a maximum flare diameter of 50mm, not 6mm. If the hose is hanging, straight or at 90, under its own weight, 1 PTFE lined PN10 flange spigots on heated hoses can only have a maximum flare diameter of 50mm, not 6mm. special construction is required, so advise Aflex Hose accordingly. If the hose is hanging, straight or at 90, under its own weight, special construction is required, so advise Aflex Hose accordingly. Page 27 Page 28