Expansion Vessels for Potable Installations

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1 4. Expansion Vessels for Potable Installations Domestic installations lose millions of litres of potable water due to expansion water leaking from the vent and expansion pipe. Flamco s Airfix diaphragm pressure expansion vessels for Potable equipment work to prevent this waste. Bacteria formation is prevented because Airfix vessels are designed to allow a continuous flow through of water to maintain constant circulation. These expansion vessels can be applied in combination with all hot water calorifiers and as surge vessels in pressure boosting systems. 112 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

2 Expansion Vessels for Sanitary Installations 4 Product overview 2013 We reserve the right to change designs and technical specifications of our products. 113

3 Airfix Expansion Vessels for Sanitary Systems Fixed diaphragm Airfix liters. Max. operating pressure: 5 bar. Small pressurized vessels with internal coating. Replaceable diaphragm (not streamlined) Airfix P liters. Max. operating pressure: 10 bar. Colour: aluminium-grey (RAL 9006). Removable Replaceable diaphragm (streamlined) Airfix DE 50-3,000 liters. Max. operating pressure: 16 bar. Pressurized vessels with streamline function. DVGW, ACS, WRAS and WRC approved. Electronic diaphragm-rupture sensor. Airfix A 8-80 liters. Max. operating pressure: 10 bar (8-25 liter) and 8 bar (35-80 liter). Pressurized vessels with streamline function. Suitable for mains-water systems. Airfix P liters. Max. operating pressure: 10 bar. Colour: aluminium-grey (RAL 9006). Airfix DEL liters. Max. operating pressure: 10 bar. Pressurized vessels with streamline function. DVGW and WRAS approved. Observation port for diaphragm rupture sensing. Airfix D 8-35 liters. Max. operating pressure: 10 bar. Pressurized vessels with advancedintegral streamline function. Includes T-piece. Suitable for mains-water systems. Airfix P liters. Max. operating pressure: 10 bar. Colour: grey (RAL 7040). With feet from Airfix P 750 upwards. Airfix P - Horizontal Standard pre-charge: 3.5 bar. Colour: aluminium-grey (RAL 9006). Airfix DEB 50-3,000 liters. Max. operating pressure: 25 bar. Pressurized vessels (without streamline function). WRAS and WRC approved. Suitable for industrial use. 114 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

4 Expansion Vessels for Sanitary Installations 4 Product overview 2013 We reserve the right to change designs and technical specifications of our products. 115

5 Airfix A and D Expansion Vessels for Potable Water Systems Altogether, households lose many millions of liters of drinking water every year due to expansion water slowly dripping away into the sewer. The Airfix A and D expansion vessels, which can be used in storage boiler systems and pressure boosting systems, operate in such a way that the water flows right through and they are continuously flushed with fresh water from the mains. This prevents tepid, stagnant water from collecting in the vessel in which bacterial growth could occur. Therefore, users can rely on high quality drinking water. The vessel has an internal epoxy coating, so that the water cannot come into contact with bare steel. The Airfix vessel comes equipped with a plastic flow divider, suitable for T-pieces, for a continuous stream of max ¾" (22 mm). This flow divider is placed in the T-piece (which does not come with the vessel). AIRFIX A The vessel must be installed in the supply line and a throughflow must be confirmed. Benefits of using Airfix expansion vessels No waste of valuable potable water. Continuous flow-through prevents bacterial growth. Special rubber (EPDM) diaphragm does not add any colour, odour or taste to the water. Corrosion-resistant coating inside. Internationally approved and certified. C E R T I F I E D 116 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

6 Expansion Vessels for Sanitary Installations 4 Internationally Used and Approved Flamco has been delivering Airfix expansion vessels for many years now. Households all over the world are entirely used to such expansion vessels as part of their potable water system. Installers all over the world confirm how easy it is to install an Airfix expansion vessel from small homes to big utility buildings and, consequently, how easy it is for your client to save precious water and energy. Our trademark white Airfix expansion vessels comply with set standards, which means they can be installed immediately. Assembling an AirfixControl between vessel and T-piece makes it possible to depressurise the Airfix vessel for maintenance purposes, without putting the system out of service. Airfix D vessels use a specially supplied T-piece, with a flowthrough design via an internal divider, to ensure complete flowthrough of the vessel. Special rubber diaphragm and vessel coating have been internationally approved for use in combination with drinking water, in accordance with CE regulation 2002/16/EG. Internal coating prevents rust formation, even in the event of a defective diaphragm. All Airfix A and Airfix D vessels are white in colour. AIRFIX D Reliable clamping ring construction that does not damage the vessel or the diaphragm and facilitates preservation of the entire vessel surface, which is not possible with scarfed vessels. Product overview 2013 We reserve the right to change designs and technical specifications of our products. 117

7 Calculation for Airfix Vessels for Mains Water Systems Basic Concepts for the Calculation of an Expansion Vessel in a Mains Water System The following concepts are important in selecting the right vessel: System water capacity The total capacity of the boiler system. Increase in water volume (in %) The table below shows data on the water volume increase in percentage points when the temperature of the water increases by between 10 C and 70 C. Increase in temperature Increase in volume C 0.75% C 1.18% C 1.68% C 2.25% Expansion volume The expansion volume is determined in the following way: expansion volume = capacity x increase in volume at the maximum temperature. Fill level The pressure of the water supply when cold must be 0.2 bar above the initial pressure of the expansion vessel; otherwise, as the vessel cooled down the total water capacity would not be pushed out of the expansion vessel. That is why there must always be a residual amount of water in the vessel at the lowest operating pressure. This is called the fill level. Initial pressure of the vessel This must be 0.2 bar under the pressure of the water supplied when cold. Residual factor 1 - fill level: This determines the residual factor of the expansion vessel. Output This is an expression of the ratio between gross and net vessel capacity. Cold water supply pressure - Initial pressure I = fill level Cold water supply pressure This means that the residual factor of the vessel can be determined. Residual factor = 1 - fill level. The end pressure must be 10% lower than the set pressure of the safety valve. The output is calculated using the formula below: End Cold water pressure - supply pressure II x residual factor = output End pressure Note: pressure in bar absolute The maximum permissible output for the Airfix D-E/D- E-B vessels is 60% (0.60), while for the A and D vessels it is 63% (0.63). End pressure This is the maximum permissible pressure of the system at the vessel itself. The end pressure is equal to 90% of the set pressure of the Prescor boiler valve or the Prescor inlet assembly if it is mounted at the same level as the vessel. Gross vessel capacity The gross capacity of the vessel is determined in the following way: expansion volume gross capacity of the vessel = output 118 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

8 Expansion Vessels for Sanitary Installations 4 Example Calculation of Expansion Vessels for Mains Water Systems Data - water capacity of the boiler = 150 litres - maximum water temperature = 70 C - cold water supply pressure = 4 bar - safety valve set pressure = 8 bar - vessel initial pressure (4-0.2) = 3.8 bar - end pressure (mean) = 7.2 bar Initial vessel pressure = Cold water supply pressure bar = 3.8 End pressure (mean) = Set pressure of safety valve x 90% = 7.2 bar. Calculation Increase in volume: at 70 ºC is 2.25% = 150 x 2.25 % = 3.4 litres (cold water supply pressure - initial pressure) ( ) - ( ) Fill level: = = 0.04 (cold water supply pressure) ( ) Residual factor: 1 - fill level= = 0.96 (end pressure - cold water supply pressure) ( ) - ( ) Output: x residual factor = x 0.96 = (end pressure) ( ) Required gross capacity of expansion vessel: 3.4 / = 9.1 litres Airfix expansion vessel to select: Airfix A 12/4.0 (adjust initial pressure locally to 3.8 bar). Product overview 2013 We reserve the right to change designs and technical specifications of our products. 119

9 Instructions for Correct Fitting of Expansion Vessels in Hot Water Potable Systems Where an expansion vessel is used in a potable system, it must always be used in combination with a Prescor inlet assembly or Prescor B boiler valve. The expansion vessel must be fitted in the coldwater line, between the non-return valve and the boiler. The expansion vessel's initial pressure must be lower than the pressure in the cold-water line or the pressure behind a governor. The use of expansion vessels in boiler systems must always comply with the demands of the local water authority. Airfix selection table Boiler capacity Initial pressure [bar] Prescor B boiler valve set pressure Prescor inlet assembly 6 bar 7 bar 8 bar 10 bar Airfix 8/3 Airfix 8/3 Airfix 8/3 Airfix 8/ Airfix 12/4 Airfix 8/4 Airfix 8/4 Airfix 8/ Airfix 12/3 Airfix 8/3 Airfix 8/3 Airfix 8/ Airfix 18/4 Airfix 12/4 Airfix 12/4 Airfix 8/ Airfix 18/3 Airfix 12/3 Airfix 12/3 Airfix 8/ Airfix 25/4 Airfix 18/4 Airfix 18/4 Airfix 12/ Airfix 18/3 Airfix 18/3 Airfix 12/3 Airfix 12/ Airfix 35/4 Airfix 25/4 Airfix 18/4 Airfix 12/ Airfix 25/3 Airfix 18/3 Airfix 18/3 Airfix 12/ Airfix 35/4 Airfix 25/4 Airfix 25/4 Airfix 18/4 120 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

10 Expansion Vessels for Sanitary Installations 4 AIRFIX A For use in potable water or fresh water installations. The inside of the Airfix vessel has a special coating which prevents oxidation. The composition of the diaphragm has been made for this range in such a way that there will be no variation in smell, colour or taste of the water. The famous Flexcon clench ring construction allows the water section to be coated before assembly. The Airfix A is fitted with a synthetic flow through device in a standard T-piece (included) which eliminates the formation of unwanted bacteria. Max. vessel temperature (bladder): 70 C. Max. working temperature (design): 70 C. Including flow through T-piece ¾". Approvals: DVGW-W270 WRAS ACS PZH KIWA approved execution available on request. Airfix A Precharge [bar] Max. work. press. [bar] Dimensions Ø H. Connection Weight Airfix A / 4" Airfix A / 4" Airfix A 8 specify / 4" Airfix A / 4" Airfix A / 4" Airfix A 12 specify / 4" Airfix A / 4" Airfix A / 4" Airfix A 18 specify / 4" Airfix A / 4" Airfix A / 4" Airfix A 25 specify / 4" Airfix A / 4" Airfix A 35 specify / 4" Airfix A / 4" Airfix A / 4" Nr AIRFIX D For use in potable water or fresh water installations. The inside of the Airfix vessel has a special coating which prevents oxidation. The composition of the diaphragm has been made for this range in such a way that there will be no variation in smell, colour or taste of the water. The famous Flexcon clench ring construction allows the water section to be coated before assembly. The Airfix D is fitted with a special synthetic full flow through device which eliminates the formation of unwanted bacteria. Max. vessel temperature (bladder): 70 C. Max. working temperature (design): 70 C. Including special full flow through device. Approvals: DVGW-W270 WRAS ACS PZH KIWA approved execution available on request. Airfix D Precharge [bar] Max. work. press. [bar] Dimensions Ø H. Connection Weight Airfix D / 4" Airfix D / 4" Airfix D / 4" Airfix D / 4" Airfix D / 4" Nr Product overview 2013 We reserve the right to change designs and technical specifications of our products. 121

11 Well-designed Airfix Technology Offers Users Significant Benefits Diaphragm pressure expansion vessels with removable diaphragms are suitable for use in hot water, boosted and water-supply systems. The Airfix D-E expansion vessel can be used in boosted systems either on the suction side or the discharge side of the pumps. These systems are designed to prevent low pressures and changes in pressure at low flow rates. AIRFIX D-E-B AIRFIX D-E-L Airfix D-E-B For domestic, process or extinguishing systems, with a coated steel single threaded connection as standard. Airfix D-E Flow through design. The coated two-way flanged system connection is directly connected to the flow of the mains water line. Airfix D-E-L Streamlined flow through diaphragm pressure expansion vessel for use in pressurising, water supply and drinkingwater systems. AIRFIX D-E Benefits Airfix D-E Vessel flow through. Low pressure drop. The standard diaphragm-rupture sensor may be configured for remote-control read-out. Easy to install, with a long service life. All vessels are ACS-certified. 122 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

12 Expansion Vessels for Sanitary Installations 4 Airfix D-E: sturdy, reliable and easy to install The Airfix D-E is a flow through vessel with two flanged connections and is equipped with a removable butyl-rubber bladder. The Airfix D-E is fitted with an electronic diaphragmrupture sensor as standard and has an internallycoated steel flow through flange. The Airfix D-E expansion vessel collects the water in its butyl-rubber bladder. Should the system pressure rise (when the pump starts up or water is no longer being drawn off) the vessel will take in water which will collect in the diaphragm; should the system pressure drop (if water is drawn off), this water will be recirculated into the draw off line. The flow rate through the vessel is coupled with a minimal loss of pressure. Pressure gauge with self-sealing reducer, vessel connection Rp 3 /8" DIN Diaphragm-rupture sensor, red LED light to indicate diaphragm rupture. Normal permissible initial gas pressure in delivery condition: 6 bar. Airfix D-E vessels have a green external coating. Coated two-way connection for the system pipework. AIRFIX P 500 AIRFIX D-E Benefits Airfix P A wide-ranging line, suitable for many different uses. Available in both vertical and horizontal models. All vessels are WRAS and ACS-certified. Product overview 2013 We reserve the right to change designs and technical specifications of our products. 123

13 Airfix Expansion Vessel Calculation for Pressure Boosting Sets (Mains water) The system can be used for the following applications: a. In small independent mains-water systems which draw water from an aquifer or well. b. in systems which, although they are connected to a water main, are so far from a pumping station or water tower that pressure must be boosted locally. The pressure expansion vessel is used to maintain uniform pressure in the system in combination with a pressure switch that activates and deactivates the pump. If the pressure expansion vessel in question has a greater capacity than required for the aforementioned use, it can also be used as a storage vessel. In this respect, the pump does not have to be activated when small amounts are removed by the system, increasing the pump's overall service life. The cut-in pressure of the pressure switch should preferably be set 0.2 bar higher than the expansion vessel's initial pressure. The cut-in pressure for a expansion vessel with 3.0 bar initial pressure is therefore 3.2 bar. Selecting the appropriate Airfix expansion vessel Two factors play an important role in the choice of an expansion vessel. The first consideration is the total flow requirements of the system. This determines the pump capacity, which can be used as the basis for the calculation. The second factor of importance is the time the pump needs to top up the expansion vessel from minimum to maximum pressure. 124 Product overview 2013 We reserve the right to change designs and technical specifications of our products.

14 Expansion Vessels for Sanitary Installations 4 The size of the pressure expansion vessel can be calculated using the following formula: Q u + Q i p u + 1 p i + 1 V = x = x x x t 2 p u p i p v + 1 This formula uses the following parameters: V = capacity of the pressure expansion vessel in litres. Q u = pump output at cut-out pressure in m 3 /h. Q i = pump output at cut-in pressure in m 3 /h. p u = pressure switch cut-out pressure in bar (abs.). p i = pressure switch cut-in pressure in bar (abs.). p v = initial pressure of the pressure expansion vessel in bar (abs.). t = time in seconds during which the vessel can be drained without the pump cutting in. If V is between the capacity values of two pressure expansion vessels, the larger of the two must always be selected. If the smaller pressure expansion vessel is selected, the switching frequency of the pump will increase significantly which, in turn, will have an adverse effect on the pump's service life. If you need to discharge small amounts of water often without the pump cutting in, choose a greater value for time; the value of V, the capacity of the pressure expansion vessel will, accordingly, rise too. The pressure expansion vessel will then also work as a storage vessel. In this situation, we recommend using a flow-through Airfix vessel. For larger capacity vessels it is possible to connect more than one pressure expansion vessel in parallel. Instructions on how to install pressure expansion vessels for potable appliances in pressure boosting sets Shut off valve Shut off valve Non-return valve Pump Reducer valve Pressure switch PS Non-return valve Airfix D-E Gas fill valve/ inspection connection Pressure gauge Pressure gauge Control valve Non-return valve Shut off valve Airfix A/D Pump Shut off valve Drain cock Non-return valve To the system Mains water systems, particularly those which draw water from an aquifer or well, have relatively high levels of air. Thus, the pressure expansion vessel must be fitted so that there is no chance of an 'air cushion' forming at the diaphragm. The pressure expansion vessel is filled with a controlled throughput. We recommend fitting a pressure regulator. Product overview 2013 We reserve the right to change designs and technical specifications of our products. 125

15 AIRFIX D-E High quality vessels for use in all (potable) water installations. Its special flow through construction eliminates the formation of unwanted bacteria. The composition of the diaphragms has been made for this range in such a way that there will be no variation in smell, colour or taste. The inside of the Airfix connection flange has a special coating which prevents oxidation. Replaceable bladder. Electronic diaphragm rupture sensor. With flange connection. Max. working temperature: 70 C. Material quality: - ASTM/ISO: A181 class 60 / S235JRG2. - EN/ISO: P245N. ACS certified. Airfix D-E bar Maximum operating pressure: 10.0 bar. Dimensions Flanges * (2x) Ø H. Weight Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN * According to EN PN16. Airfix D-E bar Maximum operating pressure: 16.0 bar. Dimensions Flanges * (2x) Ø H. Weight Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN Airfix D-E DN * According to EN PN16. Remote Signaller for Diaphragm Rupture Sensor Remote signaller for diaphragm rupture sensor for Airfix D-E expansion vessels. Only with this appliance it is possible to have a remote signal from the rupture sensor of the Airfix D-E. Remote bladder rupture detector (ordered seperately) Product overview 2013 We reserve the right to change designs and technical specifications of our products.

16 Expansion Vessels for Sanitary Installations 4 AIRFIX D-E-L Standard vessels for use in all (potable) water installations. The construction also permits use in closed HVAC installations with a maximum temperature of 70 C. Its special flow-through construction eliminates the formation of unwanted bacteria. The composition of the diaphragms has been made for this range in such a way that there will be no variation in smell, colour or taste. The inside of the Airfix vessel has a special coating which prevents oxidation. Replaceable bladder. Visual bladder rupture indication by sight-glass. Max. operating pressure: 10.0 bar. Max. working temperature: 70 C. Material quality: - ASTM/ISO: A181 class 60 / S235JRG2. - EN/ISO: P245N. Airfix D-E-L Dimensions Connection Weight Ø H. Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Airfix D-E-L G 1 1 / 4" Product overview 2013 We reserve the right to change designs and technical specifications of our products. 127

17 AIRFIX D-E-B Standard vessels for use in all (potable) water installations. The construction also permits use in closed HVAC installations with a maximum temperature of 70 C. The composition of the bladder has been made for this range in such a way that there will be no variation in smell, colour or taste. The inside of the Airfix connection flange has a special coating which prevents oxidation. Replaceable bladder. With single threaded steel connection (no flow-through function). Max. working temperature: 70 C. Material quality: - ASTM/ISO: A181 class 60 / S235JRG2. - EN/ISO: P245N. ACS certified. Airfix D-E-B bar Maximum operating pressure: 10.0 bar. Dimensions Ø H. Connection (F) Weight Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B " Airfix D-E-B " Airfix D-E-B " Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B bar Maximum operating pressure: 16.0 bar. Dimensions Ø H. Connection (F) Weight Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B " Airfix D-E-B " Airfix D-E-B " Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Product overview 2013 We reserve the right to change designs and technical specifications of our products.

18 Expansion Vessels for Sanitary Installations 4 Airfix D-E-B bar Maximum operating pressure: 25.0 bar. Dimensions Ø H. Connection (F) Weight Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B " Airfix D-E-B " Airfix D-E-B " Airfix D-E-B / 2" Airfix D-E-B / 2" Airfix D-E-B / 2" AIRFIX D-E(B) SEPARATE CONNECTIONS Material quality stainless steel executions: AISI 304. Mono Connections Connection Mono small - Stainless steel G 1 1 / 2" Mono medium - Stainless steel G 2" Mono large - Stainless steel G 2 1 / 2" Mono small - Coated steel G 1 1 / 2" Mono medium - Coated steel G 2" Mono large - Coated steel G 2 1 / 2" Duo Connections Stainless steel: AISI 304. Connection Vessel System * Duo small - Stainless steel G 1 1 / 2" PN16 DN Duo medium - Stainless steel G 2" PN16 DN Duo large - Stainless steel G 2 1 / 2" PN16 DN * According to EN PN 16. Product overview 2013 We reserve the right to change designs and technical specifications of our products. 129

19 AIRFIX P Potable water expansion vessels for use in domestic and commercial sealed chilled and hot water systems. Designed to incorporate a unique contoured, replaceable bladder. Standard gas charge: 3.5 bar. Airfix P 2-35 Maximum working pressure: 10.0 bar. Colour: coated grey (RAL 9006). WRAS and ACS certified. Dimensions Ø H. Connection (M) Weight Diaphragm Airfix P / 2" 4,6 * Butyl Airfix P / 4" 1.5 Butyl Airfix P / 4" 1.7 Butyl Airfix P / 4" 2.2 Butyl Airfix P / 4" 2.9 Butyl Airfix P / 4" 3.4 EPDM Airfix P / 4" 3.5 EPDM Airfix P / 4" 4.3 EPDM Airfix P " 8.0 EPDM * Set of four in one box. Nr Airfix P Maximum operating pressure: 10.0 bar. Colour: coated grey (RAL 9006). WRAS and ACS certified. Dimensions Ø H. Connection (M) Weight Airfix P " Airfix P " Airfix P " Airfix P " Airfix P " Airfix P / 4" Airfix P / 4" Nr Product overview 2013 We reserve the right to change designs and technical specifications of our products.

20 Expansion Vessels for Sanitary Installations 4 Airfix P Maximum operating pressure: 10.0 bar. Colour: coated grey (RAL 7040). Airfix P 750-3,000 supplied with feet. Dimensions Ø H. Connection Weight (M) Airfix P 500 * R 1 1 / 2" 86 EPDM Airfix P R 1 1 / 2" 128 EPDM Airfix P Rp 2" 163 Butyl Airfix P Rp 2 1 / 2" 423 Butyl Airfix P Rp 2 1 / 2" 483 Butyl Airfix P Rp 2 1 / 2" 537 Butyl Airfix P Rp 2 1 / 2" 766 Butyl Airfix P Rp 2 1 / 2" 1620 Butyl * WRAS and ACS certified. Airfix P Horizontal Maximum operating pressure: 10.0 bar. Colour: coated grey (RAL 9006). WRAS and ACS certified. Max. working pressure [bar] Diaphragm Dimensions Ø H. Connection (M) Weight Airfix P 24-H / 4" Airfix P 50-H " Airfix P 60-H " Airfix P 80-H " Airfix P 100-H " Airfix P 150-H " Airfix P 200-H / 4" Airfix P 300-H / 4" Airfix P 500-H / 4" Nr Product overview 2013 We reserve the right to change designs and technical specifications of our products. 131

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