Rubber pipes

Rubber pipelines

Moldings and fittings

from rubber

For corrosive and abrasive

conveyance materials such as

quartz, granulates, cullet,

salts, acids, granulated

cinder, dross, coal, wash

waste, hydrochloric acid,

gypsum, sulfurous acid,

gravel, sodium

hydroxide,sludge, etc.

In power plants, steel works,

mining, the chemical industry,

environmental technology,

surface and underground

construction, gravel

extraction, etc.

GUR

GUR for plant construction

We have many years of

comprehensive experience

working with rubber pipe parts in

plant construction. Compensators

have proven their value in flue gas

desulphurization systems on flue

gas scrubber pumps, as pipes for

gypsum slurry, lime milk circular

pipelines, and in many other

places.

Due to their lack of heat

expansion, rubber pipes are often

advantageous for the conveyance

of lyes acids, and saline

solutions. Another advantage is

their ease of assembly and the

feasibility they afford for the use

of complex parts in pressure-proof

construction.

In many cases the high heat- and

sound-absorption capacity of

rubber pipes allows for greater

savings in insulation that would

otherwise be required.

Rubberpipes

GUR

2

Sand- and gravel conveyance

For years rubber pipes – especially

suction- and pressure bends – have

been used successfully on dredger

ships. Conveyance lines for gravel

slurries have proven effective over

many years of use in wet mining

both on land and in water. The result

is an outstanding service life as

compared to lines made of steel or

high-carbon steel.

Rubber pipes can be installed to float

on pontoons. One effective type of

floating lines are those with floating

bodies, which are particularly

effective when exposed to windy

conditions.

3

Chemical industry

In the chemical industry,

compensating, reducers

have proven effective as a

replacement for wear- and

fault-prone combinations

of reducers and expansion

bellows. Bend pieces also

have a significantly

longer service life in

comparison to rubberized

pipe parts.

Rubber pipes in mining

The treatment and processing of ores, coal, and minerals includes

process steps where the conveyance of highly abrasive slurries is

necessary. In coal washing, in flotation systems, and other similar areas

of application, rubber parts have proved to have superior service life

compared to rubberized steel- and plastic pipes.

In steel mills, rubberized piping is used in slag granulation and for

descaling water lines.

Rubberpipes

GUR

GUR 1 series

The series 1 is a design with a highly

elastic and abrasion resistant inner

wear layer with a thickness of 15 mm

and high rigidity. Series 1 Pipes are

well suited both for free laying on

uneven terrain, for piping constructions

in plantsand for floating pipes on

pontoons or with lifting bodies.

GUR BR1 is optimized for the

conveyance of abrasive slurries and is

tested in the excavation of gravel and

sand, in conveying flue gas

desulphurization slurries, sinter water,

slurries, salt sludge, wash dirt,

granulates, and other highly-abrasive

materials.

Specific designs of rubber pipes, e.g. with ventilation and measurement connections or with integrated heating

elements, are available or can be designed by immuG to meet customer requirements.

GUR 3 series

The series 3 is designed with a 12 mm

thick, highly elastic and wear-proof

inner layer. It is used for pipe

constructions, especially those with

lower nominal widths, and aids in the

conveyance of abrasive materials.

Series 3 also includes the special

designs which are available for the

series 1.

4

Technical data of straight GUR rubber pipes

GUR 2 series

The GUR Series 2 is a solid rubber

construction for conveying corrosive

and aggressive materials. In this

series the standard pipe includes an 8

mm thick wear layer made from rubber

that is specially adapted for this type of

application

Rubber pipes in the series 2 are

especially suitable for transporting

acids. They are specially suited for

piping constructions in chemical plants,

water treatment systems, etc.

Information for use when selecting

rubber is provided in the resistance

table at www.immug.de.

Rubberpipes

GUR

5

Technical data for bends GUR-BG

Bends

Bends are designed and built in the same way as the rubber pipes in series 1, 2,

and 3. They differ from straight rubber pipes in that they lack a stiffening inlay.

For that reason they have some flexibility and the molding capability that

results is useful in the construction of pipes. With its residual flexibility, it

compensates for small differences in length that can result when assembling

straight segments.

The special production process used at immuG for GUR bends allows for

continuous configuring of both the bend radius and bend angle. This capability

is especially advantageous in practical use where existing complex pipes need

to be replaced with rubber pipes. For use with extremely abrasive slurries, we

offer a range of special designs with a reinforced wear layer.

Bends are not vacuum-proof in the standard design. Exposure to a vacuum will cause them to contract. An occasional

vacuum will not, however, compromise the service life of the bends. For GUR bends that are constantly exposed to a

vacuum we provide steel reinforcements.

GUR bends with leg extensions offer the user two advantages. When used for the conveyance of highly abrasive

slurries, a leg extension on the inlet side improves the service life of bends thanks to a "softer" redirection of flow.

The second advantage is that bends with leg extensions economize on equalizing- and fitting pieces. The leg extension

can also be designed as a reducer. These types of GUR bends reduce the need for variable parts in pipe construction.

ND ND ND

a a a

R R RSV RV

Bend asymmetric Bend reducing bend

Shown data are guide values. We gladly examine your requirements in respect to realisability.

Rubberpipes

GUR

6

T-pieces and junctions are components of pipes and are used in them in a very wide range of designs and dimensions.

When refitting existing pipes to the GUR system, virtually all T-pieces and junctions made with other materials can

be reproduced as a GUR part. But it is important to note that, depending on the manufacturer, T-pieces in the GUR

system will have overall lengths that are greater than those made of steel or plastic. The wear layer at the transition

between continuous and branching line is designed extra thick on GUR parts. The wear allowance that is provided

also ensures superior service life in these critical places.

In the gravel industry, T-pieces are often used as an inspection- or cleaning opening. Rubberized sealing caps are

included with delivery of the GUR system for this purpose.

Junctions can also be installed on long pipes to economize on flange connections in pipes. NW 50 and 25

measurement connections can also be installed.

The highly developed production processes at immuG Rohr + Schlauch GmbH make it possible for unusual T-piece

designs to be manufactured. Multiple outlets from a main pipe can be combined in a single part. In many instances

this results in highly cost-effective solutions. Junctions (Y-pieces) with different nominal widths and branch angles

can also be provided.

The T-pieces from immuG Rohr + Schlauch GmbH are built with FL flanges in the standard design, but they are also

in part provided with FR-, SL-, and SF flanges (details on these flange models are provided on pages 10 and 11).

On account of the wide range of variations that are possible for T-pieces, it is not possible to list the full range of

available types here. The diagrams on this page indicate which dimensions are required in preparing proposals

pertaining to T-pieces. The GUR T information sheet provides details on the possible maximum and minimum values

for NW, L, m, n, and a.

Technical data of GUR-T T-pieces for rubber pipelines

T-pipes T-pipes with multiple outlets Bifurcations

Types of construction T-pipes and Bifurcations

Rubberpipes

GUR

7

Compensators GUR-K and GUR-KR for rubber pipelines

Compensators are required for the construction of pipes. These

ensure a balancing of the horizontal, lateral, and radial

movements between pipe parts and to absorb vibrations.

Especially with larger nominal widths, the turbulence-free GUR-

K and GUR-KR models, which are used without tension rods, are

considerably more effective than expansion bellows. In addition

unlike expansion bellows they do not introduce shear forces into

the connecting flanges even at high operating pressures.

GUR-K compensators are straight compensators with a constant

nominal width along their entire length. They differ from basic

hoses in the type of textile reinforcement used, which has a

specially optimized design for any application.

A reduction in the nominal widths of pipes is often required along

the pipe route. Before and after junctions, and especially behind

and in front of pumps, reducing elements are required for purposes

of adapting flow rates. In many cases they are exposed to intense

wear and tear, as the flow expansion causes turbulence and

cavitation, which increases abrasion. Reducers that are installed

after pumps are also exposed to torsion in the flow that is caused

by the pump. Reducers made from metallic materials or plastics

often have an unsatisfactory service life in applications of this

type.

Reducers GUR-KR boast long service lives thanks to their textile-

reinforced solid rubber construction. The extra wear-proof rubber

quality and the elastic construction further minimize the wear

caused by cavitation. GUR-KR reducers are equipped with

specially designed textile reinforcement, which guarantees the

compressive strength, ensures the compensating effects of the

GUR-KR reducers, and is designed to prevent a lateral bending

moment with asymmetrical parts.

In the standard model, GUR-KR reducers have a 1:3 gradient in

the symmetrical and asymmetrical designs. This results in an

opening angle of 9.5° on both sides of the axis, or 18.9° on one

side.

immuG Rohr + Schlauch supplies reducers ranging from NWk =

25 to NWg = 1400. Details on the available dimensions and rubber

types are available in our GUR-K information sheet.

GUR-K and GUR-KR for plant construction

Reducers with large nominal widths are often required in plant construction. immuG supplies

parts up to NW 1400. The effects provided by GUR-KR in particular, which provide relief to

the connecting flanges, play an especially large role in these cases. Especially when used on

pumps, the combined reducing and compensating action results in a simple and cost-effective

design in construction. These large reducers are designed, developed, and constructed to meet

specific customer requirements and structural specifications. Measurement- and drain

connections can be integrated in them. Various flange types are also available.

Detailed information on GUR-KR reducers for plant construction is available in the GUR-KR

information sheet.

Rubberpipes

GUR

8

What are rubber pipes?

Rubber pipes represent an enhancement of rubber hoses which were designed for fixed installation in pipe systems.

They generally differ from hoses in that they are not flexible. In addition to straight pipes, the rubber pipe system

includes bends, reducers and T-pieces which are required in assembling pipes. Their application range is not the same

as that of hoses. Instead rubber pipes are a viable replacement for other types of pipe, e.g. rubberized steel pipes or

plastic pipes.

The special feature of rubber pipes, or "GUR", for short, is that they have an extra-strong wear layer which makes

them especially well suited for conveyance of abrasive slurries. The thickness of the wear layer is several times

greater than that of rubberized steel pipes. In addition, the rubber layer is also seamless with large and maximum-

sized inner diameters. This makes them less prone to unwanted separation of rubber layers, which is a frequent cause

of malfunctions in rubberized steel pipes. Compared to plastic pipes, rubber pipes are considerably more resistant to

abrasion and corrosion.

Structural features of rubber pipes

Rubber pipes have their special characteristics owing to their

typical structure. A sectional view of the flange area of a GUR is

shown in the drawing. The abrasive-resistant inner layer, also

called a core, is followed by the standard stiffening inlay for

rubber pipes. It consists of a metal plate device that ensures the

stability of the GUR. The pressure carrier made of heavy-duty

textile cord sits on the metal plate device. It is anchored on a

round steel ring in the flange area which absorbs the tensile

forces resulting from the conveyance pressure and passes them

on to the rear flange. Bends in the GUR system do not have a

stiffening inlay and are therefore more flexible than straight pipe

pieces. This feature is helpful in pipe construction because the

bends can then accommodate small length differences that arise

between the planning and execution phases of the pipe.

Likewise, compensators and reducing compensators likewise do

not have a stiffening inlay, which enables them to fulfil their

role as a compensator for vibrations, thermal expansions and

movements.

Thanks to the multi-part stiffening inlay, GUR pipes are also

self-compensating. The thermal expansions are converted to increased circumferences by the rubber pipes, thereby

minimizing the longitudinal forces affecting the flanges. Rubber piping can thus be constructed with simple fixed

bearings. Sliding bearings and compensator segments, such as those which are required with pipes made of other

materials are not used with pipes made of GUR. The good thermal insulation of rubber pipes is also noteworthy. This

is explained by the rubber material's low thermal conduction coefficient, which enables rubber piping to be

manufactured without insulation or heat tracing, as is required for steel or plastic lines. Another characteristic of

rubber pipelines is their sound insulation capacity. This is based on the plastic-elastic performance of rubber, which

results in extremely high sound reduction values.

Use of rubber pipes

Rubber pipes are especially well suited for conveyance of abrasive and corrosive materials and slurries. They are

especially useful for conveyance of fluids that are simultaneously corrosive and abrasive. Rubber pipes are

manufactured in different series, customized to the specific application. The series 1 is used for pipes of medium to

large nominal width and is characterized by an extra strong wear-proof core. Like series 3, which covers low nominal

width ranges, it is intended for applications with abrasion or a combination of abrasion and corrosion. The series 2 is

designed for use preferably with corrosive conveyance materials. The rubber quality of the core is customized to the

conveyance material. The thickness of the core in series 2 is less than that of series 1 and 3, and is available with all

rubber qualities up to FKM.

Patents and utility models are pending for production and applications of rubber pipes.

Rubberpipes

GUR

9

Rubberpipes

GUR

Installation of large compensators

Compensating reducers GUR-KR and GUR-K firstly are mounted to the pump flange. Attention shall be payed on

correct tightming torgue and supporting of the part, if it is placed horizontal, to enable mounting free of distortion.

Subsequently the piping is build to the rubber part, keeping the gap being decisive for propper function of the

compensators. The standard gap is 6 mm for parts with a nominal width up to NW 500, above that the gap is 10 mm.

After completition of the piping the gap is closed by tightuning the screws. Finally the screws are adjusted to the

givem torgue.

Assembly instructions

Screwing together of Rubber-Pipes or with other pipes

Rubber tubes are screwed together without inserting gaskets between the

individual tubes. The o-rings at the rubber sealing surfaces of the pipelines

steadily provide for a pressure-resistant sealing of the screw connection. The

flanges generaly are of FL type. In GUR special components, also FR type

flanges can be used. The assembly instructions apply to both types.

The tightening torques ensuring a pressure-resistant screwing connection are 70

Nm to NW 300.120 Nm will be sufficient up to a value of NW 500. The

tightening torques for larger NW are available on request.

Please note in general when mounting GUR not to destroy the rubber sealing surfaces by applying excessive

tightening torques. The rubber sealings must not be compressed more than 20 % of their thickness. In large flanges,

using a distance gauge may prove useful.

As an aid for keeping the correct flange distances sleeves serve als an spacer. The sleeves with adapted length are

supplied on request. FR-flanges will be mounted without distance sleeves.

When screwing together rubber tubes, common rules shall apply, i.e. crosswise screwing, evenly tightening and

avoiding any flange tilt.

With steel flanges, GUR components are screwed together in the same way. Also in steel flanges, no sealings are

used. Any hard material sealing put between a GUR and a steel flange would produce untight flange connections.

Rubber pipelaying in pipe routes

Rubber tubes are basically designed for applications to pipe routes with the same pipe prop distances as used for steel

tube assembly. However the prop distance should not exceed 6 m.

Pipe clamps or other pipe route supports. as those used for steel tubes, are also applicable for rubber tubes. Please note

that the outer diameter of rubber tubes is usually larger than of steel pipes of the same nominal width. When mounting

rubber pipelines in existing pipeline systems and existing routes, it may become required to adapt or renew the

fastening elements.

GUR type rubber pipelines are self-compensating. With the special design of the steel reinforcement construction

inside the rubber tubes, the heat-related elongations due to elastic strain within the individual rubber tubes are

compensated. The particular advantage for the user is that no compensators are required for rubber pipelines. The

pipeline itself is, so to speak, the compensator.

Rubber pipelines are therefore simply "tightened". Fixed bearings of the simplest type are used here. Any movable

bearings, slide bearings or expansion bends are not used in GUR pipelines.

GUR is designed for inserting rubber tubes in normal grippings, which are also common for steel tubes. It is not

necessary to support the rubber tube lengthwise using half shells or other constructions. The rubber tube supports

itself and its filling freely between the prop distances. Please note when pipelaying preferably not to damage the outer

rubber coat, which serves as anticorrosive for the underlying reinforcement construction. Any substantial damage

would undo its functionality.

Standard pipe clamps are suited to mount GUR. It should be kept in mind, that outer diameters of GUR are larger than

these of steel pipes of the same nominal width. Less suited are pipe clamps for fixation of bends, reducers and tees.

Instead of these parts are fastened by specially for the GUR-system developed hangers GUR-A using their flanges.

GUR-A also provide fixation and support of shorter pipes.

distance bushing

10

Flanges

Flange FL

The flange FL has proven effective over many years of use in all application areas

of rubber pipes. One of its characteristic features is the steel ring, which introduces

the forces (e.g. tensile forces) into the flange connection which move along the

longitudinal axis of the pipes. The pressure carriers are placed around it and

fastened. This anchoring device is fully embedded in rubber and

completely fills out the groove in the rear flange. During the

manufacturing process, the flange is the mold for the rubber-

encased anchoring ring. This results in a power transfer from the

flange to the pressure carrier fabric of the hose that is completely

free of play.

The design has proven effective up to maximum pressure levels and is a standard at immuG Rohr +

Schlauch GmbH for LP up to 65. The flange FL can be used universally and is easy to assemble

thanks to the freely rotating nature of the flange. Another contributing factor is the low weight of the

design. When assembling the flanges, it is necessary to ensure the uniform distribution of forces

along its circumference during transport and when bolting the pipes.

Flange FR

With the FR flange the forces that run parallel to the longitudinal

axis of the rubber pipes are transferred directly to the flange. The

guiding of the textile layers between the flange and the blank

serves to fasten them. The number of installed blanks increases as

the nominal width and pressure level of the pipe rises. The large

sealing surface, consisting of a core material with embedded O-

rings, makes this flange non-susceptible to tilting during assembly.

Hoses with an FR flange are thus well suited for assembly in

rough, spatially difficult, and cramped conditions.

SL flange

In hoses with SL flanges a steel support is placed at the end of the hose on the core.

A coil is provided at the end of the support. The core rubber on this coil is molded

to form a seal with embedded O-rings. Pressure and stability carriers of the hose are

mounted on the outside of the support. This results in a heavy-duty

design that enables hoses with very high pressure ratings to be

fitted with this flange. The entire structure is covered with rubber

and is thus protected from external influences. A freely rotating

flange is mounted behind the support coil.

The SL flange is well suited to absorb high levels of tensile forces

combined with side drag. Stress of this type is typical for hoses

where there is considerable bending during use. With its metallic surface, the support offers the

option to install overlay hoses and grounding mechanisms.

Rubberpipes

GUR

room for your planning sketches

11

Flanges

Nozzle flange SF

The structure of this flange is similar to that of the SL type, the

difference being that here the flange is mounted to the support

instead of the coil.

The nozzle flange SF also has the same application areas and

special advantages as the nozzle flange SL. It is recommended for

use when the assembly situation is free of complications and the

free rotating capacity of the flange is not essential.

Both support flange constructions are available as 150 ≤ NW ≤ 400

for DIN flanges. Steel is the standard material. Flanges made from

other metals are available by request. The same applies for

dimensions that meet different standards.

Center-sealing surface ZF

For conveyance of highly abrasive slurries, pipelines must be laid with precision so that

there is no height or lateral offset between the axes of the individual pipes. Otherwise the

flow turbulence levels in these offsets will cause premature wear and tear at the pipe

transitions.

The centering flanges ZF facilitate proper alignment during pipe installation.

The ZF profiles of the sealing surfaces can be combined with the FL and SL flange types

and are available for nominal widths between 200 and 400 in the standard version. This

covers the conveyance dimensions that are typical for the conveyance of gravel-water

slurries. ZF A ZF B

Rubberpipes

GUR

D-39356 Walbeck

Schwarzer Weg 5

Phone: 49(0)39 06 14 66 60Sales Department: 49(0)39 06 14 66 614Fax: 49(0)39 06 14 66 646

www.immug.dezentral@immug.de

Service

immuG Rohr + Schlauch GmbH supplies parts for the GUR system

described in the catalog, manufactures GUR parts based on customer

drawings and specifications, and handles all aspects of the delivery

process for pipes. This includes surveying and assessing the equipment

situation, inspecting procedural parameters, carrying out both a rough

and detailed planning for the pipes, and creating designs for them in

existing equipment using 3D-CAD. The assembly of parts then runs

smoothly using the plans and labels of individual parts, which are

manufactured for precise fit with 3d drawings, and is made simpler by

the freely rotating flanges. immuG Rohr + Schlauch will also assemble

the pipes on customer request.

Our skilled staff offers our customers competent and comprehensive

support in all aspects of the proper use of rubber pipes, both in resolving

problems and defects in existing systems and in designing technically

and economically optimized new pipes with GUR. Here they draw on

their experience from a wide range of projects in many applications of

rubber pipes in various solutions for the hydraulic and pneumatic

conveyance of abrasive and corrosive materials.

Quality

immuG Rohr- und Schlauch GmbH uses a certified quality management system that is based on ISO

9001:2008. One component of this is an ERP system which is used to ensure that all relevant product

data is consistently available for spare parts orders over a long time period. The rubber qualities used

were developed in-house and are based on decades of experience. This also enables us to meet the

sophisticated requirements of our customers.

immuG Rohr- und Schlauch GmbH is a specialized company as defined by the Water Resources

Management Act (WHG).

6/2011

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Rubberpipes

GUR