process air systems
TRANSCRIPT
Process air systemsProducts and components for
industrial needs
Process air systems
In its process air technology range, BerlinerLuft. offers
products and components for industrial needs.
The products are designed for specific applications and
specific systems and are manufactured on the basis
of the latest standards. Services range from custom
products to special corrosion protection and coating of
components.
Duct components, coated 419
Welded and folded tubing 422
Protection against corrosion by coating
the components according to requirement
FROM PRODUCT TO SYSTEM
BerlinerLuft. manufactures and supplies specific compo-
nents and systems for ventilation and air conditioning. Both
for non-residential buildings and industrial plant construction.
A public building requires a different air treatment to that
needed for an industrial production process. We develop solu-
tions and products for industrial production processes in vari-
ous industries.
Ventilation towers
and steel chimneys
Products and components
for industry
Ventilation components and parts
in folded and welded design
High performance fans and special fans
For example, our devices and systems provide for clean re-
moval of hot, toxic or aggressive media used for drying or dust
removal.
For regenerative exhaust systems, we provide components
adapted to your specific needs and develop acoustic solutions
to reduce noise.
416 | Process air technology
417
Folded ducting components in tightness classes A, B and C as per DIN EN 1505.
Welded ducting components up to airtightness class D as per DIN EN 1505.
Multi-leaf dampers for
industrial requirements
Industrial silencers, sound enclosures, splitters and welded custom products
417Process air technology |
418 | Process air systems
Service
OURSERVICES
Design, manufacture and delivery of fans and sound insulation
solutions tailored to the customer’s needs
Manufacture and delivery of ducting systems
and associated components
Coordination and assembly of the system components
Technical support for the design of ducting systems
Project and detail design according to design plans
Extended service work such as conversion
and conversion/replacement of existing systems.
Preparation of technical documentation
THE ADVANTAGES FOR YOU
Industry-specific ventilation technology products
and components for industrial applications
Easing the burden of project management and advantages
in purchasing
Customer-optimised and plant-specific solutions
Avoidance of additional interfaces
Support of the value creation process
1 | Execution drawing
2 | Example of a regenerative ventilation system
1
2
Coated ducting components
420 | Process air systems
GALVANISED STEEL DUCT COMPONENTS,
WELDED EPD COATED
Sheet metal ducts and fittings with a rectangular cross section
similar to DIN EN 1505, 1507 and DIN 18379 in welded design.
Sendzimir galvanised thin sheet metal, quality DX51D + Z275MA-C
(DIN EN 10346 and DIN EN 10143) or black sheet S 235 JRG2 as
per DIN EN 10025
With cathodic dip coating (EPD coating)
For UV-resistance: also available with additional powder coating
Sheet thickness according to pressure rating requirements
Airtightness class C and D as per DIN EN 1507
Cross connection using moulded frames.
With perforation according to factory standard
(hole spacing 125 mm)
Turning vanes as per DIN EN 1505
Fixed duct length depending on the cross connection
30 mm moulded frame 30/15 mm,
section length 1,350 mm
40 mm moulded frame 40/20 mm,
section length 1,350 mm
60 mm moulded frame 60/30 mm,
section length 1,300 mm
Other frame geometries on request
STAINLESS STEEL DUCTING COMPONENTS,
WELDED HALAR® ECTFE COATED
Sheet metal ducts and fittings with rectangular cross section
similar to DIN EN 1505, 1507 and VDI 3803 in welded design.
Stainless steel 1.4301, 1.4571 or 1.4404
With inner coating of Halar® ECTFE
Sheet thickness according to pressure rating requirements
Airtightness class C and D as per DIN EN 1507
Cross connection using moulded frames.
With perforation according to factory standard
(hole spacing 125 mm)
Turning vanes as per DIN EN 1505
Fixed duct length depending on the cross connection
30 mm moulded frame 30/15 mm,
section length 1,350 mm
40 mm moulded frame 40/20 mm,
section length 1,350 mm
60 mm moulded frame 60/30 mm,
section length 1,300 mm
Larger formed frames available on request (individual assessment)
Coated ducting components
Welded stainless steel ducting components,
Halar coated on the inside
421Process air systems |
FOLDED DUCTING COMPONENTS
– GALVANISED STEEL EPD COATED
Sheet metal ducts and fittings with rectangular cross section
similar to DIN EN 1505, 1507 and DIN 18379 in folded design.
Made of sendzimir galvanised sheet steel grade DX51D +
Z275MA-C (DIN EN 10346 and DIN EN 10143).
With cathodic dip coating (EPD coating)
For UV-resistance: also available with additional powder coating
Sheet thickness according to low pressure (-500/+1,000 Pa)
or medium pressure (-750/+2,000 Pa) pressure rating
Airtightness classes A, B and C as per DIN EN 1507
Longitudinal seams folded; end connections with slip connection
Turning vanes as per DIN EN 1505
Walls reinforced with trapezoidal corrugation
Additional reinforcements according to pressure rating as
per factory standard
Standard duct section length 1,500 mm
Section width 20 mm – up to edge length 1,000 mm
Section width 30 mm – from edge length 1,000 mm to 2,000 mm
Section width 40 mm – up to edge length 2,000 mm
Surface that is resistant to solvents and corrosions,
acid and alkali-resistant
System suitable for environmental conditions of corrosivity
category C5-M according to ISO 12944-6
Welded tubing
423Process air systems |
PRODUCT DESCRIPTION
Tubing which is welded or longitudinally folded is used in
ventilation systems to convey air for ventilation, extraction,
dedusting or exhaust air purification.
As pressure tubing for conveying media in a wide range of
applications, these tubes are suitable under very specific con-
ditions.
FOLDED DESIGN
WELDED DESIGN
Material quality, design, wall thickness, and surface treatment
depend exclusively on the respective application or use.
The respective specifications and requirements are to be
stipulated by the client or the planner, in direct consultation
with BerlinerLuft. (manufacturer).
Longitudinally folded tube
with flange
Welded and folded tubing
Welded tube,
stainless steel
Longitudinally folded tube with
recessed flange
Longitudinally folded tube
with section flange
and clamping ring (e.g. Metu)
Welded tube with flange
(sheet thickness max. 2.0 mm)
Welded tube with recessed
flange (sheet thickness
max. 2.0 mm)
Welded tube with
fixed flange
424 | Process air systems
Welded and folded tubing
1 | Tube
2 | Tube with cover
3 | Concentric reduction
4 | Eccentric reduction
5 | 90° junction
6 | 45° junction
OVERVIEW OF TUBING
AND ROUND FITTINGS AS PER DIN EN 1506
ÜBERSICHT ROHRLEITUNGEN
UND FORMTEILE RUND NACH DIN EN 1506
d1
L1
d1
L1
d1
d2
lp lp
L1d
1
d2
L1
d3
d1
d3
L1L1
d1
L1
d3
d1
L1
d3
45°
1
3
5
2
4
6
425Process air systems |
7 | 90° junction reduction
8 | 45° junction reduction
9 | 90° segment bend
10 | 45° and 30° segment bend
11 | Cross piece
12 | Y-piece
OVERVIEW OF TUBING AND ROUND FITTINGS
AS PER DIN EN 1506
3
d1
L1
d2
45°
d
d1 d2
d3
L1
d1
d2
L1
d3
lp
r
lp
d2
45°
lplp
r
d1
30
°
lp
lp
r
d145
°
d1
d2
d3
w°
d1
d2
d4
d3
7
9
11
8
10
12
426 | Process air systems
Welded and folded tubing
OVERVIEW OF TUBING
AND ROUND FITTINGS AS PER DIN EN 1506
13 | Offset piece
14 | Expansion joints
15 | Regulating dampers
16 | Base
17 | Wall sleeve
d2
lp
L1
v
d1
lp
d1
L1
d1
DA
DA
d1
d1
L113
15
17
14
16
427Process air systems |
Welded tube V2A (1.4301)
with welded flat flanges
as per DIN 24154 R2
CERTIFICATE OF CONFORMITY WITH VDI 6022
Air ducting made of sheet metal with circular cross-section
from BerlinerLuft. Technik GmbH are VDI 6022 certified and
have the following registration number: HKP/D/011/7a/8/
BL/0910/0913/MZ
STANDARDS AND GUIDELINES
In the field of air conditioning and ventilation technology, pre-
viously important national DIN standards have been replaced
by European standards (DIN EN), and international standards
(ISO) are also becoming increasingly important.
Many specifications from previously valid DIN standards have
not been adopted by the EN standards and must be defined
within the framework of the system-specific requirements.
The present documentation is based on the current standards
and the withdrawn standards mentioned here, which have been
Valid standards and guidelines
DIN EN 1506
Sheet metal air ducts circular cross-section
DIN EN 12237
Round ducts in process air systems
DIN EN 12599
Test procedures and measurement methods for handing over
installed ventilation systems
DIN EN ISO 12944
Corrosion protection by coating
DIN 25496
Ventilating components in nuclear facilities
KTA 3601
Ventilation systems in nuclear power plants
ATEX Directive
Directive 94/9/EC Article 8(1)b)ii)
VDI 6022
Hygiene requirements for ventilation systems
adopted as recognised rules for technology. These apply as
a guideline for ordering and manufacturing the components.
As a matter of principle, the latest valid standards are always
authoritative, and therefore the respective contents must al-
ways be checked before placing an order to ensure they are
up to date.
The following is an overview of withdrawn and valid standards
which were used for the documentation.
Withdrawn standards
DIN 24147
Round fittings – Survey, dimensions, general principles
DIN 24150
Tube connections
DIN 24151/1 and /2
Welded tubes, class 1 and 2
DIN 24152
Longitudinally folded tubes
DIN 24153
Tubes for flanged connection
DIN 24154/1 and /2
Flanges, class 1 and 2
DIN 59232
Tubes – Tolerances
428 | Process air systems
MATERIALS
Ducting for process air technology can be made from
different metallic materials, depending on the application.
1 Limiting value for short-time operation, no permanent load, application to be agreed with the material manufacturer or an information centre for steel
2 For all seals, only silicon-free materials are used
3 Special seals for specific applications are available on request
SURFACE PROTECTION
Measures for surface protection must always be derived from
the intended use. The necessary coating thickness must be
specified by the user in accordance with the relevant corrosion
protection guidelines.
Designs
Black and galvanised sheet steel
Surface pretreatment/wash and passivation
Undercoat or primer
Paint
Powder coating
Stainless steels
Pickling and passivation
Bead-blasted
Material type Grade Standardmax. operating temperature 1
t max (°C)
Welded designBlack sheet Galvanised steel(Sendzimir galvanised fine sheet steel)Boiler plate Stainless sheet steel (surface III C)
AluminiumFAL (hot-dip aluminised sheet steel)
S 235 JRG 2 DX51D+Z275 MA-C
16 MO 31.4301 (V2A)1.4571 (V4A)ALMg3
DIN 10130DIN 10327
EN 10028 DIN 17440DIN 17440EN 485-2 EN 1396
-40 °C-60 °C
-20 °C-200 °C-270 °C-250 °C
+450 °C+250 °C
+500 °C+550 °C+550 °C+300 °C+700 °C
Folded design (longitudinally folded tube)Galvanised steel (Sendzimir galvanised fine sheet steel)FAL (hot-dip aluminised sheet steel)Stainless sheet steel (surface III C)
DX51D+Z275 MA-C
1.4301 (V2A)
DIN 10327
EN 1396DIN 17440
-60 °C
-200 °C
+250 °C
+700 °C+550 °C
Sealant materials 2, 3 for fold sealingSingle-component sealantBasis: butyl rubber/synthetic resin
Silicone-free Permanently elasticUV-resistantResistant to fatty acids
VDI 6022 Certified
-30 °C +80 °C
Welded and folded tubing
429Process air systems |
RECOMMENDATIONS FOR USE/WALL THICKNESS
For all applications, the client or planner must determine
which material type and material quality (e.g. wear-resistant
steels) is to be used. The planner or client must also decide
which wall thickness is to be used and, if necessary, whether
a wear-resistant inner coating is to be provided.
1 Limiting value for short-time operation, no permanent load, use to be agreed with the material manufacturer or an information centre for steel
Note: Other diameters, wall thickness, bend radii or special requirements are possible in consultation with the manufacturer, BerlinerLuft. Technik GmbH.
The following data are recommendations from which no war-
ranty claims can be derived.
Uses
Diameter range/wall thickness(Minimum requirement)
Bend radius
[mm] [mm]
Welded tubing forTube series 1 Air without addition of aggressive vapours up to DN 250 1.2 R = 1.0 D
or solids that increase wear DN 280 to DN 1000 1.5
(in accordance with DIN 24151-1) DN 1120 to DN 1250 2.0
> DN 1250 3.0
Tube series 2Air without addition of aggressive vapours up to DN 250 1.5 R = 1.0 D
or solids that increase wear DN 280 to DN 500 2.0
(in accordance with DIN 24151-2) DN 560 to DN 1000 3.0
> DN 1000 3.0
Air with light suspended matter (e.g. fibres) up to DN 250 1.5 R = 1.5 D or 2.0 D
DN 280 to DN 500 2.0
DN 560 to DN 1000 3.0
> DN 1000 3.0
Dust extraction systems or chip extraction1Straight tubes
up to DN 500 2.0
> DN 500 3.0
Fittings dependant on Up to 8.0 R = 1.5 D or 2.0 D
solids content
Longitudinally folded tubes for
air without addition of aggressive vapours up to DN 150 0.6 R = 1.0 D
or solids that increase wear DN 160 to DN 560 0.8
(in accordance with DIN 24152) DN 600 to DN 900 1.0
DN 1000 to DN 1250 1.2
430 | Process air systems
PERMISSIBLE PRESSURE LOADS
The permissible pressures given in the table apply to non-
reinforced tube lengths of max. 2,000 mm. For longer tube
lengths of up to 6,000 mm, the specified pressures are reduced
by up to 50%.
Data refer to a tube length of max. 2,000 mm, without flange connection.
When using flanges as tube reinforcement at intervals of max.
2,000 mm tube length, the pressure data can be universally
applied.
Nominal diameter [mm]
Tube series 1 [Pa]
Tube series 2[Pa]
Longitudinally folded tube[Pa]
100
* -2500 to +6300 -2000 to +5000
*
*
250
300
*
* -6300 to +10000 -500 to +2500
*
500 -2000 to 6300
560
*
*
* -100 to +2500
1000
1120
1250
* -1600 to +6300 -5000 to +6300
*
*
2000
Welded and folded tubing
431Process air systems |
AIRTIGHTNESS REQUIREMENTS
Airtightness requirements for process air ducting depend
on the various applications. The essential requirements are:
The energy-saving operation of the air handling unit
An oil-tight design for extraction systems
An aerosol-tight design
The application in ventilation systems in nuclear power plants as
per DIN 25496.
The data given in the following table refer to a measuring con-
dition of t = 20 °C and an atmospheric pressure of 101,325 Pa.
Measurement conditions deviating from this are to be deter-
mined with a correction factor as per DIN EN 12237.
1 E.g. use of ventilation components in nuclear facilities as per DIN 25496. Components for this application are additionally tested with a Nekal leak test.
Airtightness classas per DIN EN 12237
Limiting value of the static pressure
Limiting value of the air leakage rate
Use recommendation
positive [Pa] negative [Pa] m³ x s-1m–2
A 500 500 0.027 x pt0.65 x 10–3 Not recommended
B 1000 750 0.009 x pt0.65 x 10–3 Not recommended
C 2000 750 0.003 x pt0.65 x 10–3 Standard requirement
D1 2000 750 0.001 x pt0.65 x 10–3 Maximum requirement
432 | Process air systems
Average internal pressure in the ducting system in Pa
100
200 2000150010008006004000,01
0,02
0,04
0,06
0,080,1
0,2
0,4
0,6
0,8
1
2
4
6810
Airtightness class A
Airtightness class B
Airtightness class C
Airtightness class D
Leak
rat
e in
10
-3 m
3/s
m2
PROOF OF AIRTIGHTNESS
The diagram below can be used to estimate the expected leak
loss for a round ducting system or a section of it.
To do this, starting with the average internal pressure2,
the leakage rate is read off of the diagram and multiplied by
the round ducting surface area.
The proof of airtightness is to be carried out in accordance
with DIN EN 12599 – Test procedures and measurement meth-
2 Static pressure difference between the internal duct pressure
and the ambient pressure (for both positive and negative pressure)
ods for handing over installed ventilation systems. To achieve
airtightness, it is essential to assemble the tubing according
to the highest standard. Leakages must always be verified in
a fully assembled section of tubing. In order to be able to in-
fluence the assembly process, random verification of the air
leakage rates must be carried out as per DIN EN 12599.
AIRTIGHTNESS
Welded and folded tubing
433Process air systems |
Not fixed, recessed flange
(only up to sheet thickness 2.0 mm)
COMPONENT CONNECTIONS –
welded AREA OF APPLICATION
Flange/flange gasket/quick release clamping ring
(only up to sheet thickness 2.0 mm)
Smooth tube end, butt welded Tube end with flange, welded
Smooth tube end with flat flange, welded Smooth tube end with angle flange, welded
DN 100 - DN 1250
DN 100 - DN 1000
DN 100 - DN 2000 (3000)
DN 100 - DN 630
DN 100 - DN 1600
DN 100 - DN 2000 (3000)
434 | Process air systems
COMPONENT CONNECTIONS –
welded AREA OF APPLICATION
Section flange with clamping ring
Flange welded externally at flange end
Section flange with clamping ring
Flange welded internally at flange end
Section flange with clamp
Flange welded externally at tube end
Section flange with clamp
Flange butt welded to tube end
DN 200 - DN 3000
DN 200 - DN 3000
DN 200 - DN 3000
DN 100 - DN 2000 (3000)
Welded and folded tubing
435Process air systems |
Tube-tube via plug-in connector
COMPONENT CONNECTIONS –
AREA OF APPLICATION, FOLDED
Tube-tube via plug-in connector
Tube-fitting directly connected
Recessed flange
DN 80 - DN 1250
DN 80 - DN 1250
DN 80 - DN 1250
DN 80 - DN 1250
436 | Process air systems
Welded tube V2A (1-4301)
with flange and not fixed
flat flanges as per DIN 24154 R2
Spigot with recessed flange
COMPONENT CONNECTIONS –
AREA OF APPLICATION, FOLDED
Flange/flange gasket/quick release clamping ring
Section flange with clamping ring
DN 80 - DN 1250
DN 80 - DN 2000
DN 80 - DN 630
Welded and folded tubing
437Process air systems |
1 Diameter related to maximum sheet thickness
2 Maximum section length of tube without circumferential weld, larger section lengths with circumferential weld
3 SSR = quick release clamping ring
4 Flange according to DIN up to DN 2000, larger flanges according to factory standard
COMPONENT CONNECTIONS –
DIMENSIONS – WALL THICKNESS
Welded tubes and fittings
Connection typeDiameter
[mm]
max. sheet thickness 1
[mm]max. nominal tube
length 2
[mm]Steel sheets Stainless steel Aluminium
Component ends, smooth(butt welded at assembly)
160-280 1.5 1.5 1.5 1500
300-710 3.0 3.0 3.0 3000
400-1600 5.0 4.0 5.0 3000
Ends with flange(assembly via quick release clamping ring 3 or not fixed, recessed flange)Quick release clamping ring – max. = 630 mm
100-1000 1.2 1.2 1.2 1500
160-1000 1.5 1.5 1.5 1500
300-1250 2.0 2.0 2.0 3000
Fixed flange 4
(assembly via threaded connection)
100-1000 1.2 1.2 1.2 1500
160-1250 1.5 1.5 1.5 1500
300-1250 2.0 2.0 2.0 3000
400-3000 5.0 4.0 5.0 3000
438 | Process air systems
Welded and folded tubing
1 Diameter-related to maximum sheet thickness
2 Maximum section length of tube without circumferential fold, larger section lengths with circumferential fold
COMPONENT CONNECTIONS – DIMENSIONS –
WALL THICKNESS
Folded tubes and fittings (tubes longitudinally folded)
Connection typeDiameter
[mm]
max. sheet thickness 1
[mm] max.
nominal tube length 2
[mm]Steel sheets Stainless steel Aluminium
Component ends, smooth(assembly via SV)
80-150 0.6 0.6 0.6 1000
160-224 0.8 0.8 0.8 1500
250-1000 1.2 1.2 1.2 1500
Ends with flange(assembly via quick release clamping ringmax. = 630 mm
80-150 0.6 0.6 0.6 1000
160-224 0.8 0.8 0.8 1500
250-630 1.2 1.2 1.2 1500
Ends with section flange(e.g. Metu flange)
80-150 0.6 0.6 0.6 1000
160-224 0.8 0.8 0.8 1500
250-1600 1.2 1.2 1.2 1500
Ends with flangerecessed(assembly via threaded connection)
80-150 0.6 0.6 0.6 1000
160-224 0.8 0.8 0.8 1500
250-1600 1.2 1.2 1.2 1500
439Process air systems |
1 The specified masses refer to a sheet thickness of 1.0 mm and do not include flange connections.
For all other sheet thicknesses, the mass is determined by multiplying by the respective sheet thickness as factor
(e.g. sheet thickness 1.5 mm = factor 1.5)
BSE = sheet segment
SURFACES AND DIMENSIONS FOR ROUND
AIR DUCTS
Nominaldiameter DN
[mm]
Cross-sectionalarea[m²]
SurfaceTube
[m²/m]
Weight 1
Tube [kg]
SurfaceBSE 90°
[m²]
Weight 1
BSE 90°[kg]
SurfaceBSE 60°
[m²]
Weight 1
BSE 60°[kg]
80100125
5.03 x 10 –3
7.85 x 10 –3
12.30 x 10 –3
0.2510.3140.393
2.002.483.12
0.030.050.08
0.240.400.64
0.020.030.05
0.160.240.40
150160180
17.70 x 10 –3
20.10 x 10 –3
25.43 x 10 –3
0.4710.5020.565
3.764.004.56
0.110.130.16
0.881.041.28
0.070.080.11
0.560.640.88
200225250
31.40 x 10 –3
39.74 x 10 –3
49.10 x 10 –3
0.6280.7060.785
5.045.606.32
0.200.250.31
1.602.002.48
0.130.170.21
1.041.361.68
280300315
61.54 x 10 –3
70.70 x 10 –3
77.90 x 10 –3
0.8790.9430.990
7.047.527.92
0.390.440.49
3.123.523.92
0.260.300.33
2.082.402.64
355400450
98.90 x 10 –3
0.1260.159
1.1101.2601.410
8.9610.0811.28
0.620.791.00
4.966.328.00
0.410.530.67
3.284.245.36
500560600
0.1960.2460.283
1.5701.7601.884
12.5614.0815.07
1.231.551.76
9.8412.4014.08
0.821.311.58
6.5610.4812.64
630710800
0.3120.3960.503
1.9802.2302.510
15.8417.8420.08
1.962.493.16
15.6819.9225.28
1.631.662.11
13.0413.2816.88
90010001120
0.6360.7850.985
2.8303.1403.520
22.6425.1228.16
4.004.937.03
32.0039.4456.24
2.663.294.97
21.2826.3239.76
125013001400
1.2301.3261.538
3.9304.0824.396
31.4432.6435.20
8.659.57
10.99
69.2076.5687.92
6.086.797.77
48.6454.3262.16
15001600
1.7662.009
4.7105.024
37.6840.24
12.5214.14
100.16113.12
8.829.93
70.5679.44
440 | Process air systems
Welded and folded tubing
1 The specified masses refer to a sheet thickness of 1.0 mm and do not include flange connections.
For all other sheet thicknesses, the mass is determined by multiplying by the respective sheet thickness as factor
(e.g. sheet thickness 1.5 mm = factor 1.5)
BSE = sheet segment
SurfaceBSE 45°
[m²]
Weight 1
BSE 45°[kg]
SurfaceBSE 30°
[m²]
Weight 1
BSE 30°[kg]
SurfaceATE 90°
[m²]
Weight 1
ATE 90°[kg]
SurfaceAYE 45°
[m²]
Weight 1
AYE 45°[kg]
SurfaceUSE[m²]
Weight 1
USE[kg]
0.020.020.04
0.160.160.32
0.010.020.03
0.080.160.24
0.100.130.17
0.801.041.36
0.140.170.20
1.121.361.60
0.030.040.05
0.240.320.40
0.060.060.08
0.480.480.64
0.040.040.05
0.320.320.40
0.250.260.31
2.002.082.48
0.260.370.44
2.082.963.52
0.100.110.08
0.800.880.64
0.100.120.15
0.800.961.20
0.070.080.10
0.560.640.80
0.390.460.59
3.123.684.72
0.520.610.78
4.164.886.24
0.090.100.13
0.720.801.04
0.190.220.24
1.521.761.92
0.130.150.16
1.041.201.28
0.730.810.87
5.846.486.96
0.970.671.18
7.765.369.44
0.170.340.36
1.362.722.88
0.310.390.50
2.483.124.00
0.210.260.33
1.682.082.64
1.081.381.66
8.6411.0413.28
1.421.812.19
11.3614.4817.52
0.230.300.38
1.842.403.04
0.620.770.88
4.966.167.04
0.410.520.59
3.284.164.72
1.962.362.64
15.7018.8521.10
2.613.313.74
20.8826.4829.92
0.420.500.55
3.364.004.40
0.981.241.58
7.849.2012.64
0.650.831.05
5.206.648.40
2.863.654.45
22.8729.1635.57
4.045.086.25
32.3240.6450.00
0.590.750.94
4.726.007.52
2.002.473.94
16.0019.7631.52
1.331.642.91
10.6413.1225.28
5.436.508.19
43.4152.0065.55
7.679.2311.78
61.3673.8494.24
1.091.221.52
8.729.7612.16
4.805.406.16
38.4043.2049.28
3.514.014.54
28.0832.0836.32
9.9110.6112.09
79.2984.9196.71
14.3116.6617.92
114.48133.28143.36
1.842.883.65
14.7223.0429.20
6.977.82
55.7662.56
5.115.72
40.8825.76
13.6615.32
109.27122.59
20.6322.79
165.04182.32
3.924.52
31.3636.16
441Process air systems |
Dimension TABLE, FLAT FLANGES
(BASED ON DIN 24154 – EDITION JULY 1990)
Note: For connecting welded tubing, preferably flat flanges series 1 or series 2 are used in accordance with DIN 24154.
Angle flanges are manufactured in accordance with DIN 24155, if required.
DIN 24155 contains various series. For production, therefore, the diameter of the bolt holes and the number of holes,
related to the respective diameter, must always be concretely specified.
Nominaldia-
meterDN
Flat flanges, series 1 Flat flanges, series 2
Bolt hole
Width x thickness
AmountHoles
HoleDN
WeightSteel
Bolthole
Width x thickness
AmountHoles
HoleDN
WeightSteel
[mm] [mm] [mm] [pieces] [mm] [kg] [mm] [mm] [pieces] [mm] [kg]
80100125150
112132157182
25x3 4 9.50.180.210.260.44
118139165190
30x6 4 100.480.550.680.89
160180200225250280
192212233257283317
25x4
6
9.5
0.460.510.560.620.690.93
200219241265292332
35x6
8
11.5
0.981.081.191.321.452.51
300315355400450500
339352392438488538
30x4
8
9.5
0.971.031.151.281.431.58
352366405448497551
40x8
8
11.5
2.782.983.103.443.844.13
12
560600630710800900
1000
6006416707508409401041
35x4
12
9.5
2.072.202.312.582.903.243.59
6296686987758619581067
50x8
16
14
5.906.256.597.388.199.17
10.20
16
24
112012501300140015001600
116912991349144915491649
40x5 24 9.5
5.746.386.657.127.638.11
120013371375147515751675
60x10
32 18
16.9018.8019.6021.0022.4023.80
40
442 | Process air systems
Welded and folded tubing
FLANGE GASKETS
Flange gaskets must always be selected taking into account
the intended use. The resistance of the respective gasket to
a specific medium also depends on other factors such as tem-
perature, pressure, duration of contact, and mechanical stress.
For this reason, it is necessary to have the seal material tested
by the manufacturer under actual or simulated conditions be-
fore it is used. It is recommended that a chemical sample of the
Note: For the production of tubing which must be “oil and/or aerosol-tight”, detailed requirement specifications must be agreed by
the client and the manufacturer of the seals and tubing.
1 Data refer to manufacturer’s designs without consideration of the specific application.
conditions of application be submitted to the manufacturer so
that appropriate tests can be carried out.
The following designs are recommendations for use without
any claim to functional safety in the respective application.
Overview of common gasket materials
for flange gaskets in ventilation tubing
Seal Properties 1 Fields of application 1
Sealing compound Butyl mastic
Single-component plastic-elastic sealing compound Excellent adhesion to galvanized bare and painted sheets High elasticity Temperature resistant -30 °C to +80 °C Permanently elastic, resistant to ageing, Silicone-free, good chemical properties Building material class B3 as per DIN 4102
Sealing of flange connections on tubes Sealing of folds, seams and small connections
Sealing tapes Made of polyethylene
Temperature resistant -70 °C to +70 °C Resistant to ageing Building material class B3 as per DIN 4102 Silicone-free (except self-adhesive strips)
Sealing of section flange/clamping ring Resistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)
Made of cellular rubber Temperature resistant -30 °C to +70 °C Resistant to ageing Building material class B3 as per DIN 4102 Silicone-free (except self-adhesive strips)
Sealing of section flange/clamping ring for air ducts without chemical load
Made of ceramic fibre Temperature resistant up to +1,100 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)
Sealing of section flange/clamping ringResistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)
Made of rock wool Temperature resistant from -50 °C up to +200 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)
Sealing of section flange/clamping ring Resistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)
443Process air systems |
Note: For the production of tubing which must be “oil and/or aerosol-tight”, detailed requirement specifications must be agreed by the client
and the manufacturer of the seals and manufacturer of the tubing.
1 Data refer to manufacturer’s designs without consideration of the specific application.
FLANGE GASKETS
Overview of common gasket materials
for flange gaskets in round ventilation ducting
Seal Properties 1 Fields of application 1
Sealing strips made of PTFE
Temperature resistant from -240 °C to +270 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)
Sealing of flange connections on round ducts resistant to all media with the exception of dissolved alkali metals and element. Fluorine leakage requirement, according to TA-Luft, of < 10–4 mbar l/sm is fulfilled if the assembly instructions are observed.
Flange – sealing rings made of APTIK (EPTIM)
Temperature resistant -40 °C to +150 °CResistant to ageing Silicone-free
Sealant for tube connections via flange or quick release clamping ring Resistant to ozone, acid, alkalis
Made of nitrile Temperature resistant -40 °C to +130 °C Resistant to ageingSilicone-free
Sealant for tube connections via flange or quick release clamping ringResistant to petrol, oil, grease, alkalis
Made of silicone Temperature resistant -80 °C to +200 °CResistant to ageing
Sealant for tube connections via flange or quick release clamping ringResistant to ozone, oil, grease
444 | Process air systems
Welded tubing
Item Description of the range of serviceQuantity
UnitEP GP
Welded tubing for ventilation systems for conveying air, in accordance with the application recommendations in the BerlinerLuft. documentation.
Longitudinally and circumferentially welded tubes and fittings According to BerlinerLuft. documentation from (insert as appropriate)
Black sheet steel
or
Sendzimir galvanised sheet steel
Hot-dip aluminised sheet steel (FAL)
Stainless steel (1.4301, 1.4404 or 1.4571)
Aluminium (AlMg3)
Boiler plate (16Mo3)
Component ends for connection (insert as appropriate)
Component ends, smooth (welded during assembly)
or
Ends with flange (for quick release clamp connection SSV)
Ends with fixed section flange (selection according to document
– BerlinerLuft.-Documentation)
For quick release clamp connection
Ends with fixed flange, series 2 (assembly via threaded connection)
Surface protection (insert as appropriate)
Black
or
Sendzimir galvanized (cold galvanised welds)
Primed
Painted (thickness of coat .......µm)
Powder coated (80µm)
Blasted (for stainless steel)
Pickled and passivated (for stainless steel)
Operating temperature: ........°C (determined by the user with consideration of BT material and seal)
Pressure load: Positive/negative pressure in accordance with DIN 24151 Part 2
Certificate of conformity as per VDI 6022 Reg. no: HKP/D/011/7a/8/BL/0910/0913/MZ
TENDER SPECIFICATION TEXTS
445Process air systems |
TENDER SPECIFICATION TEXTS
Item Description of the range of serviceQuantity
UnitEP GP
Welded tubeDimensions: Nominal width d: ......................... mm Length: l: ......................... mm Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded segment bendSize: Nominal width d1: ......................... mm Angle: ......................... ° Radius (1.0/1.5/2.0) ......................... 1.0 d1 Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded symmetrical/asymmetrical reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Sheet thickness: ......................... mmDesign: symmetrical/asymmetrical: ......................... Make: BerlinerLuft.
Welded 90°, 60°, 45° or 30° junction.Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded 90°, 60°, 45° or 30° junction with reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded 90° cross piece Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Nominal width d4: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
446 | Process air systems
TENDER SPECIFICATION TEXTS
Item Description of the range of serviceQuantity
UnitEP GP
Welded offsetSize: Nominal width d1: ......................... mm Length l1: ......................... mm Length l2: ......................... mm Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded 120°, 90°, 60° Y-pieceSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Welded opening for cleaningOpening for cleaning via a welded-on branch saddle, fixed to the tube using a threaded connection. Nominal size determined depending on diameter of tube.
Tube size d1: ......................... mmDimension opening: a x b: ......................... mm
Make: BerlinerLuft.
Quick release clamping ring for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mm
Make: BerlinerLuft.
Clamping ring with seal for section flange connectionSize: Nominal width d1: ......................... mmSeal for: maximum temperature t: ......................... °C
Make: BerlinerLuft.
Flange gasket for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mmMaterial: APTK (EPTM) Nitrile Silicone
Make: BerlinerLuft.
Welded regulating damper (max. DN 630 mm)For air volume regulation in air distribution lines. Single or double damper blade depending on the nominal size. Damper axle and axle bearing sealed. Manual damper blade adjustment via hand lever with locking device or via actuator (optionally 230 V or 24 V).
Size: Nominal width d1: ......................... mmAdjustment: Hand lever with locking device or actuator: ......................... V
Make: BerlinerLuft.
Welded tubing
447Process air systems |
Folded tubing
TENDER SPECIFICATION TEXTS
Item Description of the range of serviceQuantity
UnitEP GP
Longitudinally folded tube for ventilation systems for conveying air without the addition of aggressive vapours or solids that promote wear, in accordance with the application recom-mendations in the BerlinerLuft. documentation.
Tubes and fittings folded longitudinally and circumferentially according to BerlinerLuft. documentation made of sendzimir galvanised sheet steelComponent ends for connection (insert as appropriate)
Ends with flange for quick release clamp connection (SSV)
Ends with section flange for quick release clamp connection
Ends with fixed, recessed flange, series 1 (assembly via threaded connection)
Surface protection (insert as appropriate)
Sendzimir galvanized
or
Painted (thickness of coat .......µm)
Powder coated (80 µm)
Operating temperature: ........°C (determined by the user under consideration of BT material and seal)
Pressure load: positive/negative pressure in accordance with DIN 24151 Part 2
Certificate of conformity as per VDI 6022 Reg. no: HKP/D/011/7a/8/BL/0910/0913/MZ
Longitudinally folded tube (max. DN 630 mm for quick release clamp connection via flange, otherwise max. 1,250 mm for quick release clamp connection via section flange)Size: Nominal width d: ......................... mm Length l: ......................... mm Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded segment bendSize: Nominal width d1: ......................... mm Angle: ......................... ° Radius (1.0/1.5/2.0) ......................... 1.0 d1 Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded symmetrical/asymmetrical reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Sheet thickness: ......................... mm Design: sym./asym: ......................... mm Make: BerlinerLuft.
448 | Process air systems
Folded tubing
Item Description of the range of serviceQuantity
UnitEP GP
Folded 90°, 60°, 45° or 30° junctionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded 90°, 60°, 45° or 30° junction with reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded 90° cross piece Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Nominal width d4: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded offsetSize: Nominal width d1: ......................... mm Length l1: ......................... mm Length l2: ......................... mm Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded 120°, 90°, 60° Y-pieceSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm
Make: BerlinerLuft.
Folded opening for cleaningOpening for cleaning as inspection panel RD, nominal size determined depending on diam-eter of tube.
Tube size d1: ......................... mmDimension opening: a x b ......................... mm
Make: BerlinerLuft.
TENDER SPECIFICATION TEXTS
449Process air systems |
TENDER SPECIFICATION TEXTS
Item Description of the range of serviceQuantity
UnitEP GP
Quick release clamping ring for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mm
Make: BerlinerLuft.
Clamping ring with seal for quick release clamp connection via section flangeSize: Nominal width d1: ......................... mm Seal for: max. temp. t: ......................... °C
Make: BerlinerLuft.
Flange gasket for quick release clamp connection via flange (max. DN 630 mm)Size: Nominal width d1: ......................... mm Material: APTK (EPTM) Nitrile Silicone
Make: BerlinerLuft.
Folded regulating damper (max. DN 630 mm)For air volume regulation in air distribution lines. Single or double damper blade depending on the nominal size. Damper axle and axle bearing sealed. Manual damper blade adjustment using hand lever with locking device or actuator (optionally 230 V or 24 V).
Size: Nominal width d1: ......................... mm Adjustment: Hand lever with locking device or actuator: ......................... V
Make: BerlinerLuft.
450 | Process air systems
Parts and components for industrial use can retain their
long-term functionality by treating and coating the surface
appropriately.
They offer protection against
Adhesions
Material build-up
Soiling
Corrosion
Acids and alkalis
To prevent corrosion damage and wear in industrial applica-
tions, the following coating variants are available on request:
EPD COATING
Cathodic dip coating is a special process for coating alu-
minium and steel alloys. The coating provides a high level of
protection and thus a long service life for the components. It is
also ideal as a primer.
Process
The coating cross-links in the immersion bath to form a ho-
mogeneous, closed film. This creates a surface resistant to
solvents and corrosion.
Uses
The coating is suitable for applications in the chemical indus-
try. In addition, the system is also used in the commercial vehi-
cle and agricultural machinery industries. It protects structures
exposed to maritime climates as well as structures immersed in
sea and brackish water. To achieve UV resistance, an additional
powder coating is necessary.
Furthermore, the system is also particularly suitable for the in-
ternal coating of media-carrying ducting with high corrosion
resistance requirements. Recommended for applications in the
chemical, pharmaceutical, semiconductor, and solar industries.
Suitable for environmental conditions of corrosivity category
C5-M according to ISO 12944-6. It can be used on both folded
and welded components.
HALAR® ECTFE COATING
ECTFE (ethylene chlorotrifluoroethylene), also known as
Halar© is used as a coating against many organic media, es-
pecially acids and bases, because of its very good chemical
resistance. Due to the presence of fluorine compounds, Halar®
ECTFE forms a very smooth surface and has good non-stick
properties. The coating is temperature resistant up to 150 °C
and also has very high impact strength.
Process
Halar® ECTFE is applied by electrostatic powder spraying.
In this process, the coating is applied in several layers, which
means that the final layer thickness is variable. Depending on
the application, an optimum layer thickness can be selected.
Uses
This coating is recommended for applications in the semi-
conductor and solar industry.
Corrosion protection and coating
Welded high pressure ducting components
with EPD primer and powder top coating
(RAL 5010) inside and outside