MINING CATALOG

MINING PRODUCT GUIDE

HIGH WEAR-RESISTANT PIPELINE SYSTEMS FOR MINING APPLICATIONS

ESSERTWINPIPES.COM

03 05

Sustainability Our Process

ABOUT US

06 07 10

Pipe Diameters

PRODUCTS

Pipe & Elbow Options

Fittings

Testings & Documentations 15

16 18 22 20 24

Mining Plant Overview

APPLICATIONS

Silo Pipeline Shaft Pipeline

Borehole Pipeline

Drift Pipeline

32 28 38

Couplings

CONNECTIONS

Flanges

ZSM

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ABOUT US

PIPELINE DURABILITY EQUALS SUSTAINABILITY

Esser Twin Pipes creates quality, durable products for pipeline solutions that support sustainability and fulfill our customers' desire for environmental stewardship.

ESSER TWIN PIPES last considerably longer than unhardened mild steel pipes. Lasts Longer

Less Downtime

Slash your piping- related carbon footprint. Saves More

Get more uptime and production reliability. Avoid the environmental costs from maintenance and replacement of mild steel.

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ABOUT US

MAIN MENU

OUR PROCESS

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ABOUT US

MAIN MENU

EVERY PROJECT BEGINS WITH OUR IN-HOUSE EXPERTS

1 2 3 4

DEFINE

ENGAGE WITH OUR EXPERTS

WHAT IS REQUIRED? WHAT IS NEEDED? We analyze the framework conditions of the project with regard to the required pipeline. This includes all technical application parameters, valid standards as well as budget and delivery specifications.

PLAN

ENGINEERING & FORMAL PROPOSAL

COMPILATION OF INDIVIDUAL COMPONENTS & CONSIDERATION OF OPTIONAL SERVICES Our experienced, in-house engineers select the right system components for your piping. Custom fabrication parts are designed and calculated. Our engineering team ensures that the required product specifications can be met. Optional services such as static calculations or material and product tests are also taken into account. We prepare a formal quotation explaining the product details and development. You will also receive drawings and overviews of the system isometrics.

CHECK

CHECK & VERIFY

CUSTOMER PROPOSALS ARE READY FOR ENGINEERING FINALIZATION You evaluate our proposed solution technically and commercially. Desired changes are incorporated, implemented and improved. The aim is always to optimize our proposal so that there are no unanswered questions or issues when you activate your order.

FABRICATION, MANUFACTURING, & QUALITY PROCESSES BEGIN

EXECUTE

TECHNICAL APPROVALS & DOCUMENTATION Your approval of the planning starts the order. Our engineers monitor the manufacturing process. Material tests are carried out during production and documentation is created.

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PRODUCTS

MAIN MENU

AVAILABLE PIPE SIZES

DN 65

DN 80

COMMON SIZES DN80–DN200 OTHER SIZES ALSO AVAILABLE BASED ON VOLUME PURCHASING

DN 100

DN 125

DN 150

DN 200

DN 250

DN 300

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PRODUCTS

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PIPELINE OPTIONS

SINGLE LAYER, HARDENED

SINGLE LAYER

ESSER 160

ESSER 400

ULTRA 600

PIPE & ELBOWS

TWO-LAYER, CCI INNER LAYER

TWO-LAYER, PU INNER LAYER

TWO- LAYER, HARDENED

ESSER TWIN 900

ESSER TWIN 700

ESSER TWIN PU

PIPE & ELBOWS

PIPE

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PRODUCTS

MAIN MENU

STRAIGHT PIPES

ESSER 400

ESSER 160

ULTRA 600

Series

Description

Single layer

Single layer, hardened

S355 / P355

UT100: Modified A-53

S235 / P235, S355 / P355

Usage Material

straight line route

Origin

ESSER-WERKE, DE

UltraTechPipe, USA

Hardness

Rockwell: n.v. Vickers: Brinell:

Rockwell: 45 – 50 HRC Vickers: Brinell: 440 – 510 HV 415 – 485 HB

Rockwell: 57 HRC Vickers: Brinell: 630 HV 600 HB

120 – 160 HV 115 – 150 HB

Hardness Profile (from outside to inside)

outer wall

inner wall

outer wall

inner wall

outer wall

inner wall

Available lengths

up to 6000 mm

6000, 12000, 15000 mm Custom lengths available

DN 80 / W 7,1 DN 100 / W 4,0 DN 100 / W 7,1 DN 125 / W 4,0 DN 125 / W 7,1 DN 150 / W 8,8 DN 200 / W 12,5

DN 80 / W 7,1 DN 100 / W 4,0 DN 100 / W 7,1 DN 125 / W 4,0 DN 125 / W 7,1 DN 150 / W 8,8

DN 60 / W 7,0 DN 80 / W 7,6 DN 100 / W 6,0 DN 100 / W 8,6 DN 125 / W 6,6 DN 125 / W 9,5 DN 150 / W 7,1 DN 150 / W 11,0 DN 200 / W 8,1 DN 200 / W 12,7 DN 250 / W 9,3 DN 250 / W 12,7 DN 300 / W 9,5 DN 300 / W 12,7 DN 350 / W 9,5 DN 350 / W 12,7 DN 400 / W 9,5 DN 400 / W 12,7 DN 450 / W 12,7 DN 500 / W 12,7

Dimensions* Nominal Diameter / Wall thickness (inner wall+outer wall)

*Dimensional tolerances acc. DIN ISO 2768-1 resp. ASTM A530 / Availability and further dimensions on request. Please contact us.

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PRODUCTS

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ESSER TWIN 900

ESSER TWIN PU

ESSER TWIN 700

Two-layer, hardened

Two-layer, CCI inner layer

Two-layer, PU inner layer

S235 / P235 PU

S235 / P235, S355 / P355 C60 / 60Mn7

Outlet-pipe after elbow, special pipes S235 / P235, S355 / P355 GX350

Straight line route

ESSER-WERKE, DE

Shore:

55 bis 95 HSA (ca. bis 31 HRC, 311 HV, 302 HB)

Rockwell: Vickers: Brinell:

67 HRC

Rockwell: Vickers: Brinell:

63 HRC

920 HV n.v.

760 HV n.v.

Golf ball ~95 HSA

Tire ~65 HSA

Eraser rubber ~35 HSA Rubber bands ~25 HSA

outer wall

inner wall

Shore A

outer wall

inner wall

up to 6000 mm

up to 1000 mm

up to 9000 mm

DN 80 / W 7,2 (3,6+3,6) DN 100 / W 4,0 (2+2) DN 100 / W 7,7 (4,5+3,2) DN 125 / W 4,5 (2,5+2) DN 125 / W 8,2 (5+3,2) DN 150 / W 9,0 (5+4) DN 200 / W 8,0 (4+4)

DN 80 / W 12,2 (9+3,2) DN 100 / W 14 (10+4) DN 125 / W 10,2 (7+3,2) DN 150 / W 11 (6+5) DN 200 / W 12 (8+4)

DN 100 - DN 450

Wall thickness of wear-layer 4 - 25 mm

Further lengths, diameters or special shapes on request.

SALES-IND@ESSER-WERKE.DE ( +49-2902-896-250

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PRODUCTS

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ELBOWS

We always consider a conveyor pipeline as a whole system and design the elbows to match the straight pipes. Elbows can have a higher wall thickness in the back to better absorb the wear load. Material, hardness structure, texture and origin are essentially the same as the straight conveying pipes.

Series

ULTRA 600

ESSER 400

ESSER 160

Description

Single layer

Single layer, hardened

Small Radii

DN125 / R240 / 90 / W12,5

(On request - Contact us to review your exact specifications)

DN80 / R133 / 90 / W10 DN80 / R190 / 90 / W6,3 DN100 / R153 / 90 / W6,3 DN100 / R250 / 90 / W6,3 DN125 / R190 / 90 / W7,1 DN150 / R250 / 90 / W16 DN200 / R305 / 90 / W6,3 DN80 / R500 / 90 / W3,2 DN100 / R500 / 90 / W6,3 DN125 / R500 / 90 / W7,1 DN125 / R500 / 90 / W8,8 DN150 / R500 / 90 / W10

Nominal Diameter / Radius / max. Degrees / Wall thickness

Middle Radii

DN80 / R500 / 90 / W4 DN100 / R500 / 90 / W4 DN125 / R500 / 90 / W7,1 DN125 / R500 / 90 / W8,8

DN60 / R508 / 180 / W7 DN80 / R508 / 180 / W7,6 DN100 / R508 / 180 / W8,6 DN100 / R508 / 180 / W6 DN125 / R508 / 180 / W9,5 DN125 / R508 / 180 / W6,5 DN150 / R508 / 180 / W7,1 DN150 / R508 / 180 / W11 DN200 / R610 / 180 / W8,1 DN200 / R610 / 180 / W12,7 DN250 / R762 / 180 / W9,3 DN250 / R762 / 180 / W12,7 DN300 / R914 / 180 / W9,5 DN300 / R914 / 180 / W12,7 DN350 / R1067 / 180 / W9,5 DN350 / R1067 / 180 / W12,7 DN400 / R1219 / 180 / W9,5 DN400 / R1219 / 180 / W12,7 DN450 / R1372 / 180 / W12,7 DN500 / R1524 / 180 / W12,7 R min. 3D - R max. 4572 (180") R min. 508 (20") - R max. 4572 (180")

Nominal Diameter / Radius / max. Degrees / Wall thickness

DN80 / R1000 / 90 / W4,5 DN80 / R1000 / 90 / W7,1 DN100 / R1000 / 90 / W6,3 DN100 / R1000 / 90 / W14,2 DN125 / R1000 / 90 / W7,1 DN125 / R1000 / 90 / W8,8 DN150 / R1000 / 45 / W14,2 DN200 / R2000 / 45 / W14,2

DN100 / R1000 / 45 / W7,1 DN125 / R1000 / 90 / W7,1 DN125 / R1000 / 90 / W8,8 DN150 / R1000 / 45 / W8,8 DN150 / R1000 / 90 / W11 DN200 / R2000 / 45 / W10

Big Radii

Nominal Diameter / Radius / max. Degrees / Wall thickness

*Dimensional tolerances acc. DIN ISO 2768-1 resp. ASTM A530 / Availability and further dimensions on request. Please contact us.

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KW- REBUILD WITH HIGH-RES DROPBOX CONTENT

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ESSER TWIN 700

ESSER TWIN 900

Two-layer, hardened

Two-layer, CCI inner layer

DN100 / R250 / 90 / W5+3,2 DN125 / R240 / 90 / W7,1+3,6 DN150 / R225 / 90 / W5+4 DN200 / R305 / 90 / W6,3

DN100 / R235 / 90 / W5+3,2 DN125 / R235 / 90 / W7+2,5

DN80 / R500 / 90 / W7,1+3,2 DN100 / R500 / 90 / W5+3,2 DN125 / R500 / 90 / W7+32 DN150 / R500 / 90 / W6,3+3,2 DN200 / R500 / 30 / W6,3+6,3 -

DN80 / R1000 / 30 / W9+3,6 DN100 / R1000 / 30 / W9+4,5 DN125 / R1000 / 30 / W9+5 DN150 / R1000 / 30 / W9+7,1 DN200 / R1000 / 30 / W9+8

DN150 / R1500 / 30 / W9+7,1 DN200 / R2000 / 30 / W7+7,1

DN80 / R1000 / 45 / W7,1+3,2 DN100 / R1000 / 45 / W4,5+3,2 DN125 / R1000 / 45 / W4,5+3,6 DN150 / R1000 / 45 / W6,3+3,2

SALES-IND@ESSER-WERKE.DE ( +49-2902-896-250

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PRODUCTS

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PIPE FABRICATIONS

PIPE BENDS & FITTINGS

ESSER TWIN PIPES transport bulk materials, fluids and slurry used in mining applications that rely on pipe to move a variety of abrasive materials safely and efficiently. With so many uses and applications, a one-size-fits-all piping solution isn’t possible. Custom, hardened pipe bends and fittings are crucial for supporting every twist and turn that comes with the most mission-critical challenges.

Customized Pipe Solutions

Custom hardened bends and fittings are built to meet your exact specifications, application needs, delivery schedule, and budget for cutting-edge results.

Wear-resistant custom bends and fittings are built to last, minimizing field installation costs and future maintenance.

Expert consulting services are backed by over 75 years of industry knowledge designing custom solutions for a variety of applications.

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PRODUCTS

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ESSER MANUFACTURING

SPLIT OR BLEND FLOW STREAMS

Cut to exact lengths required Bends Tees Wyes & True Wyes

Laterals Custom fabrication available End attachments consisting of flanges or weld rings for couplings

WYES

REDUCERS

LATERALS

TEES

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PRODUCTS

MAIN MENU

REINFORCED COMPONENTS KEEP YOUR PIPELINES OPERATIONAL LESS DOWNTIME YIELDS MORE PRODUCTION

When conveyed material in a pneumatic or hydraulic pipeline is divided, it impacts the edge of the branch pipe that lies in the direction of flow. The hardness of the ESSER pipes at 63 HRC is designed to combat this pipe wear. It is essential to reinforce key pipeline sections in order to ensure a long service life of the system.

Many mines use the reinforced branches from ESSER in their pipelines. By reducing replacement and maintenance costs, the cost-benefit ratio is convincing.

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PRODUCTS

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OPTIONS

SURFACE PROTECTION

Surface treatments such as corrosion protection, painting, etc. can be applied according to customer specifications. The airless spraying process delivers high-quality results with reduced impact on workers and the environment. Special coats on request.

STATIC ANALYSIS

Vertical pipelines, whether hanging or secured with brackets, present a safety challenge. Esser engineers will consider the material being conveyed and the weight of the overall pipeline system components, in order to calculate safe operating standards. Analysis available on request.

PRODUCT & MATERIAL TESTS

The following tests can be carried out on request: Pressure testing according to customer requirements Magnetic particle testing of welded joints according to DIN EN 1290 MT 2 Visual inspection of fusion welds according to DIN EN 970 VT 2

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APPLICATIONS

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MINING PLANT APPLICATIONS SURFACE & UNDERGROUND

Backfill material or building materials for use underground

During the extraction of raw materials, cavities are created underground. Depending on the use, these must be stabilized if the route is still used for access to the mining area. For this purpose, mixing plants and pumps are used underground to produce and pump concrete. The plants are supplied with the required materials by pneumatic conveyance and are delivered through a pipeline laid in the shaft or in a borehole. Tailings can also be pneumatically conveyed underground as backfill material. Depending on the type of backfill, this dry material is either placed directly or processed further underground for flushing backfill.

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APPLICATIONS

MAIN MENU

SILO PIPELINE

SHAFT PIPELINE

DRIFT PIPELINE

BOREHOLE

PIPELINE

Flush Backfill

Dry Backfill

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APPLICATIONS

MAIN MENU

SILO PIPELINE FOR MINING

SURFACE MATERIAL TRANSPORT & STORAGE

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APPLICATIONS SILO PIPELINE SYSTEM

MAIN MENU

ESSER TWIN 700 SILO PIPELINE Bulk materials are temporarily stored in the silo, which are later transported underground for further processing or storage. Simple pneumatic filling takes place via the truck's on-board compressor, which builds up an operating pressure of up to 2 bar (30 psi). Silo pipelines are designed in nominal diameters of DN 80 (NPS 3 in.) or DN 100 (NPS 4 in.) and reach total lengths of around 50 meters; the capacity of the truck compressor is usually not sufficient for larger nominal widths. Higher values are only possible with the use of auxiliary systems when compressed air is supplied to the filling line via bypass systems. If hard bulk materials are transported quickly through the line via flight conveying (dilute phase conveying), the points that cause a change in the conveying direction are particularly exposed to increased wear. Where possible, we recommend using large radii (R >= 1000 mm) for the bends in order to keep the wear load as low as possible. In addition to pipelines with flange connections, we are also increasingly equipping silo pipelines with coupling connections. This type of pipe connection is becoming increasingly popular as it has the advantage of faster assembly. If servicing is required, it can be disconnected and reconnected quickly. From the inlet pipe with truck connection (Storz coupling) to the silo roof, we build the pipeline to the requirements of the application and the needs of our customers.

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ANWENDUNGEN

MAIN MENU

SHAFT PIPELINE FOR MINING VERTICAL SYSTEM FOR SURFACE-TO-UNDERGROUND APPLICATIONS

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APPLICATIONS SHAFT PIPELINE SYSTEM

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ESSER TWIN 700 BRACKET PIPE In free-standing or free-hanging shaft pipelines, sections of the pipeline are installed between “bracket pipes”. These are positioned in the shaft on the basis of a static weight calculation. ESSER TWIN 900 COMPENSATOR PIPE WITH STUFFING BOX These pipes compensate for length differences caused by thermal expansion. They consist of two pipes with different diameters that interlock. The stuffing box prevents the conveying material from leaking. ESSER TWIN 900 REDUCER The compensator pipe has increased the diameter of the pipe. The diameter is returned to the size of the pipe by reducing it. The pressure load increases in the direction of the smaller diameter. ESSER TWIN 900 reducers are able to compensate for these loads. ESSER TWIN 900 OUTLET PIPE The pressure and wear load caused by the reduction in diameter of the reducer has an effect on the downstream pipe. The inlet area of the following pipe is subjected to increased stress as a result. This area is often reinforced with ESSER TWIN 900 material. ESSER TWIN 700 STRAIGHT PIPE Once the flow rate in the pipe has normalized, two-layer pipes with a hardness of 63 HRC but smaller wall thickness can be used. They are economical and reliable. These pipes have a much longer service life compared to ST52 pipes. ESSER TWIN 700 TRANSITION PIPE Depending on the design of the elbow (thick-walled with a higher wear layer), it may have a larger outer diameter and require a different flange size. A transition pipe with different flange sizes is used to create the connection between the shaft pipeline and the elbow. ESSER TWIN 900 ELBOW The change in direction of the conveyed material leads to additional wear. The conveyed material collides with the outer radius of the inner bend. ESSER TWIN 900 elbows have a highly wear-resistant cast insert with a thicker wall in the outer radius, which counteracts the heavy friction and impact wear. ESSER TWIN 900 OUTLET PIPE An elbow forces a change in flow direction. At the elbow outlet, the conveyed media causes turbulence. ESSER TWIN 900 outlet pipes are equipped with highly wear- resistant cast sleeves, just like the elbows, to withstand this heavy wear load.

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APPLICATIONS

MAIN MENU

BOREHOLE PIPELINE FOR MINING

VERTICAL SYSTEM FOR DELIVERY OF PASTE BACKFILL MATERIAL

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APPLICATIONS BOREHOLE PIPELINE SYSTEM

MAIN MENU

ZSM SYSTEM - HIGH TENSILE STRENGTH, SLIMLINE DESIGN AND QUICK ASSEMBLY

In order to transport material from above ground to the underground, it can be uneconomical to lay a pipeline through a mine shaft due to the distance involved. If possible, a direct route to the point of use by means of a borehole is preferred. The pipeline is lowered through the borehole using special equipment. This places high demands on the pipe connections; they must be narrow, smooth and extremely strong. ESSER TWIN PIPES has entered into an agreement with the Carl Hamm company in order to combine the patented ZSM (tension-resistant tight sleeve connection) with wear-resistant ESSER TWIN 700 pipes. The ZSM connection is a restrained and detachable pipe connection. It is used in shaft pipes in underground mining and deep well construction as an alternative to other common connection systems due to its quick and easy assembly/disassembly, minimized space requirements and low price. In tight installation situations, the small dimensions of ZSM technology allow optimized pipe cross-sections.

In cooperation with

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APPLICATIONS

MAIN MENU

DRIFT PIPELINE FOR MINING HORIZONTAL SYSTEM FOR MATERIAL CONVEYANCE UNDERGROUND

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APPLICATIONS DRIFT PIPELINE SYSTEM

MAIN MENU

Tailings or construction materials (concrete) are often transported underground for kilometers. High-density solids pumps with high working pressures are used in this application. ESSER high-pressure pipes with multiple degrees of hardness are used in these systems. Neuralgic points can be reinforced (elbows and elbow outlet pipes). They are connected via couplings and designed for working pressures up to 200 bar. DRIFT PIPELINES FROM ESSER ARE SAFE, DURABLE, POWERFUL - RIGHT UP TO THE POINT OF NEED

ESSER 400 STRAIGHT PIPE One-layer pipe. Inside hardened to 45 HRC.

ESSER TWIN 900 ELBOW Wear-layer consists of special, hard cast iron (67 HRC) and are designed with thicker walls in the back. ESSER TWIN 900 OUTLET PIPE The elbow forces a change of direction for the pumped material. If the flow direction is straightened, there is still turbulence exposing the downstream pipe to increased wear. We recommend placing a reinforced outlet pipe after elbows and bends.

ESSER COUPLINGS Available for working pressures up to 200 bar. See pages 29 to 31 for HD, SC, and ZX Couplings.

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CONNECTIONS

MAIN MENU

CONNECTIONS PIPE MULTIPLE OPTIONS FOR EFFICIENT SYSTEM DESIGN & OPERATION

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CONNECTIONS

MAIN MENU

With a variety of connection options, you can join pipes together to create a continuous flow path for your materials. Connections are crucial for ensuring your piping system functions properly, without leaks or breaks, and with the right flow direction.

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CONNECTIONS

MAIN MENU

COUPLINGS

FOR PASTE OR HYDRAULIC CONVEYANCE UNDER HIGH OPERATING PRESSURES

Coupling connections are the first choice for the hydraulic transportation of media under high pressures. They are used for drift lines in hydraulic conveyance of paste media for flushing and backfill, or concrete for the purpose of securing sections. They are also becoming increasingly popular for above-ground, silo pipes due to their quick installation.

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CONNECTIONS COUPLING TYPES

MAIN MENU

SC ZX

According to standardization, some connection types are classified according to pressure levels. These do not have to correspond to the operating pressure of the pipeline. When designing our piping systems, we comply with the Pressure Equipment Directive PED 2014/68/EU. Other coupling types and sizes on request.

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CONNECTIONS

MAIN MENU

HD COUPLING & QF COUPLING

HD COUPLING

QF COUPLING

The HD (HeviDuty®) coupling connection is engineered for high pressure ranges. They are designed for operating pressures of up to 200 bar. The weld-on collars, in conjunction with the two-shell coupling, ensure a force-fit and extremely tight connection. The end faces of the HD weld-on collars are plain - this has the advantage that individual pipes can be replaced during servicing without having to push the pipeline apart. The HD system can be connected to any high- density solids pump using appropriate adapter pipes. THE ALL-ROUNDER FOR HIGH PRESSURE RANGES IN HYDRAULIC CONVEYING

QUICK INSTALL, EASY MAINTENANCE - THE ALTERNATIVE TO FLANGES Derived from the coupling connections of hydraulic conveying, we have developed the QuickFix system (QF) for pneumatic conveying with pressures of up to 10 bar. This type of connection saves space and is extremely quick to install with just one bolt in the coupling. This system is primarily suitable for the pneumatic transportation of bulk materials. The coupling is pressure-tested with a safety factor of 2.

Range of conveying type

Hydraulic, pneumatic, unpressurized

Pneumatic, unpressurized

Sealing surface

Plain

Sealing surface

Plain

Operating pressure range

0 < PN < 200 0 < PN < 2900 (psi)

0 < PN < 12 0 < PN < 175 (psi)

Available nominal diameter

80 < DN < 150 3 < NPS < 6 (in)

Coupling types

2-Bolt, Snap

Coupling types

1-Bolt

Sealing element

Profile gasket

Sealing element

O-Ring

PIPES WITH CONNECTIONS FOR PUMPING CONCRETE UP TO 85 BAR CAN BE FOUND IN OUR CATALOG FOR CONCRETE PUMPS.

CLICK HERE FOR SK COUPLINGS

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CONNECTIONS

MAIN MENU

SC COUPLING & ZX COUPLING

SC COUPLING

ZX COUPLING

One of the oldest connections in mining, the SC connection is form-fit and force-fit. The tongue and groove profile of the weld-on collar is centering. A profiled rubber gasket provides a complete seal. The robust coupling has a hinge on one side. It is closed by means of a metal wedge that is hammered into a metal loop. The coupling is designed for operating pressures up to 200 bar and is used for hydraulic applications. OPEN AND CLOSE WITH A STROKE - PROVEN AND IN USE FOR DECADES

EXTREMELY RESILIENT UNDER HIGH PRESSURE AND DIFFICULT MEDIA A form-fit and force-fit connection that is absolutely leak-proof and therefore particularly suitable for high pressure and long conveying distances. The male- female connection is sealed with an O-Ring, which is pressed into the groove when closing. The system is suitable for highly fluid media and high pulsating pressure up to 200 bar. The system can be equipped with different types of couplings depending on the pressure range.

Range of conveying type

Hydraulic, pneumatic, unpressurized

Sealing surface

Centered (male/female)

Operating pressure range

0 < PN < 200 0 < PN < 2900 (psi)

Available nominal diameter

125 <DN< 150 5 < NPS < 6 (in)

125 <DN< 250 5 < NPS < 10 (in)

Coupling types

Wedge

2-Bolt, 1-Bolt, Wedge

Sealing element

Profile Ring

O-Ring

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CONNECTIONS

MAIN MENU

FLANGES FOR PNEUMATIC & HYDRAULIC CONVEYING Flanging is the oldest and best-known method of connecting pipe sections to each other in a detachable, but secure manner. As a rule, a flat gasket is inserted between the flanges (both perforated), which are pressed together with nuts and bolts. The sealing elements can vary depending on the type of sealing surface. Flanges are still used worldwide today. Flanges for ESSER pipelines are generally based on the EN 1092-1 standard (steel flanges). However, flanges according to other standards can also be used on request. Please contact us.

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CONNECTIONS FLANGE TYPES

MAIN MENU

FIXED FLANGE WELDED TYPE 01

TYPE 02

LOOSE FLANGE MOVEABLE

TYPE 02 LOOSE FLANGE

TYPE 32 WELD COLLAR

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CONNECTIONS

HMAAUI PN TM E N UÜ MAIN MENU

FLANGES ACC. TO EN1092-1

OVERVIEW SIZES*

Ød

ØOD ØBC.

Example: EN1092-1 / PN10*

Borehole circle Ø BC (mm)

Ø d (mm)

Ø OD (mm)

Holes

160

200

100

180

220

125

210

250

150

240

285

200

295

340

*Further sizes and other pressure ratings on request.

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CONNECTIONS

MAIN MENU

FLANGES ACC. TO EN1092-1

OVERVIEW SHAPES PLAIN SEALING SURFACES

Sealing surface A

Sealing surface B

Gasket

Flat gaskets Shapes FF and IBC

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CONNECTIONS

HMAAUI PN TM E N UÜ MAIN MENU

FLANGES ACC. TO EN1092-1

OVERVIEW SHAPES

CENTERED SEALING SURFACES

Sealing surface C

Sealing surface D

Gasket

Flat gasket Shape TG

Sealing surface E

Sealing surface F

Gasket

Flat gasket Shape SR

Sealing surface G

Sealing surface H

Gasket

O-Ring

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CONNECTIONS

MAIN MENU

METRIC & ANSI FLANGES

METRIC FLANGES EN1092-1 FLEXIBLE, VERSATILE, TIGHT - EASY TO INSTALL AND REMOVE Flanges enable quick and easy repair or expansion of pipeline systems. They are available in a wide variety of dimensions and shapes to suit your application. As standard, we equip our pipes with flanges in accordance with the metric standard EN1092-1. However, custom-made products to special dimensions can be fabricated.

SAME PERFORMANCE, DIFFERENT DIMENSIONS ANSI FLANGES B16.5

ESSER TWIN PIPES can also be fitted with flanges to ANSI B16.5. The function is the same as for the metric standard. This is particularly advantageous if the pipe has to be connected to North American-style machines and equipment.

Range of conveying type

Hydraulic, pneumatic, unpressurized

Plain or centered (Forms A, B, C & D, E & F, G & H)

Sealing surface

Plain

Operating pressure range

0 < PN < 1600 (psi) Class 150 - 600

0 < PN < 160 0 < PN < 2320 (psi)

0 < PN < 110

Available nominal diameter

80 < DN < 200 3 < NPS < 8 (in)

80 < DN < 150 3 < NPS < 6 (in)

Fixed flange, Weld-on collar + Loose flange

Flange types

Sealing element

Flat gasket, O-Rings

Sealing element

Flat gasket

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TENSION-RESISTANT SLEEVE CONNECTION (ZSM) STRONG, TENSION-RESISTANT, TIGHT The combination of this space-saving and high-strength connection with our highly wear-resistant, double-layer pipes is thanks to the cooperation between Carl Hamm GmbH and ESSER TWIN PIPES. The tension-resistant tight sleeve connection - ZSM for short - is a restrained and detachable pipe joint. The tight sleeve system patented by Carl Hamm is a compelling alternative to other common connection systems due to its easy assembly/disassembly, minimized space requirements and low price. The small dimensions of ZSM technology allow optimized pipe cross-sections, especially in tight installation situations.

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SUITABLE FOR FREE SUSPENDED PIPELINES IN BOREHOLES

ESSER TWIN 700 PIPE

Spigot end (male part)

O-ring to protect the chain grooves against impurities

Chain entry (back)

Chain entry (front)

Shearing elements (chains) to create the axial non-positive connection O-rings to seal against the internal pressure

Spigot end (male part)

Distance ring

O-rings to seal against the internal pressure

Chain entry (front)

Shearing elements (chains) to create the axial non-positive connection

Sleeve (female part)

Chain entry (back)

Range of conveying type

Hydraulic, pneumatic, unpressurized

Sealing surface

Specific to connection

Operating pressure range

0 < PN < 200

0 < PN < 2900 (psi)

Available nominal diameter

100 < DN < 350 3 < NPS < 14 (in)

Coupling types

Push-in socket with connecting sleeve

Sealing element

O-Rings

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WATCH THIS TECHNOLOGY IN ACTION

Carl Hamm, the supplier of steel and customized piping components, and Esser Twin Pipes have cooperated to combine two of their respective premium products into a pipe system that is engineered for underground shaft construction or for laying pipelines through boreholes. The tight sleeve connection - ZSM - from Carl Hamm is an axially non-positive and detachable pipe connection. Due to the quick assembly/disassembly and space-saving design, the use of ZSM systems ensures considerable cost savings through the whole lifecycle. The patent-protected tight sleeve system is successfully used internationally in a wide range of installation applications in the mining industry. Previously, this connection was installed using unhardened steel pipes. In order to create an alternative to conventional piping systems, pipes from the ESSER TWIN 700 series were chosen. Their inner wear layer has a hardness of 63 HRC, which ensures high resistance to abrasive media. Compared to conventional pipe systems made of unhardened mild steel, ESSER TWIN PIPES offer greater cost- effectiveness due to reduced replacement and maintenance downtime. The combination of ZSM connection and ESSER TWIN PIPES is the optimum of durable pipelines and space-saving, tension-resistant connection geometry. It is widely applied in backfilling operations as well as for the transport of building materials. Both applications exert high pressure on the piping components due to the conveyed materials; excellent quality of system components is vital. ESSER is an experienced and reliable partner for any R&D project. We continuously work on the improvement of our products and have developed unique expertise in many markets and applications. Contact us for more information!

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SMART CONNECTION FOR BOREHOLES

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ESSER-WERKE GMBH ZUM PUDDELHAMMER 25 59581 WARSTEIN GERMANY

T 0049-2902-896-0 F 0049-2902-896-103

sales-ind@esser-werke.de

VISIT US AT WWW.ESSERTWINPIPES.COM

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