ProtectorFlex® PRO pipes
With a FV-O inner layer, with a protective sheath, heat-resistant, GOST R 70751, up to 500 kV
For arranging by horizontal directional drilling method with increased borehole length
01 Description
ProtectorFlex® PRO are multilayer heat-resistant pipes made of a polymer compound with a special inner layer of FV-0 category, and an additional layer of increased strength to protect the pipe from puncturing and abrasion during laying of cable lines by horizontal directional drilling method.
Black marker layer beneath the outer protective layer contributes to easy visual detection of damage during installation.
Sliding additives are introduced into the composition of the inner layer to reduce friction during cable pulling.
Design
- Inner layer: flame-resistant
- Main layer: load-bearing
- Additional layer: marker
- Outer layer: increased strength, marker
(at least 50 years)
Key advantages
- Have an additional layer of increased strength
- Flame-resistant inner layer (FV-0 category)
- Resistant to short-circuiting in the cable
- Heat-resistant throughout the entire service life
- Have increased resistance to puncturing and distribution of point loads from stones and sharp objects
- Comply with the requirements of GOST R 70751-2023
- Mechanical strength throughout the entire service life
- Butt-welded
- Flexible, bends require no fittings or manholes
02 Application area
Mechanical protection of high-voltage cable lines
Intended for mechanical protection of high-voltage cable lines up to 500 kV. Recommended for arranging power cables under aggressive conditions (rocky grounds, grounds with artificial inclusions) and for arranging by horizontal directional drilling method with increased borehole length (over 200 m).
Laying methods
- Horizontal directional drilling (HDD)
- Pipe jacking
- Open-cut installation
Approved by the Ministry of Construction of the Russian Federation
Included in the State Estimate Standards by the Ministry of Construction of the Russian Federation: Federal cost estimates for materials used in construction.
(Order No. 899/pr dated December 11, 2015).
Included in the Cost Estimate Standards Database
Included in the Construction Resources Classifier (CRC), resource codes: 22.21.21.129.59.1.24.04-0928-000 to 22.21.21.129.59.1.24.04-1032-000
Approved by Rosseti PJSC
ProtectorFlex® pipes comply with the technical requirements of Rosseti PJSC and are recommended for use at the facilities owned by Rosseti PJSC and its subsidiaries.
Certified according to GOST R 70751-2023
ProtectorFlex® pipes are certified under the requirements of GOST R 70751-2023.
03 Product range of ProtectorFlex® PRO pipes
| Pipe outer diameter D, mm | Ring stiffness SN, kN/m2 |
Thickness of protective layer, mm |
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| 12 | 16 | 24 | 32 | 48 | 64 | 96 | Minimum | Maximum | |
| Pipe wall thickness e, mm | |||||||||
| 50 | 2,5 | 2,8 | 3,1 | 3,4 | 3,9 | 4,3 | 4,8 | 0,6 | 1,2 |
| 63 | 3,2 | 3,5 | 4,0 | 4,3 | 4,9 | 5,4 | 6,1 | 0,8 | 1,6 |
| 75 | 3,8 | 4,2 | 4,7 | 5,2 | 5,9 | 6,4 | 7,2 | 0,8 | 1,6 |
| 90 | 4,6 | 5,0 | 5,7 | 6,2 | 7,0 | 7,7 | 8,7 | 0,9 | 1,7 |
| 110 | 5,6 | 6,1 | 6,9 | 7,6 | 8,6 | 9,4 | 10,6 | 1,0 | 1,8 |
| 125 | 6,3 | 6,9 | 7,9 | 8,6 | 9,8 | 10,7 | 12,0 | 1,1 | 1,9 |
| 140 | 7,1 | 7,8 | 8,8 | 9,6 | 10,9 | 11,9 | 13,5 | 1,1 | 1,9 |
| 160 | 8,1 | 8,9 | 10,1 | 11,0 | 12,5 | 13,6 | 15,4 | 1,2 | 2,0 |
| 180 | 9,1 | 10,0 | 11,3 | 12,4 | 14,0 | 15,3 | 17,3 | 1,2 | 2,0 |
| 200 | 10,1 | 11,1 | 12,6 | 13,8 | 15,6 | 17,0 | 19,3 | 1,3 | 2,2 |
| 225 | 11,4 | 12,5 | 14,2 | 15,5 | 17,6 | 19,2 | 21,7 | 1,4 | 2,3 |
| 250 | 12,7 | 13,9 | 15,7 | 17,2 | 19,5 | 21,3 | 24,1 | 1,5 | 2,4 |
| 280 | 14,2 | 15,5 | 17,6 | 19,3 | 21,8 | 23,9 | 27,0 | 1,5 | 2,4 |
| 315 | 15,9 | 17,5 | 19,8 | 21,7 | 24,6 | 26,8 | 30,4 | 1,5 | 2,4 |
| 355 | 18,0 | 19,7 | 22,3 | 24,4 | 27,7 | 30,3 | 34,2 | 1,6 | 2,6 |
| 400 | 20,2 | 22,2 | 25,2 | 27,5 | 31,2 | 34,1 | 38,5 | 1,8 | 2,8 |
| 450 | 22,8 | 24,9 | 28,3 | 31,0 | 35,1 | 38,3 | 43,4 | 2,0 | 3,0 |
| 500 | 25,3 | 27,7 | 31,5 | 34,4 | 39,0 | 42,6 | 48,2 | 2,0 | 3,0 |
| 560 | 28,3 | 31,0 | 35,3 | 38,6 | 43,7 | 47,7 | 54,0 | 2,2 | 3,2 |
| 630 | 31,9 | 34,9 | 39,7 | 43,4 | 49,2 | 53,7 | 60,7 | 2,5 | 3,5 |
04 Advantages of ProtectorFlex® PRO pipes
ProtectorFlex® PRO pipes have an outer marker layer, which enables both work supervision and quality evaluation of pipe installation. The marker layer has a thickness of up to 10% of the wall thickness of the load-bearing pipe and differs in color. The marker layer, when completely damaged, allows for easier visual inspection and assessment of the cable duct’s integrity.
Causes of marker layer damage:
- Design error (incorrect calculation of pipe tension force during HDD)
- Installation error (e.g., incorrect selection of borehole reamer)
- Force majeure situation (sharp metal object, reinforcement bar, etc.
The marker layer of ProtectorFlex® PRO pipes lies under the protective shell and allows visual monitoring of pipe surface wear during arranging.
If the marker layer shows no through damage after pipe installation, it confirms that the duct was laid correctly, preserving all performance characteristics. If the marker layer has through damage, the extent to which such damage is acceptable shall be assessed based on the specific installation and operating conditions of the cable duct.
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05 Minimum pipe bending radius
Calculation
Е — modulus of elasticity of the pipe material under tension, MPa
σ — yield strength of the pipe material under tension, MPa
D — pipe outer diameter, mm
For example, at Е = 850 MPa and σ = 21 MPa the minimum bending radius will be r = 20D.
Installation experience proves that the minimum bending radius of the pipe also depends on the ambient temperature at the time of pipe laying.
The final recommendations are presented in the table.
| Minimum allowable bending radius of the pipe depending on the ambient temperature | |||
| Ambient temperature | 0°С | 10°С | 20°С |
| Minimum allowable bending radius | 50D | 35D | 20D |
06
Standard
documentation
- TU 2248-003-34311042-2015
- GOST R 70751-2023
- GOST 35043-2023
07
Example wording for categories
or technical specifications:
-
PROTECTORFLEX PRO (III,z) – 160/11,0 SN32 F110 T105 GOST R 70751 / TU 2248-003-34311042-2015
Smooth polymer heat-resistant pipe with a flame-resistant inner layer (FV-0 category), with an external protective layer of increased strength for laying and protecting cable lines up to 500 kV -
PROTECTORFLEX PRO-OMP (III, z) pipe - 160/11,0 SN32 F110 T105 /1/ GOST R 70751 / TU 2248-003-34311042-2015
Smooth polymer heat-resistant pipe with a flame-resistant inner layer (FV-0 category), with an outer protective layer of increased strength, a fault-locating option, for laying and protecting cable lines up to 500 kV
08
Main
characteristics
Operating temperature
- Long-term allowable heating temperature of cable cores to 105°C
- Minimum permissible operating temperature is -70°C
- In overload mode of cable lines up to 120°C (for 8 hours a day)
- In short-circuit mode up to 250°C on the cable core and 350°C on the cable screen
Shipping length
Standard shipping length is a straight section 13 m (12 m) long.
Technical specifications of ProtectorFlex® PRO
| Indicator | Value |
| Climatic version and installation category | UHL1 (climatic category: cold/ temperature), M1 (standard vibration and shock resistant) |
| Mean coefficient of linear thermal expansion at 20–70°С, K-1 | 1,8 х 10-4 |
| Vicat softening point,°С |
Minimum 125 |
| Thermal conductivity, W/(m·K) | Minimum 0,5 |
| Tensile yield strength, MPa | Minimum 21,7 |
| Tensile breaking stress, MPa | Minimum 37 |
| Tensile elastic modulus, MPa | Minimum 850 |
|
Thermal stability at 200°С, min |
Minimum 180 |
| Elongation at break, % | Minimum 350 |
| Insulation resistance*, MOhm | Maximum 0,1 |
| Shore D surface hardness of the pipe | Minimum 69 |
| Resistance to oils, gasoline, groundwater |
Resistant |
| Flame-resistant inner layer | FV-0 |
| Resistance to ignition by a heated wire, °С | 960 |
| Change in pipe length after heating, % | Maximum 3 |
| Minimum bending radius at 20°С | Minimum 20D* |
* D — is the outer diameter of the pipe.
09 Documentation
10 Accessories
ProtectorFlex® ZUP protective cable caps
Polymer, watertight
For sealing the ends of backup and operational protective cable pipes
ProtectorFlex® UVK cable seals
Polymer, watertight, heat-resistant, one-phase
For sealing the space between the cable and the pipe
ProtectorFlex® UVK-3 cable seals
Polymer, watertight, heat-resistant, three-phase
For sealing the space between 3 cables and the pipe
ProtectorFlex® TAP transition adapters
Polymer, heat-resistant
For watertight connection of different types of pipes to each other
