IPEX Vinyl Process Piping Systems Brochure

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Volume I: Vinyl Process Piping Systems

Industrial Technical Manual Series

SIXTH EDITION

IPEX VINYL PROCESS PIPING SYSTEMS

• Xirtec®140 PVC Schedule 40

• Xirtec®140 PVC Schedule 80

• Corzan®CPVC

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IPEX Vinyl Process Piping Systems

Industrial Technical Manual Series

Vol. 1, 6th Edition

© 2013 by IPEX. All rights reserved. No part of this book may be used or reproduced in any manner whatsoever without prior written permission. For information contact: IPEX Management Inc., 2441 Royal Windsor Drive, Mississauga, Ontario, Canada, L5J 4C7.

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ABOUT IPEX

At IPEX, we have been manufacturing non-metallic pipe and fittings since 1951. We formulate our own compounds and maintain strict quality control during production. Our products are made available for customers thanks to a network of regional stocking locations throughout North America. We offer a wide variety of systems including complete lines of piping, fittings, valves and custom-fabricated items.

More importantly, we are committed to meeting our customers’ needs. As a leader in the plastic piping industry, IPEX continually develops new products, modernizes manufacturing facilities and acquires innovative process technology. In addition, our staff take pride in their work, making available to customers their extensive thermoplastic knowledge and field experience. IPEX personnel are committed to improving the safety, reliability and performance of thermoplastic materials. We are involved in several standards committees and are members of and/or comply with the organizations listed on this page.

For specific details about any IPEX product, contact our customer service department.

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SAFETY ALERTS

Engineered thermoplastics are safe inert materials that do not pose any significant safety or environmental hazards during handling or installation. However, improper installation or use can result in personal injury and/or property damage. It is important to be aware of and recognize safety alert messages as they appear in this manual.

The types of safety alert messages are described below.

This safety alert symbol indicates important safety messages in this manual. When you see this symbol be alert to the possibility of personal injury and carefully read and fully understand the message that follows.

WARNING

CAUTION

Note: The use of the word “NOTE” signifies special instructions which are important but are not related to hazards.

“CAUTION” identifies hazards or unsafe practices that can result in minor personal injury or product or property damage if instructions, including recommended precautions, are not followed.

“WARNING” identifies hazards or unsafe practices that can result in severe personal injury or death if instructions, including recommended precautions, are not followed.

• NEVER use compressed air or gas in PVC/CPVC/PP/PVDF

pipe and fittings.

• NEVER test PVC/CPVC/PP/PVDF pipe and fittings with

compressed air or gas, or air-over-water boosters.

• ONLY use PVC/CPVC/PP/PVDF pipe for water and

approved chemicals.

CAUTION

WARNING

For the materials described in this manual, the following warning applies.

Vinyl Process Piping Systems

Use of compressed air or gas in PVC/CPVC/PP/PVDF pipe

and fittings can result in explosive failures and cause

severe injury or death.

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NOTES

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Vinyl Process Piping Systems Manual

About IPEX

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Section One: General Information

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Material Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

- Industrial and Process Piping

- Pulp and Paper

- Food Processing

- Water and Sewage Treatment

- Irrigation

Section Two: Process and Drainage Piping Design

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Establish System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Determine Appropriate Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

A) Pressure Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

B) Temperature Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

C) Pressure/Temperature Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Expansion and Contraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Water Hammer / Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Vacuum Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Section Three: Installation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Prolonged Outdoor Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Joining Methods – Solvent Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Solvent Cementing Instructions for PVC and CPVC Pipe and Fittings . . . . .47

iii

CONTENTS

Vinyl Process Piping Systems

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Joining Methods – Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Tools & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Making the Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Joining Methods – Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Corzan

Full Pressure Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Joining Methods – Roll Grooved or Radius Cut Grooved (PVC only) . . . . . . . . . . .61

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Supports and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

General Principals of Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Supporting Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Installation of Buried Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Trench Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Trench Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Trench Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Placing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Snaking the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Resisting Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Initial Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Compacting the Final Backfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Site Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Hydrostatic Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Repairs Below Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Joint Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Repairing Thermoplastic Pipe Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Vinyl Process Piping Systems

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Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Entrapped Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Ultraviolet Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Chemical Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Heat Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Section Four: Specialty Piping Products

PVC Well Casing - ASTM F480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

PVC Exhaust System Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Section Five: Specifications

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Standards Organizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

NSF International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

CSA International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

NFPA/UL/ULC/ASTM – Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Xirtec Sch. 40 & 80 PVC Industrial Pipe and Fittings . . . . . . . . . . . . . . . .85

Corzan Sch. 40 & 80 CPVC Industrial Pipe and Sch. 80 CPVC Fittings . . .85

Corzan Full-Pressure Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

PVC SDR Pressure Rated Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

PVC Ventilation Duct Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

CPVC Ventilation Duct Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Drain, Waste and Vent Pipe (DWV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Fabricated Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Solvent Cementing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Section Six: Appendices

Appendix A: Reference Tables and Conversion Charts . . . . . . . . . . . . . . . . . . . .91

Appendix B: Useful Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Appendix C: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Appendix D: Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Appendix E: Tables and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Vinyl Process Piping Systems

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NOTES

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

GENERAL

INFORMATION

OVERVIEW

SECTION ONE: GENERAL INFORMATION

This manual provides the most up-to-date and comprehensive information about vinyl piping systems produced by IPEX. Written with the needs of the engineer and contractor in mind, all aspects of PVC and CPVC thermoplastics are covered. This includes material properties, specifications, system selection (design considerations, sizing, fittings, valves) and installation.

Our PVC and CPVC piping offers the unique combination of light weight, flexibility, durability and exceptional corrosion resistance. Substantial savings in both initial installation and ongoing maintenance costs are achieved through the selection and use of these engineered materials.

Only IPEX offers Xirtec

, a complete system of pipe, valves and fittings engineered and manufactured to IPEX’s strict quality,

performance and dimensional standards.

Xirtec®(PVC) and Corzan®(CPVC) high performance systems feature outstanding resistance to photodegradation, creep stress and immunity to oxidation, and are exceptionally suited for use with a wide range of acid, alcohols, salts and halogens.

Vinyl Process Piping Systems

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

GENERAL

INFORMATION

Vinyl Process Piping Systems

Lower Installation Costs

In addition to lower material costs than traditional piping materials, vinyl pipe can significantly reduce labor and transportation costs on a typical installation.

Vinyl material is light weight, non-toxic and relatively flexible. Vinyl pipe is easily handled, stored and cut and can be joined in a variety of ways, adapting easily to any field application. Special handling or heavy equipment for installation is not required.

Extended Life

Once properly selected for the application and correctly installed, PVC and CPVC products provide years of maintenance free service. Our materials will not rust, pit, scale or corrode on either interior or exterior surfaces. In fact, thermoplastic piping systems in a variety of demanding industrial applications have operated successfully for over 45 years.

Chemical Resistance

IPEX offers complete systems including pipe, fittings and valves with outstanding resistance to a wide range of chemicals including most acids, alcohols, alkalis, salt solutions and halogens. PVC and CPVC are also not adversely affected by atmospheric conditions and are well suited for outdoor installations. For specific applications see the IPEX Chemical Resistance Guide.

Corrosion Resistance

Our thermoplastic materials are immune to damage from naturally corrosive soil conditions as well as electrochemical or galvanic corrosion. This is particularly advantageous in underground installations where galvanic reaction often causes damage to metal piping products. Our thermoplastic’s non-corroding properties ensure improved flow, lower maintenance costs and longer performance life.

Abrasion Resistance

The blending of PVC and CPVC resins, lubricants, modifiers and assorted additives in today’s compounds, together with modern extrusion processes, result in a resilient piping product with outstanding abrasion resistance.

PVC and CPVC are often selected as the piping material for conveyance in abrasive service. The inherent abrasion resistance of vinyl allows substantial increases in life expectancy compared to other materials. In many applications, vinyls outperform other materials such as metals.

For example, installation of vinyl piping rather than the standard metal or rubber-lined steel pipe for conveyance of mining and sand slurries resulted in significantly less abrasion, dramatically reduced maintenance and increased system life.

Improved Flow

IPEX piping has a substantially lower Roughness Factor than metal and other materials, and since thermoplastics do not rust, pit, scale or corrode, the interior walls remain smooth in virtually any service. This high carrying capacity may result in the use of flatter grades or smaller diameter pipe.

Non-toxicity

Polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) are relatively inert and are suitable for use with potable water as listed with the National Sanitation Foundation (NSF) and Canadian Standards Association (CSA).

Biological Resistance

PVC and CPVC piping systems are resistant to fungi and bacterial growth, particularly those which cause corrosion in metal piping systems.

Service Temperature

IPEX offers a variety of thermoplastic materials designed to meet a broad range of service temperatures. PVC has a recommended maximum service temperature of 140°F (60°C) while CPVC has a maximum service temperature of 200°F (93°C).

Lower Thermal Conductivity

With a dramatically lower thermal conductivity factor as compared to metal, thermoplastic systems have less heat loss or gain, and sustain the temperature of the service with less variation than metal piping. As a result, pipe insulation is often not required.

Fire Performance

PVC and CPVC are self-extinguishing materials. This means that they will not burn unless an external flame source is applied, and will not support combustion once the flame source is removed.

Extensive tests on PVC and CPVC compounds prove their outstanding fire performance. Check local building codes and regulations for specific requirements.

PVC

One of the outstanding characteristics of PVC is its resistance to ignition. This is demonstrated by its flash point (ignition temperature) of 730°F (388°C), compared to 400°F (204°C), for woodchips (white pine).

This is an extremely important characteristic when considering building code restrictions for combustible pipe. Tests performed in accordance to CAN/ULC S102.2 (The

BENEFITS

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

GENERAL

INFORMATION

Vinyl Process Piping Systems

Standard Method of Test for Surface Burning Characteristics of Flooring, Floor Covering and Miscellaneous Materials), show a fuel contribution of 0 for IPEX PVC material.

CPVC

CPVC offers an even greater fire safety profile than PVC. CPVC’s ignition resistance is demonstrated by its flash point (ignition temperature) of 900°F (482°C), with a low flame spread as well. In addition, it provides outstanding smoke characteristics. In testing conducted in accordance to CAN/ULC S102.2, IPEX CPVC showed a flame spread of 10, and a smoke-developed classification of 25. And, like PVC, CPVC has a fuel contribution of 0. It does not however meet ASTM E84.

Standards and Approvals

IPEX manufactures the widest range of thermoplastic piping systems available. All products are produced to the strictest internal quality control specifications and meet or exceed applicable regulatory standards.

IPEX will assist customers in obtaining additional product approvals that may be required in a particular jurisdiction.

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

GENERAL

INFORMATION

PVC (Polyvinyl Chloride)

PVC is the most frequently specified of all thermoplastic piping materials. It has been used successfully for over 60 years. PVC is characterized by distinctive physical properties, and is resistant to corrosion and chemical attack by acids, alkalis, salt solutions and many other chemicals. It is attacked, however, by polar solvents such as ketones and aromatics.

Of the various types and grades of PVC used in plastic piping, Type 1, Grade 1 PVC (Cell Classification 12454) conforming to ASTM D1784, is the most common. The maximum service temperature for PVC is 140°F (60°C), under pressure. PVC for drainage applications is also capable of handling near boiling temperatures for intermittent flow conditions. With a hydrostatic design basis of 4000 psi at 73°F (23°C) and a design stress of 2,000 psi at 73°F (23°C), PVC has the highest long-term hydrostatic strength of any other major thermoplastic material used for piping.

CPVC (Chlorinated Polyvinyl Chloride)

CPVC (Cell Classification 24448 and 23447) conforming to ASTM D1784 has physical properties at 73°F (23°C) similar to those of PVC and chemical resistance similar to or generally better than that of PVC. The design stress of CPVC is also 2,000 psi at 73°F (23°C). The maximum service temperature is 200°F (93°C) under pressure with occasional exposure to boiling water (212°F, 100°C). CPVC has proved to be an excellent piping material for hot corrosive liquids, hot and cold water distribution and similar applications above the temperature range of PVC.

MATERIAL DESCRIPTION

Table 1 – Physical Properties

PROPERTIES MATERIALS

PVC CPVC Corzan CPVC Standards

(Standard) (High Impact)

Cell classification 12454 23447 24448

Specific gravity 1.42 1.50 1.51 ASTM D 792

Tensile strength, psi at 73°F 7,000 7,500 7,320 ASTM D 638

Modulus of elasticity tensile, psi at 73°F 400,000 380,000 423,000 ASTM D 638

Flexural strength, psi 14,500 11,400 13,200 ASTM D 790

Izod impact, ft.lbs./in. at 73°F, notched 0.65 2.0 10.0 ASTM D 256

Compressive strength, psi 9,000 10,100 10,100 ASTM D 695

Poisson’s ratio 0.38 0.33 0.33

Working stress, psi at 73°F 2,000 2,000 2,000

Coefficient of thermal expansion in./in./°F (x 10

-5

) 3.0 3.8 3.4 ASTM D 696

Linear expansion, in./10°F per 100' of pipe 0.36 0.44 - 0.46 0.41

Maximum operating temperature under pressure 140ºF (60ºC) 200ºF (93ºC) 200ºF (93ºC)

Deflection temperature under load, °F at 66 psi 173 n/a n/a ASTM D 648

Deflection temperature under load, °F at 264 psi 160 212 239 ASTM D 648

Thermal conductivity, BTU.in./hr.ft

.°F 1.2 0.95 0.95 ASTM C177

Burning rate Self extinguish Self extinguish Self extinguish ASTM D 635

Burning class V-0 V-0 V-0 UL-94

Flash ignition, °F 730 900 900

Limited oxygen index (%) 43 60 60 ASTM D 2863-70

Water absorption, %, (24 hrs. at 73°F) 0.05 0.03 0.03 ASTM D 570

Vinyl Process Piping Systems

* The properties listed in this table represent general material properties and should be used as a guideline only.

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

GENERAL

INFORMATION

APPLICATIONS

Industrial and Process Piping

• Plant Water Supply and Distribution Lines

• Cooling Water Systems

• Chemical and Washwater Systems for Photographic Laboratories

• Acid Products Handling for Refineries, Metal Works and Plating Plants

• Bleach, Dye and Acid Lines in Textile Mills

• Deionized Water

• Tailing and Slurry Lines in Mines, Smelters and Fertilizer Plants

• Vacuum Piping

• Pure Chemicals for Semiconductor & Pharmaceutical Industries

• Piping in Fish Hatcheries, Aquariums, Zoological and Biological Buildings

• Well Casings and Dewatering Lines

• Drainage and Effluent Piping

• Swimming Pool Piping

• Rainwater Leaders for Buildings

Pulp and Paper

• Pulp/Chemical Recovery Systems

• Bleach Plant Piping Systems

• Washwater Piping and Lagoon Systems

Food Processing

• Brine and Seawater Distribution in Fish Plants

• Brine Systems in Meat Packaging Plants

• Piping for the Dairy, Canning and Beverage Industries

Water and Sewage Treatment

• Alum and Ferric Chloride Handling

• Chlorine Injection Systems

• Piping in Lagoons and Settling Ponds

• Rainwater Lines

Irrigation

• Golf Courses

• Greenhouses

• Agriculture

• Residential Turf

• Commercial Turf

Vinyl Process Piping Systems

Page 15

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Vinyl Process Piping Systems

NOTES

Page 16

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

SECTION TWO: PROCESS AND DRAINAGE PIPING DESIGN

INTRODUCTION

Thermoplastics are engineered materials that are suitable for a wide variety of piping assignments in both process and drainage applications. To effectively implement the use of thermoplastics, it is considered necessary to have both a working knowledge of piping design and an appreciation of the unique properties of thermoplastics.

This section will review the design process and consider the most important factors in designing thermoplastic piping systems.

Vinyl Process Piping Systems

Page 17

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

DESIGN PROCESS

Vinyl Process Piping Systems

Establish System Requirements

Before the proper materials can be chosen, the system requirements must be determined. This establishes the scope of the project and determines design and material specifications. Factors to be considered may include:

1. Liquid composition

• Chemical characteristics

• Variations in fluid chemistry

2. Process flow

• Required flow rate

• Required pressure

• Changes in velocity

• Potential pressure drops

• Potential pressure surges

• Minimum and maximum operating temperatures

3. System Location / Environment

• Above / below ground or overhead

• Climate (extreme heat or cold)

• Expected fluctuations in ambient temperature

4. Installation

• Space restrictions

• Difficult access

• New or retrofit

• Joining of dissimilar materials

5. Budget Considerations

• Material cost

• Installation cost

• Maintenance cost

• Life expectancy

Determine Appropriate Sizing

In addition to accounting for specific system parameters, pipe size must also be determined. To select an appropriate size, it is essential that there is an understanding of the most important physical factors affecting thermoplastic pipe, which are:

• Pressure limitations

• Temperature limitations

• The pressure/temperature relationship

A) Pressure Limitations

Pressure Ratings

PVC and CPVC pipe are primarily designed to withstand internal pressure under continuous or steady state loading. Short-term higher pressure surges can be accommodated to varying degrees, but it is the long-term strength of the material that determines its performance.

In North America, PVC and CPVC pipe designed for pressure applications must have a defined minimum hydrostatic design basis (HDB) of 4000 psi (27.58 MPa) as per ASTM D 2837. To ensure useful long-term service (minimum of 50 years) a design or safety factor is applied to provide an adequate safety margin. A safety factor of 2 is usually applied.

Determining Pressure

The carrying capacity of any pipe is a function of its hoop strength and the geometry of the pipe as defined by its wall thickness and diameter at a given temperature.

Design Stress

The largest stress present in any piping system under pressure is hoop or circumferential stress. This is the governing factor in determining the pressure that a section of pipe can withstand. In calculating pressure, design stress (S) serves as the maximum hoop stress.

S = HDB

Where:

HDB = hydrostatic design basis

f = safety factor

Example 1:

What would be the hoop stress for a hydrostatic design basis of 4000 psi?

S = 4000 S = 2000 psi

Known: HDB = 4000, safety factor = f = 2

Safety Factor

Design Factor

Page 18

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Wall Thickness

To classify various thicknesses of pipe, the term DR is used. This term refers to the dimension ratio. (See Table 2)

The dimension ratio can also be calculated as follows:

DR = D

Where:

= average outside diameter

t = minimum wall thickness

Important points to remember about the DR classifications are:

• the lower the DR number, the thicker the pipe wall and the higher the pressure rating

• the pressure capacity and strength of a specific DR is constant regardless of diameter

Note: For schedule pipe, the outside diameter and wall thickness is based on conventional steel pipe dimensions. Therefore, for schedule pipe, each size of vinyl pipe has a different DR rating and a different pressure capability. See Table 2 for values.

Internal Pressure

The relationships outlined above can be described in an equation, also known as the ISO equation.

P = 2S

DR-1

where:

P = internal pressure, psi S = hoop stress, psi DR = dimension ratio (D

/t)

Example 2:

What would be the maximum pressure allowed for a 2-inch DR 21 pipe?

Known: S = 2000, DR = 21

P = 2(2000)

(21-1)

P = 4000

P = 200 psi

Example 3:

What would be the maximum pressure allowed for a 2-inch Schedule 80 pipe?

Step 1: Calculate DR

Known: DR = D

DR = 2.375 (from Table A-14 Dimensions,

0.218 Weights and Pressure Ratings)

DR = 10.9

Step 2: Calculate the maximum pressure P

Known: S = 2000, DR = 10.9

P = 2(2000)

(10.9-1)

P = 4000

9.9

P = 404 psi

Table 2 – Nominal DR Classification for PVC & CPVC Schedule Pipe

Size Schedule 40 Schedule 80

DR Average Min. Wall DR Average Min. Wall

OD. Thickness OD. Thickness

(in) (in) (in) (in) (in)

/4 - - - 4.5 0.540 0.119

/8 - - - 5.4 0.675 0.126

/2 7.7 0.840 0.109 5.7 0.840 0.147

/4 9.3 1.050 0.113 6.8 1.050 0.154

1 9.9 1.315 0.133 7.3 1.315 0.179

/4 11.8 1.660 0.141 8.7 1.660 0.191

/2 13.1 1.900 0.145 9.5 1.900 0.200

2 15.4 2.375 0.154 10.9 2.375 0.218

/2 14.2 2.875 0.203 10.4 2.875 0.276 3 16.2 3.500 0.216 11.7 3.500 0.300 4 19.0 4.500 0.237 13.4 4.500 0.337 5 21.6 5.563 0.258 14.8 5.563 0.375 6 23.7 6.625 0.280 15.3 6.625 0.432 8 26.8 8.625 0.322 17.3 8.625 0.500

10 29.5 10.750 0.365 18.1 10.750 0.593 12 31.4 12.750 0.406 18.6 12.750 0.687 14 32.0 14.000 0.438 18.7 14.000 0.750 16 32.0 16.000 0.500 19.0 16.000 0.843 18 32.0 18.000 0.562 19.2 18.000 0.937 20 33.7 20.000 0.593 19.4 20.000 1.031 24 34.9 24.000 0.687 19.7 24.000 1.218

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Page 19

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Example 4:

A piping system consisting of 2 and 4 inch pipe must be capable of sustaining a pressure of 310 psi at ambient temperature (73°F / 23ºC). What schedule of pipe is necessary?

Step 1: To calculate actual DR, refer to Table A-14 Dimensions, Weights & Pressure Ratings.

Step 2: For each pipe size and schedule of pipe, first calculate actual DR and then the resulting P.

DR = D

P = 2S

DR-1

Therefore, to sustain a pressure of 310 psi, 2" Schedule 80 pipe and 4" schedule 80 pipe are required.

Friction Loss through Piping

As fluid flows through a piping system, it will experience friction resistance between the fluid and the pipe wall resulting in a pressure loss. This pressure loss is a result of fluid:

• density

• viscosity

• velocity

• temperature

• type of flow

• smoothness of the pipe wall

Friction loss can be determined by referring to published tables, such as those in Tables 4, 5, 6, and 7 or it can be calculated. The most widely used equation to calculate friction loss in pressure systems is the Hazen-Williams equation.

Hazen-Williams Equation

where:

f = friction loss (ft. of H

O/100 ft.) Q = flow rate (gpm) D

= pipe inside diameter (in.)

C = flow coefficient

Example 5

A PVC system has a flow rate of 4000 U.S. gallons per minute. What is the friction loss in 20" Schedule 40 pipe?

Known: Q = 4000 US gpm

C = 150 (from Table 3 Flow coefficient constants) Di= 18.743 (from Table A-14 Dimensions,

Weights & Pressure Ratings)

f = 0.2083 x 0.476 x 3.006

f = 0.3 ft. per 100 ft.

The most widely used equation to calculate friction loss for open channel flow, such as in drainage applications is the Manning formula. Please refer to the section on Drainage.

Note: conversion tip (1 psi = 2.31ft of H

Table 3 – Flow Coefficient Constants (C)

f = 0.2083 x (100

)

1.852

x Q

1.852

4.8655

f = 0.2083 x (100

)

1.852

x (4000)

1.852

150 (18.743)

4.8655

Vinyl Process Piping Systems

Dimension Ratio

DR = 2.375

0.154

= 15.4

DR = 2.375

0.218

= 10.9

DR = 4.500

0.237

= 19.0

DR = 4.500

0.337

= 13.4

Maximum Pressure

P = 2 (2000)

(15.4 - 1)

= 4000

14.4

= 278 psi

P = 2 (2000)

(10.9 - 1)

= 4000

9.9

= 404 psi

P = 2 (2000)

(19.0 - 1)

= 4000

18.0

= 222 psi

P = 2 (2000)

(13.4 - 1)

= 4000

12.4

= 323 psi

2" Schedule 40

2" Schedule 80

4" Schedule 40

4" Schedule 80

Type of Pipe Flow coefficient C

Vinyl 150 Copper 140 Cast iron - unlined 90 - 120 Galvanized steel 110 Corrugated steel pipe 60

Page 20

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Table 4 – Carrying Capacity and Friction Loss for Schedule 40 Thermoplastic Pipe

1 0.002 1.13 1.16 0.50

2 0.004 2.26 4.19 1.81 1.26 1.03 0.44

5 0.011 5.64 22.88 9.90 3.16 5.60 2.42 1.93 1.69 0.73 1.10 0.43 0.19

7 0.016 7.89 42.66 18.47 4.43 10.44 4.52 2.70 3.14 1.36 1.55 0.81 0.35 1.13 0.38 0.16

10 0.022 6.32 20.21 8.75 3.86 6.08 2.63 2.21 1.57 0.68 1.62 0.73 0.32 0.98 0.21 0.09

12 0.027 7.59 28.33 12.26 4.63 8.53 3.69 2.65 2.20 0.95 1.94 1.03 0.44 1.46 0.45 0.20 1.03 0.19 0.08

15 0.033 9.48 42.82 18.54 5.79 12.89 5.58 3.31 3.32 1.44 2.42 1.55 0.67 1.95 0.77 0.33 1.37 0.33 0.14

20 0.045 7.72 21.96 9.51 4.42 5.65 2.45 3.23 2.64 1.14 2.44 1.17 0.51 1.71 0.49 0.21 1.10 0.17 0.07

25 0.056 9.65 33.20 14.37 5.52 8.55 3.70 4.04 4.00 1.73 2.93 1.64 0.71 2.05 0.69 0.30 1.32 0.24 0.10

30 0.067 11.58 46.54 20.15 6.63 11.98 5.19 4.85 5.60 2.42 3.41 2.18 0.94 2.39 0.92 0.40 1.55 0.32 0.14

35 0.078 7.73 15.94 6.90 5.66 7.45 3.23 3.90 2.79 1.21 2.73 1.18 0.51 1.77 0.41 0.18

40 0.089 8.84 20.41 8.84 6.47 9.54 4.13 4.39 3.47 1.50 3.08 1.46 0.63 1.99 0.51 0.22

45 0.100 1.15 0.13 0.06 9.94 25.39 10.99 7.27 11.87 5.14 4.88 4.22 1.83 3.42 1.78 0.77 2.21 0.61 0.27

50 0.111 1.28 0.16 0.07 11.05 30.86 13.36 8.08 14.43 6.25 5.36 5.03 2.18 3.76 2.12 0.92 2.43 0.73 0.32

55 0.123 1.41 0.19 0.08 8.89 17.21 7.45 5.85 5.92 2.56 4.10 2.49 1.08 2.65 0.86 0.37

60 0.134 1.53 0.23 0.10 9.70 20.22 8.75 6.34 6.86 2.97 4.44 2.89 1.25 2.87 1.00 0.43

65 0.145 1.66 0.26 0.11 10.51 23.45 10.15 6.83 7.87 3.41 4.79 3.32 1.44 3.09 1.15 0.50

70 0.156 1.79 0.30 0.13 1.14 0.10 0.04 11.32 26.90 11.65 7.32 8.94 3.87 5.13 3.77 1.63 3.31 1.30 0.56

75 0.167 1.92 0.34 0.15 1.22 0.11 0.05 7.80 10.08 4.36 5.47 4.25 1.84 3.53 1.47 0.63

80 0.178 2.05 0.39 0.17 1.30 0.13 0.06 8.29 11.27 4.88 5.81 4.75 2.06 3.75 1.64 0.71

90 0.201 2.30 0.48 0.21 1.46 0.16 0.07 8.78 12.53 5.43 6.15 5.28 2.29 3.97 1.82 0.79

100 0.223 2.56 0.59 0.25 1.62 0.19 0.08 1.12 0.08 0.03 9.27 13.85 6.00 6.49 5.84 2.53 4.20 2.02 0.87

125 0.279 3.20 0.89 0.38 2.03 0.29 0.13 1.40 0.12 0.05 9.75 15.23 6.59 6.84 6.42 2.78 4.42 2.22 0.96

150 0.334 3.84 1.24 0.54 2.44 0.41 0.18 1.69 0.17 0.07 8.55 9.70 4.20 5.52 3.35 1.45

175 0.390 4.47 1.65 0.72 2.84 0.55 0.24 1.97 0.22 0.10 10.26 13.60 5.89 6.62 4.70 2.03

200 0.446 5.11 2.12 0.92 3.25 0.70 0.30 2.25 0.29 0.12 1.30 0.08 0.03 7.73 6.25 2.71

250 0.557 6.39 3.20 1.39 4.06 1.06 0.46 2.81 0.43 0.19 1.62 0.11 0.05 8.83 8.00 3.46

300 0.668 7.67 4.49 1.94 4.87 1.49 0.64 3.37 0.61 0.26 1.94 0.16 0.07 11.04 12.10 5.24

350 0.780 8.95 5.97 2.58 5.69 1.98 0.86 3.93 0.81 0.35 2.27 0.21 0.09 1.44 0.07 0.03

400 0.891 10.23 7.64 3.31 6.50 2.54 1.10 4.49 1.03 0.45 2.59 0.27 0.12 1.64 0.09 0.04

450 1.003 7.31 3.15 1.36 5.06 1.29 0.56 2.92 0.34 0.15 1.85 0.11 0.05 1.30 0.05 0.02

500 1.114 8.12 3.83 1.66 5.62 1.56 0.68 3.24 0.41 0.18 2.05 0.14 0.06 1.45 0.06 0.02

600 1.337 9.75 5.37 2.33 6.74 2.19 0.95 3.89 0.57 0.25 2.46 0.19 0.08 1.74 0.08 0.03 1.44 0.05 0.02

700 1.560 11.37 7.15 3.09 7.87 2.92 1.26 4.54 0.76 0.33 2.87 0.25 0.11 2.02 0.11 0.05 1.67 0.07 0.03

800 1.782 8.99 3.73 1.62 5.18 0.98 0.42 3.29 0.32 0.14 2.31 0.14 0.06 1.91 0.09 0.04 1.47 0.05 0.02

900 2.005 1.30 0.03 0.01 10.11 4.64 2.01 5.83 1.22 0.53 3.70 0.40 0.17 2.60 0.17 0.07 2.15 0.11 0.05 1.65 0.06 0.02

1000 2.228 1.45 0.04 0.02 6.48 1.48 0.64 4.11 0.49 0.21 2.89 0.21 0.09 2.39 0.13 0.06 1.83 0.07 0.03

1250 2.785 1.81 0.06 0.03 8.10 2.24 0.97 5.13 0.74 0.32 3.61 0.31 0.14 2.99 0.20 0.09 2.29 0.10 0.04

1500 3.342 2.17 0.08 0.04 1.75 0.05 0.02 9.72 3.14 1.36 6.16 1.03 0.45 4.34 0.44 0.19 3.59 0.28 0.12 2.75 0.15 0.06

2000 4.456 2.89 0.14 0.06 2.33 0.08 0.04 8.21 1.76 0.76 5.78 0.75 0.32 4.78 0.47 0.20 3.66 0.25 0.11

2500 5.570 3.62 0.21 0.09 2.91 0.12 0.05 2.01 0.05 0.02 10.27 2.66 1.15 7.23 1.13 0.49 5.98 0.71 0.31 4.58 0.37 0.16

3000 6.684 4.34 0.29 0.13 3.49 0.17 0.08 2.41 0.07 0.03 8.68 1.59 0.69 7.18 1.00 0.43 5.50 0.52 0.23

3500 7.798 5.06 0.39 0.17 4.07 0.23 0.10 2.81 0.09 0.04 10.12 2.11 0.92 8.37 1.33 0.58 6.41 0.70 0.30

4000 8.912 5.79 0.50 0.22 4.65 0.30 0.13 3.22 0.12 0.05 9.57 1.71 0.74 7.33 0.89 0.39

4500 10.026 6.51 0.62 0.27 5.24 0.37 0.16 3.62 0.15 0.06 10.76 2.12 0.92 8.24 1.11 0.48

5000 11.140 7.23 0.76 0.33 5.82 0.45 0.19 4.02 0.18 0.08 9.16 1.35 0.58

5500 12.254 7.96 0.91 0.39 6.40 0.53 0.23 4.42 0.22 0.09 10.08 1.61 0.70

6000 13.368 8.68 1.06 0.46 6.98 0.63 0.27 4.83 0.25 0.11

6500 14.482 9.40 1.23 0.53 7.56 0.73 0.31 5.23 0.30 0.13

7000 15.596 10.13 1.42 0.61 8.14 0.83 0.36 5.63 0.34 0.15

7500 16.710 8.73 0.95 0.41 6.03 0.39 0.17

8000 17.824 9.31 1.07 0.46 6.43 0.43 0.19

8500 18.938 9.89 1.19 0.52 6.84 0.49 0.21

9000 20.052 10.47 1.33 0.57 7.24 0.54 0.23

9500 21.166 7.64 0.60 0.26

10000 22.280 8.04 0.66 0.28

3/4"

1 1/4"

1 1/2"

2 1/2"

10"

12"

14"

16"

18"

20"

24"

1/2"

CAUTION: Flow velocity should not exceed 5 feet per second.

PROCESS &

DRAINAGE PIPING DESIGN

GPM

cu ft/sec

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Vinyl Process Piping Systems

Page 21

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Table 5 – Carrying Capacity and Friction Loss for Schedule 80 Thermoplastic Pipe

1 0.002 1.48 2.24 0.97

2 0.004 2.95 8.10 3.51 1.57 1.73 0.75 0.93 0.49 0.21

5 0.011 7.39 44.21 19.14 3.92 9.47 4.10 2.33 2.67 1.16 1.30 0.64 0.28

7 0.016 10.34 82.43 35.69 5.49 17.65 7.64 3.27 4.98 2.16 1.82 1.20 0.52 1.31 0.54 0.24

10 0.022 7.84 34.18 14.79 4.67 9.65 4.18 2.59 2.32 1.00 1.88 1.05 0.46

12 0.027 9.41 47.90 20.74 5.60 13.52 5.85 3.11 3.25 1.40 2.25 1.47 0.64

15 0.033 11.76 72.42 31.35 7.00 20.44 8.85 3.89 4.91 2.12 2.81 2.23 0.96 1.68 0.63 0.27

20 0.045 9.33 34.82 15.07 5.19 8.36 3.62 3.75 3.80 1.64 2.23 1.07 0.47 1.56 0.45 0.19

25 0.056 11.66 52.64 22.79 6.49 12.64 5.47 4.69 5.74 2.48 2.79 1.63 0.70 1.95 0.68 0.29

30 0.067 7.78 17.71 7.67 5.63 8.04 3.48 3.35 2.28 0.99 2.34 0.95 0.41 1.49 0.32 0.14

35 0.078 9.08 23.56 10.20 6.57 10.70 4.63 3.91 3.03 1.31 2.73 1.26 0.55 1.74 0.43 0.18

40 0.089 10.38 30.17 13.06 7.50 13.71 5.93 4.47 3.88 1.68 3.12 1.62 0.70 1.99 0.54 0.24

45 0.100 8.44 17.05 7.38 5.03 4.83 2.09 3.51 2.01 0.87 2.24 0.68 0.29

50 0.111 1.43 0.21 0.09 9.38 20.72 8.97 5.58 5.87 2.54 3.90 2.45 1.06 2.49 0.82 0.36

55 0.123 1.57 0.25 0.11 10.32 24.72 10.70 6.14 7.00 3.03 4.29 2.92 1.26 2.74 0.98 0.43

60 0.134 1.71 0.30 0.13 9.70 20.22 8.75 6.70 8.22 3.56 4.68 3.43 1.48 2.99 1.15 0.50

65 0.145 1.85 0.34 0.15 10.51 23.45 10.15 7.26 9.54 4.13 5.07 3.97 1.72 3.24 1.34 0.58

70 0.156 2.00 0.39 0.17 11.32 26.90 11.65 7.82 10.94 4.74 5.46 4.56 1.97 3.49 1.54 0.66

75 0.167 2.14 0.45 0.19 8.38 12.43 5.38 5.85 5.18 2.24 3.74 1.74 0.76

80 0.178 2.28 0.51 0.22 1.44 0.16 0.07 8.93 14.01 6.06 6.23 5.84 2.53 3.99 1.97 0.85

90 0.201 2.57 0.63 0.27 1.62 0.20 0.09 10.05 17.42 7.54 7.01 7.26 3.14 4.48 2.45 1.06

100 0.223 2.85 0.76 0.33 1.80 0.25 0.11 11.17 21.18 9.17 7.79 8.83 3.82 4.98 2.97 1.29

125 0.279 3.56 1.16 0.50 2.25 0.38 0.16 1.57 0.16 0.07 9.74 13.34 5.78 6.23 4.49 1.95

150 0.334 4.28 1.62 0.70 2.70 0.53 0.23 1.88 0.22 0.10 11.69 18.70 8.10 7.47 6.30 2.73

175 0.390 4.99 2.16 0.93 3.15 0.70 0.30 2.19 0.29 0.13 8.72 8.38 3.63

200 0.446 5.70 2.76 1.19 3.60 0.90 0.39 2.51 0.37 0.16 1.43 0.10 0.04 9.97 10.73 4.65

250 0.557 7.13 4.17 1.81 4.49 1.36 0.59 3.13 0.57 0.24 1.79 0.14 0.06

300 0.668 8.55 5.85 2.53 5.39 1.90 0.82 3.76 0.79 0.34 2.14 0.20 0.09

350 0.780 9.98 7.78 3.37 6.29 2.53 1.10 4.39 1.05 0.46 2.50 0.27 0.12 1.59 0.09 0.04

400 0.891 11.41 9.96 4.31 7.19 3.24 1.40 5.02 1.35 0.58 2.86 0.34 0.15 1.81 0.11 0.05

450 1.003 8.09 4.04 1.75 5.64 1.68 0.73 3.21 0.43 0.18 2.04 0.14 0.06 1.44 0.06 0.03

500 1.114 8.99 4.90 2.12 6.27 2.04 0.88 3.57 0.52 0.22 2.27 0.17 0.07 1.60 0.07 0.03

600 1.337 10.79 6.87 2.98 7.52 2.86 1.24 4.28 0.73 0.31 2.72 0.24 0.10 1.92 0.10 0.04 1.59 0.07 0.03

700 1.560 8.78 3.81 1.65 5.00 0.97 0.42 3.17 0.32 0.14 2.24 0.14 0.06 1.86 0.09 0.04

800 1.782 10.03 4.88 2.11 5.71 1.24 0.54 3.63 0.41 0.18 2.56 0.18 0.08 2.12 0.11 0.05 1.62 0.06 0.02

900 2.005 6.43 1.54 0.67 4.08 0.51 0.22 2.88 0.22 0.09 2.39 0.14 0.06 1.82 0.07 0.03

1000 2.228 1.59 0.05 0.02 7.14 1.87 0.81 4.54 0.62 0.27 3.20 0.27 0.12 2.65 0.17 0.07 2.02 0.09 0.04

1250 2.785 1.99 0.07 0.03 8.93 2.83 1.23 5.67 0.94 0.41 4.01 0.40 0.17 3.32 0.25 0.11 2.53 0.13 0.06

1500 3.342 2.39 0.10 0.04 1.93 0.06 0.03 10.71 3.97 1.72 6.80 1.32 0.57 4.81 0.57 0.24 3.98 0.36 0.15 3.03 0.18 0.08

2000 4.456 3.19 0.18 0.08 2.58 0.10 0.05 9.07 2.24 0.97 6.41 0.96 0.42 5.31 0.61 0.26 4.04 0.31 0.14

2500 5.570 3.98 0.27 0.12 3.22 0.16 0.07 2.23 0.06 0.03 11.34 3.39 1.47 8.01 1.46 0.63 6.63 0.92 0.40 5.05 0.47 0.21

3000 6.684 4.78 0.37 0.16 3.86 0.22 0.10 2.67 0.09 0.04 9.61 2.04 0.88 7.96 1.29 0.56 6.06 0.66 0.29

3500 7.798 5.58 0.50 0.21 4.51 0.30 0.13 3.12 0.12 0.05 11.21 2.71 1.17 9.29 1.71 0.74 7.07 0.88 0.38

4000 8.912 6.37 0.64 0.28 5.15 0.38 0.16 3.56 0.15 0.07 10.61 2.20 0.95 8.08 1.13 0.49

4500 10.026 7.17 0.79 0.34 5.80 0.47 0.20 4.01 0.19 0.08 11.94 2.73 1.18 9.09 1.41 0.61

5000 11.140 7.97 0.96 0.42 6.44 0.57 0.25 4.45 0.23 0.10 10.10 1.71 0.74

5500 12.254 8.77 1.15 0.50 7.08 0.68 0.30 4.90 0.28 0.12

6000 13.368 9.56 1.35 0.58 7.73 0.80 0.35 5.35 0.33 0.14

6500 14.482 10.36 1.56 0.68 8.37 0.93 0.40 5.79 0.38 0.16

7000 15.596 9.02 1.07 0.46 6.24 0.44 0.19

7500 16.710 9.66 1.21 0.52 6.68 0.49 0.21

8000 17.824 10.30 1.37 0.59 7.13 0.56 0.24

8500 18.938 10.95 1.53 0.66 7.57 0.62 0.27

9000 20.052 8.02 0.69 0.30

9500 21.166 8.46 0.77 0.33

10000 22.280 8.91 0.84 0.36

GPM

cu ft/sec

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

3/4"

1 1/4"

1 1/2"

2 1/2"

10"

12"

14"

16"

18"

20"

24"

1/2"

CAUTION: Flow velocity should not exceed 5 feet per second.

Vinyl Process Piping Systems

Page 22

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

CAUTION: Flow velocity should not exceed 5 feet per second.

Table 6 – Carrying Capacity and Friction Loss for DR 21 Thermoplastic Pipe

1 0.002

2 0.004 1.88 2.68 1.16 1.08 0.70 0.30

5 0.011 4.69 14.62 6.33 2.70 3.81 1.65 1.59 1.05 0.45

7 0.016 6.57 27.27 11.81 3.78 7.11 3.08 2.22 1.95 0.84

10 0.022 9.38 52.79 22.85 5.40 13.77 5.96 3.17 3.78 1.63 1.87 1.04 0.45

12 0.027 11.26 74.00 32.03 6.48 19.30 8.35 3.81 5.29 2.29 2.24 1.45 0.63 1.70 0.74 0.32

15 0.033 8.10 29.17 12.63 4.76 8.00 3.46 2.80 2.20 0.95 2.12 1.12 0.49

20 0.045 10.80 49.70 21.51 6.35 13.63 5.90 3.73 3.75 1.62 2.83 1.91 0.83 1.80 0.64 0.28

25 0.056 7.93 20.60 8.92 4.66 5.66 2.45 3.54 2.89 1.25 2.25 0.97 0.42 1.53 0.38 0.16

30 0.067 9.52 28.88 12.50 5.60 7.94 3.44 4.24 4.05 1.75 2.71 1.35 0.59 1.84 0.53 0.23

35 0.078 11.10 38.42 16.63 6.53 10.56 4.57 4.95 5.38 2.33 3.16 1.80 0.78 2.15 0.71 0.31

40 0.089 7.46 13.53 5.86 5.66 6.89 2.98 3.61 2.31 1.00 2.45 0.90 0.39 1.65 0.34 0.15

45 0.100 8.40 16.82 7.28 6.36 8.57 3.71 4.06 2.87 1.24 2.76 1.12 0.49 1.86 0.43 0.19

50 0.111 9.33 20.45 8.85 7.07 10.42 4.51 4.51 3.49 1.51 3.07 1.37 0.59 2.06 0.52 0.23

55 0.123 10.26 24.40 10.56 7.78 12.43 5.38 4.96 4.16 1.80 3.37 1.63 0.71 2.27 0.62 0.27

60 0.134 8.49 14.60 6.32 5.41 4.89 2.12 3.68 1.91 0.83 2.48 0.73 0.32

65 0.145 1.62 0.25 0.11 9.19 16.94 7.33 5.86 5.67 2.45 3.99 2.22 0.96 2.68 0.85 0.37

70 0.156 1.75 0.29 0.12 9.90 19.43 8.41 6.31 6.50 2.81 4.29 2.55 1.10 2.89 0.97 0.42

75 0.167 1.87 0.32 0.14 10.61 22.08 9.56 6.76 7.39 3.20 4.60 2.89 1.25 3.10 1.10 0.48

80 0.178 2.00 0.37 0.16 7.21 8.32 3.60 4.91 3.26 1.41 3.30 1.25 0.54

90 0.201 2.25 0.46 0.20 8.12 10.35 4.48 5.52 4.06 1.76 3.72 1.55 0.67

100 0.223 2.50 0.55 0.24 1.63 0.20 0.09 9.02 12.58 5.45 6.14 4.93 2.14 4.13 1.88 0.81

125 0.279 3.12 0.84 0.36 2.04 0.30 0.13 11.27 19.02 8.24 7.67 7.46 3.23 5.16 2.85 1.23

150 0.334 3.74 1.17 0.51 2.45 0.42 0.18 1.73 0.18 0.08 9.20 10.45 4.52 6.19 3.99 1.73

175 0.390 4.37 1.56 0.68 2.86 0.56 0.24 2.02 0.24 0.10 10.74 13.90 6.02 7.23 5.31 2.30

200 0.446 4.99 2.00 0.86 3.27 0.71 0.31 2.31 0.30 0.13 8.26 6.80 2.94

250 0.557 6.24 3.02 1.31 4.09 1.08 0.47 2.88 0.46 0.20 1.70 0.13 0.06 10.32 10.27 4.45

300 0.668 7.49 4.23 1.83 4.90 1.51 0.65 3.46 0.65 0.28 2.04 0.18 0.08

350 0.780 8.74 5.63 2.44 5.72 2.01 0.87 4.03 0.86 0.37 2.38 0.24 0.10 1.53 0.08 0.04

400 0.891 9.99 7.21 3.12 6.54 2.57 1.11 4.61 1.10 0.48 2.72 0.30 0.13 1.75 0.10 0.05

450 1.003 11.23 8.97 3.88 7.35 3.20 1.38 5.19 1.37 0.59 3.06 0.38 0.16 1.97 0.13 0.06

500 1.114 8.17 3.89 1.68 5.76 1.66 0.72 3.40 0.46 0.20 2.19 0.16 0.07 1.55 0.07 0.03

600 1.337 9.80 5.45 2.36 6.92 2.33 1.01 4.08 0.64 0.28 2.62 0.22 0.10 1.87 0.10 0.04 1.55 0.06 0.03

700 1.560 11.44 7.25 3.14 8.07 3.10 1.34 4.76 0.86 0.37 3.06 0.29 0.13 2.18 0.13 0.06 1.80 0.08 0.04

800 1.782 9.22 3.97 1.72 5.44 1.10 0.48 3.50 0.38 0.16 2.49 0.16 0.07 2.06 0.10 0.05 1.58 0.05 0.02

900 2.005 10.37 4.94 2.14 6.11 1.37 0.59 3.94 0.47 0.20 2.80 0.20 0.09 2.32 0.13 0.06 1.78 0.07 0.03

1000 2.228 1.56 0.05 0.02 6.79 1.66 0.72 4.37 0.57 0.25 3.11 0.25 0.11 2.58 0.16 0.07 1.97 0.08 0.04

1250 2.785 1.95 0.07 0.03 8.49 2.51 1.09 5.47 0.86 0.37 3.89 0.37 0.16 3.22 0.24 0.10 2.47 0.12 0.05

1500 3.342 2.34 0.10 0.04 1.90 0.06 0.03 10.19 3.52 1.52 6.56 1.20 0.52 4.66 0.53 0.23 3.87 0.33 0.14 2.96 0.17 0.08

2000 4.456 3.12 0.17 0.07 2.53 0.10 0.04 8.75 2.05 0.89 6.22 0.89 0.39 5.16 0.57 0.25 3.95 0.30 0.13

2500 5.570 3.90 0.25 0.11 3.16 0.15 0.07 2.19 0.06 0.03 10.93 3.10 1.34 7.77 1.35 0.59 6.45 0.86 0.37 4.94 0.45 0.19

3000 6.684 4.68 0.35 0.15 3.79 0.21 0.09 2.63 0.09 0.04 9.33 1.90 0.82 7.74 1.20 0.52 5.92 0.63 0.27

3500 7.798 5.46 0.47 0.20 4.42 0.28 0.12 3.07 0.12 0.05 10.88 2.52 1.09 9.02 1.60 0.69 6.91 0.84 0.36

4000 8.912 6.24 0.60 0.26 5.06 0.36 0.16 3.51 0.15 0.06 10.31 2.05 0.89 7.90 1.07 0.46

4500 10.026 7.02 0.75 0.33 5.69 0.45 0.19 3.95 0.19 0.08 8.88 1.33 0.58

5000 11.140 7.80 0.91 0.40 6.32 0.55 0.24 4.39 0.23 0.10 9.87 1.62 0.70

5500 12.254 8.58 1.09 0.47 6.95 0.65 0.28 4.83 0.27 0.12 10.86 1.93 0.84

6000 13.368 9.36 1.28 0.55 7.58 0.77 0.33 5.27 0.32 0.14

6500 14.482 10.15 1.48 0.64 8.22 0.89 0.38 5.71 0.37 0.16

7000 15.596 8.85 1.02 0.44 6.15 0.42 0.18

7500 16.710 9.48 1.16 0.50 6.58 0.48 0.21

8000 17.824 10.11 1.31 0.57 7.02 0.54 0.23

8500 18.938 7.46 0.60 0.26

9000 20.052 7.90 0.67 0.29

9500 21.166 8.34 0.74 0.32

10000 22.280 8.78 0.81 0.35

GPM

cu ft/sec

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

3/4"

1 1/4"

1 1/2"

2 1/2"

10"

12"

14"

16"

18"

20"

24"

1/2"

Vinyl Process Piping Systems

Page 23

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Table 7 – Carrying Capacity and Friction Loss for DR 26 Thermoplastic Pipe

1 0.002

2 0.004

5 0.011

7 0.016

10 0.022

12 0.027 1.66 0.70 0.30

15 0.033 2.07 1.06 0.46

20 0.045 2.76 1.80 0.78 1.73 0.58 0.25

25 0.056 3.45 2.73 1.18 2.16 0.87 0.38

30 0.067 4.14 3.82 1.65 2.60 1.23 0.53 1.77 0.48 0.21

35 0.078 4.84 5.08 2.20 3.03 1.63 0.71 2.06 0.64 0.28

40 0.089 5.53 6.51 2.82 3.46 2.09 0.90 2.35 0.82 0.35

45 0.100 6.22 8.10 3.51 3.89 2.60 1.12 2.65 1.02 0.44 1.78 0.39 0.17

50 0.111 6.91 9.84 4.26 4.33 3.16 1.37 2.94 1.24 0.53 1.98 0.47 0.20

55 0.123 7.60 11.74 5.08 4.76 3.76 1.63 3.24 1.47 0.64 2.18 0.56 0.24

60 0.134 8.29 13.80 5.97 5.19 4.42 1.91 3.53 1.73 0.75 2.38 0.66 0.29

65 0.145 8.98 16.00 6.93 5.63 5.13 2.22 3.83 2.01 0.87 2.58 0.77 0.33

70 0.156 1.67 0.26 0.11 9.67 18.35 7.95 6.06 5.88 2.55 4.12 2.30 1.00 2.78 0.88 0.38

75 0.167 1.79 0.29 0.13 10.36 20.86 9.03 6.49 6.69 2.89 4.41 2.62 1.13 2.97 1.00 0.43

80 0.178 1.91 0.33 0.14 6.92 7.54 3.26 4.71 2.95 1.28 3.17 1.13 0.49

90 0.201 2.15 0.41 0.18 7.79 9.37 4.06 5.30 3.67 1.59 3.57 1.40 0.61

100 0.223 2.39 0.50 0.22 1.57 0.18 0.08 8.66 11.39 4.93 5.89 4.46 1.93 3.97 1.71 0.74

125 0.279 2.99 0.75 0.33 1.96 0.27 0.12 10.82 17.22 7.46 7.36 6.74 2.92 4.96 2.58 1.12

150 0.334 3.59 1.06 0.46 2.35 0.38 0.16 1.66 0.16 0.07 8.83 9.45 4.09 5.95 3.62 1.57

175 0.390 4.19 1.41 0.61 2.74 0.50 0.22 1.93 0.21 0.09 10.30 12.57 5.44 6.94 4.81 2.08

200 0.446 4.79 1.80 0.78 3.13 0.64 0.28 2.21 0.27 0.12 7.93 6.16 2.67

250 0.557 5.98 2.72 1.18 3.92 0.97 0.42 2.76 0.42 0.18 1.63 0.11 0.05 9.92 9.31 4.03

300 0.668 7.18 3.82 1.65 4.70 1.36 0.59 3.31 0.58 0.25 1.95 0.16 0.07 11.90 13.06 5.65

350 0.780 8.37 5.08 2.20 5.48 1.81 0.79 3.86 0.77 0.34 2.28 0.21 0.09

400 0.891 9.57 6.50 2.82 6.27 2.32 1.01 4.42 0.99 0.43 2.61 0.27 0.12 1.68 0.09 0.04

450 1.003 10.77 8.09 3.50 7.05 2.89 1.25 4.97 1.23 0.53 2.93 0.34 0.15 1.89 0.12 0.05

500 1.114 7.84 3.51 1.52 5.52 1.50 0.65 3.26 0.41 0.18 2.10 0.14 0.06

600 1.337 9.40 4.92 2.13 6.62 2.10 0.91 3.91 0.58 0.25 2.52 0.20 0.09 1.79 0.09 0.04

700 1.560 10.97 6.55 2.83 7.73 2.79 1.21 4.56 0.77 0.34 2.93 0.26 0.11 2.09 0.12 0.05 1.73 0.07 0.03

800 1.782 8.83 3.58 1.55 5.21 0.99 0.43 3.35 0.34 0.15 2.38 0.15 0.06 1.98 0.09 0.04 1.51 0.05 0.02

900 2.005 9.94 4.45 1.93 5.86 1.23 0.53 3.77 0.42 0.18 2.68 0.18 0.08 2.22 0.12 0.05 1.70 0.06 0.03

1000 2.228 1.50 0.04 0.02 11.04 5.41 2.34 6.51 1.50 0.65 4.19 0.51 0.22 2.98 0.22 0.10 2.47 0.14 0.06 1.89 0.07 0.03

1250 2.785 1.87 0.06 0.03 8.14 2.26 0.98 5.24 0.78 0.34 3.73 0.34 0.15 3.09 0.21 0.09 2.37 0.11 0.05

1500 3.342 2.24 0.09 0.04 1.82 0.05 0.02 9.77 3.17 1.37 6.29 1.09 0.47 4.47 0.47 0.21 3.71 0.30 0.13 2.84 0.16 0.07

2000 4.456 2.99 0.15 0.07 2.42 0.09 0.04 8.38 1.85 0.80 5.96 0.81 0.35 4.94 0.51 0.22 3.78 0.27 0.12

2500 5.570 3.74 0.23 0.10 3.03 0.14 0.06 2.10 0.06 0.02 10.48 2.80 1.21 7.45 1.22 0.53 6.18 0.77 0.34 4.73 0.40 0.17

3000 6.684 4.49 0.32 0.14 3.63 0.19 0.08 2.52 0.08 0.03 8.94 1.71 0.74 7.42 1.08 0.47 5.68 0.57 0.25

3500 7.798 5.23 0.43 0.18 4.24 0.25 0.11 2.94 0.10 0.05 10.43 2.27 0.98 8.65 1.44 0.62 6.62 0.75 0.33

4000 8.912 5.98 0.54 0.24 4.85 0.33 0.14 3.37 0.13 0.06 9.89 1.85 0.80 7.57 0.97 0.42

4500 10.026 6.73 0.68 0.29 5.45 0.41 0.18 3.79 0.17 0.07 8.52 1.20 0.52

5000 11.140 7.48 0.82 0.36 6.06 0.49 0.21 4.21 0.20 0.09 9.46 1.46 0.63

5500 12.254 8.23 0.98 0.43 6.66 0.59 0.25 4.63 0.24 0.10 10.41 1.74 0.75

6000 13.368 8.97 1.15 0.50 7.27 0.69 0.30 5.05 0.28 0.12

6500 14.482 9.72 1.34 0.58 7.87 0.80 0.35 5.47 0.33 0.14

7000 15.596 10.47 1.53 0.66 8.48 0.92 0.40 5.89 0.38 0.16

7500 16.710 9.09 1.04 0.45 6.31 0.43 0.19

8000 17.824 9.69 1.18 0.51 6.73 0.48 0.21

8500 18.938 10.30 1.32 0.57 7.15 0.54 0.23

9000 20.052 7.57 0.60 0.26

9500 21.166 7.99 0.67 0.29

10000 22.280 8.41 0.73 0.32

GPM

cu ft/sec

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

Velocity

(ft/s)

Friction Head Loss

(ft water/100ft)

Friction Pressure

(psi/100ft)

3/4"

1 1/4"

1 1/2"

2 1/2"

10"

12"

14"

16"

18"

20"

24"

1/2"

not

available

not

available

not

available

not

available

CAUTION: Flow velocity should not exceed 5 feet per second.

Vinyl Process Piping Systems

Page 24

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Friction Loss through Fittings

Friction head loss also occurs through fittings. To account for friction loss through fittings, the friction loss is estimated in equivalent feet of straight pipe that would produce the same friction loss. Values for friction loss through various fittings are given in Table 8.

Example 6

In this example, Figure 1 shows a diagram of a simple process cooling water system (P1 - P5). The system consists of 3" Schedule 80 PVC pipe with a flow rate of 100 US gpm. What is the total system friction loss due to fittings?

Figure 1 – Schematic of simple system loop

Step 1: Count the number of fittings by type as you work

your way through the system.

Step 2: Determine the fitting loss by referring to Table 8,

Friction Loss through Fittings.

Step 3: Calculate the friction loss per fitting size and type,

then sum for the total system loss due to fittings as per the table below.

To calculate the friction loss in psi, refer to Table 5 (Carrying Capacity and Friction Loss for Schedule 80 Pipe) to determine the friction loss in equivalent pipe for the given flow rate.

friction loss (psi/100 ft) x total equivalent length of pipe (psi)

100

1.29 x 121.7 = 1.57 psi 100

Therefore, the total friction loss due to fittings is 121.7 ft of pipe or 1.57 psi.

Fitting

Tee

90º

45º

Total

Type

Run

Branch

Elbow

Size Fittings

(in.) Tee Run Tee Branch 90° Elbow 45° Elbow

/2 1.0 3.8 1.5 0.8

/4 1.4 4.9 2.0 1.1

1 1.7 6.0 2.5 1.4

11/4 2.3 7.3 3.8 1.8

11/2 2.7 8.4 4.0 2.1

2 4.0 12.0 5.7 2.6

/2 4.9 14.7 6.9 3.1

3 6.1 16.4 7.9 4.0

4 7.9 22.0 11.4 5.1

6 12.3 32.7 16.7 8.0

8 14.0 49.0 21.0 10.6

10 17.5 57.0 26.0 13.5

12 20.0 67.0 32.0 15.5

14 25.0 78.0 37.0 18.0

16 27.0 88.0 43.0 20.0

18 32.0 107.0 53.0 23.0

20 35.0 118.0 58.0 25.0

24 42.0 137.0 67.0 30.0

Table 8

Friction Loss through Fittings (Equivalent pipe length in feet)

No.

Loss

6.1

16.4

7.9

4.0

Total (ft)

24.4

65.6

23.7

8.0

121.7

Vinyl Process Piping Systems

45º

pump

90º

45º

90º

LEGEND

Tee 90º Elbow 45º Elbow

Page 25

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Friction Loss through Valves

Pressure drops through valves also contribute to the overall friction loss of fluid through a piping system. Flow rate coefficients (Cv) are defined as the flow rate in gallons per minute (gpm) through an open valve resulting in a pressure drop of 1 psi. Flow rate coefficients are listed in the Thermoplastic Valve Manual (Volume 7 in the IPEX Industrial Technical Manual series) and can also be calculated using the following formula.

f = sg (Q/Cv)

Where:

f = pressure drop (friction loss) across the valve (psi) sg = specific gravity (water = 1.0) Q = flow through the valve (gpm)

Cv= flow rate coefficient

Example 7

In this example, Figure 2 shows a diagram of a simple process cooling water system. The system consists of 3" Schedule 80 PVC pipe with a flow rate of 100 US gpm. What is the total system friction loss through valves?

Figure 2 - Schematic of simple system loop with valves

Step 1: Count the number of valves by type as you work

your way through the system.

Step 2: Determine the flow rate coefficient by valve type

and size by referring to tables in valve specifications (values are given here)

Step 3: Calculate the loss per valve type and then sum for

the total system loss due to valves as per the table below.

Known: Cv= 497 for 3" VK Ball Valve

Cv= 248 for 3" Butterfly Valve Cv= 0 for TK Three Way Ball Valve Q = 100 gpm

Valve Type

VR Piston Check

VK Ball

FK Butterfly

TK Three Way Ball

Total

No.

Loss

Total (psi)

0.24

0.12

0.80

0.48

1.64

f = 1 x 100

206

f = 0.24 psi

(

)

f = 1 x 100

248

f = 0.16 psi

(

)

f = 1 x 100

497

f = 0.04 psi

(

)

f = 0.16 psi

* similar to 90º

elbow

The total friction loss due to valves is 1.64 psi.

Butterfly

45º

90º

3 way

Ball

Butterfly

90º

Butterfly

Piston check

Ball

3 way

Ball

90º

45º

LEGEND

Tee 90º Elbow 45º Elbow

Valve

Page 26

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Example 8

What is the Pressure Rating of 3" Schedule 40 PVC at 100ºF?

Step 1: Determine Maximum Working Pressure for 3"

Schedule 40 PVC from Appendix A, Table A14 = 260 psi

Step 2: Determine Correction Factor at 100ºF for PVC

= 0.62

Step 3: Maximum Working Pressure x Correction Factor will

give the pressure rating at the elevated system temperature

260 psi x 0.62 = 161.20 psi @ 100ºF

Vinyl Process Piping Systems

B) Temperature Limitations

Under pressure, for IPEX Schedule 40 and 80 PVC, the average system operating temperature ranges from 40°F (4°C) to 140°F (60°C). For IPEX Schedule 80 CPVC, the average pressure system operating temperature ranges from 40°F (4°C) to 200°F (93°C). For applications outside these

ranges please contact IPEX representatives.

C) Pressure/Temperature Relationship

Thermoplastic material strength is sensitive to temperature. Standard PVC and CPVC pipe pressure ratings are all determined at an ambient temperature of 73°F (23°C). Generally, as the operating temperature falls below the basis temperature of 73°F, there is an increase in hoop strength and a subsequent increase in pressure rating. However, as the operating temperature rises above the basis temperature, strength decreases. In the former, usually no consideration is made to the design process and the incremental strength is considered part of the safety factor. However, compensation should be made for operating temperatures above 73°F (23°C). A temperature correction factor, as shown in Table 9 must be applied to reduce the pressure rating.

Note: The temperature correction factors in Table 9 only apply to pipe and fittings. For adjustments to valve pressure ratings please consult the Thermoplastic Valve Manual (Volume 7 in the IPEX Industrial Technical Manual series) or IPEX representatives.

Table 9 – Temperature Correction Factors

Operating Temperature Correction Factors

°F °C PVC CPVC

73 23 1.00 1.00

80 27 0.88 0.96

90 32 0.75 0.91

100 38 0.62 0.82

110 43 0.50 0.74

120 49 0.40 0.65

130 54 0.30 0.58

140 60 0.22 0.50

150 66 * 0.45

160 71 * 0.40

170 77 * 0.33

180 82 * 0.25

200 93 NR 0.20

212 100 NR *

* Recommended for intermittent drainage only NR – Not Recommended

Page 27

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

DESIGN CONSIDERATIONS

Expansion and Contraction

All piping products expand and contract with changes in temperature. Linear expansion and contraction of any pipe on the longitudinal axis relates to the coefficient of thermal expansion (e) for the specific material used in the manufacturing of the product. Variation in pipe length due to thermal expansion or contraction depends on the linear expansion factor (Y) and the variation in temperature irrespective of wall thickness. This means that the factors for schedule 40 and schedule 80 pipe are the same.

Table 10 – Coefficients of Thermal Expansion

The length change due to thermal expansion or contraction depends on the system temperature differential, as well as the length of pipe run between changes in direction. Values for thermal expansion for both PVC and CPVC pipe are given in Tables 11 and 12. Expansion can also be calculated using the following formula:

ΔL = Y (T - F) x L

10 100

where:

ΔL = change in length (in.)

Y = linear expansion factor (inches of expansion per

10°F temperature change per 100 ft. of pipe)

T = maximum temperature (°F)

F = minimum temperature (°F)

L = length of pipe run (ft)

When total temperature change is less than 30°F (17°C), provisions for thermal expansion are not generally required, especially when the line includes several directional changes as there is considerable inherent flexibility in the piping system.

Caution

Caution should be exercised with threaded connections, as they are more vulnerable to bending stresses created by expansion forces. Where such conditions exist, it is advisable to use a flanged connection.

Note: Remember to allow for contraction when piping is to be exposed to temperatures substantially below installation temperature.

Piping

Material

PVC

CPVC

Thermal Exp. Coefficient

Linear Exp. Factor

in/in/°F

3.0 x 10

-5

3.8 x 10

-5

cm/cm/ºC

5.4 x 10

-5

6.8 x 10

-5

in/10ºF/100'

of pipe

0.360

0.456

mm/5ºC/10m

of pipe

2.70

3.40

Vinyl Process Piping Systems

Page 28

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Example 9

How much linear expansion can be expected in a 215 foot straight run of 3" diameter Schedule 40 PVC pipe installed at 75°F and operating at 135°F?

Known: L = 215, T = 135, F = 75, Y = 0.36 (from Table 10, Coefficients of Thermal Expansion)

ΔL = Y x (T - F) x L

10 100

ΔL = 0.36 x (135 - 75) x 215

10 100

= 0.36 x 6 x 2.15

=4.6 in.

Table 11 – PVC Linear Expansion (ΔL) in inches

Table 12 – CPVC Thermal Expansion (ΔL) in inches

Temp. change Length of Run (ft)

ΔT (°F) 10 20 30 40 50 60 70 80 90 100

10 0.04 0.07 0.11 0.14 0.18 0.22 0.25 0.29 0.32 0.36

20 0.07 0.14 0.22 0.29 0.36 0.43 0.50 0.58 0.65 0.72

30 0.11 0.22 0.32 0.43 0.54 0.65 0.76 0.86 0.97 1.08

40 0.14 0.29 0.43 0.58 0.72 0.86 1.01 1.15 1.30 1.44

50 0.18 0.36 0.54 0.72 0.90 1.08 1.26 1.44 1.62 1.80

60 0.22 0.43 0.65 0.86 1.08 1.30 1.51 1.73 1.94 2.16

70 0.25 0.50 0.76 1.01 1.26 1.51 1.76 2.02 2.27 2.52

80 0.29 0.58 0.86 1.15 1.44 1.73 2.02 2.30 2.59 2.88

90 0.32 0.65 0.97 1.30 1.62 1.94 2.27 2.59 2.92 3.24

100 0.36 0.72 1.08 1.44 1.80 2.16 2.52 2.88 3.24 3.60

Temp. change Length of Run (ft)

ΔT (°F) 10 20 30 40 50 60 70 80 90 100

10 0.05 0.09 0.14 0.18 0.23 0.27 0.32 0.36 0.41 0.46

20 0.09 0.18 0.27 0.36 0.46 0.55 0.64 0.73 0.82 0.91

30 0.14 0.27 0.41 0.55 0.68 0.82 0.96 1.09 1.23 1.37

40 0.18 0.36 0.55 0.73 0.91 1.09 1.28 1.46 1.64 1.82

50 0.23 0.46 0.68 0.91 1.14 1.37 1.60 1.82 2.05 2.28

60 0.27 0.55 0.82 1.09 1.37 1.64 1.92 2.19 2.46 2.74

70 0.32 0.64 0.96 1.28 1.60 1.92 2.23 2.55 2.87 3.19

80 0.36 0.73 1.09 1.46 1.82 2.19 2.55 2.92 3.28 3.65

90 0.41 0.82 1.23 1.64 2.05 2.46 2.87 3.28 3.69 4.10

100 0.46 0.91 1.37 1.82 2.28 2.74 3.19 3.65 4.10 4.56

Vinyl Process Piping Systems

Page 29

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Offsets and Directional Changes

A common solution to the problem of thermal expansion/contraction is to absorb the change in length by building in flexibility into the system. This can be accomplished by introducing changes of direction, offsets and expansion loops. Expansion joints may also be used, particularly in situations where it is not possible to configure added flexibility. The various pipe configurations are shown in Figure 3.

Figure 3 - Pipe Configurations for Expansion/Contraction

1/4 L

1/2 L

Directional Change Offset

Expansion Loop Expansion Joint

A = 1/2 R

L = total offset length

L = total loop length R = expansion loop leg length (2/5 L) A = expansion loop leg length (1/5 L)

Vinyl Process Piping Systems

Piston travel position

at installation

End of expansion stroke

Piston full extension

Page 30

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Expansion Loops

Normally, piping systems are designed with enough directional changes so that the system will compensate for expansion and contraction. However, when this is not the case or when there is reasonable doubt as to the flexibility of the system, expansion loops or expansion joints should be incorporated into the system. It is recommended that expansion loops and offsets should be constructed with 90º elbows and straight pipe that are solvent cemented together in order to handle the stresses during expansion more effectively. A typical expansion loop is shown in Figure 4.

Figure 4 - Typical Expansion Loop

Table 13 - Working Stress at Elevated Temperatures (psi)

To ensure that the loop is of sufficient length to absorb expansion and contraction movement without damage, the following modified beam deflection equation can be used.

where:

L = total expansion loop length (in)

E = modulus of elasticity at maximum operating

temperature (psi)

S = working stress at maximum operating

temperature (psi)

D = nominal outside diameter of pipe (in)

Δl = change in length due to thermal expansion or

contraction (in)

R = expansion loop leg length (

/5 L)

A = expansion loop leg length (1/5 L)

Example 10

For a run of 100 ft of 3" Sch 80 PVC, installed at 65ºF and operating at 140ºF, how long should the expansion loop legs be in order to compensate for the expansion?

Step 1: Calculate the amount of expansion to be expected.

Δl = Y x (T - F) x L

10 100

Known: L = 100 ft, T = 140ºF, F = 65ºF,

Y = 0.36 in/100ft/10ºF (from Table 10, Coefficients

of Thermal Expansion)

Δl = 0.36 x (140 - 65) x 100

10 100

Δl = 2.7 in.

Step 2: Calculate the expansion loop length.

Known: Δl = 2.7 in., E = 280,000 psi (from Table 13 -

Working Stress at Elevated Temperatures), S = 1000 psi (from Table 13), D = 3.5 in (from Table A-14 - Dimensions, Weights & Pressure Ratings)

Therefore the total expansion loop length is 134 inches, the expansion loop leg length R is 54 inches and the expansion loop leg length A is 27 inches.

L = 3ED(Δl)

L = 3 x 280000 x 3.5 x 2.7

440

L = 134 inches R = 2

L = 54 inches A = 1 L = 27 inches

400,000

372,000

336,000

280,000

2000

1500

1000

440

423,000

403,000

371,000

323,000

291,000

269,000

220,000

2000

1820

1480

1000

750

500

400

Modulus of

Elasticity

Working

Stress

Modulus of

Elasticity

Working

Stress

Temperature

110

140

160

180

200

PVC CPVC

Vinyl Process Piping Systems

– Hanger or Guide – Restraint

Page 31

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Expansion Joints

Expansion joints are particularly desirable for large diameter pipe or where space for offset lines is limited. An expansion joint consists of two cylinders, one telescoping inside the other. The outer cylinder is firmly anchored while the inner cylinder is allowed to move with a piston-like action as the attached pipe expands or contracts. IPEX manufactures the Telescopic Expansion Device (T.E.D.), a cost effective solution designed to relieve stress in a piping system.

In long runs of 150 feet or more, the pipeline should be anchored at each change of direction so that expansion movement of the pipe will be directed squarely into the expansion joint. Alignment of expansion joints is most important. Binding can result if the pipe is canted or cocked and does not move in the same plane as the joint. Guide loops should be installed approximately one foot from the end of each expansion joint.

Beyond the required system guides, the IPEX T.E.D. further incorporates a special self-aligning design. A wide piston guide is fitted inside the device to prevent skewing and consequent binding. To further enhance the self-aligning property of T.E.D. a triple o-ring seal is added. This combination produces higher performance reducing the chances of leaks and/or premature failure due to misalignment, thus effectively increasing the life expectancy of your entire system.

Configurations using expansion joints

Example A illustrates a long pipe run, anchored at each end, which requires absorption of thermal expansion. Calculations

have determined that a single device can be used with intermediate pipe guides. It is recommended that the device be located as close as possible to the anchor at the end of the run (based on flow direction). The first guide should be installed in the proximity of the connection between the pipe and the receiver on the moving arm of the T.E.D. unit. This will ensure that the deflection is limited to the expected axial direction. The second guide is located relatively close to the first to avoid bowing of the pipe. Additional guides, evenly spaced, will be installed as needed.

Example B illustrates an even longer pipe run. Calculations have determined that two devices must be employed. As a result, the run has been divided into two equal segments by a median anchoring point. A T.E.D. unit is positioned at each end of the previously separated runs. Guide placement is consistent with the outlines in Example A.

Example A

Example B

Anchors

FLOW

GuidesT.E.D.

FLOW

Anchors

Guides

T.E.D.

Page 32

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Example C illustrates a long run in which a larger diameter pipe is reduced to a smaller diameter near the middle of the run. Although the amount of expansion in thermoplastic is not a function of the pipe diameter, should it be determined that two separate devices are needed, it is good practice to subdivide the run with an anchor at the transition point. Subsequently identical procedures to those in Example B are to be followed.

Example D illustrates the branching of a long run. For the main pipe section an identical arrangement to that of Example B is used, however a main anchor must be used at the TEE rather than the intermediate anchor. The main anchor is designed to resist the pressure thrust of the branch line. In the direction of the main line the anchor must also resist any dynamic pressure thrust imbalance that results from the turbulence caused by the branch line. Should the run in the branch line require it, a T.E.D. unit will be installed following the procedure in Example A.

Example C

Example D

FLOW

Guides

Anchors

Guides

T.E.D.

Guides

FLOW

Guides

Main Anchors

Guides

Page 33

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

T.E.D. Installation Procedure

Common sense will dictate that if the piston is expected to travel both in (pipe expansion) and out (pipe contraction) of its cylinder, there must be travel available in both directions as shown in Figure 4. This requires that T.E.D. units must be installed with the piston partially extended. The piston should be extended based on the ambient temperature at the time of installation and can be accurately calculated by the following formula:

– T

x E

– T

where:

P = piston travel position at installation (in.)

TM= maximum operational temperature, °F (ºC)

= ambient air installation temperature, °F (ºC)

= minimum operational temperature, °F (ºC)

E = piston full extension length (in.)

Figure 5 – Expansion Joint

Example 11

For a straight run of pipe, the ambient air temperature at time of installation is 68°F and the temperature of system operation varies from 40°F to 90°F. How much piston travel should a 6" expansion joint be installed with?

Known: T

= 90ºF, TA= 68ºF, TL= 40ºF, L = 6 in

90 – 68

x 6

90 – 40

P = 2.64 in

Therefore, the piston travel position should be set during installation by compressing the piston fully, then extending it 2.64".

Vinyl Process Piping Systems

Piston full extension

Piston travel position

at installation

End of expansion stroke

Page 34

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

T.E.D. Specifications and Dimensions

The T.E.D. is available in PVC and CPVC, each featuring EPDM or FPM O-rings to meet all application requirements.

Figure 6 - IPEX Telescopic Expansion Joint

Size A 6" Travel (L = 6) 12" Travel (L = 12) Maximum (in.) (in.) Pressure Rating

C (in.) E (in.) C (in.) E (in.) at 73°F (psi)

/2 2.80 12.75 18.75 18.75 30.75 235

/4 2.80 12.75 18.75 18.75 30.75 235

1 2.80 11.75 17.75 17.75 29.75 235

/2 4.20 12.75 18.75 18.75 30.75 235

2 4.20 12.00 18.00 18.00 30.00 235

3 5.20 16.25 22.25 22.25 34.25 150

4 7.80 15.25 21.25 21.25 33.25 150

Note: For system fluid temperatures greater than 73°F (23°C), the appropriate temperature correction factor must be used. See Table 9.

Vinyl Process Piping Systems

E (extended)

C (compressed)

•

Piston guide Triple o-ring seal

Page 35

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Water Hammer / Surge

Surge pressures due to water hammer should be considered when designing a piping system. A momentary pressure rise occurs when the flow of liquid is started and stopped quickly, as a result of the fluid's momentum. Pressure rise increases with the velocity of the liquid, the length of the piping system from the liquid source, or with an increase in the speed of starting or stopping. Examples of hydraulic shock occur when valves are opened or closed quickly, or pumps are started with an empty discharge line. Proper design when laying out a piping system will minimize the possibility of hydraulic shock damage. The following suggestions will help avoid problems:

1) In any piping system, including thermoplastic, a liquid velocity not exceeding 5 ft./sec. will lessen hydraulic shock effects, even with quick-closing valves (e.g. solenoid valves).

2) Using actuated valves with a specific closing time will reduce the possibility of inadvertent opening or closing of a valve too quickly. With pneumatic and air-spring actuators, it may be necessary to place a valve in the air line to slow down the valve operation cycle.

3) Evaluate flow at pump start-up and during spin-down. Also determine how much air, if any, is introduced during pump start-up.

4) If possible, when starting a pump, partially close the valve in the discharge line to minimize the volume of liquid that is rapidly accelerated through the system. Once the pump is up to speed and the line completely full, the valve may be opened.

5) Use surge control devices and standpipes wisely to give flow storage during surge and to minimize column separation. Check valves can be used near pumps to help keep lines full.

6) Use properly sized vacuum breaker-air relief valves to control the amount of air that is admitted or exhausted throughout the system.

Note: Common industry practices suggest that in systems with quick-closing valves or cyclic surge conditions, fitting pressure rating should be calculated at not more than 60% of the equivalent pipe.

Calculations used to predict water hammer are based on elastic wave theory. The formula for calculating the surge pressure for any liquid assuming instantaneous valve closure is:

p=d

Ps= d x a x V

144 x g

where:

p = fluid density / gravity acceleration (slugs /ft

a = wave velocity (ft/sec) K = bulk modulus of fluid (psi) E = modulus of elasticity of pipe (psi)

DR = dimension ratio of pipe

g = gravitational acceleration constant (32.17 ft/sec

)

d = density (lb/ft

)

V = change in velocity (ft/s)

Ps= maximum surge pressure (psi)

Example 12

A valve is suddenly closed in a 2" PVC Schedule 80 pipe carrying fluid with a specific gravity (s.g.) of 1.2 at a flow rate of 30 US gpm. The system pressure is 160 psi at ambient temperature. Determine the surge pressure under these conditions and if the system is able to sustain it.

Known:

d = 1.2 (g/cm

) or 74.914 lb/ft

g = 32.174 ft/sec

K = 313,000 psi (for water) E = 400,000 psi (from Table 13 or Table 15)

DR = 11 (from Table A-14 Dimensions, Weights &

Pressure Ratings)

V = 30 gpm or 3.35 ft/s

p = 74.914

32.174

p = 2.328

a = 1551.514

= 74.914 x 1551.514 x 3.35

144 x 32.174

Ps= 84.04

Total line pressure = 84 + 160 = 244 psi The pressure rating for 2" Schedule 80 PVC pipe is 400 psi,

therefore the system is well able to sustain a total line pressure of 244 psi.

[

K p

[

K E

[

x (DR - 2)

a =

x 12

[

313000

2.328

[

313000 400000

[

x (11

a =

x 12

Page 36

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

To prevent rapid valve closure from creating high surge pressures, the minimum closure time of a valve can be calculated. The following formula would apply:

T = 2 x L

where:

T = minimum closure time (sec) L = length of pipe from valve to point of relief (ft) a = velocity of fluid (ft/sec)

Example 13

A 2" PVC Schedule 40 pipe is 250 feet long and is connected to a tank. The water velocity in the 2" pipeline is 5 ft./sec. What is the minimum valve closure time required to prevent an instantaneous pressure surge?

Step 1: Calculate the wave velocity (a)

Known:

d = 0.9975 (g/cm

) or 62.272 lb/ft

g = 32.174 ft/sec

K = 313,000 psi (for water) E = 400,000 psi (from Table 13 or Table 15)

DR = 16 (from Table A-14 Dimensions, Weights &

Pressure Ratings)

V = 5 ft/s

p = 62.272

32.174

p = 1.935

a = 1395.69

Step 2: Calculate the critical time

T = 2 x 250

1395.69

T = 0.36 seconds

In this case, if the valve takes 0.36 seconds or longer to close, the amount of pressure surge is considered negligible. Therefore the fitting pressure rating will not need to be derated.

Thermal Conductivity

Compared with traditional pipe materials, the thermal conductivity of vinyl is low and it essentially acts as an insulator. This insulating property provides a distinct advantage over traditional materials to prevent “sweating” or formation of condensation on the pipe wall. The need for insulation may, in certain instances, be completely eliminated by using vinyl for cold or chilled water lines. Thermal conductivity for various material types is shown in Table 14.

Thermal conductivity is expressed as BTU/hr./sq.ft./°F/in. where BTU/hr. or British Thermal Unit per hour is defined as the energy required to raise the temperature of one pound of water one degree Fahrenheit in one hour. Square feet, refers to the square foot area where heat is being transferred. Inch refers to one inch of pipe wall thickness.

The graph shown in Figure 7 gives an example of the extent to which vinyl piping products will prevent the formation of condensation at different temperatures of the process fluid. For example, copper, a good conductor of heat, will lose 2700 BTU per hour per square foot of surface area with a wall thickness of 1” while vinyl will lose only 1.2 BTU/hr. Note that if the vinyl wall thickness is reduced to 0.25 inches, the heat loss increases four times.

Figure 7 - Relative Humidity at which condensation will form

on pipe walls

Table 14 - Coefficients of Thermal Conductivity

Wall Sch 40 Sch 80

thickness (in) Vinyl Pipe Vinyl Pipe

0.3 1/2" to 6" 1/4" to 3"

0.5 8" to 16" 4" to 8"

Material BTU/hr./sq.ft./°F/in W/m/ºK CPVC 0.95 0.137

PVC 1.20 0.1731 Glass 8 1.1538 Carbon Steel 360 51.922 Aluminum 1,000 144.23 Copper 2,700 389.42

[

313000

1.935

[

313000 400000

[

x (16

a =

x 12

% RELATIVE HUMIDITY

0.3" PVC

0204060

10 30 50 70

FLUID TEMPERATURE ºF

0.5" PVC

COPPER

Page 37

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

To calculate the approximate heat loss or gain for plastic piping with no insulation in a still air environment, the following calculation formula can be used:.

where:

q = Rate of heat conduction, Δt = Difference in temperature, °F D

= Average outside diameter, ft

Di= Average inside diameter, ft

ro= Average outside radius, in.

ri= Average inside radius, in.

L = Length, ft

K = Coefficient of thermal conductivity,

ln = Natural logarithm

π =3.14

Note that in more complex situations, heat loss or gain should be calculated taking into account such things as heat transfer coefficients, fluid conductivity, fluid heat capacity, viscosity, air temperature and air velocity. Refer to engineering handbooks for more information.

Vacuum Service

Vinyl piping is often used in applications for suction or vacuum lines. Absolute vacuum or 1 standard atmosphere =

14.676 psi or 29.87 inches of mercury. Full vacuum of one atmosphere would only occur at sea level and is reduced by

0.5 psi for every 1,000 feet of elevation above sea level.

PVC Schedule 40/80 and Series pipe to 24" are suitable for vacuum service at ambient temperatures. For elevated temperatures, use the temperature correction factors in Table 9 to determine the appropriate pressure rating and suitability for service. For a circular ring subjected to a uniform external pressure or internal vacuum, the critical buckling pressure is calculated as follows:

= 2EC t

(1-σ2)Do -t

= critical buckling pressure (psi)

E = modulus of elasticity (psi)

C = critical buckling correction factor

σ = Poisson’s ratio

t = minimum wall thickness (in.)

= outside diameter (in.)

Note: For non-encased, non-deflected unburied pipe, the critical buckling correction factor (C) is 1.0. For buried pipe see the following section on vacuum service below ground.

Table 15 – Modulus of Elasticity at Elevated Temperatures (E)

Example 14

Above Ground Vacuum Service Installation

A process piping system operating at 90ºF has a suction line that requires a full vacuum (-29.86" Hg (mercury) or

-14.67 psi). Determine if 3" Schedule 80 PVC is capable of operating under these conditions.

Knowns:

σ = 0.38 (from Table 1, Physical Properties) E = 372,000 psi (from Table 15, Modulus of

Elasticity at Elevated Temperatures)

= 3.5 in. (from Table A-14 - Dimensions, Weights &

Pressure Ratings)

t = 0.3 in. (from Table A-14 - Dimensions, Weights &

Pressure Ratings)

C = 1 (the system is above ground)

= 716 psi

Therefore, the pipe is capable of vacuum service under these conditions, as the critical buckling pressure is greater than the vacuum pressure required.

[

]

Piping Material Temp, °F Temp, ºC E, psi

73 23 400,000

90 32 372,000

110 43 336,000

140 60 280,000

73 23 423,000

90 32 403,000

110 43 371,000

140 60 323,000

180 82 269,000

210 93 220,000

1 x 2 x 372000

[

(1 - 0.382)

[

0.3

3.5 - 0.3

Vinyl Process Piping Systems

Btu

Btu x in

h x ft2x oF

PVC

CPVC

π x L x (D°– Di)

q =

x K x

Δt

r° – r

Page 38

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Below Ground Installation

Pipes that are significantly out of round or deflected have less buckling resistance than round pipes. The critical buckling pressure for these elliptical shapes can be determined by using a correction factor “C” as shown in the graph in Figure 8.

Figure 8 - Critical Buckling Pressure Correction Factor (C)

for buried pipe

When pipes are buried or installed in such a manner that the soil or surrounding medium provides some resistance against buckling or deflection, the buckling pressure (Pb ) in the soil has been found to be:

where:

= buckling pressure in a given soil (psi)

= critical buckling pressure (psi)

E' = modulus of soil reaction (psi)

0.50

0.40

0.30

0.20

0.10

0.60

0.70

0.80

0.00 6

Pipe Deflection %

Buckling Correction Factor, 'C'

910

0.90

1.00

for degree of compaction of bedding (psi)

Soil Type Dumped Slight <85% Proctor Moderate 85- 95% Proctor High >95% Proctor

Fine grained soils 50 200 400 1000 (<25% coarse grained particles)

Fine grained soils 100 400 1000 2000 (>25% coarse grained particles)

Coarse grained soils 200 1000 2000 3000 (fines <12%)

Crushed Rock 1000 3000 3000 3000

*Source: Uni–Bell Handbook of PVC Pipe

Note: Values applicable for fills less than 15 ft. Table does not include any safety factor, therefore appropriate deflection lag factor must be applied for long-term deflections.

Table 16 – Average Values of Modulus of Soil Reaction (E')*

Pipe Bedding Material

Vinyl Process Piping Systems

Pb =

1.15

c r

Page 39

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Example 15

Below Ground Vacuum Service Installation

A water treatment plant has a buried tank that requires the removal of chemicals. The system operating temperature is 73ºF. The pipe work is buried 15 feet below grade in clean sand and gravel with 90% density proctor and a weight of 120 lb/ft.

. Is 4" Sch 80 PVC pipe capable of operating at

full vacuum (-14.7 psi) under these conditions?

Known:

db = 15 ft

w = 120 lb/ft

based on soil with bulk specific gravity

of 1.93 g/cm

(For more specific data see Published Soil Engineering Handbooks on soil density calculations.)

E = 400,000 psi (from Table 15, Modulus of

Elasticity at Elevated Temperatures)

σ = 0.38 (from Table 1, Physical Properties)

DR = 13 (from Table A-14, Dimensions, Weights &

Pressure Ratings)

= 4.5 in. (from Table A-14, Dimensions, Weights &

Pressure Ratings)

t = 0.337 in. (from Table A-14, Dimensions, Weights

& Pressure Ratings)

E’ = 2000 psi (from Table 16, Modulus of Soil reaction)

K = 0.11 (standard bedding factor)

In order to calculate the true buckling pressure, a number of steps are required. First the actual deflection under these conditions needs to be determined. This will allow a correct buckling pressure correction factor to be derived from the graph. Then the pipe buckling pressure can be determined and finally the soil buckling pressure can be calculated.

Step 1: Calculate Actual Deflection

(A) Determine Earth Load

= db x w

Where:

= earth load (lbs/ft2)

db = depth of burial (ft)

w = weight of soil (lbs/ft

)

= 15 x 120 = 1800 lbs/ft

or 12.5 lbs/in

(B) Determine Pipe Stiffness

= 4.47 x

(DR-1)

Where:

= pipe stiffness (psi)

E = modulus of elasticity

DR = dimension ratio

= 4.47 x 400000 = 1035 psi

(13-1)

Df= K x Pe

x 100%

(0.149 x P

+ 0.061 x E')

Where:

= pipe deflection (%)

= earth load (lbs/in2)

Note: Units (lbs/in2) can also be displayed as (psi)

K = standard bedding factor

= pipe stiffness (psi)

E' = modulus of soil reaction

= 0.11 x 12.5

x 100%

(0.149 x 1035 + 0.061 x 2000)

= 0.497%

Step 2: Determine pressure correction factor ‘C’ from the graph in Figure 8

C = 0.94

Step 3: Determine pipe critical buckling pressure

Known:

σ = 0.38 (from Table 1, Physical Properties) E = 400,000 psi (from Table 15, Modulus of

Elasticity at Elevated Temperatures)

= 4.5 in. (from Table A-14, Dimensions, Weights &

Pressure Ratings)

t = 0.3 in. (from Table A-14, Dimensions, Weights &

Pressure Ratings)

C = 0.94

= 320 psi

Step 4: Determine the Soil Critical Buckling Pressure

Known:

Pcr= 320 psi

E' = 2,000 psi (from Table 16, Modulus of Soil Reaction)

= 920 psi

Therefore the pipe can withstand full vacuum service.

2EC

[

(1 - σ2)

[

Do - t

0.94 x 2 x 400000

[

(1 - 0.382)

[

0.3

4.5 - 0.3

E'P

1.15

1.15 320 x 2000

Vinyl Process Piping Systems

Page 40

PROCESS &

DRAINAGE PIPING DESIGN

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Deflection

Thermoplastic pipe is considered to be a flexible rather than a rigid piping material when referring to deflection. This means that under loading, the pipe tends to deflect rather than crack. The amount of deflection can be derived from the depth of burial, pipe stiffness and the amount of loading (e.g. soil, traffic) on the pipe. Although the maximum allowable deflection is 7.5%, critical buckling occurs at 30%, providing for a safety factor of 4. For further detail refer to In Ground Installation in Section 3.

Drainage

Piping systems for drainage applications usually consist of low pressure, half or full flow discharge systems that are horizontal or slightly sloping. Friction loss for open channel flow can be determined by the Manning formula as follows.

V = (1.49)

0.67S0.5

where:

V = average velocity (ft/sec)

R = hydraulic radius (ft)

S = slope (ft/ft)

n = roughness coefficient

Values of the roughness coefficient (n) have been determined by many tests on actual pipe. Common values are shown in Table 17. Further sizing and flow capacity information for drainage systems can be found in Table 18.

Table 17 – Manning Roughness Coefficient (n)

As shown in Table 17, PVC and CPVC have the smoothest interior walls of several common piping materials. It should also be noted that if self cleansing velocities of 2 ft/s or more are maintained, the pipe will continue to be resistant to bacterial growth and particulate deposition and will keep friction loss to a minimum, thereby maintaining its intended flow rate over the life of the installed system.

Table 18 - Discharge Capacity for PVC Drainage Systems

* Note: Pipe capacities are based on the pipe flowing at full capacity.

(Source: ASPE Data Book)

Example 16

A drainage system consisting of 2" Schedule 40 PVC pipe is 200 feet long. The system is installed with a slope of

/4" per

ft. Determine the flow rate.

V = (1.49 ) R

0.67S0.5

Q = A x V

where:

Q = flow rate (ft

/sec)

A = cross-sectional area of pipe (π r2)

Known:

= 2.047" (from Table A-14, Dimensions, Weights &

Pressure Ratings)

R=D

/4 = (2.047/4) = 0.5112" or 0.0426'

n = 0.009 (from Table 17, Manning Roughness

Coefficient)

S = 1/4"/ft or 0.0208'/ft

A = 3.14 (0.0426/2)

= 0.023 ft

V = (1.49) x (0.0426)

0.67

x (0.0208)

0.5

0.009

V = 165.56 x 0.121 x .144 = 2.88 ft/sec

Q = 2.88 x 0.023 = 0.065 ft

/sec or 29.2 gpm

Therefore, the flow rate is 29.2 US gpm.

Pipe Size Slope Discharge Capacity Velocity (ft/s)

(in) in/ft % (gpm) US (ft

/s)

/2 4.2 27 0.061 2.80

/2 4.2 81 0.180 3.67

/2 4.2 174 0.390 4.47

/16 1.5 309 0.687 3.50

/16 0.5 420 0.937 2.68

/16 0.5 761 1.700 3.12

/16 0.6 1239 2.760 3.51

14 0.2 1074 2.390 2.24

16 0.2 1484 3.310 2.35

Material n

PVC / CPVC 0.009

Glazed surface 0.010

Concrete 0.013

Cast Iron 0.015

Corrugated Metal 0.022

Vinyl Process Piping Systems

Page 41

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Fittings

At the time of this publication, there are no accredited standards that deal with the pressure ratings of molded schedule fittings. Common industry practice values the pressure of the fitting equal to that of the corresponding size and schedule of pipe. Experience tells us however, that in systems with quick closing valves or the potential for cyclic surge conditions, (as is true of most process systems), fitting pressure ratings should be calculated at 60% of the equivalent pipe ratings to obtain a sufficient safety factor.

Molded Fittings

Molded fittings are usually preferred by engineers, contractors and end users because they are seamless (better flow), have a tighter radius (requiring less space) and are dimensionally identical (easier installation). In addition, molded fittings are cosmetically more appealing than fabricated fittings. This may be an important consideration for exposed pipelines (e.g. aquariums, water works).

Weld Lines

A weld line is a visible line on a molded fitting, both inside and out, where the plastic material fuses together during the injection molding operation.

EVERY injection molded fitting will have a weld line. It will appear wherever the material has rejoined after flowing around a core.

A weld line should not be confused with the mold parting line which also appears on a molded fitting. The parting line is formed by the two halves of a mating mold cavity. Parting lines are usually much more visible than weld lines.

Continual advances in injection molding technology have allowed manufacturers to increase their range of molded fittings. IPEX is one of the very few manufacturers capable of molding both Schedule 40 and 80 PVC and Schedule 80 CPVC fittings in 10" and 12" sizes. Thus, IPEX offers one of the most complete and technologically advanced fittings lines in the industry. IPEX Xirtec140 PVC and Corzan CPVC injection molded fittings are manufactured in accordance with ASTM standards.

Weld Line would appear opposite the gate

Gate

Weld Line

Core

Material Flow

Mold Parting Line

Moving Cavity (mold)

Core

Stationary

Cavity (mold)

Weld

Line

Core

Material Flow

Page 42

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Fabricated Fittings

IPEX fabricated fittings are high integrity fittings designed and engineered to meet demanding process pipe requirements. Fabricated fittings in larger pipe sizes (above 8") are made from segments of IPEX plastic pipe welded together or butt-fused and fiberglass reinforced. Custom configurations or standard designs such as tees and elbows are manufactured by these techniques.

Hot-air gun welding (or stick welding) is a process in which mitered segments of pipe are welded together through the use of a welding rod and a hot-air gun. This is done by first beveling the outer edges of each pipe segment. The outer edges of the segments are then lined up and held firmly together. A welding rod is held to the joint. The hot-air gun is applied to the rod and several beads are laid all around the circumferences of the joint area. The heat simultaneously melts the outer surface of the pipe segments as well as the rod. As the material cools down and hardens, a permanent bond is created between the two pieces.

Butt-fusion is a welding process that also uses heat to melt the edges of the two pipe segments to be joined. However during butt-fusion, substantial pressure is applied to the pipe, effectively increasing the density of the material at the weld. Because of this, the extent of heat penetration and the size of the welded surface area of a butt-fusion weld are greater than that of a hot-air gun weld. Therefore, a buttfusion weld has greater strength than a hot air gun weld and is the method of choice. Due to differing geometries and sizes, not all fittings can be butt-fused. In those cases, hot air welds are made.

In order to reach the highest level of performance and equivalent integrity (regardless of fabrication technique) IPEX fiberglass over-wraps its fabricated “full pressure” rated fittings. This step results in all IPEX (either hot air gun welded or butt-fused) fabricated fittings having mechanical and pressure capabilities, which often exceed those of the pipe they will be connected to. The fittings, together with IPEX thermoplastic pipe, form a complete and unified system.

Full Pressure Fabricated Fittings

Hot Air Gun

Weld

Fiberglass

reinforcement

Butt Fusion

Weld

Fiberglass

reinforcement

Page 43

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Valves

Valve Selection

The selection of a valve is based on its function and the way in which it will be operated in the system. In general, valves are used to perform at least one of three functions: (1) shut off, (2) throttling, and (3) preventing backflow. See Table 19 – Thermoplastic Valves for a complete listing of IPEX vinyl valves.

1) For on-off service, the most commonly used IPEX valves are:

• ball valves

• butterfly valves

2) For throttling or flow regulating, the most commonly used IPEX valves are:

• diaphragm valves

• butterfly valves

3) For preventing reversal or backflow, the most commonly used IPEX valves are:

• ball check valve

• piston check valve

• swing check valve

Since there can be more than one choice for a particular function, the selection process can be refined by considering specific system characteristics. These include:

• Characteristics of the flowing medium

❍

corrosiveness

❍

abrasiveness

❍

viscosity

❍

temperature

❍

pressure

• The compatibility of the valve’s fluid-control elements

(i.e. weirs, stems, seats, etc.) with the flowing medium,

• Physical space requirements

• Weight limitations

• Operational requirements

❍

manually operated valves offer a choice of levers, gears, and other handles, depending on size.

❍

remotely operated valves can be actuated either electrically or pneumatically.

Actuated Valves

Rotary valves, such as ball valves, butterfly valves and diaphragm valves can be combined with an automatic actuator. Powered either electrically or pneumatically, the actuator allows automatic sequencing of the valve operation.

The demand for actuated valves has been steadily increasing due to increasing labor costs for manually operated valves (especially in remote locations). Freeing up valuable work hours for more productive jobs is only one reason automated valves are popular. Actuated valves also increase profit and productivity, provide closer control of critical processes and help to eliminate human error.

Operational advantages of using an actuated valve are:

• Adapts easily and economically to full modulating control.

• Allows automatic sequencing of valve operation in multi-stage or multi-mix systems that are difficult, if not impossible, to coordinate manually.

• Offers a variety of cost and labor saving options that fit process requirements and industrial environments more precisely.

• Provides fail-safe modes and eliminates the need for workers to manually operate a valve carrying hazardous fluids.

Actuator Selection

The choice of actuators should not be solely influenced by either features or price. Consideration should also be given to the cost of supplying motive power, installation and maintenance, service life and possible future replacement.

There are two basic types of actuators; electric and pneumatic. If electricity and air are available, the first consideration is the type of power desired. Although electric and pneumatic actuators have approximately equal torque output ratings for sizes 4" and larger, pneumatic actuators are normally less expensive. However, in smaller sizes, the electric actuator’s lighter weight and simplified installation make it ideal for many applications.

Consideration should also be given to the speed control of both electric and pneumatic actuators. Closing a valve too quickly on flowing fluid can cause water hammer and subsequent damage to the valve and related piping. The speed of both electric and pneumatic actuators can be specifically tailored to each application. Some pneumatic actuators can be adjusted in-line to obtain the correct cycle time for a specific application.

Page 44

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PROCESS &

DRAINAGE PIPING DESIGN

Vinyl Process Piping Systems

Table 19 – IPEX Thermoplastic PVC & CPVC Valves

Valve Type Size (in) Material Connection/ Style* Rating (psi)

MP Compact Ball Valve

/2 to 2 PVC S, T 150

VE Double Blocking Ball Valve, True Union

/2 to 2 PVC S, T, Tu 232

VX Double Blocking Ball Valve, True Union

/2 to 6 PVC, CPVC F, S, T, Tu 232 (1/2 to 2)

150 (2

/2 to 6)

VK Double Blocking Ball Valve, True Union

/2 to 6 PVC, CPVC, PP F, S, T, Tu 232 (1/2 to 2)

VKD Double Blocking Ball Valve, True Union 21/2 to 4 PVC, CPVC S, Tu 232

VT/VL L-Port, T-Port Three-Way Ball Valve

/2 to 2 PVC F, S, T, Tu 150

TK Three-Way Ball Valve

/2 to 2 PVC, PP F, S, T, Tu 232

FE Butterfly Valve 1

/2 to 12 PVC F (W) 232 (11/2 to 2)

150 (21/2 to 10)

120 (12)

FK Butterfly Valve 11/2 to 12 Body GFPP F (W, L) 150 (11/2 to 10)

Disk PP 120 (12)

VB Ball Check Valve

/2 to 4 PVC, CPVC F, S, T, Tu 150

VR Piston Check Valve

/2 to 4 PVC F, S, T, Tu 232 (1/2 to 1)

F, S, T 150 (11/4 to 2)

90 (3 to 4)

SC Swing Check Valve 3 to 8 PVC F 100 (3)

70 (4 to 8)

RV Y-Pattern Sediment Strainer

/2 to 4 PVC, CPVC F, S, T, Tu 232 (1/2 to 1)

F, S, T, Tu 150 (11/4 to 2)

F, S, T 60 (3 to 4)

CM Compact Diaphragm Valve

/8 to 1/2 PVC, CPVC, S, T 90

PP, PVDF

VM Diaphragm Valve

/2 to 4 PVC, CPVC, F, S, T, Tu 150 (1/2 to 2)

PP, PVDF F, Si 150 (21/2 to 4)

DM Direct- Acting Diaphragm Valve

/2 to 2 PVC, CPVC F, S, Si, Tu 120

DV Integrally Flanged Diaphragm Valve

/2 to 6 PVC F 150

VA Air Release Valve

/4, 11/4, 2 PVC Su, T 232

SF Solenoid

/4, 1/2 PVC T, Tu 60 (1/4)

30 (

/2)

LV Lab Valve

/4 PVC T 150

F = Flanged (ANSI 150) L = Lug

S = Socket (IPS)

Si = Spigot (IPS)

Su = Single Union

T = Threaded (NPT)

Tu = True Union

W=Wafer

(See also IPEX Technical Manual, Volume VII - Thermoplastic Valve Manual)

Style Legend

Page 45

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Vinyl Process Piping Systems

NOTES

Page 46

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

SECTION THREE: INSTALLATION

INTRODUCTION

Proper installation is key to producing a stable and robust system. If installation is not done correctly, the system will not perform well and may actually fail.

This section will cover all aspects of installation and will include joining methods, in ground and above ground installation methods, pipe supports, handling and storage, other installation considerations (such as entrapped air) and testing.

Vinyl Process Piping Systems

Page 47

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

HANDLING AND STORAGE

PVC and CPVC are strong, lightweight materials, about one fifth the weight of steel or cast iron. Piping made of this material is easily handled and, as a result, there is a tendency for them to be thrown about on the jobsite. Care should be taken in handling and storage to prevent damage to the pipe.

PVC and CPVC pipe should be given adequate support at all times. It should not be stacked in large piles, especially in warm temperature conditions, as bottom pipe may become distorted and joining will become difficult.

For long-term storage, pipe racks should be used, providing continuous support along the length. If this is not possible, timber supports of at least 3" bearing width, at spacings not greater than 3' centers, should be placed beneath the piping. If the stacks are rectangular, twice the spacing at the sides is required. Pipe should not be stored more than seven layers high in racks. If different classes of pipe are kept in the same rack, pipe with the thickest walls should always be at the bottom. Sharp corners on metal racks should be avoided.

For temporary storage in the field when racks are not provided, care should be taken that the ground is level and free of sharp objects (i.e. loose stones, etc.). Pipe should be stacked to reduce movement, but should not exceed three to four layers high.

Most pipe is now supplied in crates. Care should be taken when unloading the crates; avoid using metal slings or wire ropes. Crates may be stacked four high in the field.

The above recommendations are for a temperature of approximately 80°F (27ºC). Stack heights should be reduced if higher temperatures are encountered, or if pipe is nested (i.e. pipe stored inside pipe of a larger diameter). Reduction

in height should be proportional to the total weight of the nested pipe, compared with the weight of pipe normally contained in such racks.

Since the soundness of any joint depends on the condition of the pipe end, care should be taken in transit, handling and storage to avoid damage to these ends. The impact resistance and flexibility of both PVC and CPVC pipe are reduced by lower temperature conditions. The impact strength for both types of piping materials will decrease as temperatures approach 32°F (0°C) and below. Care should be taken when unloading and handling pipe in cold weather. Dropping pipe from a truck or forklift may cause damage. Methods and techniques normally used in warm weather may not be acceptable at the lower temperature range.

When loading pipe onto vehicles, care should be taken to avoid contact with any sharp corners (i.e. angle irons, nail heads, etc.), as the pipe may be damaged.

While in transit, pipe should be well secured and supported over the entire length and should never project unsecured from the back of a trailer.

Larger pipe may be off-loaded from vehicles by rolling them gently down timbers, ensuring that they do not fall onto one another or onto a hard, uneven surface.

Prolonged Outdoor Exposure

Prolonged exposure of PVC and CPVC pipe to the direct rays of the sun will not damage the pipe. However, some mild discoloration may take place in the form of a milky film on the exposed surfaces. This change in color merely indicates that there has been a harmless chemical transformation at the surface of the pipe. A small reduction in impact strength could occur at the discolored surfaces but they are of a very small order and are not enough to cause problems in field installation.

Protection – Covering

Discoloration of the pipe can be avoided by shading it from the direct rays of the sun. This can be accomplished by covering the stockpile or the crated pipe with a light colored opaque material such as canvas. If the pipe is covered, always allow for the circulation of air through the pipe to avoid heat buildup in hot summer weather. Make sure that the pipe is not stored close to sources of heat such as boilers, steam lines, engine exhaust outlets, etc.

Protection – Painting

PVC and CPVC pipe and fittings can be easily protected from ultraviolet oxidation by painting with a heavily pigmented, exterior water-based latex paint. The color of the paint is of no particular importance; the pigment merely acts as an ultraviolet screen and prevents sunlight change. White or some other light color is recommended as it helps reduce pipe temperature. The latex paint must be thickly applied as an opaque coating on pipe and fittings that have been well cleaned and very lightly sanded.

Page 48

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

JOINING METHODS – SOLVENT CEMENT

Basic Principles

To make consistently tight joints, the following points should be clearly understood:

1. The joining surfaces must be softened and made semi-fluid.

2. Sufficient cement must be applied to fill the gap between pipe and fittings.

3. Assembly of pipe and fittings must be made while the surfaces are still wet and fluid.

4. Joint strength will develop as the cement cures. In the tight part of the joint, surfaces tend to fuse together; in the loose part, the cement bonds to both surfaces.

These areas must be softened and penetrated

Penetration and softening can be achieved by the cement itself, by using a suitable primer, or by the use of both primer and cement. For certain materials and in certain situations, it is necessary to use a primer. A suitable primer will usually penetrate and soften the surfaces more quickly and effectively than cement alone. Additionally, the use of a primer can provide a safety factor for the installer, for he can know under various temperature conditions when he has achieved sufficient softening. For example, in cold weather more time and additional applications may be required.

Apply generous amounts of cement to fill the loose part of the joint. In addition to filling the gap, adequate cement layers will penetrate the surfaces and remain wet until the joint is assembled. To prove this, apply two separate layers of cement on the top surface of a piece of pipe. First, apply a heavy layer of cement; then alongside it, a thin, brushed-out layer. Test the layers every 15 seconds by gently tapping with your finger. You will note that the thin layer becomes tacky and then dries quickly (probably within 15 seconds); the heavy layer will remain wet much longer.

Check for penetration a few minutes after applying these layers by scraping them with a knife. The thin layer will have little or no penetration, while the heavy layer will have achieved much more penetration.

If the cement coatings on the pipe and fittings are wet and fluid when assembly takes place, they tend to flow together, becoming one cement layer. Also, if the cement is set, the surfaces beneath the pipe and fittings will still be soft. These softened surfaces in the tight part of the joint will fuse together.

As the solvent dissipates, the cement layer and the softened surfaces will harden with a corresponding increase in joint strength. In the tight (fused) part of the joint, strength will develop quicker than in the looser (bonded) part of the joint.

Cement Types

The use of a reliable cement, specifically manufactured for industrial PVC or CPVC, is critical to a good, long-lasting system and must conform to applicable ASTM standards. Review Table 20 for guidelines on cement types.

Table 20 – Cement Types

Pipe Pipe Socket Cement Size Schedule Type Type

up to 6" PVC 40 All types Medium-bodied fastup to 4" PVC 80 setting cement

Use primer to soften and prepare joining surfaces

up to 12" PVC All All types Heavy-bodied medium-

setting cement for all schedules through 12" diameter water lines, drain lines and DWV

Use primer to soften and prepare joining surfaces

up to 30" PVC All All types Extra heavy-bodied slow-

setting cement

Use primer to soften and prepare joining surfaces

up to 12" CPVC All All types Heavy-bodied medium-

setting cement for pressure and nonpressure service

Use primer to soften and prepare joining surfaces

up to 16" CPVC All All types Extra heavy-bodied slow-

setting cement

Use primer to soften and prepare joining surfaces

Surfaces must be assembled while they are wet and soft

Bonded Surfaces

Fused Surfaces

Page 49

INSTALLATION

Vinyl Process Piping Systems

Handling

Solvent cements should be used as received in original containers. Adding thinners to change the viscosity of cement is not recommended. If cement is jelly-like and not free flowing, it should not be used. Containers should be kept tightly covered when not in use to stop the evaporation of the solvent.

Storage Conditions

Solvent cements should be stored at temperatures between 40°F (4°C) and 110°F (43°C) away from heat or open flame. Cements should be used before the expiry date stamped on the container. If new cement is subjected to freezing temperatures, it may become extremely thick or gelled. This cement can be placed in a warm area where it will soon return to its original, usable condition. However, if hardening is due to actual solvent loss (when a container is left open too long during use or not sealed properly after use), the cement will not return to its original condition. Cement in this condition has lost its formulation and should be discarded in an environmentally safe manner.

Safety Precautions

Solvent cements are extremely flammable and should not be used or stored near heat or open flame including pilot lights. In confined or partially enclosed areas, a ventilating device should be used to remove vapors and minimize inhalation. Capping one end of a pipeline during construction may lead to an accumulation of flammable cement vapors inside the system. Nearby sparks may ignite these vapors and create a hazardous incident. If it is required to cover the pipe ends, use an air-permeable cloth that will prevent excessive amounts of dirt from entering the pipeline while permitting cement vapors to escape to the atmosphere. Alternatively, flushing the line with water will also remove all vapors after the cement has properly cured.

Containers should be kept tightly closed when not in use, and covered as much as possible when in use. Protective equipment such as gloves, goggles and an impervious apron should be used. Do not eat, drink or smoke while using these products. Avoid contact with skin, eyes or clothing. In case of eye contact, flush repeatedly with water. Keep out of the reach of children. Carefully read the Material Safety Data Sheets (MSDS) and follow all precautions.

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

CAUTION

Cement products are formulated for specific material types. To avoid potential joint failure, DO NOT USE PVC cement on CPVC components.

WARNING

During the curing of the solvent cement joints, vapors may accumulate inside the pipeline, especially should one end of the line be capped. Nearby sparks from welders or torches may inadvertently ignite these vapors and create a hazardous incident. Attention should be given to removing all vapors using air-blowers or water flushing prior to capping one end of an empty pipeline.

Page 50

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Solvent Cementing Instructions for PVC & CPVC Pipe & Fittings

Solvent Cementing with Primer

Step 2 Cut Pipe

Pipe must be cut as square as possible. (A diagonal cut reduces bonding area in the most effective part of the joint.) Use a handsaw and miter box or a mechanical saw.

Plastic tubing cutters may also be used for cutting plastic pipe; however, some produce a raised bead at the end of the pipe. This bead must be removed with a file or reamer, as it will wipe the cement away when pipe is inserted into the fitting.

Step 1 Preparation

Assemble proper materials for the job. This includes the appropriate cement, primer and applicator for the size of piping system to be assembled. See Tables 23 and 24 for guidelines to estimate the amount of cement required.

Step 3 Deburr Pipe Ends

Use a knife, plastic pipe deburring tool, or file to remove burrs from the end of small diameter pipe. Be sure to remove all burrs from around the inside as well as the outside of the pipe. A slight chamfer (bevel) of about 15° should be added to the end to permit easier insertion of the pipe into the fitting. Failure to chamfer the edge of the pipe may remove cement from the fitting socket, causing the joint to leak. For pressure pipe systems of 2" and above, the pipe must be end-treated with a 15° chamfer cut to a depth of approximately

/32" (2.5mm).

3/32" (2.5mm) APPROX.

DEBURR PIPE ENDS

10-15˚

Page 51

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Step 5 Check Fit

Check pipe and fittings for dry fit before cementing together. For proper interference fit, the pipe must go easily into the fitting one quarter to three quarters of the way. Too tight a fit is not desirable; you must be able to fully bottom the pipe in the socket during assembly. If the pipe and fittings are not out of round, a satisfactory joint can be made if there is a “net” fit, that is, the pipe bottoms in the fitting socket with no interference, without slop.

All pipe and fittings must conform to ASTM and other recognized standards.

Step 4 Clean Pipe Ends

Remove all dirt, grease and moisture. A thorough wipe with a clean dry rag is usually sufficient. (Moisture will retard cure, dirt or grease can prevent adhesion).

Step 6 Select Applicator

Ensure that the right applicator is being used for the size of pipe or fittings being joined. The applicator size should be equal to half the pipe diameter. It is important that a proper size applicator be used to help ensure that sufficient layers of cement and primer are applied.

Step 7 Priming

The purpose of a primer is to penetrate and soften pipe surfaces so that they can fuse together. The proper use of a primer provides assurance that the surfaces are prepared for fusion.

Check the penetration or softening on a piece of scrap before you start the installation or if the weather changes during the day. Using a knife or other sharp object, drag the edge over the coated surface. Proper penetration has been made if you can scratch or scrape a few thousandths of an inch of the primed surfaces away.

Weather conditions can affect priming and cementing action, so be aware of the following:

• repeated applications to either or both surfaces may be necessary

• in cold weather, more time may be required for proper penetration

• in hot weather, penetration time may be shortened due to rapid evaporation

Page 52

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Step 8 Primer Application

Using the correct applicator, aggressively work the primer into the fitting socket, keeping the surface and applicator wet until the surface has been softened. More applications may be needed for hard surfaces and cold weather conditions. Re-dip the applicator in primer as required. When the surface is primed, remove any puddles of primer from the socket.

Step 9 Primer Application

Next, aggressively work the primer on to the end of the pipe to a point 1/2" beyond the depth of the fitting socket.

Immediately and while the surfaces are still wet, apply the appropriate IPEX cement.

Step 10 Cement Application

Stir the cement or shake can before using. Using the correct size applicator, aggressively work a full even layer of cement on to the pipe end equal to the depth of the fitting socket. Do not brush it out to a thin paint type layer, as this will dry within a few seconds.

Step 11 Cement Application

Aggressively work a medium layer of cement into the fitting socket.

Avoid puddling the cement in the socket. On bell end pipe do not coat beyond the socket depth or allow cement to run down into the pipe beyond the spigot end.

Step 12 Cement Application

Apply a second full, even layer of cement on the pipe.

Page 53

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Step 13 Assembly

Without delay, while the cement is still wet, assemble the pipe and fittings. Use sufficient force to ensure that the pipe bottoms in the fitting socket. If possible, twist the pipe a quarter turn as you insert it.

Step 14 Assembly

Hold the pipe and fitting together for approximately 30 seconds to avoid push out.

After assembly, a joint should have a ring or bead of cement completely around the juncture of the pipe and fitting. If voids in this ring are present, sufficient cement was not applied and the joint may be defective.

Step 15 Joint Cleaning

Using a rag, remove the excess cement from the pipe and fitting, including the ring or bead, as it will needlessly soften the pipe and fitting and does not add to joint strength. Avoid disturbing or moving the joint.

Step 16 Joint Setting & Curing

Handle newly assembled joints carefully until initial set has taken place. Allow curing to take place before pressurizing the system. (Note: in humid weather allow for 50% more curing time.)

For initial set and cure times for IPEX cements, refer to Tables 21 and 22.

Page 54

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Joining Large Diameter Pipe and Fittings

As pipe diameter increases so does the difficulty in installing it. For large diameter pipe, the following recommendations apply.

• Select the proper size of applicator. The use of proper

size applicators is even more important for large pipe to ensure that enough cement is applied to fill the larger gap that exists between the pipe and fittings.

• Ensure the proper selection of cement and primer (refer

to Xirtec cement product catalog or your supplier of cements and primers).

• The size of the joining crew should be increased

6" - 8" pipe: 2-3 people per joint

10" - 24" pipe: 3-4 people per joint

• The end of the pipe must be chamfered as per the

diagram below.

• The primer and cement should be applied simultaneously

to the pipe and fittings.

• Make sure to apply a second full layer of cement to the pipe.

• Because of the short sockets in many large diameter fittings, it is very important to have pipe bottomed into the fitting. It is for this reason that above 6" diameter we recommend the use of a “come-a-long”.

• Large diameter pipe and fittings will require longer set and cure times. (In cold weather, a heat blanket may be used to speed up the set and cure times.)

• Prefabricate as many joints as possible.

• If pipe is to be buried, make as many joints as possible above ground, then after the joints have cured, carefully lower the piping system into the trench.

Solvent Cementing without Primer / One Step Cements

If local codes permit, successful joints can be made without a primer using cement alone, but extra care must be given to the installation. It is important that a good interference fit exists between the pipe and fittings. It is for this reason we recommend that joints being made without a primer be limited to systems 2" and smaller for pressure applications or 6" and smaller for DWV or non-pressure applications. Extra care must also be given in applying cements to make sure proper penetration and softening of the pipe and fitting surfaces is achieved. Note that one step cements are not recommended at temperatures at or below 32°F (0°C).

3/32" (2.5mm)

Chamfer

10°-15°

Page 55

INSTALLATION

Vinyl Process Piping Systems

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Cold Weather

Although normal installation temperatures are between 40°F (4°C) and 110°F (43°C), high strength joints have been made at temperatures as low as –15°F (–26°C).

In cold weather, solvents penetrate and soften the plastic pipe and fitting surfaces more slowly than in warm weather. In this situation, the plastic is more resistant to solvent attack and it becomes even more important to pre-soften surfaces with an aggressive primer. Be aware that because of slower evaporation, a longer cure time is necessary.

Tips for solvent cementing in cold weather

• Prefabricate as much of the system as is possible in a heated work area.

• Store cements and primers in a warmer area when not in use and make sure they remain fluid.

• Take special care to remove moisture including ice and snow from the surfaces to be joined.

• Ensure that the temperature of the materials to be joined (re: pipe and fittings) is similar.

• Use an IPEX Primer to soften the joining surfaces before applying cement. More than one application may be necessary.

• Allow a longer cure period before the system is used. Note: A heat blanket may be used to speed up the set and cure times.

Hot Weather

There are many occasions when solvent cementing plastic pipe at 95ºF (35ºC) temperatures and above cannot be avoided. If special precautions are taken, problems can be avoided.

Solvent cements for plastic pipe contain high-strength solvents which evaporate faster at elevated temperatures. This is especially true when there is a hot wind blowing. If the pipe is stored in direct sunlight, the pipe surface temperatures may be 20ºF to 30ºF (10ºC to 15ºC) higher than the ambient temperature. In this situation, the plastic is less resistant to attack and the solvents will attack faster and deeper, especially inside a joint. It is therefore very important to avoid puddling the cement inside the fitting socket and to ensure that any excess cement outside the joint is wiped off.

Tips for solvent cementing in hot weather:

• Store solvent cements and primers in a cool or shaded area prior to use.

• If possible, store fittings and pipe or at least the ends to be solvent welded, in a shady area before cementing.

• Try to do the solvent cementing in cooler morning hours.

• Cool surfaces to be joined by wiping with a damp rag.

• Make sure that the surface is dry prior to applying solvent cement.

• Make sure that both surfaces to be joined are still wet with cement when putting them together. With large size pipe, more people on the crew may be necessary.

• Using a primer and a heavier, high-viscosity cement will provide a little more working time.

Note: During hot weather the expansion-contraction factor may increase. Refer to the expansion-contraction design criteria in this manual.

Page 56

INSTALLATION

Vinyl Process Piping Systems

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Table 22 – Joint Cure Schedule for IPEX and IPEX Recommended PVC/CPVC Solvent Cements *

* The figures in the table are estimates based on laboratory tests for water applications (chemical applications may require different set times). In damp or humid weather allow 50% more cure time (relative humidity over 60%).

Note 1: Due to the many variables in the field, these figures should be used as a general guideline only.

Note 2: Joint cure schedule is the necessary time needed before pressurizing the system.

Table 21 – Initial Set Schedule for IPEX and IPEX Recommended PVC/CPVC Solvent Cements *

* The figures in the table are estimates based on laboratory tests for water applications (chemical applications may require different set times). In damp or humid weather allow 50% more set time.

Note 1: Due to the many variables in the field, these figures should be used as a general guideline only.

Note 2: Initial set schedule is the necessary time needed before the joint can be carefully handled.

Temperature Temperature Pipe Size (in)

Range (ºF) Range (ºC)

/2 to 11/4 11/2 to 2 21/2 to 8 10 to 14 > 16

60 to 100 16 to 38 2 minutes 5 minutes 30 minutes 2 hours 4 hours

40 to 60 4 to 16 5 minutes 10 minutes 2 hours 8 hours 16 hours

0 to 40 –18 to 4 10 minutes 15 minutes 12 hours 24 hours 48 hours

Temperature Temperature Pipe Size (in) & system operating pressure

Range (ºF) Range (ºC)

/2 to 11/4 11/2 to 2 21/2 to 8 10 to 14 > 16

<160 psi 160 - 370 psi <160 psi 160 - 315 psi <160 psi 160 - 315 psi <100 psi <100 psi

60 to 100 16 to 38 15 min 6 hr 30 min 12 hr 11/2hr 24 hr 48 hr 72 hr

40 to 60 4 to 16 20 min 12 hr 45 min 24 hr 4 hr 48 hr 96 hr 6 days

0 to 40 –18 to 4 30 min 48 hr 1 hr 96 hr 72 hr 8 days 8 days 14 days

Table 23 – Average Number of Joints per quart of IPEX and

IPEX Recommended Cement *

* The figures in the table are estimates based on laboratory tests

Note: Due to the many variables in the field, these figures should be used as a general guideline only.

Table 24 – Average Number of Joints per US gallon of IPEX and

IPEX Recommended Cement *

* The figures in the table are estimates based on laboratory tests

Note: Due to the many variables in the field, these figures should be used as a general guideline only.

Pipe Size (in) No. of Joints / Qt.

/2 300

/4 200

1 125

/2 90

260

340

430

610

10 2 - 3

12 1 - 2

14 1

Pipe Size (in) No. of Joints / Gal.

16 3

18 2

20 1 - 2

24 1

Page 57

INSTALLATION

Vinyl Process Piping Systems

JOINING METHODS – THREADING

Characteristics

Threading of PVC or CPVC pipe is only recommended for Schedule 80. The wall thickness is diminished at the point of threading and thereby reduces the maximum working pressure by 50%. Because of this, threaded pipe should not be used in high pressure systems nor in areas where a leak might endanger personnel. Threaded joints will not withstand constant or extreme stress and strain and must be supported or hung with this in mind. The threading of pipe sizes above 4" is not recommended.

Note: Using threaded PVC or CPVC products at or near the maximum temperature range should be avoided. Consult IPEX for specific details.

Tools & Equipment

• Power threading machine

• Threading ratchet and pipe vise (if hand pipe stock is used)

• Pipe dies designed for plastic

• Strap wrench

• Teflon* tape (PTFE)

• Cutting and de-burring tool

• Ring gauge (L-1)

*Trademark of the E.I. DuPont Company

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Page 58

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Making the Pipe Thread

1. Cutting and Deburring

PVC or CPVC pipe should be cut square and smooth for easy and accurate threading. A miter box or similar guide should be used when sawing is done by hand. Burrs should be removed inside and out using a knife or plastic pipe deburring tool.

2. Threading

Threading Schedule 80 PVC and CPVC pipe can be easily accomplished using either a standard hand pipe stock or a power operated tool. Cutting dies should be clean and sharp.

Power-threading machines should be fitted with dies having a 5º negative front rake and ground especially for plastic pipe. Self opening die heads, and a slight chamfer to lead the dies will speed the operation; however, dies should not be driven at high speeds or with heavy pressure.

When using a hand-held cutter, the pipe should be held in a pipe vise. To prevent crushing or scoring of the pipe by the vise jaws, some type of protective wrap such as canvas, emery paper, rubber or light metal sleeve should be used.

For hand stocks, the dies should have a negative front rake angle of 5° to 10°. PVC and CPVC is readily threaded and caution should be taken not to over-thread. This procedure is best done in a shop or fabricating plant. Thread dimensional specifications can be found in Table 25, American National Standard Taper Pipe Threads (NPT).

Installation Guidelines

1. Preparing the Threaded Pipe

A ring gauge should be used to check the accuracy of the threads.

Tolerance = ±11/2 turns.

The threads should be cleaned by brushing away cuttings and ribbons. After cleaning, apply an IPEX recommended thread lubricant such as Teflon

tape (PTFE) or IPEX Thread Sealant to the threaded portion of the pipe.

If tape is used, wrap the tape around the entire length of threads beginning with number two thread from the end. The tape should slightly overlap itself going in the same direction as the threads. This will prevent the tape from unraveling when the fitting is tightened on the pipe. Overlapping in the wrong direction and the use of too much tape can affect tolerances between threads. This can generate stress in the wall of female fittings resulting in failure during operations.

If IPEX Thread Sealant is to be used, brush on a generous amount of sealant, using the correctly sized applicator, onto the threads beginning with the number two thread from the end.

Note: IPEX strongly recommends the use of IPEX Pipe Thread Compound (or other IPEX approved sealants) when connecting threaded fittings to other materials.

IPEX Pipe Thread Compound has been specifically formulated for use with thermoplastic piping systems. Use of other sealants may contain substances harmful to thermoplastics.

2. Assembly of Threaded Joints and Unions

After applying thread lubricant, screw the threaded fitting onto the pipe. Screwed fittings should be started carefully and hand tightened. Threads must be properly cut and a good quality thread lubricant/tape must be used. If desired, the joint may be tightened with a strap wrench. In NO INSTANCE should a pipe or chain wrench be used as the jaws of this type of wrench will scar and damage the pipe wall.

Fittings should be threaded together until hand tight with an additional

/2 to 1 turns more. Avoid stretching or distorting the pipe, fittings or threads by over tightening.

Note 1: Never apply solvent cement to threaded pipe or threaded fittings. Do not allow cleaners, primers, or solvent cements to “run” or drip into the threaded portion of the fitting.

Note 2: Avoid screwing metallic male threads into plastic female threads, except those that have metal reinforcement. Consult the factory or your IPEX sales representative for the availability of these metal reinforced fittings.

Note 3: It is recommended that pipe tape/lubricant be used when connecting union ends to threaded pipe. However, pipe tape/lubricant is not needed on the union threaded interface assembly.

Page 59

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Table 25 - American National Standard Taper Pipe Threads (NPT)

(Vanish threads due to chamfer

on die)

Taper of thread

1in 16 measured

on diameter

Pitch Line

NOTE:

1. The basic dimensions of the American National Standard Taper Pipe Thread are given in inches to four or five decimal places. While this implies a greater degree of precision than is ordinarily attained, these dimensions are the basis of gage dimensions and are so expressed for the purpose of eliminating errors in computations.

2. Also length of thin ring gage and length from gaging notch to small end of plug gage.

3. Also length of plug gage.

4. Reference dimension

Nominal

Pipe

Size

O.D.

of Pipe

(D)

Threads

per

inch

(n)

Pitch

of Thread

(P)

Pitch

Diameter at

Beginning

of External

Thread (E

)

Handtight

Engagement

Length

(L1)

Effective Thread,

External

Length

(L2)

Vanish

Thread (V)

Overall Length

External

Thread

(L4)

Height

Thread

(h)

Inch Threads Inch Threads Inch Thread

/8 0.405 27 0.03704 0.36351 0.1615 4.36 0.2639 7.12 0.1285 3.47 0.3924 0.02963

/4 0.540 18 0.05556 0.47739 0.2278 4.10 0.4018 7.23 0.1928 3.47 0.5946 0.04444

/8 0.675 18 0.05556 0.61201 0.240 4.32 0.4078 7.34 0.1928 3.47 0.6006 0.04444

/2 0.840 14 0.07143 0.75843 0.320 4.48 0.5337 7.47 0.2478 3.47 0.7815 0.05714

/4 1.050 14 0.07143 0.96768 0.339 4.75 0.5457 7.64 0.2478 3.47 0.7935 0.05714

1 1.315 11.5 0.08696 1.21363 0.400 4.60 0.6828 7.85 0.3017 3.47 0.9845 0.06957

11/4 1.660 11.5 0.08686 1.55713 0.420 4.83 0.7068 8.13 0.3017 3.47 1.0085 0.06957

11/2 1.900 11.5 0.08696 1.79609 0.420 4.83 0.7235 8.32 0.3017 3.47 1.0252 0.06957

2 2.375 11.5 0.08696 2.26902 0.436 5.01 0.7565 8.70 0.3017 3.47 1.0582 0.06957

21/2 2.875 8 0.12500 2.71953 0.682 5.46 1.1375 9.10 0.4337 3.47 1.5712 0.100000

3 3.500 8 0.12500 3.34062 0.766 6.13 1.2000 9.60 0.4337 3.47 1.6337 0.100000

31/2 4.000 8 0.12500 3.83750 0.821 6.57 1.2500 10.00 0.4337 3.47 1.6837 0.100000

4 4.500 8 0.12500 4.33438 0.844 6.75 1.3000 10.40 0.4337 3.47 1.7337 0.100000

5 5.563 8 0.12500 5.39073 0.937 7.50 1.4063 11.25 0.4337 3.47 1.8400 0.100000

6 6.625 8 0.12500 6.44609 0.958 7.66 1.5125 12.10 0.4337 3.47 1.9462 0.100000

Page 60

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Introduction

Flanging is used extensively for plastic process lines that require periodic dismantling. Thermoplastic flanges and factory flanged fittings in PVC and CPVC are available in a full range of sizes and types for joining to pipe by solvent welding and threading. Gasket seals between the flange faces should be an elastomeric full-faced gasket with a hardness of 50 to 70 durometer A. Neoprene gaskets are commonly available in sizes from 1/2" through to 24" range having a 1/8" thickness. For chemical environments beyond the capabilities of neoprene, more resistant elastomers should be used.

Dimensions

IPEX PVC and CPVC flanges have the same bolt hole dimensions as Class 150 metal flanges per ANSI B16.5. Threads are tapered iron pipe size threads per ANSI B2.1. The socket dimensions conform to ASTM D 2467 which describes 1/2" through 8". Flanges 1/2" to 12" are third party tested by NSF according to ASTM F 1970. Flange bolt sets are listed in Table 28.

Maximum pressure for any flanged system is the rating of the pipe or up to 150 psi. Maximum operating pressures for elevated temperatures are shown in Table 26. To elevate the pressure rating above 150psi, a full-pressure flange kit is available. Details on page 58.

Blind flanges in sizes 14" – 24" have a maximum working pressure of 50 psi.

Installation Guidelines

The faces of IPEX flanges have a phonographic-grooved finish providing positive seal on the gasket when the bolts are properly tightened.

Once a flange is joined to pipe, use the following method to join two flanges together:

1) Make sure all bolt holes of the matching flanges are aligned.

2) Insert all bolts.

3) Make sure the faces of the mating flanges are not separated by excessive distance prior to bolting down the flanges.

4) The bolts on the plastic flanges should be tightened by pulling down the nuts diametrically opposite each other using a torque wrench. Complete tightening should be accomplished in stages using the final torque values in Table 27, Recommended Torque. Uniform stress across the flange will eliminate leaky gaskets.

The following tightening pattern is suggested for the flange bolts.

5) If the flange is mated to a rigid and stationary flanged object or a metal flange, particularly in a buried situation where settling could occur with the plastic pipe, the plastic flange, and fitting or valve must be supported to eliminate potential stressing.

JOINING METHODS – FLANGING

Table 26 - Maximum Pressures for Flanged Systems

* intermittent drainage only NR – not recommended

Operating Temp. Max. Operating Pressure (psi)

°F °C PVC CPVC

73 23 150 150

80 27 132 144

90 32 113 137

100 38 93 123

110 43 75 111

120 49 60 98

130 54 45 87

140 60 33 75

150 66 * 68

160 71 * 60

170 77 * 50

180 82 * 38

200 93 NR 30

210 99 NR *

4-Bolt Flange

8-Bolt Flange

12-Bolt Flange

Page 61

INSTALLATION

Table 27 – Recommended Torque

* Based on using flat-faced PVC and CPVC flanges, a full-faced neoprene gasket, and well lubricated hardware, tightened in the proper sequence and applying torque in small increments. For vinyl-to-metal flange (or other materials), these torque recommendations may vary. Vanstone HD flanges should be tightened with the same torque as flat faced flanges.

Note: When thermoplastic flanges with PVC rings are used with butterfly valves or other equipment where a full-faced continuous support does not exist, a back-up ring or fiberloc ring should be used to prevent potential cracking of the flange face.

Table 28 - Recommended Flange Bolt Set

Corzan®Full Pressure Flange Kit

• One (1) Two-piece steel backing ring

• One (1) Stress-Saver XP gasket

(75-80 durometer hardness)

• SAE J429 Grade 8 bolts with associated hex nut

• Two flat washers per bolt

• One (1) Corzan CPVC one-piece socket flange

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Pipe Size No. of Holes Bolt Diameter Bolt Length

1/2 4 0.50 1.75 3/4 4 0.50 2.00

1 4 0.50 2.00 1-1/4 4 0.50 2.25 1-1/2 4 0.50 2.50

2 4 0.63 2.75 2-1/2 4 0.63 3.00

3 4 0.63 3.00

4 8 0.63 3.25

6 8 0.75 3.50

8 8 0.75 4.00

10 12 0.88 5.00 12 12 0.88 5.00 14 12 1.00 7.00 16 16 1.00 7.00 18 16 1.13 8.00 20 20 1.13 9.00 24 20 1.25 9.50

CAUTION

1. Do not over-torque flange bolts.

2. Use the proper bolt tightening sequence.

3. Make sure the system is in proper alignment.

4. Flanges should not be used to draw piping assemblies together.

5. Flat washers must be used under every nut and bolt head.

Vinyl Process Piping Systems

* Bolt length may vary depending on the style of flange and use of backing rings.

Flange Size

(in.)

Recommended Maximum Torque

Full Face/Heavy Duty Vanstone

PVC

Vanstone

1/2– 1-1/2 15 15

2 – 4 30 30

6 – 8 50 50

10 70 65

12 – 24 100 75

Not shown; receiving flange between gasket and washer

Page 62

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

IPEX is pleased to announce the launch of our new Corzan

Full Pressure (FP) Flange Kits, specifically developed to increase the pressure capability of a Schedule 80 Iron Pipe Size (IPS) Corzan CPVC one-piece flange. The Corzan FP Flange Kits have a pressure rating equal to that of Schedule 80 Corzan CPVC pipe in each of the 4 sizes offered (2-1/2" through 6"). The pressure rating is valid for connections to solid flat face metal flanges or to a second Corzan FP Flange Kit. The flange kit assembly is NSF 14 listed and meets the requirements set forth by the American Society of Testing Materials (ASTM) F1970. The special gasket and IPEX Corzan CPVC one-piece flange contained within this kit are certified to ANSI/NSF Standard 61.

Elevated Temperature Limitations

For IPEX Corzan CPVC Full-Pressure flange kits, the average pressure system operating temperature ranges from 40°F (4°C) to 200°F (93°C). At elevated temperatures the pressure capabilities of a Full-Pressure flange kit joint must not exceed the values as detailed below.

Installation Instructions for Corzan Full-Pressure Flange Kits

Background

Proper installation of this product, for mating with a metal flange, requires the use of all the components supplied to achieve a pressure rating equal to that of the pipe.

Kit Contents

– Two-Piece steel backing ring – Stress-Saver XP gasket (75-80 Durometer Hardness) – SAE J429 Grade 8 bolts with associated hex nut* – Two (2) flat washers per bolt – Corzan CPVC one-piece socket flange

*Note: the bolt length will vary for flange size and assembly configuration. The length of bolts supplied in this kit is assuming connection to a metal flange. For Corzan to Corzan flange connections, bolts should be 1/2" longer so that the bolts extend approximately 1/4" minimum beyond the nut after final assembly.

Installers will also need a torque wrench for proper assembly.

Installation Procedure

1. Assemble a Corzan flange to a Corzan pipe in a normal manner with proper solvent welding procedures in accordance with solvent cement installation procedures detailed in the Vinyl Process Piping Systems Technical Manual.

2. Allow the joint to fully cure set before installing the remaining components of the Full-Pressure Kit (refer to page 53 for recommended cure times versus temperature and size.

3. Begin kit installation by placing the backing ring over the back of the hub of the Corzan flange, ensuring that the bolt holes are aligned.

4. Slip the gasket provided between the two flanges and bring the Corzan and mating flanges together.

5. Insert the bolts through the matching holes of both the flanges and backing ring. Use only the bolts supplied or recommended above. A flat washer should be installed beneath each nut and the bolt head.

6. When the bolts are installed, a torque wrench should be placed over the nut (not on bolt head). Snug tighten the nut first, which is approximately 20 ft-lb of torque.

INSTALLATION

Vinyl Process Piping Systems

Operating

Temperature

Size

°F

°C

2-1/2" 3" 4" 6"

420 370 320 280

403 355 307 269

382 337 291 255

100

344 303 262 230

110

311 274 237 207

120

273 241 208 182

130

244 215 186 162

140

210 185 160 140

150

189 167 144 126

160

168 148 128 112

170

139 122 106 92

180

105 93 80 70

200

84 74 64 56

212

100

* * * *

* Recommended for intermittent drainage only

Pressure Capabilities of a Full-Pressure Flange Kit Joint

Page 63

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

7. Next, tighten the nuts to the specified torque values indicated below (Table XXX). A multi-step tightening process is recommended with each step requiring the installer to tighten the nuts in a star pattern (Figure XXX).

8. Once this assembly is complete, perform a check pass of the bolts by starting at one and going around in a clockwise direction ensuring each nut is tightened to the highest recommended torque level for that size.

9. Do not use the flanged connection to support the weight of a

metal system component such as a ball or butterfly valve. Those items should be supported independently.

Notes:

1. After the piping is installed, and the solvent cement is fully cured, the system should be pressure-tested in accordance with local codes using water. Do not use compressed air or gases for testing. Refer to the Vinyl Process Piping Technical Manual for further instructions on testing.

2. Flange kits cannot be installed against mating surfaces that

include an integrated gasket, like wafer-style butterfly valves. The gasket provided in the Full-Pressure Flange Kit must be the only gasket used in the assembly.

3. This Flange assembly has been certified to ASTM F 1970. As such, any components that are replaced must comply with the listing I order to maintain the certification. Replacement parts shall be: Stress-Saver XP gasket (75-80 Durometer Hardness), SAE J429 Grade 8 bolts with associated hex nut, two (2) flat washers per bolt.

Note: the bolt length will vary for flange size and assembly configuration. The length of bolts supplied in this kit is assuming connection to a metal flange. For Corzan to Corzan flange connections, bolts should be 1/2" longer so that the bolts extend approximately 1/4" minimum beyond the nut after final assembly.

INSTALLATION

Vinyl Process Piping Systems

CAUTION

1. Do not over-torque flange bolts.

2. Use the proper bolt tightening sequence.

3. Make sure the system is in proper alignment.

4. Flanges should not be used to draw piping assemblies together.

5. Flat washers must be used under every nut and bolt head.

WARNING

Failure to install flange properly may result in joint leakage or joint failure which may cause severe injury and property damage.

Page 64

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Introduction

IPEX PVC pipe can be roll or cut-grooved at each end for quick connection using mechanical couplings specifically designed for PVC pipe. This method can be used in any application where PVC pipe is acceptable and where it is desirable to have a means for quick assembly under adverse conditions.

Features

• Completely re-usable pressure system that does not require threading, solvent welding, or flanging.

• Joints are mechanically locked to produce a secure, leaktight connection under pressure or vacuum. (See coupling manufacturer’s product information for details on pressure capabilities.)

• A union at every joint allows for speed and ease of assembly and field maintenance.

• In abrasive applications, pipe can easily be rotated to distribute wear evenly.

• Flexible system permits laying on rough or uneven terrain.

• When using a gasket-type coupler, each joint will absorb some expansion and contraction due to temperature changes.

• Grooved systems facilitate fast add-ons, modifications or re-location of the pipe.

Table 29 – Recommended Piping for Roll or

Radius Cut Grooved Joints

* Consult an IPEX representative for detailed design

considerations

Installation Guidelines

1) Always use a grooved coupling that is designed and recommended for use with PVC pipe. Table 29 shows recommended piping systems for above ground assemblies.

2) The grooves are normally machined or rolled in the pipe end by IPEX before shipment. The dimensions of the groove will be as recommended by the grooved coupling manufacturer as shown in Table 30, Grooved Joint Dimensions.

3) The working pressure and/or test pressure in a grooved joint PVC piping system should not exceed the recommended maximum pressures shown in Table 31, Maximum Pressures for Grooved PVC Pipes, at temperatures at or below 73°F (23ºC).

4) The maximum recommended operating pressures in Table 31 should be multiplied by the factors in Table 32, Temperature De-rating Factors for Grooved Joints, when the system works at temperatures constantly above 73°F (23ºC). The maximum recommended operating temperature in grooved-jointed PVC pipe systems is 100°F (38ºC).

5) The installation of grooved-jointed PVC pipe should ensure that:

a) Thrust reaction is restrained at points of deflection

or dead ends by external supports or harnesses. Thrust forces should not be transferred to the joints by design.

b) Straight alignment of pipe is maintained at the

joints, using a suitable support system.

c) Thermal expansion/contraction movement does not

exceed .0625" per joint.

JOINING METHODS – ROLL GROOVED OR RADIUS CUT GROOVED (PVC ONLY)

Piping Material Recommended Grooved Joints

PVC Sch 40 (2" – 8") Roll or radius cut

PVC Sch 80 (2" – 12") Roll or radius cut

PVC SDR 26 (6" – 12") Roll or radius cut

PVC SDR 21 (4" – 12") Roll or radius cut

PVC 14" * May be cut grooved

PVC 16" * May be cut grooved

PVC 18" * May be cut grooved

PVC 24" * May be cut grooved

Vinyl Process Piping Systems

Page 65

INSTALLATION

Vinyl Process Piping Systems

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Table 30 – Grooved Joint Dimensions

* Dimension D is a convenient reference only, dimension C governs

Table 31 – Maximum Pressures (psi) for Cut Grooved PVC Pipes at 73°F

Table 32 – Temperature De-rating Factors for Grooved Joints

Pipe Size O.D. A B C D*

(in.) (in.) ± 0.031 (in.) ± 0.031 (in.) Average (in.) (in.)

2 2.375 0.625 0.312 2.250 ± 0.015 0.062

21/2 2.875 0.625 0.312 2.720 ± 0.018 0.078

3 3.500 0.625 0.312 3.344 ± 0.018 0.078 4 4.500 0.625 0.375 4.334 ± 0.020 0.083 6 6.625 0.625 0.375 6.455 ± 0.022 0.085

8 8.625 0.750 0.437 8.441 ± 0.025 0.092 10 10.750 0.750 0.500 10.562 ± 0.027 0.094 12 12.750 0.750 0.500 12.531 ± 0.030 0.109

Pipe Size (in.) SDR 26 SDR 21 SCH 40 SCH 80

2 - - 100 170

/2 - - 110 175 3 - - 100 160 4 - 75 85 140 6 60 80 70 125 8 65 85 65 115

10 70 90 - 110 12 70 90 - 110

Operating Temp. De-rating Factor

°F °C

73 38 1.00 80 27 0.90 90 32 0.75

*100 38 0.62

* Maximum recommended operating temperature for grooved PVC piping systems.

D GROOV

C. DIAO.D.

DEPTH

Page 66

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

SUPPORTS AND RESTRAINTS

Thrust

Thrust forces can occur at any point in a piping system where the directional or cross-sectional area of the waterway changes or where additional structural loads such as valves are installed. These forces must be reduced by means of anchors, risers, restraining hangers, thrust blocks or encasement. The method chosen will depend on whether the system is buried or above ground. See also the section on installation of buried pipes in this manual.

The size or need for reinforcements should be based on the design engineer’s evaluation of flow velocities and pressure increases due to the fluid’s momentum. Note that the thrust created at unrestrained fittings can be considerable (as shown in Table 33) and should be addressed during installation. For more detail regarding estimating and compensating for thrust forces, refer to engineering textbooks such as the

Uni–Bell Handbook of PVC Pipe

Note that all valves must be anchored. This includes valves installed in line, in a chamber and those that are operated infrequently. It is recommended that anchor rods be installed around the valve body or through the mounting lugs. The rods should be embedded in concrete beneath the valve.

Table 33 - Thrust at Fittings in pounds Per 100 psi (internal pressure)

General Principles of Support

Adequate support for any piping system is a matter of great importance. In practice, support spacing is a function of pipe size, operating temperatures, the location of heavy valves or fittings and the mechanical properties of the pipe material.

To ensure satisfactory operation of a thermoplastic piping system, the location and type of hangers should be carefully considered. The principles of design for steel piping systems are generally applicable to thermoplastic piping systems, but with some notable areas where special consideration should be exercised.

1) Concentrated loads (i.e. valves, flanges, etc.) should be supported directly to eliminate high stress concentrations on the pipe. Should this be impractical, the pipe must then be supported immediately adjacent to the load.

2) In systems where large fluctuations in temperature occur, allowance must be made for expansion and contraction of the piping system. Since changes in direction in the system are usually sufficient to allow expansion and contraction, hangers must be placed so movement is not restricted. (See also ExpansionContraction in the Design section in this manual). Note that in some instances it may be desirable to use a clamp-type hanger to direct thermal expansion or contraction in a specific direction. When using a clamptype hanger, the hanger should not deform the pipe when it has been tightened. (See Figure 9, Recommended Pipe Hangers)

3) Changes in direction (e.g. 90° elbows) should be supported as close as practical to the fitting to avoid introducing excessive torsional stresses into the system.

4) Since PVC and CPVC pipe are somewhat notch sensitive, hangers should provide as much bearing surface as possible. Sharp supports or sharp edges on supports should not be used with these materials since they will cause mechanical damage if the pipe moves.

5) Valves should be braced against operating torque. Heavy metal valves should be supported so as not to induce additional stress on the thermoplastic piping system.

Tables 34 and 35 give recommended maximum support spacing for PVC and CPVC pipe at various temperatures. The data is based on fluids with a specific gravity of 1.0. For heavier fluids, the support spacing from the graphs should be multiplied by the correction factors shown in Table 36.

These maximum recommendations should always be referenced against local plumbing and mechanical codes as well as the local authority having jurisdiction.

Pipe Blank ends 90° 45° 221/2º 111/4°

Size (in) & junctions Bends Bends Bends Bends

/2 60 85 50 25 15

/4 90 130 70 35 20

1 140 200 110 55 30

/4 220 320 170 90 45

/2 300 420 230 120 60

2 450 630 345 180 90

/2 650 910 500 260 130

3 970 1,360 745 385 200

4 1,600 2,240 1,225 635 320

6 3,450 4,830 2,650 1,370 690

8 5,850 8,200 4,480 2,320 1,170

10 9,100 12,750 6,980 3,610 1,820

12 12,790 17,900 9,790 5,080 2,550

14 15,400 21,500 11,800 6,100 3,080

16 20,100 28,150 15,400 7,960 4,020

18 25,400 35,560 19,460 10,060 5,080

20 31,400 43,960 24,060 12,440 6,280

24 45,300 63,420 34,700 17,940 9,060

Page 67

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Supporting Pipes

The high coefficient of thermal expansion of plastic compared with metals may result in considerable expansion and contraction of the pipe runs as the temperature changes.

The principle is to control expansion by restraining the pipe in the lateral direction while allowing free axial movement.

A hanger-type support does not provide lateral restraint to the pipe, but it does encourage snaking and should be avoided whenever possible.

The diagram below illustrates preferred and non-preferred support arrangements.

In some cases, it may be physically impossible or impractical to install a rigid support in between two widely spaced columns. In this event hanger rods with loose fitting clips should be used.

The frequency of supports for plastic pipes is greater than for metal pipes. The recommended maximum distance between supports for pipes filled with water is given in Table 34 (See Recommended Maximum Support Spacing) and applies to pipes and contents at the temperature stated.

Pipe supports should be installed so that the horizontal piping is in uniform alignment and with a uniform slope of at least 1/8" per foot, or in accordance with the local plumbing codes or authority having jurisdiction.

Calculation of Support Spacing Based on Sag Limit

L = [(SL x E x I) / (1.302 x Wt)]

0.333

Where:

L = Length between supports, ‘Span Length’, Ft.

SL = Sag Limit, the maximum permitted vertical

deflection allowed across a span, expressed as a percentage of the span length for 0.2% SL = 0.2

E = Modulus of elasticity of the pipe material, psi

(see Table 15)

OD = Outside Diameter of the pipe, ins.

π x (OD4- ID4)

Wt = 0.02837 x (δ-pipe x (OD

- ID2) + δ-fluid x ID2)

δ-pipe = Density of pipe material,

g/cc = Specific Gravity x 0.9975

δ-fluid = Density of the fluid, g/cc

ID = Inside diameter of the pipe, ins

Example 17

For a 11/2" Schedule 40 PVC pipe operating at 140ºF (60ºC), calculate the maximum allowable support spacing with a sag limit of 0.2% (System fluid density = 1.0 g/cc)

Step 1: Calculate the weight of the piping system

Wt = 0.02837 x (δ-pipe x (OD2- ID2) + δ-fluid x ID2)

Known:

Specific gravity of PVC = 1.42 (from Table 1)

E = Modulus of elasticity = 280,000 psi

OD = 1.900" (from Table A-14)

δ-pipe = 1.42 x 0.9975 = 1.416 g/cc

ID = 1.590" (from Table A-14)

wt = 0.02837 x (1.416 x (1.900

- 1.5902) + 1.0 x 1.5902)

wt = 0.11518

Step 2: Calculate the moment of inertia

I= π x (1.9004- 1.5904)

I = 0.326

Step 3: Calculate the maximum allowable support spacing

L = [(0.2 x 280,000 x 0.326) / (1.302 x 0.11518)]

0.333

L = 4.114 ft.

clip allows free axial pipe movement

fabricated angle iron support with wide bearing area

PREFERRED

RIGID SUPPORT

lateral restraint

no lateral restraint

restricted axial pipe movement

NON-PREFERRED

Page 68

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Pipe Size Schedule 40 PVC Schedule 80 PVC

(in.) 60°F (15°C) 100°F (38°C) 140°F (60°C) 60°F (15°C) 100°F (38°C) 140°F (60°C)

/2 3.0 2.9 2.6 3.1 3.0 2.7

/4 3.4 3.2 3.0 3.5 3.4 3.1

1 3.9 3.7 3.4 4.0 3.9 3.6

/4 4.3 4.2 3.9 4.6 4.4 4.1

/2 4.7 4.5 4.1 5.0 4.8 4.4

2 5.2 5.0 4.6 5.6 5.4 5.0

3 6.7 6.4 5.9 7.2 6.9 6.4

4 7.6 7.3 6.7 8.2 7.9 7.3

6 9.2 8.9 8.2 10.3 9.9 9.2

8 10.7 10.2 9.5 12.0 11.5 10.6

10 12.0 11.5 10.7 13.7 13.1 12.1

12 13.2 12.7 11.8 15.2 14.6 13.5

14 14.0 13.5 12.4 16.2 15.6 14.4

16 15.3 14.7 13.6 17.6 16.9 15.7

18 16.6 15.9 14.7 19.0 18.3 16.9

20 17.5 16.8 15.5 20.0 19.5 18.1

24 19.6 18.8 17.4 20.0 20.0 20.0

* based on a sag limit of 0.2% of span length that is well within the bending stress limits of the material. This conservative calculation is also intended to accommodate expansion and contraction, pressure surges and entrapped air.

Note 1: A maximum span of 20 ft. is recommended.

Note 2: Bearing surface of supports should be at least 2" wide.

Table 34 – Recommended Maximum Support Spacing in feet for Xirtec140 PVC *

Assume the load is uniformly distributed along the span length

Page 69

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Table 35 – Recommended Maximum Support Spacing in feet for Corzan CPVC *

Table 36 – Support Spacing Correction Factors

Specific Gravity 1.0 1.1 1.2 1.4 1.6 2.0 2.5

Correction Factor 1.00 0.98 0.96 0.93 0.90 0.85 0.80

Pipe Size Schedule 80 CPVC

(in.) 73°F (23°C) 100°F (38°C) 120°F (49°C) 140°F (60°C) 160°F (71°C) 180°F (82°C) 200ºF (92ºC)

/2 3.1 3.0 2.9 2.8 2.7 2.7 2.5

/4 3.5 3.4 3.3 3.2 3.1 3.0 2.8

1 4.1 3.9 3.8 3.7 3.6 3.5 3.3

/4 4.6 4.5 4.4 4.2 4.1 4.0 3.7

/2 5.0 4.8 4.7 4.6 4.4 4.3 4.0

2 5.6 5.5 5.3 5.2 5.0 4.9 4.5

/2 6.5 6.3 6.1 5.9 5.7 5.6 5.2

3 7.2 7.0 6.8 6.6 6.4 6.2 5.8

4 8.3 8.1 7.8 7.6 7.4 7.1 6.7

6 10.4 10.1 9.8 9.5 9.2 9.0 8.4

8 12.1 11.7 11.4 11.0 10.7 10.4 9.7

10 13.8 13.4 13.0 12.6 12.3 11.9 11.1

12 15.4 15.0 14.5 14.1 13.7 13.3 12.4

14 16.4 15.9 15.4 15.0 14.5 14.1 13.2

16 17.8 17.3 16.8 16.3 15.4 14.9 14.3

Pipe Size Schedule 40 CPVC

(in.) 73°F (23°C) 100°F (38°C) 120°F (49°C) 140°F (60°C) 160°F (71°C) 180°F (82°C) 200ºF (92ºC)

/2 3.0 2.9 2.8 2.7 2.7 2.6 2.4

/4 3.4 3.3 3.2 3.1 3.0 2.9 2.7

1 3.9 3.8 3.7 3.5 3.4 3.3 3.1

/4 4.4 4.3 4.1 4.0 3.9 3.8 3.5

/2 4.7 4.6 4.4 4.3 4.2 4.0 3.8

2 5.3 5.1 5.0 4.8 4.7 4.5 4.2

/2 6.1 5.9 5.7 5.6 5.4 5.2 4.9

3 6.7 6.5 6.3 6.1 6.0 5.8 5.4

4 7.7 7.4 7.2 7.0 6.8 6.6 6.2

6 9.4 9.1 8.8 8.6 8.3 8.1 7.5

8 10.8 10.5 10.2 9.9 9.6 9.3 8.7

10 12.2 11.8 11.5 11.1 10.8 10.5 9.8

12 13.4 13.0 12.7 12.3 11.9 11.5 10.6

14 14.2 13.8 13.4 13.0 12.6 12.2 11.3

16 15.5 15.1 14.6 14.2 13.8 13.4 12.1

*based on a sag limit of 0.2% of span length.

Note 1: Greater than 200ºF requires continuous support. Note 2: Bearing Surface of supports should be at least 2" wide.

When the fluid has a specific gravity greater than water (1.0) the hanging distance must be decreased by multiplying the recommended support distance by the appropriate correction factor.

Page 70

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Pipe Rings

Adj. Swivel Ring

Split Ring type

/4" to 8" pipe

Split Ring

/8" - 8" pipe

Adj. Ring

/2" - 8" pipe

Adj. Swivel Ring

/2" - 8" pipe

Adj. Clevis -

Standard

/2" - 30" pipe

Adj. Clevis For

Insulated Lines

/4" - 12" pipe

Pipe Rolls

Adj. Steel Yoke Pipe Roll

21/2" - 20" pipe

Adj. Swivel Pipe Roll

21/2" - 12" pipe

Single Pipe Roll

1" - 30" pipe

Adj. Pipe Roll Support

1" - 30" pipe

Roller Chair

2" - 12" pipe

Pipe Roll and Plate

2" - 24" pipe

Pipe Roll Stand Complete

2" - 42" pipe

Pipe Straps and Hooks

Wrought Strap Short

/2" - 4" pipe

One Hole Clamp

/8" - 4" pipe

Tin Strap

/2" - 2" pipe

Figure 9 – Recommended Pipe Hangers for Thermoplastic Piping Systems

Saddle Clip - PVC or

Polypropylene

/8" - 4" pipe

Pipe Clips

All pipe clips should permit free axial pipe movement at all temperatures and should provide adequate bearing support to the pipe. Metal clips and supports should be free of sharp edges to prevent damaging the pipe.

IPEX Cobra Pipe Clip -

Polyethylene

/8" - 4" pipe

Page 71

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Pipe Clamps

Pipe Clamp Medium

/2" - 24" pipe

Double Bolt Pipe Clamp

/4" - 36" pipe

Pipe Covering

Insulation Protection Shield

/2" - 24" pipe

Bolt

U Bolt*

Standard: 1/2" - 30" pipe

Light Weight: 1/2" - 10" pipe

*Also available plastic coated.

Note: Clamps used as anchors (such as U-bolts, etc.), if over-tightened, can produce a point-of-load stress on the pipe. This can result in cracking or premature burst failure. If U-bolts must be used, then a metal shield should be placed between the U-bolt and pipe surface. When anchoring plastic pipe, it is always desirable to spread the load over a wide area of contact.

Page 72

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Introduction

All buried piping systems are subjected to both internal and external loads. Internal loading is related to the requirements of the medium being carried and the material properties of the pipe as discussed previously in the Design section. For external loads, vinyl pipe is considered flexible (able to bend without breaking) and uses the pipe wall and the surrounding soil medium to support external loads. In other words, the soil and pipe form an integral structure. Depending on the loading characteristics, the pipe will either deflect or compress.

The external loads that need to be determined are earth, static and dynamic. Detail on determining external load characteristics is beyond the scope of this manual. For further information on determining load characteristics, the user is directed to other engineering textbooks such as the Uni–Bell Handbook of PVC Pipe.

Trench Preparation

Engineering documents for a project will specify the correct line and grade for the trench, however it is important to keep a few things in mind during the trenching operation.

Although the width at the top of the trench is generally dictated by local conditions, the width in the pipe zone should be as narrow as practical. The general rule is that the maximum width at the top of the pipe should not be more than the outside diameter of the pipe plus 24 inches. If trench width cannot be controlled and will exceed the maximum, then compacted backfill must be provided for a distance of 2

/2 pipe diameters on either side of the pipe to the trench wall for pipe sizes up to 10 inches. For larger size pipe (14" to 24"), the compacted haunching material should be placed one pipe diameter or 24 inches (whichever is greater) to either side of the pipe.

Trench Depth

As mentioned in the Design section of this manual, thermoplastic pipe will tend to deflect rather than crack under loading. The amount of deflection can be derived from the depth of burial, pipe stiffness and the amount of loading (e.g. soil, traffic) on the pipe. Although the maximum allowable deflection is 7.5% at a 4:1 safety factor, critical buckling occurs at 30%. For a given situation, the actual deflection and burial depth can be calculated.

For more detail regarding burial depth and estimating deflection under different conditions, consult your IPEX representative.

Minimum Cover

Although the project may have specifications for the required depth of burial, the following guidelines for minimum cover may prove helpful:

• Pipe should be placed 6 inches below the frost line

• For expected truck traffic (live loading - Highway H20), use a minimum cover of 12 inches (or 1 pipe diameter, whichever is greater) providing a minimum soil stiffness of E' = 1000.

• For expected heavy truck or train traffic, (live loading Railway E80) use a minimum cover of 36 inches (or 1 pipe diameter, whichever is greater) providing a minimum soil stiffness of E' = 1000.

Maximum Cover

Pipe that is buried too deeply is also not advisable for reasons of cost and loading. For the maximum recommended cover, refer to Table 37.

Table 37 – Maximum Recommended Cover

* as per ASTM D2321

Source: Uni–Bell Plastic Pipe Association

INSTALLATION OF BURIED PIPES

Standard E'

Soil* Proctor Modulus Maximum

Class Density of Soil Height of

Range (%) Reaction (psi) Cover (ft)

I - 3000 50

II 85-95 2000 50

75-85 1000 50 65-75 200 17

III 85-95 1000 50

75-85 400 28 65-75 100 12

IV 85-95 400 28

75-85 200 17 65-75 50 9

Vinyl Process Piping Systems

Pipe

Zone

Initial Backfill

of Pipe

Springline

Haunching

Bedding

Pipe Embedment

Foundation

(may not be required)

Page 73

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Trench Bottom

To properly support the pipe, the trench bottom should be continuous, relatively smooth, and free of rocks. Where hardpan or boulders are encountered, the trench bottom should be padded using a minimum of 4" of crushed rock or sand beneath the pipe. Frozen material should not be used to either support or bed the pipe.

Where the soil medium is unstable, (e.g. organic material), the trench bottom should be over excavated and brought back to grade with suitable material.

Placing the Pipe

The pipe and fittings should be placed into the trench using ropes and skids, slings on a backhoe bucket or by hand. Do not throw or drop the pipe or fittings into the trench, as damage may result. Particular care should be taken when handling pipe in cold weather, as the material is less impact resistant at reduced temperatures. Before assembly ensure that all materials are in good condition.

Snaking of Pipe

After the PVC and CPVC pipe has been solvent welded, it is advisable to snake the pipe beside the trench according to the following recommendation. BE ESPECIALLY CAREFUL NOT TO APPLY ANY STRESS THAT WILL DISTURB THE UNDRIED JOINT. This snaking is necessary in order to allow for any anticipated thermal contraction that will take place in the newly joined pipeline.

Loop Offset in Inches for Contraction

Snaking is particularly necessary on the lengths that have been solvent welded during the late afternoon of a hot summer’s day, because their drying time will extend through the cool of the night when thermal contraction of the pipe could stress the joints to the point of pull out. This snaking is also especially necessary with pipe that is layed in its trench (necessitating wider trenches than recommended) and is back-filled with cool earth before the joints are thoroughly dry.

Assembly

Assemble joints in accordance with instructions found in the Installation section under Joining methods.

Resisting Thrust

For buried pressure pipe applications, thrust forces can occur at any point in a piping system where the directional or cross-sectional area of the waterway changes. These forces must be reduced by means of concrete thrust blocks or concrete encasement. This can be accomplished by pouring concrete into appropriately sized forms at each point in the line where thrust forces will develop. The concrete block must be placed between the fitting and the undisturbed native soil at the side of the trench.

For more detail regarding estimating and compensating for thrust forces, refer to the IPEX Installation Guide and engineering textbooks such as the

Uni–Bell Handbook of

PVC Pipe.

Offset

Loop Length

2 Loop Lengths

Pipe Centerline

Pipe Snaking

Maximum Temperature Variation, ºF

Between Time of Solvent and Final Use

Degrees

Loop Length

20' 50' 100'

10 3" 7" 13"

20 4" 9" 18"

30 5" 11" 22"

40 5" 13" 26"

50 6" 14" 29"

60 6" 16" 32"

70 7" 17" 35"

80 7" 18" 37"

90 8" 19" 40"

100 8" 20" 42"

Page 74

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Initial Backfilling

Initial backfilling is done by covering the pipe to a depth of 6" to 12" with proper backfill material that is free from rocks, sharp objects, debris or particles larger than 3". Add layers in 6" increments ensuring that the proper compaction levels are reached for each and backfill until there is 6" to 12" of cover over the crest of the pipe.

Ensure that all joints remain exposed for visual inspection. Leave the piping to settle and normalize dimensionally then check all joints for tightness. If the piping is satisfactory then tamp the initial backfill layer.

Note 1: While tamping, ensure that the pipe alignment, both vertical and horizontal, is not disturbed.

Note 2: During hot weather it is recommended that backfilling be done in the cooler morning hours when the piping is fully contracted to avoid improper compaction due to pipe expansion.

System Testing

After the system has been assembled and initially backfilled, the system must be tested for leaks. Note that the pipe must be sufficiently backfilled to prevent movement during testing.

Conduct a pressure test as per the testing procedure in this manual in the Installation section under Testing. If the test is passed, the system can be covered. If not, make the necessary repairs and test again until the system is sound.

Compacting the Final Backfill

Final backfilling is the material that is placed over the initial backfill to the top of the trench.

Compact the haunching, initial backfill and final backfill using manual equipment in accordance with the job drawings. Observe the following precautions.

1) When a “self-compacting” material is used, such as

crushed stone, ensure that the material does not arch or bridge beneath the haunch of the pipe. Remove such voids with the tip of a spade.

2) When compacting the material underneath and at either

side of the pipe do not allow the tool or the machine to strike the pipe.

3) When compaction in excess of 85% standard proctor

density is required in the haunching area ensure that the compacting effort does not dislodge the pipe from the correct grade. If the compacting effort dislodges the pipe, re-lay the pipe to the correct grade.

4) It is not necessary to compact the initial backfill directly

over the top of the pipe for the sake of the pipe’s structural strength. However, it may be necessary for the sake of roadway integrity.

5) When laying long runs of piping in elevated air

temperatures, it is advisable to begin working from a fixed point – such as the entry or exit from a building, and work away from that point, testing and backfilling in accordance with preceding paragraphs. This procedure should then allow the piping to assume soil temperature progressively as work proceeds.

Stones no greater than 6 inch (150 mm) diameter

TAMP

6 - 12 Inches Min.

TAMP

Final Backfill

Initial Backfill

Haunchin

Bedding

Page 75

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Site Pressure Testing

The purpose of an onsite pressure test is to establish that the installed section of line, and in particular all joints and fittings, will withstand the design working pressure, plus a safety margin, without loss of pressure or fluid.

Generally a test pressure of 1

/2 times the safe working pressure for the pipe installed is adequate. Whenever possible, it is recommended that hydrostatic testing be carried out. It is suggested that the following hydrostatic test procedure be followed after the solvent-welded joints have been allowed to cure for a minimum period of 24 hours at 73ºF (23ºC) (timed from the cure of last joint). For more detail, refer to the joint cure schedules in Table 22 in the Installation section.

Hydrostatic Test Procedure

1) Fully inspect the installed piping for evidence of

mechanical abuse and/or dry suspect joints.

2) Split the system into convenient test sections not

exceeding 1,000 ft.

3) Slowly fill the pipe section with water, preferably at a

velocity of 1.0 fps or less. Any entrapped air should be evacuated by venting from the high points. Do not pressurize at this stage.

4) Leave the section for at least 1 hour to allow equilibrium

temperature to be achieved.

5) Check the system for leaks. If clear, check for and

remove any remaining air and increase pressure up to 50 psi. Do not pressurize further at this stage.

6) Leave the section pressurized for 10 minutes. If the

pressure decays, inspect for leaks. If the pressure remains constant, slowly increase the hydrostatic pressure to 1

/2 times the nominal working pressure.

7) Leave the section pressurized for a period not exceeding

1 hour. During this time, the pressure should not change.

If there is a significant drop in static pressure or extended times are required to achieve pressure, either joint leakage has occurred or air remains in the line. Inspect for leakage and if none is apparent, reduce the pressure and check for trapped air. This must be removed before further testing.

Any joint leaks should be repaired and allowed to cure fully before re-pressurizing for a minimum of 24 hours.

TESTING

• NEVER use compressed air or gas in PVC/CPVC/PP/PVDF

pipe and fittings.

• NEVER test PVC/CPVC/PP/PVDF pipe and fittings with

compressed air or gas, or air-over-water boosters.

• ONLY use PVC/CPVC/PP/PVDF pipe for water and

approved chemicals.

Use of compressed air or gas in PVC/CPVC/PP/PVDF pipe and fittings can result in explosive failures and cause severe injury or death.

WARNING

Page 76

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

REPAIRS

Repairs Below Ground

Defective joints or damaged sections in pipes below ground may be repaired quickly and easily using gasketed repair couplings as follows:

1) Cut out the damaged section (minimum 18 inches long).

2) File the ends square and chamfer by 45° to assist entry of pipe into the fitting.

3) Measure gap and cut new section of pipe to the measured length minus ¼ inches.

4) Prepare ends of this new pipe to a 45° chamfer.

5) Clean the existing and new pipe. Do not abrade.

6) Push o-ring repair couplings onto the exposed ends of the existing pipe.

7) Insert new pipe into the gap.

8) Draw repair couplings on the new pipe so that the joint between pipes is at the center of the coupling.

Note 1: Do not use solvent cement, or primer MEK cleaner with gasketed repair couplings.

Note 2: The pipe route should be examined to ensure that axial movement of the pipes will not take place upon pressurizing the system. If this seems likely, suitable anchors must be provided to resist the thrusts that occur under pressure.

Joint Repairs

Taking into consideration the cost of materials, time involved and labor costs, in most cases the installer is better off cutting out the defective joint, replacing it with new materials and taking greater care in the joining process.

However, fillet welding of a minor leak in a joint is possible.

Page 77

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Repairing Thermoplastic Pipe Joints

Scope

The most common method for repairing faulty and leaking joints is hot gas welding at the fillet formed by the fitting socket entrance and the pipe. Fillet welding of thermoplastics is quite similar to the acetylene welding or brazing process used with metals. The fundamental differences are that the plastic rod must always be the same basic material as the pieces to be joined and heated gas, rather than burning gas, is used to melt the rod and adjacent surfaces.

Welding with plastics involves only surface melting because plastics, unlike metals, must never be “puddled”. Therefore the resulting weld is not as strong as the parent pipe and fitting material. This being the case, fillet welding as a repair technique is recommended for minor leaks only. It is not recommended as a primary joining technique for pressure rated systems.

Welding Tools and Materials

• Plastic welding gun with pressure regulator, gauge and hose

• Filler rod

• Emery cloth

• Cotton rags

• Cutting pliers

• Hand grinder (optional)

• Compressed air supply or bottled nitrogen (see Caution)

• Source of compressed air

Weld Area Preparation

Wipe all dirt, oil and moisture from the joint area. A very mild solvent may be necessary to remove oil.

CAUTION: Make sure that all liquid has been removed from the portion of the piping system where the weld is to be made.

Welding Faulty Joints

1. Remove residual solvent cement from the weld area using emery cloth. When welding threaded joints, a file can be used to remove threads in the weld area.

2. Wipe the weld area clean of dust, dirt and moisture.

3. Determine the mount of the correct filler rod (see Table) necessary to make one complete pass around the joint by wrapping the rod around the pipe to be welded. Increase this length enough to allow for handling the rod at the end of pass.

4. Make about a 60º angular cut on the lead end of the filler rod. This will make it easier to initiate melting and will insure fusion of the rod and base material at the beginning of the weld.

5. Welding temperatures vary for different thermoplastic materials (500ºF – 550ºF (260ºC - 288ºC) for PVC and CPVC). Welding temperatures can be adjusted for the various thermoplastic materials as well as any desired welding rate by adjusting the pressure regulator (which controls the gas flow rate) between 3 and 8 psi.

CAUTION: For welding guns which require compressed gas, nitrogen is preferred when the compressed plant air system does not contain adequate drying and filtrations.

Because of its economy, compressed air is normally the gas of choice for most plastic welding. A welding gun which generates its own air supply is frequently desirable for fieldmade pipe joints where ultimate weld strength is not required. For welding guns which require compressed gas, nitrogen is preferable when the compressed plant air system does not contain adequate drying and filtration. (Presence of moisture in the gas stream causes premature failure in the heater element of the welding gun. Impurities in the gas stream, particularly those in oil, may oxidize the plastic polymer, resulting in loss of strength. Polypropylene is known to be affected in this manner.)

6. With air or inert gas flowing through the welding gun, insert the electrical plug for the heating element into an appropriate electrical socket to facilitate heating of the gas and wait approximately 7 minutes for the welding gas to reach the proper temperature.

CAUTION: The metal barrel of the welding gun houses the heating element so it can attain extremely high temperatures. Avoid contact with the barrel and do not allow it to contact any combustible materials.

Page 78

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Filler rod size and number of weld passes required to make a good plastic weld are dependent upon the size of the pipe to be welded as presented below:

Pipe Sizes (in) Rod Sizes (in) Number of Passes

1/2 - 3/4 3/32 3

1 - 2 1/8 3

2-1/2 - 4 3/16 3

6 - 8 3/16 5

10 - 12 3/16 5

7. Place the leading end of the filler rod through the speed tip opening and into the fillet formed by the junction of the pipe and fitting socket entrance. Holding the weld tip at a 45º angle to the fitting, slowly move the weld tip across the area to be welded while applying a slight pressure by pushing the rod from the inlet side. The weld tip should be approximately

/4" to 1/2" away from the material.

8. End each pass by mating the rod end to the starting point. Do not overlap on top or to the side of the start point. Each weld end should match perfectly with the starting point.

9. When welding large diameter pipe, more than three weld passes may be required. The first bead should be deposited at the bottom of the fillet and subsequent beads should be deposited on each side of the first bead. When making multiple pass welds, the starting points for each bead should be staggered and ample time must be allowed for each weld to cool before proceeding with additional welds.

10. Properly applied plastic welds can be recognized by the presence of small flow lines or waves on both sides of the deposited bead. This indicates that sufficient heat was applied to the surfaces of the rod and base materials to effect adequate melting and that sufficient pressure was applied to the rod to force the rod melt to fuse with base material melt. If insufficient heat is used when welding PVC or CPVC the filler rod will appear in its original form and can easily be pulled away from the base material. Excessive heat will result in a brown or black discoloration of the weld.

Welding Principles

The procedures for making good thermoplastic welds can be summarized into four basic essentials:

• Correct Heating Excessive heating will char or overmelt. Insufficient heating will result in incomplete melting.

• Correct Pressure Excessive pressure can result in stress cracking when the weld cools. Insufficient pressure will result in incomplete fusion of the rod material with the base material.

• Correct Angle Incorrect rod angle during welding will stretch the rod and the rod material with the base material.

• Correct Speed Excessive welding speed will stretch the weld bead and the finished weld will crack upon cooling.

Page 79

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Entrapped Air

Air entrapment in pressure pipelines is a much studied and discussed topic. Most designers are concerned about it but may not understand the full implications of the problem or the processes used to reduce the dangers associated with entrapped air. The problem with entrapped air is that it is a complex issue. The behavior of air in a piping system is not easy to analyze, but the effects can be devastating.

Sources of Air in Pipelines

There are many potential sources for air in pipelines and the sources are usually multiple in any given system. The most likely source occurs during filling, either initially or when refilled after drainage. In some systems, air re-enters each time the pumps are shut off as the pipelines drain through low lying sprinklers or open valves.

Air is often introduced at the point where water enters the system. This is an especially common problem with gravity fed pipelines, but may occur with pumped systems as well. Even water pumped from deep wells may be subject to air entering from cascading water in the well.

A less obvious source of air comes from the release of dissolved air in the water, due to changes in temperature and/or pressure. The quantities may be small in this case, but accumulations over time can create problems.

It is also common for air to enter through mechanical air release valves or vacuum breakers when the pressure drops below atmospheric pressure. This can occur during pump shutdown or during negative surges.

Why is Entrapped Air a Problem?

Air in a piping system tends to accumulate at high points during low flow or static conditions. As the flowrate increases, the air can be forced along the pipeline by the moving water and may become lodged at the more extreme high points where it reduces the area available for flow. Thus, these pockets of air cause flow restrictions that reduce the efficiency and performance of the system.

As an air pocket grows, the velocity past that point increases until eventually the air is swept on toward an outlet. While line restrictions are problems, a more serious situation can occur when air is rapidly vented from the system under pressure. Water is about five times more dense than air at 100 psi, so when a pocket of compressed air reaches an outlet, such as a sprinkler head or air release valve, it escapes very rapidly. As it escapes, water rushes in to replace the void.

When water reaches the opening, the velocity suddenly decreases, since air escapes about five times faster than water at 100 psi. The result is similar to instantaneous valve closure, except that the velocity change can far exceed the normal flow velocity in the pipeline. During tests at Colorado State University, pressure surges up to 15 times the operating pressure have been recorded when entrapped air was rapidly vented under pressure. Such pressure surges can easily exceed the strength of the system components and even at lower magnitudes, repeated surges will weaken the system over time.

Dealing with Entrapped Air

Obviously, the best way to reduce problems caused by entrapped air would be to prevent it from entering the system. Precautions should be taken to eliminate air entrance. When systems are filled, either initially or after draining for winterization or repair, they should be filled slowly, at a velocity of 1.0 fps or less, and the air should be vented from the high points before the system is pressurized. Even with these precautions, some air can remain in the system.

To deal with this remaining air or newly admitted air generated by the process itself, one or more continuous-acting air relief valves should be incorporated in the line. One solution would be to use manual vent valves such as ball valves. This solution is not ideal as strategically positioned manual vent valves can deal with entrapped air at startup, but will not deal automatically or effectively with recurring air entrapment problems. In addition, manually operated vents will inevitably lead to spills potentially resulting in site contamination or operator injury (depending on the carried media).

To ensure an effective means of dealing with entrapped air, continuous acting valves should be the preferred choice. Continuous-acting valves contain a float mechanism which allows the air to vent through a small orifice, even when the line is pressurized.

Also available on the market are combination air-release/vacuum braking valves. These products have dual functions. For example, when a tank is being filled, the entrapped air is allowed to escape and the liquid is allowed to rush in unopposed by air pockets. When the process is reversed, during the draining of a tank, the valve shutting mechanism opens the valve allowing air to rush in and replace the volume previously held by the liquid, thus preventing the formation of a potentially damaging vacuum.

IPEX offers the VA Air Release valve, a piston style air-release/vacuum breaker valve in

/4", 11/4" and 2" sizes. It is important to note that the open and close functions of this ‘smart’ valve are controlled by media and not pressure as in other air-release valves. This feature provides several advantages. No minimum pressure or vacuum is required to either open or close the valve, thus guaranteeing responsiveness in any and all conditions while eliminating the potential for spillage.

INSTALLATION CONSIDERATIONS

Page 80

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Ultraviolet Light

UV sterilizers for killing bacteria in de-ionized water are common. Over time, the intense light generated by these sterilizers will stress crack PVC and CPVC pipe directly connected to the sterilizer. To minimize this problem, a transition trap between the sterilizer and the vinyl pipe is recommended.

Ozone

Ozone (O3) is a form of oxygen. In its pure form, it is an unstable blue gas with a pungent odor. Ozone is used as a

bactericide in de-ionized water systems in low concentrations of 0.04 to 5 ppm. It presents no problem to thermoplastic piping in aqueous form.

Note: Ozone in gaseous form should not be used with PVC or CPVC pipe.

Commercial mixtures are ordinarily 2% ozone and are produced by the electronic irradiation of air. It is usually manufactured on the spot, as it is too costly to ship.

Butyl rubber and ethylene propylene rubber (EPDM) have good resistance to ozone, as does fluorine rubber (Viton) and chlorosulfonated polyethylene (Hypalon). NEOPRENE AND BUNA-N OR NITRILE ARE SEVERELY ATTACKED.

Chemical Resistance

Pipe, Valves and Fittings

Thermoplastics have outstanding resistance to a wide range of chemical reagents. Such resistance is a function of both temperature and concentration, and there are many reagents which can be handled for limited temperature ranges and concentrations. In borderline cases, there may be limited attack, generally resulting in some swelling due to absorption. There are also many cases where some attack will occur under specific conditions. For such applications, the use of plastic is justified on economic grounds when considered against alternative materials. Chemical resistance is often affected (and frequently reduced) when handling a number of chemicals or compounds containing impurities. When specific applications are being considered, it is often worthwhile to conduct tests using the actual fluid that will be used in service.

In general, PVC is suitable with most strong acids, alkalis, aqueous solutions, aliphatic hydrocarbons, fluorides, photographic and plating solutions, brine and mineral oils. It should not be used with aldehydes and ketones, ethers, esters or aromatic and chlorinated hydrocarbons.

CPVC has a chemical resistance similar to or marginally better than PVC.

Gaskets and Seals

EPDM has excellent resistance to oxidation products but will show a certain swelling when in contact with mineral and petroleum oils, diester base lubricants and organic solvents.

Nitrile is a general purpose oil resistant polymer known as nitrile rubber. Nitrile is a copolymer of butadiene and acrylonitrile. Nitrile has good solvent, oil, water and hydraulic fluid resistance. It displays good compression set, abrasion resistance and tensile strength. Nitirle should not be used with highly polar solvents such as acetone and methyl ethyl ketone, nor should it be used with chlorinated hydrocarbons, ozone or nitro hydrocarbons. Temperature ranges from

-65°F (-54°C) to 275°F (135°C).

FPM (Viton) has excellent resistance to chemical agents. It is virtually inert to oil and most solvents and it also exhibits good chemical capability with many aromatic and aliphatic hydrocarbons.

Please refer to the IPEX Chemical Resistance Guide for specific applications.

Heat Tracing

Although thermoplastic pipes are poor conductors of heat, heat tracing may be necessary to maintain a constant elevated temperature for a viscous liquid, to prevent liquid from freezing, or to prevent a liquid such as 50% sodium hydroxide, from crystallizing in a pipeline. Electric heat tracing with self-regulating temperature-sensing tape will maintain a 90°F (32ºC). temperature to prevent sodium hydroxide from freezing. The tape should be S-patternwrapped on the pipe, allowing for pipe repairs and avoiding deflection caused by heating one side of the pipe.

Heat tracing should be applied directly on the pipe within the insulation, and must not exceed the temperature, pressure or chemical resistance design of the system.

In some cases, it may be necessary to install 2 or more cables with reduced output to ensure a more even heat distribution and penetration without exceeding the maximum operating temperature of the pipe.

Page 81

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

INSTALLATION

Vinyl Process Piping Systems

Tapping for Instrumentation Connections

For applications that require tapping PVC systems for instrumentation connections, the following guidelines should be followed:

a. Hole drilling and tapping should be performed while the

system is non-pressurized.

b. IPEX recommends using schedule 80 pipe and fittings

to maximize wall thickness.

c. Tapping should be done by drilling through the area where

the pipe and fitting socket overlap. This area will have maximum wall thickness to allow for sufficient threads.

d. Teflon

(PTFE) tape or an IPEX approved thread sealant

should be used for sealing threads.

Listed below are the pipe sizes and maximum connection sizes that may be used:

Direct Tapping

For applications that require direct tapping of existing PVC lines, the following guidelines should be followed:

a. Hole drilling and tapping should be performed while the

line is non-pressurized.

b. Direct tapping should only be performed on Schedule 80

pipe:

i. IPEX does not recommend direct tapping 1/4" to 2"

pipe sizes.

ii. Hole sizes should be no greater than 1/2" NPT for

2-1/2" to 4" pipe sizes.

iii. Hole sizes should be no greater than 1" NPT for

6" and greater pipe sizes.

c. Taps should be made at least 3 feet from the end of the

pipe (unless tapping through a fitting socket into pipe)

d. Teflon

(PTFE) tape or an IPEX approved thread sealant

should be used for sealing threads.

e. Where saddle connections are required, hole sizing should

be no larger than one half of the nominal pipe size:

i. When assembling Saddles to PVC pipe, IPEX

recommends Industrial Polychemical Service (IPS) #719 cement, or equivalent.

ii. Although good connections may be accomplished

without Saddle Straps, IPEX recommends the use of a clamp or strap device during the assembly step to ensure good compression between the pipe and fitting surfaces as the solvent cures.

For further details, please contact your IPEX representative.

These recommendations should always be referenced against local plumbing and mechanical codes as well as the local authority having jurisdiction.

Static Electricity

The non-conductive properties of thermoplastic piping materials, such as PVC and CPVC, are generally considered advantageous, particularly in electrical or electronic applications. In certain other applications these properties are considered a disadvantage, as the flowing media can allow electrostatic charges to be generated and accumulated. The potential exists for charges to accumulate to the point of becoming sources of ignition that can create sparks.

Static electricity (electrostatic charge) is generated by the separation and insulation of like bodies. In general this occurs during the transport of dry bulk solids, powders and slurries. In the case of powders, electrical charge can accumulate on several items in the piping process, including but not limited to the material itself, containers the material is poured into, metal equipment involved in or proximate to the pouring operation, as well as on the operators themselves.

In order to prevent charge from accumulating, all equipment and personnel should be grounded and measures should be taken to directly dissipate any charges by increasing the conductivity of the pipeline. This can be done by several methods, including:

• Coating the pipe surfaces with a solvent-free conductive metallic powder coating then grounding the pipe.

• Wrapping conductive wire around the pipe for the entire length of pipe and then running it to ground.

• Increasing the relative atmospheric humidity. A thin film of moisture on the pipe will improve conductivity. Although this is a somewhat temporary measure, the film can be made more intact by treating the pipeline surface with a compatible hygroscopic (water loving) soap.

Pipe Size Size of Connection

1/4" to 2"

Use tees, reducer bushings,

and threaded fittings

2-1/2" to 4" Max tapping 1/2" NPT

6" and greater Max tapping 1" NPT

A tap should never be made through the wall of the fitting alone.

Page 82

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIALTY PIPING PRODUCTS

Vinyl Process Piping Systems

SECTION FOUR: SPECIALTY PIPING PRODUCTS

IPEX bell end PVC well casing provides corrosion-resistant, maintenance-free protection for well drop-pipe and submersible pumps. Its light weight facilitates installation with conventional tools and piping techniques. It is manufactured to ASTM standards and is available throughout North America from IPEX’s fully stocked service centers.

Features

• Meets ASTM D 1784, D 1785, D 2665*, and F 480 specifications.

• Third-party certified by NSF.

• Solvent weld joints are strong and water tight.

• Installation can be accomplished with lighter setting equipment than is required for metallic piping.

• Electrically non-conductive which reduces job site work hazards.

• Non-toxic and non-leaching with excellent chemical resistance.

• Available in bell end 2" - 16" or plain end for threading 2" - 12".

Table 38 – Dimensions for Xirtec140 PVC Well Casing Pipe – ASTM F480

Pipe Size Outside Diameter (in.) Minimum Wall Thickness (in.) Bell Length

(in.) Average Tolerance SDR21 Sch 40 Sch 80 (in.)

on Average

2 2.375 ±0.006 0.113 0.154 0.218 4.000

/2 2.875 ±0.007 0.137 0.203 0.276 5.000

3 3.500 ±0.008 0.167 0.216 0.300 5.500

4 4.500 ±0.009 0.214 0.237 0.337 6.500

5 5.563 ±0.010 0.265 0.258 0.375 6.000

6 6.625 ±0.011 0.316 0.280 0.432 8.000

8 8.625 ±0.015 0.410 0.322 0.500 7.000

10 10.750 ±0.015 0.511 0.365 0.593 7.500

12 12.750 ±0.015 0.606 0.406 0.687 8.500

14 14.000 ±0.020 0.667 0.437 0.750 9.000

16 16.000 ±0.020 0.762 0.500 0.843 10.000

PVC Well Casing – ASTM F 480

* only available in select markets. Contact you local IPEX office for further information

* schedule 40 pipe only

Page 83

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIALTY PIPING PRODUCTS

Vinyl Process Piping Systems

PVC & CPVC Exhaust System Ducting

IPEX PVC & CPVC exhaust system ducting provides effective solutions for industrial ventilation systems, protecting workers and the environment from contaminated air.

PVC Features

• Extruded seamless PVC duct in all standard diameters 6" through 24"

• PVC cell class 12454 as per ASTM D1784

• For use in industrial and institutional fume handling systems requiring high resistance to corrosive vapors

• Ideal for plating, metal finishing and laboratory installations

• Low installed cost as compared to noncorrosive metallics

• Light weight allows longer runs and speeds installation with simple tools and piping techniques

• Low maintenance requirements over extended service periods

• Low flame spread rating of 10 as per CAN/ULC S102.2

CPVC Features

• Extruded seamless CPVC duct in all standard diameters 6" through 16"

• CPVC withstands exhaust temperatures up to 200°F

• CPVC cell class 23447 as per ASTM 1784

• CPVC is inert to most mineral acids, bases, salts, and aliphatic hydrocarbons, and compares favorably to other non-metals in corrosive chemical environments.

• Ideal for chemical processing, semiconductor fabrication, metal plating & finishing, pulp & paper, waste water treatment plants, and laboratory installations

• Low installed cost as compared to non-corrosive exotic metal systems and PVDF

• Light weight allows for ease of handling and installation and reduces transportation and labor costs

• Low maintenance requirements over extended service periods

• Low flame spread rating of 10 and smoke development classification of 25 as per CAN/ULC S102.2

• Corzan

CPVC compound meets and is listed FM 4910 “Clean Room Materials Flammability Test Protocol” approval standard

CAUTION

1. A significant charge of static electricity can be generated by the flow of air through plastic duct, particularly under very dry conditions. If combustible particles or gases are being transported, then various electrical ground techniques must be applied. An expert in this area should be consulted during the design phase.

2. The need for closed-head sprinkler systems may be necessary if combustible residues or oxidizable materials are likely to accumulate in the duct work over a period of time.

3. Chemical resistance and operating temperatures must be evaluated in the same manner as for standard PVC & CPVC pipe. When in doubt, consult your local IPEX customer service center.

Duct Size (diameter

in inches)

Average

O.D.

(in.)

Average

I.D.

(in.)

Average

Wall

Thickness

(in.)

Weight (lbs/ft)

PVC

Weight

(lbs/ft)

CPVC

6 6.625 6.251 0.187 2.319 2.519

8 8.625 8.251 0.187 3.040 3.301

10 10.750 10.376 0.187 3.805 4.133

12 12.750 12.376 0.187 4.528 4.916

14 14.000 13.626 0.187 4.978 5.405

16 16.000 15.626 0.187 5.697 6.188

18 18.000 17.626 0.187 6.420 –

20 20.000 19.500 0.250 9.515 –

24 24.000 23.500 0.250 11.442 –

Table 39 – PVC & CPVC Duct Dimensions

* CPVC Duct only available up to 16" diameter.

Page 84

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

SECTION FIVE: SPECIFICATIONS

STANDARDS

Standards exist to ensure that thermoplastic piping systems meet the required level of performance for a particular application. IPEX engineers and technical staff actively participate in thermoplastic standards development throughout North America. These activities result in new standards and improvements to existing standards for thermoplastic piping.

Standards Organizations

IPEX products comply with standards developed by several standards organizations. Additional information on standards and compliance can be obtained by contacting the following organizations.

CSA International, www.csa.ca 5060 Spectrum Way, Mississauga, Ontario Canada L4W 5N6

ASTM International, www.astm.org 100 Barr Harbor Drive, West Conshohocken, Pennsylvania USA 19428-2959

Underwriters Laboratories of Canada, www.ulc.ca 7 Underwriters Rd, Toronto, Ontario Canada M1R 3B4

NSF International, www.nsf.org P.O. Box 130140, 789 N. Dixboro Rd, Ann Arbor, Michigan USA 48113-0140

Applicable Standards

The following is a list of applicable standards for IPEX PVC and CPVC piping systems. This list is up-to-date at the time of printing.

ASTM

Standard Specifications for Terminology Relating to Plastics

D883 Terminology Relating to Plastics

D1600 Terminology for Abbreviated Terms Relating to Plastics

F412 Terminology Relating to Plastic Piping Systems

D2749 Standard Symbols for Dimensions of Plastic Pipe Fittings

Standard Specifications for Plastic Materials

D1784 Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds

D2564 Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Piping Systems

D2672 Joints for IPS PVC Pipe Using Solvent Cement

D3138 Solvent Cements for Transition Joints Between Acrylonitrile-Butadiene-Styrene (ABS) and Poly (Vinyl

Chloride) (PVC) Non-Pressure Piping Components

D3915 Rigid Poly (Vinyl Chloride) (PVC) and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds for Plastic

Pipe and Fittings used in Pressure Applications

D4396 Rigid Poly (Vinyl Chloride) (PVC) and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds for Plastic

Pipe and Fittings Used in Nonpressure Applications

F493 Solvent Cements for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe and Fittings

F656 Primers for Use in Solvent Cement Joints of Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings

Page 85

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

Standard Specifications for Plastic Pipe Fittings

D2464 Threaded Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings Schedule 80

D2466 Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40

D2467 Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80

D2665 Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste and Vent Pipe and Fittings

F437 Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80

F438 Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 40

F439 Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80

F1803 Poly (Vinyl Chloride) (PVC) Closed Profile Gravity Pipe and Fittings Based on Controlled Inside Diameter

F1866 Poly (Vinyl Chloride) (PVC) Plastic Schedule 40 Drainage and DWV Fabricated Fittings

F1970 Special Engineered Fittings, Appurtenances or Valves for use in Poly (Vinyl Chloride) (PVC) or

Chlorinated Poly (Vinyl Chloride) (CPVC) systems

Standard Specifications for Plastic Pipe

D1785 Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120

D2241 Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series)

D2665 Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings

D3139 Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals

D3212 Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals

F441/ F441M Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80

442/ F442M Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe (SDR-PR)

F477 Elastomeric Seals (Gaskets) for Joining Plastic Pipe

F480 Thermoplastic Well Casing Pipe and Couplings Made in Standard Dimension Ratios (SDR), Sch 40 & Sch 80

F913 Thermoplastic Elastomeric Seals (Gaskets) for Joining Plastic Pipe

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

Standard Specifications for Method of Test

D256 Test Method for Determining the IZOD Pendulum Impact Resistance of Notched Specimens of Plastics

D570 Test Method for Water Absorption of Plastics

D635 Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position

D638 Test Method for Tensile Properties of Plastics

D648 Test Method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position

D790 Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating

Materials

D1598 Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal Pressure

D1599 Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and Fittings

D2122 Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings

D2152 Test Method for Adequacy of Fusion of Extruded Poly (Vinyl Chloride) (PVC) Pipe and Molded Fittings by

Acetone Immersion

D2412 Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate

D2444 Test Method for Determination of Impact Resistance of Thermoplastic Pipe and Fittings by Means of a

Tup (Falling Weight)

D2837 Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials

D3212 Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals

F610/ F610M Evaluating the Quality of Molded Poly (Vinyl Chloride) (PVC) Plastic Fittings by the Heat Reversion

Technique

Standard Specifications for Practices

D543 Practices for Evaluating the Resistance of Plastics to Chemical Reagents

D618 Practice for Conditioning Plastics for Testing

D2321 Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow

Applications

D2855 Practice for Making Solvent-Cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings

D4703 Practice for Compression Molding Thermoplastic Materials into Test Specimens, Plaques or Sheets

F402 Practice for Safe Handling of Solvent Cements, Primers and Cleaners Used for Joining Thermoplastic

Pipe and Fittings

F1057 Practice for Estimating the Quality of Extruded Poly (Vinyl Chloride) (PVC) Pipe by the Heat Reversion

Technique

Page 87

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

ANSI/NSF 14 Plastic Piping System Components and Related Materials

ANSI/NSF 61 Drinking Water System Components – Health Effects

NSF International

CSA International

B137.0 Definitions, General Requirements and Methods of Testing for Thermoplastic Pressure Piping

B137.2 PVC Injection-Molded Gasketed Fittings for Pressure Applications

B137.3 Rigid Polyvinyl Chloride (PVC) Pipe for Pressure Applications

B137.6 CPVC Pipe, Tubing and Fittings for Hot- and Cold-Water Distribution Systems

B181.2 PVC Drain, Waste and Vent Pipe and Pipe Fittings

NFPA/UL/ULC/ASTM – Burning

ASTM E84 Test Method for Surface Burning Characteristics of Building Materials

CAN/ULC S102.2 Surface Burning Characteristics of Flooring, Floor Covering and Miscellaneous Materials

NFPA255 Standard Method of Test of Surface Burning Characteristics of Building Materials

UL 94 Test for Flammability of Plastic Materials for Ports in Devices and Appliances

UL 723 Test for Surface Burning Characteristics of Building Materials

Page 88

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

Xirtec Schedule 40 and 80 PVC Industrial Pipe and Fittings

Scope

This specification sheet covers the manufacturers’ requirements for PVC Schedule 40 and Schedule 80 IPS pressure pipe. The pipe and fittings meet or exceed all applicable ASTM, NSF and CSA standards and are suitable for potable water.

Xirtec140 PVC Materials

Rigid PVC (polyvinyl chloride) used in the extrusion of Schedule 40 & 80 pipe and fittings complies with the material requirements of ASTM D1784 (formerly Type 1, Grade 1) and has a cell classification of 12454. Raw material used in the extrusion shall contain the standard specified amounts of color pigment, stabilizers and other additives. The compounds used are listed to the requirements of NSF 61 for use in potable water service.

Dimensions

Physical dimensions and properties of Xirtec140 PVC Schedule 40 and 80 pipe and fittings shall meet the requirements of ASTM D1785 and/or be certified to CSA B137.3. Socket dimensions of belled end pipe shall meet the requirements of ASTM D2672 or F480.

Marking

Xirtec140 PVC Schedule 40 and 80 pipe is marked as prescribed in ASTM D1785, NSF 14 and/or CSA B137.0/137.3. The marking includes the following: IPEX; Xirtec140; IPS PVC and the Schedule and Pressure Rating at 73°F (23ºC); ASTM D1785; CSA B137.3; NSF 14; and NSF 61 Potable.

Sample Specification

All Xirtec140 PVC Schedule 40 and 80 pipe shall conform to ASTM D1785, NSF 14, and/or CSA B137.0/B137.3. Xirtec140 Schedule 40 fittings shall conform to ASTM D2466. Xirtec140 Schedule 80 socket fittings shall conform to ASTM D2467 and Schedule 80 threaded fittings shall conform to ASTM D2464. All fittings must be third party certified to NSF 14.

All Xirtec Schedule 80 fabricated fittings shall be reinforced with fiberglass reinforced plastic (FRP). All PVC fittings shall be molded or fabricated from Xirtec140 PVC compound compatible with the pipe material.

Only Xirtec140 Schedule 80 pipe shall be threaded and the pressure rating shall be reduced by 50%. Belled end pipe socket dimensions shall conform to ASTM D2672 or F480.

All pipe, fittings and valves shall be compatible Xirtec140 and produced by one manufacturer; as supplied by IPEX.

Corzan Schedule 40 and 80 CPVC Industrial Pipe and Schedule 80 CPVC Fittings

Scope

This specification sheet covers the manufacturers’ requirements for CPVC Schedule 40 and Schedule 80 IPS pressure pipe and Schedule 80 IPS pressure fittings. The pipe and fittings meet or exceed all applicable ASTM and NSF standards and are suitable for potable water.

CPVC Materials

Rigid CPVC (chlorinated polyvinyl chloride) used in the manufacturing of Schedule 40 and 80 pipe complies with the material requirements of ASTM D1784 and has a cell classification of 24448 (23447 from 10" to 16"). Rigid CPVC used in the manufacture of Schedule 80 Fittings shall meet the material requirements of ASTM D1784 and Have a cell classification of 23447 and carry a pressure rating listed by PPI (Plastic Pipe Institute).

Raw material used in the manufacturing shall contain the standard specified amounts of color pigment, stabilizers, and other additives. The compounds used are listed to the requirements of NSF 61 for use in potable water service. The compound must be Corzan grade. The compound must also exhibit a flame spread rating of 10 and a smoke development classification of 25 when tested in accordance with CAN/ULC S102.2.

Dimensions

Physical dimensions and properties of CPVC Schedule 40 and Schedule 80 pipe shall meet or exceed the requirements of ASTM F441.

Physical dimensions and properties of CPVC Schedule 80 fittings – socket type – shall meet the requirements of ASTM F439. Physical dimensions and properties of CPVC Schedule 80 Fittings – threaded type – shall meet the requirements of ASTM F437. Threaded fittings have a taper pipe thread in accordance with ANSI/ASME B1.20.1

Marking

CPVC Schedule 40 and 80 pipe is marked as prescribed in ASTM F441 and NSF 14. The marking includes the following: IPEX; CORZAN 24448 (23447); IPS CPVC and the schedule and pressure rating at 73ºF (23ºC); ASTM F441; NSF 14; and NSF 61 Potable. *** 1-1/4" to 2-1/2" Schedule 80 CPVC pipe is third party certified by NSF to CSA B137.6 ***

CPVC Schedule 80 fittings are marked as prescribed in ASTM F437 and F439. The marking includes the following: IPEX; CPVC and the size of the fitting; ASTM F437 or ASTM F439; NSF 14; and NSF 61 potable.

PRODUCT SPECIFICATIONS

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

SPECIFICATIONS

Vinyl Process Piping Systems

Sample Specification

All CPVC Schedule 80 pipe shall conform to ASTM F441/F441M and be third party certified to NSF 14. All CPVC Schedule 40 and Schedule 80 pipe from 1/2" to 8" shall be made with a CPVC compound having a minimum cell classification of 24448. CPVC Schedule 80 socket fittings shall conform to ASTM F439 and Schedule 80 threaded fittings shall conform to ASTM F437. All fittings must be third party certified to NSF 14. The CPVC fitting compound shall be pressure rated in accordance with ASTM D2387 and have a hydrostatic design basis of 4000 psi at 72F and 1000 psi at 180F as listed in PPI publication TR-4.

All CPVC Schedule 40 and 80 pipe and fittings shall be made from a 4000 psi HDB PPI rated compound. All CPVC Schedule 80 fabricated fittings shall be reinforced with fiberglass reinforced plastic (FRP). All CPVC fittings shall be molded or fabricated from CPVC compound that is compatible with the pipe material.

Only IPEX CPVC Schedule 80 pipe shall be threaded and the pressure rating shall be reduced by 50%. All pipe, fittings and valves shall be compatible, produced using Corzan* compound and be produced by one manufacturer as supplied by IPEX.

Corzan®Full-Pressure Flange Kit

Scope

This specification covers the requirements for a Corzan

High-Pressure Flange Kit, designed and tested for use with a Corzan CPVC one-piece flange. The intent is to bring the pressure bearing capability of a Corzan CPVC one-piece flange connection up to the corresponding pressure rating of Corzan CPVC pipe. The flange kit components are manufactured in North America and meet the requirements set forth by the American Society for Testing Materials (ASTM) F1970. The Corzan CPVC one-piece flanges and Full Pressure – Stress-Saver XP gasket (75-80 Durometer Hardness) are manufactured in North America and meet the requirements set forth by the American Society for Testing Materials (ASTM) F1970 and ANSI/NSF Standard 61.

Materials

CPVC one-piece flanges manufactured by IPEX are molded from Corzan CPVC compounds. Components within Corzan Full-Pressure Flange Kit must not be substituted, the Corzan Full-Pressure Flange Kit contains the following: one (1) Full Pressure – Stress-Saver XP gasket (75-80 Durometer Hardness); one (1) Zinc-Plated Two-Piece Steel Backing Ring, complete with decal stickers informing maintenance personnel of installation requirements; four (4) or eight (8) Grade 8 Yellow Zinc Hex Cap Bolts, depending on bolt pattern of flange; four (4) or eight (8) Grade 8 Yellow Zinc Finished Hex Nuts, depending on number of bolts required; eight (8) or sixteen (16) Zinc Plated Thru Hard High Strength Flat Washers, depending on number of bolts required; one (1) installation manual. The gasket shall be certified by NSF International for use with potable water.

Dimensions and Properties

The pressure bearing capability of a one-piece IPEX Corzan CPVC flange assembled with the IPEX Corzan Full-Pressure Flange Kit meets the requirements of ASTM F1970. The flange kit can only be used with one-piece IPEX Corzan CPVC flange of the same nominal pipe size.

Marking

The marking on the IPEX one-piece Corzan CPVC flange meets the requirements of ASTM Standard F1970. The decal on the flange ring informs the end user of the proper gasket and bolts with which to install the ring, as well as the elevated pressure rating. The flange kit box includes installation instructions.

Page 90

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

PVC SDR Pressure Rated Pipe

Scope

This specification sheet covers the manufacturers’ requirements for PVC Standard Dimension Ratio (SDR) pressure rated pipe. The pipe meets or exceeds all applicable ASTM, NSF and CSA standards and is suitable for potable water.

PVC Materials

Rigid PVC (polyvinyl chloride) used in the extrusion of SDR pressure rated pipe complies with the material requirements of ASTM D1784 (formerly Type 1, Grade 1) and has a cell classification of 12454. Raw material used in the extrusion shall contain the standard specified amounts of color pigment, stabilizers and other additives. The compounds used are listed to the requirements of NSF 61 for use in potable water service.

Dimensions (Plain End)

Physical dimensions and properties of PVC SDR pressure rated pipe shall meet the requirements of ASTM D2241 (available in sizes

/2" through 48") and CSA B137.3.

Dimensions (Bell End)

Physical dimensions and properties of PVC SDR pressure rated pipe bells shall meet the requirements of ASTM D2672 or ASTM F480.

Marking

PVC SDR rated pressure pipe is marked as prescribed in ASTM D2241 and/or CSA B137.3 as follows: IPEX; PVC; SDR# and/or the pressure rating in psi for water at 73°F (23ºC); ASTM D2241; CSA B137.3; and NSF 61 potable.

Sample Specification

All PVC SDR/PR 160 and 200 pipe shall conform to ASTM D2241 and/or CSA B37.0/B137.3. Belled ends shall meet the requirements of ASTM D672 or ASTM F80. SDR pipe and Schedule 40 fittings shall be compatible and produced by one manufacturer Xirtec140 as supplied by IPEX.

PVC Ventilation Duct Pipe

Scope

This specification sheet covers the manufacturers’ requirements for PVC Ventilation Duct pipe. This pipe meets or exceeds all applicable ASTM and ULC standards.

PVC Materials

Rigid PVC (polyvinyl chloride) used in the extrusion of Ventilation Duct pipe complies with the material requirements of ASTM D1784 (formerly Type 1, Grade 1) and has a cell classification of 12454.

Raw materials used in the extrusion shall contain the standard specified amounts of color pigment, stabilizers, and other additives. The compound must also exhibit a flame spread rating of 10 when tested in accordance with CAN/ULC S102.2.

Marking

PVC Ventilation Duct pipe is marked as prescribed in the above applicable standard to indicate size of pipe, material designation, compliance to standard, and manufacturer’s name or trademark.

Sample Specification

All extruded PVC Ventilation Duct pipe shall be manufactured from PVC compound conforming to ASTM D1784 (formerly Type 1, Grade 1) and have a cell classification of 12454. All extruded PVC Ventilation Duct Pipe shall conform to CAN/ULC S102.2.

All pipe shall be produced by one manufacturer as supplied by IPEX.

SPECIFICATIONS

Vinyl Process Piping Systems

Page 91

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

CPVC Ventilation Duct Pipe

Scope

This specification sheet covers the manufacturers’ requirements for CPVC Ventilation Duct pipe. This pipe meets or exceeds all applicable ASTM and ULC standards.

CPVC Materials

Rigid CPVC (chlorinated polyvinyl chloride) used in the extrusion of Ventilation Duct pipe complies with the material requirements of ASTM D1784 and has a cell classification of

23447.

Raw materials used in the extrusion shall contain the standard specified amounts of color pigment, stabilizers, and other additives. The compound must be Corzan grade. The compound must also exhibit a flame spread rating of 10 and a smoke development classification of 25 when tested in accordance with CAN/ULC S102.2. The Corzan CPVC compound is listed to FM 4910 “Clean Room Materials Flammability Test Protocol”.

Marking

CPVC Ventilation Duct pipe is marked as prescribed in the above applicable standard to indicate size of pipe, material designation, compliance to standard, and manufacturer’s name or trademark.

Sample Specification

All extruded CPVC Ventilation Duct pipe shall be manufactured from CPVC compound conforming to ASTM D1784 and have a cell classification of 23447. All extruded CPVC Ventilation Duct Pipe shall conform to CAN/ULC S102.2. The Corzan CPVC compound is listed to FM 4910 “Clean Room Materials Flammability Test Protocol”.

All pipe shall be produced using Corzan compound and be produced by one manufacturer as supplied by IPEX.

Drain, Waste and Vent Pipe (DWV)

Scope

This specification sheet covers the manufacturers’ requirements for PVC DWV pipe. This pipe meets or exceeds all applicable ASTM, NSF and CSA standards.

PVC Materials

Rigid PVC (polyvinyl chloride) used in the extrusion of DWV pipe complies with the material requirements of ASTM D1784 (formerly Type 1, Grade 1) and has a cell classification of 12454.

Dimensions

Physical dimensions and tolerances of PVC-DWV pipe shall meet the requirements of ASTM D2665 or CSA B181.2.

Marking

PVC DWV pipe is marked as prescribed in ASTM D2665 or CSA B181.2. The marking includes the following: IPEX; nominal pipe size; PVC-DWV; ASTM D2665, NSF 14 or CSA B181.2.

Sample Specification

All PVC DWV pipe shall conform to ASTM D1785 and/or CSA B181.2. In Canada, pipe and fittings shall be IPEX “System 15”.

All pipe and fittings shall be compatible and produced by one manufacturer as supplied by IPEX.

SPECIFICATIONS

Vinyl Process Piping Systems

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Fabricated Fittings

Pressure Rating

The pressure rating of the fitting shall be the same as that of the pipe used in the fabrication of the fitting. The pipe shall be certified to CSA B137.3 and NSF 14.

Hydrostatic Pressure Test of Fittings

At the engineer’s or customer’s request, representative sample fittings may be assembled and pressure tested for 1,000 hours at 1

/2 times the pressure rating of the pipe at 73°F (23ºC). At the end of the 1,000 hours, the pressure shall be increased to 2

/2 times the pressure rating within two

minutes. No failure shall occur.

Quality Control Tests

Joints from fittings shall be subjected to a spark test (power source of 24,000 volts). The joint shall not permit any passage of spark at any point along the weld.

Fiberglass Reinforcing

Fiberglass reinforcing should be applied to the fitting in such a manner and thickness to meet the hydrostatic pressure requirements specified. Bonding shall be done with primer resin to provide an adequate bond to the PVC pipe.

Marking

All fittings to have an exterior label identifying size, configuration, pressure rating and manufacturer’s name.

Socket Weld Depths

Each solvent weld bell must have a minimum socket depth of one-half times the pipe diameter.

One-Source Supply

All components of a piping system including pipe, fittings and valves, shall be supplied by one manufacturer as supplied by IPEX.

Joining

The PVC and CPVC pipe and socketed fittings shall be joined by use of solvent base cements manufactured in accordance with ASTM D2564. Ends of pipe shall be cut square; pipe and sockets of fittings cleaned; all dirt, grease and glossy finish removed. Joints shall be made in accordance with the pipe manufacturer’s recommendations and conform to the recommended practice for making solvent-cemented joints described in ASTM D2855. The ends of pipe and sockets of fittings shall be prepared with an approved pipe primer and coated with an approved solvent cement and pushed together. Where piping is to be joined to other materials or fittings, suitable socketed adapters shall be used. Where metallic couplings or other connections are used, the manufacturer’s recommendations shall be strictly adhered to.

Solvent Cementing

All socket type joints shall be made using primers and solvent cements that meet or exceed the requirements of ASTM F656 and ASTM F493 respectively. The standard practice for safe handling of primer and cement shall be in accordance with ASTM F402 and the manufacturer’s material safety data sheets (MSDS). Only PVC primer and solvent cement shall be used when making PVC solvent cement joints. Only CPVC primer and solvent cement shall be used when making CPVC solvent cement joints.

Installation

Pipe and fittings shall be installed in such a manner as to accommodate movement resulting from thermal expansion or contraction. Where pipe is not free to move, expansion loops, offsets or expansion joints shall be used.

Where short offsets are made in the pipe run to clear obstructions, the pipe shall be securely anchored on both sides of the fittings to prevent stress on the joints and fittings caused by thermal expansion and contraction.

Where there are insufficient offsets to accommodate thermal expansion and contraction on long runs of pipe, and where there is not adequate space for expansion loops, mechanical expansion joints compatible with the fluid being carried shall be used.

Standard pipe hangers and supports having a broad surface at the bearing point of the pipe and free of sharp edges in contact with the pipe shall be used. The spacing of hangers shall be in accordance with the pipe manufacturer’s recommendations or local authorities having jurisdiction.

All valves and equipment shall be supported independent of the pipe. Valves shall be anchored to prevent the turning moment resulting from their operation from being transmitted to the pipe.

Vertical risers shall be supported below the fitting shoulder at each 20' length. Pipe passing through walls, floors or partitions shall be sleeved and not securely anchored at these points

Testing

The water-testing requirements on any complete piping system vary dramatically depending on the operating pressure, temperature, installation conditions, jointing method and the proposed service medium. If the testing is not determined by the engineer or governed by regulatory code, the manufacturer should be contacted.

SPECIFICATIONS

Vinyl Process Piping Systems

WARNING

Air or compressed gas shall never be used for pressure testing rigid thermoplastic piping systems.

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

NOTES

Vinyl Process Piping Systems

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Vinyl Process Piping Systems

APPENDICES

SECTION SIX: APPENDICES

APPENDIX A: REFERENCE TABLES AND CONVERSION CHARTS

Table A-1Pipe Capacity

Table A-2 Weights of Water

Table A-3 Decimal & Millimeter Equivalents of Fractions

Table A-4 Volume Conversion

Table A-5 Pressure Conversion

Table A-6 Flow Conversion

Table A-7 Temperature Conversion

Table A-8 Length Conversion

Table A-9 Area Conversion

Table A-10 Weight Conversion

Table A-11 Density Conversion

Table A-12 Energy Conversion

Table A-13 Power Conversion

Table A-14 Dimensions, Weights & Pressure Ratings

APPENDIX B: USEFUL FORMULAS

• Area of a Circle

• Circumference of a Circle

• Length of Circular Arc

• Area of Circle Sector

• Equation of a Circle (cartesian coordinates)

• Equation of a Line (quadratic formula)

• Basic Trigonometric Functions

• Area of an Ellipse

• Circumference of an Ellipse

• Area of a Triangle

• Area of a Trapezoid

• Area of a Parallelogram

• Surface Area of a Sphere

• Volume of a Sphere

• Surface Area of a Cylinder

• Volume of a Cylinder

• Surface Area of an Elliptical Tank

• Volume of an Elliptical Tank

• Surface Area of a Cone

• Volume of a Cone

• Surface Area of a Rectangular Solid

• Volume of a Rectangular Solid

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CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

APPENDICES

Vinyl Process Piping Systems

TABLE A-1 PIPE CAPACITY

Pipe Size Outside Diameter – IPS OD Pipe Volume for 1 foot length of pipe

(in.) inch feet cm in

US Gal Imp Gal

/4 0.250 0.021 0.098 0.589 0.0003 9.648 0.003 0.002

/8 0.375 0.031 0.148 1.325 0.001 21.708 0.006 0.005

/2 0.500 0.042 0.197 2.355 0.001 38.591 0.010 0.008

/4 0.750 0.063 0.295 5.299 0.003 86.831 0.023 0.019

1 1.000 0.083 0.394 9.420 0.005 154.366 0.041 0.034

11/4 1.250 0.104 0.492 14.719 0.009 241.196 0.064 0.053

/2 1.500 0.125 0.591 21.195 0.012 347.322 0.092 0.076

2 2.000 0.167 0.787 37.680 0.022 617.462 0.163 0.136

3 3.000 0.250 1.181 84.780 0.049 1,389.290 0.367 0.306

4 4.000 0.333 1.575 150.720 0.087 2,469.849 0.652 0.543

5 5.000 0.417 1.969 235.500 0.136 3,859.139 1.019 0.849

6 6.000 0.500 2.362 339.120 0.196 5,557.159 1.468 1.222

8 8.000 0.667 3.150 602.880 0.349 9,879.395 2.610 2.173

10 10.000 0.833 3.937 942.000 0.545 15,436.554 4.078 3.396

12 12.000 1.000 4.724 1,356.480 0.785 22,228.638 5.872 4.890

14 14.000 1.167 5.512 1,846.320 1.068 30,255.646 7.993 6.655

16 16.000 1.333 6.299 2,411.520 1.396 39,517.578 10.439 8.693

18 18.000 1.500 7.087 3,052.080 1.766 50,014.435 13.212 11.002

20 20.000 1.667 7.874 3,768.000 2.181 61,746.216 16.312 13.582

24 24.000 2.000 9.449 5,425.920 3.140 88,914.551 23.489 19.559

TABLE A-2 WEIGHTS OF WATER

Units of Volume Weight

pounds kilograms

1 US Gallon 8.350 3.791

1 Imperial Gallon 10.020 4.549

1 litre 2.210 1.003

1 cubic yard 1,685.610 765.267

1 cubic foot 62.430 28.343

1 cubic inch 0.036 0.016

1 cubic cm 0.002 0.001

1 cubic metre 2,210.000 1,000.000

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Vinyl Process Piping Systems

APPENDICES

TABLE A-3 DECIMAL & MILLIMETER EQUIVALENTS OF FRACTIONS

Fractions

1/64 1/32 3/64 1/16 5/64 3/32 7/64

1/8 9/64 5/32

11/64

3/16

13/64

7/32

15/64

1/4

Decimals

0.015625

0.03125

0.046875

0.0625

0.078125

0.09375

0.109375

0.125

0.140625

0.15625

0.171875

0.1875

0.203125

0.21875

0.23475

0.250

0.397

0.794

1.191

1.588

1.984

2.381

2.778

3.175

3.572

3.969

4.366

4.763

5.159

5.556

5.953

6.350

Fractions

33/64 17/32 35/64

9/16 37/64 19/32 39/64

5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64

3/4

Decimals

0.515625

0.53125

0.546875

0.5625

0.578125

0.59375

0.609375

0.625

0.640625

0.65625

0.671875

0.6875

0.703125

0.71875

0.734375

0.750

13.097

13.494

13.891

14.288

14.684

15.081

15.478

15.875

16.272

16.669

17.066

17.463

17.859

18.256

18.653

19.050

17/64

9/32

19/64

5/16 21/64 11/32 23/64

3/8 25/64 13/32 27/64

7/16 29/64 15/32 31/64

1/2

0.265625

0.28125

0.296875

0.3125

0.328125

0.34375

0.359375

0.375

0.390625

0.40625

0.421875

0.4375

0.453125

0.46875

0.484375

0.500

6.747

7.144

7.541

7.938

8.334

8.731

9.128

9.525

9.922

10.319

10.716

11.113

11.509

11.906

12.303

12.700

49/64 25/32 51/64 13/16 53/64 27/32 55/64

7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64

0.765625

0.78125

0.796875

0.8125

0.828125

0.83475

0.859375

0.875

0.890625

0.90625

0.921875

0.9375

0.953125

0.96875

0.984375

1.000

19.447

19.844

20.241

20.638

21.034

21.431

21.828

22.225

22.622

23.019

23.416

23.813

24.209

24.606

25.003

25.400

TABLE A-4 VOLUME CONVERSION

1728

46,656

0.0610

61,023.7

61.02

231

277.42

0.00058

35.31

0.0353

0.1337

0.1605

0.0370

1.308

0.0013

0.0050

0.0059

16.387

28,317.8

1000

3785.4

4546.1

0.0283

0.7646

0.001

0.0038

0.0045

liter

0.0164

28.32

764.55

0.001

1000

3.785

4.546

U.S. gal.

0.0043

7.481

201.97

0.0003

264.17

0.2642

1.201

Imp. gal.

0.0036

6.229

168.8

0.0002

220.0

0.22

0.8327

Units of Volume

cubic inch

cubic foot

cubic yard

cubic centimeter

cubic meter

liter

U.S. gallon

Imp. gallon

Inches Inches

Millimeters

Page 97

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

APPENDICES

Vinyl Process Piping Systems

TABLE A-5 PRESSURE CONVERSION

Units of Pressure atm bar lb/in

lb/ft

kg/cm

kg/m

inch H

0 inch Hg inch air ft H

0 ft air mm Hg mm H

0 kilopascal N/m

atmosphere (atm) 1 0.987 0.068 - 0.968 - 0.002 0.033 - 0.029 - 0.001 - 0.01 -

bar 1.013 1 0.069 - 0.981 - 0.002 0.034 - 0.03 - 0.001 - 0.01 -

pound 14.7 14.5 1 0.007 14.22 0.001 0.036 0.491 - 0.434 0.001 0.019 0.001 0.145 -

per square inch (psi)

pound 2,116 2,089 144 1 2,048 0.205 5.2 70.73 0.006 62.43 0.076 2.784 0.205 20.89 0.021

per square foot (psf)

kilogram 1.033 1.02 0.07 - 1 0.0001 0.003 0.035 - 0.03 - 0.001 - 0.01 -

per square centimeter

kilogram 10,332 10,197 703 4.88 10,000 1 25.4 345.3 0.031 304.8 0.373 13.6 1 101.97 0.102

per square meter

inch of water (H

0) (4ºC) 406.78 401.46 27.68 0.192 393.7 0.039 1 13.6 0.001 12 0.015 0.535 0.039 4.015 0.004

inch of mercury (Hg) (0ºC) 29.921 29.53 2.036 0.014 28.96 0.003 0.074 1 - 0.883 0.001 0.039 0.003 0.295 -

inch of air (15ºC) 332,005 327,664 22,592 148.7 321,328 32.13 816.2 11,096 1 9,794 12 436.8 32.13 3,277 3.106

foot of water (4ºC) 33.9 33.46 2.307 0.016 32.81 0.003 0.083 1.133 - 1 - 0.045 0.003 0.335 -

foot of air (15ºC) 27,677 27,305 1,883 13.07 26,777 2.678 0.006 924.7 0.083 816.2 1 36.4 2.678 273.1 0.273

millimeter of mercury (0ºC) 760 750 51.71 0.36 735.6 0.074 1.868 25.4 0.002 22.42 0.027 1 0.074 7.5 0.008

millimeter of water (4ºC) 10,332 10,197 703 4.88 10,000 1 25.4 345.3 0.031 304.8 0.373 13.6 1 101.97 0.102

kilopascal (kP) 101.3 100 6.89 0.048 98.07 0.01 0.249 3.386 - 2.99 0.004 0.133 0.01 1 0.001

Newton per square meter - - - 0.021 - 0.102 0.004 - 3.277 - 0.273 0.008 0.102 0.001 1

Page 98

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Vinyl Process Piping Systems

APPENDICES

TABLE A-6 FLOW CONVERSION

Units of Flow Rate US gps US gpm US gph US gpd Imp gps Imp gpm Imp gph Imp gpd liters/sec liters/min liters/hr liters/day

US gal/sec (gps) 1 0.017 - - 1.2 0.02 - - 0.264 0.004 - US gal/min (gpm) 60 1 0.017 0.001 72.06 1.2 0.02 0.001 15.85 0.264 0.004 US gal/hr (gph) 3,600 60 1 0.042 4,323 72.06 1.2 0.05 951.02 15.85 0.264 0.011 US gal/day (gpd) 86,400 1,440 24 1 103,762 1,729.40 28.82 1.2 22,824 380.41 6.34 0.264

Imperial gal/sec 0.833 0.014 - - 1 0.017 - - 0.22 0.004 - Imperial gal/min 49.96 0.833 0.014 0.001 60 1 0.017 0.001 13.2 0.22 0.004 Imperial gal/hr 2,997.60 49.96 0.833 0.035 3,600 60 1 0.042 791.89 13.2 0.22 0.009 Imperial gal/day 71,943 1,199 19.98 0.833 86,400 1,440 24 1 19,005 316.76 5.279 0.22

Liters/sec 3.79 0.063 0.002 - 4.55 0.076 0.001 - 1 0.017 - Liters/min 227.12 3.785 0.063 0.003 272.77 4.55 0.076 0.003 60 1 0.017 0.001 Liters/hr 13,627 227.12 3.785 0.158 16,366 272.77 4.55 0.189 3,600 60 1 0.042 Liters/day 327,060 5,451 90.85 3.785 392,782 6,546 109.11 4.55 86,400 1,440 24 1

Cubic ft/sec (cfs) 0.134 0.002 - - 0.161 0.003 - - 0.035 0.001 - Cubic ft/min (cfm) 8.02 0.134 0.002 - 9.633 0.161 0.003 - 2.119 0.035 0.001 Cubic ft/hr (cfh) 481.25 8.02 0.134 0.006 577.96 9.63 0.161 0.007 127.13 2.119 0.035 0.001 Cubic ft/day (cfd) 11,550 192.5 3.21 0.134 13,871 231.18 3.853 0.161 3,051.20 50.85 0.848 0.001

Acre in/min 0.002 - - - 0.003 - - - 0.001 - - Acre in/hr 0.133 0.002 - - 0.159 0.003 - - 0.035 - - Acre in/day 3.182 0.053 0.001 - 3.821 0.064 0.001 - 0.841 0.001 - -

Cubic m/sec 0.004 - - - 0.005 - - - 0.001 - - Cubic m/min 0.227 0.004 - - 0.273 0.005 - - 0.06 0.001 - Cubic m/hr 13.628 0.227 0.004 - 16.366 0.273 0.005 - 3.6 0.06 0.001 Cubic m/day 327.06 5.451 0.091 0.004 392.78 6.546 0.109 0.005 86.4 1.44 0.024 0.001

Units of Flow Rate ft3/sec ft3/min ft3/hr ft3/day Acre in/min Acre in/hr Acre in/day m3/sec m3/min m3/hr m3/day

US gal/sec (gps) 7.48 0.125 0.002 - 452.6 7.54 0.31 264.2 4.4 0.073 0.003 US gal/min (gpm) 448.8 7.48 0.125 0.005 27,154 452.6 18.86 15,850 264.2 4.403 0.183 US gal/hr (gph) 26,930 448.83 7.481 0.312 1.629E+06 27,154 1,131 951,019 15,850 264.17 11.007 US gal/day (gpd) 646,317 10,772 179.53 7.481 3.910E+07 651,703 27,154 2.282E+07 380,408 6,340 264.17

Imperial gal/sec 6.229 0.104 0.002 - 376.8 6.28 0.26 220 3.67 0.061 0.003 Imperial gal/min 373.73 6.229 0.104 0.004 22,611 376.8 15.7 13,198 220 3.666 0.153 Imperial gal/hr 22,424 373.73 6.229 0.259 1.357E+06 22,611 942.1 791,889 13,198 220 9.165 Imperial gal/day 538,171 8,970 149.49 6.229 3.256E+07 542,656 22,611 1.901E+07 316,756 5,279 220

Liters/sec 28.32 0.472 0.008 - 1,713 28.6 1.19 1,000 16.67 0.278 0.012 Liters/min 1,699 28.32 0.472 0.2 102,790 1,713 71.38 60,000 1,000 16.67 0.694 Liters/hr 101,941 1,669 28.32 1.18 6.167E+06 102,790 4,283 3.600E+06 60,000 1,000 42.67 Liters/day 2,446,575 40,776 679.6 28.32 1.480E+08 2.467E+06 102,790 8.640E+07 1.440E+06 24,000 1,000

Cubic ft/sec (cfs) 1 0.017 - - 60.5 1.008 0.042 35.31 0.589 0.01 Cubic ft/min (cfm) 60 1 0.017 - 3,630 60.5 2.52 2,119 35.31 0.59 0.025 Cubic ft/hr (cfh) 3,600 60 1 0.042 217,800 3,630 151.25 127,133 2,119 35.31 1.471 Cubic ft/day (cfd) 86,400 1,440 24 1 5.227E+06 87,120 3,630 3,051,187 50,853 847.55 35.31

Acre in/min 0.017 - - - 1 0.017 0.001 0.584 0.01 - Acre in/hr 0.992 0.001 - - 60 1 0.042 35.02 0.584 0.01 Acre in/day 23.8 0.033 0.006 - 1,440 24 1 840.55 14.001 0.233 0.001

Cubic m/sec 0.028 - - - 1.71 0.029 0.001 1 0.017 - Cubic m/min 1.7 0.028 - - 102.8 1.71 0.071 60 1 0.017 0.001 Cubic m/hr 101.94 1.7 0.028 0.001 6,167 102.8 4.283 3,600 60 1 0.042 Cubic m/day 2446.6 40.78 0.68 0.028 148,018 2,467 102.79 86,400 1,400 24 1

Page 99

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

APPENDICES

Vinyl Process Piping Systems

TABLE A-7 TEMPERATURE CONVERSION

-60

-50

-40

-30

-20

-10 0 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21

-51

-46

-40

-34

-29

-23.0

-17.8

-17.2

-16.7

-16.1

-15.6

-15.0

-14.4

-13.9

-13.3

-12.8

-12.2

-11.7

-11.1

-10.6

-10.0

-9.4

-8.9

-8.3

-7.8

-7.2

-6.7

-6.1

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

-5.6

-5.0

-4.4

-3.9

-3.3

-2.8

-2.2

-1.7

-1.1

-0.6

0.0

0.6

1.1

1.7

2.2

2.8

3.3

3.9

4.4

5.0

5.6

6.1

6.7

7.2

7.8

8.3

8.9

9.4

50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

10.0

10.6

11.1

11.7

12.2

12.8

13.3

13.9

14.4

15.0

15.6

16.1

16.7

17.2

17.8

18.3

18.9

19.4

20.0

20.6

21.1

21.7

22.2

22.8

23.3

23.9

24.4

25.0

78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

99 100 110 120 130 140 150

25.6

26.1

26.7

27.2

27.8

28.3

28.9

29.4

30.0

30.6

31.1

31.7

32.2

32.8

33.3

33.9

34.4

35.0

35.6

36.1

36.7

37.2

37.8 43 49 54 60 66

160 170 180 190 200 210 212 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400

71 77 82 88 92

99 100 104 110 116 121 127 132 138 143 149 154 160 166 171 177 182 188 193 199 204

Degrees Celsius °C = (°F - 32) Degrees Fahrenheit °F = °C + 32

Degrees Kelvin °T = °C + 273.2 Degrees Rankine °R = °F + 459.7

5 9

9 5

TABLE A-8 LENGTH CONVERSION

(1 micron = 0.001 millimeter)

ºF ºC ºF ºC ºF ºC ºF ºC ºF ºC

Units of

Length

inch

foot

yard

mile

millimeter

centimeter

meter

kilometer

in.

0.0394

0.3937

39.37

ft.

0.0833

5280

0.0033

0.0328

3.281

3281

yd.

0.0278

0.3333

1760

0.0109

1.094

1094

mile

0.6214

25.4

304.8

914.4

1000

2.54

30.48

91.44

0.100

100

0.0254

0.3048

0.9144

1609.3

0.001

0.01

1000

1.609

0.001

Page 100

CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.

Vinyl Process Piping Systems

APPENDICES

Units of Area

sq inch

sq foot

acre

sq mile

sq centimeter

sq meter

hectare

sq kilometre

144

0.155

1550

0.0069

43,560

2.79E+6

0.001

10.76

1.076E+5

1.076E+7

acre

640

2.471

247

sq mile

0.0016

0.004

0.386

6.452

929.0

10,000

0.0929

4047

2.59E+6

0.0001

10,000

1.0E+6

sq hectare

0.4047

259.0

0.0001

100

0.004

2.59

0.01

TABLE A-9 AREA CONVERSION

Units of Weight

grain

ounce

pound

ton

gram

kilogram

metric tonne

TABLE A-10 WEIGHT CONVERSION

TABLE A-11 DENSITY CONVERSION

Units of Density

pound/cubic in.

pound/cubic ft.

pound/gal.

gram/cubic cm

gram/liter

lb/in

0.00433

0.0361

lb/ft

1728

7.481

62.43

0.0624

lb/gal

231.0

0.1337

8.345

0.00835

g/cm

27.68

0.0160

0.1198

0.001

g/l

27,680

16.019

119.83

1000.0

778.2

3.0860

0.7377

2,655,656

1,980,000

0.001285

0.003966

0.000948

3412.8

2544.5

0.3240

252.16

0.2390

860,563

641,617

1.3556

1054.9

4.1833

0.7456

1.3412

ft lb BTU g cal Joule kw hr hp hr

foot-pound

British Thermal Unit

gram calorie

Int. Joule

Int. kilowatt-hour

horsepower-hour

Units of Energy

TABLE A-12 ENERGY CONVERSION

grain

437.5

7000

15.43

32,000

0.0353

35.27

35,274

0.0625

2000

2.205

2205

ton

0.0005

1.1023

gram

0.0648

28.35

453.6

1000

0.0283

0.4536

907.2

0.001

1000

metric tonne

0.9072

0.001

IPEX Vinyl Process Piping Systems Brochure

Specifications and Main Features

Frequently Asked Questions

User Manual