IPEX Volume I User Manual

Volume I: Pressure Piping Systems Design

Municipal T echnical Manual Series

Blue Brute®Piping Systems

Bionax®Piping Systems

IPEX Centurion®Piping Systems

IPEX FusibleTMPipe

TerraBrute®CR Piping Systems

CycleTough®Piping Systems

Blue904TMWater Service Tubing

Q-Line®Water Service Tubing

We Build Tough Products for Tough Environments

®

FOURTH EDITION

© 2014 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.

The information contained here within is based on current information and product design at the time of publication and is subject to change without notification. IPEX does not guarantee or warranty the accuracy, suitability for particular applications, or results to be obtained therefrom.

IPEX Pressure Piping Systems Design

Municipal Technical Manual Series

Vol. 1, 4th Edition

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 (contact information is listed on the back cover).

Pressure Piping Systems Design Manual

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Section One: Product Information

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Summary of Pressure Pipe and Fittings Testing . . . . . . . . . . . . . . . . . . . . . . . .3

Blue Brute

®

Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Bionax

®

Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

IPEX Centurion

®

Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

IPEX Fusible

TM

PVC Pipe for Trenchless Applications . . . . . . . . . . . . . . . . . . .16

TerraBrute

®

CR Restrained Joint Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

CycleTough

®

Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Blue904

TM

PEX Water Service Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Q-Line

®

Water Service Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Standards for PVC Pressure Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Section Two: Properties of PVC Pressure Pipe and Pressure System Design

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Material Properties of PVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Design Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Design Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Chemical Permeation and Installation of PVC Pipe in Contaminated Soils . . . . . .40

UV Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Thermal Effects - Pressure Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Thermal Effects - Expansion and Contraction . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Design Calculations

Calculating a Pressure/Class Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Calculating Friction Headloss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Calculating Surge Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Calculating Wave Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Air Entrapment in Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Cyclic Design for PVC Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Thrust Restraint in Gasketed Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Assembly, Installation and Testing of PVC Pressure Pipe Systems . . . . . . . . . . . .49

Section Three: Design Examples

#1: Sewage Forcemain – AWWA C905 PVC Pipe . . . . . . . . . . . . . . . . . . . . . .51

#2: Sewage Forcemain – ASTM F1483 PVCO Bionax Pipe . . . . . . . . . . . . . . .55

#3: Transmission Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Section Four: Appendices

Appendix A: References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Appendix B: Reference Tables and Conversion Charts . . . . . . . . . . . . . . . . .66

Appendix C: Useful Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Appendix D: Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Appendix E: Tables and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

i

CONTENTS

Pressure Piping Systems Design

ii

Pressure Piping Systems Design

NOTES

______________________________________________________

1

Pressure Piping Systems Design

OVERVIEW

IPEX is one of the largest manufacturers of plastic piping systems in North America. IPEX manufactures piping systems for many different applications, including:

• Sewer collection and transmission

• Water supply

• Electrical and communications systems

• Plumbing systems

• Industrial piping systems.

This design manual covers the technical aspects of designing pressure pipe systems with PVC pipe. More specifically, municipal potable water systems, as well as irrigation and sewer force main systems are described.

The manual is organized into three sections:

Section 1 deals with specific products and includes detailed information on applications, dimensions and applicable standards for each system.

Section 2 deals with general design issues associated with PVC systems such as hydraulics, cyclic design and other topics that are applicable to all the products described in the manual.

Section 3 consists of design examples that apply the concepts from the first two sections.

This manual is designed for Engineers, Technologists and other municipal infrastructure professionals who require a deeper understanding of municipal piping systems than can be gleaned from the more general overview literature available from IPEX.

2

Pressure Piping Systems Design

NOTES

______________________________________________________

3

Pressure Piping Systems Design

PRODUCT INFORMATION

IPEX offers a number of different pressure piping systems that are used for various applications. While they are all plastic systems, they vary in outside diameter configurations and in available pressure ratings.

The products offered are:

Blue Brute

®

and IPEX Centurion®Piping Systems – Cast-iron outside diameter (CIOD) pipe and fittings

Bionax Pipe®– Cast-iron outside diameter (CIOD)

IPEX FusibleTM– Fusible BruteTM(CIOD) and Fusible SeriesTM(IPS) pipes are available in sizes ranging from 100mm (4") to

750mm (30") with larger sizes in development.

TerraBrute®Cr Pipe – CIOD pipe modified for use with trenchless installation methods such as directional drilling or pipe bursting

CycleTough

®

Piping Systems – Iron Pipe Size outside diameter (IPSOD) pipe and fittings

Blue904

TM

PEX Water Service Tubing – 3/4" through 2" PEX pipe designed for commercial and residential water service connections.

Q-Line®Water Service Tubing – 3/4" and 1" composite pipe designed for use as a water service to connect houses to main lines.

INTRODUCTION

SECTION 1: PRODUCT INFORMATION

SUMMARY OF PRESSURE PIPE AND FITTINGS TESTING

All IPEX pressure pipes and fittings are manufactured to standards from various recognized organizations such as AWWA, CSA, ASTM and others. As a result, all pressure pipe products undergo a variety of testing and quality procedures.

CIOD Pipe: Blue Brute, IPEX Centurion, Bionax, Fusible Brute and TerraBrute CR Piping Systems

These piping systems are manufactured under various AWWA standards, including AWWA C900 (Blue Brute and TerraBrute CR), C905 (IPEX Centurion), and C909 (Bionax). Fittings are manufactured under the C900, C905 and C907 standards.

Each length of Blue Brute, IPEX Centurion, Bionax and TerraBrute CR CIOD pipe is hydrostatically tested in order to verify the pressure capabilities of each pipe as dictated by AWWA C900 and C905. In addition, burst tests are carried out regularly to verify the integrity of the pipe and joint system. It should be remembered that the hydrostatic test is done using the pipe’s own gasket, which means that both the pipe and the joining system are being checked. AWWA standards also require a number of non-pressure tests.

TerraBrute CR pipe does not strictly comply with AWWA C900/905 standards because of the dimensional change imposed by the grooving procedure, however it is tested using the same procedures as conventional Blue Brute and IPEX Centurion. The hydrostatic proof test is carried out on each length of TerraBrute CR to the same pressures and durations as for standard Blue Brute or IPEX Centurion.

In addition to Standard requirements, Certifications require very stringent testing and QA/QC procedures. For example, joint assemblies are regularly tested for full vacuum pressure .

The CSA Certification Program also requires impact testing to be carried out at 0ºC (32ºF).

In addition to the pressure and impact testing, finished PVC pipe is tested by using acetone immersion tests and heat reversion tests. Both tests are used to check that the proper degree of fusion has occurred during the extrusion process.

The dimensional characteristics of each pipe and fitting are checked constantly during the extrusion and molding processes, and samples are taken for detailed dimensional analysis during each extrusion or molding run.

IPSOD Pipe: CycleTough and Fusible Series

Cycletough pipe undergoes testing identical to that of Blue Brute and IPEX Centurion pipe with the exception of the hydrostatic proof test of each length of pipe. This does not mean that the pipe is of any lesser quality than Blue Brute or IPEX Centurion pipe – it only means that it is manufactured under a different standard (ASTM D2241) that does not require the hydrostatic proof test.

In addition to performance and dimensional checks, National Sanitation Foundation (NSF) requirements mean that all products are thoroughly tested to ensure they have no effect on potable water.

To summarize – There are many standards governing the manufacture and design of IPEX pressure pipes and fittings. IPEX also has internal testing standards that are often well in excess of published requirements to ensure acceptable performance on the jobsite.

PRODUCT INFORMATION

4

Pressure Piping Systems Design

Sizes larger than 8 inches are fabricated and dimensions are available on request.

BLUE BRUTE®PIPING SYSTEMS

Blue Brute is one of the most well known names in municipal water supply, as it has built up an enviable reputation for performance and reliability over the years. Blue Brute pipe and fittings eliminate the threat of corrosion, while providing reliable long-term service. While Blue Brute pipe is compatible with iron fittings, IPEX recommends the use of Blue Brute fittings as they are made to match the pipe, and eliminate the “Achilles heel” of many systems – corroding iron fittings.

It is advisable to specify pipe and fittings from the same manufacturer in order to ensure a completely matched system. Only by specifying Blue Brute fittings can you ensure that the fittings have the same long term strength as the pipe itself.

Applications:

Municipal water distribution systems and fire lines.

Irrigation, sewage forcemains, industrial lines.

Gasket Options For Contaminated Soils

Blue Brute pipe and fittings have removable gaskets. This allows oil resistant (nitrile) gaskets to be easily substituted when installing piping systems in contaminated soils. Please refer to Section 2 – Chemical Permeation and Resistance for more information on this topic.

Standards:

Blue Brute Pipe:

AWWA C900, CSA B137.3 certified, FM 1612 approved, UL 1285 listed, NSF 61 certified, Certified to NQ 36240-250

Blue Brute Fittings:

AWWA C907, CSA B137.2 (100mm – 300mm) certified, AWWA C900, CSA B137.3 (250mm – 300mm) certified, FM 1612 listed, UL 1285 listed

Short Form Specifications

General

Blue Brute pipe shall be certified to CSA B137.3 “Rigid Polyvinyl Chloride PVC Pipe for Pressure Applications” and shall conform to AWWA C900 “Polyvinyl Chloride (PVC) Pressure Pipe, 4" – 12" for Water Transmission and Distribution.” Blue Brute DR25 pipe shall have a pressure class/rating of 1120 kPa (165 psi). DR18 pipe shall have a pressure class/rating of 1620 kPa (235 psi). DR14 pipe shall have a pressure class/rating of 2100 kPa (305 psi).

Material

Blue Brute pipe shall be made from PVC compound conforming to ASTM D1784 cell class 12454.

Product

Pipe shall be suitable for use at maximum hydrostatic working pressure equal to the pressure class/rating at 23°C (73°F). Laying lengths shall be 6.1 metres (20 feet). Pipe shall have cast-iron outside diameters. Each length of pipe must be proof-tested at two times the pressure class.

Joining

The gasket shall be carefully fitted to the bell groove if not already factory installed. Both bell and spigot shall be clean and free of debris before approved lubricant is applied. The pipe and/or fittings shall be joined by pushing the spigot into the bell to the depth line marked on the spigot. When pipe has

been cut in the field, the end shall be made square and beveled to a 15º chamfer. All insertion lines should be re-drawn, according to the IPEX Pressure Pipe Installation Guide.

Molded Fittings

Blue Brute fittings shall conform to AWWA C907 “Polyvinyl Chloride (PVC) Pressure Fittings for Water (4" through 12")” and be certified to CSA B137.2 “PVC Injection Molded Gasketed Fittings for Pressure Applications.” They shall also be UL Listed and FM approved.

Fabricated Fittings

Fabricated fittings shall be made from segments of AWWA C900 PVC pipe. Segements are bonded together and may be over-wrapped with fibreglass-reinforced polyester. The pressure class must match the pipe. The fittings must meet the requirements of CSA B137.3.

Lubricant

Pipe must be assembled with IPEX non-toxic, water soluble lubricant listed by the National Sanitation Foundation.

Color Coding

Water pipe and fittings shall be color coded blue.

BLUE BRUTE®PIPING SYSTEMS

5

Pressure Piping Systems Design

PRODUCT INFORMATION

Dimensions:

Blue Brute pipes and fittings are manufactured with cast-iron outside diameters (CIOD), which means that they are compatible with much of the existing infrastructure of older

iron pipes. This means that no special transition fittings are needed with Blue Brute.

DR 25 Class 165

AWWA pressure class 165 psi

CSA pressure rating 1 130 kPa

DR 18 Class 235

AWWA pressure class 235 psi

CSA pressure rating 1 620 kPa

DR 14 Class 305

AWWA pressure class 305 psi

CSA pressure rating 2 130 kPa

Size Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD

in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm

4 100 4.42 112 0.192 4.88 4.80 122 4.27 108 0.267 6.78 4.80 122 4.11 104 0.343 8.71 4.80 122

6 150 6.35 161 0.276 7.01 6.90 175 6.13 155 0.383 9.73 6.90 175 5.91 149 0.493 12.52 6.90 175

8 200 8.33 212 0.362 9.20 9.05 230 8.05 204 0.502 12.80 9.05 230 7.76 198 0.646 16.42 9.05 230

10 250 10.21 260 0.444 11.30 11.10 282 9.87 250 0.616 15.70 11.10 282 9.51 242 0.793 20.14 11.10 282

12 300 12.15 309 0.527 13.41 13.20 335 11.73 297 0.733 18.62 13.20 335 11.31 287 0.943 23.95 13.20 335

PRODUCT INFORMATION

BLUE BRUTE®PIPING SYSTEMS

6

Pressure Piping Systems Design

Size L1

in mm in mm

4 100 2.6 67 6 150 4.3 108 8 200 5.5 140

Size Minimum Maximum

in mm in mm in mm

4 100 5.44 138 5.61 142 6 150 7.84 199 8.03 204

8 200 10.29 261 10.55 268 10 250 12.63 322 12.96 329 12 300 15.07 383 15.46 393 14 350 17.28 439 17.73 450 16 400 19.64 448 20.17 512

Bell OD for Joint Restraint Selection

Size L1

in mm in mm

4 100 1.3 33 6 150 1.8 46

8 200 2.2 56 10 250 2.7 70 12 300 3.2 82

45° Elbow

Size L1

in mm in mm

4 100 3.0 75

6 150 0.8 20

8 200 0.9 23

11-1/4° Elbow

Sizes larger than 8 inches are fabricated and dimensions are available on request.

Size L1

in mm in mm

6 150 1.0 25

8 200 1.1 28 10 250 1.7 43 12 300 1.9 48

22-1/2° Elbow

Note: Other DR’s and sizes up to 48" (1200mm) are available on request.

90° Elbow

OD

L1

BLUE BRUTE®PIPING SYSTEMS

7

Pressure Piping Systems Design

PRODUCT INFORMATION

Sizes larger than 8 inches are fabricated and dimensions are available on request.

Size L1 L2

in mm in mm in mm

6 x 4 150 x 100 5.6 141 4.3 108

8 x 6 200 x 150 6.5 165 5.7 145

10 x 8 250 x 200 7.0 178 5.8 147

12 x 10 300 x 250 7.9 202 6.6 167

Reducing Adapter Spigot x Bell

Size L1

in mm in mm

4 100 0.2 5

6 150 0.3 8

8 200 0.3 7

10* 250 0.5 13

12* 300 0.5 13

Coupling

(available w/o center stop as a Repair Coupling)

* One-piece machined coupling. Note: 3/4" (20mm) Taps to 2" (50mm). Taps: AWWA Thread

Size L1 L2

in mm in mm in mm

4 x 4 x 4 100 x 100 x 100 2.6 67 2.6 67

6 x 6 x 4 150 x 150 x 100 4.0 102 3.3 87

6 x 6 x 6 150 x 150 x 150 4.3 108 4.3 108

8 x 8 x 4 200 x 200 x 100 5.1 130 3.6 91

8 x 8 x 6 200 x 200 x 150 5.3 136 4.7 120

8 x 8 x 8 200 x 200 x 200 5.6 143 5.8 148

10 x 10 x 4 250 x 250 x 100 6.7 171 6.7 171

10 x 10 x 6 250 x 250 x 150 6.7 171 6.7 171

10 x 10 x 8 250 x 250 x 200 6.7 171 6.7 171

10 x 10 x 10 250 x 250 x 250 6.7 171 6.7 171

12 x 12 x 4 300 x 300 x 100 7.7 195 7.7 195

12 x 12 x 6 300 x 300 x 150 7.7 195 7.7 195

12 x 12 x 8 300 x 300 x 200 7.7 195 7.7 195

12 x 12 x 10 300 x 300 x 250 7.7 195 7.7 195

12 x 12 x 12 300 x 300 x 300 7.7 195 7.7 195

Te e

Size L1 L2

in mm in mm in mm

10 x 10 x 6 250 x 250 x 150 7.0 178 6.7 171 12 x 12 x 6 300 x 300 x 150 8.1 206 7.7 195

Hydrant Tee

L1

L2

L1

L2

L1

L2

L1

PRODUCT INFORMATION

BLUE BRUTE®PIPING SYSTEMS

8

Pressure Piping Systems Design

Size A L1

in mm in mm in mm

4 x 4 x 3/4 100 x 100 x 20 3/4 20 2.0 50

4 x 4 x 1 100 x 100 x 25 1 25 2.0 50

6 x 6 x 3/4 150 x 150 x 20 3/4 20 3.0 76

6 x 6 x 1 150 x 150 x 25 1 25 3.0 76

6 x 6 x 1-1/4 150 x 150 x 32 1-1/4 32 3.0 76

6 x 6 x 1-1/2 150 x 150 x 40 1-1/2 40 3.0 76

8 x 8 x 3/4 200 x 200 x 20 3/4 20 3.0 76

8 x 8 x 1 200 x 200 x 25 1 25 3.0 76

8 x 8 x 1-1/4 200 x 200 x 32 1-1/4 32 3.0 76

8 x 8 x 1-1/2 200 x 200 x 40 1-1/2 40 3.0 76

8 x 8 x 2 200 x 200 x 50 2 50 3.0 76

10 x 10 x 3/4* 250 x 250 x 20 3/4 20 3.0 76

10 x 10 x 1* 250 x 250 x 25 1 25 3.0 76

12 x 12 x 3/4* 300 x 300 x 20 3/4 20 3.0 76

12 x 12 x 1* 300 x 300 x 25 1 25 3.0 76

Single Tapped Coupling

Size A B L

in mm in mm in mm in mm

6 x 3/4 x 3/4 150 x 20 x 20 3/4 20 3/4 20 3.0 76

6 x 1 x 3/4 150 x 25 x 20 3/4 20 1 25 3.0 76

6 x 1 x 1 150 x 25 x 25 1 25 1 25 3.0 76

6 x 1-1/4 x 3/4 150 x 32 x 20 3/4 20 1-1/4 32 3.0 76

6 x 1-1/4 x 1 150 x 32 x 25 1 25 1-1/4 32 3.0 76

6 x 1-1/2 x 3/4 150 x 40 x 20 3/4 20 1-1/2 40 3.0 76

6 x 1-1/2 x 1 150 x 40 x 25 1 25 1-1/2 40 3.0 76

6 x 2 x 3/4 150 x 50 x 20 3/4 20 2 50 3.0 76

6 x 2 x 1 150 x 50 x 25 1 25 2 50 3.0 76

8 x 3/4 x 3/4 200 x 20 x 20 3/4 20 3/4 20 3.0 76

8 x 1 x 3/4 200 x 25 x 20 3/4 20 1 25 3.0 76

8 x 1 x 1 200 x 25 x 25 1 25 1 25 3.0 76

8 x 1-1/4 x 3/4 200 x 32 x 20 3/4 20 1-1/4 32 3.0 76

8 x 1-1/4 x 1 200 x 32 x 25 1 25 1-1/4 32 3.0 76

8 x 1-1/2 x 3/4 200 x 40 x 20 3/4 20 1-1/2 40 3.0 76

8 x 1-1/2 x 1 200 x 40 x 25 1 25 1-1/2 40 3.0 76

8 x 2 x 3/4 200 x 50 x 20 3/4 20 2 50 3.0 76

8 x 2 x 1 200 x 50 x 25 1 25 2 50 3.0 76

Double Tapped Coupling

Sizes larger than 8 inches are fabricated and dimensions are available on request.

* One-piece machined coupling. Note: 3/4" (20mm) Taps to 2" (50mm). Taps: AWWA Thread

Note: 3/4" (20mm) Taps to 2" (50mm). Taps: AWWA Thread

A

L

A B

L

BLUE BRUTE®PIPING SYSTEMS

9

Pressure Piping Systems Design

PRODUCT INFORMATION

Sizes larger than 8 inches are fabricated and dimensions are available on request.

Size L1

in mm in mm

10 250 3.5 89

12 300 3.5 89

High Deflection Coupling

Size L1

in mm in mm

4 100 6.5 164

6 150 7.8 198

8 200 9.1 231

10 250 10.2 258

12 300 9.8 249

Plug

Size L1

in mm in mm

4 x 3/4 100 x 20 6.5 164

4 x 1 100 x 25 6.5 164

4 x 1-1/2 100 x 40 6.5 164

4 x 2 100 x 50 6.5 164

6 x 3/4 150 x 20 7.8 198

6 x 1 150 x 25 7.8 198

6 x 1-1/2 150 x 40 7.8 198

6 x 2 150 x 50 7.8 198

8 x 3/4 200 x 20 9.1 231

8 x 1 200 x 25 9.1 231

8 x 1-1/2 200 x 40 9.1 231

8 x 2 200 x 50 9.1 231

Tapped Plug (IPS Threads)

E

D

L1

Thread

L1

PRODUCT INFORMATION

10

Pressure Piping Systems Design

BIONAX®PIPING SYSTEMS

Bionax PVCO pipe and Blue Brute PVC fittings eliminate corrosion and provide a reliable long-term piping system. Although Bionax is compatible with iron fittings, IPEX recommends the use of Blue Brute fittings since they result in an all-plastic system that prevents corroding iron fittings.

It is advisable to specify pipe and fittings from the same manufacturer to ensure a completely matched system. If Bionax pipe is specified with Blue Brute fittings, the pipe and fittings will provide matched pressure capacities.

Applications:

Municipal water distribution systems

Sewage forcemains, industrial process piping

Pressure Class/Rating

Bionax CIOD pipe has a Pressure Rating (CSA) or a Pressure Class (AWWA) of 235 psi. It also has a Pressure Class of 150psi for FM and a Pressure Rating of 200psi by ASTM.

Surge Pressure

Surge pressures generated in Bionax pipe are lower than for any other municipal pipe.

The short-term rating of Bionax CIOD pipe is 376 psi (for occasional surge-pressure applications).

Standards

Bionax pipe:

ANSI/NSF Standard 14, ANSI/NSF Standard 61

ASTM D1784, D3139, F477 and F1483

NSF-certified to AWWA C909-09 and ASTM F1483-05, CSA-certified to B137.3.1 and FM-certified to FM1612.

NQ3660-950

11

Pressure Piping Systems Design

PRODUCT INFORMATION

Short Form Specifications

General

Bionax CIOD pipe shall be certified to AWWA C909 “Molecularly Oriented Polyvinyl Chloride (PVCO) Pressure Pipe (4" – 24") for Water, Wastewater, and Reclaimed Water Service” and certified to CSA B137.3.1 “MOLECULARLY ORIENTED POLYVINYLCHLORIDE (PVCO) PIPE FOR PRESSURE APPLICATIONS.” Bionax shall have a pressure class (AWWA) or pressure rating (CSA) of 235 psi.

Material

PVCO pipe shall be manufactured from rigid polyvinyl chloride (PVC) compound meeting the requirements of ASTM D1784 cell class 12454.

Gaskets shall meet ASTM F477 for high-head applications.

Product

Finished PVCO pipe shall have an HDB of 7100 psi. Laying lengths shall be 6.1 meters (20 feet). Pipe shall have cast-iron outside diameters. Every length must be proof-tested at two times the pressure class.

Fittings

Bionax piping systems shall include IPEX Blue Brute molded and fabricated fittings.

Lubricant

Pipe must be assembled with IPEX water-soluble lubricant listed to NSF Standard 61.

Color Coding

CIOD pipe shall be color coded blue.

Joining

The gasket shall be carefully fitted to the bell groove if not already factory-installed. Both bell and spigot shall be clean and free of debris before lubricant is applied. The pipe shall be joined by push-fitting bell and spigot joint to the depth line marked on the spigot. When pipe has been cut in the field, the end shall be made square and bevelled to a 10-degree chamfer and the insertion line shall be redrawn per IPEX’s Pressure Pipe Installation Guide.

BIONAX®PIPING SYSTEMS

Dimensions

Size

Pressure Class/Rating 235 psi @ 73ºF (1 620 kPa @ 23ºC)

Average OD Min Wall Thickness Average ID

in mm in mm in mm in mm

4 100 4.80 122 0.154 3.91 4.48 114

6 150 6.90 175 0.221 5.62 6.44 163

8 200 9.05 230 0.290 7.36 8.44 214

10 250 11.10 282 0.356 9.03 10.35 263

12 300 13.20 335 0.423 10.74 12.31 313

14 350 15.30 389 0.347 8.83 14.57 370

16 400 17.50 442 0.395 10.04 16.57 421

18 450 19.50 495 0.443 11.25 18.54 471

PRODUCT INFORMATION

12

Pressure Piping Systems Design

IPEX CENTURION®PIPING SYSTEMS

IPEX Centurion extends the benefits of Blue Brute to larger diameters of pipe and new applications. The versatility and ease of installation of IPEX Centurion is unmatched – and costly and difficult to install corrosion protection is eliminated. In addition, unlike HDPE or concrete pressure pipe, every length of IPEX Centurion is tested to double its pressure rating.

Applications:

Water transmission lines, forcemains.

Irrigation, gravity lines, industrial lines

Standards:

AWWA C905, CSA B137.3, NQ 3624-250, NSF 61

Factory Mutual FM 1612:

DR18 is FM approved to 20" (500mm diameter)

Underwriter’s Laboratories UL 1285:

DR18 is listed to 24" (600mm diameter) DR25 is listed to 30" (750mm diameter)

Pressure Ratings

IPEX Centurion can withstand extremely high short term pressures, in addition to lower levels of long-term pressure. As a result, AWWA C905 standard includes both long term pressure ratings (LTR) and short term ratings (STR).

Surge Pressures

Transient pressures in pipelines occur as a result of the fluid velocity changing over a relatively short time. The method for approximating a surge pressure is described in section 2. However it should be noted that for most large diameter pipelines, a formal transient analysis should be carried out by a qualified person in order to fully understand the effects of transients in any given system. The method shown in section 2 is certainly appropriate for initial design purposes however.

The table below shows the surge pressure generated assuming an instantaneous stoppage of a flow moving at 0.3 m/s (1 ft/s).

DR

Surge Pressure

psi kPa

51 10.8 75

41 11.4 79

32.5 12.8 88

25 14.7 101

18 17.4 120

14 19.8 137

Bionax (PC235) 14.1 97

DR

Short Term Rating Long Term Rating

psi kPa psi kPa

51 125 880 80 550

41 160 100 100 690

32.5 200 1 380 125 860

25 264 1 820 165 1 140

18 376 2 590 235 1 620

14 488 3 370 305 2 100

IPEX CENTURION®PIPING SYSTEMS

13

Pressure Piping Systems Design

PRODUCT INFORMATION

Short Form Specifications

General

Pipe must conform to AWWA C905 and be certified to CSA B137.3 “RIGID POLYVINYL CHLORIDE (PVC) PIPE FOR PRESSURE APPLICATIONS.” DR51, 41, 32.5, 25, 18, and 14 pipe must have the following pressure/class ratings: 80 psi (550 kPa), 100 psi (690 kPa), 125 psi (860 kPa), 165 psi (1 140 kPa), 235 psi (1 620 kPa) and 305 psi (2 100 kPa). For pressure applications, each length of pipe must be hydrotested at twice the rating and a short-term pressure test must be conducted once per production run. Pipe to be IPEX Centurion or approved equal.

Fabricated Fittings

Fabricated fittings shall be made from segments of AWWA C905 pipe that are butt-fused or bonded together. Some fittings are over-wrapped with fiberglass-reinforced polyester. The fittings must always meet the pressure/class rating of the pipe system.

PRODUCT INFORMATION

IPEX CENTURION®PIPING SYSTEMS

14

Pressure Piping Systems Design

1. Deflection values shown include effect of H20 live load and

dead load.

2. External loading based upon a prism load of soil weight of 120 lbs. per cubic foot (1 900 kg/m

3

).

3. Bedding classifications correspond to ASTM D2321.

4. The deflection lag factor is 1.0 for a prism load.

5. DR18 & DR 14 deflections have not been shown because they are insignificant in most cases.

6. Recommended maximum deflection is 7.5%.

Contact IPEX for applications where greater deflections are anticipated.

7. n/r - not recommended for H20 live load (ok with dead load)

Table 1 – Percent (%) Deflection for IPEX Centurion Pressure Pipe

ASTM EMBEDMENT

MATERIAL

CLASSIFICATION

DENSITY

(PROCTOR)

AASHO T-99

E' psi

(kPa)

DR

DEPTH OF COVER

ft12468101520253035404550

m 0.3 0.6 1.2 1.8 2.4 3.0 4.6 6.1 7.6 9.1 10.7 12.2 13.7 15.2

Manufactured

Granular

Angular

CLASS I 90%

3,000

(20 700)

51 n/r 0.5 0.3 0.4 0.4 0.5 0.7 0.9 1.1 1.4 1.6 1.8 2.0 2.3

41 n/r 0.5 0.3 0.4 0.4 0.4 0.7 0.9 1.1 1.3 1.6 1.8 2.0 2.2

32.5 0.7 0.5 0.3 0.3 0.4 0.4 0.7 0.9 1.1 1.3 1.5 1.7 2.0 2.2

25 0.7 0.5 0.3 0.3 0.4 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.9 2.1

Clean Sand &

Gravel

CLASS II

90%

2,000

(13 000)

51 n/r 0.7 0.5 0.5 0.6 0.7 1.0 1.3 1.7 2.0 2.3 2.7 3.0 3.4

41 n/r 0.7 0.5 0.5 0.6 0.7 1.0 1.3 1.7 2.0 2.3 2.6 3.0 3.3

32.5 1.0 0.7 0.5 0.5 0.5 0.6 1.0 1.3 1.6 1.9 2.2 2.6 2.9 3.2

25 1.0 0.7 0.4 0.5 0.5 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 2.9

80%

1,000

(7 000)

51 n/r 1.5 1.0 1.1 1.1 1.3 2.0 2.6 3.3 4.0 4.6 5.3 5.9 6.6

41 n/r 1.4 1.0 1.0 1.1 1.3 1.9 2.6 3.2 3.8 4.5 5.1 5.8 6.4

32.5 2.0 1.3 0.9 1.0 1.0 1.2 1.8 2.4 3.0 3.6 4.2 4.8 5.4 6.0

25 1.7 1.1 0.8 0.8 0.9 1.0 1.6 2.1 2.6 3.1 3.6 4.2 4.7 5.2

Sand & Gravel

with Fines

CLASS III

90%

1,000

(7 000)

51 n/r 1.5 1.0 1.1 1.1 1.3 2.0 2.6 3.3 4.0 4.6 5.3 5.9 6.6

41 n/r 1.4 1.0 1.0 1.1 1.3 1.9 2.6 3.2 3.8 4.5 5.1 5.8 6.4

32.5 2.0 1.3 0.9 1.0 1.0 1.2 1.8 2.4 3.0 3.6 4.2 4.8 5.4 6.0

25 1.7 1.1 0.8 0.8 0.9 1.0 1.6 2.1 2.6 3.1 3.6 4.2 4.7 5.2

85%

500

(3 500)

51 n/r n/r 1.9 2.0 2.2 2.6 3.8 5.1 6.4

7.7 8.9 10.2 11.5 12.8

41 n/r n/r 1.8 1.9 2.1 2.4 3.6 4.8 6.0 7.2

8.4 9.6 10.8 12.0

32.5 n/r 2.4 1.6 1.7 1.8 2.1 3.2 4.3 5.3 6.4 7.5

8.5 9.6 10.7

25 n/r 1.9 1.3 1.3 1.4 1.7 2.5 3.3 4.2 5.0 5.9 6.7 7.5 8.4

Silt & Clay CLASS IV 85%

400

(2 760)

51 n/r n/r 2.4 2.5 2.7 3.1 4.7 6.3

7.9 9.4 11.0 12.6 14.1 15.7

41 n/r n/r 2.2 2.3 2.5 2.9 4.4 5.8 7.3

8.8 10.2 11.7 13.1 14.6

32.5 n/r 2.8 1.9 2.0 2.2 2.5 3.8 5.1 6.3 7.6 8.9 10.1 11.4 12.7

25 n/r 2.1 1.4 1.5 1.6 1.9 2.9 3.8 4.8 5.7 6.7 7.6 8.6 9.5

IPEX Centurion for Gravity Applications

With its pressure rated joints and non-corroding construction, IPEX Centurion is a natural choice for gravity flow lines. When designing any flexible conduit application, the ring deflection should be calculated for the applicable loading conditions. The table below shows the ring deflections for a variety of different DRs based on depth of bury and H20 loading. For more information on how to calculate ring deflections for PVC pipe, please refer to the IPEX Sewer Design Manual.

IPEX CENTURION®PIPING SYSTEMS

15

Pressure Piping Systems Design

PRODUCT INFORMATION

Dimensions

IPEX Centurion is manufactured with a cast-iron outside diameter (CIOD) so it is compatible with much of the existing older infrastructure of iron pipes. In addition, IPEX Centurion can be field-cut, which means unexpected changes in the field can be accommodated quickly, without having to wait for new shop drawings.

IPEX Centurion Fittings are manufactured using sections of AWWA C905 pipe that are fused or bonded together. Some fittings are overwrapped with a layer of fibre reinforced plastic (FRP). While IPEX Centurion is compatible with iron fittings, IPEX recommends the use of IPEX Centurion fittings exclusively with IPEX Centurion pipe.

PR/PC 80 (SDR51) PR/PC 100 (SDR41) PR/PC 125 (SDR32.5)

Size Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD

in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm

14 350 - - - - - - 14.6 369.7 0.37 9.5 15.3 388.6 - - - - - -

16 400 - - - - - - 16.6 420.4 0.43 10.8 17.4 442.0 - - - - - -

18 450 18.7 475.9 0.38 9.71 19.5 495.3 18.5 471.1 0.48 12.1 19.5 495.3 - - - - - -

20 500 20.8 527.0 0.42 10.80 21.6 548.6 20.5 521.8 0.53 13.4 21.6 548.6 - - - - - -

24 600 24.8 629.6 0.50 12.90 25.8 655.3 24.5 623.3 0.63 16.0 25.8 655.3 24.2 615.0 0.80 20.2 25.8 655.3

30 750 30.7 780.9 0.63 15.93 32.0 812.8 30.4 773.2 0.78 19.8 32.0 812.8 30.0 762.8 0.98 25.0 32.0 812.8

36 900 36.8 934.7 0.75 19.10 38.3 972.8 36.4 925.3 0.93 23.7 38.3 972.8 35.9 912.9 1.18 29.9 38.3 972.8

42 1050 42.6 1082.8 0.87 22.20 44.5 1130.3 42.2 1071.4 1.09 27.5 44.5 1130.3 41.6 1056.6 1.37 34.8 44.5 1130.3

48 1200 48.7 1236.2 1.00 25.30 50.8 1290.3 48.2 1223.0 1.24 31.5 50.8 1290.3 - - - - - -

PR/PC 165 (DR25) PR/PC 235 (DR18) PR/PC 305 (DR14)

Size Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD Avg. ID

Min. Wall

Thickness

Avg. OD

in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm

14 350 14.1 357.5 0.61 15.60 15.3 388.6 13.6 345.4 0.85 21.6 15.3 388.6 13.1 333.0 1.09 27.8 15.3 388.6

16 400 16.0 406.6 0.70 17.70 17.4 442.0 15.5 392.9 0.97 24.6 17.4 442.0 14.9 378.8 1.24 31.6 17.4 442.0

18 450

17.9 455.7 0.78 19.81 19.5 495.3 17.3 440.3 1.08 27.5 19.5 495.3 - - - - - -

20 500 19.9 504.7 0.86 22.00 21.6 548.6 19.2 487.6 1.20 30.5 21.6 548.6 - - - - - -

24 600

23.7 602.9 1.03 26.21 25.8 655.3 22.9 582.5 1.43 36.4 25.8 655.3 - - - - - -

30 750 29.4 747.8 1.28 32.51 32.0 812.8 - - - - - - - - - - - -

36 900

35.2 895.0 1.53 38.91 38.3 972.8 - - - - - - - - - - - -

42 1050 - - - - - - - - - - - - - - - - - -

48 1200 - - - - - - - - - - - - - - - - -

PRODUCT INFORMATION

IPEX FUSIBLETMPVC PIPE FOR TRENCHLESS APPLICATIONS

16

Pressure Piping Systems Design

By combining the mechanical properties of PVC with an innovative, patented butt fusion process, IPEX provides the only available method of installing a continuous, monolithic, fully restrained PVC pipe system. Capable of being used in a variety of trenchless or conventional direct bury applications, Fusible PVC

TM

pipe systems have been installed at numerous sites throughout the United States, Canada and Mexico for both pressure and non-pressure installations in the water and sewer industries.

Fusible Brute (CIOD) and Fusible Series (IPS) pipes are available in sizes ranging from 100mm (4") to 750mm (30") with larger sizes in development. The proprietary PVC formulation, fusion process as well as our licensing and training program allow for the consistent, reliable fusion of Fusible Brute and Fusible Series pipes to create piping systems of unparalleled strength.

Applications:

Water mains, sanitary sewers, process and raw water, reclaimed water and storm drains.

Installations:

• Slip Lining

• Pipe Bursting

• Direct Bury

• Horizontal Directional Drilling

Standards:

AWWA C900 & C905, CSA B137.3, NSF 61 and ASTM cell

classification 12454.

Pipe used in IPEX Fusible BruteTMand Fusible SeriesTMproduct lines Certified to CSA B137.3.

IPEX Fusible Brute

TM

products meet the AWWA C900 and

C905 standards.

IPEX Fusible Brute

TM

and Fusible SeriesTMproducts are marked

with NSF 61 when used for potable service.

Minimum Bend Radius

Minimum bend radii are independent of DR.

Bend Radius calculations are based on the assumption that a fitting or flange is present/to be installed in the bend. The Bend Radius for PVC includes a safety factor of 2.5 [Unibell Handbook of PVC, 4th Edition, Equation 8.6].

Effect of Temperature

Critical Buckling Pressure & Grout Pressure

– Initiates deformation of pipe through external pressure – Important to backfilling and grouting – Maximum recommended pressure:

Critical Buckling Pressures are calculated using a Long Term Modulus of Elasticity (400,000 PSI for PVC), and published Poisson's Ratio [Unibell Handbook of PVC, 4th Edition, equation 7.13]. No safety factor is included in the calculation for Critical Buckling Pressures.

Note: These maximum pressures are based on the temperature in the wall of the pipe not exceeding 73ºF (23ºC)

Maximum grouting pressures must be reduced with increased wall temperatures.

See the IPEX pressure pipe installation guide for more details.

IPEX FUSIBLETMPVC PIPE FOR TRENCHLESS APPLICATIONS

17

Pressure Piping Systems Design

PRODUCT INFORMATION

Short Form Specifications

Fusible PVC Pipe

IPEX pipe used in Fusible applications is certified to CSA B137.3 and NSF61, and conforms to AWWA C900 or AWWA C905. Testing shall be in accordance with CSA B137.3 and AWWA standards for all pipe types.

Fusion Technician Requirements

The PVC Fusion contractor must be identified in the tender documents and the Fusion Technician shall be fully qualified by IPEX to fuse Fusible PVC pipe of the type(s) and size(s) being used. Qualification shall be current as of the actual date of the tender and of fusion on the project.

Temperature

Pressure

Rating Factor

Tensile

Factor (Pull

Force)

Modulus of

Elasticity Factor

(Bend Radius)

ºF ºC % % %

73.4 23 100 100 100

80 26.7 88 95 98

90 32.2 75 87 94

100 37.8 62 78 88

120 48.9 40 63 78

140 60 22 58 70

DR

Critical Buckling Pressure Grout Pressure

psi psi

14 426 213

18 190 85

25 67 33.5

32.5 27 13.5

41 14.6 7.3

51 7.4 3.7

Pipe Size Bend Radius

inches mm ft m

4 100 328.08 30.5

6 150 492.12 43.7

8 200 656.17 57.5

10 250 820.21 70.4

12 300 984.25 83.7

14 350 1148.29 97.1

16 400 1312.33 110.4

PRODUCT INFORMATION

IPEX FUSIBLETMPVC PIPE FOR TRENCHLESS APPLICATIONS

18

Pressure Piping Systems Design

Nominal Size

DR

Avg. O.D. Min. Wall Avg. I.D.

Safe Pulling

Force

Pressure

Rating

Critical Buckling

Pressure

Min. Allowable

Bend Radius

(in) (mm) (mm) (mm) (mm) (lbf) (psi) (psi) (m)

4 100 DR 14 122.00 8.71 104.00 13,877 305 426 30.5

6 150 DR 14 175.00 12.52 149.00 28,736 305 426 43.7

8 200 DR 14 230.00 16.42 198.00 46,720 305 426 57.5

10 250 DR 14 282.00 20.14 242.00 71,499 305 426 70.4

12 300 DR 14 335.00 23.95 287.00 101,846 305 426 83.7

4 100 DR 18 122.00 6.78 108.00 10,984 235 190 30.5

6 150 DR 18 175.00 9.73 155.00 22,514 235 190 43.7

8 200 DR 18 230.00 12.80 204.00 38,492 235 190 57.5

10 250 DR 18 282.00 15.70 250.00 58,073 235 190 70.4

12 300 DR 18 335.00 18.62 297.00 81,924 235 190 83.7

14 350 DR 18 388.60 21.60 345.40 108,166 235 190 97.1

16 400 DR 18 442.00 24.60 392.90 139,838 235 190 110.4

18 450 DR 18 495.30 27.50 440.30 175,535 235 190 123.7

20 500 DR 18 548.60 30.50 487.60 215,617 235 190 137.1

24 600 DR 18 655.30 36.40 582.50 307,392 235 190 163.7

4 100 DR 25 122.00 4.88 112.00 7,982 165 67 30.5

6 150 DR 25 175.00 7.01 161.00 15,518 165 67 43.7

8 200 DR 25 230.00 9.20 212.00 26,616 165 67 57.5

10 250 DR 25 282.00 11.30 260.00 40,438 165 67 70.4

12 300 DR 25 335.00 13.41 309.00 57,247 165 67 83.7

14 350 DR 25 388.60 15.60 357.50 77,491 165 67 97.1

16 400 DR 25 442.00 17.70 406.60 99,719 165 67 110.4

18 450 DR 25 495.30 19.81 455.70 125,284 165 67 123.7

20 500 DR 25 548.60 22.00 504.70 153,768 165 67 137.1

24 600 DR 25 655.30 26.21 602.90 218,545 165 67 163.7

30 750 DR 25 812.80 32.51 747.80 335,507 165 67 203.1

36 900 DR 25 972.80 38.91 895.00 480,557 165 67 243.0

20 500 DR 32.5 548.60 16.90 512.83 118,256 125 30 137.1

24 600 DR 32.5 655.30 20.20 615.00 168,551 125 30 163.7

IPEX Fusible Brute Pipe Data CIOD

IPEX FUSIBLETMPVC PIPE FOR TRENCHLESS APPLICATIONS

19

Pressure Piping Systems Design

PRODUCT INFORMATION

Nominal

Size

DR

Avg. O.D. Min. Wall Avg. I.D.

Safe Pulling

Force

Pressure

Rating

Critical Buckling

Pressure

Min. Allowable

Bend Radius

(in) (mm) (mm) (mm) (mm) (lbf) (psi) (psi) (m)

4 100 DR 21 114.30 5.44 102.77 7,783 200 117 28.6

6 150 DR 21 168.30 8.02 151.30 16,931 200 117 42.0

8 200 DR 21 219.10 10.40 197.00 28,612 200 117 54.7

10 250 DR 21 273.10 13.00 245.49 44,887 200 117 68.2

12 300 DR 21 323.90 15.40 291.25 63,280 200 117 80.9

14 350 DR 21 355.60 16.90 319.77 76,343 200 117 88.8

16 400 DR 21 406.40 19.40 365.27 99,895 200 117 101.5

18 450 DR 21 457.20 21.80 410.98 126,646 200 117 114.2

20 500 DR 21 508.00 24.20 456.70 155,897 200 117 126.9

24 600 DR 21 609.60 29.00 548.12 223,407 200 117 152.3

4 100 DR 26 114.30 4.37 105.01 6,255 160 60 28.6

6 150 DR 26 168.30 6.48 154.56 13,694 160 60 42.0

8 200 DR 26 219.10 8.41 201.20 23,166 160 60 54.7

10 250 DR 26 273.10 10.50 250.79 36,328 160 60 68.2

12 300 DR 26 323.90 12.40 297.61 51,146 160 60 80.9

14 350 DR 26 355.60 13.70 326.56 62,091 160 60 88.8

16 400 DR 26 406.40 15.60 373.33 80,612 160 60 101.5

18 450 DR 26 457.20 17.60 419.89 102,675 160 60 114.2

20 500 DR 26 508.00 19.60 466.45 126,725 160 60 126.9

24 600 DR 26 609.60 23.50 559.78 181,538 160 60 152.3

Notes:

1

PVC safe pull stress of 7,000 psi is based on the published value of 7,000-8,000 PSI for short term tensile strength and a safety factor of 2.5 [Unibell Handbook of PVC, 4th Edition].

2

PVC safe pull forces are based on minimum wall thickness and the safe pull stresses as calculated per Note 1.

3

Critical Buckling Pressures are calculated using a Long Term Modulus of Elasticity (400,000 PSI for PVC), and published Poisson's Ratio [Unibell Handbook of PVC, 4th Edition, equation 7.13]. No safety factor is included in the calculation for Critical Buckling Pressures.

4

Pressure Ratings are per AWWA C900, AWWA C905 at 73° F.

5

Bend Radius calculations are based on the assumption that a fitting or flange is present/to be installed in the bend. The Bend Radius for PVC includes a safety factor of 2.5 [Unibell Handbook of PVC, 4th Edition, Equation

8.6].

IPEX Fusible Series Pipe Data IPS

PRODUCT INFORMATION

20

Pressure Piping Systems Design

TERRABRUTE®CR RESTRAINED JOINT PIPE

TerraBrute CR is a modified AWWA C900 pipe that has been specifically designed for use with trenchless installation techniques like horizontal directional drilling (HDD) and pipe bursting. Using an innovative system of rings and pins, TerraBrute CR can withstand higher pull forces than any other mechanically restrained plastic piping system, while simultaneously being able to bend and flex in a borehole.

In addition to trenchless installations, TerraBrute CR's versatile joint is perfect for above ground installations like bridge crossings where there may be significant temperature extremes. Where other piping systems require costly and maintenance intensive expansion joints, the wide groove in each TerraBrute CR joint allows expansion and contraction of each pipe.

Another key attribute of the TerraBrute CR joint is that it allows pipe rotation without damage. This can be an issue in seismic zones where piping systems are subjected to a wide variety of soil induced stresses during earthquake events.

External Pressures

Drilling fluids are used under many different soil conditions both to keep the borehole open and to remove the spoil from drilling and reaming operations. This drilling fluid is pressurized, and as a result, it is important that a pipe joint be able to withstand these external pressures without leaking fluid into the pipe string. IPEX has tested fully deflected joints to well over 100 psi external pressure with zero leakage.

Applications:

HDD, pipe bursting, bridge crossings, seismic zones, casing installations and steep slopes.

Standards

AWWA C900

TerraBrute CR is made with pipe conforming to AWWA C900. However once the pipe is grooved on the spigot end its dimensions do not match those published in the C900 standard. Because of this small dimensional difference the pipe, once grooved, does not strictly conform to the C900 standard. It is important to note however, that TerraBrute CR is subjected to the same testing program as IPEX’s Blue Brute (C900) pipe.

CSA B137.3

TerraBrute CR is certified to CSA B137.3.

NQ 3624-250

Factory Mutual and Underwriter’s Laboratories

TerraBrute CR is made from starting stock that is Factory Mutual approved, and ULC and ULI listed.

TERRABRUTE®CR RESTRAINED JOINT PIPE

21

Pressure Piping Systems Design

PRODUCT INFORMATION

Short Form Specifications

PVC pipe used for horizontal directional drilling (HDD) or other trenchless installation methods shall be manufactured with a cast iron outside diameter (CIOD) and shall be made with starting stock certified to CSA B137.3 for 100mm 300mm (4" - 12") diameters. Pipe will meet the requirements of AWWA C900, must be Factory Mutual approved, and listed by ULC or UL.

The maximum allowable pulling force shall be the ultimate tensile capacity of the piping system divided by a safety factor of 2, as shown in the adjacent table.

PVC pipe must be manufactured with an integral bell, and must have removable gaskets to allow the use of oil-resistant (nitrile) gaskets in contaminated soils.

Dimensions

TerraBrute CR is virtually identical to Blue Brute dimensionally. It has a slightly shorter laying length, as a result of the extended bell, as well as a groove cut into the spigot end of the pipe.

One key dimension that must be remembered when planning pre-ream operations is the absolute maximum outside diameter of the pipe. The table below shows the maximum outside diameter of each size.

Due to the extended bell configuration, TerraBrute CR has slightly shorter laying length than standard Blue Brute pipe:

TerraBrute CR Pipe Stops

IPEX TerraBrute CR Pipe Stops have been specifically designed to simplify the installation of 8", 10", and 12" (200mm, 250mm, and 300mm) TerraBrute CR. Due to fairly large insertion forces, it can often be difficult to align the internal groove with the pin holes on the larger diameter TerraBrute CR; the new TerraBrute CR Pipe Stops will virtually eliminate this problem of over-homing the pipe. TerraBrute CR Pipe Stops will reduce stoppages in the installation process to pull back and reposition the pipe.

IPEX TerraBrute CR Pipe Stops can be placed on the pipe quickly and easily; a pair of vicegrips is all that is needed to secure the Pipe Stop in place. Made from high-strength steel, TerraBrute CR Pipe Stops are designed to withstand repeated use for all of your installations.

Easy to Use

TerraBrute CR Pipe Stops are simple and easy to use, offering quick assembly and disassembly to help prevent installation delays. A pair of vice grips is all that is needed to secure the Pipe Stop in place.

Strong and Tough

Made from steel, TerraBrute CR Pipe Stops are built strong, tough and are durable enough to withstand repeated use on every job.

Prevent Over-homing

TerraBrute CR Pipe Stops virtually eliminate the risk of overhoming the pipe. There is no need to pull back and reposition the pipe as the groove will always end up properly aligned with the pin holes.

Nominal Size Maximum Allowable Pulling Force

mm Inches kN Lbs.

100 4 50 11200

150 6 110 24700

200 8 115 25800

250 10 187 42100

300 12 275 61800

Nominal Size

Maximum Outside Diameter

(Outside Ring)

mm Inches mm Inches

100 4 160 6.3

150 6 230 9.1

200 8 290 11.4

250 10 350 14.2

300 12 415 16.3

Nominal Size Laying Lengths

mm Inches m Feet/Inches

100 4 6.04 19' 10"

150 6 6.03 19' 9"

200 8 6.01 19' 9"

250 10 6.01 19' 9"

300 12 6.01 19' 9"

PRODUCT INFORMATION

TERRABRUTE®CR RESTRAINED JOINT PIPE

22

Pressure Piping Systems Design

Pulling Forces

The magnitude of pulling force exerted on a pipe string during pulled-in-place type installation methods depends on a number of factors, including:

• The length of the pull

• The diameter of the pipe

• The type of soil

• Selection of drilling fluid.

TerraBrute CR has been designed to withstand extremely high pulling forces in order to perform under even the toughest conditions. While most projects will use only a fraction of the ultimate strength of TerraBrute CR, the extra strength acts as an “insurance policy” against unexpected conditions.

TerraBrute CR’s ultimate pull strength has been verified by laboratory tests, and can be calculated using a semiempirical design method derived by researchers at the University of Western Ontario (UWO). The following table shows both the ultimate pulling capacity of the product (no safety factor) as well as the recommended maximum pulling capacity (2:1 safety factor)

Bending Forces

PVC pipe is much stiffer than the pipe material most commonly used for HDD and other trenchless methods – HDPE pipe. This has led some designers to wonder if PVC is too rigid to be used for these types of applications. In fact, stiffness and flexibility are two different properties. It is possible for a material to be very stiff and strong but still quite flexible. TerraBrute CR is flexible enough for virtually any HDD or pipe bursting operation, and can be installed to a much tighter radius than other PVC products. In fact, since TerraBrute CR is more flexible than the drilling rods, there is virtually no way to “over bend” the pipe. In addition, the high stiffness of the material means that there is very little deformation of the pipe string during pulling operations. As a result, appurtenances such as services and hydrant leads can be installed immediately after pulling operations are completed.

One of the most important characteristics of the TerraBrute CR joint is that it allows significant joint deflection. A significant portion of the bending is taken up by the joints, which reduces the amount of stress exerted on the pipe bell from bending. This allows TerraBrute CR to be installed to a much tighter radius than other PVC products.

The table below shows how much TerraBrute CR can be deflected at the joint during pullback operations, as well as how much the pipe barrel itself can be bent. Most projects will involve both pipe bending and joint deflection, often at the same time.

Nominal Size

Recommended

Pulling Limit

Ultimate Pulling

Capacity

(Straight Pull)

mm Inches kN lbs kN Lbs.

100 4 50 11200 100 22400

150 6 110 24700 220 49500

200 8 115 25800 230 51700

250 10 187 42100 375 84300

300 12 275 61800 550 123600

Nominal

Size

Allowable Joint

Deflection

Allowable Pipe

Bending

Minimum

Allowable Radius

mm in (degrees) (degrees) meters Feet

100 4 8.5 5.7 24.2 79.4

150 6 8.5 4 27.5 90.2

200 8 7.5 3 32.7 107.4

250 10 5 2.5 45.8 150.3

300 12 5 2.1 48.4 158.8

23

Pressure Piping Systems Design

PRODUCT INFORMATION

TERRABRUTE®CR RESTRAINED JOINT PIPE

Joint Assembly

Lubricate and assemble joint as for standard PVC pressure pipe.

Insert spigot up to the insertion line, aligning the internal ring and the pin holes.

Line up the pins on the external half

ring with the holes in the bell so that the half ring covers either the left or right side of the pipe

** SAFETY

GLASSES MUST BE WORN DURING PIN INSTALLATION.

3

1

2

One Ring at a time, place ring over pin holes and tap pins in until they bottom out on the inner groove.

4

PRODUCT INFORMATION

24

Pressure Piping Systems Design

CYCLETOUGH®PIPING SYSTEMS

CycleTough piping systems are specially designed for applications where pressures are expected to cycle up and down repeatedly, such as sewage forcemains, irrigation systems and other applications. One of the most important things to remember with CycleTough systems is that the fittings are made with PVC compound that has the same hydrostatic design basis (HDB) as the pipe. Always specify a complete system of pipes and fittings from the same manufacturer to ensure matching fittings.

Applications:

Forcemains, irrigation. Rural water supply, water distribution and transmission.

Standards

CycleTough Pipe

Certified to CSA B137.3 – Rigid Poly (Vinyl Chloride) (PVC) Pipe for Pressure Applications

ASTM D2241 – Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDRPR) PVC, ASTM D3139 and D2241.

NSF-PW listed for potable water

NQ 3660-950

CycleTough Fittings

Certified to CSA B137.3

Various ASTM Standards

NSF-PW

NQ 3660-950

Pressure Ratings

CycleTough pipe is available in long term pressure ratings from 100 to 200 psi.

For more information on how these ratings are calculated, please refer to section 3.

SDR

Short Term Rating (STR) Long Term Rating (LTR)

psi kPa psi kPa

41 160 1 100 100 690

32.5 200 1 380 125 860

26 256 1 770 160 1 100

21 320 2 210 200 1 380

CYCLETOUGH®PIPING SYSTEMS

25

Pressure Piping Systems Design

PRODUCT INFORMATION

Dimensions

CycleTough pipe and fittings are manufactured with an Iron Pipe Size outside diameter (IPSOD). This outside diameter

configuration is consistent with that used for Schedule piping (sch. 40 and 80) as well as steel pipe sizes.

Series 100 (SDR41) Series 125 (SDR32.5)

Size Avg. ID Min. Wall Thickness Avg. OD Avg. ID Min. Wall Thickness Avg. OD

in mm in mm in mm in mm in mm in mm in mm

4 100 4.278 108.41 .109 2.78 4.50 114.3 4.208 106.88 .138 3.50 4.50 114.3

6 150 6.282 159.57 .162 4.12 6.63 168.3 6.194 157.32 .204 5.18 6.63 168.3

8 200 8.180 207.77 .209 5.32 8.62 219.1 8.063 204.80 .265 6.72 8.62 219.1

10 250 10.194 258.93 .262 6.66 10.75 273.1 10.049 255.24 .331 8.40 10.75 273.1

12 300 12.093 307.15 .311 7.90 12.75 323.9 11.921 302.78 .392 9.96 12.75 323.9

14 350 13.277 337.24 .341 8.66 14.00 355.6 13.090 332.49 .429 10.90 14.00 355.6

16 400 15.174 385.41 .390 9.90 16.00 406.4 14.957 379.90 .492 12.50 16.00 406.4

18 450 17.074 433.67 .437 11.10 18.00 457.2 16.823 427.31 .555 14.10 18.00 457.2

20 500 18.985 481.71 .488 12.40 20.00 508.0 18.698 474.93 .614 15.60 20.00 508.0

24 600 22.756 578.01 .587 14.90 24.00 609.6 22.431 569.74 .740 18.80 24.00 609.6

Series 160 (SDR26) Series 200 (SDR21)

Size Avg. ID Min. Wall Thickness Avg. OD Avg. ID Min. Wall Thickness Avg. OD

in mm in mm in mm in mm in mm in mm in mm

1-1/2 40 1.731 43.97 .080 2.02 1.90 48.3 1.709 43.42 .090 2.28 1.90 48.3

2 50 2.184 55.47 .091 2.30 2.38 60.4 2.137 54.29 .113 2.86 2.38 60.4

2-1/2 65 2.642 67.11 .109 2.78 2.87 73.0 2.584 65.62 .137 3.48 2.87 73.0

3 75 3.215 81.65 .135 3.42 3.50 88.9 3.146 79.91 .167 4.24 3.50 88.9

4 100 4.134 105.01 .172 4.38 4.50 114.3 4.046 102.77 .214 5.44 4.50 114.3

6 150 6.085 154.56 .255 6.48 6.63 168.3 5.957 151.30 .316 8.02 6.63 168.3

8 200 7.921 201.20 .331 8.42 8.62 219.1 7.756 197.00 .409 10.40 8.62 219.1

10 250 9.874 250.79 .413 10.50 10.75 273.1 9.665 245.49 .512 13.00 10.75 273.1

12 300 11.717 297.61 .488 12.40 12.75 323.9 11.467 291.25 .606 15.40 12.75 323.9

14 350 12.857 326.56 .539 13.70 14.00 355.6 12.589 319.77 .665 16.90 14.00 355.6

16 400 14.698 373.33 .614 15.60 16.00 406.4 14.381 365.27 .764 19.40 16.00 406.4

18 450 16.531 419.89 .693 17.60 18.00 457.2 16.180 410.98 .858 21.80 18.00 457.2

20 500 18.364 466.45 .772 19.60 20.00 508.0 17.980 456.70 .953 24.20 20.00 508.0

24 600 22.039 559.78 .925 23.50 24.00 609.6 21.580 548.12 1.142 29.00 24.00 609.6

Short Form Specifications

Pipes

IPSOD PVC pipe shall be manufactured from PVC compound with ASTM D1784 cell class 12454. PVC pipe will have a minimum hydrostatic design basis (HDB) of 4000 psi and a short-term strength of 6400 psi. Pipe shall be certified to CSA B137.3.

Fittings

Injection-molded PVC fittings shall be made from PVC compound with a minimum HDB of 4000 psi.

Fabricated fittings shall be made from sections of pipe certified to CSA B137.3 and fittings shall also be certified to CSA B137.3.

All pipes and fittings shall be listed to NSF Standard 61 and shall be color coded white.

Size L R

in mm in mm in mm

2 50 1.18 29.5 0.75 18.8

2-1/2 65 1.80 45.0 1.00 25.0

3 75 2.00 50.0 1.00 25.0

4 100 2.20 55.0 1.00 25.0

6 150 2.80 70.0 1.25 31.3

8 200 4.87 121.8 1.50 37.5

90° Elbow G x G

Size L R

in mm in mm in mm

2 50 0.60 15.0 0.75 18.8

2-1/2 65 1.80 45.0 1.00 25.0

3 75 1.12 28.0 1.00 25.0

4 100 1.10 27.5 1.00 25.0

6 150 1.60 40.0 1.25 31.3

8 200 2.40 60.0 1.50 37.5

45° Elbow G x G

Size C H L

in mm in mm in mm in mm

2 50 1.30 32.5 1.10 27.5 7.60 190.0

2-1/2 65 1.67 41.8 1.63 40.8 9.50 237.5

3 75 1.99 49.8 1.99 49.8 10.80 270.0

4 100 2.57 64.3 2.65 66.3 12.50 312.5

6 150 3.76 94.0 3.77 94.3 14.90 372.5

8 200 4.91 122.8 4.91 122.8 21.65 541.3

Tee G x G x G

PRODUCT INFORMATION

CYCLETOUGH®PIPING SYSTEMS

26

Pressure Piping Systems Design

CYCLETOUGH®PIPING SYSTEMS

27

Pressure Piping Systems Design

PRODUCT INFORMATION

Size C H L

in mm in mm in mm in mm

2 x 1/2 50 x 15 1.40 35.0 2.15 53.8 7.10 177.5

2 x 3/4 50 x 20 1.40 35.0 2.15 53.8 7.10 177.5

2 x 1 50 x 25 1.40 35.0 2.15 53.8 7.10 177.5

2 x 1-1/4 50 x 32 1.40 35.0 2.15 53.8 7.10 177.5

2 x 1-1/2 50 x 40 1.40 35.0 2.15 53.8 7.10 177.5

2-1/2 x 1/2 65 x 15 1.45 36.3 2.50 62.5 7.90 197.5

2-1/2 x 3/4 65 x 20 1.45 36.3 2.50 62.5 7.90 197.5

2-1/2 x 1 65 x 25 1.45 36.3 2.50 62.5 7.90 197.5

2-1/2 x 1-1/4 65 x 32 1.45 36.3 2.50 62.5 7.90 197.5

2-1/2 x 1-1/2 65 x 40 1.45 36.3 2.50 62.5 7.90 197.5

2-1/2 x 2 65 x 50 1.45 36.3 2.50 62.5 7.90 197.5

3 x 1/2 75 x 15 1.50 37.5 2.70 67.5 9.75 243.8

3 x 3/4 75 x 20 1.50 37.5 2.70 67.5 9.75 243.8

3 x 1 75 x 25 1.50 37.5 2.70 67.5 9.75 243.8

3 x 1-1/4 75 x 32 1.50 37.5 2.70 67.5 9.75 243.8

3 x 1-1/2 75 x 40 1.50 37.5 2.70 67.5 9.75 243.8

3 x 2 75 x 50 1.50 37.5 2.70 67.5 9.75 243.8

4 x 1/2 100 x 15 1.56 39.0 3.10 77.5 10.17 254.3

4 x 3/4 100 x 20 1.56 39.0 3.10 77.5 10.17 254.3

4 x 1 100 x 25 1.56 39.0 3.10 77.5 10.17 254.3

4 x 1-1/4 100 x 32 1.56 39.0 3.10 77.5 10.17 254.3

4 x 1-1/2 100 x 40 1.56 39.0 3.10 77.5 10.17 254.3

4 x 2 100 x 50 1.56 39.0 3.10 77.5 10.17 254.3

6 x 1/2 150 x 15 1.80 45.0 3.96 99.0 13.00 325.0

6 x 3/4 150 x 20 1.80 45.0 3.96 99.0 13.00 325.0

6 x 1 150 x 25 1.80 45.0 3.96 99.0 13.00 325.0

6 x 1-1/4 150 x 32 1.80 45.0 3.96 99.0 13.00 325.0

6 x 1-1/2 150 x 40 1.80 45.0 3.96 99.0 13.00 325.0

6 x 2 150 x 50 1.80 45.0 3.96 99.0 13.00 325.0

Tap Service Tee - NPT Outlet

PRODUCT INFORMATION

CYCLETOUGH®PIPING SYSTEMS

28

Pressure Piping Systems Design

Size C H L

in mm in mm in mm in mm

2 x 1-1/2 50 x 40 1.30 32.5 1.10 27.5 7.60 190.0

2-1/2 x 2 65 x 50 1.67 41.8 1.63 40.8 9.50 237.5

3 x 1-1/2 75 x 40 1.85 46.3 1.60 40.0 10.80 270.0

3 x 2 75 x 50 1.85 46.3 1.60 40.0 10.80 270.0

3 x 2-1/2 75 x 65 1.90 47.5 1.60 40.0 10.80 270.0

4 x 2 100 x 50 1.90 47.5 2.00 50.0 11.30 282.5

4 x 2-1/2 100 x 65 1.90 47.5 2.00 50.0 11.30 282.5

4 x 3 100 x 75 1.90 47.5 2.00 50.0 11.30 282.5

6 x 2 150 x 50 2.40 60.0 2.80 70.0 14.90 372.5

6 x 2-1/2 150 x 65 2.40 60.0 2.80 70.0 14.90 372.5

6 x 3 150 x 75 2.40 60.0 2.80 70.0 14.90 372.5

6 x 4 150 x 100 2.40 60.0 2.80 70.0 14.90 372.5

8 x 2 200 x 50 3.85 96.3 4.87 121.8 19.50 487.5

8 x 3 200 x 75 3.85 96.3 4.87 121.8 19.50 487.5

8 x 4 200 x 100 3.85 96.3 4.88 122.0 19.50 487.5

8 x 6 200 x 150 3.85 96.3 4.88 122.0 19.50 487.5

Reducing Tee - G x G x G

Size C H L

in mm in mm in mm in mm

4 100 4.00 100.0 4.00 100.0 12.50 312.5

6 150 4.50 112.5 4.50 112.5 16.00 400.0

Cross G x G x G x G

Size L D

in mm in mm in mm

2 50 5.00 125.0 3.35 83.8

2-1/2 65 7.14 178.5 4.15 103.8

3 75 7.00 175.0 5.00 125.0

4 100 7.40 185.0 6.13 153.3

6 150 10.00 250.0 8.73 218.3

8 200 12.30 307.5 10.62 265.5

Stop Coupling G x G

CYCLETOUGH®PIPING SYSTEMS

29

Pressure Piping Systems Design

PRODUCT INFORMATION

Size L D

in mm in mm in mm

2 50 7.20 180.0 3.35 83.8

2-1/2 65 7.00 175.0 4.15 103.8

3 75 7.00 175.0 5.00 125.0

4 100 7.40 185.0 6.13 153.3

6 150 10.00 250.0 8.73 218.3

8 200 12.30 307.5 10.62 265.5

Repair Coupling G x G

Size L

in mm in mm

1-1/2 40 2.50 62.5

2 50 2.50 62.5

2-1/2 65 3.50 87.5

3 75 3.50 87.5

4 100 3.75 93.8

6 150 4.50 112.5

Permanent Plug Spigot

Size L C

in mm in mm in mm

1-1/2 x 2 40 x 50 2.40 60.0 0.20 5.0

2 x 2-1/2 50 x 65 2.40 60.0 0.20 5.0

2 x 3 50 x 75 3.40 85.0 0.55 13.8

2-1/2 x 3 65 x 75 3.40 85.0 0.38 9.5

2 x 4 50 x 100 3.00 75.0 0.40 10.0

2-1/2 x 4 65 x 100 3.00 75.0 0.40 10.0

3 x 4 75 x 100 3.00 75.0 0.40 10.0

2 x 6 50 x 150 4.30 107.5 0.50 12.5

2-1/2 x 6 65 x 150 4.30 107.5 0.50 12.5

3 x 6 75 x 150 4.30 107.5 0.50 12.5

4 x 6 100 x 150 4.30 107.5 0.50 12.5

4 x 8 100 x 200 5.10 127.5 0.60 15.0

6 x 8 150 x 200 5.10 127.5 0.60 15.0

Increaser Bushing - G x Sp

PRODUCT INFORMATION

CYCLETOUGH®PIPING SYSTEMS

30

Pressure Piping Systems Design

Size C D L

in mm in mm in mm in mm

1-1/2 40 3.85 96.3 5.00 125.0 4.25 106.3

2 50 4.75 118.8 6.00 150.0 4.75 118.8

2-1/2 65 5.50 137.5 7.00 175.0 5.75 143.8

3 75 6.00 150.0 7.50 187.5 6.50 162.5

4 100 7.48 187.0 9.02 225.5 10.52 263.0

6 150 9.55 238.8 10.97 274.3 13.48 337.0

8 200 11.75 293.8 13.50 337.5 12.00 300.0

Adapter - Flange x Gasket Bell

Size L

in mm in mm

1-1/2 40 1.50 37.5

2 50 1.80 45.0

2-1/2 65 2.00 50.0

3 75 2.10 52.5

4 100 2.30 57.5

6 150 3.10 77.5

Spigot Adapter G x Sp

Size L

in mm in mm

1-1/2 40 1.05 26.3

2 50 1.20 30.0

2-1/2 65 1.55 38.8

3 75 2.10 52.5

4 100 2.25 56.3

6 150 2.50 62.5

Male Adapter G x Male Pipe Thread

CYCLETOUGH®PIPING SYSTEMS

31

Pressure Piping Systems Design

PRODUCT INFORMATION

Size L

in mm in mm

1-1/2 40 2.60 65.0

2 50 3.00 75.0

2-1/2 65 3.80 95.0

3 75 4.10 102.5

4 100 4.40 110.0

6 150 5.40 135.0

Adapter Bell x Female IPT

Size L C

in mm in mm in mm

3 75 4.30 107.5 2.00 50.0

4 100 4.40 110.0 2.25 56.3

6 150 5.90 147.5 2.50 62.5

Adapter - PE (Plain End) x Male Pipe Thread

BLUE904TMPEX WATER SERVICE TUBING

Blue904 is fully certified, lightweight and flexible PEX water service tubing. Installation friendly, Blue904 will resist corrosion, maximizing water flow over the lifetime of the system.

Blue904 PEX Municipal Water service tubing has unique features and performance characteristics that make it the leading alternative to copper tubing. IPEX Blue904 conforms to CTS OD dimensions, allowing common compression fittings to be used.

Applications:

Water service lines that connect municipal watermains to buildings.

PRODUCT INFORMATION

32

Pressure Piping Systems Design

Codes and Standards

Blue904 PEX water service tubing is certified to cNSFus-PW, AWWA C904, ASTM F876, F877, F2023 and CSA B137.5, NQ 3660-950 as requirements of the following national codes.

American Water Works Association

NSF Standards 14 & 61

American Society for Testing and Materials

Bureau de Normalisation du Québec

Uniform Plumbing Code

33

Pressure Piping Systems Design

PRODUCT INFORMATION

BLUE904TMPEX WATER SERVICE TUBING

Pressure Rating

Long Service Life

Blue904 will resist the effects of chlorine and scaling and will not corrode in soil. It is also freeze resistant due to its low thermal conductivity when compared to copper tubing.

Jobsite Safe

Unlike copper tubing, PEX tubing has no scrap value, eliminating the threat of jobsite theft common with copper. As a result, no special storage precautions are necessary.

Packaging and Markings

Blue904 is available in 100 ft and 300 ft coils and is packaged in boxes for UV protection and portability. Each coil has footage markings to assist during installation and is identified with product name, size, certifications and manufacturing date.

Short Form Specification

Water service tubing shall be cross-linked polyethylene (PEX) tubing certified to cNSFus-PW, CSA B137.5 and ASTM F876. PEX tubing shall have PPI approved pressure ratings of: 160psi @ 23ºC (73ºF), 100psi @ 82ºC (180ºF) and 80psi @93ºC (200ºF).

The outside diameter of the pipe shall be copper tube size (CTS) and must have a standard dimension ratio (SDR) of 9.

PEX Tubing may be shaped by hand to a minimum radius of 8 times the outside diameter of the tubing. External end supports or sleeves may be required to maintain desired position and shape.

Note: When using pipe in coils and bending against the coil direction, the minimum bending radius is 3 times the radius given above. (e.g. 3/4" CTS pipe = 3 x 4.5" = 13.5")

Note: To avoid kinking, care should be taken when bending the tubing in sub zero temperatures. For bending in cold temperatures, use a minimum bend radius of 2 times that listed in the chart.

Dimensions

Nominal Size I.D.

Minimum Bend

Radius

mm Inches mm inches mm inches

19 3/4 17.3 0.68 178 7

25 1 22.2 0.88 229 9

38 1-1/2 31.5 1.24 330 13

51 2 41.3 1.63 432 17

Sizes Pressure Ratings

3/4" - 2"

(20mm - 50mm

)

160 psi @ 73ºF (1100 kPa @ 23ºC) 100 psi @ 180ºF (690 kPa @ 82ºC)

80 psi @ 200ºF (550 kPa @ 93ºC)

Q-Line is a composite pipe made with a layer of aluminum sealed between two layers of a special thermoplastic designed for use as water service tubing. The result is a pipe with all the advantages of both materials, and none of the weaknesses. It has the strength of metal service tubing and will never corrode as the metal is sealed in plastic. It rolls out flat like a metal pipe, but it is lightweight like a plastic pipe.

Non-Conductor

Roughly 370 serious electric shock incidents occur in the U.S. water utility industry every year

1

. While the AWWA has opposed the practice of grounding to the water system for over 80 years, it is still routinely done, despite the availability of grounding rods and plates. Since Q-Line is a non-conductor, it eliminates the risk of electric shock from stray currents. Specifying Q-line helps to eliminate the risk to municipal workers.

Effective Permeation Barrier

Chemical permeation is a real issue with small diameter service tubing made of PE. Q-Line’s aluminum core is an effective barrier and has been tested against the most aggressive contaminants such as termiticides.

Zero Scrap Value

The high scrap value of copper pipe has resulted in significant pilferage problems on job sites across North America. This has resulted in storage problems as all copper pipe must be properly secured each day.

Applications:

Water service lines, reclaimed water lines (purple pipe available)

PRODUCT INFORMATION

34

Pressure Piping Systems Design

Q-LINE®WATER SERVICE TUBING

Codes and Standards

Q-Line water service tubing is certified to cNSFus-PW, NQ 3660-950, ASTM F1282 and certified to CSA B137.9, and

meets AWWA C903 requirements as well as requirements of the following national codes.

Uniform Plumbing Code

International Residential Code

National Standard Plumbing Code

SBCCI Standard Plumbing Code

Bureau de Normalisation du Québec

35

Pressure Piping Systems Design

PRODUCT INFORMATION

Q-LINE®WATER SERVICE TUBING

1

Duranceau, Schiff, Bell. “Electrical Grounding, Pipe Integrity and Shock Hazard”, Journal of the AWWA, July 1998, pp. 40-51

Pressure Ratings

Q-Line is rated at 200 psi working pressure at 23ºC (73ºF). In addition, Q-Line is rated at 100 psi at 82ºC (180ºF). Since most water services operate at between 40 and 70 psi, even a back-up of hot water from the building into the water service will not compromise Q-Line.

Flow Rates

Q-Line has larger inside diameters than CTS PE piping and a better flow coefficient than copper pipe (C = 150 for Q-Line versus only 100 for copper pipe.) This gives Q-Line the best flow rates in the industry. And unlike copper pipe, Q-Line does not corrode or allow build-up of flow-constricting deposits on the ID of the pipe.

Flow Rate

(U.S. gpm)

Head Loss (psi/100 ft) Velocity (fps)

Flow Rate

(I/s)

Head Loss (kPa/100m) Velocity (m/s)

3/4" 1" 3/4" 1" 20mm 25mm 20mm 25mm

1.0 .1 0.0 .7 0.4 0.1 7.2 2.4 0.3 0.2

2.0 .5 0.2 1.3 0.8 0.2 26.1 8.8 0.6 0.4

3.0 1.0 0.4 2.0 1.3 0.3 55.3 18.7 1.0 0.6

4.0 1.8 0.6 2.6 1.7 0.4 94.2 31.8 1.3 0.8

5.0 2.7 0.9 3.3 2.1 0.5 142.4 48.1 1.6 1.0

6.0 3.8 1.3 4.0 2.5 0.6 199.6 97.4 1.9 1.2

7.0 5.0 1.7 4.6 3.0 0.7 265.5 89.7 2.2 1.4

8.0 6.4 2.2 5.3 3.4 0.8 340.0 114.8 2.6 1.6

9.0 8.0 2.7 5.9 3.8 0.9 422.9 142.8 2.9 1.8

10.0 9.7 3.3 6.6 4.2 1.0 514.0 173.6 3.2 2.0

11.0 11.6 3.9 7.2 4.6 1.1 613.3 207.1 3.5 2.2

12.0 13.6 4.6 7.9 5.0 1.2 720.5 243.3 3.8 2.5

13.0 15.7 5.3 8.5 5.5 1.3 835.7 282.2 4.1 2.7

14.0 18.0 6.1 9.2 5.9 1.4 958.6 323.7 4.5 2.9

15.0 20.5 6.9 9.9 6.3 1.5 1089.2 367.8 4.8 3.1

16.0 23.1 7.8 10.5 6.7 1.6 1227.5 414.5 5.1 3.3

17.0 25.8 8.7 11.2 7.1 1.7 1373.4 463.8 5.4 3.5

18.0 28.7 9.7 11.8 7.6 1.8 1526.8 515.5 5.7 3.7

19.0 31.7 10.7 12.5 8.0 1.9 1687.5 569.8 6.1 3.9

20.0 34.9 11.8 13.2 8.4 2.0 855.7 616.6 6.4 4.1

21.0 38.2 12.9 13.8 8.9

22.0 41.7 14.1 14.5 9.2

23.0 45.2 15.3 15.1 9.7

24.0 - 16.5 - 10.1

25.0 - 17.8 - 10.5

26.0 - 19.2 - 11.0

27.0 - 20.6 - 11.4

28.0 - 22.0 - 11.8

29.0 - 23.5 - 12.2

30.0 - 25.0 - 12.7

Table 2 – Q-Line Flow Rates

Short Form Specifications

Water service tubing shall be composite PE-AL-PE tubing manufactured in accordance with the requirements of AWWA C903 and certified to CSA B137.9 and ASTM F1282. It shall have a long term pressure rating of 1380kPa at 23ºC (200 psi at 73ºF) and 690kPa at 82ºC (100 psi at 180ºF). The pipe shall be third-party tested and certified to comply with NSF-PW

potable water and NSF CL-TD chlorine resistance requirements. The service tubing shall be color coded light blue as manufactured by IPEX under the trade name “Q-Line” or approved equal.

Fittings for composite PE-AL-PE tubing shall be brass water service fittings conforming to AWWA C800.

PRODUCT INFORMATION

36

Pressure Piping Systems Design

Q-LINE®WATER SERVICE TUBING

Dimensions

Q-Line has unique inside and outside diameters that are different both from copper and conventional PE service tubing. Easily installed adapters that allow Q-line to be used with standard brass fittings are widely available. Unlike PE pipe, Qline does not require a stiffening insert to be used.

Nominal Size Avg. ID

Min. Wall

Thickness

Avg. OD Weight Volume

Min. Bending

Radius

in mm in mm in mm in mm lbs/100ft kg/100m U.S. gal/ft l/m in mm

3/4 20 .79 20 .10 2.5 .98 25 12.4 18.4 .025 .314 5.0 125

1 25 .98 25 .14 3.2 1.26 32 21.0 31.2

.040

.500 6.3 160

37

Pressure Piping Systems Design

PRODUCT INFORMATION

STANDARDS FOR PVC AND PVCO PRESSURE SYSTEMS

Standards and Certifications

There are two main classes of standards governing PVC piping systems, those which define products that are certified by a third party and those which define products that are nonpoliced. While non-policed standards can be very useful in a specification, the standards that are certified by a third party offer the customer an additional level of quality assurance. Thirdparty certification means that an independent organization has scrutinized the manufacturing process and QA/QC procedures for the products in question, and has verified that they meet the minimum requirements for approval. Compliance with a nonpoliced standard requires the customer to take the manufacturer at his word that his product conforms to the standard. Most manufacturers perform accurate in-house testing and are honest and up front, and if they state that their products meet a certain standard, you can be quite certain that they do. There is no question however, that certification by a third party provides a much higher degree of assurance that the products in question in fact meet the applicable standard and that they will perform as stated.

Third-Party Certified Standards

Canadian Standards Association (CSA)

CSA B137.0 CSA B137.1 CSA B137.2 CSA B137.3 CSA B137.3.1 CSA B137.5 CSA B137.9

CSA staff visit all IPEX plants producing certified product several times each year. In addition to witnessing manufacturing and QA/QC procedures, CSA staff also inspect records, and select product samples for independent testing. The CSA standards refer to a wide variety of external standards (such as ASTM standards) for items such as testing methods. As a result, certifying the product to a CSA standard often has the effect of indirectly certifying the product to other standards as well.

Factory Mutual (FM)

FM 1612

This third-party-certified standard is often required whenever the piping system is going to be used as a fire-protection line. In the case of FM, insurance regulations sometimes dictate the standard to be used. The certification methods are similar to those used by the CSA.

National Sanitation Foundation (NSF)

NSF 14 NSF 61

Both of these standards are third-party-certified. The NSF 14 standard includes two major areas: material testing for potability and product testing for performance. Listing to this standard means that the pipe/fitting material will have no adverse effect on water quality and that the pipe/fitting product will meet the performance requirements of the standard. NSF 61 includes the potability testing portion of NSF 14.

Underwriters Laboratories (UL, ULI, ULC)

UL 1285

This standard is also third-party-certified and is often required when the pipeline is used in fire-protection applications. Certification methods are similar to those employed by CSA.

Accreditation of Standards Labs and Organizations

While the standards discussed above are normally certified by a third party, that third party can sometimes be a separate organization. For example, Intertek Warnock-Hersey is a laboratory accredited by the Standards Council of Canada, and as a result, it is capable of certifying products to standards. It is common for Intertek Warnock-Hersey to certify a product to a CSA standard, and NSF also has this capability.

Non-Certified Standards

American Water Works Association AWWA C900 AWWA C903 AWWA C904 AWWA C905 AWWA C907 AWWA C909 certified by NSF for Bionax

C900, C905 and C907 all deal with PVC pressure pipe and fittings. C909 covers PVCO pressure pipe (Bionax) and C903 is for composite service piping (Q-line). AWWA standards are used when specifying water transmission or service piping.

ASTM Standards (Various standards)

ASTM Standards are referenced by all the above standards. They cover everything from materials to manufacturing to testing to installation, which is why there are so many different ASTM standards associated with our products. While they are “non-policed”, the fact that many ASTM standards are included in policed standards means that indirectly, they are third-party certified standards.

Design and Installation Standards

AWWA C605

This standard provides guidance and instruction for underground installation of PVC/PVCO piping systems.

AWWA Manual M23

The M23 Manual includes information for proper design and installation of PVC and PVCO pipe. Because the AWWA C900, C905 and C909 standards are being revised, Manual M23 will also need major revision. When using the 2002 edition of M23, it is recommended that information found in the Manual be supplemented by study of the most current edition of the three product standards.

38

Pressure Piping Systems Design

NOTES

______________________________________________________

Properly designed and installed PVC piping systems will last virtually forever. Recent research has unearthed PVC systems that were installed in the 1930’s that exhibit virtually no reduction in serviceability. This section focuses on the physical properties of PVC pipes and fittings, as well as how to approach some of the conditions likely to be encountered during a project.

Various design issues will also be addressed including;

• The hydrostatic design basis (HDB) of PVC pipe

• Calculating pressure ratings

• Hydraulics and headloss calculations

• Restraint design

• Installation in contaminated soils

• Surge pressures in PVC pipe

• Air entrapment and proper location of air release valves

• Thermal effects

• Design for cyclic fatigue

MATERIAL PROPERTIES OF PVC

Design Life

Designers should use a minimum 100 year design life when carrying out lifecycle costing calculations for PVC systems. This is backed up both by research and real world installations.

Current Research

PVC pressure pipes have been in service for over 70 years in Europe

2

. Samples of 70 year old pipe have been excavated and have exhibited no reduction in serviceability. PVC pipe’s installed history in North America is approaching 50 years, with a similar record for excellent service. The single most destructive force attacking our municipal water and sewer infrastructure is corrosion. By using materials that are immune to electrolytic corrosion or chemical attack, designers eliminate the single most common problem associated with buried infrastructure.

Research dealing with the longevity of PVC pipe in various conditions is on-going, however there have been a number of notable research papers presented over the years, including:

• AWWA Research Foundation – “Quantifying Future

Rehabilitation and Replacement Needs of Watermains”, 1998

This study used a highly specialized computer model to estimate the life of various materials based on past performance. In the one North American city studied with a significant amount of PVC pipe installed, PVC was rated at a minimum 100 years while concrete and ductile iron were rated at 85 and 60 years respectively.

• “PVC Pipe Study – Performance of PVC Water Main

Pipe installed in the City of Edmonton between 1977 and 1994”

A comprehensive study of PVC pipe used in the City’s water distribution system rated its service life at a minimum of 88 years with minimal maintenance.

Case Studies from Europe and North America including:

• Dallas, Texas – A PVC sewer pipe installed in 1973 was excavated and subjected to each of the tests outlined in ASTM D3034. The results show that the excavated pipe still met all the standards applicable to new pipe

• Denmark – A PVC Sewer pipe installed in 1963 was excavated and testing results show that the pipe has the same material properties as newly produced pipe. Most of the pipes installed were directly into native soil without bedding, and have performed acceptably for over 40 years.

These research papers are available upon request from your IPEX marketing representative at marketing@ipexinc.com or visit the IPEX website at www.ipexinc.com./www.ipexamerica.com.

SECTION 2: PROPERTIES OF PVC PRESSURE PIPE AND PRESSURE SYSTEM DESIGN

INTRODUCTION

2

Hulsmann, Nowack,”70 Years of Experience with PVC Pipes” Conference Paper, Plastic Pipes XII, Milan, April 2004

39

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Pressure Piping Systems Design

Design Strength for PVC Pipe

While Blue Brute pipes are casually referred to as PVC pipes, in reality they are made of a special PVC compound designed specifically for use in piping systems. The Hydrostatic Design Basis (HDB) of a PVC compound is the minimum stress that the material is able to withstand over a given time. The HDBs of IPEX compounds are established through both short-term and long-term testing (up to 10,000 hours sustained pressure). By plotting the results on a logarithmic scale, the 50 or 100 year design stresses can be easily extrapolated. The diagram below shows a typical life line for a PVC compound.

As can be seen from the diagram, PVC compounds have:

• High Short Term Strength While all IPEX PVC pressure pipes have a long-term hydrostatic design basis of 4000 psi, in the short term their strength is much higher – 6400 psi. This means that the pipe can easily withstand extremely high short term pressures, such as those generated by transient surges. For example, although a DR18 pipe is rated at 235 psi, it routinely withstands well over 750 psi during quick burst tests.

• Dependable Long-Term Strength At normal operational stress levels, the lifespan of the material is virtually unlimited. Because of the large reserves of strength, even stresses that build to levels above the normal safety factors can be accommodated.

Summary of Material Properties

All PVC pressure pipes are made of a proprietary PVC compound formulated specifically for pressure pipe applications.

Table 3 – Summary of Properties for PVC Pipe

Chemical Permeation and Installation of PVC Pipe in Contaminated Soils

There is a misconception among some designers that PVC pipe is unsuitable for installation in areas that contain soils contaminated by organic compounds. This misconception stems from the fact that there have been rare occurrences where small diameter plastic service lines have been permeated by organic chemicals. This is not an issue with larger diameter PVC pipes because:

1. The vast majority of documented permeation incidents occurred with thin wall service pipes made of lower density materials such as polybutylene or polyethylene

3

. These small diameter pipes are indeed unsuitable for contaminated soils. Only service pipe with a built in permeation barrier (such as Q-Line) should be used in these cases.

2. PVC pipe has an effective permeation time of many centuries, even at extremely high levels of environmental contamination. This has been conclusively proven through research

4

.

3. The high density and non-porous finish of PVC pipe makes it very difficult for permeation to occur. Samples of IPEX pressure pipe we partially filled with gasoline and sealed for seven years. When the inside surface of the pipe was examined microscopically, no evidence of permeation was found

5

.

Gaskets are the weak link when installing gasketed piping systems in contaminated soils. The most important consideration is the gasket material, regardless of the piping material. To ensure safe, long-term operation of the pipeline, oil-resistant (nitrile) gaskets should always be specified.

Lastly, many designers consult chemical resistance guides for information about installation in contaminated soils. These guides are usually inappropriate for this application as they typically deal with a 100% concentration of the material in question. You should consult with your IPEX technical representative before making any decisions with respect to suitability for a particular application.

Material Property

Hydrostatic Design Basis (HDB) 26.6 MPa (4000 psi)

Short-Term Strength (STS) 44.1 Mpa (6400 psi)

ASTM Cell Class (ASTM F1784) 12454

Young’s Modulus 266 Mpa (400,000 psi)

Poisson’s Ratio 0.38

3

Jenkins, Thompson,”Review of Water Industry Plastic Pipe Practices”, AWWA Research Foundation, 1987

4

Berens, A.R., “Prediction of Chemical Permeation through PVC Pipe”, Journal of the AWWA, November 1985

5

Hoogensen Metallurgical Engineering Ltd.,”Examination of Submitted PVC Pipe Section”, Report to IPEX, December 1998

Figure 1 – Stress Regression Line - Cell Class 12454

40

10000

4000

Stress (psi)

2000

1000

1

100

10

1000

10000

100000

HDB Intercept

Time (hours)

6

10

(114 Years)

7

8

10

9

10

41

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

UV Resistance

PVC pipe can become discolored when exposed to direct sunlight for a long period of time. This discoloration affects only the surface of the material (to a depth of 0.003 inches), and does not appreciably affect the performance of the pipe. A slight reduction in the impact strength of the pipe occurs, while the tensile strength and the modulus of elasticity are unaffected. If gasketed PVC pressure piping will be used in an exposed location, painting the surface of the pipe with a latex-based paint, or covering it with an opaque barrier will eliminate the effects of U.V. exposure.

The vast majority of gasketed pressure piping is installed underground, eliminating the issue of UV exposure.

Thermal Effects – Pressure Derating

PVC is a thermoplastic, which means its mechanical properties change with temperature. The pressure rating for PVC pipe (and most other thermoplastic piping materials) is calculated at 73ºF (23ºC). Above that temperature, the tensile strength of the material decreases, and the pressure rating must be de-rated by the factors shown in the table below. The maximum recommended service temperature for PVC pressure pipe is 140ºF (60ºC). PVCO pipe uses the same table , with the exception that the maximum recommended temperature is 130ºF (54ºC).

Table 4 – Temperature Effects on PVC Pressure Pipe

Thermal Effects – Expansion and Contraction

While buried applications seldom involve significant temperature variations, applications such as bridge crossings or casing installations can have temperature variations. When considering the use of unrestrained joints or TerraBrute CR joints, expansion and contraction should be calculated per length of pipe. If the joints are restrained using conventional restrainers, or a solvent cemented joint is used, expansion and contraction should be calculated using the full length of restrained pipe.

DESIGN CALCULATIONS

How to Calculate Pressure Capacity

The ISO Equation for thermoplastics makes calculating required dimension ratios and pressure capacities very simple.

While it is referred to as the ISO Equation, it was actually developed in 1852 for use with all sorts of pressure vessels, and has been used ever since. The derivation is simple.

Referring to the figure, we can see that the force in the pipe wall is:

Therefore, the maximum stress in the pipe wall is:

The conservative design procedure of PVC and PVCO pipe requires that a safety factor be applied to the Hydrostatic Design Basis (HDB) in order to arrive at a hydrostatic design Stress (S). This design stress then becomes the maximum allowable stress in the material. It is important to note that the short and long term strengths of each material are different and, therefore, the short-term and long-term design stresses will be different.

The safety factors for all PVC/PVCO pressure pipes in North America have traditionally been either 2.0 or 2.5, depending on the application and the standard governing the design. The new standards are moving towards a safety factor of 2.0 for all cases. However, since not all of the standards have been published, the information below conservatively continues to use the Manual M23 safety factor of 2.5 for short term stresses.

This form of the equation allows the pressure capabilities of a given dimension ratio to be quickly and easily calculated.

ºC ºF

Multiply the pressure

rating by these factors

32 90 0.75 38 100 0.62 43 110 0.50 49 120 0.40 54 130 0.30 60 140 0.22

Material

Expansion Coefficient

in/in/ºF

Expansion Coefficient

in/100ft/10ºF

Expansion

Coefficient

mm/mm/ºC

Expansion Coefficient

mm/10m/10ºC

PVC

3.0 x 10

-5

0.36

5.4 x 10

-5

5.4

PVCO 3.1 x 10

-5

0.36

5.4 x 10

-5

5.4

HDPE

12.0 x 10

-5

1.44

14 x 10

-5

21.6

Ductile Iron

0.62 x 10

-5

0.07

1.1 x 10

-5

1.1

Concrete

0.55 x 10

-5

0.07

1.0 x 10

-5

1.0

Steel

0.65 x 10

-5

0.08

1.2 x 10

-5

1.2

σ

max

SF

S=

P(DR – 1) 2S

2 (DR – 1)

S=

∴ P =

PiD

2

Force =

(

)

PiD

2t

σ

max

= , where D = the average diameter of the pipe

Pi(Do – t)

2t

D = Do – t ∴ σ

max

=

Do P1(DR –1)

t 2

But since DR = , then σ

max

=

PiD

2

PiD

2

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Pressure Piping Systems Design

Calculating a Pressure Rating (CSA) or Class (AWWA)

There are two ratings for every PVC pipe – a long term pressure rating (LTR) which is used for evaluating working pressure capacity, and a short term pressure rating (STR) designed for evaluating surge and pressure capability.

To calculate an STR, simply apply the ISO equation using the short term strength:

Recall that:

For short term stresses, AWWA standards set the safety factor

(SF) = 2.0. Using the s hort term strength gives:

Therefore for DR41 pipe, the STR is given by

For long term stresses, the safety factor is also set at 2.0:

Using the HDB gives:

Applying the ISO Equation:

The table below shows both the LTR and the STR for various thicknesses of PVC pipe:

*Values have been rounded down to the nearest 5 psi

For PVCO pipe:

Calculating Friction Headloss in PVC Piping Systems

One of the advantages in using PVC pipe is that its smooth inside finish dramatically reduces friction headloss when compared to other materials. As a result, pumping costs are lower and flows are higher when considering the same nominal diameter between materials.

The Hazen-Williams equation is one of the most commonly used methods for calculating friction headloss in a pipeline. It allows the friction headloss to be easily calculated for any piping system using flow coefficients that reflect the roughness of the piping material. Research has established that the Hazen-Williams flow coefficient for PVC pipe can vary between 155 to 165 for both new and previously used PVC pipe

6

. Therefore, a conservative coefficient of 150 is appropriate for all design situations. This value is also recommended by the AWWA M23 Design Manual.

V = 1.318Cr

0.63S0.54

in USCS Units

V = 0.8492Cr

0.63S0.54

in SI Units

Where:

V = average pipe velocity, ft/s (m/s)

C = Hazen-Williams Friction factor (150 for PVC Pipe)

R = Hydraulic radius (D/4 for a full pipe), ft (m)

S = Hydraulic gradient or frictional head loss per unit

length of pipe, ft/ft, (m/m)

SDR

Short Term Rating

STR* (2.5:1 S.F.) (psi)

Long Term Rating

LTR* (2:1 S.F.)

(psi)

51 128 80

41 160 100

32.5 200 125

26 256 160

25 264 165

18 376 235

14 488 305

σ

max

SF

S=

6400

2.0

S

str

=

= 3200 psi

2(3200) (41 – 1)

STR =

= 160 psi

4000

2

S

ltr

=

= 2000 psi

2(2000) (41 – 1)

LTR =

= 100 psi

6

Uni-Bell PVC Pipe Association, “Handbook of PVC Pipe – Design and Construction”, fourth edition, (August 2001)

Pressure Class

Short Term Rating

(psi)

Long Term Rating

(psi)

235 301 235

42

43

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Comparing Headloss Among Various Piping Materials

For any given nominal diameter of pipe, there are two factors which will largely dictate the headloss per unit length:

1. Internal diameter – It is the internal diameter of the pipe that should be used for hydraulic calculations, not the nominal diameter. A larger internal diameter promotes a greater fluid flow and therefore a lower headloss.

2. Internal friction coefficient – While internal diameter is important, the influence of the pipeline’s internal finish should not be neglected. While PVC and other plastics can sustain a smooth inside surface indefinitely, other materials tend to become rougher as a result of corrosion byproducts forming over the long term. As a result, older iron pipes have been shown to have friction factors less than

100.

While experimental data has shown that the “C” factor can be as high as 155-165 for both new and used PVC pipe, AWWA M23 Manual recommends a “C” factor of 150 for PVC

7

.

Table 5 – Hazen-Williams “C”-Factors

Comparing various materials it can be seen that PVC pipe has a much lower headloss at any given flow than other nonplastic piping materials:

• Class 52 iron pipe has a slightly larger inside diameter than DR18 PVC, but its low long-term C factor of 100 or less results in poor flow characteristics.

• SDR9 HDPE has a high C factor of 150, however it has a much thicker pipe wall and thus has a much smaller inside diameter than PVC DR18.

Calculating Surge Pressures – PVC Pipe

Surge pressures (water hammer) are generated in a piping system whenever the fluid flowing in that system changes velocity. These changes in velocity can be caused by many things, including:

• The operation of valves and pumps

• Entrapped air being expelled

• Changes in demand

There are two main types of surge pressures - transient surges that occur as the system moves from one steady state condition to another (ie: the closing of a single valve), and cyclic surges, that occur as part of the normal operation of some types of pipelines. A good example of this is a sewage forcemain, where a pump is activated each time the level in a wet well reaches a certain point.

The magnitude of pressure surges is dependent upon a number of things, including the type of fluid being pumped, the magnitude of the velocity change, and also the type of pipe material. Rigid piping materials typically generate much higher surge pressures than flexible systems, which are able to absorb much more of the shock generated by a surge. In addition, the high short term strength of PVC allows it to have a much higher safety factor against short term pressures than other piping materials.

The calculation of transient effects in a large piping system (regardless of the piping material) is a complicated procedure requiring considerable expertise. Fortunately, there are many engineering firms that are highly qualified to undertake this type of analysis. IPEX has worked closely with some of these experts, and we would be happy to refer interested designers to them. We highly recommend that detailed transient analysis be performed on all systems, particularly large diameter systems.

While a detailed analysis can be beneficial, it is possible to calculate the magnitude of individual surges in a pipeline using the elastic wave theory of surge analysis. The magnitude of the surge pressure caused by a rapidly closing valve, for example, is related to the rate of change of the flow, while the rate of travel of the pressure wave is related to the speed of sound in the fluid (modified by the piping material).

Material “C” Factor

Plastic (PVC, PVCO & HDPE) 150

Iron (new) 130

Iron (20 yrs old) 100

7

AWWA Manual M23, 2ndEdition – PVC Pipe – Design and Installation, 2002, American Water Works Association

8

“Pump Handbook – Third Edition” – Karassik, messina, Cooper & Heald, pp.8.36

Figure 2 – Pipe Material

Headloss - 200 mm Pipe at 25 L/s

SDR9 HDPE

0.006

0.005

0.004

0.003

0.002

Headloss, m/m

0.001 0

DR18 PVC

CL52 DI

Pipe Material

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

44

Pressure Piping Systems Design

Calculating Wave Velocity – Pipe

Where:

a = Wave velocity, ft/s

K = Bulk fluid modulus (300,000 psi for water)

E = Modulus of Elasticity for the pipe (400,000 psi

for PVC and 500,000 psi for PVCO)

Surge Pressure – PVC Pipe

Once the wave speed has been calculated, the maximum pressure surge can be calculated using the equation:

Where:

a = wavespeed (ft/s)

ΔV = maximum velocity change (ft/s)

g = acceleration due to gravity (32.2 ft/s

2

)

P = maximum pressure surge (psi)

Applying the equations to all DRs of PVC pipe, assuming a 1 ft/s (0.3 m/s) stoppage, gives the results in the table below:

Vacuum Pressures

While pipe joints are tested to –10.8 psi to meet CSA Standards, IPEX has simulated negative pressures far in excess of full vacuum (–14.7 psi) by applying external pressures in excess of 100 psi. This proves conclusively that IPEX pipe joints can easily withstand full vacuum pressures.

Calculating Surge Pressures – PVCO Pipe

For PVCO pipe, DR is not used. Instead, Do/t is the dimension based variable for calculating wave velocity. The modulus of

elasticity for calculating surge pressures is 500,000 psi. Using the equations above and the PVCO values, the surge pressure for a velocity change of 0.3 m/s (1.0 fps) in PC 235 PVCO pipe is 14.6 psi.

Air Entrapment in Pipelines

Air in pipelines can cause significant difficulties in any pipeline system, and should be avoided wherever possible. This can be accomplished by careful design of the pump or gravity inlet, employing proper filling and testing procedures, laying the pipe to grade wherever possible and by properly siting and sizing air release valves.

Some of the problems caused by air entrapment include:

1. Air pockets can reduce the amount of cross sectional area available for fluid flow at some points in the pipeline. This can result in higher headloss and fluctuations in flow rates caused by air movement

2. Flow fluctuations can cause surge pressures in the pipeline

3. Release or venting of the air can cause extremely high surge pressures.

Sources of Air in Pipelines

The most common air sources are:

• Entrapment of air during filling operations

• Entrapment at the pump or gravity inlet

• Release of dissolved air from the fluid in the pipeline

• Air intake from air release valves

Problems Associated with Air Entrapment

The key problem with air entrapment is that at some point the air may be vented in an uncontrolled way. As an air pocket travels along a pipeline, it may reach an area where it can be vented. This could be at an air release valve (good) or perhaps at a gasketed joint (bad). The gasketing systems in most pipelines are designed to work with water, not air. While in most cases the gasket will hold back a high pressure air pocket, at some point the gasket may be blown out of the joint, causing a rapid release of air. Since the air can be vented extremely quickly, the air pocket collapses at an extremely high rate. The water surges toward the orifice created by the blown gasket, but cannot be expelled at the same velocity as the air due to its much higher density. The result is a rapid deceleration of the flow and a huge transient shock wave – sometimes at a magnitude that can cause pipe failure.

SDR PVC Surge Pressure (psi)

51 10.8

41 11.4

32.5 12.8

26 14.5

25 14.7

18 17.4

14 19.8

P= a(ΔV)

(2.31) g

a = 4,660

( 1+ (k/E) (DR – 2)

45

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Air Release Valves

Air release valves are designed to exhaust air under various different pressure conditions in the pipeline, while restricting the flow of liquid. Air release valves are different from Air/Vacuum release valves in that Air/Vacuum release valves have a much larger orifice and are designed to exhaust or intake very large volumes of air, such as during the filling or draining process. The orifice size for an air release valve is generally between 1/16" and 1/4" diameter, while air/vacuum release valves can be between 1" and 8".

A third type of valve combines the two functions, and is called a combination air/vacuum release valve. It contains both a large and a small orifice, the larger being open during filling and draining operations, and the smaller being open continuously to exhaust any air that might collect during normal operation of a pipeline.

Automatic air release valves with a riser diameter to main pipe ratio, d/D, in the order of 0.01 should be used when untrained personnel fill or test the pipeline. Air release valves in this size range tend to limit the passage of air and allow time for the water to slow down before reaching the vent.

Hydrants are not useful for the venting of air from pipelines. The reason is that hydrant leads typically are located at the 3 o’clock or 9 o’clock position on a pipeline. Air vents must be located at high points (ie at 12 o’clock) to be effective.

Pipeline Testing and Air Entrapment

The initial filling and testing of a pipeline is one of the most critical events in the lifetime of a pipeline system. The reason is that the potential for air entrapment is highest during this period. As a result, Design Engineers should include details and procedures covering filling and testing in their project specifications:

1. Pipelines should be installed at a grade which results in a minimum of high points. Abrupt transitions and sharp peaks should be avoided.

2. Automatic air and vacuum release valves should be properly sized and installed at all high points or other areas where air could be expected to accumulate

3. The average water velocity when filling the pipeline should not exceed 1 ft/s (0.3 m/s)

4. All air should be purged from the pipeline before checking for leaks or performing pressure or acceptance tests on the system

5. If a large quantity of water is needed to increase the pressure during testing, then entrapped air or a leak is possible. Testing should be discontinued until the source of the problem is identified

Further References:

Perhaps the most easily accessible work on the subject of air entrapment in pipelines was a film produced in the late 1960’s at Colorado State University. It was commissioned by a major pipe manufacturer and clearly shows the effect of air entrapment in pipelines and the importance of properly sizing and situating air release valves. Contact your IPEX technical representative for a copy on CD.

Nominal Size Max Filling Rate

In mm gpm L/s

4 100 40 2.5

6 150 87 5.5

8 200 157 9.9

10 250 245 15

12 300 353 22

14 350 480 30

16 400 627 39

18 450 793 50

20 500 979 61

24 600 1410 89

30 750 2203 139

36 900 3173 200

42 1050 4318 272

48 1200 5640 355

Cyclic Design for PVC Pipes

Fatigue is a well known phenomenon that can affect many different materials. Only when a piping system is subjected to extreme cyclic loading conditions does fatigue in PVC pipe become a design factor. Fortunately, there has been a great deal of research done on this topic, and some recent research completed by Dr. A. Moser at Utah State University has contributed greatly to the understanding of this phenomenon.

Dr. Moser has determined that the number of cycles to failure (C) of PVC pipe is a function of the average stress in the pipe walls, as well as the amplitude of the cycles. This builds on previous work done by H.W. Vinson that based the cycles to failure only on the maximum stress in the material.

While cyclic loading is possible in many different applications, it is typically encountered in sewage forcemain and irrigation applications (Most water distribution mains or transmission mains have relatively constant pressures.) Any application that has pumps starting up and shutting down at regular intervals (ie more than a couple of times per day) should be analyzed using Dr. Moser’s method.

The following graph shows how the average stress and the amplitude are related to the number of cycles to failure.

A worked example of a cyclic design for a sewage forcemain can be found in section 3.

Further Reading:

Vinson, H.W.: “Response of PVC Pipe to Large, Repetitive Pressure Surges” Proceedings of the International Conference on Underground Plastic Pipe (March 1981)

Moser, Folkman, Jeffrey:”Long-Term Cyclic Testing of 6 inch PVC Pipe” Utah State University, (March 2003)

Cyclic Design for PVCO Pipes

Research has shown that PVCO pipe has more cyclic-fatigue resistance than PVC pipe does. However, the PVC-type design curves in Figure 3 have not been developed for PVCO.

The design approach recommended for PVCO pipe is to treat the PVCO pipe as PVC pipe of the same pressure class. Verify that the PVC pipe is adequate for the design conditions and then recognize that the actual PVCO pipe provides an additional safety factor against cyclic fatigue.

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

46

Pressure Piping Systems Design

Positive Negative Boundary

3000

2500

2000

1500

1000

500

0

10

2

10310410510610710810910101011101210

13

Average Stress (psi)

Cycles to Failure

Resulting Cyclic-Failure Curves for PVC

20

30

40

50

70

100

150

200

300

500

700

1000

1500

2000

3000

Stress

Amplitude

(psi)

Figure 3 – Resulting Cyclic-Failure Curves for PVC

Thrust Restraint in Gasketed Piping Systems

Resisting Thrust at Fittings and Valves

At many locations in a pressurized pipeline, an imbalance in hydrostatic forces may occur as a result of the pipeline configuration. These unbalanced forces are called thrust forces. Thrust forces can occur at any point in a piping system where the direction or the cross-sectional area of the waterway changes. Pipeline installers must balance these forces by means of thrust blocks or mechanical restraint. Three areas that require restraint are described below.

• at valves

All valves must be anchored. This includes valves installed in a chamber or in line with the pipe, whether it is operated frequently or only once a year.

Install anchor rods around the valve body or through the mounting lugs and embed the rods in a concrete pour beneath the valve. Valves installed in chambers must also be anchored in this fashion. The critical time for restraint of valves is during opening or closing.

• at changes in direction (vertical or horizontal)

Fittings such as elbows, tees, or dead ends, must be restrained since they involve a significant directional change for the fluid.

• at reductions in size

The thrust component at reductions in size will depend on the amount of the reduction, and must be adequately restrained.

Concrete Thrust Blocks

At each point in the line where thrust forces will develop, pour a concrete block between the fitting and undisturbed native soil at the side of the trench. Use plywood sheets to form the block and control the pour so that the area of contact with the undisturbed trench will provide the necessary support.

Bearing Strength of Undisturbed Soils

Organic Material (such as Peat, etc.) . . . . . . . . . .0 psf

Soft Clay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 psf

Sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 psf

Sand and Gravel . . . . . . . . . . . . . . . . . . . . . .1500 psf

Sand & Gravel with Clay . . . . . . . . . . . . . . . .2000 psf

Sand & Gravel Cemented with Clay . . . . . . .4000 psf

Hard Pan . . . . . . . . . . . . . . . . . . . . . . . . . . .5000 psf

These soil bearing capacities are approximate and conservative. For greater design precision, IPEX recommends that soil bearing tests be carried out by a competent soils engineer.

The recommended bearing area to be established by the concrete pour may be given by the engineer. The area (ft.²) may also be calculated by determining the total thrust generated at the fitting. Simply divide the bearing strength of the soil into the thrust developed (lbs force), as found in the accompanying table. The result is the area of the soil required to resist the thrust (A). The area calculated will be for the area of concrete up against the trench wall (i.e. the back side of the block).

47

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Thrust Force

Bearing Strength of Soil

area A =

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

48

Pressure Piping Systems Design

Table 6 – Thrust Developed per 100 psi Pressure (lbs. force)

Note: Pre-cast thrust blocks should not be placed directly

against PVC fittings.

Resisting Thrust in Very Poor Soils

Where the pipeline passes through soils having little or no bearing strength, thrust forces may be restrained by the encasement of the fitting in concrete and the extension of this pour to form a monolith having sufficient inertia to resist the thrusts. It may also be possible to loop tie rods around the fitting and anchor the tie rods into an upstream concrete pour across the trench in more stable soils. Mechanical thrust restraints may also be used in these cases.

Resisting Vertical Thrust

Where the pipeline will change direction downwards to pass under a creek bed or roadway, etc., upward thrust will be developed at the fitting. Anchor the fitting as though it were a valve, and ensure that the concrete base is keyed into undisturbed soil.

Pipe Diameter

in mm

Valves & Dend

Ends, Tees

90º

Bends

45º

Bends

22½º Bends

11¼º

Bends

4 100 1810 2560 1390 635 320

6 150 3740 5290 2860 1370 690

8 200 6430 9100 4920 2320 1170

10 250 9680 13680 7410 3610 1820

12 300 13690 19350 10470 5080 2550

14 350 18380 25990 14100 6100 3080

16 400 23780 33630 18280 7960 4020

18 450 29860 42230 22970 10060 5080

20 500 36640 51820 28180 12440 6280

24 600 52280 73930 40200 17940 9060

30 750 80425 113737 61557 31500 15800

36 900 115200 162929 88181 45000 22600

42 1050 155500 219950 119000 60700 30500

48 1200 202700 286700 155200 79000 39800

Typical thrust block locations

Trim the trench bearing area using hand tools to be sure of undisturbed soil.

This type of hydrant foundation acts as a thrust block, as an anchorage against frost heave and eliminates washouts from wastewater drain.

Straps should be 2 inches (50 mm) wide or greater.

Pressure Piping Systems Design

PROPERTIES OF PVC

PRESSURE PIPE & DESIGN

Holding Pipe to Steep Slopes

Normal bedding practices for pipelines installed up a hill will be sufficient to prevent backsliding and decoupling. When the height of cover is less than 6 feet (1.8 m), and the soil conditions are marginal, and where the slope is greater than 20° (36% slope), a special anchoring method may be desirable. One recommended procedure is to lay the pipe with the bells facing uphill and pour a concrete block behind the bells and keyed into the undisturbed trench sidewalls. Usually every third length of pipe will need to be anchored in this fashion to achieve a stable condition. The use of solvent welded joints for short sections of the pipeline may also be considered on steep slopes.

Mechanical Thrust Restraints

Several mechanical thrust restraint devices are available which clamp to the wall of the pipe and tie back to a mating collar on the fitting or the pipe bell. The use of these devices may provide the entire thrust restraint necessary at the fitting, in sizes up to 48 inches (1200 mm). The use of several thrust restraints to tie together two or three lengths of pipe on either side of the fitting may be desirable to enlist the clamping effect of the backfill around the pipe barrel.

When a thrust restraint device is used, the maximum pressure in the pipeline (usually the test pressure) must not exceed the pressure rating of the restraint device.

It is important to use restraints that are specifically tested and approved for use with PVC and/or PVCO pipe. Also, it is essential that the bolt-torque values provided by the restraint manufacturer be complied with by the installer.

Assembly, Installation and testing of PVC Pressure Pipe Systems

Detailed information on how to install IPEX pressure pipes and fittings can be found in IPEX’s Installation Guide for PVC Pressure Pipe and Fittings. This guide contains complete information on:

• Receiving and handling pipe shipments

• Trench preparation

• Lowering pipe into the trench

• Assembling joints

• Curvature of the pipeline.

• Assembling to valves and appurtenances

• Machining and chamfering the pipe

• Tapping, flanges and sleeves

• Outside diameter considerations

• Backfilling and installing bedding

• Pressure testing the pipeline

• Installing the pipeline through a casing

• Lubricant usage tables.

The Guide is available from your IPEX rep. or visit our technical library at www.ipexinc.com or www.ipexamerica.com.

49

50

Pressure Piping Systems Design

NOTES

______________________________________________________

51

Pressure Piping Systems Design

DESIGN EXAMPLES

INTRODUCTIONS

SECTION 3 – DESIGN EXAMPLES

Three design examples are presented in this section:

1. PVC sewage forcemain – this example shows the design method for a low-pressure line that is subjected to significant recurring surges. Cyclic fatigue controls the design.

2. Large-diameter PVC transmission line – this example illustrates the concept of changing the DR of the pipes in the pipeline as system pressures allow. Four different DRs are included.

3. High-velocity PVCO pipeline experiencing extreme change in velocity. This line undergoes significant occasional surge pressure, but the ability of plastic pipe to withstand short-term loads means that occasional surge does not control the design.

Design Example #1: Sewage Forcemain – AWWA C905 PVC Pipe

Select the appropriate pipe size and pressure rating for a sewage forcemain with the following characteristics:

Peak Flow = 450 L/s (7130 gpm)

Elevation Change (static head): 30 meters (98 feet)

Length: 3000 meters (9850 feet)

Average pump cycles per day: 36

System peak pressure during controlled pump operations: 500 kPa (73 psi)

Minimum pressure during controlled pump operations: 200 kPa (29 psi) Minimum design life: 50 years

Step 1 – Select an initial nominal pipe size and pressure rating

A maximum velocity of 1.5 m/s (5 ft/s) is typical in forcemain design.

Q=vA

···

A =

Q

v

Where,

A = required pipe cross sectional area, m

2

V = fluid velocity, m/s

Q = Flow, m

3

/s

A=

0.450m

3

/s

= 0.3m

2

1.5m/s

Required diameter:

a=

πD

2

···

D=

4a =4(0.3)

= 0.618m = 618mm

is the required diameter

4 ππ

Static pressure is 298 kPa (43 psi). Therefore select 600mm (24") nominal diameter SDR51 (pressure rated 80 psi) for initial calculations.

600mm SDR51 Inside Diameter = 630 mm (24.8").

Note: The purpose of these initial calculations is to select a nominal pipe size and pressure rating, so the required diameter numbers do not have to match. It is more important to select the proper pipe that corresponds with the initial system static head. This will give a basis for further calculations of dynamic head and surge pressures in the next steps

DESIGN EXAMPLES

52

Pressure Piping Systems Design

Step 2 – Calculate dynamic head (friction and minor losses) and total system head

In this step the Hazen-Williams equation is used to calculate the friction losses in the system. For this example we will neglect the minor losses through fittings and valves. For systems with large numbers of fittings, the minor losses should be calculated as they can be significant. Note that the appropriate “C” factor for PVC pipe is 150.

Hazen-Williams Equation:

hf= 10.654

Q1

L = 10.654

0.450m

3

/s 1

3000m = 6.5m

CD

4.87

150 (0.630m)

4.87

The headloss due to friction is 6.5 meters of head or 63 kPa (9 psi). This friction head is added to the static head to get the total system head Note: When using the Hazen-Williams equation with imperial units use the proper imperial form of the equation shown in section 2.

h

sys

= 30m + 6.5m = 36.5m or 358kPa (52 psi)

Therefore, SDR51 with a pressure rating (PR) of 80 psi is adequate for the working pressure requirements of this system.

Step 3 – Calculate the short term (surge) requirements of the system

In section 2 a method to calculate the surge pressure for a given velocity change in a PVC pipe system was shown. The results of those calculations will be used here without reproducing the actual calculations again. To see exactly how these numbers were determined, refer to “Calculating Surge Pressures” in Section 2.

First calculate the actual maximum velocity of a 450 L/s flow in 600mm SDR51:

Q=va

···

Q

=

.450m

3

/s

= 1.44m/s

a π (0.630m)

2

4

For every 0.3 m/s change in velocity, the surge pressure generated in SDR51 is 75 kPa (10.8psi).

Ps=

1.44m/s 75kPa = 361kPa (52.3 psi)

0.3

From Section 2 – the short term rating (STR) of SDR51 is 880 kPa (128psi)

Short term requirements of the system: 358 kPa + 361 kPa = 719 kPa (104 psi)

In this case SDR51 is slightly under designed for the short term rating, so we reiterate the design using SDR41 with an STR of 130 psi. Since the I.D. is slightly different and the surge generated slightly higher – we re-calculate steps 1 to 3 to obtain the following results:

h

sys

= 30m + 7.1m = 37.1m or 364 kPa (52.8 psi)

P

s

=

1.48m/s 79 = 389kPa (56.4 psi)

0.3

Short term requirements of the system: 364 kPa + 389kPa = 753 kPa (109 psi)

STR of SDR41 = 130 psi (>109 psi) therefore adequate for long-term and short-term requirements

(

)

(

)

(

)

1

0.54

1

0.54

(

)

(

)

(

)

(

)

53

Pressure Piping Systems Design

DESIGN EXAMPLES

Step 4 – Cyclic Analysis

Recent research by Dr. A. Moser at Utah State University with respect to cyclic fatigue in PVC pipes has both simplified and improved the accuracy of cyclic calculations. Note that the pressures used for the cyclic analysis are those that will occur during controlled start-up and shut down operations. The majority of today’s pumping systems are equipped with soft start/stop capabilities, thus minimizing system shocks. The short-term system peak pressure (in this case 108 psi) is often not appropriate for cyclic analysis as it is the peak pressure that would be attained only during uncontrolled events (ie: a power outage), and is not cyclic in nature.

It was given that there are 36 cycles a day which means 36 startups and 36 shut downs for a total of 72 surge events per day.

Controlled max system pressure: 500 kPa (73 psi) {given}

Controlled minimum pressure: 200 kPa (29 psi) {given}

Calculate the average system stress:

σ

avg

=

(P

max

+ P

min

)(DR–1) = (500 kPa + 200 kPa)(41–1)

= 7000 kPa (1020 psi)

4 4

Calculate the stress amplitude:

σ

amp

=

(P

max

– P

min

)(DR–1) = (500 kPa – 200 kPa)(41–1)

= 3000 kPa (438 psi)

44

DESIGN EXAMPLES

54

Pressure Piping Systems Design

Determine the predicted number of cycles to failure using Moser’s curves. From the figure above, the predicted cycles to failure are roughly 3 x 106or 3,000,000 cyclic life pump starts/stops.

Calculate cyclic life:

Number of events: 72 per day x 365days/year = 26,280 per year

Events to failure: 3,000,000

Cyclic life = 3,000,000/26280 = 152 years

Safety factor = 152 years / 100-year design life = 1.52 < 2.0 required

SDR51 is slightly under-designed for cyclic fatigue, so the next thicker pipe (SDR41) is analysed. Using the same method, the following results are obtained:

Average stress = 6 200 kPa (900 psi)

Stress amplitude = 2 200 kPa (320 psi)

Predicted cycles to failure are approximately 18,000,000.

Cyclic life = 680 years

This provides a safety factor against cyclic failure of 6.8, which exceeds the required safety factor of 2.0.

Therefore, SDR41 is adequate for the design conditions.

3x10

6

997

Positive Negative Boundary

3000

2500

2000

1500

1000

500

0

10

2

10310410510610710810910101011101210

13

Average Stress (psi)

Cycles to Failure

Resulting Cyclic-Failure Curves for PVC

20

30

40

50

70

100

150

200

300

500

700

1000

1500

2000

3000

Stress

Amplitude

(psi)

Figure 3 – Resulting Cyclic-Failure Curves for PVC

55

Pressure Piping Systems Design

DESIGN EXAMPLES

Design Example #2: Sewage Forcemain – ASTM F1483 PVCO Bionax Pipe

Select the appropriate pipe size and pressure rating for a sewage forcemain with the following characteristics:

Peak Flow = 100 L/s (1590 gpm)

Static Pressure: 400 kPa (58 psi)

Length: 5000 meters (16400 feet)

Average pump cycles per day: 36

System peak pressure during controlled pump operations: 620 kPa (90 psi)

Minimum pressure during controlled pump operations: 180 kPa (26 psi) Minimum design life: 100 years

Step 1 – Select an initial nominal pipe size and pressure rating

A maximum velocity of 1.5 m/s (5 ft/s) is typical in forcemain design.

Q=vA

···

A =

Q

v

Where,

A = required pipe cross sectional area, m

2

V = fluid velocity, m/s

Q = Flow, m

3

/s

A=

0.100m

3

/s

= 0.067m

2

1.5m/s

Required diameter:

a=

πD

2

···

D=

4a =4(0.067)

= 0.291m = 291mm

is the required diameter

4 ππ

Static pressure is 400 kPa (58 psi). Therefore select 6300mm (12") nominal diameter PR160 (pressure rated 160 psi) for initial calculations.

300mm PR160 Inside Diameter = 309 mm (12.2").

Note: The purpose of these initial calculations is to select a nominal pipe size and pressure rating, so the required diameter numbers do not have to match. It is more important to select the proper pipe that corresponds with the initial system static head. This will give a basis for further calculations of dynamic head and surge pressures in the next steps

Step 2 – Calculate dynamic head (friction and minor losses) and total system head

In this step the Hazen-Williams equation is used to calculate the friction losses in the system. For this example we will neglect the minor losses through fittings and valves. For systems with large numbers of fittings, the minor losses should be calculated as they can be significant. Note that the appropriate “C” factor for PVC pipe is 150.

Hazen-Williams Equation:

hf= 10.654

Q1

L = 10.654

0.100m

3

/s 1

5000m = 21.3m = 209 kPa

CD

4.87

150 (0.309m)

4.87

The loss due to friction is 209 kPa (30 psi). This friction head is added to the static head to get the total system head Note: When using the Hazen-Williams equation with imperial units use the proper imperial form of the equation shown in section 2.

hf= 400 kPa + 209 kPa = 609 kPa (88 psi)

Therefore, PR160 Bionax pipe with a pressure rating (PR) of 160 psi is adequate for the working pressure requirements of this system.

1

0.54

1

0.54

(

)

(

)

(

)

(

)

DESIGN EXAMPLES

56

Pressure Piping Systems Design

Step 3 – Calculate the short term (surge) requirements of the system

In section 2 a method to calculate the surge pressure for a given velocity change in a PVC pipe system was shown. The results of those calculations will be used here without reproducing the actual calculations again. To see exactly how these numbers were determined, refer to “Calculating Surge Pressures” in Section 2.

First calculate the actual maximum velocity of a 100 L/s flow in 300mm PR160:

Q=va

···

Q

=

.100m

3

/s

= 1.33m/s

a π (0.309m)

2

4

For every 0.3 m/s change in velocity, the surge pressure generated in PR160 is 80 kPa (11.6 psi).

Ps=

1.33m/s 80 kPa = 356 kPa (51.6 psi)

0.3

From Section 2 – the short term rating (STR) of PR160 is 1380 kPa (200psi)

Short term requirements of the system: 609 kPa + 356 kPa = 965 kPa (140 psi)

STR of PR160 = 200 psi (>140 psi) therefore adequate for long-term and short-term requirements

Step 4 – Cyclic Analysis

Recent research by Dr. A. Moser at Utah State University with respect to cyclic fatigue in PVC pipes has both simplified and improved the accuracy of cyclic calculations. Note that the pressures used for the cyclic analysis are those that will occur during controlled start-up and shut down operations. The majority of today’s pumping systems are equipped with soft start/stop capabilities, thus minimizing system shocks. The short-term system peak pressure (in this case 108 psi) is often not appropriate for cyclic analysis as it is the peak pressure that would be attained only during uncontrolled events (ie: a power outage), and is not cyclic in nature.

It was given that there are 36 cycles a day which means 36 startups and 36 shut downs for a total of 72 surge events per day.

Controlled max system pressure: 620 kPa (90 psi) {given}

Controlled minimum pressure: 180 kPa (26 psi) {given}

Calculate the average system stress:

σ

avg

=

(P

max

+ P

min

)(DR–1) = (620 kPa + 180 kPa)(41–1)

= 5000 kPa (729 psi)

4 4

Calculate the stress amplitude:

σ

amp

=

(P

max

– P

min

)(DR–1) = (620 kPa – 180 kPa)(41–1)

= 2750 kPa (401 psi)

44

(

)

(

)

57

Pressure Piping Systems Design

DESIGN EXAMPLES

Determine the predicted number of cycles to failure using Moser’s plot.

From the plot, the predicted cycles to failure are roughly 9 x 10

6

pump starts and stops

Calculate cyclic life:

72 events per day x 365 = 26,280 events per year

0 x 106/26280 = 342 years

Therefore, SDR41 is more than adequate for the application.

9x10

6

997

Positive Negative Boundary

3000

2500

2000

1500

1000

500

0

10

2

10310410510610710810910101011101210

13

Average Stress (psi)

Cycles to Failure

Resulting Cyclic-Failure Curves for PVC

20

30

40

50

70

100

150

200

300

500

700

1000

1500

2000

3000

Stress

Amplitude

(psi)

Figure 3 – Resulting Cyclic-Failure Curves for PVC

DESIGN EXAMPLES

58

Pressure Piping Systems Design

This analysis of a relatively simple pipeline will illustrate the use of the design principles discussed in this guide section. PVC pipe standards offer a variety of pipe strengths and sizes. Ideally, the designer will make selections that minimize capital and operating costs while maintaining an adequate design safety factor.

The project is a 20,000' long PVC water transmission main designed for an ultimate capacity of 4,000 gpm (5.76 mgd).

The profile of the pipeline is shown below. Water is being pumped to a ground storage tank (point f) with a maximum water level of 35' from the floor. The centerline of the discharge end of the main, at the tie-in to the storage tank, will be 5' below the tank floor.

Key stations and their elevations along the pipeline are:

The objective of the design process will be to select proper DRs of PVC for appropriate sections of pipeline while never exceeding the PR nor the WPR of the pipe at any point. An effort will be made to select DRs that meet the design criteria while providing optimum economic value for the utility or owner.

The key determinant of PVC pressure pipe design is the internal pressure. The pipe dimensions can be found in the AWWA pipe standards. For this example, AWWA Standard C905, Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 In. through 48 In. (350mm through 1,200mm), for Water Transmission and Distribution, was used. The exact pipe dimensions are required to determine the flow velocity. The total pressure in the pipeline at any point is the sum of the static head, the friction loss, and the pressure rise as a result of sudden velocity changes. For simplicity, the selection of PVC pipe in this example will be limited to four PRs in CIOD only (PR 235, 165, 125 and 100).

Design Example #3: Transmission Pipe (Taken from AWWA M23 - PVC Pipe Design & Installation Manual)

Point Station Elevation at Pipe Centerline (ft)

a 0 + 00 600

b 45 + 00 670

c 75 + 00 720

d 115 + 00 800

e 165 + 00 940

f 200 + 00 940

Figure 4 – Pipeline Profile

1,032

960

888

816

Elevation (ft)

744

672

600

Ft

f

19,998

Tank

165+00

16,665

Energy Grade Line

e

940

d

800

115+00

c

720

45+00

b

670

3,333

Pump House

a

600

0

13,332

9,999

75+00

6,666

DESIGN EXAMPLES

59

Pressure Piping Systems Design

Step 1 – Determine the maximum flow velocity

Assume that 20" PVC pipe will be used. In AWWA C905, the heaviest wall shown to be available in 20" pipe is DR 18. The assumption of beginning with the heaviest wall (i.e., the lowest DR) is recommended for most designs in the initial stage. The first assumption may be confirmed or revised as the design is developed.

Average ID = Average OD – 2 (minimum wall thickness x 1.06)

Note: The tolerance on wall thickness is approximately +12%. There is no minus tolerance. Manufacturers will generally aim to produce PVC pressure pipe with wall thicknesses about 6% over minimum.

Assume: 20" DR 18 per AWWA C905

Avg. ID = 21.60 – 2 (1.200 x 1.06)

= 19.05 in = 1.59 ft

V=Q/A

Where,

Q=Flow in ft3/sec = 4,000 gpm or 8.91 ft3/sec A =area, ft

2

V=velocity, ft/sec

A = (3.14) (1.59/2)

2

= 1.98 ft

2

Therefore,

V=8.91/1.98 = 4.5 ft/sec

Because the velocity is within an acceptable range, the design may proceed with 20" pipe.

Step 2 – Determine the surge factor

In a transmission pipeline, the amplitude and location of the surge pressure envelope will often be analyzed by computer. For this example, the assumption has been made that the maximum surge pressure will be equal to an instantaneous stop -page of flow at full velocity. In practice, the costs of pipe materials may be significantly reduced through the use of appropriate surge control devices and proper pipeline operating procedures.

The pressure rise resulting from a

V = 4.5 ft/sec instantaneous velocity change in PVC pressure pipes can be charted as

follows:

Dimension Ratio, DR

1 ft/sec Surge, Ps' (psi) V x Ps' (psi)

41 11.4 51.3

32.5 12.8 57.6

25 14.7 66.2

18 17.4 78.3

DESIGN EXAMPLES

60

Pressure Piping Systems Design

Step 3 – Determine the WPR for each of the DRs of Step 2

The WPR is a job-specific pressure rating of the pipe, taking into account the maximum possible surges versus the short-term strength of the pipe. The WPR may be either higher or lower than the PR of the pipe, depending on the flow conditions. The lower value between the WPR and the PR should be used as the upper limit for system steady-state operating pressure.

WPR = STR – V x Ps'

It can be seen that the governing parameter for the pressure design of this example will be the WPR analysis since it is lower than the PR of each DR.

Step 4 – Determine the friction loss f under full-flow conditions

Continue to assume DR 18 for this calculation because this pipe will produce slightly greater losses than the other DRs under consideration. The result will be conservative for all design operations.

The Hazen-Williams equation is convenient to use:

f = 0.2083 (100/C)

1.852

Q

1.852

d

i

4.8655

Where,

f=friction head, ft of water per 100 ft of pipe

d

i

= inside diameter of pipe, in.

Q=flow, gpm

C=flow coef ficient, 150 for PVC

Substituting for 20" PR 235 pipe, where d = 19.05 in

f=0.273 ft of water per 100 ft of pipeline

= 0.118 psi per 100 ft (station) of pipeline

DR STR (psi)

V x Ps' (psi)

WPR (psi) PR (psi)

41 130 51.3 78.7 100

32.5 165 57.6 107.4 125

25 215 66.2 148.8 165

18 300 78.3 221.7 235

61

Pressure Piping Systems Design

DESIGN EXAMPLES

Step 5 – Determine the pressures at key points in the pipeline under steady-state, full-flow conditions

This pressure, P, at any point is the sum of the static head as a result of difference in elevations and the friction loss.

Referring to Figure 4, the pressure at key points can be calculated as follows:

Starting at the storage tank:

The pressure, P, at each of the key points are summarized as follows:

Station 200 + 00

Static Head = 980 – 940 = 40 ft

or 40 ft x (0.43 psi/ft) = 17.3 psi

Station 165 + 00

Static Head = (980 – 940) ft x (0.43 psi/ft) = 17.3 psi

Friction Head = (3,500 ft) x (0.118 psi/100 ft) = 4.1 psi

Total Head = 21.4 psi

Station 115 + 00

Static Head = (980 – 800) ft x (0.43 psi/ft) = 77.4 psi

Friction Head = (8,500 ft) x (0.118 psi/100 ft) = 10.0 psi

Total Head = 87.4 psi

Station 75 + 00

Static Head = (980 – 720) ft x (0.43 psi/ft) = 111.8 psi

Friction Head = (12,500 ft) x (0.118 psi/100 ft) = 14.8 psi

Total Head = 126.6 psi

Station 45 + 00

Static Head = (980 – 670) ft x (0.43 psi/ft) = 133.3 psi

Friction Head = (15,500 ft) x (0.118 psi/100 ft) = 18.3 psi

Total Head = 151.6 psi

Station 0 + 00

Static Head = (980 – 600) ft x (0.43 psi/ft) = 163.4 psi

Friction Head = (20,000 ft) x (0.118 psi/100 ft) = 23.6 psi

Total Head = 187.0 psi

Point Station Static Head (psi) Friction Head (psi) Pressure, P (psi)

f 200 + 00 17.3 0 17.3

e 165 + 00 17.3 4.1 21.4

d 115 + 00 77.4 10.0 87.4

c 75 + 00 111.8 14.8 126.6

b 45 + 00 133.3 18.3 151.6

a 0 + 00 163.4 23.6 187.0

DESIGN EXAMPLES

62

Pressure Piping Systems Design

Step 6 – Determine the appropriate DR of pipe for each section of the pipeline

From previous calculations in Step 3, DR 18 PVC pressure pipe has a working pressure rating 221.7 psi. For the next greater DR, DR 25, the WPR is 148.8 psi. Therefore, DR 18 is selected to start out at the pumphouse until a point in the system where the operating pressure, P, drops to be equal to the WPR of DR 25. At this point, DR 25 may be used. Subsequent steps will determine the starting points for DR 32.5 as well as DR 41.

It can be seen from the above summary of pressures by section that the transition to DR 25 will occur between Stations 45 + 00 and 75 + 00, in section bc. To pinpoint the exact location, the pressure gradient for that section must be calculated.

Δ P(bc) =

(Pc + Pb)

Station Length of bc

=

126.6 psi – 151.6 psi (75 – 45) x (100 ft)

= –0.83 psi/100 ft

The length beyond Station 45 + 00 (point b) can be calculated as follows:

Station Length

=

WPR(DR 25) – Pb

Δ P(bc)

=

(148.8 psi) – (151.6 psi)

–0.83 psi/100 ft

= 337 ft (i.e., at 337 ft downstream of Station 45 + 00)

Therefore, begin using DR 25 at Station 48 + 37.

Similarly, the transition point for DR 32.5 can be found.

From the summary of pressures and knowing the WPR of DR 32.5 is 107.4 psi, DR 32.5 can be used between Station 75 + 00 and Station 115 + 00, i.e., section cd.

First, calculate the pressure gradient in section cd.

Δ P(cd) =

(Pd – Pc)

Station Length of cd

=

87.4 psi – 126.6 psi

(115 – 75) x (100 ft)

= –0.98 psi/100 ft

Next, the Station Length beyond Station 75 + 00 can be calculated:

Station Length

=

WPR(DR 32.5) – Pc

Δ P(cd)

=

(107.4 psi) – (126.6 psi)

–0.98 psi/100 ft

= 1,959 ft (i.e., at 1,959 ft downstream of Station 7 5 + 00)

Therefore, begin using DR 32.5 at Station 94 + 59.

63

Pressure Piping Systems Design

DESIGN EXAMPLES

Similarly, it can be calculated where DR 41 usage may begin.

From review of the summary of pressures and knowing the WPR of DR 41 is 78.7 psi, the range for DR 41 begins between Station 115 + 00 and Station 165 + 00, i.e., section de.

First, calculate the pressure gradient in section de.

Δ P(de) =

(Pe – Pd)

Station Length of de

=

21.4 psi – 87.4 psi

(165 – 115) x (100 ft)

= –1.32 psi/100 ft

Next, the Station Length beyond point d:

Station Length

=

WPR(DR 41) – Pd

Δ P(de)

=

(78.7 psi) – (87.4 psi)

–1.32 psi/100 ft

= 659 ft (i.e., at 659 ft downstream of Station 115 + 00)

Therefore, DR 41 may begin usage at Station 121 + 59 and continue for the duration of the pipeline up to its terminus at the reservoir.

The design for internal pressure may be summarized as follows:

In this example of a 3.8 mile pipeline, the designer has the opportunity to make significant cost savings through the use of several PVC pipe pressure ratings. Computer modeling may disclose even further potential savings by showing exactly where and how surge control is most effective. (Note that the above pipe selection was made assuming that the potential exists for the instantaneous stoppage of flow.)

If the pipeline is operated in a cycle mode (i.e., like some sewage force mains), an analysis of fatigue life should be made. Both present and future modes of operation should be examined.

Distance from Pumphouse (ft) Use 20 in. Pressure Gradient (psi)

0 – 4.837 DR 18 (PR 235) 187.0 – 148.8

4,837 – 9,459 DR 25 (PR 165) 148.8 – 107.4

9,459 – 12,159 DR 32.5 (PR 125) 107.4 – 78.7

12,159 – 20,000 DR 41 (PR 100) 78.7 – 17.3

64

Pressure Piping Systems Design

NOTES

______________________________________________________

65

Pressure Piping Systems Design

APPENDICES

SECTION FOUR: APPENDICES

APPENDIX A: REFERENCES

1 Duranceau, Schiff, Bell. “Electrical Grounding, Pipe Integrity and Shock Hazard”,

Journal of the AWWA, July 1998, pp. 40-51

2 Hulsmann, Nowack,”70 Years of Experience with PVC Pipes” Conference Paper,

Plastic Pipes XII, Milan, April 2004

3 Jenkins, Thompson,”Review of Water Industry Plastic Pipe Practices”,

AWWA Research Foundation, 1987

4 Berens, A.R., “Prediction of Chemical Permeation through PVC Pipe”,

Journal of the AWWA, November 1985

5 Hoogensen Metallurgical Engineering Ltd.,” Examination of Submitted PVC Pipe Section”,

Report to IPEX, December 1998

6 Uni-Bell PVC Pipe Association, “Handbook of PVC Pipe – Design and Construction”,

fourth edition, (August 2001)

APPENDICES

66

Pressure Piping Systems Design

TABLE B-2 WEIGHTS OF WATER

Units of Volume

Weight

pounds kilograms

1 US Gallon 8.35 3.79

1 Imperial Gallon 10.02 4.55

1 litre 2.21 1.00

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

APPENDIX B: REFERENCE TABLES AND CONVERSION CHARTS

Table B-1 Pipe Capacity

Table B-2 Weights of Water

Table B-3 Decimal & Millimeter Equivalents of Fractions

Table B-4 Volume Conversion

Table B-5 Pressure Conversion

Table B-6 Flow Conversion

Table B-7 Temperature Conversion

Table B-8 Length Conversion

Pipe Size Outside Diameter – IPS OD Pipe Volume for 1 foot length of pipe

inches inch feet cm in3 ft3 cm3 US Gal Imp Gal

1/4 0.250 0.021 0.098 0.589 0.0003 9.648 0.003 0.002

3/8 0.375 0.031 0.148 1.325 0.001 21.708 0.006 0.005

1/2 0.500 0.042 0.197 2.355 0.001 38.591 0.010 0.008

3/4 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

1-1/4 1.250 0.104 0.492 14.719 0.009 241.196 0.064 0.053

1-1/2 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 B-1 PIPE CAPACITY

67

Pressure Piping Systems Design

APPENDICES

TABLE B-3 DECIMAL & MILLIMETER EQUIVALENTS OF FRACTIONS

TABLE B-4 VOLUME CONVERSION

Inches Inches

Fractions Decimals Millimeters Fractions Decimals Millimeters

1/64 0.015625 0.397 33/64 0.515625 13.097

1/32 0.03125 0.794 17/32 0.53125 13.494

3/64 0.046875 1.191 35/64 0.546875 13.891

1/16 0.0625 1.588 9/16 0.5625 14.288

5/64 0.078125 1.984 37/64 0.578125 14.684

3/32 0.09375 2.381 19/32 0.59375 15.081

7/64 0.109375 2.778 39/64 0.609375 15.478

1/8 0.125 3.175 5/8 0.625 15.875

9/64 0.140625 3.572 41/64 0.640625 16.272

5/32 0.15625 3.969 21/32 0.65625 16.669

11/64 0.171875 4.366 43/64 0.671875 17.066

3/16 0.1875 4.763 11/16 0.6875 17.463

13/64 0.203125 5.159 45/64 0.703125 17.859

7/32 0.21875 5.556 23/32 0.71875 18.256

15/64 0.23475 5.953 47/64 0.734375 18.653

1/4 0.250 6.350 3/4 0.750 19.050

17/64 0.265625 6.747 49/64 0.765625 19.447

9/32 0.28125 7.144 25/32 0.78125 19.844

19/64 0.296875 7.541 51/64 0.796875 20.241

5/16 0.3125 7.938 13/16 0.8125 20.638

21/64 0.328125 8.334 53/64 0.828125 21.034

11/32 0.34375 8.731 27/32 0.83475 21.431

23/64 0.359375 9.128 55/64 0.859375 21.828

3/8 0.375 9.525 7/8 0.875 22.225

25/64 0.390625 9.922 57/64 0.890625 22.622

13/32 0.40625 10.319 29/32 0.90625 23.019

27/64 0.421875 10.716 59/64 0.921875 23.416

7/16 0.4375 11.113 15/16 0.9375 23.813

29/64 0.453125 11.509 61/64 0.953125 24.209

15/32 0.46875 11.906 31/32 0.96875 24.606

31/64 0.484375 12.303 63/64 0.984375 25.003

1/2 0.500 12.700 1 1.000 25.400

Units of Volume in

3

ft

3

yd

3

cm

3

m

3

liter U.S. gal. Imp. gal.

cubic inch 1 0.00058 - 16.387 - 0.0164 0.0043 0.0036

cubic foot 1728 1 0.0370 28,317.8 0.0283 28.32 7.481 6.229

cubic yard 46,656 27 1 - 0.7646 764.55 201.97 168.8

cubic centimeter 0.0610 - - 1 - 0.001 0.0003 0.0002

cubic meter 61,023.7 35.31 1.308 - 1 1000 264.17 220.0

liter 61.02 0.0353 0.0013 1000 0.001 1 0.2642 0.22

U.S. gallon 231 0.1337 0.0050 3785.4 0.0038 3.785 1 0.8327

Imp. gallon 277.42 0.1605 0.0059 4546.1 0.0045 4.546 1.201 1

APPENDICES

68

Pressure Piping Systems Design

TABLE B-5 PRESSURE CONVERSION

Units of Pressure atm bar lb/in

2

lb/ft2kg/cm2kg/m2inch H20

atmosphere (atm) 1 0.987 0.068 - 0.968 - 0.002

bar 1.013 1 0.069 - 0.981 - 0.002

pound per square inch (psi) 14.7 14.5 1 0.007 14.22 0.001 0.036

pound per square foot (psf) 2,116 2,089 144 1 2,048 0.205 5.2

kilogram per square centimeter 1.033 1.02 0.07 - 1 0.0001 0.003

kilogram per square meter 10,332 10,197 703 4.88 10,000 1 25.4

inch of water (H20) (4ºC) 406.78 401.46 27.68 0.192 393.7 0.039 1

inch of mercury (Hg) (0ºC) 29.921 29.53 2.036 0.014 28.96 0.003 0.074

inch of air (15ºC) 332,005 327,664 22,592 148.7 321,328 32.13 816.2

foot of water (4ºC) 33.9 33.46 2.307 0.016 32.81 0.003 0.083

foot of air (15ºC) 27,677 27,305 1,883 13.07 26,777 2.678 0.006

millimeter of mercury (0ºC) 760 750 51.71 0.36 735.6 0.074 1.868

millimeter of water (4ºC) 10,332 10,197 703 4.88 10,000 1 25.4

kilopascal (kP) 101.3 100 6.89 0.048 98.07 0.01 0.249

Newton per square meter - - - 0.021 - 0.102 0.004

Units of Pressure inch Hg inch air ft H20 ft air mm Hg mm H20 kilopascal N/m

2

atmosphere (atm) 0.033 - 0.029 - 0.001 - 0.01 -

bar 0.034 - 0.03 - 0.001 - 0.01 -

pound per square inch (psi) 0.491 - 0.434 0.001 0.019 0.001 0.145 -

pound per square foot (psf) 70.73 0.006 62.43 0.076 2.784 0.205 20.89 0.021

kilogram per square centimeter 0.035 - 0.03 - 0.001 - 0.01 -

kilogram per square meter 345.3 0.031 304.8 0.373 13.6 1 101.97 0.102

inch of water (H20) (4ºC) 13.6 0.001 12 0.015 0.535 0.039 4.015 0.004

inch of mercury (Hg) (0ºC) 1 - 0.883 0.001 0.039 0.003 0.295 -

inch of air (15ºC) 11,096 1 9,794 12 436.8 32.13 3,277 3.106

foot of water (4ºC) 1.133 - 1 - 0.045 0.003 0.335 -

foot of air (15ºC) 924.7 0.083 816.2 1 36.4 2.678 273.1 0.273

millimeter of mercury (0ºC) 25.4 0.002 22.42 0.027 1 0.074 7.5 0.008

millimeter of water (4ºC) 345.3 0.031 304.8 0.373 13.6 1 101.97 0.102

kilopascal (kP) 3.386 - 2.99 0.004 0.133 0.01 1 0.001

Newton per square meter - 3.277 - 0.273 0.008 0.102 0.001 1

69

Pressure Piping Systems Design

APPENDICES

TABLE B-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

APPENDICES

70

Pressure Piping Systems Design

ºF ºC ºF ºC ºF ºC ºF ºC ºF ºC

-60 -51 22 -5.6 50 10.0 78 25.6 160 71

-50 -46 23 -5.0 51 10.6 79 26.1 170 77

-40 -40 24 -4.4 52 11.1 80 26.7 180 82

-30 -34 25 -3.9 53 11.7 81 27.2 190 88

-20 -29 26 -3.3 54 12.2 82 27.8 200 92

-10 -23.0 27 -2.8 55 12.8 83 28.3 210 99

0 -17.8 28 -2.2 56 13.3 84 28.9 212 100

1 -17.2 29 -1.7 57 13.9 85 29.4 220 104

2 -16.7 30 -1.1 58 14.4 86 30.0 230 110

3 -16.1 31 -0.6 59 15.0 87 30.6 240 116

4 -15.6 32 0.0 60 15.6 88 31.1 250 121

5 -15.0 33 0.6 61 16.1 89 31.7 260 127

6 -14.4 34 1.1 62 16.7 90 32.2 270 132

7 -13.9 35 1.7 63 17.2 91 32.8 280 138

8 -13.3 36 2.2 64 17.8 92 33.3 290 143

9 -12.8 37 2.8 65 18.3 93 33.9 300 149

10 -12.2 38 3.3 66 18.9 94 34.4 310 154

11 -11.7 39 3.9 67 19.4 95 35.0 320 160

12 -11.1 40 4.4 68 20.0 96 35.6 330 166

13 -10.6 41 5.0 69 20.6 97 36.1 340 171

14 -10.0 42 5.6 70 21.1 98 36.7 350 177

15 -9.4 43 6.1 71 21.7 99 37.2 360 182

16 -8.9 44 6.7 72 22.2 100 37.8 370 188

17 -8.3 45 7.2 73 22.8 110 43 380 193

18 -7.8 46 7.8 74 23.3 120 49 390 199

19 -7.2 47 8.3 75 23.9 130 54 400 204

20 -6.7 48 8.9 76 24.4 140 60

21 -6.1 49 9.4 77 25.0 150 66

TABLE B-7 TEMPERATURE CONVERSION

TABLE B-8 LENGTH CONVERSION

Units of Length in. ft. yd. mile mm cm m km

inch 1 0.0833 0.0278 - 25.4 2.54 0.0254 -

foot 12 1 0.3333 - 304.8 30.48 0.3048 -

yard 36 3 1 - 914.4 91.44 0.9144 -

mile - 5280 1760 1 - - 1609.3 1.609

millimeter 0.0394 0.0033 - - 1 0.100 0.001 -

centimeter 0.3937 0.0328 0.0109 - 10 1 0.01 -

meter 39.37 3.281 1.094 - 1000 100 1 0.001

kilometer - 3281 1094 0.6214 - - 1000 1

(1 micron = 0.001 millimeter)

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

71

Pressure Piping Systems Design

APPENDICES

APPENDIX C: 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

APPENDICES

72

Pressure Piping Systems Design

APPENDIX C: USEFUL FORMULAS

r

S

O

Length of Circular Arc

S = Ø x

(

π )x r Ø in degrees

180

S = Ø x r Ø in radians

Area of Circle Sector

A= x

(

Ø )x π x r

2

Ø in degrees

360

A= x

(

Ø )x r

2

Ø in radians

2

Equation of a Circle (cartesian co-ordinates)

- for a circle with center (j, k) and radius (r)

(x - j)

2

+ (y - k)2= r

2

Equation of a line (quadratic formula)

ax + by + c = 0

or

ax

2

+ bx + c = 0

x -b + b2 - 4ac

2a

Circle

Diameter = r

2

Circumference = πD = 2πr

Area = πr

2

Sine Law

9 = 6 = c = 2R

sin A sin B sin C

Cosine Law

C2=a2+ b2- 2ab cos C

b

2=a2

+ c2- 2ac cos B

a

2=b2

+ c2- 2bc cos A

Trigonometry

sin Ø = b

c

cos Ø = a

c

tan Ø = b

a

Ellipse

Area = π x a x b

Circumference

= π

(

3 (a + b) – (3a + b) (a + 3b)

Triangle

Area = w h

2

Trapezoid

Area = 1 (b1+ b2) h

2

Parallelogram

Area = b h

Sphere

Surface Area = 4 π r

2

Volume = 4 π r

3

b

a

h

w

b

h

b

B

A

c

b

O

a

C

h

b

r

73

Pressure Piping Systems Design

APPENDICES

Cylinder

Surface Area = (2 π r2) + (2 π r h)

Volume = π r

2

h

r

Elliptical Tank

Surface Area

Volume = π abh

2 π a2 +

2

b

2

(

h + (2π ab)

Cone

Surface Area = π r S

Volume = π r2h

3

Rectangular Solid

Surface Area = 2 (Lw + Lh + wh)

Volume = L w h

h

a

b

h

S

h

r

L

w

h

APPENDICES

74

Pressure Piping Systems Design

APPENDIX D: ABBREVIATIONS

AGA - American Gas Association

ANSI - American National Standards Institute

API - American Petroleum Institute

ASME - American Society of Mechanical Engineers

ASTM - American Society for Testing and Materials

AWWA - American Water Works Association

BOCA - Building Officials and Code Administrators

BS - British Standards Institution

CPVC - Chlorinated poly (vinyl chloride) plastic or resin

CS - Commercial Standard, see Product Standard

CSA - Canadian Standards Association

DR - Dimension Ratio

DIN - German Industrial Norms

FHA - Federal Housing Administration or Farmers Home Administration

HDB - Hydrostatic design basis

HDS - Hydrostatic design stress

IAPD - International Association of Plastics Distributors

IAPMO - International Association of Plumbing and Mechanical Officials

IPC - International Plumbing Code

ISO - International Standards Organization

JIS - Japanese Industrial Standards

NSF - National Sanitation Foundation International

PPI - Plastics Pipe Institute

PS - Product Standard when in reference to a specification for plastic pipe and fittings. These

specifications are promulgated by the U.S. Department of Commerce and were formerly known as Commercial Standards.

PVC - Poly-(vinyl chloride) plastic, resin or compound

PVCO - Molecularly Oriented Polyvinyl Chloride Plastic

RVCM - Residual Vinyl Chloride Monomer

SCS - Soil Conservation Service

SDR - Standard Dimension Ratio

SI - International System of Units

SPI - Society of the Plastics Industry, Inc.

UPC - Uniform Plumbing Code

USASI - United States of America Standards Institute (formerly American Standards Association)

WOG - Water, Oil, Gas

75

Pressure Piping Systems Design

APPENDICES

APPENDIX E: TABLES AND FIGURES

Table 1 Percent (%) Deflection for IPEX Centurion Pressure Pipe pg 14

Table 2 Q-Line Flow Rates pg 35

Table 3 Summary of Properties for PVC Pipe pg 40

Table 4 Temperature Effects on PVC Pressure Pipe pg 41

Table 5 Hazen-Williams “C”-Factors pg 43

Table 6 Thrust Developed per 100 psi Pressure (lbs. force) pg 48

Figure 1 Stress Regression Line - Cell Class 12454 pg 40

Figure 2 Pipe Material pg 43

Figure 3 Resulting Cyclic-Failure Curves for PVC pgs 46, 54 & 57

Figure 4 Pipeline Profile pg 58

76

Pressure Piping Systems Design

NOTES

______________________________________________________

SALES AND CUSTOMER SERVICE

U.S. Customers call IPEX Inc.

Toll free: (800) 463-957 www.ipexamerica.com

About the IPEX Group of Companies

As leading suppliers of thermoplastic piping systems, the IPEX Group of Companies provides our customers with some of the largest and most comprehensive product lines. All IPEX products are backed by more than 50 years of experience. With state-ofthe-art manufacturing facilities and distribution centers across North America, we have established a reputation for product innovation, quality, end-user focus and performance.

Markets served by IPEX group products are:

• Electrical systems

• Telecommunications and utility piping systems

• PVC, CPVC, PVCO, PP, ABS, PEX, FR-PVDF and PE pipe and

fittings (1/4" to 48")

• Industrial process piping systems

• Municipal pressure and gravity piping systems

• Plumbing and mechanical piping systems

• PE Electrofusion systems for gas and water

• Industrial, plumbing and electrical cements

• Irrigation systems

This literature is published in good faith and is believed to be reliable. However it does not represent and/or warrant in any manner the information and suggestions contained in this brochure. Data presented is the result of laboratory tests and field experience.

A policy of ongoing product improvement is maintained. This may result in modifications of features and/or specifications without notice.

Products manufactured by IPEX Inc. and distributed in the United States by IPEX USA LLC.

Bionax

®

, Blue904TM, IPEX Centurion®, CycleTough®, IPEX FusibleTM,

Q-Line

®

and TerraBrute®CR and are trademarks of IPEX Branding Inc.

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