Volume I: Vinyl Process Piping Systems - Aerodinamica › at_ad ›...

Volume I:Vinyl ProcessPiping Systems

Industrial TechnicalManual Series

S E V E N T H E D I T I O N

IPEX VINYL PROCESS PIPING SYSTEMS

• Xir tec ®140 PVC Schedule 40• Xir tec ®140 PVC Schedule 80• Corzan ® CPVC

IPEX Vinyl Process Piping Systems

Industrial Technical Manual Series

Vol. 1, 7th Edition

© 2017 by IPEX. All rights reserved. No part of this book may be used orreproduced in any manner whatsoever without prior written permission.

For information contact: IPEX Management Inc., 1425 North Service Road East,Unit 3, Oakville, Ontario, Canada, L6H 1A7.

ABOUT IPEX

At IPEX, we have been manufacturing non-metallic pipe and fittings since 1951. We formulate our own compounds andmaintain strict quality control during production. Our products are made available for customers thanks to a network ofregional 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, IPEXcontinually 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 inseveral 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.

SAFETY ALERTS

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

The types of safety alert messages are described below.

This safety alert symbol indicates important safety messages inthis manual. When you see this symbol be alert to the possibilityof personal injury and carefully read and fully understand themessage that follows.

WARNING CAUTION

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

“CAUTION” identifies hazards or unsafe practices thatcan result in minor personal injury or product orproperty damage if instructions, includingrecommended precautions, are not followed.

“WARNING” identifies hazards or unsafe practices thatcan result in severe personal injury or death ifinstructions, including recommended precautions, arenot followed.

• NEVER use compressed air or gas in PVC/CPVC/PP/PVDF pipe and fittings.

• NEVER test PVC/CPVC/PP/PVDF pipe and fittings with compressed air or gas, or air-over-water boosters.

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

CAUTION

i

WARNING

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

Vinyl Process Piping Systems

Use of compressed air or gas in PVC/CPVC/PP/PVDF pipeand fittings can result in explosive failures and causesevere injury or death.

ii

NOTES

Vinyl Process Piping Systems Manual

About IPEX

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

Section One: General Information

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

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

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

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

- Industrial and Process Piping

- Pulp and Paper

- Food Processing

- Water and Sewage Treatment

- Irrigation

Section Two: Process and Drainage Piping Design

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section Three: Installation

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

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

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

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

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

iii

CONTENTS


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

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

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

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

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

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

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

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


Corzan® Full Pressure Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

iv Vinyl Process Piping Systems

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

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

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

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

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

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

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

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

Section Four: Specialty Piping Products

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

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

Section Five: Specifications

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Solvent Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Section Six: Appendices

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

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

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

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

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

vVinyl Process Piping Systems

vi

NOTES

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

GENERAL

INFORM

ATION

OVERVIEW

SECTION ONE: GENERAL INFORMATION

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

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

Only IPEX offers Xirtec®, a complete system of pipe, valves and fittings engineered and manufactured to IPEX’s strict quality,performance and dimensional standards.

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

7Vinyl Process Piping Systems


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8 Vinyl Process Piping Systems

Lower Installation Costs

In addition to lower material costs than traditional pipingmaterials, vinyl pipe can significantly reduce labor andtransportation costs on a typical installation.

Vinyl material is light weight, non-toxic and relatively flexible.Vinyl pipe is easily handled, stored and cut and can be joinedin a variety of ways, adapting easily to any field application.Special handling or heavy equipment for installation is notrequired.

Extended Life

Once properly selected for the application and correctlyinstalled, PVC and CPVC products provide years of maintenancefree service. Our materials will not rust, pit, scale or corrode oneither interior or exterior surfaces. In fact, thermoplastic pipingsystems in a variety of demanding industrial applications haveoperated successfully for over 45 years.

Chemical Resistance

IPEX offers complete systems including pipe, fittings andvalves with outstanding resistance to a wide range ofchemicals including most acids, alcohols, alkalis, saltsolutions and halogens. PVC and CPVC are also not adverselyaffected by atmospheric conditions and are well suited foroutdoor installations. For specific applications see the IPEXChemical Resistance Guide.

Corrosion Resistance

Our thermoplastic materials are immune to damage fromnaturally corrosive soil conditions as well as electrochemicalor galvanic corrosion. This is particularly advantageous inunderground installations where galvanic reaction oftencauses damage to metal piping products. Our thermoplastic’snon-corroding properties ensure improved flow, lowermaintenance costs and longer performance life.

Abrasion Resistance

The blending of PVC and CPVC resins, lubricants, modifiersand assorted additives in today’s compounds, together withmodern extrusion processes, result in a resilient pipingproduct with outstanding abrasion resistance.

PVC and CPVC are often selected as the piping material forconveyance in abrasive service. The inherent abrasionresistance of vinyl allows substantial increases in lifeexpectancy compared to other materials. In manyapplications, vinyls outperform other materials such asmetals.

For example, installation of vinyl piping rather than thestandard metal or rubber-lined steel pipe for conveyance ofmining and sand slurries resulted in significantly lessabrasion, dramatically reduced maintenance and increasedsystem life.

Improved Flow

IPEX piping has a substantially lower Roughness Factor thanmetal and other materials, and since thermoplastics do notrust, pit, scale or corrode, the interior walls remain smooth invirtually any service. This high carrying capacity may result inthe use of flatter grades or smaller diameter pipe.

Non-toxicity

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

Biological Resistance

PVC and CPVC piping systems are resistant to fungi andbacterial growth, particularly those which cause corrosion inmetal piping systems.

Service Temperature

IPEX offers a variety of thermoplastic materials designed tomeet a broad range of service temperatures. PVC has arecommended maximum service temperature of 140°F(60°C) while CPVC has a maximum service temperature of200°F (93°C).

Lower Thermal Conductivity

With a dramatically lower thermal conductivity factor ascompared to metal, thermoplastic systems have less heat lossor gain, and sustain the temperature of the service with lessvariation than metal piping. As a result, pipe insulation isoften not required.

Fire Performance

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

Extensive tests on PVC and CPVC compounds prove theiroutstanding fire performance. Check local building codes andregulations for specific requirements.

PVC

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

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

BENEFITS


GENERAL

INFORM

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

CPVC

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

Standards and Approvals

IPEX manufactures the widest range of thermoplastic pipingsystems available. All products are produced to the strictestinternal quality control specifications and meet or exceedapplicable regulatory standards.

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


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PVC (Polyvinyl Chloride)

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

Of the various types and grades of PVC used in plasticpiping, Type 1, Grade 1 PVC (Cell Classification 12454)conforming to ASTM D1784, is the most common. Themaximum service temperature for PVC is 140°F (60°C),under pressure. PVC for drainage applications is also capableof handling near boiling temperatures for intermittent flowconditions. With a hydrostatic design basis of 4000 psi at73°F (23°C) and a design stress of 2,000 psi at 73°F(23°C), PVC has the highest long-term hydrostatic strength ofany other major thermoplastic material used for piping.

CPVC (Chlorinated Polyvinyl Chloride)

CPVC (Cell Classification 24448 and 23447) conforming toASTM D1784 has physical properties at 73°F (23°C) similarto those of PVC and chemical resistance similar to orgenerally better than that of PVC. The design stress of CPVCis also 2,000 psi at 73°F (23°C). The maximum servicetemperature is 200°F (93°C) under pressure with occasionalexposure to boiling water (212°F, 100°C). CPVC has provedto be an excellent piping material for hot corrosive liquids,hot and cold process water distribution and similarapplications above the temperature range of PVC.

MATERIAL DESCRIPTION

Table 1 – Physical Properties

PROPERTIES MATERIALS

PVC CPVC Corzan CPVC Standards(Standard) (High Impact)

Cell classification 12454 23447 24448

Specific gravity 1.42 1.50 1.51 ASTM D 792

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

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

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

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

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

Poisson’s ratio 0.38 0.33 0.33

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

Coefficient of thermal expansion in./in./°F (x 10-5) 3.0 3.8 3.4 ASTM D 696

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

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

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

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

Thermal conductivity, BTU.in./hr.ft2.°F 1.2 0.95 0.95 ASTM C177

Burning rate Self extinguish Self extinguish Self extinguish ASTM D 635

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

Flash ignition, °F 730 900 900

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

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


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


GENERAL

INFORM

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APPLICATIONS

Industrial and Process Piping

• Plant Water Supply and Distribution Lines

• Cooling Water Systems

• Chemical and Washwater Systems for Photographic Laboratories

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

• Bleach, Dye and Acid Lines in Textile Mills

• Deionized Water

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

• Vacuum Piping

• Pure Chemicals for Semiconductor & Pharmaceutical Industries

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

• Well Casings and Dewatering Lines

• Drainage and Effluent Piping

• Swimming Pool Piping

• Rainwater Leaders for Buildings

Pulp and Paper

• Pulp/Chemical Recovery Systems

• Bleach Plant Piping Systems

• Washwater Piping and Lagoon Systems

Food Processing

• Brine and Seawater Distribution in Fish Plants

• Brine Systems in Meat Packaging Plants

• Piping for the Dairy, Canning and Beverage Industries

Water and Sewage Treatment

• Alum and Ferric Chloride Handling

• Chlorine Injection Systems

• Piping in Lagoons and Settling Ponds

• Rainwater Lines

Irrigation

• Golf Courses

• Greenhouses

• Agriculture

• Residential Turf

• Commercial Turf


CAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water boosters.12 Vinyl Process Piping Systems

NOTES


PROCESS &DRAIN

AGE PIPING DESIGN

SECTION TWO: PROCESS AND DRAINAGE PIPING DESIGN

INTRODUCTION

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

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



PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN

DESIGN PROCESS


Establish System Requirements

Before the proper materials can be chosen, the systemrequirements must be determined. This establishes the scopeof the project and determines design and materialspecifications. Factors to be considered may include:

1. Liquid composition

• Chemical characteristics• Variations in fluid chemistry

2. Process flow

• Required flow rate• Required pressure• Changes in velocity• Potential pressure drops• Potential pressure surges• Minimum and maximum operating temperatures

3. System Location / Environment

• Above / below ground or overhead• Climate (extreme heat or cold)• Expected fluctuations in ambient temperature

4. Installation

• Space restrictions• Difficult access• New or retrofit• Joining of dissimilar materials

5. Budget Considerations

• Material cost• Installation cost• Maintenance cost• Life expectancy

Determine Appropriate Sizing

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

• Pressure limitations • Temperature limitations• The pressure/temperature relationship

A) Pressure Limitations

Pressure Ratings

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

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

Determining Pressure

The carrying capacity of any pipe is a function of its hoopstrength and the geometry of the pipe as defined by its wallthickness and diameter at a given temperature.

Design Stress

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

S = HDBf

Where:

HDB = hydrostatic design basisf = safety factor

Example 1:

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

S = 4000 S = 2000 psi2

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

Safety Factor1

Design Factor=

SF1

DF=


Wall Thickness

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

The dimension ratio can also be calculated as follows:

DR = Do/tWhere:

Do = average outside diametert = minimum wall thickness

Important points to remember about the DR classifications are:

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

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

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

Internal Pressure

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

P = 2S DR-1

where:P = internal pressure, psiS = hoop stress, psiDR = dimension ratio (Do/t)

Example 2:

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

Known: S = 2000, DR = 21

P = 2(2000)(21-1)

P = 4000 20

P = 200 psi

Example 3:

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

Step 1: Calculate DR

Known: DR = Do/t

DR = 2.375 (from Table A-14 Dimensions, 0.218Weights and Pressure Ratings)

DR = 10.9

Step 2: Calculate the maximum pressure P

Known: S = 2000, DR = 10.9

P = 2(2000)(10.9-1)

P = 4000 9.9

P = 404 psi

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

Size Schedule 40 Schedule 80 DR Average Min. Wall DR Average Min. Wall

OD. Thickness OD. Thickness(in) (in) (in) (in) (in)

1/4 - - - 4.5 0.540 0.1193/8 - - - 5.4 0.675 0.1261/2 7.7 0.840 0.109 5.7 0.840 0.1473/4 9.3 1.050 0.113 6.8 1.050 0.154

1 9.9 1.315 0.133 7.3 1.315 0.179

11/4 11.8 1.660 0.141 8.7 1.660 0.191

11/2 13.1 1.900 0.145 9.5 1.900 0.200

2 15.4 2.375 0.154 10.9 2.375 0.218

21/2 14.2 2.875 0.203 10.4 2.875 0.276

3 16.2 3.500 0.216 11.7 3.500 0.300

4 19.0 4.500 0.237 13.4 4.500 0.337

5 21.6 5.563 0.258 14.8 5.563 0.375

6 23.7 6.625 0.280 15.3 6.625 0.432

8 26.8 8.625 0.322 17.3 8.625 0.500

10 29.5 10.750 0.365 18.1 10.750 0.593

12 31.4 12.750 0.406 18.6 12.750 0.687

14 32.0 14.000 0.438 18.7 14.000 0.750

16 32.0 16.000 0.500 19.0 16.000 0.843

18 32.0 18.000 0.562 19.2 18.000 0.937

20 33.7 20.000 0.593 19.4 20.000 1.031

24 34.9 24.000 0.687 19.7 24.000 1.218

PROCESS &DRAIN

AGE PIPING DESIGN



PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN

Example 4:

A piping system consisting of 2 and 4 inch pipe must becapable of sustaining a pressure of 310 psi at ambienttemperature (73°F / 23ºC). What schedule of pipe isnecessary?

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

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

DR = Do/t

P = 2S DR-1

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

Friction Loss through Piping

As fluid flows through a piping system, it will experiencefriction resistance between the fluid and the pipe wallresulting in a pressure loss. This pressure loss is a result offluid:

• density• viscosity• velocity• temperature• type of flow • smoothness of the pipe wall

Friction loss can be determined by referring to publishedtables, such as those in Tables 4, 5, 6, and 7 or it can becalculated. The most widely used equation to calculatefriction loss in pressure systems is the Hazen-Williamsequation.

Hazen-Williams Equation

where:f = friction loss (ft. of H2O/100 ft.)

Q = flow rate (gpm)

Di = pipe inside diameter (in.)

C = flow coefficient

Example 5

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

Known: Q = 4000 US gpm

C = 150 (from Table 3 Flow coefficient constants)

Di = 18.743 (from Table A-14 Dimensions, Weights & Pressure Ratings)

f = 0.2083 x 0.476 x 3.006

f = 0.3 ft. per 100 ft.

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

Note: conversion tip (1 psi = 2.31ft of H2O)

Table 3 – Flow Coefficient Constants (C)

16

f = 0.2083 x (100)1.852 x Q1.852C Di4.8655

f = 0.2083 x (100 )1.852 x (4000)1.852150 (18.743)4.8655


Dimension Ratio

DR = 2.3750.154

= 15.4

DR = 2.3750.218

= 10.9

DR = 4.5000.237

= 19.0

DR = 4.500

0.337

= 13.4

Maximum Pressure

P = 2 (2000)(15.4 - 1)

= 400014.4

= 278 psi

P = 2 (2000)(10.9 - 1)

= 40009.9

= 404 psi

P = 2 (2000)(19.0 - 1)

= 4000 18.0

= 222 psi

P = 2 (2000)(13.4 - 1)

= 400012.4

= 323 psi

2" Schedule 40

2" Schedule 80

4" Schedule 40

4" Schedule 80

Type of Pipe Flow coefficient CVinyl 150Copper 140Cast iron - unlined 90 - 120Galvanized steel 110Corrugated steel pipe 60


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

10.

002

1.13

1.16

0.50

20.

004

2.26

4.19

1.81

1.26

1.03

0.44

50.

011

5.64

22.8

89.

903.

165.

602.

421.

931.

690.

731.

100.

430.

197

0.01

67.

8942

.66

18.4

74.

4310

.44

4.52

2.70

3.14

1.36

1.55

0.81

0.35

1.13

0.38

0.16

100.

022

6.32

20.2

18.

753.

866.

082.

632.

211.

570.

681.

620.

730.

320.

980.

210.

0912

0.02

77.

5928

.33

12.2

64.

638.

533.

692.

652.

200.

951.

941.

030.

441.

460.

450.

201.

030.

190.

0815

0.03

39.

4842

.82

18.5

45.

7912

.89

5.58

3.31

3.32

1.44

2.42

1.55

0.67

1.95

0.77

0.33

1.37

0.33

0.14

200.

045

7.72

21.9

69.

514.

425.

652.

453.

232.

641.

142.

441.

170.

511.

710.

490.

211.

100.

170.

0725

0.05

69.

6533

.20

14.3

75.

528.

553.

704.

044.

001.

732.

931.

640.

712.

050.

690.

301.

320.

240.

1030

0.06

711

.58

46.5

420

.15

6.63

11.9

85.

194.

855.

602.

423.

412.

180.

942.

390.

920.

401.

550.

320.

1435

0.07

87.

7315

.94

6.90

5.66

7.45

3.23

3.90

2.79

1.21

2.73

1.18

0.51

1.77

0.41

0.18

400.

089

8.84

20.4

18.

846.

479.

544.

134.

393.

471.

503.

081.

460.

631.

990.

510.

2245

0.10

01.

150.

130.

069.

9425

.39

10.9

97.

2711

.87

5.14

4.88

4.22

1.83

3.42

1.78

0.77

2.21

0.61

0.27

500.

111

1.28

0.16

0.07

11.0

530

.86

13.3

68.

0814

.43

6.25

5.36

5.03

2.18

3.76

2.12

0.92

2.43

0.73

0.32

550.

123

1.41

0.19

0.08

8.89

17.2

17.

455.

855.

922.

564.

102.

491.

082.

650.

860.

3760

0.13

41.

530.

230.

109.

7020

.22

8.75

6.34

6.86

2.97

4.44

2.89

1.25

2.87

1.00

0.43

650.

145

1.66

0.26

0.11

10.5

123

.45

10.1

56.

837.

873.

414.

793.

321.

443.

091.

150.

5070

0.15

61.

790.

300.

131.

140.

100.

0411

.32

26.9

011

.65

7.32

8.94

3.87

5.13

3.77

1.63

3.31

1.30

0.56

750.

167

1.92

0.34

0.15

1.22

0.11

0.05

7.80

10.0

84.

365.

474.

251.

843.

531.

470.

6380

0.17

82.

050.

390.

171.

300.

130.

068.

2911

.27

4.88

5.81

4.75

2.06

3.75

1.64

0.71

900.

201

2.30

0.48

0.21

1.46

0.16

0.07

8.78

12.5

35.

436.

155.

282.

293.

971.

820.

7910

00.

223

2.56

0.59

0.25

1.62

0.19

0.08

1.12

0.08

0.03

9.27

13.8

56.

006.

495.

842.

534.

202.

020.

8712

50.

279

3.20

0.89

0.38

2.03

0.29

0.13

1.40

0.12

0.05

9.75

15.2

36.

596.

846.

422.

784.

422.

220.

9615

00.

334

3.84

1.24

0.54

2.44

0.41

0.18

1.69

0.17

0.07

8.55

9.70

4.20

5.52

3.35

1.45

175

0.39

04.

471.

650.

722.

840.

550.

241.

970.

220.

1010

.26

13.6

05.

896.

624.

702.

0320

00.

446

5.11

2.12

0.92

3.25

0.70

0.30

2.25

0.29

0.12

1.30

0.08

0.03

7.73

6.25

2.71

250

0.55

76.

393.

201.

394.

061.

060.

462.

810.

430.

191.

620.

110.

058.

838.

003.

4630

00.

668

7.67

4.49

1.94

4.87

1.49

0.64

3.37

0.61

0.26

1.94

0.16

0.07

11.0

412

.10

5.24

350

0.78

08.

955.

972.

585.

691.

980.

863.

930.

810.

352.

270.

210.

091.

440.

070.

0340

00.

891

10.2

37.

643.

316.

502.

541.

104.

491.

030.

452.

590.

270.

121.

640.

090.

0445

01.

003

7.31

3.15

1.36

5.06

1.29

0.56

2.92

0.34

0.15

1.85

0.11

0.05

1.30

0.05

0.02

500

1.11

48.

123.

831.

665.

621.

560.

683.

240.

410.

182.

050.

140.

061.

450.

060.

0260

01.

337

9.75

5.37

2.33

6.74

2.19

0.95

3.89

0.57

0.25

2.46

0.19

0.08

1.74

0.08

0.03

1.44

0.05

0.02

700

1.56

011

.37

7.15

3.09

7.87

2.92

1.26

4.54

0.76

0.33

2.87

0.25

0.11

2.02

0.11

0.05

1.67

0.07

0.03

800

1.78

28.

993.

731.

625.

180.

980.

423.

290.

320.

142.

310.

140.

061.

910.

090.

041.

470.

050.

0290

02.

005

1.30

0.03

0.01

10.1

14.

642.

015.

831.

220.

533.

700.

400.

172.

600.

170.

072.

150.

110.

051.

650.

060.

0210

002.

228

1.45

0.04

0.02

6.48

1.48

0.64

4.11

0.49

0.21

2.89

0.21

0.09

2.39

0.13

0.06

1.83

0.07

0.03

1250

2.78

51.

810.

060.

038.

102.

240.

975.

130.

740.

323.

610.

310.

142.

990.

200.

092.

290.

100.

0415

003.

342

2.17

0.08

0.04

1.75

0.05

0.02

9.72

3.14

1.36

6.16

1.03

0.45

4.34

0.44

0.19

3.59

0.28

0.12

2.75

0.15

0.06

2000

4.45

62.

890.

140.

062.

330.

080.

048.

211.

760.

765.

780.

750.

324.

780.

470.

203.

660.

250.

1125

005.

570

3.62

0.21

0.09

2.91

0.12

0.05

2.01

0.05

0.02

10.2

72.

661.

157.

231.

130.

495.

980.

710.

314.

580.

370.

1630

006.

684

4.34

0.29

0.13

3.49

0.17

0.08

2.41

0.07

0.03

8.68

1.59

0.69

7.18

1.00

0.43

5.50

0.52

0.23

3500

7.79

85.

060.

390.

174.

070.

230.

102.

810.

090.

0410

.12

2.11

0.92

8.37

1.33

0.58

6.41

0.70

0.30

4000

8.91

25.

790.

500.

224.

650.

300.

133.

220.

120.

059.

571.

710.

747.

330.

890.

3945

0010

.026

6.51

0.62

0.27

5.24

0.37

0.16

3.62

0.15

0.06

10.7

62.

120.

928.

241.

110.

4850

0011

.140

7.23

0.76

0.33

5.82

0.45

0.19

4.02

0.18

0.08

9.16

1.35

0.58

5500

12.2

547.

960.

910.

396.

400.

530.

234.

420.

220.

0910

.08

1.61

0.70

6000

13.3

688.

681.

060.

466.

980.

630.

274.

830.

250.

1165

0014

.482

9.40

1.23

0.53

7.56

0.73

0.31

5.23

0.30

0.13

7000

15.5

9610

.13

1.42

0.61

8.14

0.83

0.36

5.63

0.34

0.15

7500

16.7

108.

730.

950.

416.

030.

390.

1780

0017

.824

9.31

1.07

0.46

6.43

0.43

0.19

8500

18.9

389.

891.

190.

526.

840.

490.

2190

0020

.052

10.4

71.

330.

577.

240.

540.

2395

0021

.166

7.64

0.60

0.26

1000

022

.280

8.04

0.66

0.28

3/4"

1"1

1/4"

1 1/

2"2"

2 1/

2"

3"

4"

5"

6"

8"

10"

12"

14"

16"

18"

20"

24"

1/2"

CA

UTI

ON

:Fl

ow v

eloc

ity

shou

ld n

ot e

xcee

d 5

fee

t pe

r se

cond

.

PROCESS &DRAIN

AGE PIPING DESIGN

GPM

cu ft/sec

Velocity (ft/s)

Friction Head Loss(ft water/100ft)

Friction Pressure(psi/100ft)

Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity(ft/s)



Velocity (ft/s)





PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN

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

10.

002

1.48

2.24

0.97

20.

004

2.95

8.10

3.51

1.57

1.73

0.75

0.93

0.49

0.21

50.

011

7.39

44.2

119

.14

3.92

9.47

4.10

2.33

2.67

1.16

1.30

0.64

0.28

70.

016

10.3

482

.43

35.6

95.

4917

.65

7.64

3.27

4.98

2.16

1.82

1.20

0.52

1.31

0.54

0.24

100.

022

7.84

34.1

814

.79

4.67

9.65

4.18

2.59

2.32

1.00

1.88

1.05

0.46

120.

027

9.41

47.9

020

.74

5.60

13.5

25.

853.

113.

251.

402.

251.

470.

6415

0.03

311

.76

72.4

231

.35

7.00

20.4

48.

853.

894.

912.

122.

812.

230.

961.

680.

630.

2720

0.04

59.

3334

.82

15.0

75.

198.

363.

623.

753.

801.

642.

231.

070.

471.

560.

450.

1925

0.05

611

.66

52.6

422

.79

6.49

12.6

45.

474.

695.

742.

482.

791.

630.

701.

950.

680.

2930

0.06

77.

7817

.71

7.67

5.63

8.04

3.48

3.35

2.28

0.99

2.34

0.95

0.41

1.49

0.32

0.14

350.

078

9.08

23.5

610

.20

6.57

10.7

04.

633.

913.

031.

312.

731.

260.

551.

740.

430.

1840

0.08

910

.38

30.1

713

.06

7.50

13.7

15.

934.

473.

881.

683.

121.

620.

701.

990.

540.

2445

0.10

08.

4417

.05

7.38

5.03

4.83

2.09

3.51

2.01

0.87

2.24

0.68

0.29

500.

111

1.43

0.21

0.09

9.38

20.7

28.

975.

585.

872.

543.

902.

451.

062.

490.

820.

3655

0.12

31.

570.

250.

1110

.32

24.7

210

.70

6.14

7.00

3.03

4.29

2.92

1.26

2.74

0.98

0.43

600.

134

1.71

0.30

0.13

9.70

20.2

28.

756.

708.

223.

564.

683.

431.

482.

991.

150.

5065

0.14

51.

850.

340.

1510

.51

23.4

510

.15

7.26

9.54

4.13

5.07

3.97

1.72

3.24

1.34

0.58

700.

156

2.00

0.39

0.17

11.3

226

.90

11.6

57.

8210

.94

4.74

5.46

4.56

1.97

3.49

1.54

0.66

750.

167

2.14

0.45

0.19

8.38

12.4

35.

385.

855.

182.

243.

741.

740.

7680

0.17

82.

280.

510.

221.

440.

160.

078.

9314

.01

6.06

6.23

5.84

2.53

3.99

1.97

0.85

900.

201

2.57

0.63

0.27

1.62

0.20

0.09

10.0

517

.42

7.54

7.01

7.26

3.14

4.48

2.45

1.06

100

0.22

32.

850.

760.

331.

800.

250.

1111

.17

21.1

89.

177.

798.

833.

824.

982.

971.

2912

50.

279

3.56

1.16

0.50

2.25

0.38

0.16

1.57

0.16

0.07

9.74

13.3

45.

786.

234.

491.

9515

00.

334

4.28

1.62

0.70

2.70

0.53

0.23

1.88

0.22

0.10

11.6

918

.70

8.10

7.47

6.30

2.73

175

0.39

04.

992.

160.

933.

150.

700.

302.

190.

290.

138.

728.

383.

6320

00.

446

5.70

2.76

1.19

3.60

0.90

0.39

2.51

0.37

0.16

1.43

0.10

0.04

9.97

10.7

34.

6525

00.

557

7.13

4.17

1.81

4.49

1.36

0.59

3.13

0.57

0.24

1.79

0.14

0.06

300

0.66

88.

555.

852.

535.

391.

900.

823.

760.

790.

342.

140.

200.

0935

00.

780

9.98

7.78

3.37

6.29

2.53

1.10

4.39

1.05

0.46

2.50

0.27

0.12

1.59

0.09

0.04

400

0.89

111

.41

9.96

4.31

7.19

3.24

1.40

5.02

1.35

0.58

2.86

0.34

0.15

1.81

0.11

0.05

450

1.00

38.

094.

041.

755.

641.

680.

733.

210.

430.

182.

040.

140.

061.

440.

060.

0350

01.

114

8.99

4.90

2.12

6.27

2.04

0.88

3.57

0.52

0.22

2.27

0.17

0.07

1.60

0.07

0.03

600

1.33

710

.79

6.87

2.98

7.52

2.86

1.24

4.28

0.73

0.31

2.72

0.24

0.10

1.92

0.10

0.04

1.59

0.07

0.03

700

1.56

08.

783.

811.

655.

000.

970.

423.

170.

320.

142.

240.

140.

061.

860.

090.

0480

01.

782

10.0

34.

882.

115.

711.

240.

543.

630.

410.

182.

560.

180.

082.

120.

110.

051.

620.

060.

0290

02.

005

6.43

1.54

0.67

4.08

0.51

0.22

2.88

0.22

0.09

2.39

0.14

0.06

1.82

0.07

0.03

1000

2.22

81.

590.

050.

027.

141.

870.

814.

540.

620.

273.

200.

270.

122.

650.

170.

072.

020.

090.

0412

502.

785

1.99

0.07

0.03

8.93

2.83

1.23

5.67

0.94

0.41

4.01

0.40

0.17

3.32

0.25

0.11

2.53

0.13

0.06

1500

3.34

22.

390.

100.

041.

930.

060.

0310

.71

3.97

1.72

6.80

1.32

0.57

4.81

0.57

0.24

3.98

0.36

0.15

3.03

0.18

0.08

2000

4.45

63.

190.

180.

082.

580.

100.

059.

072.

240.

976.

410.

960.

425.

310.

610.

264.

040.

310.

1425

005.

570

3.98

0.27

0.12

3.22

0.16

0.07

2.23

0.06

0.03

11.3

43.

391.

478.

011.

460.

636.

630.

920.

405.

050.

470.

2130

006.

684

4.78

0.37

0.16

3.86

0.22

0.10

2.67

0.09

0.04

9.61

2.04

0.88

7.96

1.29

0.56

6.06

0.66

0.29

3500

7.79

85.

580.

500.

214.

510.

300.

133.

120.

120.

0511

.21

2.71

1.17

9.29

1.71

0.74

7.07

0.88

0.38

4000

8.91

26.

370.

640.

285.

150.

380.

163.

560.

150.

0710

.61

2.20

0.95

8.08

1.13

0.49

4500

10.0

267.

170.

790.

345.

800.

470.

204.

010.

190.

0811

.94

2.73

1.18

9.09

1.41

0.61

5000

11.1

407.

970.

960.

426.

440.

570.

254.

450.

230.

1010

.10

1.71

0.74

5500

12.2

548.

771.

150.

507.

080.

680.

304.

900.

280.

1260

0013

.368

9.56

1.35

0.58

7.73

0.80

0.35

5.35

0.33

0.14

6500

14.4

8210

.36

1.56

0.68

8.37

0.93

0.40

5.79

0.38

0.16

7000

15.5

969.

021.

070.

466.

240.

440.

1975

0016

.710

9.66

1.21

0.52

6.68

0.49

0.21

8000

17.8

2410

.30

1.37

0.59

7.13

0.56

0.24

8500

18.9

3810

.95

1.53

0.66

7.57

0.62

0.27

9000

20.0

528.

020.

690.

3095

0021

.166

8.46

0.77

0.33

1000

022

.280

8.91

0.84

0.36

GPM

cu ft/sec

Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity(ft/s)



Velocity (ft/s)



3/4"

1"1

1/4"

1 1/

2"

2"2

1/2"

3"

4"

5"

6"

8"

10"

12"

14"

16"

18"

20"

24"

1/2"

CA

UTI

ON

:Fl

ow v

eloc

ity

shou

ld n

ot e

xcee

d 5

fee

t pe

r se

cond

.



PROCESS &DRAIN

AGE PIPING DESIGN

CA

UTI

ON

:Fl

ow v

eloc

ity

shou

ld n

ot e

xcee

d 5

fee

t pe

r se

cond

.

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

10.

002

20.

004

1.88

2.68

1.16

1.08

0.70

0.30

50.

011

4.69

14.6

26.

332.

703.

811.

651.

591.

050.

457

0.01

66.

5727

.27

11.8

13.

787.

113.

082.

221.

950.

8410

0.02

29.

3852

.79

22.8

55.

4013

.77

5.96

3.17

3.78

1.63

1.87

1.04

0.45

120.

027

11.2

674

.00

32.0

36.

4819

.30

8.35

3.81

5.29

2.29

2.24

1.45

0.63

1.70

0.74

0.32

150.

033

8.10

29.1

712

.63

4.76

8.00

3.46

2.80

2.20

0.95

2.12

1.12

0.49

200.

045

10.8

049

.70

21.5

16.

3513

.63

5.90

3.73

3.75

1.62

2.83

1.91

0.83

1.80

0.64

0.28

250.

056

7.93

20.6

08.

924.

665.

662.

453.

542.

891.

252.

250.

970.

421.

530.

380.

1630

0.06

79.

5228

.88

12.5

05.

607.

943.

444.

244.

051.

752.

711.

350.

591.

840.

530.

2335

0.07

811

.10

38.4

216

.63

6.53

10.5

64.

574.

955.

382.

333.

161.

800.

782.

150.

710.

3140

0.08

97.

4613

.53

5.86

5.66

6.89

2.98

3.61

2.31

1.00

2.45

0.90

0.39

1.65

0.34

0.15

450.

100

8.40

16.8

27.

286.

368.

573.

714.

062.

871.

242.

761.

120.

491.

860.

430.

1950

0.11

19.

3320

.45

8.85

7.07

10.4

24.

514.

513.

491.

513.

071.

370.

592.

060.

520.

2355

0.12

310

.26

24.4

010

.56

7.78

12.4

35.

384.

964.

161.

803.

371.

630.

712.

270.

620.

2760

0.13

48.

4914

.60

6.32

5.41

4.89

2.12

3.68

1.91

0.83

2.48

0.73

0.32

650.

145

1.62

0.25

0.11

9.19

16.9

47.

335.

865.

672.

453.

992.

220.

962.

680.

850.

3770

0.15

61.

750.

290.

129.

9019

.43

8.41

6.31

6.50

2.81

4.29

2.55

1.10

2.89

0.97

0.42

750.

167

1.87

0.32

0.14

10.6

122

.08

9.56

6.76

7.39

3.20

4.60

2.89

1.25

3.10

1.10

0.48

800.

178

2.00

0.37

0.16

7.21

8.32

3.60

4.91

3.26

1.41

3.30

1.25

0.54

900.

201

2.25

0.46

0.20

8.12

10.3

54.

485.

524.

061.

763.

721.

550.

6710

00.

223

2.50

0.55

0.24

1.63

0.20

0.09

9.02

12.5

85.

456.

144.

932.

144.

131.

880.

8112

50.

279

3.12

0.84

0.36

2.04

0.30

0.13

11.2

719

.02

8.24

7.67

7.46

3.23

5.16

2.85

1.23

150

0.33

43.

741.

170.

512.

450.

420.

181.

730.

180.

089.

2010

.45

4.52

6.19

3.99

1.73

175

0.39

04.

371.

560.

682.

860.

560.

242.

020.

240.

1010

.74

13.9

06.

027.

235.

312.

3020

00.

446

4.99

2.00

0.86

3.27

0.71

0.31

2.31

0.30

0.13

8.26

6.80

2.94

250

0.55

76.

243.

021.

314.

091.

080.

472.

880.

460.

201.

700.

130.

0610

.32

10.2

74.

4530

00.

668

7.49

4.23

1.83

4.90

1.51

0.65

3.46

0.65

0.28

2.04

0.18

0.08

350

0.78

08.

745.

632.

445.

722.

010.

874.

030.

860.

372.

380.

240.

101.

530.

080.

0440

00.

891

9.99

7.21

3.12

6.54

2.57

1.11

4.61

1.10

0.48

2.72

0.30

0.13

1.75

0.10

0.05

450

1.00

311

.23

8.97

3.88

7.35

3.20

1.38

5.19

1.37

0.59

3.06

0.38

0.16

1.97

0.13

0.06

500

1.11

48.

173.

891.

685.

761.

660.

723.

400.

460.

202.

190.

160.

071.

550.

070.

0360

01.

337

9.80

5.45

2.36

6.92

2.33

1.01

4.08

0.64

0.28

2.62

0.22

0.10

1.87

0.10

0.04

1.55

0.06

0.03

700

1.56

011

.44

7.25

3.14

8.07

3.10

1.34

4.76

0.86

0.37

3.06

0.29

0.13

2.18

0.13

0.06

1.80

0.08

0.04

800

1.78

29.

223.

971.

725.

441.

100.

483.

500.

380.

162.

490.

160.

072.

060.

100.

051.

580.

050.

0290

02.

005

10.3

74.

942.

146.

111.

370.

593.

940.

470.

202.

800.

200.

092.

320.

130.

061.

780.

070.

0310

002.

228

1.56

0.05

0.02

6.79

1.66

0.72

4.37

0.57

0.25

3.11

0.25

0.11

2.58

0.16

0.07

1.97

0.08

0.04

1250

2.78

51.

950.

070.

038.

492.

511.

095.

470.

860.

373.

890.

370.

163.

220.

240.

102.

470.

120.

0515

003.

342

2.34

0.10

0.04

1.90

0.06

0.03

10.1

93.

521.

526.

561.

200.

524.

660.

530.

233.

870.

330.

142.

960.

170.

0820

004.

456

3.12

0.17

0.07

2.53

0.10

0.04

8.75

2.05

0.89

6.22

0.89

0.39

5.16

0.57

0.25

3.95

0.30

0.13

2500

5.57

03.

900.

250.

113.

160.

150.

072.

190.

060.

0310

.93

3.10

1.34

7.77

1.35

0.59

6.45

0.86

0.37

4.94

0.45

0.19

3000

6.68

44.

680.

350.

153.

790.

210.

092.

630.

090.

049.

331.

900.

827.

741.

200.

525.

920.

630.

2735

007.

798

5.46

0.47

0.20

4.42

0.28

0.12

3.07

0.12

0.05

10.8

82.

521.

099.

021.

600.

696.

910.

840.

3640

008.

912

6.24

0.60

0.26

5.06

0.36

0.16

3.51

0.15

0.06

10.3

12.

050.

897.

901.

070.

4645

0010

.026

7.02

0.75

0.33

5.69

0.45

0.19

3.95

0.19

0.08

8.88

1.33

0.58

5000

11.1

407.

800.

910.

406.

320.

550.

244.

390.

230.

109.

871.

620.

7055

0012

.254

8.58

1.09

0.47

6.95

0.65

0.28

4.83

0.27

0.12

10.8

61.

930.

8460

0013

.368

9.36

1.28

0.55

7.58

0.77

0.33

5.27

0.32

0.14

6500

14.4

8210

.15

1.48

0.64

8.22

0.89

0.38

5.71

0.37

0.16

7000

15.5

968.

851.

020.

446.

150.

420.

1875

0016

.710

9.48

1.16

0.50

6.58

0.48

0.21

8000

17.8

2410

.11

1.31

0.57

7.02

0.54

0.23

8500

18.9

387.

460.

600.

2690

0020

.052

7.90

0.67

0.29

9500

21.1

668.

340.

740.

3210

000

22.2

808.

780.

810.

35

GPM

cu ft/sec

Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity(ft/s)



Velocity (ft/s)



3/4"

1"

1 1/

4"1

1/2"

2"2

1/2"

3"

4"

5"

6"

8"

10"

12"

14"

16"

18"

20"

24"

1/2"



PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN

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

10.

002

20.

004

50.

011

70.

016

100.

022

120.

027

1.66

0.70

0.30

150.

033

2.07

1.06

0.46

200.

045

2.76

1.80

0.78

1.73

0.58

0.25

250.

056

3.45

2.73

1.18

2.16

0.87

0.38

300.

067

4.14

3.82

1.65

2.60

1.23

0.53

1.77

0.48

0.21

350.

078

4.84

5.08

2.20

3.03

1.63

0.71

2.06

0.64

0.28

400.

089

5.53

6.51

2.82

3.46

2.09

0.90

2.35

0.82

0.35

450.

100

6.22

8.10

3.51

3.89

2.60

1.12

2.65

1.02

0.44

1.78

0.39

0.17

500.

111

6.91

9.84

4.26

4.33

3.16

1.37

2.94

1.24

0.53

1.98

0.47

0.20

550.

123

7.60

11.7

45.

084.

763.

761.

633.

241.

470.

642.

180.

560.

2460

0.13

48.

2913

.80

5.97

5.19

4.42

1.91

3.53

1.73

0.75

2.38

0.66

0.29

650.

145

8.98

16.0

06.

935.

635.

132.

223.

832.

010.

872.

580.

770.

3370

0.15

61.

670.

260.

119.

6718

.35

7.95

6.06

5.88

2.55

4.12

2.30

1.00

2.78

0.88

0.38

750.

167

1.79

0.29

0.13

10.3

620

.86

9.03

6.49

6.69

2.89

4.41

2.62

1.13

2.97

1.00

0.43

800.

178

1.91

0.33

0.14

6.92

7.54

3.26

4.71

2.95

1.28

3.17

1.13

0.49

900.

201

2.15

0.41

0.18

7.79

9.37

4.06

5.30

3.67

1.59

3.57

1.40

0.61

100

0.22

32.

390.

500.

221.

570.

180.

088.

6611

.39

4.93

5.89

4.46

1.93

3.97

1.71

0.74

125

0.27

92.

990.

750.

331.

960.

270.

1210

.82

17.2

27.

467.

366.

742.

924.

962.

581.

1215

00.

334

3.59

1.06

0.46

2.35

0.38

0.16

1.66

0.16

0.07

8.83

9.45

4.09

5.95

3.62

1.57

175

0.39

04.

191.

410.

612.

740.

500.

221.

930.

210.

0910

.30

12.5

75.

446.

944.

812.

0820

00.

446

4.79

1.80

0.78

3.13

0.64

0.28

2.21

0.27

0.12

7.93

6.16

2.67

250

0.55

75.

982.

721.

183.

920.

970.

422.

760.

420.

181.

630.

110.

059.

929.

314.

0330

00.

668

7.18

3.82

1.65

4.70

1.36

0.59

3.31

0.58

0.25

1.95

0.16

0.07

11.9

013

.06

5.65

350

0.78

08.

375.

082.

205.

481.

810.

793.

860.

770.

342.

280.

210.

0940

00.

891

9.57

6.50

2.82

6.27

2.32

1.01

4.42

0.99

0.43

2.61

0.27

0.12

1.68

0.09

0.04

450

1.00

310

.77

8.09

3.50

7.05

2.89

1.25

4.97

1.23

0.53

2.93

0.34

0.15

1.89

0.12

0.05

500

1.11

47.

843.

511.

525.

521.

500.

653.

260.

410.

182.

100.

140.

0660

01.

337

9.40

4.92

2.13

6.62

2.10

0.91

3.91

0.58

0.25

2.52

0.20

0.09

1.79

0.09

0.04

700

1.56

010

.97

6.55

2.83

7.73

2.79

1.21

4.56

0.77

0.34

2.93

0.26

0.11

2.09

0.12

0.05

1.73

0.07

0.03

800

1.78

28.

833.

581.

555.

210.

990.

433.

350.

340.

152.

380.

150.

061.

980.

090.

041.

510.

050.

0290

02.

005

9.94

4.45

1.93

5.86

1.23

0.53

3.77

0.42

0.18

2.68

0.18

0.08

2.22

0.12

0.05

1.70

0.06

0.03

1000

2.22

81.

500.

040.

0211

.04

5.41

2.34

6.51

1.50

0.65

4.19

0.51

0.22

2.98

0.22

0.10

2.47

0.14

0.06

1.89

0.07

0.03

1250

2.78

51.

870.

060.

038.

142.

260.

985.

240.

780.

343.

730.

340.

153.

090.

210.

092.

370.

110.

0515

003.

342

2.24

0.09

0.04

1.82

0.05

0.02

9.77

3.17

1.37

6.29

1.09

0.47

4.47

0.47

0.21

3.71

0.30

0.13

2.84

0.16

0.07

2000

4.45

62.

990.

150.

072.

420.

090.

048.

381.

850.

805.

960.

810.

354.

940.

510.

223.

780.

270.

1225

005.

570

3.74

0.23

0.10

3.03

0.14

0.06

2.10

0.06

0.02

10.4

82.

801.

217.

451.

220.

536.

180.

770.

344.

730.

400.

1730

006.

684

4.49

0.32

0.14

3.63

0.19

0.08

2.52

0.08

0.03

8.94

1.71

0.74

7.42

1.08

0.47

5.68

0.57

0.25

3500

7.79

85.

230.

430.

184.

240.

250.

112.

940.

100.

0510

.43

2.27

0.98

8.65

1.44

0.62

6.62

0.75

0.33

4000

8.91

25.

980.

540.

244.

850.

330.

143.

370.

130.

069.

891.

850.

807.

570.

970.

4245

0010

.026

6.73

0.68

0.29

5.45

0.41

0.18

3.79

0.17

0.07

8.52

1.20

0.52

5000

11.1

407.

480.

820.

366.

060.

490.

214.

210.

200.

099.

461.

460.

6355

0012

.254

8.23

0.98

0.43

6.66

0.59

0.25

4.63

0.24

0.10

10.4

11.

740.

7560

0013

.368

8.97

1.15

0.50

7.27

0.69

0.30

5.05

0.28

0.12

6500

14.4

829.

721.

340.

587.

870.

800.

355.

470.

330.

1470

0015

.596

10.4

71.

530.

668.

480.

920.

405.

890.

380.

1675

0016

.710

9.09

1.04

0.45

6.31

0.43

0.19

8000

17.8

249.

691.

180.

516.

730.

480.

2185

0018

.938

10.3

01.

320.

577.

150.

540.

2390

0020

.052

7.57

0.60

0.26

9500

21.1

667.

990.

670.

2910

000

22.2

808.

410.

730.

32

GPM

cu ft/sec

Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity (ft/s)



Velocity(ft/s)



Velocity (ft/s)



3/4"

1"1

1/4"

1 1/

2"

2"

2 1/

2"

3"

5"

6"

8"

10"

12"

14"

16"

18"

20"

24"

1/2" 4"not

avai

labl

eno

tav

aila

ble

not

avai

labl

eno

tav

aila

ble

CA

UTI

ON

:Fl

ow v

eloc

ity

shou

ld n

ot e

xcee

d 5

fee

t pe

r se

cond

.



PROCESS &DRAIN

AGE PIPING DESIGN

Friction Loss through Fittings

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

Example 6

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

Figure 1 – Schematic of simple system loop

Step 1: Count the number of fittings by type as you workyour way through the system.

Step 2: Determine the fitting loss by referring to Table 8,Friction Loss through Fittings.

Step 3: Calculate the friction loss per fitting size and type,then sum for the total system loss due to fittings asper the table below.

To calculate the friction loss in psi, refer to Table 5 (CarryingCapacity and Friction Loss for Schedule 80 Pipe) todetermine the friction loss in equivalent pipe for the givenflow rate.

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

1.29 x 121.7 = 1.57 psi100

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

P5

P4

P3

P2

P1

S

90º

90º

90º

45º

45º

LEGEND

Tee

90º Elbow

45º Elbowpump

Fitting

Tee

Tee

90º

45º

Total

Type

Run

Branch

Elbow

Elbow

Size Fittings

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

1/2 1.0 3.8 1.5 0.8

3/4 1.4 4.9 2.0 1.1

1 1.7 6.0 2.5 1.4

11/4 2.3 7.3 3.8 1.8

11/2 2.7 8.4 4.0 2.1

2 4.0 12.0 5.7 2.6

21/2 4.9 14.7 6.9 3.1

3 6.1 16.4 7.9 4.0

4 7.9 22.0 11.4 5.1

6 12.3 32.7 16.7 8.0

8 14.0 49.0 21.0 10.6

10 17.5 57.0 26.0 13.5

12 20.0 67.0 32.0 15.5

14 25.0 78.0 37.0 18.0

16 27.0 88.0 43.0 20.0

18 32.0 107.0 53.0 23.0

20 35.0 118.0 58.0 25.0

24 42.0 137.0 67.0 30.0

Table 8 Friction Loss through Fittings (Equivalent pipe length in feet)

No.

4

4

3

2

Loss

6.1

16.4

7.9

4.0

Total (ft)

24.4

65.6

23.7

8.0

121.7

3"



PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN


Friction Loss through Valves

Pressure drops through valves also contribute to the overallfriction loss of fluid through a piping system. Flow ratecoefficients (Cv) are defined as the flow rate in gallons perminute (gpm) through an open valve resulting in a pressuredrop of 1 psi. Flow rate coefficients are listed in theThermoplastic Valve Manual (Volume 7 in the IPEX IndustrialTechnical Manual series) and can also be calculated usingthe following formula.

f = sg (Q/Cv)2

Where:

f = pressure drop (friction loss) across the valve (psi)

sg = specific gravity (water = 1.0)

Q = flow through the valve (gpm)

Cv = flow rate coefficient

Example 7

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

Figure 2 - Schematic of simple system loop with valves

Step 1: Count the number of valves by type as you workyour way through the system.

Step 2: Determine the flow rate coefficient by valve typeand size by referring to tables in valve specifications(values are given here)

Step 3: Calculate the loss per valve type and then sum forthe total system loss due to valves as per the tablebelow.

Known: Cv = 497 for 3" VK Ball Valve

Cv = 248 for 3" Butterfly Valve

Cv = 0 for TK Three Way Ball Valve

Q = 100 gpm

P5

P4

P3

P2

P1

S

90º

90º

90º

45º

45º

LEGEND

Tee

90º Elbow

45º Elbow

Butterfly

Butterfly

Butterfly

Butterfly

Butterfly

3 way

3 way

Pistoncheck Ball

Ball

Valve

3 way

Ball

Valve Type

VR Piston Check

VK Ball

FK Butterfly

TK Three Way Ball

Total

No.

1

3

5

3

Loss Total (psi)

0.24

0.12

0.80

0.48

1.64

f = 1 x 100 2206

f = 0.24 psi

( )

f = 1 x 100 2248

f = 0.16 psi

( )

f = 1 x 100 2497

f = 0.04 psi

( )

f = 0.16 psi* similar to 90º

elbow

The total friction loss due to valves is 1.64 psi.


PROCESS &DRAIN

AGE PIPING DESIGN

Example 8

What is the Pressure Rating of 3" Schedule 40 PVC at100ºF?

Step 1: Determine Maximum Working Pressure for 3"Schedule 40 PVC from Appendix A, Table A14 = 260 psi

Step 2: Determine Correction Factor at 100ºF for PVC= 0.62

Step 3: Maximum Working Pressure x Correction Factor willgive the pressure rating at the elevated systemtemperature

260 psi x 0.62 = 161.20 psi @ 100ºF


B) Temperature Limitations

Under pressure, for IPEX Schedule 40 and 80 PVC, theaverage system operating temperature ranges from 40°F(4°C) to 140°F (60°C). For IPEX Schedule 80 CPVC, theaverage pressure system operating temperature ranges from40°F (4°C) to 200°F (93°C). For applications outside theseranges please contact IPEX representatives.

C) Pressure/Temperature Relationship

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

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

Table 9 – Temperature Correction Factors

Operating Temperature Correction Factors

°F °C PVC CPVC

73 23 1.00 1.00

80 27 0.88 0.96

90 32 0.75 0.91

100 38 0.62 0.82

110 43 0.50 0.74

120 49 0.40 0.65

130 54 0.30 0.58

140 60 0.22 0.50

150 66 * 0.45

160 71 * 0.40

170 77 * 0.33

180 82 * 0.25

200 93 NR 0.20

212 100 NR *

* Recommended for intermittent drainage onlyNR – Not Recommended


PROC

ESS

&DR

AIN

AGE

PIPI

NG

DESI

GN

24

DESIGN CONSIDERATIONS

Expansion and Contraction

All piping products expand and contract with changes intemperature. Linear expansion and contraction of any pipe onthe longitudinal axis relates to the coefficient of thermalexpansion (e) for the specific mate

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