Piping Engineering Design Guide

ENGINEERING DESIGN GUIDE

ASAHI/AMERICA Malden, Massachusetts

Disclaimer Asahi/America, Inc. provides this guide to assist engineers in the design of systems, installers in the installation and owners in the operation. This guide is designed to provide the best possible recommendations known at the time of printing. Each and every type of piping system is different and no one recommendation can cover all conditions. This guide is made available to assist in the design and installation, but in no way should be construed as a written recommendation on any system. Each system should be individually designed and installed based on the responsibility and decisions of the purchaser. This guide is not a substitute for contacting Asahi/America for specific recommendations on a system. In addition, Asahi/America is not responsible for items not appearing in the guide or recommendations that may have changed after the printing of this guide. It is recommended in each case to consult Asahi/America for specific recommendations on each system. Copyright 2002 Asahi /America, Inc. All rights reserved.

Printed in U.S.A.

This Design Guide is dedicated in the memory of Timothy Robinson. He loved this business, our company and all the people associated with Asahi/America, Inc. He is missed everyday.

A

Introduction

The Plastic Benefit Thermoplastics at a Glance

PVDF E-CTFE

B

Materials

PP General Discussion PPH, PPR, PPS, PPR (Eng. Data) PVDF General Discussion

HDPE General Discussion PE80, PE100 (Eng. Data) E-CTFE General Discussion

C

Engineering Theory and Design Considerations

Hanging Leak Detection in Double Systems Heat Tracing

D

Application and System Design

Theory Fluid Dynamics Thermal Expansion Burial Pure Water System Design Chemical System Design Double-Wall Containment System Design

E

Chemical Resistance

Explanation Tables Chemical-Resistance Check Req Form

F

Installation Practices

Duo-Pro Systems Fluid-Loc Systems Poly-Flo Systems Compressed Air Piping Systems

G

Valves

Cost Estimation Welding Methods High-Purity Installations Chemical Single Wall Systems Types Selection Process

Physical Properties Burial Data Fluid Dynamics Dimensional Pipe Data Prism Load Values for A/A Pipe Marston Soil Values for A/A Pipe Modulus of Soil Bedding Constant General Tables Volumetric Flow Rate Table Pressure Table Viscosity Table

Vacuum Rating Heat Loss per Linear Foot Valve Heat Loss Factor Heat Gain per Linear Foot

Ventilation System Design Compressed Air System Design

I A

Appendix A System Tables

B

Appendix B General Engineering Tables Appendix C Conversion Tables

C D

Appendix D Bibliography

E

Index

Force Table Heat Transfer Coefficient Table Thermal Conductivity Coefficient Table Values of the Ideal Gas Law Constant

Introduction A Materials B Engineering Theory and Design Considerations C Application and System Design D Chemical Resistance E Installation Practices F Valves G

Appendix A – System Tables A Appendix B –General Engineering Tables B Appendix C– Conversion Tables C Appendix D – Bibliography D Index E

ABOUT THE COMPANY

The Asahi /America story begins in 1974 when the forward thinking and keen business instincts of its founder and CEO, Leslie B. (Bud) Lewis, put the company in the industrial plastics manufacturing and distribution business. The company’s first significant achievement was an agreement to become the exclusive master distributor in the United States and Latin America for Asahi Yukizai Kogyo Co. Ltd., a company believed to be one of the largest manufacturers of thermoplastic valves in the world. The next major move by the company was in 1985 when it obtained the exclusive right to distribute, in the United States, the polypropylene and PVDF products produced by Alois-Gruber GMBH, a major producer of thermoplastic products based in Austria marketing under the name AGRU. The company’s growth continues by capitalizing on its exclusive agreements and enhancing those products through actuation manufacturing, specialty fabrication, and acquisitions. The company developed its own system of double containment, marketed under the name Duo-Pro, and acquired a patented dual containment extrusion system called Poly-Flo. Other acquisitions that helped propel Asahi /America’s growth were a line of pressure relief valves, a patented industrial filtration system, and an established line of vortex flow meters. The company has taken its diverse line of products and grown their markets through a network of more than 400 U.S. distributors, approximately 20 foreign distributors, and an organization of independent reps. Asahi/America, an ISO 9001 quality control certified manufacturer, markets and sells its wide variety of products in a vast array of environmentally sensitive and industrial applications; applications that include, but are not limited to, semiconductor manufacturing, chemical processing, waste treatment processes, and pharmaceutical manufacturing. The company’s progressive management style continues to foster growth and expansion into new markets and new products. From its humble beginnings to its current stature as a major player in the industrial plastics arena, both domestically and internationally, Asahi /America has established itself as an example for others to imitate. Asahi /America, now a wholly-owned subsidiary of Asahi Organic Chemical, is proud to present this Engineering Design Guide to you. This publication represents over 27 years of experience, talent, and engineering expertise. It is intended to aid in the process of engineering, specification, and design of industrial plastic piping systems using the family of Asahi plastic piping systems. We encourage you to use it often and call upon our staff of piping and valve engineers if there is something we have neglected to cover. This is your guide to sound plastic system design.

Section A INTRODUCTION

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . .A-2 The Plastic Benefit . . . . . . . . . . . . . . . . . . .A-2 Thermoplastics at a Glance . . . . . . . . . . .A-3 Plastic Resins . . . . . . . . . . . . . . . . . . . . . . .A-4 Solvay’s High-Purity PVDF Solef ® Resin . . . . . . . . . .A-4

ASAHI /AMERICA Rev. EDG-02/A

P.O. Box 653 • 35 Green Street, Malden, MA 02148 • Tel: (800) 343-3618, (781) 321-5409 Fax: (800) 426-7058 • Internet: http://www.asahi-america.com • Email: [email protected]

A-1

INTRODUCTION

THE PLASTIC BENEFIT

A INTRODUCTION

Low Friction Loss

Plastic piping systems are offered today in a wide assortment of materials and sizes. Each material has unique and specific mechanical properties. These diverse properties allow plastic to become the preferred system for many applications ranging from the transport of aggressive chemicals to the distribution of ultra pure water. Because each material has its own unique properties, understanding them becomes vital to the successful design, installation, and operation of a system.

Because the interior surface of plastic piping is generally very smooth, less power may be required to transmit fluids in plastic piping compared with other piping systems. Furthermore, the excellent corrosion resistance of plastics means that the low friction loss characteristic will not change over time.

Asahi/America is proud to present this design guide to assist design engineers and system installers with the proper engineering, layout, and installation of plastic systems. Asahi/America has been a pioneer in the manufacture and distribution of plastic systems in the United States process industries. For over 27 years, we have dedicated ourselves to assisting our customers in achieving the maximum benefits plastic systems offer. Designing a system made of thermoplastic materials differs considerably than that of metallic materials. No one understands this as well as Asahi /America’s sales and technical staff. Our trained staff of professionals is available to assist with all aspects of plastic piping systems. The information contained herein is designed to minimize the efforts of engineers, designers, contractors, and research professionals in sizing and selecting all aspects of fluid systems.

THE PLASTIC BENEFIT For pipe, fittings, and valves, thermoplastic materials offer superior corrosion resistance, lighter weight, simple installation, and are generally more cost effective than their alternatives.

Corrosion Resistance Plastics are non-conductive and are therefore immune to galvanic or electrolytic erosion. Because plastics are corrosion resistant, pipe can be buried in acidic, alkaline, wet or dry soils, and protective coatings are not required. In addition, cathodic protection devices are not required.

Chemical Compatibility Impervious to many chemicals, thermoplastics are gaining an ever-increasing acceptance and preference in a large variety of applications. Additionally, the variety of materials available allow a wide range of chemical solutions to be handled successfully by plastic piping.

Thermal Conductance All plastic piping materials have low thermal conductance properties. This feature maintains more uniform temperatures when transporting fluids in plastic than in metal piping. Low thermal conductivity of the wall of plastic piping may eliminate or greatly reduce the need for pipe insulation to control sweating.

A-2

Long-Term Performance Owing to the relative chemical inertness and the minimal effects of internal and external corrosion, there is very little change in the physical characteristics of plastic piping over dozens of years. Examinations of pipe samples taken from some systems have shown no measurable degradation after 25 years of service. In most cases, Asahi/America pipe systems are designed for 50 years of service.

Light Weight Most plastic piping systems are on the order of one-sixth the weight of steel piping. This feature means lower costs in many ways: lower freight charges, less manpower, simpler hoisting and rigging equipment, etc. This characteristic has allowed some unique cost saving installation procedures in several applications. ,

Variety of Joining Methods Plastic piping can be joined by numerous methods. For each material there are several appropriate methods. Some of the most common are solvent cementing, socket fusion, butt fusion, non-contact IR fusion, threaded joints, flanges, 0-rings, rolled grooves, and mechanical compression joints. This variety of joining methods allow plastic piping to be easily adapted to most field conditions.

Nontoxic Plastic piping systems have been approved for potable water applications and certain systems are recognized by the FDA as appropriate material to be in contact with food stuff. As evidence of this, all plastic-potable water piping materials and products are tested and listed for compliance to ANSI/NSF Standards 14 and 61. All ASTM and AWWA standards for plastic pressure piping that could be used for potable water contain a provision whereby the regulatory authority or user can require product that has been tested and found to be in conformance with ANSI/NSF Standard 61– Drinking Water System Components– Health Effects. When plastic pipe or fittings are ANSI/NSF Standard 14 listed, and have the NSF-pw (potable water) mark, they also meet the ANSI / NSF Standard 61 requirements. The NSF-pw mark certifies to installers, users, and regulators that the product meets the requirements of ANSI / NSF Std 14 for performance and the ANSI / NSF STD 61 for health effects.


ASAHI /AMERICA Rev. EDG– 02/A

THERMOPLASTICS AT A GLANCE

INTRODUCTION A

Biological Resistance To date, there are no documented reports of any fungi, bacteria, or termite attacks on any plastic piping system. In fact, because of its inertness, plastic piping is the preferred material in deionized and other high-purity water applications.

Abrasion Resistance Plastic piping materials provide excellent service in handling slurries such as fly ash, bottom ash, and other abrasive solutions. The material toughness and the smooth inner-bore of plastic piping make it ideal for applications where abrasionresistance is needed.

Low Maintenance A properly designed and installed plastic piping system requires very little maintenance because there is no rust, pitting, or scaling to contend with. The interior and exterior piping surfaces are not subject to galvanic corrosion or electrolysis. In buried applications, the plastic piping is not generally affected by chemically aggressive soil.

THERMOPLASTICS AT A GLANCE PVC (Polyvinyl Chloride). Asahi /America uses an unplasticized PVC polymer in all of its PVC valves. PVC has excellent chemical resistance, strength, and rigidity. It resists attack by most acids and strong alkalies, as well as gasoline, kerosene, aliphatic alcohols and hydrocarbons, and salt solutions. Aromatic, chlorinated organic compounds, and lacquer solvents do affect PVC chemical properties. Its low cost and overall balance of properties make PVC material best suited to the widest number of corrosive applications. Its temperature limit is 140° F (60° C). CPVC (Chlorinated Polyvinyl Chloride). The properties of CPVC and its advantages are very similar to those of PVC; however, its working temperature range is higher (195° F/90° C) than that of PVC. It should be specified, in some instances, where hot corrosive liquids are being handled, an extra margin of safety is required. PE (Polyethylene). PE is produced from the polymerization of ethylene. Depending on the polymerization process, PE piping systems are available in low and high-density versions. These forms of PE are distinguished by specific gravity. Low-density PE (LDPE) generally has a specific gravity of 0.910 to 0.925 g/cc. High-density PE (HDPE), on the other hand, usually has a specific gravity of 0.941 to 0.959 g/cc. The different grades of PE have different mechanical properties. Where HDPE is generally superior to LDPE, it is important to know which mechanical properties you are reviewing when selecting PE for your appli-

cation. Polyethylene can be used in low temperatures (32° F or colder) without risk of brittle failure. Thus, a major application for certain PE piping formulations is for low temperature heat transfer applications such as radiant floor heating, snow melting, ice rinks, geothermal ground source heat pump piping, and compressed air distribution. These properties also make PE ideal for many single and double wall water reclaim systems. PP (Polypropylene). A member of the polyolefin family, PP is one of the lightest plastics known. It possesses excellent chemical resistance to many acids, alkalies, and organic solvents. PP is one of the best materials to use for systems exposed to varying pH levels, as many plastics do not handle both acids and bases as well. It is not recommended for use with hydrocarbons and aromatics. Its upper temperature limit is 195° F (90° C). PVDF (Polyvinylidene Fluoride). This high molecular weight fluorocarbon has superior abrasion resistance, dielectric properties, and mechanical strength. These characteristics are maintained over a temperature range of 32° F (0° C) to 250° F (121° C), with a limited usage range extended to 302° F (178° C). In piping systems, PVDF is best suited for systems operating from 0° F (-17.8° C) to 250° F (121° C). PVDF is highly resistant to wet or dry chlorine, bromine and other halogens, most strong acids, aliphatics, aromatics, alcohols, and chlorinated solvents. Because of its extremely low amounts of extractables, PVDF is widely used in the transport of ultra pure water for the semiconductor and pharmaceutical industries. E-CTFE (Ethylene Tetrafluoroethylene). E-CTFE fluoropolymer is commonly known by its trade name Halar®(1). E-CTFE is essentially a 1:1 alternating copolymer of ethylene and CTFE (chlorotrifluoroethylene). It contains about 80% CTFE, one of the most chemically resistant building blocks that can be used to make a polymer. However, CTFE homopolymers are difficult to fabricate, extrude, or mold. By the copolymerization with ethylene, E-CTFE displays much of the chemical resistance of CTFE with the case of processing. It provides excellent chemical resistance-handling applications that almost all other materials cannot. In particular, E-CTFE demonstrates effective handling of fuming acids and chlorinated bases. It is most likely the best material for handling high concentrations of sodium hypochlorite. Additionally, E-CTFE has good electrical properties, and a broad-use temperature range from cryogenic to 300° F (150° C). E-CTFE is a tough material with excellent impact strength over its broad-use temperature range. E-CTFE also maintains useful properties on exposure to cobalt 60 radiation at dosages of 200 megarands. It is one of the best fluoropolymers for abrasion resistance.(2)

(1) Halar is a registered trademark of Ausimont Corporation. (2) Halar® E-CTFE Fluororpolymer Chemical Resistance Data; Ausimont USA, Inc., Technical Data Brochure.



A-3

INTRODUCTION

PLASTIC RESINS

A PLASTIC RESINS All plastic piping systems begin with the production of resin. Some resin, such as Solef TM PVDF, is produced pure without any additives. Others, such as PVC, must have stabilizers added in order to make them suitable for pipe and fitting production. When evaluating the suitability of plastics for your application, you should know and understand which resin is being used and its effects. The effects of stabilizers and copolymerization differ from material to material. Furthermore, a desired effect in material for one application may be undesirable for a different application. A prime example of this is PVC. In order to be producible, pure PVC requires the addition of stabilizers. These stabilizers allow PVC to be molded and extruded, as well as adding to its overall strength. For simple plumbing, some chemical distribution, and other applications, this is acceptable and desired. However, these same stabilizers make PVC unusable for higher quality, ultra pure water applications because they contribute to the water's contamination through leaching extractables.

Solvay’s High-Purity PVDF Solef® Resin

If a manufacturer uses resins with large differences between the MFI in its fittings and pipe, the overall integrity of the system becomes reduced. Pipe and fittings do not weld together properly and the mechanical properties may be extremely different. Therefore, the art and science of polymer pipe system manufacturing is to develop the skill and expertise to manufacture with resins of the closest MFI without sacrificing product quality. Purad achieves this through the use of high-purity 1000 Series Solef resins by Solvay. Purad exclusively offers its system of resin with the closest MFI and produced by the same manufacturer. Furthermore, manufacturing and packaging of high-purity PVDF resin is an important factor in the overall quality of PVDF components. The purity of its components begins in essence with the resin. Solvay understands this important fact and carefully manufactures and packages Solef 1000 Series resin with the strictest attention to high-purity concerns. Asahi /America and Agru's Purad Systems are designed for a variety of applications from ultra pure water to aggressive chemical distribution. Purad PVDF offers the user a broad range of chemical resistance and temperature operation.

Not all PVDF resin is the same. As a polymer, resin can differ by the length of the polymer and its molecular weight. While maintaining similar chemical compatibility, resins of different molecular weight have different mechanical properties, welding characteristics, and Melt Flow Indexes (MFI). Manufacturers intentionally use resin with slightly different polymer structures for their pipe, fittings, and valves. The reason for this is simple. For the extrusion of pipe it is desirable to use a polymer with a lower MFI, which easily maintains its form as it exits the extruder. Conversely, fitting resin is required to freely flow through the mold and evenly fill the entire internal cavity. Therefore, a high MFI is desired. Solef is a registered trademark of Solvay Advanced Polymers Corporation.

A-4



Section B MATERIALS

Contents Polypropylene . . . . . . . . . . . . . . . . . . . . . . .B-2 Special Grade Polypropylene . . . . . . . . . .B-3 Polyethylene . . . . . . . . . . . . . . . . . . . . . . . .B-4 Polyvinylidene Fluoride . . . . . . . . . . . . . . .B-5 Halar® . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6



B-1

MATERIALS

POLYPROPYLENE

POLYPROPYLENE (PPR AND PPH)

B

Asahi /America is the pioneer of piping systems made of polypropylene in the United States. For over 15 years, polypropylene systems have been successfully applied for a wide variety of applications. Polypropylene is used in double containment systems, chemical piping, and pure water systems. It is chemically resistant to many strong and weak acids. In addition, it is one of the few materials that is recommended for strong bases such as sodium hydroxide. It is not ideal for strong oxidizing acids, aromatics, and chlorinated hydrocarbons. An all inclusive chemical resistant table is available in Section E. Polypropylene has an extended operating range up to a maximum temperature of 200° F. See Appendix A for pressure rating charts on all materials. Polypropylene is a fairly ductile material at ambient temperatures and it demonstrates good impact strength. Polypropylene is available in two grades: copolymer and homopolymer. Homopolymer polypropylene is a Type I resin according to ASTM D 4101 and is produced from 100% propylene monomer. Copolymer polypropylene is a blend of (6%) ethylene and

(94%) propylene. Copolymer resins generally exhibit better mechanical strength and offer higher safety factors into a system design. In addition, copolymer PP shows a greater purity level when tested in a static leach test, making it the ideal material for pure water systems. Table B-1 shows the differences between the two types of polypropylenes. Asahi /America uses both types of material based on the application. Copolymer is referred to as PPR, with the R designating the term random copolymer. PPH is the standard designation for homopolymer polypropylene.

Toxicity Polypropylene (PPR and PPH materials) comply with the ¨ relevant food stuff regulations as defined by ONORM B 5014, Part 1, FDA, BGA, KTW guidelines. Other modified polypropylenes are not compliant due to additives. Such materials include PPH-s, PPR-el, and PPR-s-el, which have been modified for improved fire ratings and electro-conductivity. These are discussed in the next section.

Table B-1. Polypropylene Physical Properties Characteristic Density

Standard

Units

PPR

PPH

ISO/R 1183

g/cm3

0.91

0.91

ISO 1133 DIN 53 735 ISO/R 527

g/10 min

0.50

0.50

psi

3625

4350

DIN 53 455 ISO/R 527

N/mm2 psi

DIN 53 455 ISO/R 527 DIN 53 455 ISO 178 DIN 53 457 ISO 179/2C DIN 53 453 ISO 179/2D DIN 53 453 DIN 53 752

N/mm2

25 5800 40

30 6525 45

%

>50

>50

psi N/mm2

108750

166750

750

1150

kJ/m2

20

50

kJ/m2

50

35

1/° C 1/° F °C °F

1.5 x 10-4 8.33 x 10-5 150 - 154 302 - 309

1.5 x 10-4 8.33 x 10-5 160 - 165 320 - 329

° C/° F ° C/° F — W/mK Ohm Ohm cm kV/mm —

45/113 68/154 94-HB 0.24 >1013 >1016 75 gray

50/122 90/194 94-HB 0.22 >1013 >1016 75 gray

MFI 190/5 Code T Melt Flow Index

Tensile Strength at Yield Tensile Strength at Break Percent Elongation at Break Modulus Elasticity (tensile test) Charpy Impact Strength 23° C, notched Charpy Impact Strength -30° C, notched Coefficient of Thermal Expansion Crystallinity Melt Temperature Deflection Temperature Under Load Method A Method B UL 94 Fire Rating Thermal Conductivity (23° C) Surface Resistivity Specific Volume Resistivity Dielectric Strength Color

B-2

DIN 53 736

DIN 53 461 ISO 75 UL 94 DIN 52 612 DIN 53 482 DIN 53 482 part 1 DIN 53 481 RAL



MATERIALS

SPECIAL GRADE POLYPROPYLENE

SPECIAL GRADE POLYPROPYLENE • Self-extinguishing polypropylene: PPH-s • Electro-conductive polypropylene: PPR-el • Self-extinguishing electro-conductive polypropylene: PPR-s-el Polypropylene is also available in highly specialized grades developed for specific applications. PPH-s is a self-extinguishing homopolymer polypropylene with enhanced fire ratings as compared to standard polypropylenes. PPR-el is a copolymer polypropylene with the added property of being electro-conductive. Many applications call for a piping system to be grounded due to the transport of flammable materials. During operation, a static charge can build on the surface of a standard plastic pipe. If the material is not conductive, it cannot

be properly grounded and, therefore, runs the risk of potential static discharge to the media. Electro-conductive polypropylene can be grounded to avoid this hazard. Finally, PPR-s-el is the combination of the electro-conductive property and the enhanced fire ratings. PPR-s-el is a copolymer polypropylene. PPH-s, PPR-el, and PPR-s-el have slightly different properties than standard polypropylene. These changes in the material also change the chemical resistance of the material. While the resistance to chemical attack is similar to that of common polypropylenes, verification of each application with the Engineering Department at Asahi /America is recommended. These materials are produced by Agru and are available from Asahi /America. Consult Asahi /America for availability.

Table B-2. Special Grade Polypropylene Physical Properties Characteristic Density

Standard

Units

PPH-S

PPR-EL

PPR-S-EL

ISO/R 1183

g/cm3

0.934

0.94

1.12

ISO 1133 DIN 53 735 ISO/R 527

g/10 min

0.5-0.8

1.0

1.0

psi

4060-5365

4350

4205

DIN 53 455 ISO/R 527

N/mm2 psi

DIN 53 455 ISO/R 527 DIN 53 455 ISO 178 DIN 53 457 ISO 179/2C DIN 53 453 ISO 179/2D DIN 53 453 DIN 53 752

N/mm2

28-37 — —

30 4060 28

29 2900 20

%

>50

15

>50

psi N/mm2

152,250

87,000

145,000

1050

600

1000

kJ/m2

10

3.5

4

kJ/m2

40

2.5

—

1/° C 1/° F °C °F

1.5 x 10-4 8.33 x 10-5 164 - 168 327 - 334

— — — —

1.5 x 10-4 8.33 x 10-5 148 298


55/131 83-110/181-230 V-2 0.22 >1013 >1015 30-45 dark gray

50/122 75/167 94-HB — 3 x 104 — — black

— — V-0 — 3 x 102 3 x 102 — black


Tensile Strength at Yield Tensile Strength at Break Percent Elongation at Break Modulus Elasticity (tensile test) Charpy Impact Strength 23° C, notched Charpy Impact Strength -30° C, notched Coefficient of Thermal Expansion Crystallinity Melt Temperature Deflection Temperature Under Load Method A Method B UL 94 Fire Rating Thermal Conductivity (23 °C) Surface Resistivity Specific Volume Resistivity Dielectric Strength Color


DIN 53 736



B-3

B

MATERIALS

POLYETHYLENE

POLYETHYLENE (PE80 AND PE100)

B

Polyethylene is one of the most common thermoplastic materials. Polyethylene is available in a diverse variety of grades providing varying physical properties for specified applications. PE is commonly available in low density (LDPE), medium density, (MDPE), high density (HDPE), and ultra high molecular weight (UHMWPE) forms. Within each of the designations there are various classes of material. Classes of polyethylene are specified according to ASTM D-3350 which depicts the differences between grades of material. In piping systems the most common type of PE is high density polyethylene. Due to the extensive range of HDPE materials, discussion will be centered around materials offered by Asahi /America. The first grade of HDPE offered by A / A is generally known as PE80. PE80 is a black color material that is 100% UV resistant. PE80 has fairly good chemical resistance to strong and weak acids, as well as many base chemicals. It has a maximum operating temperature range of 140° F. PE80 also has fairly ductile properties in cold temperature conditions. PE80 is generally used for simple, less aggressive applications. It can be readily applied in double containment pipe systems, and is ideal for wastewater applications.

The other material, HDPE, offered by Asahi /America, is PE100. This is a special high grade PE that is not commonly available. For certain applications, only PE100 can be used. PE100 is available in both blue and black color depending on the application, but it is not limited to those colors. PE100 is a further development of PE materials by modifying the polymerization process. PE100 has a higher density than PE80. PE100 also has superior mechanical strength and a higher cell classification as compared to PE80. It provides higher pressure ratings and higher safety factors in all applications. It is one of few materials available to the market that meets Cal-OSHA requirements for thermoplastic use in unprotected compressed gas applications. Due to its extremely ductile nature, it will resist shattering in all failure modes and even in cold temperatures. PE100 has a maximum temperature rating of 140° F. It is available in multiple pressure ratings and is commonly available in a high pressure rated version of 230 psi at 70° F. See Appendix A for system pressure ratings. In general, PE100 material offers higher pressure rated piping systems without the addition of more material or a thicker wall, which can lead to greater pressure drop in larger diameter systems.

Table B-3. Polyethylene Physical Properties Characteristic Density

Standard

Units

PE80

PE100

ISO/R 1183

g/cm3

0.953

0.96

ISO 1133 DIN 53 735 ISO/R 527

g/10 min

0.4 - 0.5

0.3 - 0.55

psi

3045

3480 - 3625

DIN 53 455 ISO/R 527

N/mm2 psi

DIN 53 455 ISO/R 527 DIN 53 455 ISO 178 DIN 53 457 ISO 179/2C DIN 53 453 ISO 179/2D DIN 53 453

N/mm2

21 4350 - 4785 30 - 33

24 - 25 5365 37

%

>600

>600

psi N/mm2

116000

145000

800

1000

kJ/m2

10

17 - 26

kJ/m2

16

9 - 13

DIN 53 752

1/°C

2.0 x 10-4

2.0 x 10-4

DIN 53 736

°C °F

128 - 133 262 - 271

128 - 135 262 - 275



42/108 73/163 V2 0.43 >1015 >1015 53 black

41/105 61/141 V2 0.40 >1015 >1015 22 - 53 blue or black


Tensile Strength at Yield Tensile Strength at Break Percent Elongation at Break Modulus Elasticity (tensile test) Charpy Impact Strength 23° C, notched Charpy Impact Strength -30° C, notched Coefficient of Thermal Expansion Crystallinity Melt Temperature Deflection Temperature Under Load Method A Method B UL 94 Fire Rating Thermal Conductivity (23° C) Surface Resistivity Specific Volume Resistivity Dielectric Strength Color

B-4



MATERIALS

POLYVINYLIDENE FLUORIDE

POLYVINYLIDENE FLUORIDE (PVDF) PVDF is a thermoplastic fluorocarbon polymer with wide thermal stability from -62° C (-80° F) to 148° C (300° F) and crystalline melting point of 171° C (340° F). In terms of piping systems, PVDF has a usage range of up to 121° C (250° F).

The suspension process, as opposed to emulsion or Type I PVDF, allows the manufacture of polymers with fewer structural defects in the molecular chain. In other words, the PVDF polymers are more crystalline. Thus, the melting temperature and the mechanical characteristics are higher than homopolymers with the same average molecular weights obtained by emulsion polymerization.

Material Grade Purad PVDF pipe, valves, and fittings are manufactured of natural polyvinylidene fluoride resin. PVDF is part of the fluorocarbon family and has the following molecular structure. PVDF resin is partially crystalline and has F H a high molecular weight. Purad is 100% C C PVDF with absolutely no antioxidants, anti-static agents, colorants, fillers, flame F H n retardants, heat stabilizers, lubricants, plasticizers, preservatives, processing aids, UV stabilizers, or any other additives. Purad is also resistant to the effects of gamma radiation and has a V-O rating according to the UL-94 vertical flame test. Purad PVDF has been tested for its inherent purity through extensive testing performed by internationally recognized independent laboratories. The outstanding performance of Purad material, with respect to extreme conditions, is well documented and available upon request. Therefore, it is well suited to handle such aggressive media as ultra pure water and ultra pure, electronic grade acids. Just as importantly, it conforms to FDA regulations as outlined in Title 21, Chapter 1, Part 177-2510 (contact with food).

Purad PVDF systems offer the broadest protection for the chemical process industries, pulp mill bleaching, bromine processing, and electronic product manufacturing in both etching operations and ultra pure deionized water lines. Purad-PVDF resins resist most corrosive chemicals and many organic solvents. It is particularly good against strong oxidants, strong acids, all salts, and solvents such as chlorinated, aromatic, and aliphatic. Strong base amines and ketones such as hexamethylene diamine and propyldimethylformamide, and methylethyl ketone are not recommended for use with PVDF. A comprehensive table is available in Section E, Chemical Resistance.

Solvay Solef Resin Purad PVDF is exclusively produced from Solvay Solef 1000 Series high-purity resin. Solef 1000 Series resins use a suspension production process according to ASTM D 3222, Type II PVDF resin.

Rev. EDG– 02/A

The polymer powder form is then subjected to extensive washing and rinsing operations, and then, after drying, is stored in homogenizing silos. All the while, strict inspections are performed on line in order to ensure optimal quality control. When complete, Solef PVDF contains a high percentage of fluorine. The bond between the highly electronegative fluorine and carbon atom is extremely strong with a dissociation energy of 460 kj/mol. Thus, the importance of exclusively using Solef PVDF high-purity resin is two fold: 1. Provides for a cleaner, mechanically superior system. 2. Allows the closest melt flow indices between system components, which in turn, provides superior welding/joining capabilities.

Table B-4. Polyvinylidene Fluoride Physical Properties

Corrosion Resistance

ASAHI /AMERICA

Solef PVDF is thus manufactured by suspension polymerization of vinylidene fluoride. The process uses a recipe where the monomer is first introduced in an aqueous suspension and then polymerized by means of a special organic peroxide-type polymerization initiator at low dosage. The polymerization is performed in a heated autoclave under high pressure.

Characteristic

Standard

Units

Specific Gravity

ASTM D 792

g/cm3

1.78

Tensile Strength

ASTM D 638

psi

7975

Ultimate Tensile Strength Elongation at Break Flexural Strength

ASTM D 638 ASTM D 638 ASTM D 790

psi % psi

6960 50 12,180

E-Modulus Impact Strength Hardness–Shore D Abrasion Resistance Friction Coefficient Dynamic Friction Coefficient

ASTM D 790 ASTM D 256 ASTM D 2240 DIN 53 754 DIN 375 —

psi ft-lb/in — mg/100 cycle — —

435,000 2.80 80 0.5–1 0.4–5 0.34

DIN 53 736

°C °F

350 177

Vicat Point

ASTM D 3418

°C °F

293 144

Brittleness Temperature

ASTM D 746

°C °F

-40 -40

Thermal Conductance Coefficient of Thermal Expansion Specific Volume Resistivity Surface Resistivity Dielectric Strength Burning Rate Limiting Oxygen Index

ASTM D 177 DIN 53 453 ASTM D 257 DIN 53 482 ASTM D 149 UL94 ASTM D 2863

Btu–in/hr ft 2•°F ° F-1 Ohm•cm Ohm kv/mm — %

1.32 6.7 x 10-5 5 x 1014 >1013 40 V-O 44

Crystalline Melting Point


Value

B-5

B

MATERIALS HALAR® (E-CTFE)

B

Halar is a durable copolymer of ethylene and chlorotrifluoroethylene. It is resistant to a wide variety of corrosive chemicals and organic solvents including strong acids, chlorine, and aqueous caustics. Best known as its trade name Halar, it has excellent abrasion resistance and electrical properties, extremely low permeability, and handles temperatures from cryogenic to 171° C (340° F), with continuous service to 149° C (300° F). Its brittleness temperature is 105° F. Severe stress tests have demonstrated that Halar is not subject to chemically induced stress cracking from strong acids, bases, or solvents. Only hot amines and molten alkali metals affect Halar. There is no known solvent for Halar below 250° F. Additionally, Halar is most likely the best known material for handling high concentrations of sodium hypochlorite.

HALAR®

Asahi /America Halar systems are manufactured from unpigmented fluoropolymer E-CTFE resin. Their chemical structure, a one-to-one alternating copolymer of ethylene and chlorotrifluoroethylene, provides a unique combination of properties. In addition to superior chemical resistance and unmatched mechanical properties, Halar maintains its usefulness during exposure to cobalt 60 radiation at dosages of 200 megarads, and meets the fire requirements of UL-94 V-0 vertical flame tests. For these reasons, Halar is considered one of the most durable and versatile thermoplastics used in piping systems. Applications ranging from the harshest of chemicals to the purest of hot DI water are ideal. No other known thermoplastic offers as much versatility in chemical resistance and strong mechanical properties as Halar.

Table B-5. Halar Physical Properties Characteristic

Standard

Units

Specific Gravity

ASTM D 792

g/cm3

1.69

Tensile Strength

ASTM D 638

psi

4500

Ultimate Tensile Strength Elongation at Break Flexural Modulus

ASTM D 638 ASTM D 638 ASTM D 792

psi % psi

7250 200 6200

E-Modulus Impact Strength (IZOD with V-notch) Hardness–Shore D Abrasion Resistance Friction Coefficient Dynamic Friction Coefficient

ASTM D 790 ASTM D 256 ASTM D 2240 DIN 53 754 DIN 375 —

psi — — mg/100 cycle — —

240,000 No Break 75 0 0.15 0.65

Crystalline Melting Point

DIN 53 736

°C °F

240 464

Brittleness Temperature

ASTM D 648

°F

-105

ASTM D 177

Btu–in/hr ft 2° F Btu–in/hr ft 2° F

1.07 1.11

DIN 53 453

° F-1

4.4 x 10-5

ASTM D 257 DIN 53 482 ASTM D 149 UL94 ASTM D 2863

Ohm•cm Ohm V/mil — %

1015 >1015 500 V-O 60

Thermal Conductance @ 69° F (20° C) @ 302° F (150° C) Coefficient of Thermal Expansion -22 to 122° F (-30 to +50° C) Specific Volume Resistivity Surface Resistivity Dielectric Strength Burning Rate Limiting Oxygen Index

Value

NOTE: Halar® is a registered trademark of Ausimont USA, Inc. Solef® is a registered trademark of Solvay.

B-6



Section C ENGINEERING THEORY AND DESIGN CONSIDERATIONS Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . .C-2 Design Basis . . . . . . . . . . . . . . . . . . . . . . . .C-2 Fluid Dynamics . . . . . . . . . . . . . . . . . . . . . .C-4 Non-Compressible Fluids . . . . . . . . . . . . . . . . . . . . . .C-4 Calculating System Pressure Drop . . . . . . . . . . . . . . .C-7 Compressible Fluids . . . . . . . . . . . . . . . . . . . . . . . . .C-10

Thermal Expansion Design . . . . . . . . . . .C-11 Thermal Expansion (single wall) . . . . . . .C-11 Thermal Expansion (double wall) . . . . . C-16 Duo-Pro and Fluid-Lok Systems . . . . . . . . . . . . . . .C-16 Poly-Flo Thermal Expansion Design . . . . . . . . . . . .C-20

Hanging Practices . . . . . . . . . . . . . . . . . .C-21 Burial Practices for Single Wall Piping .C-23 Burial Practices for Double Wall Piping .C-25 Installation of a Buried System . . . . . . . .C-26 Pipe Bending . . . . . . . . . . . . . . . . . . . . . .C-28 Heat Tracing and Insulation . . . . . . . . . .C-29 Thermal Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-29 Ext. Self-Regulating Elec. Heat Tracing Design . . . .C-30



C-1

ENGINEERING THEORY INTRODUCTION This section of the guide is to assist in the engineering and theory of a thermoplastic pipe system. Asahi /America provides the theory and the data on the design within this section. When designing a pipe system, all of the topics in this section should be considered. The complexity of your system will dictate how detailed the engineering needs to be. For safety reasons, it is important to consider all topics.

C

While thermoplastics provide many advantages in terms of weight, cleanliness, ease of joining, corrosion resistance, and long life, it does require different considerations than that of metal pipe and valves. Like any product on the market, thermoplastic has its advantages and its limitations. Use the engineering data in this section, coupled with the design requirements of Section D, for optimal results in a thermoplastic piping system.

DESIGN BASIS Outside Diameter of Pipe Outside diameter (OD) of piping is designed, produced, and supplied in varying standards worldwide. The two prevalent systems are metric sizes and iron pipe sizes (IPS). IPS is a common standard in the United States for both metal and plastic piping. PVC, C-PVC, stainless steel, high density polyethylene (as examples) are generally found with an IPS OD. The difference is the inside diameter (ID). Each of these materials will be produced with a different ID based on the wall thickness. Asahi /America pipe systems are provided both in metric and IPS OD dimensions depending on the material. Polypropylene and PVDF systems are always produced to metric outside diameters. However, these systems are also provided with standard ANSI flanges and NPT threads to accommodate attaching to standard US equipment and existing pipe systems.

Inside Diameter and Wall Thickness The ID of a pipe can be based on various standards. The two common standards for determining the ID or wall thickness of a pipe is a Schedule rating and a Standard Dimensional Ratio (SDR).

C-2

DESIGN BASIS

Normally metal pipes and PVC pipes are sized according to Schedule ratings. A common Schedule rating for PVC is Sch 40 or 80. The higher the number, the higher the pressure rating. In schedule systems, no matter what the material, the wall thickness will always be the same. For example, a Sch 40 PVC pipe will have the same wall thickness as a Sch 40 PVDF pipe. However, due to the differences in material properties, these pipes will have very different pressure ratings. Schedule ratings offer the convenience of tradition and dimensional consistency. Since all plastic materials have varying strength and are normally connected with 150 psi flanges, Schedule ratings are not really the best standard to be used. If a material offers superior mechanical strength, such as PVDF, it can be extruded with a thinner pipe wall than perhaps a Sch 80 rating, while still providing a 150 psi rating. The conclusion is that Schedule ratings ignore material properties, and in many cases, waste excess material and cost just to meet the required wall thickness of the standard. A better system being used is SDR. This is a ratio between the OD of the pipe and the wall thickness. SDR is simply the outside diameter of the pipe divided by the wall thickness. All PVDF and polypropylene pipes supplied by Asahi /America are produced according to ISO 4065 standards, which outlines a universal wall thickness table. From the standard, the following equation for determining wall thickness is derived. 2S D = -1 = (SDR) - 1 t P

(C-1)

which can be reconfigured to determine pipe and wall thickness as: t=D

Where: D t P S

(

1 2S +1 P

(C-2)

)

= outside diameter = wall thickness = allowed pressure rating = design stress



ENGINEERING THEORY

DESIGN BASIS

The design stress is based on the hydrostatic design basis (HDB) of the material. S = (HDB) / F

(C-3)

where F is a safety factor. HDB is determined from testing the material according to ASTM D 2837-85 to develop a stress regression curve of the material over time. By testing and extrapolating out to a certain time, the actual hoop stress of the material can be determined. From the determination of the actual HDB, the exact allowed pressure rating and required wall thickness is determined. The advantage is that piping systems based on SDR are properly designed based on material properties instead of a random wall thickness.

C

One key advantage to using SDR sizing is that all pipes in a Standard Dimensional Ratio have the same pressure rating. For example, a polypropylene pipe with an SDR equal to 11 has a pressure rating of 150 psi. This pressure rating of 150 psi is consistent in all sizes of the system. A 1/2" SDR 11 and a 10" SDR 11 pipe and fitting have the same pressure rating. This is not the case in schedule systems. The wall thickness requirement in a schedule system is not based on material properties, so a 4" plastic pipe in Sch 80 will have a different pressure rating than a 10" Sch 80 pipe. It should be noted that in all SDR systems the determined allowed pressure rating is based on the material properties. Therefore, the actual SDR number will be consistent within a material type, but not consistent across different materials of pipe. Table C-1. Example of SDRs Material

150 psi

Polypropylene

SDR 11

230 psi SDR 7

PVDF

SDR 33

SDR 21

All material ratings are indicated in Asahi /America literature, drawings, price sheets, and on the product itself. For more information on SDR, contact Asahi /America’s Engineering Department.



C-3

ENGINEERING THEORY

FLUID DYNAMICS

FLUID DYNAMICS

To determine maximum velocity for clear liquids:

Sizing a thermoplastic pipe system is not much different than that of a metal pipe system. Systems transporting compressible fluids and non-compressible fluids are sized very differently and have different concerns. This section will approach each subject separately.

C

Non-Compressible Fluids

Where:

v = velocity (ft /s)

ρ = fluid density, (lb/ft3)

Liquid Service When sizing for erosive or corrosive liquids, Equation C-8 should be halved. The corresponding minimum diameters for liquid service can be estimated from the following equations:

The basic definition for the liquid flow of any liquid is as follows:

∆P =

ρ∆h

=

144

∆h X (SG) 2.31

1

(C-4)

Basic definitions for fluid flow:

Clear liquids:

d = 1.03

d = 1.475

ρ = fluid density, ∆h = head loss, (ft)

(lb/ft3)

hp = P = pressure head (ft)

ρ

hv =

2g

= velocity head (ft)

(C-6)

C-4

( ρ) 3 1

1

Equations C-8, C-9, and C-10 represent the maximum velocity and minimum diameter that should be used in a piping system. To determine typical velocities and diameters, the following equations can be used to determine a starting point for these values:

(C-11)

Typical diameters, pressure piping: (C-7) d = 2.607

Preliminary Sizing The first step in designing a piping system is to decide what diameter sizes to use. If the only basis to begin with is the required flow rates of the fluid to be handled, there must be some way to estimate the diameter sizes of the piping. Without this knowledge, it would be a lengthy trial and error process. The diameter must first be known to calculate velocities and thus the pressure drop across the system. Once the pressure drop is found, a pump can be sized to provide the proper flow rate at the required pressure. Equations C-8, C-9, and C-10 represent quick sizing methods for liquid flow to give an initial sizing of diameter size of a piping system. 48

(C-10)

ρ3

v = 5.6 d0.304

Sizing a Thermoplastic Piping System

v=

1 2

Typical velocities:

v = fluid velocity (ft/s) g = gravitational acceleration (32.174 ft/s2)

hg = z = gravitational head = 32.174 ft

w

(C-5)

For water: Where:

(C-9)

Where: w = flow rate (1000 lb/h) d = piping inside diameter (in) ρ = fluid density (lb/ft3)

SG = specific gravity = ρ/62.4 ∆P = pressure loss in psi

v2

ρ

1 3

Corrosive or erosive liquids:

For liquid: Where:

w2

(C-8)

()

(C-12)

()

(C-13)

w ρ

0.434

Suction or drain piping: d = 3.522

w ρ

0.434

Determination of Reynolds’ Number Once the diameter sizes have been selected for a given piping system, the next step is to determine whether the flow through the pipes is laminar or turbulent. The only accepted way of determining this characteristic through analytic means is by calculating the Reynolds’ Number. The Reynolds’ Number is a dimensionless ratio developed by Osborn Reynolds, which relates inertial forces to viscous forces.



ENGINEERING THEORY

FLUID DYNAMICS

To determine type of flow from Reynolds’ Number value, use Equation C-14:

Nre =

De vρ

µg

=

De G

µ

=

Dev

Ω

∆P = (C-14)

Nre <2100 2100 3000

There are a number of different methods for calculating pressure loss in a piping system. Two of the more common methods are the Darcy method and the Hazen and Williams method. The Hazen and Williams method has been the more commonly accepted method for calculating pressure loss in plastic pipes. However, the Darcy method is the more universally accepted method for piping made of all materials, although its use requires more tedious calculations. Below is an explanation of both methods.

Darcy Method The Darcy formula states that the pressure drop is proportional to the square of the velocity, the length of the pipe, and is inversely proportional to the diameter of the pipe. The formula is valid for laminar or turbulent flow. Expressed in feet of fluid flowing, the Darcy formula is: hf =

f L v2 2d g

(C-15)

Where: h f = head loss due to friction (ft) f = Darcy (Moody) friction factor L = total length of pipe, including equivalent lengths of fittings, valves, expansions, and contractions, etc. (ft) v = fluid velocity (ft/sec) d = inside diameter (ft) g = gravitational acceleration (32.174 ft/s2)


144 d 2g

(C-16)

The equation is based upon the friction factor (f), which in this form is represented as the Darcy or Moody friction factor. The following relationship should be kept in mind, as it can be a source of confusion: f DARCY = f MOODY = 4f FANNING In Perry’s Handbook of Chemical Engineering, and other chemical and /or mechanical engineering texts, the Fanning friction factor is used, so this relationship is important to point out. If the flow is laminar (Nre <2000), the friction factor is: f =

Once the Reynolds’ Number is determined, it can be used in other equations for friction and pressure losses.

Pressure Loss Calculations

ρ f Lv2

∆P = pressure loss due to friction (psi) ρ = fluid density (lb/ft3)

Where:

Where: Nre = Reynolds’ Number (dimensionless) De = equivalent diameter (ft) = (inside diameter fully-filled circular pipe) v = velocity (ft/s) ρ = fluid density (lb/ft3) µ = relative viscosity (lb x sec/ft2) g = gravitational acceleration = (32.174 ft/s2) G = mass flow rate per unit area (lb/h-ft3) Ω = ratio of specific heats (dimensionless) Laminar flow: Transition region: Turbulent flow:

The Darcy method expressed to determine pressure drop:

64 (laminar flow only) Nre

(C-17)

If this quantity is substituted into Equation C-16, the pressure drop becomes the Poiseuille equation for pressure drop due to laminar flow:

∆P = 0.000668 µLv (laminar flow only) d2

(C-18)

If the flow is turbulent, as is often the case for plastic pipes, the friction factor is not only a factor of Reynolds’ Number, but also upon the relative roughness (ε/d). (ε/d) is a dimensionless quantity representing the ratio of roughness of the pipe walls, ε, and the inside diameter, d. Since Asahi /America’s thermoplastic systems are extremely smooth, friction factor decreases rapidly with increasing Reynolds’ Number. The roughness has a greater effect on smaller diameter pipes since roughness is independent of the diameter of the pipes. This relationship can be seen graphically in Figure C-1. (Note: ε has been determined experimentally to be 6.6 x 10-7 ft for PVDF. ε for polypropylene pipe is approximately the same as that for drawn tubing = 5 x 10-6 ft) The friction factor can be found from the plot of ε/d versus friction factor shown in Figure C-2, which is known as the Moody chart. The Moody chart is based on the Colebrook and White equation:

1 1

(f) 2

ε d 2.51 = -2 log + 1 3.7 Nre(f) 2

(C-19)

This equation is difficult to solve, since it is implicit in f, requiring a designer to use trial and error to determine the value.


C-5

C

ENGINEERING THEORY

FLUID DYNAMICS

Hazen and Williams Method The Hazen and Williams formula is valid for turbulent flow and usually provides a sound, conservative design basis for plastic piping sizing. The formula, simply stated is:

Laminar Flow 0.01

C

hf = 0.2083

( ) ( )

Where: hf d Q C

= = = =

100 C

1.85

1.85

x

Q d 4.87

(C-20)

friction head (ft of water/100 ft of pipe) inside diameter of pipe (ft) flow rate (gpm) roughness constant

f

ε

0.005

d 0.0001 0.00005 0.000025 0.00001

Hydraulically Smooth 0.001 103

To determine pressure loss in psi:

d

1.85 4.87

107

Figure C-2. Friction factor versus Reynolds’ Number for Asahi /America pipe

For plastic piping, it has been generally accepted that C varies from 165 to 150. Therefore, most designs have been sized using C = 150 as the basis, providing a conservative design. This compares quite favorably with that of carbon steel, which generally is assigned a value of C = 120 for new pipe and C = 65 for used piping. Substituting C = 150 into Equation C-20 yields the following relationship in Equation C-22: Q

106

(C-21)

∆P = pressure loss (psi/100 ft of pipe)

hf = 0.0983

105

d ub P Re = µ

∆P = 0.4335hf Where:

104

(for C = 150)

(C-22)

Asahi/America has already calculated the pressure drop in our pipe systems at most flow rates using the Hazen and Williams method. These tables are found by material in Appendix A. 0.001

Quick Sizing Method for Pipe Diameters By modifying the Darcy equation, it can be seen that pressure loss is inversely proportional to the fifth power of the internal diameter. The same is approximately true for the Hazen and Williams formula as shown in Equation C-22. Therefore, when pressure drop has been determined for one diameter in any prescribed piping system, it is possible to prorate to other diameters by ratio of the fifth powers. The following relationship is used to prorate these diameters when the Darcy formula has been used in Equation C-23:

∆P2 = ∆P1 Where:

d 51

(C-23)

d 52

∆P1 = pressure drop of 1st diameter, psi ∆P2 = pressure drop for new diameter, psi d1 = 1st diameter selected (in) d2 = new diameter selected (in)

0.0001

ε

This formula assumes negligible variation in frictional losses through small changes in diameter sizes, and constant fluid density, pipe length, and fluid flow rate. When using Hazen and Williams, the formula itself is easy enough to use if the value of C is considered to be constant and is known.

Proline PP and HDPE (Equivalent to Drawn Tubing)

d 0.00001

Purad PVDF 0.000001

1

2

3

4

6 8 Pipe Diameter (inches)

10

12

14

Figure C-1. Relative roughness of Asahi /America pipe

C-6



ENGINEERING THEORY

FLUID DYNAMICS

Calculating System Pressure Drop For a simplified approach to calculating pressure drop across an entire pressure piping system consisting of pipe, fittings, valves, and welds, use the following equation:

∆Ptotal = ∆Ppipe+∆Pfittings+∆Pvalves+∆Pwelds

(C-24)

λ 144

L d

x

x

S G v2 2g

(C-25)

Where: λ = frictional index, 0.02 is sufficient for most plastic pipe L = pipe length (ft) d = inside pipe diameter (ft) SG = specific gravity of fluid (lb/ft3) v = flow velocity (ft/s) g = gravitational acceleration (32.174 ft/s2) Pressure Drop for Fittings To determine pressure drop in fittings, use Equation C-26.

where: Table C-2.

ε 144

x

v2 2g

(C-26)

ε = resistance coefficient of the fitting.

ε Resistance Coefficient (by fitting)

Size

Std 90

Ext Lg 90

45

Tee

1.5 1.0 0.6 0.5

2.0 1.7 1.1 0.8

0.3 0.3 0.3 0.3

1.5 1.5 1.5 1.5

1/2"

(20 mm) 1" (32 mm) 11/2" (50 mm) ≥ 2" (63 mm)

Pressure Drop for Valves To determine the pressure drop across a valve requires the Cv value for the valve at the particular degree of open. The Cv value is readily available from a valve manufacturer on each style of valve. Use Equation C-27 to determine the pressure drop across each valve in the pipe system. Sum all the pressure drops of all the valves. ∆Pvalves =

Q2 • SG Cv2

(C-27)

Pressure Drop for Welds Finally, determine the pressure drop due to the welding system. In actuality it would be very difficult and time consuming to determine the pressure drop across each weld in a system.


Table C-3. Pressure Drop for Various Welding Systems 1/2

To determine the pressure drop due to the pipe alone, use one of the methods already described or Equation C-25.

∆Pfittings =

Table C-3 shows pressure drop % by various welding systems.

Size (inches)

Pressure Drop for Pipe

∆Ppipe =

Therefore, a rule of thumb of 3 to 5% of pressure loss across a system can be used to compensate for the welding effects.

– 11/4 11/2 – 21/2 3 –4 6 8

10

– 12

Butt/IR

HPF

Socket

5.0% 3.0% 2.0% 1.5% 1.0% 0.5%

0% 0% — — — —

8% 6% 4% — — —

C

Outlet Piping for Pumps, Pressure Tanks, or Reservoirs When piping is used to convey pressurized liquids, and a pump is used to supply these liquids, the pump outlet pressure can be found by making an energy balance. This energy balance is defined by the Bernoulli equation:

Z1 + p1 v1 +

v 21 v 22 + Z2 (C-28) = hpump + hf + p2 v2 + 2g 2g

Where: Z1, Z 2 = elevation at points 1 and 2 (ft) P1, P2 = pressure in system at points 1 and 2 (psi) v1, v2 = average velocity at points 1 and 2 (ft/lb) v1, v2 = 1r = specific volume at points 1 and 2 (ft3/lb) hf = frictional head losses (ft) hpump = pump head (ft) Note: This balance is simplified to assume the following: constant flow rate, adiabatic (heat loss = 0), isothermal (constant temp.), low frictional system.

Once frictional losses in the piping are known along with elevational changes, the pump head can be calculated and the pump sized. If a pump already exists, then an analysis can be made from the hf value to determine which diameter size will give frictional losses low enough to allow the pump to still deliver the fluid. It may occur that the application does not involve pumps at all, but instead involves gravity flow from an elevated tank, or flow from a pressurized vessel. In either case, Equation C-28 can be solved with the term hpump = 0 to determine elevation necessary of the reservoir to convey the fluid within a given diameter size, or calculate the amount of pressure required in the pressure tank for the given diameter size. If the application is such that a pressure tank or elevation of reservoir is already set, then hf can be solved to determine diameter size required to allow the fluid to be delivered.


C-7

ENGINEERING THEORY

FLUID DYNAMICS

Inlet Piping to Pumps

C

Inlet sizing of diameters of piping to supply a pump depends on the Net Positive Suction Head (NPSH) required by the pump. NPSH is given by the manufacturer of a pump for each specific pump to be supplied. If the pressure at the entrance to the pump is less than the NPSH, a situation known as cavitation will occur. Cavitation will occur at pump inlets whenever the fluid pressure drops below the vapor pressure at the operating temperature. As the pump “sucks” too hard at the incoming fluid, the fluid will tend to pull apart and vaporize, resulting in a subsequent damaging implosion at the impeller face. In addition, NPSH must be higher than the expected internal loss between the pump and impeller blades. To determine NPSH, the following equation is used: NPSH = hatmos + Zpump - hfriction - hminor - hvapor (Z is positive if the pump is below inlet)

d=

[

0.205

0.2083

( ) 100 C hf

1.85

]

1.85

xQ

(C-30)

Compound Pipe Sizing Flow through a network of two or more parallel pipes connected at each end is proportional to the internal diameters, and lengths of the parallel legs, for constant friction factors (coefficients) and turbulent flow. The following relationships will be true: 2

1

(C-29)

4

Q

Q 3

Where: hatmos = atmospheric pressure head = (pa /62.4; pa is in lb/ft2) (ft) (corrected for elevation) Zpump = elevation pressure head (ft) (difference between reservoir exit and pump inlet) hf = total of pipe fittings and valve frictional head losses (ft) hminor = entrance and/or exit losses (ft), (use inlet loss formulas or hc = 0.0078v2) hvapor = vapor head (ft), (use property tables for specific fluid, i.e., steam tables for H2O)

Figure C-3. Typical compound pipe

R =

(C-31)

Where: Q3 = flow rate in leg 3 (gpm) Q2 = flow rate in leg 2 (gpm) R = ratio of total flow, Q, through compound network l2 = length of leg 2 l3 = length of leg 3 And:

To determine diameter of piping required to supply the minimum NPSH, the following procedure is outlined.

Step 1.

Q3 Q2

R=

Or:

Obtain the minimum NPSH at the pump inlet from the pump specifications.

R=

1 2

[( )( ) ] [( ) ( ) ] l2 l3

l2 l3

d3 d2

1.08

5

5.26

d3 d2

(C-32)

1 2

(C-33)

Step 2. Calculate hatmos, Zpump, hminor, and hvapor.

Step 3.

Equation C-32 is used when using the Darcy equation and Equation C-33 is used when using Hazen-Williams to determine velocities in legs. For other velocities, use Equation C-34.

Determine hf by subtracting items in Step 2 from NPSH in Step 1. v2 =

Step 4. Determine minimum inside diameter by rearranging Equation C-20. The resulting equation for d follows.

Where: v2 v3 A2 A3

= = = =

q2 448.8 A2

; v3 =

q3 448.8 A3

(C-34)

velocity in leg 2 (ft/s) velocity in leg 3 (ft/s) cross-sectional area in leg 2 (ft2) cross-sectional area in leg 3 (ft2)

448.8 is derived from (60 sec/min) x (7.48 gal/ft3)

C-8



ENGINEERING THEORY

FLUID DYNAMICS

Q = 27.8 (rs)1.67 (d)2.67

Since total head loss is the same across each parallel leg, total head loss can be calculated by:

(C-38)

Where: Q = capacity of the stack (gpm) h f = h1 + h2 + h4 = h1 + h3 + h4

(C-35) rs = ratio of cross-sectional area of the fluid at terminal velocity to internal diameter of the stack

Where: h f = total head loss through entire piping system (ft)

d = inside diameter (in)

Sizing of Drain, Waste, and Vent Piping Flow in a Vertical Stack As flow in a vertical stack is accelerated downward by the action of gravity, it assumes the form of a sheet around the pipe wall shortly after it enters the sanitary tee or wye. The acceleration of the sheet continues until the frictional force exerted by the walls of the stack equals the force of gravity. The maximum velocity that is thus attained is termed “terminal velocity” and the distance required to achieve this velocity is termed “terminal length.” It takes approximately one story height for this velocity to be attained. The terminal velocity normally falls into the range of somewhere between 10 to 15 feet per second. Some simplified equations for terminal velocity and terminal length are as follows:

The value of rs is determined according to local building codes. Also, the maximum number of fixture units, laboratory drains, floor drains, etc. is normally established by the local building codes.

Flow in Sloping Drains Where Steady Uniform Flow Exists There are many formulas useful to determine flow for sloping drains with steady uniform flow. The most commonly used equation is the Manning equation:

v= Where:

VT = 3

() Q d

0.4

LT = 0.052(VT)2 Where:

VT LT Q d

= = = =

(C-36)

C

1.486R 0.67 S 0.5 n

(C-39)

v = mean velocity (ft/s) R = hydraulic radius = area flowing/wetted perimeter (ft) S = hydraulic gradient (slope) n = Manning coefficient

(C-37)

terminal velocity in stack (ft/s) terminal length below entry point (ft) flow rate (gpm) inside diameter of stack (ft)

The value of n varies from 0.012 for 11/2" pipe to 0.016 for pipes 8" and larger under water flow. The quantity of flow is found from: Q = Av

When flow in the stack enters the horizontally sloping building drain at the bottom of the stack, the velocity is slowed from the terminal velocity. The velocity in the horizontally sloping drain decreases slowly and the depth of flow increases. This continues until the depth increases suddenly and completely fills the cross section of the sloping drain. The point at which this occurs is known as hydraulic jump. The pipe will then flow full until pipe friction along the walls establishes a uniform flow condition of the draining fluid. The distance at which jump occurs varies considerably according to flow conditions, and the amount of jump varies inversely with the diameter of the horizontal building drain.

(C-40)

Where: Q = flow rate (ft3/s) A = cross section of the flow (ft2) v = velocity (ft/s) This equation is not valid for conditions where surging flow might exist. A more detailed analysis should be used in surging flow situations, with the Manning equation serving as a rough check on the calculated values.

Flow capacity of the vertical stack depends on the diameter of the stack and the ratio of the sheet of fluid at terminal velocity to the diameter of the stack:



C-9

ENGINEERING THEORY Compressible Fluids Designing pipe lines for compressed air or gas is considerably different from designing a non-compressible liquid system. Gases are compressible, so there are more variables to consider. Designs should take into account current and future demands to avoid unnecessarily large pressure drops as a system is expanded. Elevated pressure drops represent unrecoverable energy and financial losses.

C

FLUID DYNAMICS

To design the main line of a compressed gas system, the following equation has been developed: d = Where:

Main Lines Normal compressed air systems incorporate two types of pipe lines when designed correctly: the main (or the trunk) line and the branch lines. Mains are used to carry the bulk of the compressed gas. Undersizing the main can create large pressure drops and high velocities throughout the system. In general, systems should be oversized to allow for future expansion, as well as reduce demand on the compressor. Oversizing the main line will be more of an initial capital expense, but can prove to be an advantage over time. In addition to reducing pressure drop, the extra volume in the trunk line acts as an added receiver, reducing compressor demand and allows for future expansion. Small mains with high velocities can also cause problems with condensed water. High air velocities pick up the condensed water and spray it through the line. With a larger diameter, velocities are lowered, allowing water to collect on the bottom of the pipe while air flows over the top. A generally accepted value for velocity in the main line is 20 feet per second. It may also be preferred to arrange the mains in a loop to have the entire pipe act a reservoir.

d L Q P ∆P

= = = = =

0.00067 L Q1.85

0.2

(C-41)

∆P P

inside diameter (inches) length of main line (ft) standard volumetric flow rate (make-up air) output pressure from compressor (psi) allowable pressure drop (psi)

Equation C-41 relates the pipe’s inside diameter (id) to the pressure drop. In order to use the equation, certain information must be known. First, the required air consumption must be predetermined. Based on required air consumption, choose a compressor with an output pressure rating (P). The length of the main pipe line to be installed and the number of fittings in the main line must also be known. For fittings use Appendix A to determine the equivalent length of pipe per fitting style. Specify the allowable pressure drop in the system. Typically, a value of 4 psi or less is used as a general rule of thumb for compressed air systems.

Branch Lines Lines of 100 feet or less coming off the main line are referred to as branch lines. Since these lines are relatively short in length, and the water from condensation is separated in the main lines, branches are generally sized smaller and allow for higher velocities and pressure drops. To prevent water from entering the branch line, gooseneck fittings are used to draw air from the top of the main line, leaving condensed water on the bottom of the main.

Figure C-4. Main compressed air loop with branches

Figure C-5. Gooseneck fitting

C-10



THERMAL EXPANSION DESIGN (single wall)

THERMAL EXPANSION DESIGN

Thermal Expansion (inches/100 ft/10° F)

Plastic pipe systems will expand and contract with changing temperature conditions. It is the rule and not the exception. The effect of thermal expansion must be considered and designed for in each and every thermoplastic pipe system. Thermal effects in plastic versus metal are quite dramatic. To illustrate the point, Figure C-6 below outlines the differences in growth rates between different plastics and metal piping materials.

ENGINEERING THEORY THERMAL EXPANSION AND CONTRACTION IN SINGLE WALL PIPING SYSTEMS First, calculate the stress that will be present in the system due to all operating systems. These include stresses due to thermal cycling and the stress due to internal pressure. Thermal stress can be calculated with Equation C-42. ST = E α

∆T

(C-42)

1.0

Where: ST = thermal stress (psi) E = modulus of elasticity (psi) α = coefficient of thermal expansion in/in ° F ∆T = (Tmax – Tinstall) (° F)

0.9 0.8 0.7 0.6 0.5

Next calculate the stress due to internal pressure.

0.4 0.3 0.2

Sp = P

0.1 0

PVC

C-PVC

PP

PVDF

STEEL

Figure C-6. Comparison of thermal expansion of plastic and steel piping material An increase in temperature in a system will cause the pipe to want to expand. If the system is locked in position and not allowed to expand, stress in the system will increase. If the stress exceeds the allowable stress the system can tolerate, the piping will fatigue and eventually could fail. Progressive deformation may occur upon repeated thermal cycling or on prolonged exposure to elevated temperature in a restrained system. Thermoplastic systems, therefore, require sufficient flexibility to prevent the expansion and contraction from causing: • Failure of piping or supports from over strain or fatigue • Leakage • Detrimental stresses or distortion in piping or connected equipment Asahi /America has put together simplified equations to predict the stress in a system to avoid fatigue. For safety reasons, Asahi /America takes a conservative approach to design considerations. With over 5,000 successful installations of thermoplastic piping systems, Asahi /America is providing the right approach. Many of the equations below are applicable for single and double wall piping systems. A dual contained piping system will have a few more design variables, but the approach is similar. Review the single wall section first to fully comprehend thermal expansion design issues.


Where: Sp D t P

= = = =

(D-t)

(C-43)

2t internal pressure stress (psi) pipe OD (in) wall thickness (in) system pressure (psi)

Now combine the stresses of ST and Sp using Equation C-44 to obtain the total stress placed on the system due to the operating parameters.

Sc =

√S

2+

T

Sp2

(C-44)

Where: Sc = combined stress (psi) Having the combined stress of the system, the total end load on the piping and anchors can be calculated using Equation C-45. F = Sc A Where:

(C-45)

F = end Load (lbs) SC = combined stress (psi) A = cross-sectional area of pipe wall (in2)

Knowing the combined stress and force generated in a system now allows the designer to make decisions on how to compensate for the thermal effects. By comparing the combined stress to the hoop stress of material allows a safety factor to be determined.


C-11

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ENGINEERING THEORY

THERMAL EXPANSION DESIGN (single wall) Restraint Only

EXAMPLE A PVDF single wall pipe system with a combined stress of 500 psi is compared to the hoop stress or allowable stress of PVDF, which is 1100 psi with all the appropriate safety (HDB = 2200 psi, S = HDB/2 = 1100 psi) factors: SF = 1100 psi /500 psi = 2.2

C

Therefore if this system was fully restrained, it would have 2.2 to 1 safety factor. The factor assumes that the system will be properly anchored and guided to avoid pinpoint loads. If the value of the combined stress was 600 psi and the resulting safety factor is now below 2, the designer should / may choose to compensate for the expansion using a flexible design.

Restraining a System If a system design is deemed safe to restrain, proper hanging design becomes critical. If fittings such as 90° elbows are not properly protected, the thermal end load could crush the fitting. It is important to remember that end load is independent of pipe length. The expansion in one foot of piping compared to the expansion in 100 feet of piping under the same operating conditions will generate the same force. A proper design will protect fittings using anchors and guides. Use guides to keep pipe straight and not allow the material to bow or warp on the pipe rack. Use anchor or restraint style fittings to protect fittings at changes of direction or branches.

Figure C-9. Improper design

Flexible System Design A flexible pipe design is based on strategically using expansion and contraction compensating devices to relieve the stress in the piping system. Common devices are, but are not limited to: • Expansion loops • Expansion offsets • Changes in direction • Flexible bellows • Pipe pistons To compensate for thermal expansion, Asahi /America recommends using loops, offsets, and changes in direction. By using the pipe itself to relieve the stress, the integrity of the pipe system is maintained. The use of bellows or pistons will also work, but often introduce other concerns such as mechanical connections and possible leaky seals. Although these occurrences are not common, using the pipe eliminates the chance altogether. The following section outlines how to size expansion loops. An example is included to better understand how to use the equations and lay out a system. To start, first determine the amount of growth in the pipe system due to the temperature change. The change in pipe length is calculated as follows:

∆L = 12 x L x α x ∆T Where:

Figure C-7. Restraint fitting and hanger Finally, ensure proper hanging distances are used based on the actual operating temperature of the system. Figures C-8 and C-9 are illustrations of proper and improper design and installation hanging techniques. Restraint Guide

(C-46)

∆L = change in length (in) L = length of the pipe run (ft) = coefficient of thermal expansion (in/in/° F) = 6.67 x 10-5 for PVDF = 8.33 x 10-5 for PP = 8.33 x 10-5 for HDPE = temperature change (° F)

α α α α ∆T

∆T is the maximum temperature (or minimum) minus the install temperature. If the installation temperature or time of year is unknown, it is practical to increase the ∆T by 15% for safety. It is not necessary or practical to use the maximum temperature minus the minimum temperature unless it will truly be installed in one of those conditions.

Figure C-8. Proper design

C-12




ENGINEERING THEORY The loop width is the length A divided by 2. Figure C-11 illustrates a typical loop.

EXAMPLE A 3" SDR 11 (150 psi) PP pipe system running up a wall 10 feet from a pump. It then runs 25 feet north by 100 feet east to an existing tank. The system will be installed at about 60° F and will see a maximum temperature in the summer of 115° F. See Figure C-10 and following equation for calculating the expansion for the 25-foot run and the 100-foot run.

A/2

Anchor

C

A 100 ft

25 ft

Growth

Growth

Figure C-11. Loop

Fixed Point Vertical Riser

An offset can be calculated in the same manner using Equation C-48. Figure C-12 depicts a typical offset used to accommodate for thermal expansion.

10 ft

A=C

2 D ∆L

(C-48)

Figure C-10. Sample layout Growth

For the 100-foot run: L = 12 (100)(8.33 x 10-5)(115-60)

∆L = 5.50 inches

A

Using the same procedure we now determine the growth on the 25-foot run. Growth

∆L = 1.40 inches Figure C-12. Offset After determining the amount of expansion, the size of the expansion/contraction device can be determined. The use of loops, offsets, or existing changes in directions can be used in any combination to accommodate for the expansion. To determine the length and width of an expansion loop, use Equation C-47. A=C

D ∆L

(C-47)

The last choice is to accommodate the expansion using existing changes in direction. By allowing pipe to flex at the corners, stress can be relieved without building large expansion loops. For a change in direction to properly relieve stress, it must not be locked for a certain distance allowing the turn to flex back and forth. Use Equation C-49 and Figure C-13 to properly design changes in direction.

Where: A = loop length (in) C = constant = 20 for PVDF = 30 for PP, PE D = pipe OD (in) ∆L = change in length (in)



C-13

ENGINEERING THEORY A=C

D ∆L


EXAMPLE

(C-49)

5.5 ft

Anchor Point

11 ft

∆L

Growth Direction Anchor Point

C

Anchor Point

A

Figure C-13. Changes in direction Figure C-14. In-line expansion loop The distance A is the amount of distance required prior to placing an anchor on the pipe from the elbow. By leaving the distance “A” free floating, the pipe can expand and contract freely to eliminate stress on the system. Within the distance A, it is still required to support the pipe according to the standard support spacing, but without fixing it tightly. Since the pipe will be moving back and forth, it is important to ensure the support surface is smooth and free of sharp edges that could damage the pipe.

Figure C-15 is an elevation view of how the change in direction can be used.

25 ft

Expansion Direction

Growth

Anchor Points

EXAMPLE

Anchor Point

A

Consider two possible approaches to solve the expansion in the system. For the shorter run of 25 feet, use the change in direction to compensate for the growth. For the longer 100 feet, use an expansion loop in the middle of the run. First consider the expansion loop. Calculate the length of the loop’s legs as follows: A=C

D ∆L

A = 30 3.5 x 5.50

Guide

Figure C-15. Use of change in direction The distance A is the length of pipe on the vertical run that must be flexible to compensate for the growth. A is calculated as follows: D ∆L

A = 132 inches = 11 feet

A=C

A / 2 = 5.5 feet

A = 30 3.54 x 1.40 A = 66.7 inches = 5.5 feet

The 25-foot long run must still be considered. Since the 100-foot pipe run is anchored on the end of the pipe system, it is difficult to use the horizontal change in direction to compensate for the growth. However, the 90° elbow on the end of the vertical can be used.

C-14

Therefore, the vertical run should be guided 5.5 feet from the bottom of the horizontal run. This allows the expansion to relax itself by use of the flexible 90° elbow.




ENGINEERING THEORY

As with all three methods of expansion, it is necessary to use hangers that will anchor the pipe in certain locations and be a guide in other locations. Guides are extremely important to ensure that the expansion is eliminated within the compensating device and not by the pipe bowing or snaking. Also, restraint fittings are required at the point of anchoring. See Hanging Practices in this section.

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C-15

ENGINEERING THEORY

THERMAL EXPANSION DESIGN (double wall)

THERMAL EXPANSION AND CONTRACTION IN DOUBLE WALL PIPING SYSTEMS The effect of thermal changes on a double containment piping system is the same as a single wall system. However, the design considerations are more involved to ensure a safe operation.

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Duo-Pro and Fluid-Lok Systems For thermal expansion in a double contained system, it is necessary to discuss and design it based on the system. Not all double wall piping can be designed in the same manner, and some systems truly may not be able to be designed around large changes in temperature. In a double contained piping system, three types of expansion can occur: • Carrier pipe exposed to thermal changes, containment remains constant. Typical possibility when carrier pipe is exposed to liquids of various temperature, while outer containment is in a constant environment such as in buried applications. • Containment piping experiences thermal changes, while carrier remains constant. Typical application is outdoor pipe racking with constant temperature media being transported in carrier. • Both inner and outer experience temperature changes. A double containment system can be restrained the same way as a single wall system. The values for actual stress in a system versus those allowable can also be determined. Then, the decision can be made according to the system’s needs to use either flexible or restrained supports.

Next, calculate the stress due to internal pressure.

Sp = P

(D-t) 2t

Where: Sp D t P

(C-51)

= stress due to internal pressure (psi) = pipe OD (in) = wall thickness (in) = system pressure (psi)

Now combine the stresses of Sp and ST using Equation C-52 to obtain the total stress placed on the system due to the operating parameters. SScc==√SSTT22 ++ S SPp22

(C-52)

Where: Sc = combined stress (psi) Having the combined stress of the system, the total end load on the piping and anchors can be calculated using Equation C-53. F = Sc A

(C-53)

Where: F = end load (lbs) Sc = combined stress (psi) A = area of pipe wall (in2) Knowing the combined stress and force generated in a system now allows the designer to make decisions on how to compensate for the thermal effects. By comparing the combined stress to the hoop stress of material allows a safety factor to be determined.

Determining Stress This method is the same for all types of double containment expansion. First, calculate the stress that will be present in the system due to all operating systems. These include stresses due to thermal cycling and the stress due to internal pressure.

EXAMPLE A PVDF carrier with a combined stress of 500 psi is compared to the hoop stress or allowable stress of PVDF, which is 1100 psi with all the appropriate safety (HDB = 2200 psi, S = HDB/2 = 1100 psi) factors: SF = 1100 psi/500 psi = 2.2:1

Thermal stress can be calculated with Equation C-50. ST = E α

∆T

(C-50)

Where: ST = thermal stress (psi) E = modulus of elasticity (psi) α = coefficient of thermal expansion (in/in° F) ∆T = (Tmax – Tinstall) (° F) See Section B on Materials for the values of modulus of elasticity and coefficient of thermal expansion for each material.

C-16

Therefore, if this system was fully restrained, it would have 2.2 to 1 safety factor. The factor assumes that the system will be properly anchored and guided to avoid pinpoint loads. If the value of the combined stress was 600 psi and the resulting safety factor is now below 2, the designer should/ may choose to compensate for the expansion using a flexible design.




ENGINEERING THEORY

Carrier Expansion, Containment Constant

Carrier Constant, Containment Expansion

Restraint Design If a system design is deemed safe to be restrained, proper design and layout must be engineered to ensure the system functions properly.

Restraint Design In systems where the containment pipe will see thermal expansion and the inner pipe is constant, and where it has been determined that the pipe can safely be restrained, the installation is simplified. Since the outer pipe will be locked into position and the inner pipe does not want to expand, the design is based on the secondary pipe only.

First is the use of the Dogbone fitting, also known as a Force Transfer Coupling. In systems where thermal expansion is on the carrier pipe and the secondary piping is a constant temperature, the Dogbone fitting is used in order to anchor the inner pipe to the outer pipe. The Dogbone fitting is a patented design of Asahi /America making our system unique in its ability to be designed for thermal expansion effects. Dogbones are available in annular and solid design. Annular Dogbones allow for the flow of fluid in the containment piping to keep flowing, while solid Dogbones are used to stop flow in the containment pipe and compartmentalize a system. Figure C-16 depicts a Dogbone fitting.

Solid

Vent Hole and Annular Cut Out

Figure C-16. Solid and flow through Dogbones In a buried system, the outer wall pipe is continuously restrained. Welding the standard Dogbone restraint into the system fully anchors the pipe. In systems where the pipe is not buried, a special Dogbone with restraint shoulders is required to avoid stress from the carrier pipe to pull on the containment pipe. Below is a detail of a Dogbone with restraint shoulders.

Solid

In these cases, only an outer wall anchor is required. However, since the pipe will most likely be joined using simultaneous butt fusion (where inner and outer welds are done at the same time), the restraint shoulder Dogbone is the logical choice for a restraint fitting.

Restrained Systems — General If restraining a system, proper layout design becomes critical. If fittings such as 90° elbows are not properly protected, the thermal end load could crush the fitting. It is important to remember that end load is independent of pipe length. The expansion in one foot of piping compared to the expansion in 100 feet of piping under the same operating conditions will generate the same force. A proper design will protect fittings using Dogbones and guides. Use guides to keep pipe straight and not allow the material to bow or warp on the pipe rack. In an underground system, the pipe will be naturally guided by use of trench and backfill. Use Dogbones to protect fittings at changes of direction or branches. It is important to note that Duo-Pro and Fluid-Lok systems use support discs on the end of pipe and fittings to ensure proper centering of the components. These support discs are designed to be centering guides and locks for fusion. The support disc is not an anchor fitting. Finally, ensure the proper hanging distances are used based on the actual operating temperature of the system. Figures C-18 and C-19 are illustrations of proper and improper design and installations to highlight the importance of proper hanging techniques.

Vent Hole and Annular Cut Out

Figure C-17. Restraint shoulder Dogbones



C-17

C

ENGINEERING THEORY Carrier and Containment Axial and Radial Restraints Containment Radial Restraints


To start, first determine the amount of growth in the pipe system due to the temperature change. The change in pipe length is calculated as follows:

∆L = 12 x L x α x ∆T Where:

∆L = change in length (in) L = length of the pipe run (ft) = coefficient of thermal expansion (in/in/° F) = 6.67 x 10-5 for PVDF = 8.33 x 10-5 for PP = 8.33 x 10-5 for HDPE = temperature change (° F)

α α α α ∆T

C Figure C-18. Proper design Carrier and Containment Axial Restraints

(C-54)

∆T is the maximum temperature (or minimum) minus the install temperature. If the installation temperature or time of year is unknown, it is practical to increase the ∆T by 15% for safety. It is not necessary or practical to use the maximum temperature minus the minimum temperature unless it will truly be installed in one of those conditions.

Figure C-19. Improper design

Flexible System Design — General

After determining the amount of expansion, the size and type of the expansion/contraction device can be determined. The use of loops, offsets, or existing changes in directions can be used in any combination to accommodate for the expansion. To determine the length and width of an expansion loop, use Equation C-55.

A flexible double containment system requires additional design work to ensure safe working operation. A flexible pipe design is based on strategically using expansion and contraction compensating devices to relieve the stress in the piping system. Common devices are, but are not limited to: • Expansion loops • Expansion offsets • Changes in direction • Flexible bellows • Pipe pistons

A = C √D∆ AL= C Where:

C-18

(C-55)

A = loop length (in) C = constant = 20 for PVDF = 30 for PP, PE D = pipe OD (in) ∆L = change in length (in)

The loop width is the length A divided by 2. See Figure C-20 for an example of a typical loop.

Asahi /America recommends compensating for thermal expansion by using loops, offsets, and changes in direction. By using the pipe itself to relieve the stress, the integrity of the pipe system is maintained. The use of bellows or pistons will also work, but often introduce other concerns such as mechanical connections and possible leaky seals. Although these occurrences are not common, using the pipe eliminates the chance altogether. The following section outlines how to size expansion loops. The method of calculation of loop size is independent of the type of system expansion. An example is included to better understand how to use the equations and lay out a system.

D ∆L

A/2

Dogbone

A

Growth

Growth

Figure C-20. Loop




An offset can be calculated in the same manner using Equation C-56. Figure C-21 depicts a typical offset to be used to accommodate for thermal expansion. AL= C A = C √2D∆

2 D ∆L

(C-56)

ENGINEERING THEORY Carrier Expansion, Containment Constant Flexible Design Using the equations and methods previously described will allow for the design on the inner loop dimensions. However, the containment pipe must be sized to allow the movement of the inner pipe. Below is an example of a short run of pipe designed to be flexible.

Growth

C

EXAMPLE A 3 x 6 – 75 foot run of Pro 150 x Pro 45 polypropylene pipe is locked between existing flanges that will not provide any room for expansion. The double containment pipe is continuous and will be terminated inside the two housings. The ∆T will be 60° F. The containment pipe is buried, and the thermal expansion only affects the carrier pipe.

A

Growth

Figure C-21. Offset Manhole

The last choice is to accommodate the expansion using existing changes in direction. By allowing pipe to flex at the corners, stress can be relieved without building large expansion loops. For a change in direction to properly relieve stress, the pipe must not be locked for a certain distance allowing the turn to flex back and forth. Use Equation C-55 and Figure C-22 to properly design changes in direction.

Growth

A

Manhole

3"x 6" P150 x P45

75 feet

Figure C-23. Detail of system From the proposed installation, all the thermal expansion will need to be made up in the pipe run itself. Since the pipe run is straight, the use of an expansion loop(s) is the best method. First, determine the amount of expansion that must be compensated.

∆L = 12 α L ∆T ∆L = 12 • (8.33 x 10-5)(75)(60) Figure C-22. Changes in direction The distance A is the amount of distance required prior to placing an anchor on the pipe from the elbow. By leaving the distance “A” free floating, the pipe can expand and contract freely to eliminate stress on the system. Within the distance A, it is still required to support the pipe according to the standard support spacing, but without fixing it tightly. Since the pipe will be moving back and forth, it is important to ensure the support surface is smooth and free of sharp edges that could damage the pipe. As with all three methods of expansion compensation, it is necessary to use hangers that will anchor the pipe in certain locations and allow it to be guided in other locations. Guides are extremely important to ensure that the expansion is eliminated within the compensating device and not by the pipe bowing or snaking.


∆L = 4.50 inches Next, determine the size of the loop. Based on the result of the calculation, it can be determined if more than one loop will be required. A=C A = 30

D ∆L 3.54 (4.5)

A = 119 inches = 10 feet For this application, it is determined that one loop is sufficient. The system will have the following layout.


C-19

ENGINEERING THEORY EXAMPLE (continued)

Carrier Constant, Containment Expansion Flexible Design These systems are designed in the same fashion. Work with the equations as if the outer wall piping is a single wall pipe system.

5 feet 10 feet

C

The use of loops, offsets, or changes in direction is the same design method, accept in this case it is important that the carrier pipe does not restrict the growth of the containment piping. The methodology to avoid this from occurring is the same as in the previous section.

37.5 feet

Figure C-24. Expansion layout The last step is to determine the size of the outer wall pipe. Since the loop has been designed to compensate for a maximum growth of 4.5 inches, it is known that the carrier pipe will grow into the loop 2.25 inches from both directions. See Figure C-25 for clarification.

Growth

3"


2.25"

6"

Figure C-25. Expansion into the loop The annular space in the containment pipe must be designed to allow for the free movement of the carrier pipe, a total distance of 2.25 inches. In this particular case, based on the OD of the carrier and ID of available containment piping, the containment pipe must be increased in size to a 10" Pro 45 outer wall pipe. Figure C-26 depicts the cross-sectional view of the pipe and the new expansion loop design.

Flexible System — Final Considerations In all double wall piping systems that require a flexible design, some similar installation and design practices apply. All flexible systems require staggered butt-fusion assembly. Since the inner and outer piping are expanding and contracting at different rates, the support disc that locks the two pipes together for simultaneous fusion cannot be used. For a flexible system, the inner weld must be conducted and then the outer weld. See Section F, Installation Practices, for staggered welding procedures. As in a single wall flexible system, it is important to control and direct the direction of the expansion. In hanging systems, the use of guides and anchors is critical to properly direct the growth. In buried systems, the spider clips provided within the pipe are used to guide the carrier pipe inside the containment. Dogbones are again used to anchor the pipe. From the location of the anchoring Dogbone, the direction of the expansion is known. These fittings are used at all points of required anchoring.

Poly-Flo Thermal Expansion Design 2.5"

2.5"

3" P150

1/2 Moon Style Support

10" P45

A Poly-Flo double containment piping system is similar to that of a single wall pipe. Poly-Flo pipe is made with continuous supports between the carrier and containment pipe. The pipe is extruded all as one piece, different than any other fabricated double containment pipe system available in the world. Since the carrier, the containment, and the ribs are all one homogenous component, the containment pipe will expand and contract at the same rate as the carrier pipe.

Figure C-26. Cross-sectional view Dogbone

Asahi /America has tested the effect of expanding the inner pipe and verified that the outer pipe will expand at the same rate with minimal stress to the rib support system. Therefore, a Poly-Flo system should be designed for thermal expansion in the same manner as a single wall piping system. For further understanding of thermal expansion, consult with the Asahi /America, Inc. Engineering Department to review any needs of a specific project.

Figure C-27. New double contained expansion loop

C-20



ENGINEERING THEORY

HANGING PRACTICES

HANGING PRACTICES Hanging any thermoplastic system is not that much different than hanging a metal system. Typically the spacing between hangers is shorter, due to the flexibility of plastic. In addition, the type of hanger is important.

Hanging Distances Hangers should be placed based on the spacing requirements provided in Appendix A. Since thermoplastic materials vary in strength and rigidness, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, then the amount of hangers will be increased. Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical. In these cases, the hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation.

C

All Th l l clamp i H Figure C-28a. Recommended If a clamp will be used as an anchor and it will be exposed to high end loads, a more heavy duty clamp may be required, as well as a special anchoring setup. In these cases it is advised to either consult a mechanical engineer with experience in pipe stress analysis or receive detailed recommendations from the clamp manufacturer .

Hanger Types When selecting hangers for a system, it is important to avoid using a hanger that will place a pinpoint load on the pipe when tightened. For example, a U-bolt hanger is not recommended for thermoplastic piping. Pressure Point

Pressure Point

Figure C-28. Effects of U-bolt on pipe Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps, as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp. This is a must for PVDF and E-CTFE systems, which are less tolerant to scratching. Figure C-28a illustrates some recommended hanger types.



C-21

ENGINEERING THEORY

C

All Thermoplastic Hanger (recommended for plastic pipe) Available from Asahi/America

HANGING PRACTICES

Adjustable Solid Ring (swivel type)

Clevis Hanger

Roller Hanger

Pipe Roller and Plate

Single Pipe Roller

Band Hanger with Protective Sleeve

Riser Clamp

Double-Bolt Clamp

Vertical Clamp

Vertical Pipe Clip

Vertical Offset Clamp

U-Type Clamp

Horizontal Pipe Clip

Suspended Ring Clamp

Figure C-29. Typical plastic piping restraints

C-22



ENGINEERING THEORY

BURIAL PRACTICES (single wall)

BURIAL PRACTICES FOR SINGLE WALL PIPING When designing for underground burial of thermoplastic piping, both static earth loads and live loads from traffic must be taken into account. The static load is the weight of the column of soil on the piping. The actual static load that the pipe is subjected to is dependent on many factors: the type of soil, the compaction of the soil, the width and detail of the trench, and the depth that the pipe is buried. The deeper the burial, the higher the load.

C

Burial of Single Wall Piping Live loads decrease radially from the point at the surface from which they are applied. Live loads will have little effect on piping systems except at shallow depths. Polypropylene, polyethylene, and PVDF are flexible conduits. According to a basic rule of thumb, at least 2% deflection can be achieved without any structural damage or cracking. When analyzing a system for capability of withstanding earth and live loading, deflection under proposed conditions are compared to maximum allowable deflection (5% for PP and PE and 3% for PVDF) and the adequacy is thus judged.

Figure C-30. Example of underground installation The load coefficient, Cd, depends on the ratio of the height of the fill to the trench width and can be determined from the following equation.

Determination of Earth Loads The method for determining earth loads of a flexible conduit is the Marston Theory of loads on underground conduits. From the theory, it is concluded that the load on a rigid conduit is greater than on a flexible conduit. To determine the earth load on a flexible conduit, the Marston equation for earth loads is used. The ratio of the load on a rigid conduit to the load on a flexible conduit is: Wc (rigid) Wc (flexible)

=

Wc = Cd w Bd Bc

Bd Bc

(C-57)

(C-58)

Where: Wc= load on conduit, (lbs/linear ft) w = soil density, (lbs/ft3) Bc = horizontal width of conduit (ft) Bd = horizontal width at top of trench (ft) Cd = load coefficient

Therefore, the theory implies that a trench width twice the width of a conduit being buried will result in a load on a rigid conduit twice that of a flexible conduit. Figure C-30 displays the dimensions indicated in Equation C-57.


Cd =

(1-e(-2K µ H/Bd)) 2K µ

(C-59)

Where: e = natural logarithm base K = Rankine’s ratio of lateral to vertical pressure µ = coefficient for friction between backfill material and sides of the trench From Equation C-59, a larger load can be expected at increasing widths. As trench width increases, this load increases at a decreasing rate until a value as prism load is attained. For most applications, this value can be calculated as follows: Wc = H w Bc

(C-60)

And prism load, expressed in terms of soil pressure, is as follows: P = Wc H Where: P = pressure due to soil weight at depth H (lbs/ft2) H = height of fill (ft) Prism loading is the maximum attainable load in a burial situation and represents a conservative design approach. Due to the fact that frost and water action in a soil may dissipate frictional forces of the trench, the long-term load may approach the prism load. Therefore, it is recommended that this load be considered when designing an underground thermoplastic piping system.


C-23

ENGINEERING THEORY Simplified Method for Burial Design To properly determine the feasibility of thermoplastic piping system in a buried application, follow the steps below. These steps will provide the proper design to resist static soil loads.

Step 1. Determine the soil load exerted on the pipe in lbs/linear foot. The following information is required: Pipe Diameter: _____________________________________ Soil Type: _________________________________________ Trench Width: ______________________________________ Burial Depth: ______________________________________ With this data, use the Martson Soil Load Tables found in Appendix B to determine the actual load on the pipe. It is critical to pay particular attention to the trenching details. If proper trenching cannot be accomplished, values for the load should be determined using the prism load values, also found in Appendix B. Actual Soil Load: ______________________ per linear foot

If the maximum allowable is less than the actual load, changes will have to be made, such as burial depth, trench details, or pipe wall thickness. The allowable loads for Duo-Pro pipe are based on an allowable ring deflection of 5% for PP and HDPE and 3% for PVDF.

Live Load Designs For applications where live loads are present, a general rule of thumb is to place the pipe 5 feet below the source of the live load. If piping is only being exposed to a live load in a short length, and cannot be placed 5 feet down, it may be advantageous to sleeve the pipe through a steel pipe or enclose it in concrete. In general, live loads should be added to static earth loads to determine the total load exerted on the pipe under site conditions. In Figure C-31, H20 highway loading, the effects of live load and static earth loads combined on a pipe can be viewed. In shallow depths, shallower than the 5-foot mark, the effect of traffic is significant and needs to be added to the static load to determine the effect. From the graph, it is demonstrated that at deeper depths the effect of a live load becomes a minimal effect. In all cases of static and live loads, consult Asahi /America’s Engineering Department for assistance on design.

Step 2.

16

Determine the E' Modulus of the soil.

Live load applied on assumed area of 30 x 40 14

E' Modulus values are based on the soil type and the proctor (see Appendix B for table). If on-site conditions are not known, use a low value to be conservative. E' = _______________________________________________

Step 3. Determine the allowable load on the pipe. The allowable load on the pipe is compared to the actual load to determine suitability of the burial application. In addition, safety factors can be calculated. Allowable loads are based on the pipe diameter, material, wall thickness, and E' Modulus. To determine the allowable loads, use the tables in Appendix A for Polypropylene, PVDF, and HDPE. Be sure to use the tables by wall thickness and material.

12 Height of Cover (feet)

C

BURIAL PRACTICES (single wall)

H20 live load + impact

10

Dead load = 120 lb/ft3 8 6 Total load (live and dead)

4 2 0 0

500

1000

1500

2000

Vertical Soil Pressure (lbs/ft2) Source: American Iron and Steel Institute, Washington, DC

Max allowable soil load _________________ per linear foot Figure C-31. H20 highway loading If the actual load is less than the allowable load, the installation is acceptable, providing a 2:1 safety factor is present. Safety Factor = Max allowable load/ actual soil load. SF = ______________________________________________

C-24



ENGINEERING THEORY

BURIAL PRACTICES (double wall)

BURIAL PRACTICES FOR DOUBLE WALL PIPING The procedure is the same as that of a single wall system. All calculations should be based on the outer wall, containment, pipe OD, and wall thickness. If leak detection cable is used on a buried double wall system, it is necessary to calculate the actual deflection and the resulting annular space to ensure the cable will have adequate clearance. See Figure C-32.

C

Deflection of Containment Pipe Restricts Annular Space

Leak Detection Cable

Figure C-32. Deflection of double contained pipe The following formula is used to calculate deflection on the containment pipe. ∆X = DL

Where:

(K Wc r3)

(C-61)

(E I + 0.061 E'r3)

∆X = horizontal deflection based on inside diameter (in) DL = deflection lag factor (use 1.5) K = bedding constant (Appendix B) Wc = Marston load per unit length of pipe (lbs/linear in) r = radius of pipe (in) E = modulus of elasticity of pipe materials (psi) I = moment of inertia of the pipe wall (in3) = t3/12 (App A, Table A-28 to A-32) E' = modulus of soil reaction (psi)



C-25

ENGINEERING THEORY

These preparations can be used for either single wall or double contained piping systems.

shifting, thereby preventing shearing and bending stresses on the piping. It is strongly suggested that an elastomeric material be used to prevent stress concentration loading on the piping caused by the reinforcing rod.

Trench Preparation–General

Laying of Pipe Line and Backfilling Procedure

The recommended trench width for both single wall and double can be found by adding one foot to the width of the pipe to be buried. Larger trench widths can be tolerated, but trench widths greater than the diameter plus two feet typically produce large loads on the pipe. For small diameter pipes (4" and less), smaller trench widths are suggested. The important point to remember is the trench width at the top of the conduit is the dimension that determines the load on the pipe. Therefore, the sides of the trench can be sloped at an angle starting above this point to assist in minimizing soil loads in loose soil conditions (prior to compaction). If the trench widths described are exceeded, or if the pipe is installed in a compacted embankment, it is recommended that embedment should be compacted to 2.5" pipe diameters from the pipe on both sides. If this distance is less than the distance to the trench walls, then the embedment materials should be compacted all the way to the trench wall.

Caution must be exercised so that the laying of straight lengths or piping prepared above ground do not exceed the minimum bending radius of the piping. For a given trench height, "h", the minimum length of piping necessary to overcome failure due to bending strain can be determined by the following procedure.

INSTALLATION OF A BURIED SYSTEM

C


When installing long lengths of piping underground, it may not be necessary to use elbows, as long as the minimum radius of bending for specific diameters and wall thicknesses are observed. If the soil is well compacted, thrust blocks are not required. However, if changes of directions are provided with tees or elbows, or if the soil is not well compacted, thrust blocks should be provided. The size and type of a thrust block is related to maximum system pressure, size of pipe, direction of change (vertical or horizontal), soil type, and type of fitting or bend. To determine thrust block area, it is suggested that a geotechnical engineer be consulted, and soil bearing tests be conducted if deemed necessary. If the bottom of the trench is below the water table, actions must be taken to adequately correct the situation. The use of well points or under-drains is suggested in this instance, at least until the pipe has been installed and backfilling has proceeded to the point at which flotation can no longer occur. The water in the trench should be pumped out, and the bottom of the trench stabilized with the use of suitable foundation material, compacted to the density of the bedding material. In a double containment system, annular spaces must be sealed to prevent water from getting into the space. For unstable trench bottoms, as in muddy or sandy soils, excavate to a depth 4 to 6 inches below trench bottom grade, backfill with a suitable foundation material, and compact to the density of the bedding material. Be sure to remove all rocks, boulders, or ledge within 6 inches in any direction from the pipe. At anchors, valves, flanges, etc., independent support should be provided by the use of a reinforcing concrete pad poured underneath the pipe equivalent to five times the length of the anchors, valves, or flanges. In addition, reinforcing rods should be provided to securely keep the appurtenance from

C-26

Step 1. Determine trench height = “h”. This trench height will equate to the offset value “A”. A = 2Rb (sin Q)2

(C-62)

Step 2. Determine Rb from longitudinal bending tables (see Appendix A) for the pipe diameter to be laid.

Step 3. Determine the angle of lateral deflection (α).

α = sin-1

1/2

( ) h 2Rb

(C-63)

Step 4. Determine the central angle β.

Step 5. Determine the minimum length “L” in inches. βR

L = 57.3b

(C-64)

Where: h = A = height of trench (in) β = 2α = central angle (degrees) Rb= radius of bending (in) (Appendix A) L = minimum laying length (in) If the value determined in Step 5 is greater than the entire length to be buried, due to a deep trench or short segment, then the entire length should be lifted with continuous support and simultaneously placed into the trench. If the pipe is pulled along the ground surface, be sure to clear the area of any sharp objects. Some means to prevent scarring to minimize soil friction should be used. Since the allowable



ENGINEERING THEORY


working stress at pipe laying surface temperature should not be exceeded, pulling force should not exceed: PF = SF x S x A

(C-65)

Where: PF = maximum pulling force (Ibs) S = maximum allowable stress (psi) A = cross-sectional area of pipe wall (in2) SF = safety factor = 0.5 Since the soil will provide friction against a pipe that is being pulled on the ground, a length “L” will be achieved where the pipe can no longer be pulled without exceeding maximum allowable stress of the piping. This length can be estimated by: 2.3 SF S L= (µ cos ∅ + sin ∅)

(C-66)

Where: L = maximum pulling length (feet) S = maximum allowable stress (psi) SF= safety factor = 0.5 µ = coefficient of friction between the soil and pipe wall ∅ = gradient (ground slope)

Pipe Depth Backfill 85% Proctor

9"

Sand 95% Proctor

9"

Pea Gravel

C

6" 6"

6"

Figure C-33. Example of underground installation The piping location should be accurately recorded at this point, and it may be a wise idea to place a conductive wire or shield in the vicinity in order to locate the piping at a later date by the use of an underground metal detector. This will ensure that piping can still be located if the installation plans are misplaced. Offset

Snaking Length

Muddy soil with a low coefficient of friction will allow for a longer length to be pulled. Offset

For small diameter pipes (21/2" and under), the pipe should be snaked, particularly if installed during the middle of a hot summer day. The recommendations for offset distance and snaking length should be observed, as outlined in this section, Thermal Expansion. It is suggested that the laying of the pipe into the trench on a summer day take place first thing in the morning to minimize thermal contraction effects. For larger diameter pipes with well compacted soil, friction should prevent pipe movement due to thermal expansion and minimize the need for snaking, although it is still recommended.

Figure C-34. Illustration of terms relating to snaking of pipe within a trench

The initial backfilling procedure should consist of filling in on the sides of the piping with soil free of rocks and debris. The filling should be compacted by hand with a tamping device, ensuring that the soil is forced under the pipe, and should continue until a level of compacted fill 6" to 12" above the top of the pipe is achieved. This process should be performed in gradual, consistent steps of approximately a 4" layer of fill at any one time to avoid the arching effect of the soil. When this procedure is accomplished, the final backfill can proceed. With a soil that is free of large rocks or other solids, the final fill can be accomplished.



C-27

ENGINEERING THEORY

PIPE BENDING

PIPE BENDING As previously mentioned, many thermoplastic piping systems can be bent to reduce the usage of fittings. Pipe bending procedures are dependent on the intended radius, the material, and size and wall thickness of the pipe. Consult with Asahi/America for procedural recommendations.

C

To determine the minimum allowable radius, see Appendix A. Tables App. A-15 and App. A-16 provide factors for bending based on material and size. Polypropylene and HDPE can be bent in the field, but bending PVDF is not recommended.

Di OD

Rb

L

C

α

90°

Figure C-35. Asahi /America pipe allowable bend

C-28



ENGINEERING THEORY

HEAT TRACING AND INSULATION


Step 3.

Heat tracing of thermoplastic pipes differs considerably than that of metals. Some of the important contrasts include: poor thermal conductivity of the pipe material, upper-temperature limitations of the pipe material due to low melting ranges and combustibility features, high expansion and contraction characteristics and the resulting insulation restrictions, poor grounding qualities for electrical currents, and the typical harsh environmental consideration to which plastic piping is frequently exposed to. External steam tracing is strongly not recommended, due to the upper temperature limitations. However, there are two very reliable methods of providing freeze protection and/or temperature maintenance: external electrical heat tracing using “self-regulating” style electrical heaters, and the internal method of using a smaller diameter pipe that conveys a hot fluid to transfer heat to the fluid flowing in the annular space. Both methods require a slightly different design method, and also require their own unique fabrication techniques. When designing a system using either of these methods, it is suggested that the factory be contacted for technical advice pertaining to the particular situation. Manufacturers of heat tracing also now offer computer programs to determine the proper system for an application. Raychem offers the TraceCalc program for such applications.

Determine Q (heat loss) in watts per linear foot by using Equation C-67 or by using the heat loss tables found in Appendix A.

Thermal Design The heat loss calculations to determine the amount of heat that must be replaced by the heater are based on the Institute of Electrical and Electronics Engineers (IEEE) Standard 515-1983, Equation 1, with the following modification. Since the factor for pipe wall resistance cannot be neglected for plastics, a term for pipe wall resistance is also included. Pipe heat losses are shown at a variety of temperature differences and insulation thicknesses. Heat loss for Asahi /America piping can be found in Appendix A. The information is based on foamed elastomer insulation, according to ASTM C-534, located outdoors in a 20 mph wind, no-insulating air space assumed between insulation and outer cladding, and negligible resistance of the outer cladding; thereby, providing an additional margin of safety in the calculations. To determine heat loss through the insulated pipe, the following procedure should be used.

π L ∆T

Q= 1 hi Di

+

ln(Do/Di) 2kp

+

1

+

ho Do

ln(Dins/Do) 2kins

+

1 hins Dins

+

1 hwb Dwb (C-67)

Where: Kp = thermal conductivity of the pipe (BTU.in/ft2 h ° F) Kins = thermal conductivity of the insulation (BTU.in/ft2 h ° F) Di = inside pipe dimension (in) ho = inside air contact coefficient, pipe to insulation (BTU.in/ft2 h ° F) Do = pipe outside diameter (in) Dins = combined outside diameter of the pipe plus insulation (in) hins = inside air contact coefficient, insulation to weather barrier (BTU.in/ft2 h ° F) Dwb = combined outside diameter of the pipe, insulation, and weather barrier (in) hwb = heat transfer coefficient of the outside air film (BTU.in/ft2 h ° F) Hi = heat transfer coefficient of the inside air film (BTU.in/ft2 h ° F)

Di Do

Dins Dwb

Figure C-36. Double containment pipe

Step 1. Determine applicable conditions such as type of piping, internal fluid, minimum expected temperature condition, desired maintenance temperature, outdoor or indoor condition (applicable wind velocity for outdoor condition), amount and type of insulation desired, etc.

Step 2. Determine ∆T by subtracting the minimum expected design temperature from the desired maintenance temperature.

Step 4. If the desired type of insulation is not foamed elastomer, do not adjust the number found in the table by applying a design factor. Instead, Equation C-67 should be used to determine the heat loss. The resistance of the plastic pipe prevents the use of these quick insulation factors, unlike the situation experienced for metal piping where there is no pipe resistance to heat transfer.

Step 5. For piping located indoors, multiply the values for Q (heat loss) found in the heat loss tables in Appendix A, by 0.9 to determine the corrected values.



C-29

C

ENGINEERING THEORY External Self-Regulating Electrical Heat Tracing Design

C

Plastic piping melts at comparatively low temperatures with respect to that of metallic piping. If high enough temperatures are achieved, the external walls of a plastic pipe may become charred or burned causing damage to the external walls. Due to these features, the only recommended type of electrical heat tracer is the self-regulating type. A product with high reliability that is compatible with thermoplastic piping systems is Chemelex® Auto-Trace® heaters, manufactured by Raychem Corporation of Menlo Park, CA. By automatically varying heat output, Auto-Trace heaters compensate for installation and operating variables such as voltage fluctuations, installation, heat sinks, and ambient temperature changes, while continuing to provide necessary heat for system operation. Self-regulation works by the use of a unique heating element that is a specially blended combination of polymer and conductive carbon, creating electrical paths between the parallel bus wires at every point along the circuit. As it warms, the core expands microscopically, increasing resistance to electrical flow and causing the heater to reduce its power output. As the surrounding temperature cools the core, it contracts microscopically, decreasing resistance and increasing the heater output. In addition, the heat distribution along the pipe surface can be more evenly controlled as the heater will vary its power output in accordance with the state of the heater core. In cold spots, the core contracts microscopically creating many electrical paths through the conductive carbon. The flow of electricity through the core generates heat. In warmer sections, the core expands microscopically, disrupting many electrical paths. The increased electrical resistance causes the heater to reduce its power output. In hot sections, the microscopic core expansion disrupts almost all the electrical paths. With this high resistance to electrical flow, power output is virtually zero. Thus the heat distribution is very even, and hot spots along the temperature sensitive plastic pipe and insulation are avoided. Other features of self-regulating heaters include parallel circuitry for cut-to-length convenience at the job site, flexibility for easy field installation, and circuit length up to 1,000 feet (305 meters). In addition, reduced operating cost is achieved by balancing heat loss through efficient energy use, compensation for local temperature variation, and minimal maintenance due to long lasting reliability. Engineering design assistance is provided through Asahi /America’s Engineering Department on request. To design a system with electrical heat tracing, the following variables must be known: design temperature difference (∆T) found as shown in the thermal design section of this chapter in watts per linear foot of pipe, voltage, area classification, chemical environment, type and number of valves, flanges and supports, and total pipe length. Once these factors are known, the following procedure is used to design the electrical heat tracing for the piping system.

C-30


Step 1. Select the appropriate family of heater based upon the maximum exposure temperature and the desired maintenance temperature.

Step 2. Select an appropriate heater from the thermal output curves for that particular heater, so that the thermal output at the maintenance temperature equals or exceeds the heat loss. Since polypropylene, HDPE, and PVDF have much lower thermal conductivities than that of metals, the power output curves should be adjusted. It is suggested that a power output adjustment factor of between 0.5 to 0.75 be used to derate the stated power outputs at the design temperature of the pipe. This factor takes into account that ∆T-180 aluminum tape be used over the heater. It is suggested the tape be used both over and under the heater to aid in heat transfer. Without any tape at all, a factor between 0.3 and 0.5 should be applied to the power to derate the stated power outputs.

Step 3. Should the heat loss already calculated be greater than the power output of the selected heater: • Use thicker insulation • Use insulation with a lower thermal conductivity • Use two or more parallel strips • Spiral the heat tracing or • Use product from the same family with higher thermal output rating

Step 4. When spiralling of the heater is chosen as in Step 3 above because more than one foot of heater is required per foot of pipe, divide the pipe heat loss per foot by the heat output of the selected heater (at the desired maintenance temperature) to calculate the spiral factor. Use Table C-4 to determine the pitch. Refer to Figure C-44 for an illustration on how to measure pitch.

Step 5. Determine the total length of the heater required by combining lengths from each component in the piping system. For the piping, calculate the amount of heater required for the pipe length. In the case of a straight heater run, this quantity is equal to the total length of piping. For each pair of bolted flanges, add a heater length equal to two times the pipe diameter. For each valve, add a heater length determined by multiplying the heat loss Q by the valve factor provided in Table C-5 and dividing by the heater output at the maintenance temperature.



ENGINEERING THEORY


Lh = Where:

Q Fv

(C-68)

Tm

L h = length of heater (ft) Q = pipe and insulation loss (watts/linear foot • hour) Fv = valve factor (see Table C-5) Tm = maintenance temperature (°F)

For each pipe hanger, add a heater length equal to three times the pipe diameter.

Step 6. In hazardous or classified areas, or in applications where a ground path must be provided, or in general harsh environments, select the optional heater coverings as follows: For dry and non-corrosive environments where a ground path is required, use the tinned copper shield covering. For limited exposure to aqueous inorganic chemicals, use the tinned copper shield with modified polyolefin outer jacket. (For BTVTM type heater only.) For limited exposure to organic or inorganic chemicals, use the tinned copper shield with the fluoropolymer outer jacket.

Insulation Insulation is a good method of protecting a pipe system from UV exposure, as well as providing required insulation for the system or media being transported. A serious difference between plastic and metal is plastic’s thermal properties. A metal pipe system will quickly take the temperature of the media being transported. A system carrying a media at 150° F will have an outer wall temperature close to or at 150° F. In contrast, thermoplastics have an inherent insulating property that maintains heat inside the pipe better than a metal system. The advantage is that a plastic pipe has better thermal properties, which translates into improved operating efficiencies and reduced insulation thickness. In a double contained plastic piping system, you have the benefit of the inherent insulation properties of the plastic plus the additional benefit of the air in the annular space between the carrier and containment pipes.

Table C-5. Valve Heat Loss Factor Valve Type

Heat Loss Factor

Gate Butterfly Ball Globe

4.3 2.3 2.6 3.9

For Example: Heat loss for a 2" gate valve is 4.3 times the heat loss for one foot of pipe of the same size and insulation.

Step 7. Select the heater voltage from either the 120 Vac or 240 Vac options. If the 240 Vac option is selected, but the available voltage differs from the product rating, the heater output must be adjusted by using appropriate factors. Consult the maker of the heat tracing for the appropriate factors.

Table C-4. Spiral Factor/Pitch Pipe Size

Spiral Factor (feet of auto-tractor per feet of pipe)

(ips)

1.1

1.2

1.3

1.4

1.5

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 6.0 8.0

NR NR 17 20 24 28 31 35 39 46 59

NR NR NR 14 17 19 21 24 26 31 41

NR NR NR NR 13 15 17 19 21 25 33

NR NR NR NR NR 13 14 16 18 21 28

NR NR NR NR NR NR NR 14 15 18 24

Note: 1 inch = 2.54 cm



C-31

C

ENGINEERING THEORY


Locate Multiple Cables 90° Apart or Equally Spaced

Self-Regulating Heater Cable Rain Shield Thermal Insulation Watertight Jacket

45°

45°

Two Heater Cables

45°

One Heater Cable

C

End Seal 1 ft

Grade

Glass Tape

Underground lagging must be waterproofed to prevent seepage into thermal insulation

Thermal Insulation Glass Tape

Frost Line Self-Regulating Heating Tape 24" (closer as necessary for good contact of heater to pipe)

Seal Thoroughly Weatherproofing Coupled or Welded Pipe

Flanged Pipe

Figure C-37. Positioning of heating tape on pipe Figure C-40. Applying heating tape below grade

Bar Hanger Thermal Insulation

Sealer Self-Regulating Heater Cable Glass Tape

Glass Tape Plastic Pipe

Thermal Insulation Self-Regulating Heating Tape

Weatherproofing

Glass Tape

Heater cable is normally applied to outside (long) radius of elbow

Figure C-41. Positioning of heating tape around bar hanger

Figure C-38. Positioning of heating tape on elbows Self-Regulating Heater Tape

Flange Glass Tape

Self-Regulating Heating Tape

Figure C-39. Positioning of heating tape around flanges

C-32

Glass Tape

Figure C-42. Heating tape placed on tees




ENGINEERING THEORY

Valve Body


Glass Tape

Glass Tape

Note: Heater cable installations will be different for different valve shapes


C Pipe Support

Adjust cable length for valve body

Apply glass tape as necessary to hold heater cable in place

Figure C-43. Heating tape placed around valves Figure C-45. Positioning of heating tape on pipe supports

Thermal Insulation

Glass Tape

Pitch Spiral Method No. 1

Wrap loops in opposite directions

Apply glass tape before spiralling cable on pipe

Tape after spiralling cable

Pitch

Spiral Method No. 2

Figure C-44. Spiral wrapping of heating tape around pipes



C-33

ENGINEERING THEORY

C

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C-34



Section D APPLICATION AND SYSTEM DESIGN Contents High-Purity System Design . . . . . . . . . . . . .D-2

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . .D-15

Materials of Construction . . . . . . . . . . . . . . . . . . . .D-2

Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . .D-2

Burial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16

System Sizing

. . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . .D-16

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . .D-3

UV Exposure and Weatherability . . . . . . . . . . . . . .D-17

Minimize Dead Legs . . . . . . . . . . . . . . . . . . . . . . . .D-3

Leak Detection Design . . . . . . . . . . . . . . . .D-18

System Monitoring . . . . . . . . . . . . . . . . . . . . . . . . .D-5

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-20

Other Considerations . . . . . . . . . . . . . . . . . . . . . . .D-5

Sensor Cable Requirements . . . . . . . . . . . . . . . . .D-21

Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

Ventilation System Design . . . . . . . . . . . . .D-23

Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

Materials of Construction . . . . . . . . . . . . . . . . . . .D-23

Single Wall Chemical Pipe System Design . . D-7

Operating Parameters . . . . . . . . . . . . . . . . . . . . . .D-23

Materials of Construction . . . . . . . . . . . . . . . . . . . .D-7

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-23

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . .D-7

Layout Recommendations . . . . . . . . . . . . . . . . . .D-23

System Sizing

. . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . .D-24

UV Considerations . . . . . . . . . . . . . . . . . . . . . . . . .D-8

UV Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24

Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . .D-24

Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Compressed Air System Design . . . . . . . .D-27

Double Wall System Design . . . . . . . . . . . .D-10

Materials of Construction . . . . . . . . . . . . . . . . . . .D-27

When to Use Double Containment Piping . . . . . .D-10 Materials of Construction . . . . . . . . . . . . . . . . . . .D-10 System Selection . . . . . . . . . . . . . . . . . . . . . . . . .D-12 System Sizing

. . . . . . . . . . . . . . . . . . . . . . . . . . .D-13

Specialty Fittings . . . . . . . . . . . . . . . . . . . . . . . . . .D-14 Double Contained Valves . . . . . . . . . . . . . . . . . . .D-15


Operating Parameters, Oils . . . . . . . . . . . . . . . . . .D-27 System Sizing

. . . . . . . . . . . . . . . . . . . . . . . . . . .D-27

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . .D-28 Other Considerations . . . . . . . . . . . . . . . . . . . . . .D-29 Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-29 Welding Methods . . . . . . . . . . . . . . . . . . . . . . . . .D-29


D-1

APPLICATION AND SYSTEM DESIGN HIGH-PURITY SYSTEM DESIGN A pure water system comprised of PVDF or polypropylene is similar to most chemical feed systems. The critical factor in a pure system is to design it in a continuous moving loop without dead legs to avoid the possibility of microorganism growth.

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Systems should also be sized to have turbulent flow as part of the method of inhibiting bacteria growth. PVDF and PP systems are ideally suited for pure water as they have extremely smooth inner surfaces that reduce particle generation and inhibit sites for bacteria to adhere to and proliferate. In addition, PVDF and PP systems have low extractables, thus not contaminating the water being transported. See the Purad High Purity Guide for more data on material purity. In designing a thermoplastic high-purity water system, the following items need to be considered: • Materials of Construction • Operating Parameters • System Sizing • Thermal Expansion • Minimize Dead Legs • System Monitoring • Other Considerations • Hanging • Welding Methods

Materials of Construction PVDF is the premier material for high-purity water systems. PVDF has been used in ultra pure water systems for over 15 years because it is superior to materials such as stainless steel or PVC. PVDF combines excellent surface finish with low extractables to provide the highest quality piping material for the application. In addition to its purity attributes, PVDF is also available in a variety of components and welding methods that are well suited for UPW applications. PVDF is a crystalline material that can withstand high pressures. However, the nature of PVDF requires special planning and handling during the installation. These types of requirements are now commonplace on the market and are accepted as standard operating methods. For the strictest applications, requiring low bacteria counts and virtually undetectable levels of metal ions, PVDF is recommended for this service. For applications less stringent in water quality level, polypropylene is an excellent alternative. PP offers excellent surface smoothness, as well as low extractable levels as compared to stainless steel. Polypropylene systems are thermally fused together, eliminating the use of glues, which will continue to

HIGH-PURITY SYSTEM DESIGN

leach into a water system for extended periods of time. PP is an extremely weldable material, making fusion joints simple and reliable. For more information on PP, consult Section B. The third alternative is E-CTFE. This material, also known as Halar®, provides superior surface even compared to PVDF. Its extraction levels are also similar to that of PVDF. Halar is a very ductile material, making its use and welding methods extremely reliable. E-CTFE is normally available only in certain sizes and does have some pressure limitations at higher pressure. Halar has become the preferred material for tank lining applications.

Operating Parameters Because thermoplastic systems have varying ratings at different temperatures, it is important to design a system around all the parameters to which it will be subjected. As a first pass, verify the following operating parameters: • Continuous operating temperature • Continuous operating pressure • Media and concentration By knowing the above parameters, thermal plastic pipe systems can be selected. Compare the actual conditions to the allowable ratings of the material being selected for the job. It is important to predict elevated temperatures, as thermoplastics have reduced pressure ratings at higher temperatures. Valves should be verified in terms of temperature and pressure separately from a piping system, as certain styles and brands of valves have lower ratings than the pipe system. Finally, if the media is not water, a chemical compatibility check should be conducted with the manufacturer. See Section E, Chemical Resistance. After verifying the standard operating conditions, it is necessary to examine other operations that might affect the piping. The following is a sample of items to investigate prior to specifying a material. • Will there be spikes in temperature or pressure? • Is there a cleaning operation that the piping will be exposed to? • If yes, what is the cleaning agent? What temperature will the cleaning be conducted at? • Will the system be exposed to sunlight or other sources of UV? Each of the above questions should be answered and the desired material should be checked for suitability based on the above factors, as well as any others that might be special to the system in question.

® Halar is a registered trademark of Ausimont Corporation.

D-2




APPLICATION AND SYSTEM DESIGN

System Sizing

Thermal Expansion

It is well known that high-purity water systems are designed to operate in a continuously flowing loop to prevent stagnant water in the system. Stagnant water can proliferate the growth of bacteria and bio-film. The pattern and design of the loop will vary depending on the facility requirements.

Typically, Purad and PolyPure systems are designed for ambient or cold DI water. In these cases, since the systems operate continuously and are normally inside a fairly constant temperature building, the need to compensate for thermal expansion is not required. Although, it is an important factor that should be reviewed on each and every installation design.

The flow rate in the system is important in determining the pipe diameter size. In a pure water system, elevating flow velocities is recommended to reduce the possibility of bio adhesion to the pipe wall or welded surfaces. Many specifications will state that the flow should be set at a minimum of 5 feet per second, which will always be turbulent flow at this velocity. However, a more sensible approach may be to review the Reynolds’ Number of the system to ensure the flow is turbulent (see Section C, Equation C-14, for the calculation). Use of the Reynolds’ Number may reduce waste oversizing of pumps to overcome excessive pressure drops due to unnecessarily high velocities. Since many HP systems are now produced from high-quality Purad PVDF, high velocities in a continuously flowing system may not be as necessary. High velocities are generally accomplished by undersizing the pipe diameter, which is directly proportional to increased pressure drops. In fact, high minimum velocities are detrimental to the ability of a system to deliver adequate point of use pressure during peak demand conditions.(1) Therefore, using cleaner, smoother material such as PVDF is desirable for design and operation.

Sizing Laterals A pure water and an ultra pure water system will be made of main loop branches known as laterals. It is important in design to not dead end laterals and ensure there is always flow movement in the main and in the lateral. Systems are designed with different loop configurations to accommodate the needs of production. However, all laterals must be designed for continuous flow and should feed back unused water into the return line. For supply laterals feeding multiple tools, the lateral needs to be sized based on an acceptable pressure drop.(1) A general rule of thumb is 2 psig per 100 feet. Consideration of point of use water consumption, length, and frequency of demand must be factored into the sizing process of the lateral.

Hot DI systems normally operating at temperatures of 65° C to 120° C, depending on the water usage, require a more complex design. PVDF systems can be used in hot water applications and applications where the temperature is cyclical. These systems require analysis of the thermal expansion effects. Section C walks through the steps of calculating thermal expansion, end loads, and expansion compensating devices. In most cases, the use of expansions, offsets, and proper hanging techniques are all that is required to ensure a proper design. Hot DI systems also reduce the rigidity of thermoplastic piping systems, which, in turn, decreases the support spacing between pipe hangers. In smaller dimensions, it is recommended to use continuous support made of some type channel or split plastic pipe. Finally, the use of hangers as guides and anchors becomes important. As the design procedures in Section C indicate, certain hangers should be used as guides to allow the pipe to move back and forth in-line, while other hangers should be anchoring locations used to direct the expansion into the compensating device. The anchors and hangers should be designed to withstand the end load generated by the thermal expansion.

Minimize Dead Legs The term dead leg refers to a stagnant zone of water in the system. Dead legs are normally formed in the branch of a tee that is closed off with a valve. See Figure D-1.

Flow

Dead Zone

Sizing Mains Main trunk lines are sized using the demand for water by the tools plus the tool and return lateral minimum flows. Tool demand can be calculated by taking the average flow demand and multiplying it by 1.2 to 1.8 to accommodate for peak demand. This should be based on the tool manufacturer’s parameters.(1) Figure D-1. Dead legs due to poor design The return lines should be sized for minimal pressure drop when the tool demand is at a minimum, thus corresponding to maximum bypass at the end of a main pressure control station(1).


(1) Ultra Pure Water, May/June 2000: “Criteria, Tools and Practices for High Purity Water Distribution”


D-3

D

APPLICATION AND SYSTEM DESIGN A rule of thumb in designing a system is to keep all dead legs to a maximum of 6 internal pipe diameters in length. The turbulent flow in the main trunk line will create a significant amount of movement to keep the leg moving and prevent bacteria from adhering to the pipe wall. However, the Purad system allows designers to avoid dead legs altogether with the advent of T-diaphragm valves and zero dead leg fittings.


Since these tee configurations are narrow in diameter, they create a dead leg in the branch where microorganism growth can be initiated. The use of instrumentation fittings eliminate dead legs while being a safe adapter for gauges or sample valves. See Figure D-4.

Gauge or Sample Valve

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T-valves (see Figure D-2) take the place of a tee, reducer, and diaphragm valve by combining all three into one component. T-valves reduce the quantity of welds in a system as well. By using a T-valve, branch lines can be shut off at any time without creating a dead leg and turned back on without an extensive flush procedure.

Instrument Fitting Flow

Figure D-4. Proper use of instrument fitting to avoid dead space. Can be used with gauge guard.

Diaphragm T-Valve

Flow

Figure D-2. T-valve eliminates dead leg Dead legs in a system can be found in more than just branch lines. Often, the introduction of a gauge, measurement device, and /or sampling valve can create a dead leg. Since it is not recommended to tap into the side of a PVDF pipe for safety reasons, gauges are installed using tees and caps as shown in Figure D-3.

The insert of a resistivity probe can also be a possible source for dead legs. Since most probe manufacturers recommend that fluid flows directly at the probe, they are often situated in the leg of a tee and the tee acts as a 90° elbow. Since most probes are supplied as a 3/4" NPT fitting or sanitary adapter, there is the necessity to weld reducers onto the tee leg to accommodate the sensor, which will create dead zone. A simple fitting, the probe adapter, conveniently eliminates the need for reducers and shortens the leg of the tee. See Figure D-5. Probe adapters are available in all sizes and pressure ratings.

Tee

Flow

Flow

Female Adapter

Dead Zone

Probe

Tee Probe

Probe Adapter Fitting

Sanitary Adapter

Reducer

Figure D-5. Proper adapter setups Tee

Flow

Figure D-3. Dead leg due to improper instrument installation

D-4




APPLICATION AND SYSTEM DESIGN Flow Tube

Bluff Body

System Monitoring In the proper design of an ultra pure water system, it is important to monitor the quality of the water, temperature, pressure, and the flow rate. All devices should be picked on the following criteria: • Accuracy of indication • Repeatability • No moving parts • Clean • Devices in contact with the water should be thermoplastic • Ease of use In regard to monitoring flow, it is important to use devices that do not have moving parts to determine the flow rate. All thermoplastic construction is ideal to exactly match that of the pipe. An ideal flow measurement device is the vortex meter. A vortex meter from Asahi /America will provide accurate, repeatable flow without any moving parts. The features translate into the benefit of clean operating design and long lifetime. With no moving parts, no particles will be generated and there are no parts to wear out. In addition, vortex meters are simple to install and wire up. With all thermoplastic components, the device is unobtrusive to the process and provides years of reliable, clean operation.

Vortices

Figure D-7. The vortex principle

Other Considerations Ultraviolet All plastics react differently to UV exposure. Section C defines the effects on PVDF, PP, and E-CTFE materials. In addition to the external exposure of UV lights, it is also common for UV sterilizing lamps to be used to control bacteria levels in a water system. These lamps give off high intensity light to break up living bacteria in water. Depending on the wave length of the lamp, trace amounts of ozone can be generated from these lamps. The combination of the intense UV and ozone can create stress cracking in piping components directly in contact with the light source. To avoid a possible problem, build a light trap from stainless steel (SS) components. The use of SS diaphragm valves or a couple of changes in direction will eliminate the concern altogether. Figure D-8 illustrates an efficient light trap.

Stainless Steel Light Trap

PVDF UV Light Sterilizer PVDF

Stainless Steel Light Trap

Figure D-8. UV light trap

Ozone Figure D-6. Vortex meter Vortex meters operate on the vortex principal. A bluff in the flow body causes a slight pressure drop behind it as the flow passes by. The water turns inward into the pressure differential causing the formation of small eddies or whirlpools. The vortices, as they are called, alternate from one side to the other in direct proportion to the flow. The frequency is calculated to flow and is transmitted as a 4–20 mA signal or a digital pulse, depending on customer preference.


The use of ozone for system sterilization has proven itself as the preferred industry method. Dosing a PVDF or E-CTFE system with ozone for sterilization purposes is acceptable and does not damage the material. The exact concentration and period of ozonation should be verified with the pipe supplier. Using ozone in polypropylene systems is not recommended. Ozone has a tendency to breakdown PP at an alarming rate. For these systems an alternate chemical, such as hydrogen peroxide, should be used. The piping manufacturer should verify the peroxide concentration and period of exposure to the polypropylene system.


D-5

D



Hanging

Heater

See Section C for hanging details and proper placement distances. Since plastic reacts differently than metal, varying hanger styles are required. The designer of a system should specify the exact hanger and location and not leave this portion up to the installer.

Pipe

Pipe

Welding Methods Asahi /America offers several choices for joining PVDF and PP together. The choice of a particular method should be based on the following concerns: purity of the system installation, location, size range, and system complexity.

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While the welding method is instrumental in the purity of a water system, the choice of a welding method is not the final factor. The environment where welding occurs may be more important than the actual welding method. Asahi /America recommends the welding method be based on the type of installation, rather than the desire to have the most advanced equipment on site. PVDF can be installed using butt fusion, IR fusion, socket fusion, and beadless HPF fusion. All methods are proven in DI water systems, and each has its own advantages. Polypropylene is weldable using butt, IR or socket fusion. In addition, Asahi /America offers electro-fusion couplings for PP that are ideal for repairs. E-CTFE can be welded using butt or IR fusion. It is recommended to assemble Halar with IR fusion, as special heating elements are required for welding Halar with conventional butt-fusion equipment. Socket fusion is ideal for small, simple, low cost systems. In small diameters, 1/2"–11/4" socket fusion can be done quite easily with a hand-held welding plate and a few inserts. With just a limited amount of practice, an installer can make clean and reliable joints. For larger dimensions, up to a maximum of 4", bench style socket fusion equipment is available for keeping joints aligned. For systems that have larger dimensions above 4", butt and IR fusion make a logical choice. Both systems are available for welding all dimensions from 1/2" to 10". IR fusion has several advantages; during the welding process the material is not in contact with the heat source, thus eliminating a source of contamination. In the course of an IR weld, there is no force against the heating element like in butt fusion, therefore the weld beads are smaller when making an IR weld. In a flowing system, an IR bead will flush cleaner, due to its round, smoother shape as compared to a butt weld. See Figure D-9.

Start of Heating Molten End

Molten End

Heat Soak Time

Joining and Cooling

Figure D-9. IR fusion welding process IR fusion has become the standard welding choice within the semiconductor industry for the above reasons. IR fusion is neat, clean, and reliable. Current day welding equipment is computer controlled, making each weld identical, and inspection processes more reliable. IR fusion equipment also allows for complete traceability of each weld, by each operator. IR fusion is suited for cleanroom environments and bench top type welding. Equipment is highly sophisticated, making field or location welds difficult. Butt fusion is similar in practice to IR fusion; however the components to be welded are in contact with the heat source. Butt fusion is the parent of IR fusion and still maintains its one advantage; it can be done in a variety of environments. Wind or a strong breeze can make IR welding troublesome. In these cases butt fusion is preferred. If welds are made outside or in a windy area, butt fusion should be used. Field welds in place can also be accomplished with butt fusion. A variety of different types of butt-fusion equipment are available, making location welds possible, where an IR fusion would not be recommended. For a more detailed analysis of welding methods and equipment, refer to Section F, Installation Practices.

D-6



SINGLE WALL CHEMICAL PIPE


SINGLE WALL CHEMICAL PIPE SYSTEM DESIGN When properly designing a single wall pipe system for the transport of chemicals, several factors need to be reviewed. A properly designed thermoplastic system will provide years of reliable service without the headaches of corrosion problems. At the time of design, consider and plan for the following items: • Materials of Construction • Thermal Expansion • System Sizing • UV Considerations • Insulation • Hanging • Welding Methods

Materials of Construction The first and foremost item in any system design (metal or thermoplastic) is the media that will be running through the pipes and parameters of operation. Using accurate data for the system design will transfer to years of reliable operation. When considering the system design, answer the following questions: • What is the chemical(s) to be in contact with the system? • What are the chemical concentrations? • What temperature will the system operate at? • What pressure will the system operate at? • What is the flow of the media in the system? By answering these questions, the proper material of construction can be selected for the project. To assist in the material selection, refer to the chemical resistance tables in Section E, Chemical Resistance. A thermoplastic system’s ratings for temperature and pressure are based on water. The addition of certain chemicals will add stress to the system and may reduce the recommended operating parameters. For less aggressive chemicals, the use of printed resistance tables in Section E is perfectly suitable. For more aggressive chemicals or mixtures of chemicals, the manufacturer of the pipe system should be consulted. After verifying the standard operating conditions, it is necessary to examine other operations that might affect the piping. The following is a sample of items to investigate prior to specifying a material. • Will there be spikes in temperature or pressure? • Is there a cleaning operation that the piping will be exposed to? • If yes, what is the cleaning agent? What temperature will the cleaning be conducted at? • Will the system be exposed to sunlight or other sources of UV?


Each of the these questions should be answered and the desired material should be checked for suitability based on these factors, as well as any others that might be special to the system in question. Finally, in addition to verifying the temperature, pressure, and media with the thermoplastic pipe material, it is also necessary to verify other components in the system, such as valves, gaskets, valve seat and seals, etc. These should be examined in the same manner as the pipe material.

Thermal Expansion Based on your operating criteria, thermal expansion must be considered. For systems maintained at consistent temperatures, compensation for thermal effects may not be required. It is, however, important to review all aspects such as the operating environment. Is it outdoors where it will be exposed to changing weather? Is the system spiked with a high temperature cleaning solution? Will the system run at a significantly higher temperature than the installation temperature? The occurrence of any thermal change in a plastic system will cause the material to expand or contract. As an example of the effect, polypropylene will grow roughly one inch for every 100 linear feet and 10 ∆T. Thermoplastic systems can be used in hot applications and applications where the temperature is cyclical; it just requires analysis of the thermal expansion effects. Section C walks through the steps of calculating thermal expansion, end loads, and expansion compensating devices. In most cases, the use of expansions, offsets, and proper hanging techniques are all that is required to ensure a proper design. Hot systems also reduce the rigidity of thermoplastic piping, which, in turn, decreases the support spacing between pipe hangers. In smaller dimensions, it is recommended to use continuous support made of some type channel or split plastic pipe. Finally, the use of hangers as guides and anchors becomes important. As the design procedures in Section C indicates, certain hangers should be used as guides to allow the pipe to move back and forth in-line, while other hangers should be anchoring locations used to direct the expansion into the compensating device. The anchors and hangers should be designed to withstand the end load generated by the thermal expansion. Figure D-10 is an example of an anchor type restraint fitting that is available from Asahi /America, Inc.


D-7

D

APPLICATION AND SYSTEM DESIGN Place Clamp Here Butt End

Figure D-10. Restraint fitting

D

For calculation of allowed stresses and design of expansion compensation devices, refer to Section C, Engineering Theory and Design Considerations.

Insulation Insulation is a good method of protecting a pipe system from UV exposure, as well as providing required insulation for the system or media being transported. A serious difference between plastic and metal is plastic’s thermal properties. A metal pipe system will quickly take the temperature of the media being transported. A system carrying a media at 150° F will have an outer wall temperature close to or at 150° F. In contrast, thermoplastics have an inherent insulating property that maintains heat inside the pipe better than a metal system. The advantage is that a plastic pipe has better thermal properties, which translates into improved operating efficiencies and reduced insulation thickness.

Hanging

System Sizing In Section C, there is a detailed discussion on fluid dynamics and determination of flow rates and pressure drops. When using any thermoplastic with a hazardous chemical, it is recommended to maintain flow rates below a velocity of 5 ft/second. High velocities can lead to water hammer in the event of an air pocket in the system. Water hammer can generate excessive pressures that can damage a system. For safety reasons, high velocities should be avoided. In addition, high velocities also mean added pressure drop, which, in turn, increases demand on the pump. If the flow velocity is not required, it is recommended to size a system with minimal pressure drop. It is also recommended to oversize a design to allow for future expansion or chemical demand. Once a system is in place, it is difficult to add capacity to it.

UV Considerations All thermoplastic materials react to the exposure of UV differently. PVDF and E-CTFE materials are almost completely UV resistant over the course of its design life. However, certain chemicals containing Cl anions exposed to UV light can create a free radical Cl, which will attack the PVDF pipe wall. For more information on these chemicals, refer to UV Exposure and Weatherability later in this section. Polypropylene is not UV stable. In direct exposure to sunlight it will break down. The effect can be seen in a noticeable color change in the pipe. In a pigmented PP system, the color change will actually create a protective shield on the outer layer of the pipe and prevent further degradation. For PP pipes with a wall thickness greater than 0.25", the effect of UV is reduced and can be used outside. However, it is still recommended to protect it from UV exposure for added safety. Natural PP will not self create a UV shield as the pigment PP does; therefore, UV protection is required all the time on natural PP systems. Other materials, such as HDPE, may or may not be UV stabilized. PE containing carbon black are generally UV stable and can handle direct exposure. Other HDPE materials may require protection. Use of protection should be based on the individual grade of the polyethylene. Consult the manufacturer for details.

D-8


See Section C for hanging details and proper placement distances. Since plastic reacts differently than metal, varying hanger styles are required. The designer of a system should specify the exact hanger and location and not leave this portion up to the installer.

Welding Methods The system designer should specify the welding method to be used in any given project. Asahi/America offers several choices for joining PVDF and PP together. The choice of a particular method should be based on the following concerns: • Installation location • Size range • System complexity PVDF can be installed using butt fusion, IR fusion, socket fusion, and beadless HPF fusion. All methods are proven in chemical systems and each has its own advantages. Polypropylene is weldable using butt, IR, or socket fusion. In addition, Asahi /America offers electro-fusion couplings for PP that are ideal for repairs. (Electro-fusion PP couplings may have reduced chemical resistance. Consult factory.) E-CTFE can be welded using butt or IR fusion. It is recommended to assemble Halar with IR fusion, as special heating elements are required for welding Halar with conventional butt-fusion equipment. Socket fusion is ideal for small, simple, low cost systems. In small diameters, 1/2"–11/4" socket fusion can be done quite easily with a hand-held welding plate and a few inserts. With just a limited amount of practice, an installer can make safe and reliable joints. For larger dimensions, up to a maximum of 4", bench style socket fusion equipment is available for keeping joints aligned. For systems that have larger dimensions above 4", butt and IR fusion make a logical choice. Butt fusion is available in every pipe size made available by Asahi /America. Welding can take place in a variety of climates and conditions. In addition, butt fusion offers the widest variety of welding equipment options. Tools are available for bench welding, trench welding, and





welding in the rack, making it completely versatile for almost all applications. Refer to Section F for guidance in tool selection. IR fusion is available for welding 1/2" to 10". IR is an extension of the butt-fusion method. The operation is the same with the exception that material being joined is not in contact with the heat source. Rather, the material is brought in close to the heating element and the heat radiates off to the components. The advantage of this method for chemical systems is the elimination of molten material sticking to the heat source. IR fusion is better suited for indoor applications. IR fusion equipment is highly sophisticated, providing the operator with detailed information on the weld process and quality. For critical applications with dangerous media, IR fusion may be best suited due to the quality assurance built into each piece of equipment.

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For a more detailed analysis of welding methods and equipment, refer to Section F, Installation Practices.



D-9


D

DOUBLE WALL SYSTEM DESIGN


When to Use Double Containment Piping

Double containment piping systems are one of the most economical and reliable methods for protecting against primary piping leaks of corrosive or hazardous fluids. The Duo-Pro and Fluid-Lok systems offered by Asahi /America are the original and flagship products of the industry. When designed and applied correctly, the system can be expected to have a long service life often exceeding 50 years. Double contained systems constructed from thermoplastic materials offer significant cost savings and superior chemical resistance over their metal counterparts. A combination of government regulations, increased concern over environmental and personal safety, and a growing fear of litigation has hastened the development and improvement of double contained piping components into highly engineered systems. With over 15 years of experience in thermoplastic double containment piping, no other company can match Asahi /America’s experience and quality.

Underground EPA Requirements The U.S. Environmental Protection Agency (EPA) has adopted regulations on underground storage tanks (USTs) and related piping. The EPA states these systems pose threats to the environment. EPA regulation 40 CFR 280 spells out the minimum requirements for USTs that contain petroleum or hazardous chemicals. A summary of the EPA’s requirements that affect doublecontainment piping follows. This is a brief overview. A project engineer needs a thorough understanding of the regulations prior to designing a system. EPA’s Regulations Cover Media: All chemicals listed under Subtitle 1 of 40 CFR 280.

Use this guide to assist in the design and layout of a double wall pipe system for multiple applications. This guide highlights the areas of consideration that an engineer should take when designing a system. This section should be used in conjunction with Section C, Engineering Theory and Design Considerations, to achieve a proper design. Cost, reliability, and ease of installation can all be improved by careful planning in the conceptual and design phase of any piping project. Specific to double containment systems, the following items must be given careful consideration: • When to Use Double Containment Piping • Materials of Construction • System Selection • System Sizing • Specialty Fittings • Double Contained Valves • Thermal Expansion (particularly important in thermoplastic systems) • Hanging • Burial • Welding Methods • UV Exposure and Weatherability Leak detection is an important part of double containment systems. Leak detection of some sort is required on all underground double containment systems. The type of leak detection, the installation method, and the system set up are very different from system to system. For this reason, leak detection will be discussed in the next section separately.

D-10

Systems: All USTs and related piping. System requirements: All USTs and pipes must be installed so that a release from the product pipe is contained or diverted to a proper collection system. Containment may be done via a trench, dike, or double containment pipe and tanks. The containment materials must be able to hold the leaking product for a minimum of 30 days. By then, scheduled inspections and periodic monitoring should identify the failure and correct the situation. Leak detection: Drainage and suction lines require monthly manual inspections for product line leaks. Pressurized systems require automatic monitoring for product failure. In case of a leak, the system must automatically restrict flow of the product. Compliance dates: The EPA has set requirements for the date of compliance for both new and existing systems. Contact Asahi /America for the latest standard, or visit the EPA’s website at www.epa.org. Above ground: In addition to the EPA requirements for below grade systems, many companies have adopted policies for overhead piping to protect personnel from a possible leak of a harmful chemical.

Materials of Construction The majority of double containment systems installed worldwide are thermoplastic due to the ease of joining and chemical resistance to hazardous media, as well as underground moisture. Asahi /America offers several materials to handle a wide range of applications. Materials include: • • • •

Polypropylene PVDF E-CTFE: Halar® HDPE: High Density Polyethylene





The carrier pipe (the inner pipe also known as the product pipe) material is selected based on common piping practices using variables such as: • What is the chemical(s) to be in contact with the system? • What are the chemical(s) concentrations? • What temperature will the system operate at? • What pressure will the system operate at? • What is the flow of the media in the system? By answering these questions, the proper materials of construction for the carrier can be selected for the project. To assist in the material selection, refer to the chemical resistance table in Section E, Chemical Resistance. A thermoplastic system's ratings for temperature and pressure are based on water. The addition of certain chemicals will add stress to the system and may reduce the recommended operating parameters. For less aggressive chemicals, the use of printed resistance tables is perfectly suitable. For more aggressive chemicals or mixtures of chemicals, the manufacturer of the pipe system should be consulted. After verifying the standard operating conditions, it is necessary to examine other operations that might affect the piping. The following is a sample of items to investigate prior to specifying a material. • Will there be spikes in temperature or pressure? • Is there a cleaning operation that the piping will be exposed to? • If yes, what is the cleaning agent? What temperature will the cleaning be conducted at? • Will the system be exposed to sunlight or other sources of UV? Each of the above questions should be answered and the desired material should be checked for suitability based on the above factors, as well as any others that might be special to the system in question. Finally, in addition to verifying the temperature, pressure, and media with the thermoplastic pipe material, it is also necessary to verify other components in the system, such as valves, gaskets, valve seat and seals, etc. These should be examined in the same manner as the pipe material. Once the product pipe has been selected, the containment pipe must be selected. In most cases, the containment pipe is the same as the carrier pipe, such as in polypropylene and HDPE systems. Using the same material internally and externally yields many time-saving advantages on a project. However, in many systems where the product pipe required is a more expensive material, such as PVDF or E-CTFE, a polypropylene outer shell is often used. Sizing the containment pipe requires consideration of many factors that are different than those used to size the carrier.


These include: • Static and live burial loading • Leak detection requirements • Hanging requirements for above-ground applications • Physical space constraints • Manufacturability and availability • Operating pressure When a double contained system is buried, the containment pipe bears the static soil load and the dynamic loading imposed by traffic, equipment, etc. Section C provides a detailed discussion for calculating static and dynamic loading to determine required wall thickness. Leak detection requirements must also be considered. Depending on the type of leak detection chosen, there may be minimum requirements for the amount of annular space necessary for successful installation and operation. As a general rule of thumb, a minimum of 3/4 inches annular space is required for installation of a continuous cable system. Leak detection options are discussed in detail later in this section. Hanging requirements and physical space constraints are also important considerations. Often, trenches or pipe racks are crowded with other systems, so the containment must not be too large. Hanging criteria including support, restraint, and guide spacing are discussed in Section C. The designer of a system should specify the exact hanger location and not leave this portion up to the installer. Manufacturability and availability can also influence the selection of containment pipe. There must be adequate clearance between the carrier and containment to facilitate efficient manufacturing. This is especially important for the manufacture of fittings. Asahi /America has spent several years improving fabrication techniques to offer the widest variety of sizes in the marketplace. The designer should also be careful to design with standard pipe sizes to avoid costly delays due to lack of availability. Operating pressure parameters may be quite different for the containment pipe than for the carrier. Often, systems are designed so that any leaks into the annular space drain directly into a manhole or sump. In these open-ended systems, it is virtually impossible to build up significant pressure. As a matter of economy, the containment pipe often has a lower pressure rating and thus a higher dimensional ratio than the carrier pipe. The final consideration when choosing the containment pipe is the environment in which it will be installed. Outer UV exposure is not ideal for polypropylene systems and protection of the pipe may be required. If surrounding temperatures are extremely low, then certain materials will become brittle in the cold. Consult Asahi /America for specific recommendations in these cases.


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System Selection As stated in the previous section, the material must be selected based on the media to run through the system, as well as the operating conditions such as pressure, temperature, and media concentration. In a double containment system, the selection of pipe and associate pipe pressure ratings can be complex, as any combination of material can be used. Table D-1 lists possible pipe ratings that can be used for both the inner and outer pipe wall. Table D-1. Pressure Ratings and SDR Values

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System Name PRO 150 PRO 90* PRO 45 PVDF 230 PVDF 150 HDPE 150 HDPE 90 HDPE 45 Halar®

Material** Polypropylene Polypropylene Polypropylene PVDF PVDF High Density PP High Density PP High Density PP E-CTFE

Pressure Rating (psi)

Standard Dimensional Ratio

150 90 45 230 150 150 90 45 Non-Standard

SDR 11 SDR 17 SDR 33 SDR 21 SDR 11 SDR 11 SDR 17 SDR 33

Molded

Fabricated

Spider Clip

Figure D-11. Support discs and spider clip fittings Per the EPA’s requirements, any double contained system needs to have leak detection. The methods of leak detection include manual inspection, low point sensors, and continuous leak detection cable. Leak detection cable is installed in between the annular space between the inner and outer pipe. Duo-Pro is designed to provide sufficient space for the installation of leak detection cable. Contact Asahi /America technical staff for an exact recommendation.

* Available, but less common. ** Not all materials are available in every diameter size.

In addition to all the choices in material, Asahi /America offers three systems for double containment piping. • Duo-Pro • Poly-Flo • Fluid-Lok Each system has its ideal purposes and advantages. A description of the three systems follows. Figure D-12. Duo-Pro piping system

Duo-Pro The Duo-Pro system is the flagship of the Asahi /America double containment piping system offerings. Duo-Pro is available in polypropylene, PVDF, and E-CTFE, and in any combination of the three. Duo-Pro is available in systems ranging from 1"x 3" to 18"x 24". In addition, larger systems have been made available on request. Duo-Pro is a fabricated system made from extruded pipe and primarily molded fittings. It has a complete range of molded pressure fittings that are fabricated at the factory into double containment fittings. In addition, Duo-Pro is ideal for drainage applications, having a complete compliment of fittings for drainage applications. It can be assembled using simultaneous butt fusion or staggered butt fusion. The Duo-Pro system is assembled using a support disc on each end of a pipe or fitting. The support disc centers the carrier inside the containment and locks the two pipes together for simultaneous fusion. On pipe runs, the spider clip fitting is used to support the pipe inside the containment piping. Spider clips are spaced based on hanging criteria by size and material and are designed to avoid point loading of the pipes.

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Poly-Flo The Poly-Flo system is a unique dual extruded and molded system. In all other double containment pipe systems, the inner and outer components are made separately and then assembled into a double wall configuration. This adds time and labor to each project. The Poly-Flo system produces both the inner and outer piping at the same time. Asahi /America’s patented extrusion process locks the pipe together by use of continuous support ribs. In addition, most fittings in the system are molded as one piece components. The only deviation is HDPE material, where many fittings are fabricated from double wall pipe. Poly-Flo is available in 1"x 2", 2"x 3", and 4"x 6". (Consult Asahi /America for the availability of 6"x 8".) Poly-Flo is available in three materials: black polypropylene (UV stabilized), PVDF, and HDPE. It is a unique system, where the carrier pipe has an OD consistent with IPS pipe, while the outer pipe is a jacket not corresponding to an IPS dimension. Poly-Flo is assembled using simultaneous butt fusion only. The system is available with manual and low point leak detection sensors only. The use of leak detection cable is not possible due to the limited annular space.




APPLICATION AND SYSTEM DESIGN Question/Answer Q: Are you operating under pressure or drainage? A:

Pressure systems may need to have consistent pressure rating fittings on both the carrier and containment pipe. DWV fittings are not allowed in pressure systems.

Q: Do you require consistent pressure ratings on the carrier and containment? A:

If not, cost can be saved by using 150 psi carrier piping and 45 psi containment piping.

Q: What material are you using? A:

Material requirements may determine the system you can choose.

Q:

Do you require continuous cable leak detection?

A:

Only the Duo-Pro and Fluid-Lok systems can accommodate cable systems.

Figure D-13. Poly-Flo piping system

Fluid-Lok The Fluid-Lok system is an all HDPE system. It is manufactured in a similar process to the Duo-Pro system. Fluid-Lok is available in many sizes ranging from 1"x 3" to systems as large as 36"x 42". Besides being an all HDPE system, Fluid-Lok is different than Duo-Pro in that most fittings are fabricated and not molded. Fabricated fittings are ideal for the application of long sweep 90's and 45's, often required in these systems. Fluid-Lok is designed to accommodate leak detection low point sensors or cable. In addition, HDPE manholes are available and can be directly welded to the pipe system to avoid unnecessary fittings and provide more consistency and leak protection.

Based on knowing the operating parameters and the desired material, one of the following systems can be chosen for the installations. Table D-2. Double Containment Systems Product Name PRO 150 x 150 PRO 150 x 45 PRO 45 x 45 PVDF x Pro 150 PVDF x Pro 45 PVDF x PVDF Poly-Flo BPP Poly-Flo PVDF* Poly-Flo HDPE HDPE SDR 21x21 HDPE SDR 17x17 HDPE SDR 17x33 HDPE SDR 33x33

System Name**

Material

Size Range (inches)

Duo-Pro Duo-Pro Duo-Pro Duo-Pro Duo-Pro Duo-Pro Poly-Flo Poly-Flo Poly-Flo Fluid-Lok Fluid-Lok Fluid-Lok Fluid-Lok

Polypropylene Polypropylene Polypropylene PVDF x Polypro PVDF x Polypro PVDF x PVDF Black Polypropylene PVDF HDPE HDPE HDPE HDPE HDPE

1 x 3 to 16 x 20 2 x 4 to 18 x 24 4 x 8 to 18 x 24 1 x 3 to 12 x 16 2 x 4 to 12 x 16 1 x 3 to 8 x 12 1 x 2, 2 x 3, 4 x 6 1 x 2, 2 x 3 1 x 2, 2 x 3, 4 x 6 1 x 3 to 16 x 20 3 x 6 to 18 x 24 3 x 6 to 18 x 24 3 x 6 to 18 x 24

* Consult factory for availability. ** Fluid-Lok is available in other SD ratios, as well as larger dimensions.

System Sizing

Figure D-14. Fluid-Lok piping system The availability of many materials and three piping systems creates many choices. Each system is designed for specific applications and assembly techniques. To assist in the proper selection of the system, answer the following questions.


In Section C, Engineering Theory and Design Considerations, there is a detailed discussion on fluid dynamics and determination of flow rates and pressure drops. It is recommended when using any thermoplastic with a hazardous chemical to maintain flow rates below a velocity of 5 ft /second. High velocities can lead to water hammer in the event of an air pocket in the system. Water hammer can generate excessive pressures that can damage a system. For safety reasons, high velocities should be avoided. In addition, high velocities also mean added pressure drop, which, in turn, increases demand on the pump. If the flow velocity is not required, it is recommended to size a system with


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APPLICATION AND SYSTEM DESIGN minimal pressure drop. It is also recommended to oversize a design to allow for future expansion or chemical demand. Once a system is in place, it is difficult to add capacity to it.

Dogbone fittings are available in the Duo-Pro and Fluid-Lok system. The Poly-Flo system does not require the fitting, as the pipe is continuously supported and locked together.

Specialty Fittings

Finally, the Dogbone can be used for connecting in low point leak detectors, ventilation, and drainage. When designing a double wall system, it is important to incorporate high point vents to eliminate air from the system. In addition, in the event of a leak, a drainage method for the containment pipe is required. Connection methods for these valve requirements are shown in Figures D-17 through D-20.

Double containment systems, for the most part, can be thought of in the same manner as single wall piping systems with a few exceptions. In a double wall system, the issue of thermal expansion is more complicated (see next page), welding is similar but not the same, and finally, the outer containment pipe must have a start and stop.

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The major fitting that sets Asahi /America systems apart from all other double wall systems is the patented Dogbone force transfer fitting. The Dogbone fitting can be used in many ways to assist in the design of a proper double containment piping system. The Dogbone is used for: • Locking the inner and outer pipes together • Compartmentalizing pipe section • Termination of the containment pipe • Sensor installation • Control of thermal expansion

Dogbone

Figure D-17. Ventilation of inner pipe: Duo-Pro and Fluid-Lok Dogbone

Figures D-15 through D-18 depict a few uses of the Dogbone.

Dogbone

Figure D-15. Outer containment termination

Figure D-18. Drainage of containment pipe: Duo-Pro and Fluid-Lok

Dogbone Ball Valve

Outer Wall Reducer (if necessary)

Socket Adapter

Figure D-16. Locking inner and outer pipes Dogbones are available in solid and annular forms. A solid Dogbone does not allow the passage of fluid in the annular space to pass through, while annular Dogbones will allow the passage. The placement and purpose of the fitting will determine the style required. Figure D-19. Ventilation of inner pipe: Poly-Flo system

D-14




APPLICATION AND SYSTEM DESIGN Removable Cover Dogbone Seal Optional (2 sides)

Outer Wall Adapter Outer Wall Reducer (if necessary) Containment Box

1" x 2" Outer Wall Flange

1" x 2" Outer Wall O Ring Flange

Figure D-22. Double contained ball valve without stem extension: Poly-Flo system

N/C Valve

N/C Valve

Water Inlet (for rinse-out)

Drainage Outlet

Signal Wires to Control System

Float Switch Adapter

Dogbone Seal Optional (2 sides)

Removable Cover

Float Switch

Figure D-20. Drainage of containment pipe: Poly-Flo system with low point sensor

Double Contained Valves

Containment Box

In pressurized systems, the necessity of valves can be accomplished without interrupting the integrity of the double containment system. Double contained valves are available in many shapes and forms. Double contained valves are available in any style valve such as ball, butterfly, diaphragm, check, and gate. The valve selected, based on the application, determines the shape of the outer containment. The following figures demonstrate a few valve configurations that are available from Asahi /America, Inc. Other options are readily available on request.

Figure D-23. Double contained diaphragm valve with stem extension: Poly-Flo system More than valves can be installed. Items such as flow meters, and temperature and pressure monitors can also be incorporated into the internal containment portion of the system. Contact Asahi /America’s Engineering Department to discuss your particular needs. It is important to specify and design in the need to access valves for maintenance purposes.

Thermal Expansion

Dogbone Seal Optional (2 sides)

Figure D-21. Double contained ball valve with stem extension: Duo-Pro system

Based on your operating criteria, thermal expansion must be considered. For systems maintained at consistent temperatures, compensation for thermal effects may not be required. In a double contained piping system, three types of expansion can occur: • Carrier pipe exposed to thermal changes, while containment remains constant. Typically possible when carrier pipe is exposed to liquids of various temperature, while outer containment is in a constant environment such as in buried applications. • Containment piping experiences thermal changes, while carrier remains constant. Typical application is outdoor pipe racking with constant temperature media being transported in carrier. • Both inner and outer experience temperature changes. The Dogbone fitting is a proven and effective way to control thermal expansion where a restrained system is acceptable. It can also be used to direct the growth of a flexible system. For systems maintained at consistent temperatures, compensation for thermal effects may not be required. It is, however, impor-



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APPLICATION AND SYSTEM DESIGN tant to review all aspects of the operating environment such as: • Is it outdoors where it will be exposed to changing weather? • Is the system spiked with a high temperature cleaning solution? • Will the system run at a significantly higher or lower temperature than the installation temperature? The occurrence of any thermal change in a plastic system will cause the material to expand or contract.

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Thermoplastic systems can be used in hot applications and applications where the temperature is cyclical; it just requires analysis of the thermal expansion effects. Section C, Engineering Theory and Design Considerations, walks through the steps of calculating thermal expansion, end loads, and expansion compensating devices. In most cases, the use of expansions, offsets, and proper hanging techniques are all that is required to ensure a proper design. Hot systems also reduce the rigidity of thermoplastic piping, which, in turn, decreases the support spacing between hangers. In smaller dimensions, it is recommended to use continuous supports made of some type of channel or split plastic pipe. Finally, the use of hangers as guides and anchors becomes important. As the design procedures in Section C indicates, certain hangers should be used as guides to allow the pipe to move in-line, while other hangers should be anchoring locations used to direct the expansion into the compensating device. The anchors and hangers should be designed to withstand the thermal end load. In a buried system, the standard Dogbone fitting will lock the inner and outer pipe together. The surrounding ground and fill should eliminate the movement of the outer pipe. In systems that are hung, the outer pipe hanger must withstand the thermal end load. To properly hang these systems, a special Restraint Dogbone is recommended at the hanger locations.

Non-Restraint

Restraint

Figure D-24. Dogbones For calculation of allowed stresses and design of expansion compensation devices, refer to Section C, Engineering Theory and Design Considerations.

D-16


Hanging See Appendix A for proper hanging distances by size and material. As in any thermoplastic system, the selection of hangers is an important decision. Hangers that scratch or create point loads on the pipe are not recommended. The ideal hanger is a thermoplastic component. In many cases an all plastic hanger may not be available. In these cases a metal hanger is acceptable, but precautions should be taken. Any sharp edges on the hanger should be removed. A cushion made of rubber is recommended in the event that the pipe shifts, thus preventing scratching. Section C provides detailed recommendations on hanging double containment pipe. Please consult this section prior to specifying the hangers.

Burial Due to EPA requirements, burial of double containment piping is a common practice. In most cases, the burial of double wall pipe is the same as that of a single wall pipe system. Careful consideration of the soil type, compaction, trench detailing, back fill, load, etc. are necessary to consider in the proper design. Section C, Engineering Theory and Design Considerations, provides a step-by-step detailed process of how to properly bury the system. Live loads also pose the added complication when burying a system. It is important to look at the possibility of the pipe system being driven over, as well as the type of vehicle that would be creating the live load. In the design it is imperative to call out the recommendations of the burial in the details of the drawing set. By calling these details out, the contractor will be in a better position to properly install the pipe as required.

Welding Methods All double containment systems offered by Asahi /America, Inc. are available for butt-fusion assembly. Butt fusion provides reliable fusion, but is also ideally suited for the double wall system. By properly aligning the carrier and containment piping with the support disc, both the inner and outer pipe can be welded at the same time. This reduces the assembly time, as well as the need for extra fittings such as couplings. What can be accomplished in one weld can take up to 4 welds in other systems (weld the inner and outer separately on either side of a coupling). When building a system that is made of dissimilar materials (example: PVDF x Pro 45), the pipes cannot be welded simultaneously due to different heat and joining force requirements. For these systems staggered welding is required, where the inner pipe is welded first and the outer pipe welded second using a special annular heating element. Staggered fusion does take more time due to the extra welds, but still proves econom-





ical when compared to using like materials such as PVDF on both the carrier and containment pipe depending on pipe size, project requirements, and installation environment. See Section F, Installation Practices, for detailed information on double containment welding methods.

UV Exposure and Weatherability All thermoplastic materials react to the exposure of UV differently. PVDF and E-CTFE materials are completely UV resistant over the course of its design life. However, certain chemicals containing Cl anions exposed to UV light can create a free radical Cl that will attack the PVDF pipe wall. For more information on these chemicals, refer to Section F, Good Installation Practices, on weatherability and UV exposure of the piping.

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Polypropylene is not UV stable. In direct exposure to sunlight it will break down. The effect can be seen in a noticeable color change in the pipe. In pigmented PP systems, the color change will actually create a protective shield on the outer layer of the pipe and prevent further degradation. For PP pipes with a wall thickness greater than 0.25", the effect of UV is normally reduced and can be used outside. However, it is still recommended to protect it from UV exposure for added safety. The Fluid-Lok HDPE material is UV stabilized. Fluid-Lok pipes contain carbon black to make the material UV stable and acceptable for use in outside applications. Other HDPE materials made by other manufacturers may require protection. Be sure to consult a manufacturer prior to selecting a pipe system.



D-17

APPLICATION AND SYSTEM DESIGN LEAK DETECTION DESIGN In all buried applications of double containment piping, the EPA (40 CFR 280) has set a requirement for leak detection. Drainage and suction lines require monthly manual inspections for product line leaks. Pressurized systems require automatic monitoring for product failure. In case of a leak, the system must automatically restrict the flow of the product.

D

LEAK DETECTION DESIGN

also require a valve for drainage. When using low point sensors in below grade applications, it is important that special considerations in the excavation are taken to ensure that sensors are not damaged during installation or during back fill. Figures D-25 through D-28 depict a few assemblies for mounting low point sensors into the annular space of a double contained pipe system.

Asahi/America’s systems are designed to accommodate many different technologies for detecting a leak. The following methods are acceptable: • Low point leak detection sensors • Continuous leak detection cable systems • Visual inspection (only acceptable on drainage systems) The selection of the leak detection system will play a critical role in the layout of the piping system. For instance, if a cable method is used, it will require additional fittings called access ports for pulling the cable. Pipe and fittings will need to be ordered with pull ropes installed at the factory. And finally, the placement of the cable will need to be factored in. In some installations only the main trunk line will have cable; while in others, the cable will split and run up each of the branch lines. This guide has been created to assist in the pipe layout and design of a leak detection system. Each type of system is discussed below in regard to its use in an Asahi /America double containment piping system.

Outer Wall Adapter Outer Wall Reducer (if necessary)

1" x 2" Outer Wall Flange

1" x 2" Outer Wall O Ring Flange N/C Valve

N/C Valve

Water Inlet (for rinse-out)

Drainage Outlet

Signal Wires to Control System

Float Switch Adapter Float Switch

Figure D-25. Drain and low point Poly-Flo system Dogbone

Low Point Leak Detection Sensors Low point leak detection sensors can be used in any of Asahi /America’s double wall systems. • Poly-Flo • Duo-Pro • Fluid-Lok For the Poly-Flo system, low point sensors are the only automatic system available. Low point leak detection is relatively straightforward in terms of design. The sensing technology consists of either capacitive or float type switches. These switches are placed in strategic locations throughout a system to properly identify leaks and then determine their location within a reasonable length of pipe. If an insufficient amount of sensors are used and a leak occurs, determining the location of that leak can be extremely difficult, especially if the piping is buried. It is always more practical to use a few more sensors at the time of installation, as it could be a huge cost savings in the long run in the event of a system leak. Mounting of the Sensor Asahi /America pipe systems can accommodate mounting sensors in a variety of different methods. In some cases, it is ideal to place the sensor with as tight a profile to the pipe as possible; in other instances, a low point leak sensor installation may

D-18

Low Point Sensor

Figure D-26. Simple connection, Duo-Pro/Fluid-Lok systems Dogbone

Valve Low Point Sensor

Figure D-27. Connection with drain valve, Duo-Pro/ Fluid-Lok systems





Using the Dogbone fitting, sections of the annular space can be made into individual compartments. In the case of a leak, the fluid will pass into the annular space, but will be locked into a compartment and not allowed to spread throughout the system. This method has two advantages: one helps to identify leak locations, the other reduces the need to dry out a large section of the annular space once the leak is found and repaired.

Dogbone

Figure D-30 demonstrates the use of solid Dogbones to create compartments. Primary Tank

Dogbone

Section with Leak

Secondary Containment Tank

Low Point Sensor

Dogbone

Low Point Sensor

Figure D-30. Leak detection compartments

Figure D-28. End-of-line connection option, Duo-Pro/ Fluid-Lok systems

Continuous Cable Leak Detection Systems

Location of the Sensors The location of sensors should be based on finding the leak with relatively no confusion. By placing the sensors on the branch of tees or lateral (wye) type connections, the line causing the leak is identified. In addition, placing the sensor every 100 to 150 feet also reduces the area that would be in question if a leak was to occur. Figure D-29 shows an example of a system and the ideal locations for the low point sensors.

Continuous cable leak detection systems offer the best method for locating a leak in the annular space of a double containment pipe system. A cable system can generally pinpoint the location of the leak with an accuracy of ±0.5 feet. It can also incorporate low point probes to offer maximum flexibility to the designer. Entire systems can be mapped out, installed, and fed back to an easy to understand operating panel. Most large systems use leak detection cable as the preferred method for monitoring the system. All pressure double wall pipe systems are required to have automated leak detection in below grade applications. In these cases, cable is the recommended method.

Sensor 1

The discussion of leak detection cable is broken down into two topics: the pipe layout requirements and the electrical cable layout requirements.

Sensor 2

Pipe Layout Requirements (Annular Space) Sensor 4

Sensor 3

Figure D-29. Sample locations for low point sensors

Compartmentalizing the System The practice of compartmentalizing the outer containment pipe is in conjunction with strategic placement of sensors. If a major leak were to occur, it is possible that more than one sensor could be tripped in a short time frame. If you have no way of knowing which sensor tripped first, then the value of multiple sensors is lost.


Leak detection cable can be used in the following Asahi /America systems: • Duo-Pro • Fluid-Lok Unfortunately due to the narrow annular space in a Poly-Flo system, the cable cannot be pulled through the system, eliminating its use. Continuous cable systems require a minimum of 0.75" of annular space to pull cable through easily. In Duo-Pro and Fluid-Lok systems, certain pipe configurations can have small annular space making the cable pull difficult or impossible. For instance, 1 x 3 Pro 150 x 150 Duo-Pro systems have a 0.813 space all around. After accounting for the weld bead, the


D-19

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space will be lower than 0.75". For this application, 1 x 4 Pro 150 x 150 or 1 x 4 Pro 150 x 45 should be considered to ease the installation. Consult Appendix A for the available annular space on Duo-Pro systems. For Fluid-Lok systems, consult Asahi /America’s Engineering Department. To clarify once again, for ease of installation the annular space needs to be a minimum of 3/4" to accommodate easy cable pulls.

Height can be variable depending on burial depth

Figure D-32. Access tee with threaded cover

Pipe

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There are no special requirements for pipe. Both the Duo-Pro and Fluid-Lok systems are designed to accommodate cable leak detection. Support discs on the ends of pipe and fittings provide a wide opening on the bottom of the pipe, as well as either cut outs or vent holes in other sections, depending on the pipe size. On pipe runs, the carrier pipe is supported by use of spider clips, which support the carrier pipe without blocking the bottom of the annular space. Fabricated

Molded

Figure D-31. Two typical end of pipe support discs to accommodate leak detection There are only two important items to keep in mind. When ordering pipe, ensure that pull rope is ordered to be installed on the pipe. The second is during installation. It is critical to align pipe and fittings properly to ensure that support disc openings are located on the bottom. Forgetting this can lead to significant difficulty when trying to pull cable into the system. Access Points Asahi /America offers a standard fitting for accessing the annular space known as the Access Tee or Pull Port Tee. While it can be common practice in HDPE systems to cut windows into the pipe to access the rope or cable, and then weld a saddle on afterwards, this is not an acceptable design. While it is possible to cut windows, this should only be used when the rope or cable is caught in the line and no other alternative is available. Access tees are supplied with a low pressure thread on cap, or for full pressure rating on the outer wall pipe, a flange and blind flange configuration is available.

D-20

Figure D-33. Access tee with flanged cover Access tees are supplied in two pieces, allowing the installer to weld the proper pipe height to the tee base to come up to grade. Once the selection of the access tee style is determined, then the strategic location of the pull ports is required. In general, pull ports should be located at no more than 500-foot intervals on straight runs. Each 90° change in direction is approximately equal to 150 feet of straight run. Pull ports should be installed to avoid binding the pull rope. Access tees should also be placed at the beginning and the end of branch locations requiring cables. For tie-ins to the main cable, it is best to place the access tee on the main run in front of the branch location. Figure D-34 shows a small schematic on a drainage system and the proper location of the access port.

Pull Port

Pull Port

Pull Port

Pull Port

Pull Port

Figure D-34. Pull port locations for leak detection cable





Dogbones in a Cable System In a double containment system, the Dogbone fitting is used to lock the inner pipe together for proper restraint or for the control of thermal expansion. Unlike low point systems, creating compartments in the system is not practical. If Dogbone fittings are required in the system, the use of the annular style is required to allow cable to pass through.

capable of monitoring several systems simultaneously. Care must also be taken to specify a panel that is capable of monitoring the required length of sensor cable. The control panel should have a visual readout of some sort, as well as a keypad for operation. It should also provide provisions to interface with a computer to use diagnostic and programming tools that are available. Panel

Dogbone

20 Feet (at end) 50 Feet (at beginning)

Annular Openning Cable

Containment Pipe

D Figure D-35. Annular Dogbone with cable

Sensor Cable Requirements

Access Port

Sensor Cable Proper selection of the sensor cable is imperative to the successful operation of any leak detection system. Most systems use a specially designed coaxial cable for sensing leaks. Some cables are designed to sense only water, others are designed to sense corrosive chemicals, and some are designed to sense the presence of hydrocarbons. There are also combinations of these available that can sense corrosive water-based liquids while ignoring hydrocarbons and vice versa; or there are some cables that can sense water and hydrocarbons. These selections increase the flexibility of system applications. The chemistry of the media must be considered to ensure proper selection of the sensing cable.

Connector

Jumper Cable Jumper cable is used to connect sensor cable segments and probes together to form the sensing string. Jumper cable is not affected by contact with water. However, installation in conduit is recommended to prevent physical damage. If needed, jumper cable can be direct buried.

Leak Detection Cable Jumper Cable Inner Carrier Pipe Not Shown

Figure D-36. Layout of the cable with jumpers

Visual Inspection Monitoring In drainage only applications, an alternative method to automated leak detection is manual inspection. As long as monitoring can be accomplished every 30 days and recorded, manual inspection is allowed. For manual inspection, low point drains are placed at collection points in line as required. By designing in wells, systems can be opened and the annular space inspected to sight a possible leak. Manual inspection can also be accomplished at the end of the line. Figures D-37 and D-38 show two possible designs for manual leak detection. Probes can also be placed in wells as a manner of automated detection with a view point. Probe Option

The Connectors

Grade

The cable connection is perhaps the most critical component to a hassle free commissioning of the system. Factory training of all personnel installing connectors is strongly recommended to save many hours troubleshooting a system with poor connections. The connectors are typically standard UHF coaxial cable connectors that are connected together with an adapter. Since there is the possibility of the connection getting wet in the event of a leak, each connection must be carefully sealed with shrink tubing upon commissioning of the system.

The Control Panel The control panel is the heart of the leak detection system. It is typically mounted in a location that is convenient for an operator to monitor its status. The control panel can be ordered in several configurations. Some are multi-channel devices that are


Figure D-37. In-line inspection well


D-21



Removable Cover

Figure D-38. End-of-line inspection well

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D-22



VENTILATION SYSTEM DESIGN


VENTILATION SYSTEM DESIGN In the past 10 years thermoplastic materials have started to be used for ventilation applications. A thermoplastic vent system provides many features that standard sheet metal cannot in terms of functionality, ease of installation, and corrosion resistance. In designing a thermoplastic water system, the following items need to be considered: • Materials of Construction • Operating Parameters • Codes • Layout Recommendations • Thermal Expansion • UV Exposure • Hanging • Welding Methods

FM approval will require the use of an internal sprinkler head system. In case of a fire, the sprinkler system would eliminate the possibility of the vent system spreading the fire. There are sprinkler systems on the market that are specifically designed for this application and dramatically reduce the installation labor, as well as the required sprinkler head inspection process after installation. Figure D-39 shows a detail of a typical flexible sprinkler head and the mounting component offered by Asahi/America. Flexhead® Exhaust Duct Sprinkler Attachment Sprinkler Connection Fitting

Outside Diameter

D

2" Dia Hole

Materials of Construction For the construction of ventilation systems, Asahi/America provides the ProVent system. ProVent components are now available in Polypropylene and PVDF. The system is designed specifically for ventilation and transport of hazardous fumes and potentially corrosive gases. Both polypropylene and PVDF offer different resistance to chemical applications that should be verified prior to purchase.

Operating Parameters The ProVent system is available in multiple wall thickness in polypropylene. The selection of material pressure rating shall be based on the following criteria: • Operating temperature • Media to be transported • Operating pressure, positive or negative • Economics • Required fire codes • Size to be installed

18"

Figure D-39. Detail of a flexible sprinkler head and mounting component ProVent PVDF is a material that is considered self-extinguishing. PVDF has significantly better smoke and flame ratings as compared to most other thermoplastic materials. PVDF material offered by Asahi/America is an FM approved material according FM 4910 Standards. Contact Asahi/America for further information on installation requirements for PVDF systems. In addition, Asahi/America has on file the test results according to multiple smoke and flame standards for both polypropylene and PVDF. In short, there may be a need or requirement for internal closed-head sprinklers in a ProVent system if combustible materials can accumulate inside the pipe line.

Layout Recommendations By evaluating the above parameters, the proper system can be chosen. In many applications polypropylene will more than exceed the application; however, if the media to be transported is at an elevated temperature PVDF may be required. In general, PP systems are available in a larger selection of sizes and pressure rating options. Refer to Asahi/America’s ProVent Dimensional Guide for availability of components.

Codes In designing a ventilation system, the most pertinent code may be the fire code or the need for Factory Mutual approval. ProVent systems made of polypropylene can be installed according to FM regulations and the final installed product can meet FM requirements. The use of PP in systems requiring

Ventilation systems are often the most custom design of any pipe system in the factory. They are large in diameter and generally need to be connected to multiple equipment vents. Asahi/America offers a wide range of standard components for assembling a system. However, many systems cannot be accomplished using standard components. A skilled installer can make special fabrications in the field to accomplish the layout requirement of a system. In addition, Asahi/America can design and prefabricate pipe systems and ship them ready for installation. Figure D-40 shows a detail of a component that could not be made with standard fittings, but can easily be produced in Asahi /America’s fabrication shop and shipped to the job-site ready to be installed. Flexhead is a registered trademark of Flexhead Industries.



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Finally, the use of hangers as guides and anchors becomes important. As the design procedures in Section C indicate, certain hangers should be used as guides to allow the pipe to move back and forth in-line, while other hangers shall be anchoring locations used to direct the expansion into the compensating device. The anchors and hangers should be designed to withstand the end load generated by the thermal expansion. Figure D-40. Asahi/America prefabricated assembly For more information on fabrication assistance, contact Asahi/America’s Engineering Department.

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Thermal Expansion Based on a system’s operating criteria, thermal expansion must be considered. For systems maintained at consistent temperatures, compensation for thermal effects may not be required. It is, however, important to review all aspects fo the the operating environment such as: • Is it outdoors where it will be exposed to changing weather? • Is the system spiked with a high temperature cleaning solution? • Will the system run at a significantly higher temperature than the installation temperature? The occurrence of any thermal change in a plastic system will cause the material to expand or contract. As an example of the effect, Polypropylene will grow roughly one inch for every 100 linear feet at 10° F ∆T. Ventilation systems will often reach an equilibrium with the temperature of the ambient environment. Therefore, if the pipe is to be hung in a ceiling where the temperature will vary in summer and winter, the change in temperature that most affects the pipe may be due to the ambient temperature changing rather than media temperature changing. This is almost always the case in systems installed outdoors. ProVent systems can be used in hot applications and applications where the temperature is cyclical; it just requires analysis of the thermal expansion effects. Section C in this guide walks through the steps of calculating thermal expansion, end loads, and expansion compensating devices. In most cases, the use of expansions, offsets, and proper hanging techniques are all that is required to ensure a proper design. Hot systems also reduce the rigidity of thermoplastic piping, which, in turn, decreases the support spacing between pipe hangers. In smaller dimensions it is recommended to use continuous support made of some type channel or split plastic pipe. Review hanging requirements that are based on the actual operating temperatures.

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For calculation of allowed stresses and design of expansion compensation devices, refer to Section C, Engineering Theory and Design Considerations.

UV Exposure As a rule, PVDF material is UV resistant and can be installed in direct exposure to sunlight without protection. In certain applications with Chlorine content this may not be true. Free radical Chlorine can cause a breakdown of PVDF when exposed to UV light. For these applications it is best to protect the pipe by wrapping or insulating it. Contact Asahi /America for information on chemicals that can cause this effect. Polypropylene is not 100% UV stable. Over time, the outer surface of a standard gray Polypropylene pipe will change color and will become brittle. The surface becomes chalky to the touch. Generally if the surface is left untouched, the effect of the UV change will stop and not continue through the pipe. A pipe with a heavy wall thickness may not require protection as the change will only occur on the outer most surface. The effect to the mechanical strength of the pipe will be minimal. However, most ventilation systems operate at low pressures and use thin walled pipe for cost savings. Therefore, the ProVent PP, in most cases, should be wrapped or protected from UV exposure.

Hanging Since plastic reacts differently than metal, varying hanger styles are required. The designer of a system should specify the exact hanger and location and not leave this portion up to the installer. See Appendix A (Pro 45) for the hanging distance required on ProVent systems.

Welding Methods There are several options for installing a ProVent system. Most projects will incorporate two or three different joining techniques. The methods are • Conventional butt fusion • Hot air welding • Extrusion welding





ProVent is made to the same outer wall dimensions (DIN Standards) as all other polypropylene and PVDF pipe systems offered by Asahi /America. The same butt-fusion equipment and methodology can be used to assemble these systems. Butt fusion provides full pressure rated welds and offers a high degree of reliability for ventilation welding. However, depending on the size of pipe and location of the welds, butt fusion can be cumbersome. To conduct a weld in a ceiling of 24" pipe will be difficult and will consume a significant amount of time to lift the pipe, the tool, and an operator into position. In many cases, it is recommended to prefabricate a system on the ground or in a workshop and then conduct final assembly using flange connections. In addition to using flange connections for final hook-up, couplings and slip flanges can be used. These components can be hot air welded or extrusion welded depending on the size of the pipe and the required system operating pressure.

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Hand welding, (hot air or extrusion welding) is a convenient method for welding in place or in prefabrication. Below is a detail of a slip coupling being hand welded. This method, while convenient, is highly reliant on an operator’s skill. Hot air welding is simple and requires minimal practice to become proficient; however, extrusion welding is more complicated and a more extensive training course is required. Once these skills are mastered, they will prove highly useful during installation. It is recommended on all ProVent projects to buy at least one hot air welding tool as there is always a need for it.

Slip Flange Provent Pipe

Hot Gas Weld Single Bead

Extrusion Bead

Figure D-41. Weld option



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D-26



COMPRESSED AIR SYSTEMS


COMPRESSED AIR SYSTEM DESIGN A compressed air system made of thermoplastic piping is a simplified installation. The Air-Pro system by Asahi /America provides fast, safe installation with all the long-term corrosion resistance of plastics that are ideal for the air systems. This section reviews the necessary items to consider when designing a compressed air system. The topics covered are: • Materials of Construction • Operating Parameters, Oils • System Sizing • Thermal Expansion • Other Considerations • Hanging • Welding Methods

By knowing the above parameters, thermal plastic pipe systems can be selected. Compare the actual conditions to the allowable ratings of the material being selected for the job. It is important to predict elevated temperatures, as thermoplastics have reduced pressure ratings at higher temperatures. The AirPro system is rated at 230 psi at 68° F. Table D-3 lists correction factors for higher temperatures. Table D-3. Air-Pro Pressure Rating Correction Factor Temperature (° F)

Correction Factor

68 86 104 140

1.00 0.88 0.79 0.65

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Multiply the standard rating of 230 psi by the correction factor that correlates with a system’s expected operating temperature.

Materials of Construction When designing a compressed air system, it is critical to use materials that are manufacturer recommended for the application. Only certain thermoplastics are approved for use in compressed air applications due to safety precautions that must be considered. Thermoplastics, such as PVC, are not recommended for use in compressed air applications due to its highly crystalline structure. Under pressure, air will compress, generating a high potential energy. In the event of a failure, the release of the compressed air turns the potential energy into kinetic energy, which releases at high velocities as the air decompresses. Brittle materials can shatter and brake into fragments at the point failure. The plastic pieces that break off are dangerous to surrounding personnel, causing injury and possible death. The use of Air-Pro for compressed air service is recommended by Asahi /America, Inc. The Air-Pro system was specifically designed for compressed air. The material’s ductile nature makes it safe in the event of any possible failure. In a failure mode, the material will stretch and tear, without the fragmentation of any material. Air-Pro is similar to copper pipe when it breaks open due to failure in a frozen application. Air-Pro has been tested for impact failure at full pressure and full pressure at cold temperatures, displaying safe ductile properties under all conditions. For compressed air systems, Air-Pro is recommended.

Operating Parameters, Oils Because thermoplastic systems have varying ratings at different temperatures, it is important to design a system around all the parameters that will be subjected to it. As a first pass, verify the following operating parameters: • Continuous operating temperature • Continuous operating pressure • Oil to be used in compressor


Valves should be verified separately in terms of temperature and pressure from a piping system, as certain styles and brands of valves have lower ratings than the pipe system. Finally, in compressed air systems, oil is used in the compressor as a lubricant. Depending on the filter and drying system, it is common for the oil to get into the pipe system. With certain plastics, such as ABS, synthetic oils can break down the plastic or the glue and cause failures over time. For most mineral and synthetic compressor oils, Air-Pro is resistant to the effects of the oil. For an exact recommendation, contact Asahi /America’s Engineering Department to verify your oil and application. After verifying the standard operating conditions, it is necessary to examine other operations that might affect the piping. The following is a sample of items to investigate, prior to specifying a material. • Will there be spikes in temperature or pressure? • Is there a cleaning operation that the piping will be exposed to? • If yes, what is the cleaning agent? What temperature will the cleaning be conducted at? • Will the system be exposed to sunlight or other sources of UV? Each of the above questions should be answered and the desired material should be checked for suitability based on the above factors, as well as any others that might be special to the system in question.

System Sizing Designing pipe lines for compressed air or gas is considerably different from designing a non-compressible liquid system. Gases are compressible, so there are more variables to consider. Designs should take into account current and future demands to avoid unnecessarily large pressure drops as a system is expanded. Elevated pressure drops represent unrecoverable energy and financial losses.


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One advantage in designing an Air-Pro system is its smooth internal bore and resistance to corrosion in moist environments, which means the material can be used for years with extraordinarily low maintenance and without increases in pressure drop common to metal systems. Condensate and moist environments cause most metal systems to scale, pit, and corrode, resulting in increased pressure drop. For Air-Pro piping, the roughness factor, C, of the pipe internals is approximately 150 to 165. This factor is inversely proportional to friction head losses. As C decreases, system friction increases. Since Air-Pro pipe is resistant to corrosion, the roughness factor will not decrease over time, thus the pressure drop will not increase. Conversely, a carbon steel system with an initial roughness factor of 120 will scale over time, causing an increase in friction, increased pressure drops, and greater demand on the air compressor unit.

Main Lines Normal compressed air systems incorporate two types of pipe lines when designed correctly: the main (or the trunk) line and the branch lines. Main lines are used to carry the bulk of the compressed gas. Undersizing the main line can create large pressure drops and high velocities throughout the system. In general, systems should be oversized to allow for future expansion, as well as reduce demand on the compressor. Oversizing the main line will be more of an initial capital expense, but can prove to be an advantage over time. In addition to reducing pressure drop, the extra volume in the trunk line acts as an added receiver, reducing compressor demand and allowing for future expansion. Small mains with high velocities can also cause problems with condensed water. High air velocities pick up the condensed water and spray it through the line. With a larger diameter, velocities are lowered, allowing water to collect on the bottom of the pipe while air flows over the top. A generally accepted value for velocity in the main line is 20 feet per second. It may also be preferable to arrange the mains in a loop to have the entire pipe act as a reservoir. Goosenecks


To design the main line of a compressed gas system, Equation D-1 has been developed: d = (0.00067 L Q1.85 ∆P)0.2

(D-1)

where: d = inside diameter (in) L = length of main line (ft) Q = standard volumetric flow rate (make-up air) P = output pressure from the compressor (psi) ∆P = allowable pressure drop (psi) Equation D-1 relates the pipe’s inside diameter (d) to the pressure drop. In order to use the equation, certain information must be known. First, the required air consumption must be predetermined. Based on required air consumption, a compressor can be chosen with an output pressure rating (P). The length of the main pipe line to be installed, and the number of fittings in the main line must also be known. For fittings, use Appendix A to determine the equivalent length of pipe per fitting style. The allowable pressure in the system has to be specified. Typically, a value of 4 psi or less is used as a general rule of thumb for compressed air systems. To summarize, the following data should be specified: L = length of main line (ft) Q = standard volumetric flow rate (make-up air) P = output pressure from the compressor (psi) ∆P = allowable pressure drop (psi)

Branch Lines Lines of 100 feet or less coming off the main line are referred to as branch lines. Since these lines are relatively short in length, and the water from condensation is separated in the main lines, branches are generally sized smaller and allow for higher velocities and pressure drops. To prevent water from entering the branch line, gooseneck fittings are used to draw air from the top of the main line, leaving condensed water on the bottom of the main line.

Thermal Expansion

Figure D-42. Main compressed air loop with branches

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Based on your operating criteria, thermal expansion must be considered. For systems maintained at consistent temperatures, compensation for thermal effects may not be required. It is, however, important to review all aspects of the operating environment, such as: • Is it outdoors where the pipe will be exposed to changing weather? • Is the system spiked with a high temperature cleaning solution? • Will the system run at a significantly higher temperature than the installation temperature?





The occurrence of any thermal change in a plastic system will cause the material to expand or contract. Thermoplastic systems can be used in hot applications and applications where the temperature is cyclical. It just requires analysis of the thermal expansion effects. Section C discusses the steps of calculating thermal expansion, end loads, and expansion compensating devices. In most cases the use of expansions, offsets, and proper hanging techniques is all that is required to ensure a proper design. Hot systems also reduce the rigidity of thermoplastic piping pipe, which, in turn, decreases the support spacing between pipe hangers. In smaller dimensions, using continuous supports made of some type of channel or split plastic pipe is recommended. Finally, the use of hangers as guides and anchors becomes important. As the design procedures in Section C indicate, certain hangers should be used as guides to allow the pipe to move back and forth in-line, while other hangers should be anchoring locations used to direct the expansion into the compensating device. The anchors and hangers should be designed to withstand the thermal end load. For calculation of allowed stresses and design of expansion compensation devices, refer to Section C, Engineering Theory and Design Considerations.

Other Considerations

Hanging Since plastic reacts differently than metal, varying hanger styles are required. The designer of a system should specify the exact hanger and location and not leave this portion up to the installer. Use Table D-4 for determining the hanging distance required on Air-Pro systems. In smaller dimensions, it may be advantageous to use a continuous support for horizontal piping. Table D-4. Maximum Hanging Distances for Air-Pro Systems Pipe Size (inches) 3/4

The Air-Pro system is not rated for direct UV exposure. In certain outdoor applications, wrapping the pipe for protection is recommended. There are a variety of methods to accomplish this wrapping. Consult with Asahi /America’s Engineering Department for recommendations on Air-Pro in UV exposed applications.

Insulation Insulation is a nice method of protecting a pipe system from UV exposure, as well as providing required insulation for the system or media being transported. A serious difference between plastic and metal is plastic’s thermal properties. A metal pipe system will quickly take the temperature of the media being transported. A system carrying a media at 150° F will have an outer wall temperature close to or at 150° F. In contrast, thermoplastics have an inherent insulating property that maintains heat inside the pipe better than a metal system. The advantage is that a plastic pipe has better thermal properties, which translates into improved operating efficiencies and reduced insulation thickness.

Rev. EDG– 02/A

As with any material, Air-Pro has upper temperature and pressure rating limitations. For the majority of compressed air systems, Air-Pro is ideal and meets the requirements. One common concern with compressed air systems is the temperature of the air directly leaving the compressor. In many cases, this temperature is extremely high and can exceed the rating of Air-Pro. In these locations, it is not recommended to directly attach the Air-Pro system to the compressor. Instead, start the Air-Pro system after a cooler or dryer, where temperatures are lower. In between the compressor and the dryer/cooler, use metal piping to handle the higher temperatures. The length of metal pipe in these locations is generally very little and should have minimal effect on the air quality.

1/2

UV Exposure

ASAHI /AMERICA

Direct Connection to a Compressor

1 11/4 11/2 2 3

Support Spacing (° F) 68° F 104° F 2.8 3.2 3.6 4.1 4.5 5.1 8.4

2.6 2.9 3.3 3.6 4.1 4.6 8.1

Welding Methods The system designer should specify the equipment method to be used in any given project. The choice of particular equipment should be based on the following concerns: • Installation location • Size range • System complexity Socket fusion is ideal for small, simple, low cost systems. Socket fusion can be done quite easily with a hand-held welding plate and a few inserts. With just a limited amount of practice, an installer can make safe and reliable joints. For larger dimensions, up to a maximum of 4", bench style socket fusion equipment is available for keeping joints aligned.


D-29

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For systems that have larger dimensions above 4", butt fusion is a logical choice. Welding can take place in a variety of climates and conditions. In addition, butt fusion offers the widest variety of welding equipment options. Tools are available for bench welding, trench welding, and welding in the rack, making it completely versatile for almost all applications. Refer to Section F, Installation Practices, for a tool selection guide.

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Since Air-Pro is available as a socket system from 1/2" to 4", the only selection of equipment is between the hand-held tool or the larger bench style tool. However, if a system is mostly pipe with long straight runs, then the use of butt fusion can be considered. Using butt fusion on the pipe-to-pipe welds will reduce the amount of welds, as well as decrease the need for coupling fittings to connect the pipe. However, in these installations, two welding methods on the job site are required: butt fusion for the pipe and socket fusion for the fitting connections. For a more detailed analysis of welding methods and equipment, refer to Section F, Installation Practices.

D-30



Section E CHEMICAL RESISTANCE Contents Overview of Materials . . . . . . . . . . . . . . . .E-2 General Nature of Corrosion and Plastics . . . .E-3 Criteria for Material Selection . . . . . . . . . . . . . . . . . . .E-3 Chemical Attack Mechanisms . . . . . . . . . . . . . . . . . .E-4

Testing for Environmental Stress Cracking . . .E-5 Creep Rupture Test . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Cantilever Beam Test . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Stress-Relaxation Test . . . . . . . . . . . . . . . . . . . . . . . .E-6

Chemical Resistance Table . . . . . . . . . . . . . .E-7 Chemical Resistance Check Request Form . .E-21



E-1

CHEMICAL RESISTANCE

OVERVIEW OF MATERIALS

OVERVIEW OF MATERIALS Polypropylene (PP), polyethylene (PE), PVDF, and Halar are superior materials in terms of resistance to environmental corrosive agents. All materials are resistant to a wide variety of organic and inorganic chemicals up to high concentrations and temperatures. PP and PE are members of the polyolefin family of plastics, with excellent chemical inertness, resistance to moisture flow, and complete resistance to attack by ambient moisture. They are not affected by most inorganic chemicals, or organic solvents below 180° F and 140° F respectfully, and detergents. Both PP and PE are affected, however, by the halogens, fuming nitric and sulfuric acids, and other highly oxidizing environments. Aromatic and chlorinated hydrocarbons tend to cause swelling and softening at elevated temperatures as well. ™

E

Polypropylene has a high temperature resistance, making it more suitable for a wider range of chemical process applications. PP is generally suitable up to a maximum temperature of 180° F. High density polyethylene is rated to a maximum operating temperature of 140° F. HDPE (class and resin dependent) is a ductile material making it preferable for lower temperature application. PVDF and Halar™ are members of the inert fluoropolymer family. PVDF is made from polyvinylidene fluoride, with even greater chemical inertness and resistance to moisture flow as compared to PP and PE. PVDF resists many corrosives, including inorganic substances such as mineral acids with very low pHs

PVDF

PROLINE (Polypropylene)

up to operating temperatures of 280° F. It shows excellent resistance to the halogens, strong oxidants, and ultra pure water solutions. It is affected by strong baseous solutions, members of the amine family, and is not recommended for highly polar solvents such as ketones or esters. Halar™ (E-CTFE) is resistant to the widest selection of chemical media. Halar™ is perfectly suitable for strong acid and bases, halogens, and ultra pure water. It does have a reduction in resistance to certain ketones. Halar™ has the highest temperature rating of 300° F for continuous operation. Asahi /America has a very detailed corrosion resistance database available for these specific products, which include over 600 corrosive solutions at a variety of concentrations and operating temperatures. At all times refer to the specific chemical resistance guide appropriate for each product. Asahi /America, Inc. databases all of its chemical projects. Chemical verifications conducted by resin manufacturers are also kept on file for reference. When using aggressive chemicals or mixtures of multiple chemicals, consult Asahi /America for a written recommendation on the specific application. To receive a documented recommendation, submit the chemical concentration, temperature, and operating pressure to the Asahi /America Engineering Department. A formal response can be generated normally in one week or less. A Chemical Resistance Check Request Form is included at the end of this section.

Polyvinyl Chloride (PVC)

ULTRA PROLINE (Halar™, E-CTFE)

Polyester (Glass Fiber Reinforced)

Excelent

Inert

Good

Slight Attack

Fair

Mild Attack Attacked Softened/ Swollen Severe Attack/ Deterioated

Poor Unacceptable Strong Acids

Halogens

Strong Oxidants

Aromatic Solvents

Strong Bases

Chlorinated Solvents

Esters & Ketones

Aliphtic Solvents

Weak Bases & Salts

Figure E-1. General comparison of chemical performance of various plastic piping materials

E-2



CORROSION AND PLASTICS

GENERAL NATURE OF CORROSION AND PLASTICS Chemical resistance varies greatly between any two particular families of plastics. Within a given family of plastics, there are also differences between any two particular plastics. To compound the matter further, chemical resistance will vary slightly between different grades of a particular plastic or between resins made by different manufacturers. A specific plastic will vary slightly with respect to molecular weight, distribution, degree of crystallinity, amount of internal plasticization that may be present (co-polymerization), and other properties. Therefore, it is not suggested that general chemical resistance tables be used for determining the chemical resistance of a given manufacturer’s resin. In addition, it is strongly recommended that the practice of extrapolating on the basis of chemical similarity of a substance with respect to different plastics of a given family be avoided. What is recommended is that a specific manufacturer’s chemical resistance table be consulted for the particular product, such as the Asahi /America tables for Asahi /America products. The manner in which a type of chemical might affect a plastic also varies, due to the fact that differing chemicals produce differing reaction mechanisms when interacting with a plastic material. Depending on the reaction mechanism, an affected plastic may become embrittled, softened, charred, crazed, delaminated, discolored, dissolved, blistered, or swelled. The reaction mechanisms that produce these types of effects can be grouped into major categories such as: chemical reaction; solvation; absorption; plasticization; and environmental stresscracking. Combinations of these reaction mechanisms do occur and when it does, the detection is thus more complex. Chemical reaction is a very general heading, and can be broken down into many distinct categories. Some of these include: oxidation, where chemical bonds are attacked; hydrolysis (not possible for PP, PE, PVDF, and E-CTFE); dehydration (mostly caused by heat); alkylation; halogenation; radiation; and others. Certain reactions are predictable due to chemical structure of the resin. However, attack usually occurs in a complex manner with respect to polymers, suggesting that testing be performed under actual conditions in order to make a decision on performance.

Criteria for Material Selection There are several conditions that bear particular importance on the individual chemical attack mechanisms, and thus have a great effect on the selection process. The conditions of direct importance include: temperature, type of corrosive reagent to be handled, the concentration of the particular reagent, and the operating pressure of the system.

The Effect of Temperature Temperature has a large effect on all of the attack mechanisms. The attack will almost always be directly related to temperature, with increasing temperature resulting in increasing attack on the plastic material. Not only does an increase in temperaASAHI /AMERICA Rev. EDG– 02/A

CHEMICAL RESISTANCE ture result in a lowering of the activation energy required for a reaction to proceed, but it also causes a polymer to expand. This results in an increase in permeability, penetrability, and solubility characteristics of the polymer, which aid in a combination of the different mechanisms. One important point should be noted regarding temperature. As a plastic increases through its temperature profile, there may be a certain transition temperature where the basic stress crack mechanism may be altered appreciably. The significance of this fact is that by trying to extrapolate from known performance at a low temperature to a high temperature may lead to erroneous results. A particular danger exists if a data point is presented at ambient temperature only, and an attempt is made to make a prediction near the design temperature limit of the polymer.

The Effect of Concentration There are many different families and types of reagents, each with different properties concerning solubility, reaction between other chemical groups, etc. Each will present a slightly different concern due to the different attack mechanisms they might potentially trigger with respect to a given polymer type. The concentration of a reagent will also pose a concern, and can result in differing reaction rates at differing concentration levels. This is true for a variety of complex reasons. Of particular concern, but certainly not alone in importance, is the mineral acids. This group can show substantially different effects at various levels along the concentration profile. Again, importance must be given to the concentration effect of a given chemical for the same reason that temperature causes great concern. A level of concentration may be obtained where suddenly a transition is achieved and the stress cracking mechanism can show substantial alteration. Extrapolating results on the basis of known concentrations is a very dangerous situation, and is strongly advised against. The larger the number of data points available, the better will be the prediction. However, testing is always recommended if performance is not known.

Manufacturing Effect The manner in which a product is manufactured can induce molded-in stresses that can produce changes in chemical resistance, particularly with regard to environmental stress cracking. Manufacturing can also produce surface irregularities that vary from manufacturer to manufacturer. In general, a smoother surface will show better results in terms of all of the attack mechanisms. Built in stress due to poor extrusion methods will decrease a system’s overall resistance to a chemical. Temperature, pressure, and chemical attack all add to a system’s stress level. If the amount of stress exceeds the allowable hoop stress, environmental stress cracking will occur. It is, therefore, necessary to carefully review all the parameters of an application.


E-3

E

CHEMICAL RESISTANCE Chemical Attack Mechanisms

Plasticization

Chemical Reaction Mechanism

Plasticization typically arises as an imperfect solvent is selectively absorbed into the surface of the product and incorporates itself into the molecular structure of the molecule through secondary bonding. The typical result is the significant lowering of mechanical properties, and the lowering of glass-transition temperature. The plastic might also tend to gain in weight or dimension, but this is likely to be used only as an indication of the effect. The significance of the effect is better described through measuring the mechanical properties, as described earlier, and measuring the glass-transition temperature.

Chemical attack by virtue of chemical reaction can proceed along the paths of any of the types of reactions described earlier, depending on the given chemical and plastic. If the active sites to be attacked along the polymer chain are at the ends, a chain reaction may be initiated leading to a complete “unzipping” of the polymer structure. If the sites are distributed, then at these distributed sites, the polymer will become scissioned or separated. This will lead to a consequent chemical breakdown of the polymer.

E

CORROSION AND PLASTICS

The ease of detecting a chemical reaction occurrence through testing depends a great deal on the rates at which these reactions can occur. The typical properties to be measured include molecular weight, dimensions, overall appearance, and shortterm properties, such as tensile strength, elongation, flexural properties, and the like. A rapid reaction can easily be detected through molecular weight change, color, appearance, etc. A slower reaction is better detected by the changes in the aforementioned short-term mechanical properties. A challenge to the designer in analyzing chemical effect is to try to quantify these results. The point at which a given plastic’s change in properties makes it no longer acceptable for a given time of application is arbitrary according to design needs. The most likely property to pay close attention to for piping systems is the tensile creep rupture tests, since this data is the most important property in analyzing design strength of a plastic piping system.

Solvation Mechanism Solvation effect of a given solvent on a thermoplastic usually manifests itself in terms of swelling of the plastic, and weight and dimensional changes. Simple tests similar to those described for chemical attack can readily detect these changes in the plastic. Asahi/America materials are very stable due to their high molecular weights and stable molecular structures, and thus are not subject to solvation by many known common solvents.

E-4

Environmental Stress Cracking Mechanism When a plastic is subjected to stresses, it may be subject to catastrophic failure due to the initiation and propagation of cracks and crazes. This is the process known as environmental stress cracking and is inherently difficult to predict. A basic mechanism is assumed in which a source of localized weakening on the surface of the plastic due to the chemical action of a chemical reagent is commonly accepted as what takes place. As this localized weakening takes place, a crack appears, creating greater surface area, while also acting as a stress concentrator. The effect is thus multiplied, and further failure occurs until the inevitable catastrophic failure results. A crack may appear through selective absorption of the reagent into the polymer chain, selective solvation by the reagent of polymer from localized areas, or complexing along the polymer chain at localized sites. No matter what the selective mechanism for the localized attack is, the result is always a weakening of the localized area resulting in an initial failure, followed by crack propagation. The result of the crack propagation is as described above, greater surface area and stress concentration with subsequent catastrophic failure. To test for environmental stress cracking, both exposure and stress must occur in unison in order to reveal the mechanism. Since this is the most important mechanism with respect to piping performance, three tests are described to assist in detecting this phenomenon. • Creep Rupture Test • Cantilever Beam Test • Stress-Relaxation Test



TESTING FOR STRESS CRACKING

TESTING FOR ENVIRONMENTAL STRESS CRACKING Creep Rupture Test To test for environmental stress cracking under this procedure, the basic test for tensile creep (ASTM D-2990) is modified to produce the desired results. To conduct tests under ambient temperatures, a set-up similar to Figure E-2 might be used. To conduct measurements of creep strain and rupture at a variety of temperatures, a test set-up similar to Figure E-3 might be adapted. In this set-up, the encasing stainless steel outer pipe could be immersed into a constant temperature bath in which the temperature could be varied.

CHEMICAL RESISTANCE The advantages of these test procedures include the fact that stress-crack resistance is measured as a direct variable in terms of the reduction in design strength (stress) of the plastic. In addition, the expected service life could be extrapolated in a realistic fashion from these results.

Cantilever Beam Test The cantilever test is a fairly simple test in comparison to the Creep Rupture Test previously described. It is valid primarily when short exposure times are required and when the material does not show significant creep. It is an excellent test for large numbers of test specimens. A suggested test set-up is shown in Figure E-4. Vise

Top View

Blotting Paper

Specimen

Weight

Stress Cracking Agent

Blotting Paper

Front View

0.5" .5" .5" Specimen

Figure E-4.

Detail of creep rupture test (ambient temperatures)

Indicator

Threaded Shaft Adjustment Nut Spirit Level

Stainless Steel Base Plate

Specimen

Weight

Where: Sc F L b t

ε

Liquid Environment Threaded Tap

Figure E-3.

Detail of creep rupture test (elevated temperatures)


0.25"

Detail of cantilever beam test for environmental stress cracking (room temperature)

Sc = 6FL bt2

Lever Arm

Stainless Steel Pipe

3.5" 5"

In the test, the test reagent is applied to the blotted paper, and the beam is bent by the clip attached to the end. Initially, trial and error is used to determine a weight that will produce cracking near the mid-point of the bar. Stress and strain will vary in a cantilevered beam from zero at the free end to the maximum at the clamped end. Cracks will, therefore, appear from the free end, all the way to the distance at which the combination of stress cracking reagent and stress reach the critical stress and strain point. The following formula can be used to determine critical stress and strain:

Weight

Figure E-2.

E

Clip

Specimen

Where:

(E-1)

= critical stress (psi) = weight (lb) = critical distance (measured from free end) (in) = width of the bar (in) = thickness of the bar (in) = Sc E

(E-2)

εc

= critical strain (in / in) E = short-term flexural modulus (psi)


E-5

CHEMICAL RESISTANCE

TESTING FOR STRESS CRACKING

Stress-Relaxation Test A third alternative is to test a specimen under stress by subjecting it to a fixed deflection. This test eliminates the need for weights, and takes up little space. A suggested set-up is shown in Figure E-5. The test is limited to the more flexible plastics, and to situations where stress-cracking is of short duration, due to the effect of stress relaxation. To calculate critical strain at which stress-cracking first appears, use the following equation:

εc Where:

=

εc a b x t

E

[ ( )( bt 1-x2 2a 2

1 b a2 a4

)]

(E-3)

= critical strain (in / in) = semi-major axis of ellipse (in) = semi-minor axis of ellipse (in) = distance along major axis (in) = thickness (in)

X

Blotting Paper Strip Wet with Test Reagent Specimen Clamp Specimen Test Block

A

X B Ellipse

Figure E-5. Detail of stress-relaxation test

E-6



CHEMICAL RESISTANCE TABLE

CHEMICAL RESISTANCE TABLE The following table gives qualitative information as to the resistance of PVDF (polyvinylidene fluoride), PP (polypropylene), and HDPE (high density polypropylene) to specific chemicals under various conditions. The values given correspond to the most accurate information available from raw materials suppliers of the specific resins, based upon testing results and other relevant literature. It should be emphasized that this data has been compiled for initial consultation purposes. The information is in no way intended to replace testing based on actual conditions. Also, the user should contact a competent corrosion expert (certified by NACE or with sufficient experience in these materials) to verify any recommendation or to interpret the tables. Furthermore, any special or unusual factors, including the length of time or level of stress in the system, should be taken into consideration. In all circumstances, the Engineering Department of Asahi /America, Inc. should be consulted to review and verify final recommendations.

CHEMICAL RESISTANCE The following abbreviations are used for concentrations in some cases where a specific numeric value is not given. VL — aqueous solution, percentage of mass less than 10% L — aqueous solution, percentage of mass higher than 10% GL — aqueous solution, saturated at 68° F (20° C) TR — minimum technically pure concentration H — commercially available concentration The following footnotes are used in the body of the table: 1. Penetration of HCI possible 2. Oxidizing 3. Penetration of HF possible 4. Medium might cause stress cracking 5. Penetration of HBr possible

E

The following symbols are used in the table: –––––––––––

RESISTANT SYMBOL On the basis of the data, little or no effect on the material has been evident within the given range of pressure and temperature limits.

• • • • • • • CONDITIONALLY RESISTANT SYMBOL Suitability has to be checked in each individual case. Further testing may have to be performed to offer a specific recommendation. Please consult with the Engineering Department of Asahi /America for a specific recommendation. 0

NON-RESISTANT SYMBOL The material is generally regarded to be unsuitable. Therefore, the application is not recommended.



E-7

CHEMICAL RESISTANCE ConcenMedium

40

100 Acetaldehyde and Acetic acid

90/10

Acetic acid aqueous

10

Acetic acid aqueous (glacial acetic acid) min 96 Acetic acid - ethyl ester (ethyl acetate)

E

Temperature ° F

tration Material

Acetaldehyde

Acetic acid - methyl ester (methyl acetate) Acetic anhyhrid

TR

TR

TR Acetone GL

100 Acetophenone TR Acrylic acid ethylic ester

100

Acrylonitrile TR Adipic acid aqueous

GL

Air * TR Allyl alcohol (2-propen -1- ol)

96

Aluminium chloride GL Aluminium fluoride GL Aluminium sulphate GL Alums (metal(l)-and metal (III)-sulphates)

GL


PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE

68

104 140 176 212 248

0 ---------------------------------0 •••• •••• 0 •••• •••• --------------------------------------------------------------------------------------------- • • • • • • --------- • • • • • • • • --------- • • • • • • • • •••••••• --------- • • • • • • • • --------- • • • • • • • • ---------------------------------0 --------- • • • • • • • • ------------------• • • • 0 --------------------------------------------------0 ------------------------------------------------------------------- • • • • • • • • --------••••

•••• --------- • • • • ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

ConcenMedium

tration

Ammonia gas TR Ammonia liquid TR Ammonia solution aqueous (ammonia water) Ammonia aluminium sulphate (ammonia alum) Ammonia carbonate and ammonium hydrogen carbonate Ammonium chloride

33

L

GL

GL Ammonium iron (III) sulphate (iron alum)

L

Ammonium fluoride L Ammonium nitrate GL Ammonium phosphate

GL

Ammonium sulphide

L

Ammonium sulphate

GL

Amyl acetate TR Aniline hydrochloride aqueous Aniline pure

GL

TR Anone

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TR Anthraquinone sulphone acid

GL

Anti-freezers (motor vehicles)

H

Antimony chloride aqueous

90

Aqua regia (HCI/HNO2)

75/25

Temperature ° F Material PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE

68

104 140 176 212 248

---------------------- • • • • • • • • • • --------------------------------------------------0 ---------------------------------0 -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------•••• ----------------- • • • • ------------------------------------------------------------------••••••••••••

•••••••••••• ----------------- • • • • ----------------- • • • • • • • • ---------------------------------------------------------------------------------------------------------------------------------------------------------•••• 0 0

* Compressed air is not recommended for any system except Air-Pro.

E-8




ConcenMedium Arsenic acid aqueous

tration

80

Barium carbonate GL Barium chloride GL Barium hydroxide GL Barium salts GL Barium sulphate GL Beater glue H Beer H Beer dye (sugar dye)

VL

Bees-wax H Benzaldehyde GL Benzene TR Benzine H Benzine - benzole mixture .

80/20

Benzoic acid GL Benzoyl chloride TR Benzyl alcohol TR Bisulphite lye containing SO2 Bleaching solution (sodium hypochloride) Boric acid aqueous

GL

20

GL


CHEMICAL RESISTANCE


68

104 140 176 212 248

-------------------------- • • • • • • • • ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------0 ---------------------------------------------------

ConcenMedium Borax, aqueous (sodium tetraborate) Bromine liquid

tration

GL

TR Bromine fumes TR Bromine5 (bromine water)

GL

Butadiene gas ---------------------------------------------------------------------

TR Butane gas

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TR Butanediol aqueous

L

Butanediol TR Butanol (butyl alcohol)

TR

1,2,4-Butanetriol --------- • • • • • • • • ------------------ • • • • --------- • • • • • • • • • • • • ------------------------------------------- • • • • --------- • • • • • • • • •••• •••• --------------------------––––––– •••• --------- • • • • • • • •

TR 2-Butene-1,4-diol TR Butindiol TR Butyric acid (and isobutyric acid)

TR

Butylacetate •••• --------- • • • • • • • • --------------------------–––––––––––––– -----------------------------------------------------------• • • • • • • • • •••• ••••••••••••• ------------–––-• • • • • • • • • ---------• • • • • • • • • --------------–-- • • • • • ----------------------------------••••••••••••••••• ••••••••••••• •••• ------------------------------------------------------------------------------------------------------------------

TR Butylene liquid TR Butylene glycol (1,4-butanediol) aqueous Butylene glycol (ethylene glycol monobutyl ether) Butylphenol

TR

TR

GL Butylphenone GL Butylphthalate (dibutyphthalate)

TR


68

104 140 176 212 248

-------------------------------------------------------------------------------------------------------------------------------------------------0 0 -------------------------------------------0 0 -------------------------------------------•••• -------•••• •••• ---------------------------------

E

------------------------------------------------------------------------------------------------------------ • • • • -----------------------------------------------------------------------------------------------------------------------••••••••••••••••• ------------------------ • • • • •••• •••• ••••

--------• • • • • • • • • ------------------------------------------------------------------------------0 --------- • • • • • • • • • • • • • • • • --------- • • • • • • • •


E-9


tration

Calcium carbonate

GL

Calcium chlorate GL Calcium chloride aqueous

GL

Calcium hydroxide GL Calcium hypochlorite (chloride of lime), aqueous Calcium nitrate aqueous

E

L

GL

Calcium sulphate GL Calcium sulphide VL Camphoric oil (Camphor oil)

TR

Carbolineum H Carbon monoxide gas

TR

Carbonic disulphide

TR

Carbon dioxide gas

TR

Carbonic acid aqueous

GL

Carbonic acid dry H Carbonic acid wet H Castor oil TR Caustic Lye aqueous 50 Caustic lye aqueous

L

Caustic soda (sodium hydroxide)

60

E-10


Concen-


68

104 140 176 212 248

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------• • • • • • • • • • • • • • • • • • •• ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------•••••••••••• ••••••••••••

Medium Chloracetic acid (mono), aqueous

L

Chloracetic acid (mono), aqueous

85

Chloral (trichlor acetaldehyde)

TR

Chloral hydrate TR Chloramine aqueous

H Chloroethane (ethyl chloride) 2-Chlorethanol (ethylenechlorohydrin)

TR

TR

1 Chloric acid aqueous

------------------------------------------------0 •••• --------------------------------------------------------------------------------------------------

L

Chlordiphenyl

0 0 ---------------

tration

10

20 Chloride or lime (slurry in water)

any

Chlorine liquid TR Chlorine gas, wet

--------------------------------

0.5

-------------------------------------------------

1 Chlorine gas, dry

-------------------------------------------------------------------------------------------------

TR Chlorine water (chlorine)

GL

Chlormethyl -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

100 Chlorobenzene .

TR

Chloroform (trichloromethane)

TR



68

104 140 176 212 248

----------------------------------------------------------------------------------------------------•••••••••• --------------------------------------------------•••• -----------------------------------------------------0 •••• ------------------------------------------------------------------------------------------–– --------- • • • • • • • • -----------------------------------------------------------------–– --------- • • • • • • • • ---------------------------------

----------------------------------------------------------------------0 0 ••••••••••••••••• •••• •••• ••••••••••••••••• 0 0 ----------------------------------0 •••• --------------------••••

0 --------------------• • • • • • • • • • • •••• •••• --------------------•••• ••••



ConcenMedium

TR

Chrome alum aqueous

GL

TR

Chrome acid4) (chrome (VI)-oxide4)-) aqueous

20

40 Chromosulphuric acid Chromic acid/ sulphuric acid Citric acid

15/35/50

GL Citric acid aqueous VL Coconut butter alcohol

TR

Common salt aqueous

VL

Common salt (natrium chloride)

GL

Copper (II)-chloride GL Copper (II)-cyanide GL Copper fluoride aqueous

GL

Copper (II)-nitrate aqueous

30

Copper (II)-nitrate GL Copper (II)-sulphate GL Copper sulphate aqueous

GL

Cotton seed oil TR Cresol aqueous <90


Temperature ° F

tration Material

Chloromethane (methylchloride gas) Chlorosulphonic acid

CHEMICAL RESISTANCE


68

104 140 176 212 248

--------

ConcenMedium Cresol aqueous ≥90

•••• Crotonaldehyde 0 0

TR

--------------------------------------------------------- • • • • • • • • ----------------- • • • •

Cyanide of potassium (potassium cyanide)

L

Cyanide of potassium aqueous

GL

Cyclohexanol --------- • • • • • • • • ••••

TR Cyclohexanone

0 0 -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TR Cyclohexane TR Decalin® (decahydronaphthaline) Detergents

--------- • • • • • • • • --------- • • • • • • • •

TR

H Dextrine aqueous

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

L Dextrose (starch sugar glucose)

20

1,2-Diaminoethane (ethylene diamine)

TR

Dibutyl phthalate TR Dichloroethane (vinylidene dichloride and vinylene dichloride) Dichloroethylene (11 and 12)

TR

Dichloroacetic acid aqueous

50

Dichloroacetic acid aqueous

TR

Dichloroacetic acid methyl ester

TR

TR

Dichlorobenzene --------------------------------

TR Diesel fuel

-------------------------------------------------

Temperature ° F

tration Material

H


68

104 140 176 212 248

--------------- • • • • • • • • -----------------------------------------------------------------–––––––------------------------------------------------–––––––-–––––––------------------------------------------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • --------––––––––––––––––––– ---------------------------------

E

•••• -------- • • • • • • • • -------------------------- • • • • • • • • --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- • • • • • • • • -------- • • • • • • • • 0 0 0

------------------------------------------------••••••••••••• --------------------------------- • • • • • • • • ------------------------•••• •••• ------------------------------------------ • • • • • • • • -------- • • • • • • • •


E-11


TR Diethyl ether (ethyl ether)

TR

Diglycolic acid aqueous

GL

Dibexylphthalate TR Diisobutyl ketone (2,6-dimethyl-4heptanone) Diisooctyl phthalate

TR

TR

E

Diisopropyl ether TR Dimethylamine gas

100

Di-n-Butylether TR Dinonylphthalate ( DNP)

TR

Dioctylphthalate (DOP)

TR

1,4-Dioxan (diethylene dioxide)

TR

Emulsions photographic

H

Enzyme mash H Ester 40 Ethanol (ethyl alcohol)

TR

Ethyl acetate 100 Ethyl alcohol aqueous 96 Ethyl alcohol + acetic acid (enzyme compound) Ethyl alcohol (enzyme mash)

E-12

Temperature ° F

tration Material

Diethanolamine

H

H



68

Concen-

104 140 176 212 248

Medium Ethyl alcohol methylated with Toluol 2% Ethyl benzene

--------------•••••••• ••••••••

96

TR

--------------------------------------------------------- • • • • • • • • ---------------------• • • • • • • • • • • • • • • ----------------------- • • • • • • • • --------- • • • • • • • • •••• --------- • • • • • • • •

Ethyl chloride gas (chloroethane)

TR

Ethylenechlorohydrin (chloroethanol)

TR

Ethylenediamine (1,2-diaminoethane)

TR

Ethylene glycol (1,2-ethanediol)

TR

Ethylene oxide gas (oxiran)

TR

Ethyl ether . ---------------- • • • • • • • • •••• •••• -------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • •••• ••••••••••••• ------------------------------------------------------------------------------------------------------------------------•••••••••••• •••••••••••• -------- • • • • • • • • • • • • • • • • -------------------------------------------------------------------

.

100 Exhaust gases containing SO2 Exhaust gases containing carbon dioxide Exhaust gases containing hydrochloric acid1) Exhaust gases containing hydrogen fluoride Exhaust gases containing nitrogen Exhaust gases containing oleum Exhaust gases sulphuric acid wet Fatty acids

VL

any

any

VL

VL

VL

any

100 Fertilizer salt

-------- • • • • • • • • -------- • • • • -------------------------------------------------------------------

H Fixing solutions photographic

H

Fluor gas, dry -------------------------------------------------------------------------------------------------

TR Fluorammonium aqueous

Temperature ° F

tration Material

20



68

104 140 176 212 248

--------------••••••••••••••••••••• •••• •••• 0 0 --------------------------------------------------------------------••••••••••• -------------------------------------------------------------------------------------------------------------------------------------------------------------------0 --------------•••• •••• --------------------------------------------------------------------------------------------------– ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------0 0 0 --------------------------------------------------------------------------------------------------•••••••••••• -------- • • • • • • • • ---------------------------------------------------------------------------------------0 0 -------------------------------------------------



ConcenMedium

32

40 Formaldehyde aqueous

40

Formic acid aqueous 85 Fructose L Fruit juices, pulp H Fruit pulp H Fuel oil H Furturyl alcohol TR Gaswater H Gelatine L Glacial acetic acid 100 Glucose aqueous 20

GL Glycerine (glycerol), aqueous

any

Glycol aqueous H Glycocol aqueous 10 Glycolic acid aqueous

30

70 Heptane TR


Temperature ° F

tration Material

Fluosilicic acid aqueous

CHEMICAL RESISTANCE


68

104 140 176 212 248

-----------------------------------------–-------------------------------------------------------------------------–--------------------------------------------------------------------------------------------------------------------------------------------------------------------------–-------- • • • • • • • • -----------------------------------------------------------------–-------------------------

ConcenMedium Hexane TR Hexanetriol (1,2,6) TR Hydrazine hydrate TR Hydrobromic acid (solution) aqueous4)

48

Hydrochloric acid aqueous1)4)

VL

-----------------------------------------–-------------------------

>32 Hydrocyanic acid

-------------------------------------––––––––– -------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • ---------------- • • • •

L Hydrocyanic acid aqueous Hydrofluoric acid aqueous3)4)

TR

4

-------------------------------

40

---------------------------------------–-------------------------

60

-------- • • • • • • • • ---------------- • • • • ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------–– ----------------------------------------–-----------------------------------------–------------------------–– ----------------------------------------–------------------––––––––––––– --------------------------------------------------------------–-------------------------–------------------------–------------------------------------------------- • • • • • • • • -----------------------------------------------------------------------––––––– ----------------------------------------------------------------------- • • • • • • • • -------- • • • •

70 Hydrofluosilicic acid aqueous

32

40 Hydrogen bromide gas5) Hydrogen chloride gas wet and dry2)

TR

TR

Hydrogen gas TR Hydrogen peroxide aqueous

30

90 Hydrogen sulphide aqueous

Temperature ° F

tration Material

GL


68

104 140 176 212 248

---------------------------- • • • • • • • • -------- • • • • • • • • -------------------------– ------------------------–••••••••••• -------------------------------------------------------------------------------- • • • • • • • • ------------------------------------------------------------------– ------------------------–- • • • • -------------------------– --------------------------------------–----------- • • • • • • • • • • • • --------------------------------------------------------------–----------------------------------------------------

E

-----------------------------------------------------------------–--------------------------------------------------------------------------------------–----------------------------------- • • • • • • • • ---------------––––--------------------- • • • • -------- • • • • • • • • --------------------––––-------- • • • • • • • • -------- • • • • • • • • -------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------

-------------------------------------------------------- • • • • • • • • •••• •••• •••• -------------------------------------------------


E-13

CHEMICAL RESISTANCE ConcenMedium Hydrogen sulphide gas, dry Hydrogenhyposulphite aqueous Hydroquinone

VL

L Hydroquinone GL Hydroxylamine sulphate aqueous

≥12

Iodine, tincture H

E

Iron (II)-chloride GL Iron (III)-chloride GL Iron (III)-nitrate L Iron (II)-sulphate GL Iron (III)-sulphate GL Isobutanol TR Isobutyric acid TR Isooctane TR Isopropyl alcohol TR Lactic acid TR Lactic acid aqueous

90

Lanolin (wool oil) H

:

Lead acetate aqueous

GL

Lead tetraethyl (tetraethyl lead)

TR

E-14

Temperature ° F

tration Material

TR



68

104 140 176 212 248

ConcenMedium Light liquid paraffin

-------------------------------------------------

TR Lighting gas

-------------------------------------------------

H Linseed oil

--------------- • • • • --------------- • • • • -------------------------------------------------------------------------- • • • • • • • • ----------------- • • • • --------------------------------------–-----------------------------––––––– -----------------------------------------------------------------–------------------------------––––––– -----------------------------------------------------------------–------------------------------––––––– -----------------------------------------------------------------–-----------------------------–––––– -------------------------------------------------------------------------------------------------------------------–––––––------------------------------------------ • • • • • • • • • • • • • • • • ------------------------••••••••••••• --------------- • • • • • • • • --------––––––––––––––––––––––––– -------- • • • • • • • • -------- • • • • • • • • -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

H Liquid ammonia (ammonia water)

GL

Magnesium carbonate

GL

Magnesium chloride aqueous

GL

Magnesium hydroxide

GL

Magnesium hydroxide carbonate

GL

Magnesium nitrate GL Magnesium salts GL Magnesium sulphate aqueous

GL

Maize seed oil TR Malic acid aqueous GL Menthol TR Mercury TR Mercury (II)-chloride GL Mercury (II)-cyanide GL Mercury (II)-nitrate

-------- • • • • • • • • -------- • • • • • • • • -------------------------------------------------------------------- • • • • • • • • ---------------------------------------

L Mercury salts GL Methane bromide (methyl bromide)

Temperature ° F

tration Material

TR



68

104 140 176 212 248

-------- • • • • • • • • -------- • • • • • • • • -----------------------------------------------------–---------------------------------------------------0 ---------------------------------------------------------------------------------------–------------------------------------------–------------------------------------------------------------------–----––––––– ---------------------------------------------------------------------------------------–--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------–--------------------------------------------------------------------------------------------------------– ------------------------------------------------------------------ • • • • • • • • --------------------------------------------------– –––––– -------------------------------------------------------- • • • • • • • • ----------------- • • • • ------------------------------------------- • • • • -------------------------------------------------------------------------------------------– -------------------------------------------------------------------------------------------– -----------------------------------------------------------------------------------------–------------------------------------------------------------------------------------------------------------------------------------------–-0 0



ConcenMedium

Methanesulphonic acid (methylsulphuric acid), aqueous

TR

≥50

>50 Methyl alcohol (methanol)

5%

Methylamine aqueous 32 Methoxybutanol TR Methoxybutyl alcohol TR Melhylbenzoin acids (Toluene acids)

GL

Methyl bromide TR Methyl chloride TR Methylene chloride (dichloromethane)

TR

Methyl ethyl ketone TR Milk H Mineral oil H Mineral water H Molasses H Naptha H Natural gas TR N,N-Dimethalformamide

TR

Nickel (II)-chloride GL


Temperature ° F

tration Material

Methanol (methyl alcohol)

CHEMICAL RESISTANCE


68

104 140 176 212 248

-------- • • • • • • ----------------------–-------------------------–-----------------------–--•••••••••••••••• -----------------------------–--•••• •••• -------–––––––- • • • • • • • • • • • • ------------------------------------------------•••• ---------------

ConcenMedium Nickel (II)-nitrate GL Nickel salts GL Nickel (II)-sulphate GL Nicotinic acid VL Nitric acid aqueous

VL

10-50

-------- • • • • • • • • -------- • • • • • • • •

>50 <85

-------- • • • • • • • • Nitrobenzene

TR

-------- • • • • •••• Nitrous fumes2) 0 0 -------0 •••• -------•••• •••• 0 -------- • • • • • • • • -------- • • • • • • • • ----------------------------------------------------------------------------------------------------------------------------------------------------------------------- • • • • • • • • -------- • • • • • • • • ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------–-------------–––––––––– ----------------------------0 ----------------------------------------- • • • • -------------------------------------------------------------------------------------------

GL 2-Nitroluene TR Octycresole TR Oil of turpentine TR Oils essential TR Oils, vegetable and animal

TR

Oleic acid TR Oleum (H2SO4 + SO3)

Temperature ° F

tration Material

TR

Oleum fumes VL

L Oxalic acid aqueous GL Oxygen TR


68

104 140 176 212 248

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- • • • • • • • • ------------------------------------------------------------------•••• •••• --------------------- • • • • • • • • • • 0 •••• --------------------------- • • • • • • • • -------- • • • • • • • •

E

•••• •••• --------------------------------- • • • • • • • • -------- • • • • •••• •••• 0 •••• •••• •••• -------------------------------------------------- • • • • • • • • -------- • • • • • • • • --------------------------------- • • • • • • • • -------- • • • • • • • • 0 0 0 0 0 0 0 0 0 -------------------------------------------------------------------------------------------------------------------------------------------–––––––----------------- • • • •


E-15


0.5 ppm Paraffin emulsions TR Paraffin oil TR Peanut oil TR

E

1-Pentanol (n-amylalcohol)

TR

2-Pentanol (sec-n-amylalcohol)

TR

Peppermint oil TR Perchloric acid aqueous

20

50

70 Perchloroethylene (tetrachloroethane)

TR

Petroleum TR Petroleum ether TR Phenol aqueous 5

90 Phenylhydrazine TR Phenylhydrochloride TR Phosgene gas TR Phosgene liquid TR Phosphates inorganic GL

E-16

Temperature ° F

tration Material

Ozone gas4)



68

104 140 176 212 248

---------------------– -------•••• -------------------------------- • • • • • • • • ---------------------------------- • • • • • • • • -------- • • • • • • • • --------------------------------------------------------------------------- • • • • ----------------------------------------- • • • • ------------------------------------------------------------- • • • • ---------------------------------------------------------------

ConcenMedium Phosphoric acid aqueous

95

50 Phosphoric acid (ortho-)

85

Phosphorus (III) chloride

TR

Phosphorus oxychloride

TR

Phosphorus pentoxide

TR

Phosphorus tricloride

TR

Photographic developing agents

H

Phthalic acid -------- • • • • • • • • -------- • • • • • • • • •••• ------------------------------------------ • • • • •••••••••••• •••• ----------------------------------------------------------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------•••••••••••• •••••••••••• -------- • • • • • • • • -------•••••••••••• ••••

GL Picric acid (2, 4, 6 trinitrophenole)

GL

Pine needle oil H Potable water (chlorous) Potassium aluminium sulphate (potassium alum) Potassium bicarbonate

TR

L

GL Potassium bisulphate GL Potassium hydrogen sulphite (potassium bisulphite) Potassium borate aqueous Potassium bromate aqueous

L

1

10

Potassium bromate GL

0 0 -------------------------------------------------

Potassium bromide aqueous

Temperature ° F

tration Material

GL



68

104 140 176 212 248

--------------- • • • • • • • • -------- • • • • • • • • --------––––––––––––––––––––––––– -------------------------------------------------------------------------------------------------------------------------------------------------------------•••• -------- • • • • • • • • ---------------------•••• -------- • • • • • • • • -----------------------------------------------------------------------------------------------–––––––------------------- • • • • • • • • ------------------------------------------------•••••••• •••••••• ----------------------------------------------------------------------------------------------------------------- • • • • • • • • ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------––––––– --------------------------------------------------------––––––– -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------



ConcenMedium

GL

Potassium chlorate GL Potassium chloride aqueous

GL

Potassium chromate aqueous

GL

Potassium chrome (III) sulphate (chrome alum) Potassium cyanide (cyanide of potassium) Potassium dichromate aqueous Potassium ferricyanide and potassium ferrocyanide, aqueous Potassium fluoride

L

L

GL

GL

L Potassium hexacyano ferrate (II) and (III) yellow and red prussiate Potassium hypochlorite

GL

L

Potassium iodide GL Potassium nitrate aqueous Potassium perchlorate aqueous

GL

10

GL Potassium permanganate aqueous

6

20 Potassium peroxodisulphate (potassium persulphate) Potassium phosphate

GL

GL Potassium sulphate GL


Temperature ° F

tration Material

Potassium carbonate (potash)

CHEMICAL RESISTANCE


68

104 140 176 212 248

0 ------------------------------------------------••••••••••••••••••••• --------------------------------------------------------------------------------------------------------------------------------------------------------------•••• ------------------------------------------------•••• -------------------------------------------------

ConcenMedium Potassium sulphide L Potatoe spirit oil TR Propane gas TR Propane liquid TR Propionic acid aqueous

50

Propionic acid ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TR Propanol-(1) (propyl alcohol) Propargyl alcohol aqueous

TR

7

Propylene glycol TR Pyridine

------------------------------------------------•••• •••• -------- • • • • • • • •

TR Roaster dry any Salicylic acid

--------------------------------------------------------------------------------------------------------------------------------------------

GL Sea water (lake water)

H

Silicic acid aqueous -------------------------------- • • • • • • • • •••••••••••••••• --------------- • • • • • • • • -----------------------------------------------------------------------------------------------------------------------------------------–––––––-----------------------------

H Silicone emulsion H Silicone oil TR Silver acetate GL Silver cyanide

-------- • • • • • • • • -------------------------------------------------––––––– --------------------------------------------------------------------------------------------------------------------------------------------

GL Silver nitrate aqueous

Temperature ° F

tration Material

GL

Silver salts GL


68

104 140 176 212 248

••••••••••••••••••••• -------------------------------------------------------------------------------------------------- • • • • •••• -----------------------•••• -------•••• --------------------------------------------------------------------------------– --------------- • • • • • • • • ---------------------------------------------------------------------

E

----------------------------------------------------------------------------------------------------------------------------------------•••••••••••• -------- • • • • • • • • ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------–––––––– --------------------------------------------------------------------------------–––––––– -------------------------------------------------------------------------------------------------------------------- • • • • • • • • --------------------------------------------------------–––––––– -------------------------------------------------


E-17

CHEMICAL RESISTANCE Temperature ° F

ConcenMedium

tration Material

Soaps aqueous GL Soda (sodium bicarbonate)

50

Soda lye (sodium hydroxide) aqueous

40

60 Sodium acetate GL Sodium benzoate GL

E

Sodium benzoate aqueous

35

Sodium borate hydrogene peroxide (sodium perborate) Sodium bromide

GL

GL Sodium carbonate GL Sodium carbonate aqueous

50

Sodium chlorate aqueous

GL

Sodium chlorite aqueous

2-20

Sodium cyanide GL Sodium dichromate GL Sodium fluoride GL Sodium hexacyanferrat (II) (sodium ferrocyanide) Sodium hexacyanferrat (III) (sodiumferrocyanide) Sodium hexametaphosphate Sodium hydrogen carbonate (sodium bicarbonate)

E-18

GL

GL

L

GL



68

104 140 176 212 248

-----------------------------------------------------------------------------------------------------------0 -------------------------------------------------------------------0 ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ • • • • • • • • ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------• • • • • • • • ------------------------••••••••••••••••••••• -------------------------------------------------------- • • • • • • • • --------

ConcenMedium Sodium hydrogen sulphate Sodium hydrogen sulphite (sodium bisulphite) Sodium hypochlorite aqueous

GL

L

10

20 Sodium hypochloride (bleaching lye) 15% act Cl2, aqueous Sodium nitrate

L

GL Sodium nitrite GL Sodium phosphate (-tri-) Sodium silicate (water glass)

GL

L

Sodium sulphate GL Sodium sulphide GL Sodium sulphide aqueous

40

Sodium tetraborate (borax)

L

-------------------------------------------------

GL Sodium thiosulphate

---------------------------------------------------------------------------------------------------------------------------------------------------------------

GL Soybean oil TR Spindle oil TR

------------------------Spirits of all kinds -------------------------------------------------

H Starch syrup

----------------------------------------------------------------------------------------------------------------------------------------------

any Starch aqueous

Temperature ° F

tration Material

any



68

104 140 176 212 248

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------•••••••••••••••••

•••••••••••••••••

0 •••• •••• ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------– ••••••••••••••••••••• ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • -------- • • • • • • • • -------------------------------------------------------------------------------------------------------------------------------------------------



ConcenMedium

GL

Stearic acid TR Succinic acid GL Sulphur dioxide aqueous

any

Sulphur dioxide wet and aqueous

any

Sulphur dioxide, gas dry

any

Sulphur trioxide TR Sulphurous acid aqueous

any

Sulphuryl chloride (sulphonyl chloride)

TR

Sulphuric acid TR Sulphuric acid aqueous

VL

10-50 Tallow TR Tannic acid (tannin) aqueous

10

Tanning extracts of cellulose

H

Tanning extracts vegetable

H

Tartaric acids aqueous

H

Test benzene TR Tetrachloroethane TR Tetrachloroethene (perchloroethylene)


Temperature ° F

tration Material

Starch sugar (glucose), aqueous

TR

CHEMICAL RESISTANCE


68

Concen-

104 140 176 212 248

Medium Tetrachloromethane

--------------------------------------------------------------------

TR Tetrahydrofuran

••••••••••••• -------- • • • • • • • • ------------------------------------------------0 ------------------------------------------------0 ---------------------------------------------------------------------------------------------------------------------------------------------------0 0 0 0 ------------------------------------------------0 0 --------------------- • • • • • • •••• • • • •• • • • --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TR Tetralin (tetrahydronaphthaline)

TR

Tin (IV)-chloride GL Tin (II)-chloride GL Thionyl chloride TR Thiophene TR Toluene TR Transformer oil (insulating oil)

TR

Trichloroacetic acid aqueous

50

Trichloroethylene (trichloroethene)

TR

Tricresyl phosphate TR Trietanolamine

-----------------------------------------------------------------------------------------

L Trioctyl phosphate

Urea aqueous ---------------

L

------------------------------------------------------------------------------------------------------------------------------------ • • • •• • • • -------- • • • • ••••••••••••••••••••• •••• •••• ---------------------------------- • • • • • •••••••••••• ••••••••

GL Urine

Vinegar (wine vinegar)

H

Vinyl acetate TR Vinylidene chloride (1, 1-dichloroethylene)

Temperature ° F

tration Material

TR


68

104 140 176 212 248

----------------------------------0 0 ••••••••••• •••• •••••••• 0 •••• ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------••••••••••• 0 0 -------- • • • • • • • • •••• ---------------------• • • • • • • • • • • •••• •••• -------- • • • • -------- • • • • • • • • --------------------- • • • • • • -----------------------------------------------------------------------------------------•••• -------- • • • • • • • • ---------------------------------------------------------------------------- • • • • ----------------------- • • • • --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------• • • • • • • • • ------------------• • • • 0 0


E-19

E


H Wines and spirits (sodium benzoate)

H

Wine vinegar (edible vinegar)

H

Xylene (all isomers) TR Yeast GL Yeast bitter H

E

Zinc carbonate GL Zinc chloride aqueous

GL

Zinc oxide GL Zinc salts GL Zinc sulphate aqueous

Temperature ° F

tration Material

Water pure

GL


PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE PVDF PP HDPE

68

104 140 176 212 248

-----------------------------------------––––––------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------––––––– 0 •••• •••• --------------------------------------------------------------------------------------------------------------------------------------------------------------------––––––– -------------------------------------------------––––––––––––– -------------------------––––––– ---------------------––– -------------------------------------------------------------------------––––––––––––– ---------------------------------------------------------------------------------------------------------------------------------------––––––– -------------------------

Symbols: 1. Penetration of HCI possible 2. Oxidizing 3. Penetration of HF possible 4. Medium might cause stress cracking 5. Penetration of HBr possible 6. PVDF requires UV protection

E-20



CHEMICAL RESISTANCE CHECK FORM

CHEMICAL RESISTANCE

CHEMICAL RESISTANCE CHECK REQUEST FORM PIPING SYSTEMS Attention: Engineered Products Division

Requester’s Information Company Name Address

Phone Fax Contact Name

Project Information End User Name Project Name Contact Address

Phone

Chemical Information Chemical (s) and Concentration

Operating Temperature Operating Pressure Flow Rates UV Exposure Comments (Note any other information that may assist in material selection)



E-21

CHEMICAL RESISTANCE

E


E-22



Section F INSTALLATION PRACTICES Contents Good Installation Practices . . . . . . . . . . . .F-2

Double Wall Systems . . . . . . . . . . . . . . . .F-45

Flanging and AV Gaskets . . . . . . . . . . . . . . . . . . . . . .F-2 Butterfly Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2 Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2 Weatherability/UV . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3 Chlorine/Chlorinated Hydrocarbon Installations . . . . .F-3

Step 1. Welding Environment . . . . . . . . . . . . . . . . . .F-45 Step 2. Tool Selection . . . . . . . . . . . . . . . . . . . . . . . .F-45 Step 3. Material Handling . . . . . . . . . . . . . . . . . . . . .F-47 Step 4. Training and Preparation . . . . . . . . . . . . . . . .F-47 Step 5. Tool Commission and Daily Checks . . . . . . .F-48 Step 6. Pipe Cutting . . . . . . . . . . . . . . . . . . . . . . . . .F-48 Step 7. Weld Preparation . . . . . . . . . . . . . . . . . . . . .F-48 Step 8. Weld Inspection . . . . . . . . . . . . . . . . . . . . . .F-49 Step 9. Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-50 Step 10. Trenching and Burial . . . . . . . . . . . . . . . . . .F-51 Step 11. System Testing . . . . . . . . . . . . . . . . . . . . . .F-51 Step 12. Repair Procedures . . . . . . . . . . . . . . . . . . .F-54

Welding Methods . . . . . . . . . . . . . . . . . . . .F-4 Socket Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4 Butt Fusion – Single Wall . . . . . . . . . . . . . . . . . . . . . .F-5 Butt Fusion – Double Wall . . . . . . . . . . . . . . . . . . . . . .F-6 Butt Fusion – Double Wall w/o Leak Detection Cable F-7 Butt Fusion – Double Wall w/Leak Detection Cable . .F-9 IR Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12 HPF Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13 Side-Wall Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-14 Hand-Held Welding . . . . . . . . . . . . . . . . . . . . . . . . . .F-14 Extrusion Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .F-16 Electro-Fusion Welding . . . . . . . . . . . . . . . . . . . . . . .F-18

High-Purity Installations . . . . . . . . . . . . .F-20 Step 1. Welding Environment . . . . . . . . . . . . . . . . . .F-20 Step 2. Tool Selection . . . . . . . . . . . . . . . . . . . . . . . .F-21 Step 3. Material Handling . . . . . . . . . . . . . . . . . . . . .F-24 Step 4. Training and Preparation . . . . . . . . . . . . . . . .F-25 Step 5. Tool Commission and Daily Checks . . . . . . .F-25 Step 6. Weld Inspection . . . . . . . . . . . . . . . . . . . . . .F-26 Step 7. Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29 Step 8. System Testing . . . . . . . . . . . . . . . . . . . . . . .F-30 Step 9. Repair Procedures . . . . . . . . . . . . . . . . . . . .F-31

Chemical Single Wall Systems . . . . . . . .F-33 Step 1. Welding Environment . . . . . . . . . . . . . . . . . .F-33 Step 2. Tool Selection . . . . . . . . . . . . . . . . . . . . . . . .F-34 Step 3. Material Handling . . . . . . . . . . . . . . . . . . . . .F-36 Step 4. Training and Preparation . . . . . . . . . . . . . . . .F-36 Step 5. Tool Commission and Daily Checks . . . . . . .F-37 Step 6. Pipe Cutting . . . . . . . . . . . . . . . . . . . . . . . . .F-37 Step 7. Weld Inspection . . . . . . . . . . . . . . . . . . . . . .F-37 Step 8. Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-40 Step 9. Trenching and Burial . . . . . . . . . . . . . . . . . . .F-41 Step 10. System Testing . . . . . . . . . . . . . . . . . . . . . .F-41 Step 11. Repair Procedures . . . . . . . . . . . . . . . . . . .F-42


Poly-Flo Systems . . . . . . . . . . . . . . . . . . .F-57 Step 1. Welding Environment . . . . . . . . . . . . . . . . . .F-57 Step 2. Tool Selection . . . . . . . . . . . . . . . . . . . . . . . .F-57 Step 3. Material Handling . . . . . . . . . . . . . . . . . . . . .F-58 Step 4. Training and Preparation . . . . . . . . . . . . . . . .F-59 Step 5. Tool Commission and Daily Checks . . . . . . .F-59 Step 6. Pipe Cutting . . . . . . . . . . . . . . . . . . . . . . . . .F-60 Step 7. Weld Inspection . . . . . . . . . . . . . . . . . . . . . .F-60 Step 8. Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-61 Step 9. Trenching and Burial . . . . . . . . . . . . . . . . . . .F-62 Step 10. System Testing . . . . . . . . . . . . . . . . . . . . . .F-63 Step 11. Repair Procedures . . . . . . . . . . . . . . . . . . .F-64

Compressed Air Piping Systems . . . . . .F-67 Step 1. Welding Environment . . . . . . . . . . . . . . . . . .F-67 Step 2. Tool Selection . . . . . . . . . . . . . . . . . . . . . . . .F-67 Step 3. Material Handling . . . . . . . . . . . . . . . . . . . . .F-69 Step 4. Training and Preparation . . . . . . . . . . . . . . . .F-70 Step 5. Tool Commission and Daily Checks . . . . . . .F-70 Step 6. Pipe Cutting . . . . . . . . . . . . . . . . . . . . . . . . .F-70 Step 7. Weld Inspection . . . . . . . . . . . . . . . . . . . . . .F-71 Step 8. Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-72 Step 9. Trenching and Burial . . . . . . . . . . . . . . . . . . .F-73 Step 10: System Testing . . . . . . . . . . . . . . . . . . . . . .F-73 Step 11: Repair Procedures . . . . . . . . . . . . . . . . . . .F-74

High-Purity Weld Inspection Table . . . . .F-75 Weld Inspection Table . . . . . . . . . . . . . . .F-76


F-1

INSTALLATION PRACTICES GOOD INSTALLATION PRACTICES

Butterfly Valves

Flanging and AV Gaskets

Most Asahi /America piping systems are produced to metric dimensions according to ISO standards. However, Asahi / America butterfly valves are produced according to iron pipe size dimensions. The outcome is that in certain sizes, the disk of the butterfly valve can meet interference with inside pipe wall when opening. The interference is typical in SDR 11 polypropylene systems in 6" and larger and SDR 32.5 polypropylene in 8" and larger. In PVDF systems, the effect is 8"–12" in SDR 33 and 6" and larger in SDR 21 systems.

When bolting a flange connection, it is required to tighten the bolts in a specified pattern as well as tighten them to a required specification. Asahi /America offers a line of low torque AV gaskets in sizes 1/2"–12" for single wall pipe connections. These gaskets offer a unique double-convex ring design that gives optimum sealing with one third the torque of a common flat gasket seal. The gaskets are available in the following materials: • EPDM • PVDF bonded over EPDM • TeflonTM over EPDM They are available in both standard and high-purity grade. PTFE and PVDF bonded gaskets are produced in a proprietary laminating process for bonding to EPDM. The use of the rubber backing provides greater elasticity for lower bonding torques.

Detail of Gasket

F

GOOD INSTALLATION PRACTICES

When tightening a flange, the torque rating is dependent on the gasket used. For the AV gasket, see Table F-1 for the recommended tightness. In addition, when tightening follow the star pattern shown below. Conduct two or three passes, tightening the flange uniformly. Finish by doing a circular pass to check the torque values. Always use a torque wrench when tightening a flange. A common mistake when tightening a flange is to squeeze it as tightly as possible. This action will damage the gasket and eventually lead to reduced elasticity and leakage. Do not tighten beyond the rating. Table F-1. Recommended Bolt Torque for AV Gaskets (lbs) Size (inches)

Teflon-PVDF

EPDM

174 174 174 191 217 217 304 304 304 348 435 435 522

157 157 157 165 174 174 217 217 217 260 304 304 435

1/2 3/4

1 11/4 11/2 2 21/2 3 4 6 8 10 12

1 5

8

3

4

6

7

Polypropylene stubs in the interfering dimensions are always beveled at the factory to avoid this issue. PVDF stub ends mounted for butterfly valve installation must be ordered special from Asahi /America. PVDF stubs are not automatically supplied with a beveled end for other reasons. Contact Asahi /America for special part numbers on PVDF beveled stub ends.

Threading In general, threaded connections are not recommended for high pressure thermoplastic piping systems. If thermoplastic pipe is threaded, the pressure rating is derated significantly. In certain instances an installer may choose to thread the system. Recommendations for threading plastic piping have been developed by the Plastic Piping Institute. It should be noted that certain Asahi /America systems with thinner walls simply cannot be threaded. In addition, metric pipe systems, even with thick pipe walls, cannot be threaded since the outside diameters are not the same as IPS pipe, making the threads too short in height. Only pipe having a wall thickness greater than Sch 80 should be threaded. Only pipe dies that are clean and sharp and specifically designed for plastic piping should be used. If a vise is used to restrain the pipe during the cutting, exercise caution not to scratch or deform the pipe. Wooden plugs inserted in the pipe ends can reduce this risk. Before cutting threads, the pipe must be deburred of all sharp edges. A die stock with a proper guide that will start and go on square to the pipe axis should be used. The use of cutting oil should be kept to a minimum. Once the threads are cut, they should be seated with PTFE tape. In most cases, the use of threading pipe can be avoided altogether by use of molded male and female adapters. These fittings have been designed and produced to provide a full 150 psi pressure rating at 70° F. The male and female adapters address the need to connect to existing pipe systems or equipment without derating the system. The use of these fittings welded to the pipe is recommended instead of attempting to thread pipe. Asahi /America does not recommend threading or threaded fittings made of HDPE.

2

Figure F-1. Torque pattern

F-2



GOOD INSTALLATION PRACTICES

INSTALLATION PRACTICES

Weatherability/UV

Chlorine and Chlorinated Hydrocarbon Installations

Special Considerations Weather Effects Polypropylene, HDPE, and PVDF are resistant to almost all the effects of weather. They differ, however, on one important characteristic: resistance to ultraviolet light degradation. PVDF is almost completely unaffected by UV light. HDPE, with its black additive, is resistant to UV light, as is Poly-Flo black polypropylene. Standard polypropylene from Asahi /America is a European gray polypropylene that is affected as the energy from ultraviolet radiation initiates a chemical reaction in the polymer. Natural polypropylene is not UV resistant. The reaction between polypropylene (gray) and UV radiation only takes place at the surface to shallow depths measured in minute fractions of an inch. The molecules at the surface of the plastic are permanently altered to form a complex formation of various chemicals, such as polypropylene-type formations. A noticeable chalky-yellow appearance ensues, with a resulting slight reduction in impact strength. This effect will only become noticeable upon prolonged exposure, and will not continue to progress if the ultraviolet source is removed. The effect can be measured after a prolonged period of time as a slight increase in tensile strength, a slight increase in elastic modulus, and a minor decrease in impact strength. The degradation only occurs to a shallow depth, although in time there may be some slight flaking off of the chemically altered surface molecules.

When PVDF is used to transport chlorine or chlorinated hydrocarbons, special precautions should be taken if the possibility of a reaction is suggested by the application. In certain post chlorination pipe lines, downstream in a bleached paper process (chlorine dioxide reactor, for instance), there exists a small amount of spent reactants that ordinarily will not proceed to completion. However, it has been shown that ultraviolet light from sunlight or fluorescent light fixtures may offer enough energy to initiate this reaction to completion. In the process, free-radical chlorine is released instantaneously, and there is a tendency for some substitution of chlorine molecules for hydrogen in the polymer chain. As this happens, stress cracks may appear in the pipe wall through a mechanism not yet completely understood, and the system may fail. Therefore, it is required to protect any PVDF system from the possibility of ultraviolet light propagation from reactions involving the generation of free-radical chlorine. One method of providing this protection is through the same method of taping described in the previous section for protecting polypropylene piping from ultraviolet attack.

Thin wall polypropylene pipe fittings should be protected against ultraviolet light penetration if placed in an outdoor environment. Some of the various methods include painting, providing a “shield,” or taping/wrapping the pipe. In order to paint the piping, polypropylene must first receive a coating of a suitable primer to allow the acrylic lacquer to be applied. The primer can be applied by brush to small diameter pipes and sprayed onto larger diameter pipes. Then a suitable paint can be selected and applied in a similar fashion. It is advisable to strictly adhere to the manufacturers’ instructions concerning safe operating practices when applying the selected paint. A thin-walled insulation type shield or rigid vapor jacket barrier can eliminate the effects of ultraviolet light. A thin aluminum shield should provide all the protection that is necessary. A third method includes covering the piping with tape. A recommended type of tape is called “TapeCoat” and is made by TapeCoat, Inc. of Evanston, IL. This tape should be applied with 50% overlap, and when properly applied, will completely protect the piping against ultraviolet attack.



F-3

F


WELDING METHODS

Coupling

WELDING METHODS

Heater Inserts

Pipe

Socket Fusion In socket welding, the pipe end and socket fittings are heated to welding temperature by means of a socket and spigot heater inserts. Socket welding may be manually performed on pipe diameters up to 2.0" (63 mm). Sizes above that require a Bench Socket Tool due to the required joining forces. In sizes greater than 1", a bench style machine may be preferred for ease of operation.

Heater Preparation of the Weld

Welding Process Hand-Held Socket Fusion Once the heating element is warmed to the proper temperature, welding proceeds as follows: 1. Follow the welding parameters provided with Asahi /America’s socket welding equipment (see Tables F-2, F-3, and F-5 for sample welding data).

F

Alignment and Preheat

2. a. Cut the pipe faces at right angles and remove burrs using a deburring tool. b. Clean the pipe and fittings with lint free paper and cleansing agents (isopropyl alcohol or similar). c. Mark the socket depth with a scraper knife or marker on the pipe to ensure proper insertion depth of the pipe during welding. d. Thoroughly clean heater inserts before each weld. 3. Quickly push pipe and fittings in an axial direction into heater inserts until the pipe bottoms (or meets the marking). Avoid twisting while heating. Hold in place for the heat soak time (column A). 4. After the heat soak time, remove the fitting and pipe from the heating element and immediately push them together within the change over time (column B) without twisting them until both welding beads meet. The change over time is the maximum period of time between the removal from the heating element and final settings of the components.

Joining and Cooling

Figure F-2. Socket fusion welding process

5. Components shall be held together and allowed to cool per the specified cool down time prior to stressing the joint.

Gap

No Gap

No Gap

Good Socket Weld

Bad Socket Weld

Figure F-3. Socket fusion welding samples Visual Inspection During the final joining step, it is important that the bead formed on the pipe meets the bead on the fitting. If the beads do not meet, a small gap will be present. Welds that have a gap between the fusion beads should be cut and rewelded (see Figure F-2). The bead on the pipe should be uniform around 360° of the pipe. Beads that vary in size or disappear altogether are a sign of improper heating and/or joining.

F-4

Table F-2. Sample Welding Data

(time-sec)

Pipe Size

A

B

C

(inches)

Heat Soak Time 8

Change Over Time 6

Cooling Time 240

1" Pro 150




WELDING METHODS

Butt Fusion (for single wall piping systems) The butt fusion of PP, HDPE, PVDF, and E-CTFE is accomplished with Asahi /America’s recommended butt-fusion welding equipment. Asahi /America provides welding equipment to handle all diameter sizes offered, and has an extensive line of equipment available to buy or rent for every application. The principle of butt fusion is to heat two surfaces at the melt temperature, then make contact between the two surfaces and allow the two surfaces to fuse together by application of force. The force causes flow of the melted materials to join. Upon cooling, the two parts are united. Nothing is added or changed chemically between the two components being joined. Butt fusion does not require solvents or glue to join material. Butt fusion is recognized as the industry standard, providing high integrity and reliability. It does not require couplings or added material. The procedure, recommended by Asahi /America, conforms to ASTM D-2857 for Joining Practices of Polyolefin Materials, and the recommended practices of the ASME B 31.3 Code (Chemical Plant and Petroleum Refinery Piping).

(Column D). Change over time is the maximum period of time when either the pipes or fittings can be separated from the heating element, yet still retain sufficient heat for fusion. Bring the melted end together to its welding pressure. 6. The heat soak time may need to be increased in cold or windy environments. Several practice welds should be conducted at the installation site to ensure welding can be performed as a test of conditions. Consult Asahi /America for any modification of weld parameters. 7. A visual inspection must be performed as well. After joining, a bead surrounding the whole circumference will have been created. A good weld will have two symmetrical beads on both the pipe or fittings almost equally sized and having a smooth surface. 8. Allow components to cool to the touch or until a fingernail cannot penetrate the bead. This is recommended in ASTM D-2857, Section 9. The pipes or fittings may be removed from the welding equipment at the completion of the specified cooling time. 9. Do not put components under stress or conduct a pressure test until complete cooling time (Column F) has been achieved.

F

Welding Process Once the pipes or fittings have been secured in the proper welding equipment, aligned and planed with the facing tool (planer), and the heating element warmed to the proper temperature, welding proceeds as follows:

Pipe

Heater

Pipe

1. Follow the welding parameters (temperature, time, and force) provided with Asahi /America’s butt-fusion equipment (see sample welding data in Table F-3). 2. Insert heating element between secured pipes or fittings, making sure full contact is made around surfaces.


Molten End

3. Apply full welding pressure, as shown in (Column A), until a maximum 1/64" ridge of melted material is present around the outside circumference of both pipes or fittings. This indicates proper melt flow has been accomplished and further guarantees two parallel surfaces. 4. Reduce the pressure to the recommended melt pressure (Column B) and begin timing for recommended heat soak time (Column C). 5. At the end of the heat soak time, in a quick smooth motion, separate the pipe fitting from the heating element, then apply weld pressure (Column E). It is important to gradually increase pressure to achieve welding pressure. The weld must be performed within the allowable change over time

Heat Soak Time

Joining and Cooling

Figure F-4. Butt-fusion welding process Table F-3. Sample Welding Data

(time-sec, pressure-psi)

Pipe Size

A

B

C

(inches)

Initial Melt Pressure 23

Melt Pressure 2

Heat Soak Time 60

2" Pro 150

Pipe Size

D

E

F

(inches)

Change Over Time 5

Welding Pressure 23

Cooling Time 420

2" Pro 150


Figure F-5. Butt-fusion welding example


F-5

INSTALLATION PRACTICES Butt Fusion (for double wall piping systems) Installation of Duo-Pro, Fluid-Lok, and Poly-Flo piping systems involves the use of thermal butt fusion for both the carrier and containment piping. Depending on system design, the size, material, and layout will determine the required equipment. Asahi /America offers all the necessary sizes and styles of equipment for any installation type. Systems that are fully restrained and consist of the same carrier and containment materials can take advantage of the simultaneous butt-fusion method. Simultaneous fusion allows for the quickest and easiest installation by conducting the inner and outer weld all at once. For Duo-Pro designs that consist of dissimilar materials, or require the inner (carrier) piping to be loose for thermal expansion, use the staggered welding procedure. Staggered welding consists of welding the inner carrier pipe first and the containment piping second. Finally, if a leak detection cable system is required, special heating elements or procedures are provided to accommodate for pull ropes.

F

The basic installation techniques for double containment piping systems follow the principles that apply to ordinary plastic piping applications.

Simultaneous Butt-Fusion Method The object of simultaneous fusion is to prepare both the carrier and containment pipe so that both pipes are fixed to each other and thus can be welded at the same time. In some systems, such as Asahi /America’s Fluid-Lok and Poly-Flo, simultaneous fusion can only be performed due to their design. The net result of the simultaneous method is a substantial reduction of labor and equipment requirements. As previously discussed, simultaneous fusion is only applicable for welding installations having the same carrier and containment material. In addition, simultaneous fusion is used for systems that are completely restrained. Prior to using the simultaneous method, an analysis based on operating conditions is required in order to determine the suitability of a restrained design. Refer to Section C, Engineering Theory and Design Considerations, or contact the Asahi /America, Inc. Engineering Department for assistance.

WELDING METHODS

ing required in the field and, in turn, reduce labor time. If an installation is pipe intensive, labor costs may be reduced by ordering prefabricated pipe spools in longer dimensions.

Welding Procedure Welding theory for double containment is the same as for the single wall pipe. Asahi /America has developed welding tables for the appropriate heating times and forces for simultaneous fusion. The following procedure outlines the necessary steps for simultaneous fusion.

Double Wall Pipe Assembly Pipe and fittings in a simultaneous double wall system from Asahi /America are always prefabricated at the factory and supplied to a job site ready for butt fusion. However, when varying lengths are required, in-the-field assembly is necessary. In staggered welded systems, pipe and fitting assembly is common. The basic procedure for properly assembling Duo-Pro and Fluid-Lok components is outlined below. In double containment piping assembly, proficiency in hand and extrusion welding procedures is necessary. 1. A good weld requires proper preparation of the material. The pipe should be free of any impurities such as dirt, oil, etc. Additionally, some thermoplastics develop a thin layer of oxidized molecules on the surface that require scraping or grounding of the material. Another effect, especially with HDPE, is the migration of unchained lower density molecules to the surface caused by internal pressure of the material. This gives the usually “waxy” surface appearance of HDPE. Grinding or scraping is required. Wipe off any dust with a clean cloth. Do not use solvents or cleaners; they introduce chemicals with unknown and likely negative effects. 2. Using Table F-4, place the molded or fabricated support spider clips, with tops aligned, on the carrier pipe, and then hot gas (PP) or extrusion weld (HDPE) the clips into place as shown in Figure F-6. Use the required amount of clips on the full lengths of the carrier pipe. Table F-4. Double Containment Internal Support Spacing (inches) Carrier Pro 150 Pro 45 PVDF Halar HDPE 11 HDPE 17 HDPE 32

Equipment For simultaneous welding, standard butt-fusion equipment used for single wall systems is used. No special heating elements are required. For Duo-Pro and Fluid-Lok systems, hot air or extrusion welding equipment is necessary to weld the support discs and spider clips to the pipes. Hot air welding is not used for any pressure rated components. Fittings Fittings used for simultaneous fusion are either molded or prefabricated at the factory with the necessary support discs. Prefabricated fittings greatly reduce the amount of hot air weld-

F-6

1" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20"

42 54 66 72 84 90 102 114 120 126 138 NA

NA NA NA 42 48 48 54 60 66 72 78 78

42 54 66 72 84 90 102 114 NA NA NA NA

44 59 69 72 NA NA NA NA NA NA NA NA

30 42 48 54 66 78 84 96 102 108 114 120

NA 36 42 48 60 72 78 84 90 96 102 108

NA NA 36 42 54 60 66 72 78 84 90 96

NOTE: At 68° F (See Appendix A for temperature deratings.)




WELDING METHODS

Tack and Weld Hot Gas PP, Extrusion HDPE

Spider Clip


5. The pipe and fitting with support discs are now ready for simultaneous butt fusion using the recommended ASTM D-2857 joining practices.

Butt-Fusion Procedure for Double Wall Pipe without Leak Detection Cable Systems

Figure F-6. Spider clip attached to carrier pipe 3. Insert carrier pipe into containment pipe. Be sure the two pipes have been stored in the same environment for equal expansion or contraction to occur before welding end centralizers into place. Containment Pipe

Spider Clip

Simultaneous fusion as outlined below is ideal for: • Duo-Pro systems made of similar carrier and containment material • Fluid-Lok HDPE systems • Restrained double wall systems only • All Poly-Flo systems Fusing Duo-Pro and Fluid-Lok is accomplished with Asahi / America’s recommended butt-fusion welding equipment. Asahi /America provides welding equipment to handle all diameters and system configurations. Equipment is available for rental or purchase. The principle of butt fusion is to heat two surfaces at a fusion temperature, then make contact between the two surfaces and allow the two surfaces to fuse together by application of force. After cooling, the original interfaces are gone and the two parts are united. Nothing is added or changed chemically between the two pieces being joined.

Figure F-7. Carrier pipe and spider clips inserted into containment pipe 4. For simultaneous welding, end centralizers, known as support discs, are hot air or extrusion welded to the carrier and containment pipes. This prevents any movement of the carrier pipe during the butt-fusion process. The alignment must match that of the spider supports for the installation of leak detection cables, as well as for leak flow. In fitting assemblies, install end centralizers only. All centralizers are installed approximately 1" from the ends using 4 mm welding rod. Install Cutout and Center Leg of Spider Clip at Top

Support Disc Centralizer

Butt fusion is recognized in the industry as a cost effective joining method of very high integrity and reliability. The procedure recommended by Asahi /America conforms to ASTM D-2857 for Joining Practices of Polyolefin Materials, and the recommended practices of the ASME B 31.3 Code (Chemical Plant and Petroleum Refinery Piping). The procedure is outlined as follows: Once the pipes or fittings have been secured in the proper welding equipment with the tops and annular space aligned and the heating element warmed to the proper temperature, welding should proceed as follows: 1. Follow the welding parameters provided with Asahi /America butt-fusion equipment (see sample welding data in Table F-5). Table F-5. Sample Welding Data Pipe Size

A

B

C

(inches)

Initial Melt Pressure 49

Melt Pressure 5

Heat Soak Time 60

2" x 4"

Pipe Size

D

E

F

(inches)

Change Over Time 4

Welding Pressure 49

Cooling Time 420

2" x 4"

Annular Space for Leak Detection


Figure F-8. Support disc attached to carrier and containment pipes


(time-sec, pressure-psi)

2. To ensure the carrier pipe is planed and flush with the containment pipe, put 4 marks on the end of the carrier pipe at 3, 6, 9 and 12 o’clock prior to planing. If the outer pipe is completely planed and the marks on the carrier have been removed, planing is complete. With experience, visual


F-7

F

INSTALLATION PRACTICES inspection can determine the planing process is complete. Remove all shavings and recheck alignment. For Poly-Flo, the pipes should be installed in the machines so that the ribs do not align, thereby allowing any fluid to flow to the low point of the annular space in the event of a leak. Planing Unit

WELDING METHODS

5. Reduce the pressure to the recommended melt pressure (Column B) and begin timing for recommended heat soak time (Column C). 6. At the end of the heat soak time, in a quick smooth motion, separate either the pipes or fittings, remove the heating element, then apply weld pressure (Column E). It is important to gradually increase pressure to achieve welding pressure in Column E. The weld must be performed within the allowable change over time (Column D). Change over time is the maximum period of time when either the pipes or fittings can be separated from the heating element, yet still retain sufficient heat for fusion. Bring the melted end together to its welding pressure. Weld Pressure

Weld Pressure

Figure F-9. Plane carrier pipe flush with containment pipe 3. Insert heating element between secured pipes or fittings, making sure full contact is made around surfaces.

F

Heater Plate

Figure F-12. Bring pipe ends together and apply welding pressure 7. The heat soak time should be increased if the environment is cold or windy or if either the pipes or fittings are cold. As a test of environmental conditions, several practice welds should be done at the installation site to ensure welding can be performed. Consult with Asahi /America for recommendations on cold weather welding.

Figure F-10. Insert heating element between pipe ends

8. A visual inspection must be performed as well. After joining, a bead surrounding the whole circumference must have been created. A good weld will have a symmetrical bead on both pipes or fittings and will have a smooth surface.

4. Apply full welding pressure (as shown in Table F-5, Column E) until a maximum 1/64" ridge of melted material is noticed around the outside circumference of the components. This indicates proper melt flow has been accomplished and further guarantees two parallel surfaces. Constant Pressure Heat Soak

Constant Pressure Heat Soak

Figure F-13. Visual inspection of welds 9. Allow components to cool to the touch or until a fingern ail cannot penetrate the bead. This is recommended in ASTM D-2857, Section 9. The pipes or fittings may be removed from the welding equipment at this time. Figure F-11. Apply welding pressure to the heating element

F-8

10. Do not put pipe or fittings under any type of stress or conduct a pressure test until complete cooling time (Column F) has been achieved.




WELDING METHODS

Heater Plate

Butt-Fusion Procedure for Double Wall Pipe with Leak Detection Cable Systems This method is available for the following systems: • Duo-Pro made of similar material on the carrier and containment • Fluid-Lok HDPE system • Restrained systems only Asahi /America split-leak detection heating elements allow both the carrier and containment pipes to be welded simultaneously, with a pull cable in place. The mirror design, as shown in Figure F-14, is capable of splitting apart and wrapping around a wire. The small hole centered at the bottom of the heater allows a pull wire to be in place during the fusion process. Once the pipe is heated, the heating element is split apart and removed, leaving the wire in place for the final pipe joining.

Pull Rope Connected by Wire

Split Heating Mirror

Figure F-16. Pull rope connected by wire through heating element



F Pull Rope Connected by Wire Closed

Open

Symmetrical Bead on Outer and Inner Walls

Split Heating Mirror

Figure F-14. Split heating elements for leak detection systems A short piece of wire is attached to the pull rope on both ends after planing. The wire runs through the heater during welding in order to prevent damaging or melting the pull rope (see Figures F-15 to F-18). After each section is complete, the wire is pulled down to the next joint to be welded. The installation of pull rope is at the six o’clock position. A continuous pull rope, free from knots and splices, should be pulled through as the system is assembled.

Figure F-17. Pipe ends heated with pull rope installed

Weld Pressure

Weld Pressure

Planing Unit

Symmetrical Bead

Figure F-18. Welding complete with pull rope installed Follow standard butt-fusion procedure for welding. Other methods for welding with a solid heating element are available that will accommodate a leak detection cable system. Leak Detection Pull Rope

Figure F-15. Planing ends with pull rope installed



F-9


WELDING METHODS

Staggered Butt-Fusion Method Using the staggered fusion procedure to assemble a Duo-Pro system is more complicated and labor intensive than simultaneous fusion. However, it offers the ability to install a double containment system with a flexible inner pipe or with different carrier and containment materials. Asahi /America provides all the necessary equipment for this welding method. In staggered welding, the carrier pipe is welded first, followed by the containment pipe. In a staggered system there are no end support discs. This allows for movement of the carrier components. It is important to plan which welds will be made and in what order. Enough flexibility is required to move the inner pipe out from the outer pipe to perform a carrier weld. In long straight runs the procedure is simple, due to significant carrier pipe movement. In systems that are fitting intense, the procedure becomes more difficult, because the pipe movement is limited to the amount of annular space between the carrier and containment fittings (see Figure F-19).

F

L

A. Cut carrier and containment pipes to length L

B. Pull carrier elbow out of containment elbow and weld to carrier pipe

Welding Procedure 1. Begin by attaching spider clips to the carrier pipe (follow steps in double wall pipe assemblies). 2. Insert carrier pipe or fittings into the appropriate containment line. At the start of a system, it may be easier to weld the carrier first and then slide the containment pipe over the carrier pipe. However, as the installation moves along, this will not be possible. Note: If containment piping has been roughly cut, make sure to plane it prior to welding the carrier pipe. Once the carrier is welded, the containment pipe cannot be planed. 3. In the machine, use the two innermost clamps to hold the carrier pipe for welding. Use the outer clamps to hold containment pipe in place. In cases where movement is limited, fitting clamps will be necessary to hold the carrier pipe. 4. Once all pieces are locked in place, weld the carrier pipe using standard butt-fusion techniques (see Figures F-19 A and F-19 B). 5. Once the carrier weld is complete, remove the inner clamps and pull the containment pipe together for welding (see Figures F-19 C and F-19 D). At this point, switch all clamps to containment sizing. It may be preferable to use two machines to eliminate the constant changing of clamps. Also, in some designs, two machines may be required to weld the two different diameter pipes.

C. Weld containment elbow to containment pipe

D. Flex carrier elbow and pipe toward tee and weld to carrier tee pipe

E. Weld containment pipe to containment tee

6. To weld the containment pipe, a split annular mirror is required (see Figure F-19 F). The mirror is hinged to let it wrap around the carrier pipe while welding the containment pipe. 7. It is important to ensure the mirror is properly centered so it does not rest on and melt the carrier pipe. 8. Once the mirror is in place, the welding procedure is the same as standard single wall butt fusion.

Closed

Open

F. Annular heating element Figure F-19. Staggered butt fusion

F-10



WELDING METHODS


Helpful Hints • When welding PVDF and Halar, move swiftly when removing the mirror and joining the pipes. Delayed reaction will cause material to cool and a “cold weld” to form. PVDF and Halar cool off more quickly than polypropylene. • Always plan welding so the longest and heaviest section of pipe is positioned on the stationary side of the welding machine. • Start at one end and work to the other end of the pipe system. Do not start on two different ends and meet in the middle. Moving the pipe for welding will be extremely difficult or impossible. • When planing, long strips indicate you are flush all the way around. • Consult the factory for a proper equipment recommendation for the system being installed. • Machines are extremely adaptable and can be positioned in many ways to accommodate difficult welds.

F



F-11

INSTALLATION PRACTICES IR Fusion Improving upon conventional butt fusion, IR welding uses a non-contact method. IR welding uses the critical welding parameters of heat soak time, change over time, and joining force as found with butt fusion. However, by avoiding direct contact with the heating element, IR fusion produces a cleaner weld with more repeatable and smaller bead sizes. The end result is a superior weld for high-purity applications.

WELDING METHODS

Ramping up and monitoring the force is critical for repeatable and successful IR welding. This ensures the molten material has joined at the right force and prevents against cold welds, which are caused by the molten material being overly pushed to the inside and outside of the weld zone.

Heater Pipe

Pipe

The graph in Figure F-21 outlines the forces applied during the non-contact joining process. Notice that the ramp up force to full joining pressure is a smooth curve where force is gradually ascending over time. Even force build-up is critical to join material without creating a cold joint. Start of Heating

Welding Process

F

Molten End

Material is prepared for IR fusion by preparing smooth arid level surfaces among the ends to be joined. Butting the material against an internal planer acts as a centering and leveling device. The planer is then used to cut a clean and smooth surface. The material should then be checked for vertical and horizontal alignment. Welding machines should allow for minor adjustments to the vertical and horizontal orientation of the material.

Molten End

Heat Soak Time

Once alignment has been verified, the material is heated by close proximity to the heating source. Through radiant heat and proper heat soak time, the material becomes molten to allow physical bonding between the two pieces. Joining and Cooling

After the heating source has been removed, the material should be joined together in a steady manner, slowly ramping up the force until the desired joining force has been achieved.

Figure F-20. IR fusion welding process

Pressure/Temperature Welding Time Total Joining Time Welding Temperature Pressure

Alignment Jointing Pressure

Temperature Heat Soak Time Adjusting Time Joining Time Cooling Time

Pressure Time

Figure F-21. IR fusion timing diagram

F-12




WELDING METHODS

HPF Fusion The HPF welding technology is an electric socket fusion system that joins Purad PVDF piping components, providing a smooth internal surface.

Welding Process

HPF Heating Process without Balloon

Pipes and/or fittings are to be planed except standard 90s, which are planed at the factory. The HPF coupling is placed in the wide mounting clamp. Using the mechanical stop on the clamp, the pipe is centered in the coupling. The pipe or fitting ends should be tight against each other without a gap.

Figure F-23. HPF fusion heating process without balloon

Once the components are fixed in the clamp, the leads are connected and the proper welding times and voltage are scanned through a bar code reader. The entire welding process from this point is automatic and controlled by the HPF unit. HPF provides a weld without any internal obstruction or any outside contamination. Since the coupling is the heating element and is closed to the external environment, contamination is avoided during the fusion process.

HPF Heating Process with Balloon

Figure F-24. HPF fusion heating process with balloon

HPF uses most butt-fusion fittings. Extended leg fittings are not required.

F

HPF welding is capable of being conducted with or without an internal balloon. With the balloon, the joint is completely smooth without any bead or seam. Without the balloon, the joint is still beadless. The advantage of HPF is that all joints within its size range can be conducted without the need of a union, flange, or alternative welding method. Use the HPF Operation Manual for further details on weld procedures. Planer

Planing

Coupling in Clamp

Preparation of the Weld

Figure F-22. HPF fusion welding preparation



F-13

INSTALLATION PRACTICES Side-Wall Fusion

Hand-Held Welding

Side-wall fusion is a process that allows branch outlets of smaller diameter pipes to be fused to the side-wall of a larger main pipe line. The side-wall procedure for polypropylene and polyethylene can be accomplished by using the manufacturer’s suggested equipment. Size, availability, and pricing can be obtained through Asahi /America representatives.

Welding Instructions

The following steps, along with machine instructions, should be carried out to complete the fusion process: 1. Install fusion machine on the pipe (main). 2. Clean the pipe with a clean cotton cloth. Prepare surface of pipe (main) by roughing with emery cloth or equal abrasive. 3. Prepare the base of the main and tighten clamp. 4. Align branch on main and tighten clamp. 5. Check branch for square alignment on main. 6. Retract moveable clamp, roll, and center heater plate with adapter between base of branch and main.

F

7. For all sizes, apply a strong, firm, continuous pressure until complete melt bead can be seen on the main. Release pressure to light pressure. Continue heat soak cycle until allotted time occurs. 8. Retract moveable clamp and cleanly remove heater plate. 9. Bring melted surfaces together within allotted time. Gradually apply continuous pressure until the proper pressure is reached. Maintain pressure until joint cools and hardens.

WELDING METHODS

The Process in General Hot air (gas) welding is the process of fusing a bead of material against a like material. This welding is common with sheet fabrication and applications not requiring pressure resistance. Asahi/America uses hot air (gas) welding to locate support discs for pipe centering in its Duo-Pro system. In hot air (gas) welding, the heat transfer medium is a heated gas, either nitrogen or clean air. Originally the use of nitrogen proved most successful, preventing material contamination and oxidation. With today’s material quality and equipment technology, nitrogen is becoming less common, except with critical materials. The combination of clean, oil, and moisture free air with the controlled temperature proves equally successful, eliminating the continuous expense of the inert gas. The temperature of the hot air ranges between 300° C – 350° C for HDPE and 280° C – 330° C for PP, when outside welding conditions are about 20° C. The temperature range will vary with changing ambient conditions. To accomplish high-quality welds, it is important the fillers (welding rod) are of the same material and type. The most common welding fillers are 3 mm and 4 mm round. There are also special profiles, such as oval and triangular rods. The welding tip used must also match the cross section of the welding rod.

Processing Guidelines Hand Wheel Pressure Gauge

Sidewinder

Branch Outlet Heater Main Pipe

Figure F-25. Fixture for side wall fusion

F-14

Install welding tent or equivalent if weather conditions suggest. A good weld requires proper preparation of the material. The part should be free of any impurities such as dirt, oil, etc. Additionally, some thermoplastics develop a thin layer of oxidized molecules on the surface that require scraping or grounding of the material. Another effect, especially with HDPE, is the migration of unchained lower density molecules to the surface caused by internal pressure of the material. This gives the usually “waxy” surface appearance of HDPE. Grinding or scraping of the surface is required. Wipe off any dust with a clean cloth. Do not use solvents or cleaners; they introduce chemicals with unknown and likely negative effects. The forms of the welding seams on plastic components generally correspond with the welding seams on metal parts. In particular, pay attention to the general principles for the formation of the welding seams. The most important welding seam forms are: V-weld, Double V-weld, T-weld, and Double T-weld.




WELDING METHODS

Tack Welding The initial step in the welding process is the “tack weld.” The objective is to put the parts into place, align them, and prevent any slippage of the material during the structural welding process. Welder should use own discretion when applying an intermittent or continuous tack. Larger structures and thick gauged materials may require addition clamping.

60°-70°

V-Weld

High-Speed Welding In this process a filler material, the welding rod, is introduced into the seam to give supportive strength. Standard rod profiles are round or triangular. Triangular rod is a single supportive weld and does not allow for the kind of surface penetration achieved with round welding rod.

60°-70°

Round welding rod is used where heavy-duty welds are required. It allows the fabricator to lay several beads of welding rod on top of each other. This way, a relatively thin welding rod can be used to produce a strong weld.

Double V-Weld

By performing a few practice welds, the welder will develop speed and force necessary to complete a successful weld. Heat the welding rod within the rod-drawing nozzle and push into the welding groove. The force applied on the rod controls the speed of the welding. The operator should look for a small bead of melted rod on both sides. Apply additional welds to fill the groove.

45°

Hot Air Welding Rod T-Weld Guide and Preheat of Welding Rod

Pressure Shoe Forced Down on Rod and Base Material Preheat Slot for Base Material Base Material 45°

Figure F-27. High-speed welding process Double T-Weld

Figure F-26. Typical welding seam forms


Free Hand The oldest method of welding filler rod. This process is much slower than high-speed welding, but it must be used where very small parts are being welded, or where the available space prohibits the use of high-speed welding tips. The only nozzle used in this process is a small jet pipe with an opening of 1/8" or 5/32" to concentrate the heat. The welder performs a waving action of the nozzle at the base material and the welding rod with an “up and down” and “side to side” motion to bring the rod and material to melting form. Hand apply pressure vertically at 90° to begin. After reaching the correct amount of pressure and heat to the rod and base material, a small wave of molten material forms in front of the welding rod. If bent backward, the


F-15

F


WELDING METHODS

welding rod will stretch and thin out; if bent forward, no wave will occur in front, resulting in insufficient pressure. Free-hand welding requires a highly skilled operator and should be avoided if a simpler method can be used. Air Heater Round Nozzle Welding Rod

Welding Seam Forms for Extrusion Welding Pressure

3 mm

Hot Air V-Weld without Sealing Run

F

Figure F-28. Free-hand welding

3 mm

Extrusion Welding Extrusion welding is an alternative to multiple pass hand welding and can be used whenever physically possible to operate the extruder. Extrusion welding is used for joining low pressure piping systems, construction of tanks and containers, for joining liners (for buildings, linings for ground work sites), as well as special tasks. This welding technique is characterized as follows: 1. Welding process is performed with welding filler being pressed out of a compound unit. 2. The welding filler is homogenous with the material being joined. 3. The joining surfaces have been heated to welding temperature. 4. Perform joining under pressure.

Double V-Butt Welding

45°- 60°

3 mm T-Joint with Single Bevel Groove with Fillet Weld

Welding Seams Prepare adequately before welding (e.g., scraping or grinding). Do not use solvents or cleaners; they introduce chemicals with unknown and likely negative effects. 45°- 60°

When choosing welding seam forms, consider the general technical principles for welding seam formations shown in Figure F-29. Qualification of Welder and Requirement on Welding Devices The plastic welder must have the knowledge and level of skill required for the performance of the welding process. The operator performing the welding must be a trained, certified welder.

F-16

3 mm T-Joint with Double Bevel Groove

Figure F-29. Typical welding seam forms




WELDING METHODS

Equipment and Procedure For extrusion welding, a portable welding device consisting of a small extruder and a device for generating hot air is the most common.

A

A = 0.7 x S N = 1.4 x S

N

An extruder uses either pellets or welding rods as a filler material. Do not use pellets or rods of unknown origin, uncontrolled composition, or regenerated material for welding. Make sure the filler is dry and clean before beginning the welding process. The extrusion welder includes a melting chamber with an extrusion screw, driven by an electric motor.

S

With the pellet extruder, the pellets are gravity fed from a hopper into the melting chamber. A rod extruder has a feed mechanism attached to the rear of the extrusion screw that pulls the welding rod into the melting chamber. The adjusting surfaces of the parts to be welded are heated up to the welding temperature by means of hot air passing out of the PTFE nozzle on the welding device. The welding filler, continuously flowing out of the extruder device, is pressed into the welding groove. The welding pressure is applied onto the PTFE nozzle, directly fastened at the extruder end, which corresponds to the welding seam. The discharged material pushes the welder ahead determining the welding speed.

NOTE: If material thickness does not match, use the “s” value from the thicker material to calculate bead size.

Lap Joint

Testing

In order to accomplish sufficient heating and thorough welding, it is necessary to provide an air gap depending on wall thickness (width of air gap should be 1 mm minimum).

The means for non-destructive testing are limited. Therefore, visual checking of the weld appearance becomes important. A good weld on thermoplastic material will show a slight distortion along the edge of the welding rod, indicating proper heat and pressure. Changes of the surface appearance of the base material right next to the weld indicated proper preheat temperature. A uniform appearance of this area indicates constant welding speed.

Lap Joint with Filet Weld

Figure F-31. Guideline for calculation of extrusion bead size

Visual Inspection The primary function of the operator is to ensure sufficient pressure be applied along with maintaining proper speed. Too little pressure will result in the molten mass not being formed into the final bead, and too much speed will cause the bead to thin. Both of these mistakes are easy to spot on the finished product.

If bead shows no distortion, the bead lacked proper pressure. Combine no distortion with a shinny appearance, the bead lacks proper pressure and too much speed. On the other end of the scale, a too high welding temperature or too slow a welding speed will overheat the base material, and/or welding rod. Overheating PP or PE will result in the bead looking extremely shinny and small splashes of material seem to spray away from the bead.

Lap Joint with Lap Weld (for liners with a thickness up to 3.5 mm)

In pipe seams, the best method for testing is to conduct a hydrostatic pressure test according to Asahi /America procedures. >12

>12

Lap Joint with Extrusion Weld (for liners with a thickness up to 3.5 mm)

Figure F-30. Lap joints



F-17

F


WELDING METHODS

Electro-Fusion Welding

Welding Procedure

Electro fusion is a simplified and safe method of joining pipe and/or fittings based on melting the outer surface of the pipe and the inner surface of the electro-fusion coupling using an integral electric wire. Electro fusion is a cost effective method for joining polypropylene and HDPE pipe. As an alternative to butt fusion, electro fusion can be used for repairs, double containment assembly and difficult connections in tight quarters.

Observe the operating instructions for the welding device, as individual tools may vary. Plug-type socket connections should be turned upward and then connected with the cable. After the welding equipment has been properly connected, the welding parameters are input by means of the bar code reader. An audio signal will acknowledge the data input. Heated Area

Welding Equipment The Polymatic Electro-Fusion equipment performs the welding of all Asahi/America’s electro fittings. The control box has a computerized command system for fully automatic control and energy supply monitoring. Each fitting has a bar code label, which contains the information needed for correct fusion. The welding time is preprogrammed at the factory and set by use of the bar code. Simply scan the bar code to set up the machine for material to be joined.

Preparation before Welding

F

Cut pipe at right angles and mark the insert length (insert length = socket length /2). To obtain successful welding, it is essential to clean and scrape the surface of the parts to be joined. In addition, cuts must be straight to ensure proper insertion into the coupling. Scraping must be done using a proper hand-operated or mechanical scraper. Do not use tools such as rasp, emery paper, or sand paper. Slide the socket on the prepared end of pipe right to its center stop until it reaches the marking. Insert the second pipe end (or fitting) into the socket and clamp both pipes into the holding device. The clamping device protects against the components from being pushed out during fusion.

The molten area increases and heat is transfered to the surface of the pipe, which in turn begins to melt.

Figure F-33. Initial heating occurs in coupling Pressing the start key initiates the welding process. The time on the display also is programmed into the machine and allows the correct heating time for various pipe sizes. Molten Material

Plug Type Socket Connection Socket Coupling Surrounded Material

Figure F-34. Molton material from both coupling and pipes form weld Pipe Clamp The electric wire heats and melts the surrounding material.

Figure F-32. Electro-fusion welding setup

F-18




WELDING METHODS

Figure F-35. Completed electro-fusion weld During the welding process (including the cooling time), the clamping device shall remain in place. The end of the welding process is indicated by an audio signal. The welding indicator on the socket performs visual control. Before pressure testing, all welded joints must have completely cooled down based on welding parameters provided with the equipment. The pressure test must be performed according to recommended procedures.

F



F-19


HIGH-PURITY INSTALLATIONS

HEPA Filters

HIGH-PURITY INSTALLATIONS Installing a high-purity system properly requires preplanning. The installation is more than the welding of components. It requires the proper environment, material inventory, welding equipment, tools, and thorough training. This guide will concentrate mainly on materials such as PVDF, E-CTFE, and PP, as supplied by Asahi /America, Inc. However, certain sections in regard to fusing PFA are also inserted to assist in the assembly of a Purebond® PFA piping system. Asahi /America and Agru are fully licensed by Entegris to provide IR welding for PFA Purebond® piping components. The SP110 welding tool is the only tool available on the market designed and outfitted to weld PVDF, PP, E-CTFE, and PFA. This means one tool to conduct welding of all materials on an HP installation.

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Asahi /America’s recommendations for project management follow. Step 1. Welding Environment Step 2. Tool Selection Step 3. Material Handling Step 4. Training and Preparation Step 5. Tool Commission and Daily Checks Step 6. Weld Inspection Step 7. Hanging Step 8. System Testing Step 9. Repair Procedures

Step 1. Welding Environment Asahi /America does not set requirements for proper welding environments. As the installer, it is necessary to choose the environment based on the installation type, timing, or quality goal. In all cases, the environment for welding should be monitored to ensure the temperature is in the range of 41° F to 105° F. The humidity should not exceed 70%. If using IR fusion, wind must be avoided. All PuradTM PVDF components are manufactured and packaged in a cleanroom environment. Great care is taken to ensure that they arrive on the project site in protective packaging to maintain their purity. To be consistent, it is ideal to conduct welds in a clean or cleanroom environment. Particles, dust, or dirt in the air will adhere to the pipe during the welding process. To reduce contamination in the system, as many welds as possible should be conducted in a clean type environment. A class 100 or 1000 room is perfectly suitable. Portable style cleanrooms make for an efficient set up when conducting all the welds on site.

Purebond is a registered trademark of Entegris Corporation.

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Flexible Clear Walls

Flexible Door

Wheels for Portability

Figure F-36. Portable cleanroom Within the clean zone it is recommended to build spool pieces. The size and configuration is dependent on the ability to safely transport it to its final destination. The ends of the spool pieces should be prepared for final connection once in the pipe rack. In smaller dimensions, 1/2 "– 2", the ends should be fitted with unions or sanitary fittings to reduce welds in the pipe rack, as they are more difficult. One advantage of the Purad PVDF system is the availability of the HPF welding method in 1/2 "– 2". HPF is a portable welding method designed specifically for Purad. HPF provides a bead free joint, while allowing for welds in extremely tight locations. HPF welds through use of an electric socket, which melts the components together evenly without producing a bead internally. When building spool pieces, plane the ends to be welded prior to placing in the pipe rack. This avoids the need to bring planing equipment into the pipe rack. If components are properly supported once in place, HPF welds can be conducted with one clamp that is no longer than 11/2 inches. See Figure F-37 for a sample of a portable fusion. Leads PVDF Pipe

Proper Support HPF Clamp

Figure F-37. Portable HPF fusion makes welding in the rack reliable In sizes larger than 2", it is recommended to build spool pieces with flange connections. This avoids having to conduct difficult butt-fusion welds in tight locations. Flanged spool pieces also offer the benefit of being able to make changes later. In some instances, field welds can or must be conducted in a pipe rack. For these occasions, the use of contact butt-fusion equipment to ensure proper heating for larger diameter pipe is recommended. Consult with Asahi /America’s Engineering Department for specific tool selection and weld procedure recommendations.





Many installations do not require the same level of purity and care as others. Polypropylene is often chosen as a cost effective alternative to PVDF for these installations. In these cases, a cleanroom environment may not be necessary. It is still recommended to have a dedicated welding zone. The welding area should be clean and measures should be taken to reduce foot traffic through the area. Keeping the tools in one location reduces wear and tear, as well as the possibility of physical damage during a transport.

Socket Fusion Socket fusion is the oldest and simplest method for assembling thermoplastic materials. Socket fusion is available for welding PVDF (SDR 21) and PP in sizes 1/2 "– 4". In socket fusion, material is in direct contact with the heat source. The pipe is inserted into a heated mandrel and the pipe’s exterior becomes molten. Fittings are inserted over a mandrel and the interior becomes molten. After proper heat soak time has been accomplished, the two components are forced together until they bottom-out.

In all HP installations it is necessary to have a set of dedicated tools, such as levels, pipe cutters, tape measures, etc. Keep these tools dedicated to the high-purity installation to avoid cross contamination with other non-purity installations.

Air Movement Finally, in all cases, it is preferable to weld in ambient temperature environments of 20 to 25 °C. The avoidance of windy areas and fans is also recommended. When using welding methods such as IR fusion, it is absolutely required to avoid air movement in the weld zone. For other methods such as butt or socket, wind is not as troublesome, but should be avoided if possible as it raises the chances of contamination, as well as improper heating of the pipe components.

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Step 2. Tool Selection The selection of the type of welding method conducted on a high-purity project should be based on the following criteria: • • • • • •

Material Sizes to be installed Welding location Type of installation Available expertise Required documentation

Materials available for high-purity water and chemical systems are PVDF, polypropylene (natural and pigmented), and HalarTM (E-CTFE). PVDF is the most common choice due to its low ion extractable and surface smoothness. In addition, the Purad PVDF system is available in a wide selection of sizes and pressure ratings, as well as having a full complement of specialty valves and fittings that are specifically designed for ultra pure systems. Table F-6 identifies by material type welding methods available from Asahi /America. Discussions on each method and the advantages of each method for installing HP systems follows. Table F-6. Available Welding Material

Socket Fusion

Purad PVDF- HP Proline PP PolyPure PP Halar E-CTFE PFA (Purebond)

* *


(by material)

Butt Fusion * * * *

IR Fusion * * * * *

HPF *

Figure F-38. Hand-held socket fusion for 1/2"– 2" Socket fusion is fairly tolerant to temperature conditions and is simple to do. Untrained personnel can be trained in a short period of time to make consistent and reliable joints. The disadvantage of socket fusion is that it provides the most uneven weld of all the methods. Beads are formed on the pipe and fitting and final stop position is random, depending on the operator. Mechanically the weld is reliable, but smooth, clean welds are more difficult to achieve consistently. Additionally, weld inspection is limited as the weld area is not visible from the outside. Socket fusion is ideal for smaller systems and is quite simple and practical for welding 1/2 " through 1". Systems consisting primarily of 3” (90 mm) and 4” (110 mm) may be better suited for IR or butt fusion.

Butt Fusion The butt-fusion welding method was pioneered by Asahi /America for use in high-purity systems. Butt fusion offers smaller, cleaner, and stronger welds as compared to socket fusion. Butt fusion allows visual inspection of the weld quality through an examination of the bead formation. It is available in all sizes and all materials offered by Asahi /America. Multiple styles of equipment are available and vary from small, light manual tools to large diameter, hydraulic driven equipment. Butt fusion is ideal for all dimensions, and proves quite practical in sizes 1" through 12". See Figures F- 39, F-40 and F-41 for examples of tool types.


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During the butt-fusion process, components are forced against a flat heating element or plate to melt the ends for the fusion. At the completion of heating, the materials are joined together at a force proportionate to the welding surface area. The result is a clean, double bead formation. Since the material is in contact with the heating element, there is the slight possibility of contamination if the heat plate is not properly cleaned and maintained throughout the project. In addition, molten plastic can also adhere to the heating plate if not properly released from the plate at the conclusion of the heat soak period.

Figure F- 39. Shop 4 (1/2" – 4")

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The advantage of butt fusion is its weld strength. When properly conducted it is a strong, reliable joint. Butt fusion can be done in any size range, reducing the training time at the job start-up. In addition, butt fusion is fairly weather tolerant. This does not mean it can be conducted in any environment, but it will work in conditions other methods will not. An advantage of working with Asahi /America’s system is the availability of multiple equipment and methods. For a given project, IR fusion may be the primary welding method; however, if field welds are required, butt fusion is the method of choice in many sizes. It reduces risks when welding outside or in areas with significant air movement.

IR Fusion IR fusion has become the welding method of choice in ultra pure semiconductor water and chemical systems. It should also be considered for pure water systems in pharmaceutical and biotech applications. IR fusion has many of the advantages of butt fusion, but eliminates the concerns of contacting the heating element. IR fusion is available in sizes 1/2 "–10" and multiple styles of equipment. PVDF, polypropylene, and Halar™ can be welded with IR equipment. IR fusion equipment is highly sophisticated. Asahi /America offers two styles of equipment: the UF2000 series and the new acclaimed SP series. Both tools are computer driven and offer a high level of quality control. Figures F- 42 and F-43 depict both styles of tools in terms of traceability and weld documentation. Figure F- 40. Shop 12 (11/2" – 12")

Figure F- 41. Field machine (3" – 12")

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Figure F- 42. SP 110 (1/2" – 4")





Figure F- 45. Cross-sectional view of IR joint IR fusion is recommended for controlled environments where temperature is consistent and air flow levels can be minimized. IR fusion equipment is designed for bench/shop style work and should not be hoisted into pipe racks.

HPF Fusion

Figure F-43. UF 2000/1 (1/2" – 2")

AGRU SP-110

Built-in printers provide data labels at the end of each weld, identifying the process was properly conducted, the material programmed, and the dimensions welded. Weld labels also provide the date and time of the fusion, as well as the joint number for physical tracking. See Figure F- 44.

00263179.W01

1/1

03.05.2001 15:53 SerNo:W11199-179 PP-n/50/4.6/IR

WELD .OK

Figure F- 44. Weld label from a SP tool On-board computers also provide control of the welding process and data logging of each weld. Data can be downloaded on each weld at any time to verify the quality of the system.

HPF is portable, bead free fusion method for welding sizes 1/2 " through 2". HPF is ideally suited for pure water systems in the Pharmaceutical Industry. In addition, HPF is extremely practical for welding in tight locations, whether in the pipe rack or under a sub floor. HPF is only available currently for PVDF material. For conducting beadless fusion, HPF is provided with two options: with balloon and without. For beadless and seam free welds, balloons are available. This ensures a smooth weld and no crevice. Joints welded with balloon will have a small wave in the joint due to the weight of the coupling and the outward force of the inflated balloon. Sometimes it is not possible to place a balloon in the weld area and then be able to remove it after, such as in the case of a repair or addition. For this reason, HPF can also be conducted without a balloon. These joints will also be beadless, but will have a small seam around the joint. In comparison to alternatives, such as a union or flange, it provides a smaller seam without a gasket.

IR fusion for Asahi /America systems enhances the weld quality. The bead formation is consistent, making weld inspection more reliable. The bead formation is greatly reduced when compared to socket or contact butt fusion. The welds are smoother, more rounded, due to a reduction of excess molten material and weld force required. The net result is a cleaner and more reliable weld. Figure F-45 is a cross-sectional view of a pipe wall welded with IR fusion.



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the end. The pipe is then sleeved in a large single PE bag and heat sealed on both ends. Finally, the entire pipe is placed in a hard HDPE tube and capped. Tubes are labeled appropriately, identifying the product and size inside. See Figure F-47 for a typical pipe package.

Figure F- 46. HPF equipment Figure F-47. High-purity PVDF packaging

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HPF uses an electric socket for each weld, and is energized by a computer controlled transformer. Weld parameters are preprogrammed into the control unit and selected via a bar code reader. The HPF is available in a bench type configuration, as well as having accessories for working in tight quarters. HPF is recommended for welding in or outside of a cleanroom environment. During the weld process, HPF is closed to the external environment, so issues of wind, temperature, and contamination are greatly reduced. HPF is the tool of choice for repairs or additions to an existing system. HPF is available for PVDF in sizes 1/2 "– 2".

Step 3. Material Handling Purad PVDF and HP Specifications TM

High-purity Purad components are received from the factory in special packaging to ensure its purity. Fittings and valves are double packaged in a class 100 cleanroom immediately after production and cleaning. Double bagged fittings are shipped in protective boxes. Valves are shipped in individual boxes. Once on site, fittings should be inspected for damage from the transport. Damaged fittings and /or packaging should be set aside. If welding in a cleanroom or clean environment, remove the outer bag in a staging area and store the fitting inside the cleanroom in the single bag until ready for use. It is recommended to store the fittings in plastic bins within the cleanroom and not to use a cardboard box within a clean environment. Label bins on size and fitting style.

In sizes 11/4" (40 mm) and larger, there is a single pipe per tube. In sizes 1/2 "–1", there are multiple pipes per tube. Purad uses hard PE tubes that provide superior protection from contamination in the environment. Hard HDPE tubes provide protection from moisture, dragging, and outside dust and dirt. The use of cardboard tubes has been forbidden due to its nature of particle generation. Cardboard protective tubes will create particles that can contaminate a cleanroom environment. Preferably, pipe should be stored inside or in a trailer. Care should be taken to properly support pipe during storage. Use the hanging criteria for the proper support distance. Pipe can be stacked during storage. Heavier pipes of larger dimensions should be stored at the bottom; however, it may prove more practical to segregate by size for easier access during the project. Pipe should not be stacked above the maximum height of 4 feet. Storage should be in the HDPE tube. When ready to transport pipe into the clean zone, open the outer cap on the HDPE tube. Place the tube next to the clean zone entry and slide the pipe directly from the tube into the cleanroom. This will eliminate any need of wiping down the bag prior to entry. In the cleanroom, remove the single bag if ready for immediate usage. If stored in the clean environment, it is preferred to leave the pipe in its original packaging. When ready for welding, remove all packaging and caps. Remember to save the caps for sealing the ends of prefabricated spool pieces.

Pipe is also packaged in a class 100 cleanroom environment at the factory. At the final stage of extrusion, pipe is sealed on the end with a piece of PE sheet and a hard PE cap is placed over

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PolyPure and Pure Polypropylene Systems PolyPure is a natural polypropylene system made available specifically for pure water and chemical systems. PolyPure fittings and valves are single bagged (unless specified otherwise). Fittings are shipped in protective boxes and valves are packed in individual boxes. Pipe is capped and bagged after production. It is shipped wrapped and protected, depending on the quantity of pipes required for the project.

the seminar. On simple installations, it may be faster; and on more complex installations, it may be longer. It is important that only personnel who will be conducting the weld operation during the project participate in the training to reduce the distraction within the class. A third party QC should attend the full training course to fully understand the welding process and QC parameters.

Preparation PolyPure fittings should be left in their bag and brought into the clean zone as is. If for some reason the outside of the bag is contaminated, it should be wiped down with IPA prior to entering the clean zone. Valves should be handled in the same manner. Pipes can remain in their shipping packaging until ready for use or transported into the fabrication cleanroom.

Step 4. Training and Preparation An ultra pure water or chemical system is a critical utility within a plant’s operation. An unplanned shutdown can prove to be more costly than the water piping construction itself. One bad weld can cause hours of repair and frustration, as well as significant lost revenue. For these reasons it is critical to receive training at the time of job start-up and use certified personnel throughout the course of a project. Tool operation is only one of several factors in a thorough training course. Operators, inspectors, and managers need to understand the physical nature of the material: how to properly handle it, how to inspect welds, how to identify potential problems, how to properly maintain equipment, and finally, how best to tie into a line and test it. All of the above topics are discussed during Asahi /America’s certified training sessions. For the installation of a high-purity system, the following training sessions are available: • Tool Operator Training • Quality Control Inspection • Level 3 Operator/Controller (SP equipment only) In addition to the above on-site training, Asahi /America also offers courses that are held at the corporate office for the following topics: • Certified Maintenance and Repair (SP and UF equipment only) • Certified Trainer (prerequisites apply) Consult with Asahi /America’s Engineering Department for dates and availability of corporate programs. During the on-site training process, Asahi /America certified trainers will set recommendations for the class size based on the tool type. In general, groups of four are recommended for the welding operation portion of the training. Typically, two groups can be certified in one day on the welding portion of


To best use training time, preparation should be made prior to the trainers’ arrival on site. A recommended list of preparations follows. • Ensure that project material is on site. It is not critical to have all material, but enough to start the project. Once training is complete, it is practical for the trainer to oversee the beginning portion of the installation. Many times new questions and challenges arise once the actual installation starts. In addition, if there is a significant period of time between the training and actual installation, operators may forget portions of the training or different operators may now be slated for the welding operation. Both scenarios require additional training. • Ensure required tools are on site. Do not open the tools until a certified trainer is present. If more tools are ordered during a project, this is no longer required as proper unpacking and set up of the equipment is covered in the training process. • Ensure that the correct power is available. Many pieces of equipment require 220 Volt single or three phase power supply. Consult with the factory or distributor at the time of tool ordering. • If possible, have a conference room with an overhead projector available for the classroom portion of the training. If this is not available, select an area where all personnel will be able to see and hear the trainer for this portion of the discussion. • Ensure that pipe samples are available for the training session. Asahi /America does not normally provide samples for the training. Formal training can be the key factor in starting a project off in the right direction. Take advantage of this service while on site. Asahi /America also offers field technicians for hire to oversee project welding and training for any specified amount of time. Contact Asahi /America for more information.

Step 5. Tool Commission and Daily Checks Checking equipment and welding technique daily is recommended. This is particularly important on larger projects where there are many welders on site. This daily check will allow QA to ensure all welders are up to speed on tool operation, welding technique, and inspection. Most problems in the field occur due to improper usage of equipment, rather than equipment failure.


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INSTALLATION PRACTICES During the initial training of the project, many welds are produced in the presence of a qualified trainer. These welds should be kept and used for the daily checks. Each welder should conduct one coupon test weld and submit it to QA. The coupons should be compared to initial samples. Inspection should include bead formation, sizing, and weld label. It is required to conduct preventive maintenance to the equipment at the beginning of each day. The maintenance recommended varies on each weld tool type. Consult the Operation Manual for items to be checked daily. In all cases, tools need to be kept clean and free of debris. Weld shavings should be removed at all times. By keeping equipment in good operating condition and ensuring all operators are up to speed, tool problems or welding errors are less lightly to occur.

To ensure a safe and on-time system start-up, initiating a standard inspection process on each project is recommended. This quality assurance measure can be conducted by third party QC or can be done by each individual operator after each weld. A recommended inspection report for recording quality assurance on each weld is attached at the end of Section F. Use the recommendation of this weld inspection guide in conjunction with the equipment manual to achieve the best project results.

Inspection Labels

AGRU SP-110

IR equipment is designed to help guard against the possibilities of cold welds or incomplete fusion. The label feature should be used in a manner to track all welds. Information can either be handwritten into the log book, or the entire label can be placed into the log. It is important to tag the pipe joint physically with the weld number for traceability. In the case of the SP series, up to three labels can be printed at the time of the weld; one for the book, one for the pipe, and one for other use. An example of a weld label follows:

00258179.W01

When inspecting weld labels, items to look for include the following: • Correct material setup • Correct OD and wall thickness setup • Weld parameters indicated as OK Conventional butt and socket fusion equipment do not provide labels or data recording on each weld. However, using the log in conjunction with an inspection process will decrease the chances of a failure occurring. HPF equipment also does not generate a label after each weld. The equipment does, however, store the data of each weld. This information can be printed any time on 81/2" by 11" paper. Consult the HPF Operation Manual for details on printing weld data.

Bead Formations

Step 6. Weld Inspection

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Depending on the type of fusion machine being used and the material being joined, the bead formations will vary slightly. However, the basic concept of inspection applies to each weld and material, with only slight differences.

Bead Formations: PVDF IR Non-Contact Butt Fusion The Purad PVDF system has a unique and characteristic weld that makes inspection simplified. Details are shown in Figures F-49 and F-50 of normal welds from both a UF2000 and the SP series. In general, the weld formations are similar. The SP equipment has tighter controls, thus allowing for the smallest weld formation on the market.

1/1

25.04.2001 14:39 SerNo:W11199-179 PVDF/110/3.4/IR

WELD, OK

Figure F-48. SP series label Using the weld label helps the inspector to ensure the operators are running the equipment in the correct fashion to produce continuous and reliable fusion welds. If the tool was operated incorrectly, the error numbers on the welding label will easily identify it. Any joint with a printed error code is required to be cut and done again. Figure F-49. UF2000 IR weld-PVDF

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Figure F-52. IR weld On both IR and conventional butt fusion, there will be a variation in the welds when welding pipe-to-pipe, pipe-to-fitting, and fitting-to-fitting. Since PVDF fittings have a higher melt flow index than PVDF pipe, they tend to flow more when melted. This effect translates into the fitting bead being generally larger than the pipe bead.

Bead Formations: PVDF Socket Fusion

Figure F-50. SP series IR weld-PVDF When inspecting IR fusion, look for primarily consistent and uniform welding joints. Since both ends of the components being joined are melted, there will be a seam down the middle of the joint with almost equal amounts of bead material on either side. The more sophisticated the tool, such as the SP, the more difficult it is to view the seam. The joints are generally smooth on the outer surface and slightly larger on the outside as compared to the inner bead. Due to the effects of gravity during the melting process, it will be common to see a slight variation on the top and bottom of the pipe after the fusion is complete. Refer to the individual tool guide for specifics on how and when to reject a fusion weld. Each guide also has a table on the bead size measurements and tolerances. Measuring each weld is not practical, but for welds in question it may prove to be a useful tool.

Bead Formations: PVDF Conventional Butt Fusion Conventional butt-fusion welds have the same basic formation as an IR weld; however, they are slightly larger and have a pronounced roll back. Contact butt welds have a seam in the middle and a bead on either side. Below is a cross-sectional view of a butt and IR weld to see the difference in bead formation. In butt fusion, the inspection process consists of examining each weld for the double weld 360° around the pipe. The disappearance of the double bead formation and drastic reduction in bead size can indicate that a problem existed during the fusion process.

Socket fusion joints can be inspected for bead formation as well. The most important factor of inspecting a socket joint is to ensure the pipe bead and the fitting bead are in contact with each other. After melting the pipe and fitting in the heating mandrels, it is necessary to ensure proper insertion of the pipe into the melted socket fitting. Not meeting the full socket depth can leave a small gap between the pipe and fitting where the pipe has thinned wall thickness due to the melting. In the event of this occurrence, the weld should be rejected and redone. Figure F-53 is a drawing of the proper bead formation in a socket weld. No Gap

No Gap

Figure F-53. Proper socket weld Conducting a sample weld is recommended on a periodic basis, as well as with each new operator. After the sample weld is complete, cut the weld into two pieces and inspect the insertion depth. Since manual socket fusion equipment is available, the results of quality will vary from operator to operator. It is important to verify all welders are not under or over inserting the pipe into the socket fitting.

Bead Formations: PVDF Beadless Fusion HPF is a non-bead forming weld process. The inspection on HPF is simplified since the socket coupling itself covers the weld. When welding with balloon, the indicator on the side of each fitting can identify proper fusion. The plastic indicator will push out from the HPF coupling due to the heat from the weld. This device, much like a turkey timer, indicates that the fitting has been properly heated. When welding without balloon, the indicator will not necessarily push out.

Figure F-51. Butt weld



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Bead Formations: PFA PFA material, in particular PurebondTM pipe from Entegris, can also be fused using the SP110 IR fusion tool. Welding PFA takes on a slightly different process and, therefore, the bead size and shape is slightly different than that of any material supplied by Asahi /America. The method for weld tracking and data logging for PP, E-CTFE, and PFA is the same as for welding PVDF in the SP110 welding equipment.

Bubbles in the Joint

Figure F-54. HPF indicator

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The HPF equipment shows the weld count on the screen of each weld. This number should be logged on the supplied charts. In addition, the data from each weld can be printed using a standard dot matrix printer. The tracking of the joint on the pipe, the log, and the tool printout allows quality assurance to track each weld to ensure welds in the system were conducted properly. In addition, the printout will indicate the method of welding on each joint, balloon or without balloon. Other techniques employed with HPF to ensure proper insertion depth is the marking of the depth. When setting a component into the clamp and centering it, mark the side of the component up tight against the clamp. This mark will allow inspectors to verify the pipe was properly installed into the clamp after the weld is completed. The distance of the mark to the side of the coupling will be identical for each dimensional size. Marks that are too close or too far to the coupling should be rejected. Not carefully inserting the fitting and centering it into the coupling may cause problems. Since the process is controlled with bar coding the parameters and computer control of the heating and cooling, the welding process itself is extremely reliable. The proper set up is the main variable that is the responsibility of the operator.

Bead Formations: Polypropylene and E-CTFE Polypropylene weld inspection is similar to that of PVDF inspection. In traditional methods, such as butt and socket welding, PP fusion is extremely reliable and simple. Many of the challenges of PVDF, such as material sticking to the heating element, do not occur in polypropylene. The nature of PP makes fusion easier and a more repeatable process. Use the same methods of inspection as in PVDF.

In the fusion process, it is possible to find tiny bubbles trapped in the welded region primarily on the outer bead. This may be most noticeable with PVDF, for its clear nature allows it to be visible. These bubbles are a common occurrence in non-contact butt fusion. The bubbles are from one of two sources; either air has been trapped in the weld during the joining process, or small vacuums appear due to material shrinkage during the cooling down time. In either case, the bubbles are not an area of concern and there is no specification for the size of a bubble that would cause a joint failure. The combination of the welding parameters and the melt flow index of the Solef® PVDF resin help to ensure against tiny bubbles affecting the quality of the joint.

Limitations of Inspection As mentioned in Step 1 (Welding Environment), the IR equipment is designed to assist in preventing against a cold weld. A cold weld is a weld that has either not been heated properly or has been joined together with improper force. In both cases, there is insufficient molten material that is joined together to create a proper fusion of the materials. The other type of welding error that can occur is incomplete fusion. This type of error occurs typically from the following types of errors: 1. Air movement. 2. Incorrect capping of the joints. 3. Chimney effect in 90° elbows turned upward. 4. Incorrect welding parameters such as OD and wall thickness. 5. Poor planing or alignment.

IR fusion with PP is also quite reliable. The inspection process is again the same as PVDF, except that weld beads will be larger in PP due to the thickness of PP pipe. The IR infusion of polypropylene is more difficult than PVDF due to higher joining forces. Closer attention to bead formation and QC is recommended.

These errors can usually be identified and replaced prior to system test. To identify these types of welds, look for the following symptoms: 1. Significantly decreased bead size in certain sections of the joint. 2. Significantly decreased bead size all around as compared to other joints of the same size. 3. No bead formation in one section of the weld. 4. Misalignment of open pipe in joint area.

Halar® is fused using butt or IR fusion. The weld inspection is also identical to that of PVDF.

Welds that have the above problems should be cut out and replaced for safety insurance.

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of the pipe have been forced together in the pipe wall region. In the proper Weld 1, you can see there is material joined together in the pipe wall, as well as in the inner and outer beads.

The cold weld is more difficult to identify, and virtually impossible to detect with the naked eye. Two cross-sectional views of a pipe wall that has been welded are shown in Figure F-55. Weld 1 is a good fusion joint, while Weld 2 is a cold weld. Notice in the cold weld there is very little material joined together in the pipe wall area. The molten material has been forced to the outer and inner bead and the unheated sections

The problem with inspecting a cold weld is the outer bead is the same as a good joint. In Figure F-55, the top bead represents the outer look of the weld. It can be seen very clearly that both welds look the same according to the bead formation. Since the occurrence of a cold weld is difficult to find and inspect, the IR welding equipment from Asahi /America and Agru has been designed to measure the joining force during the fusion process. By measuring the weld force throughout the entire welding process, the possibility of a cold weld is drastically reduced. In the event of over forcing the weld, this will be identified by the tool and marked as an error on the weld label.

Downloading Data /Data Transfer

Weld 1, standard IR joint

All computerized IR and HPF welding equipment offered by Asahi/America will store the welding data in its memory. This data can be downloaded and printed for quality assurance purposes. Each tool will have a memory of 1,000 welds. The data on each weld can be transferred to a PC computer using software that is provided by Asahi/America. The data on each weld from a transfer provides an inspector with more information about the weld than what appears on the printout label. Figures F-56 and F-57 show examples of data from the SP series, and UF series welding machines.

Weld 2, cold weld

Figure F-55. Cross-sectional view of wall with weld

DATAFILE/WELDING NUMBER

SER. NO. [MACHINE] W22597-005 SER. NO. [TOUCHPANEL] TP198041

PRESSURE [ N ]

00526041.W00 800 720 640 560 480 400 320 240 160 80 0

0

30

60

90

120

150 TIME [sec]

180

PRINT-DATE 08 . 03 . 2001

210

240

270

SOFTWARE 2.11

MATERIAL PVDF

TEMP-NOM oC 500

OPERATOR agru3-00010

WAY [mm] 2.0

DATE 28 . 09 . 2000

da [mm] 250

TEMP-ACT oC 499

ADDRESS AGRU

STATUS WELD . OK

TIME 08: 25

S [mm] 11 . 9

TEMP-WET oC 22

ROOM RAUM

METHOD IR

300

Figure F-56. Weld chart from an SP tool series



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Table F-7. PVDF Support Spacing Recommendation (feet) AGRU UF 2000/1 Serial No. 1293005 *********************************************** date: 02.09.01/10:58 ident-key AA01 proj. no: 1265 joint no. 405 dia: 63 mm wth: 3.0 mm mat: PVDF nitro. Pres: 0.0bar method: IRamb temp: 21 C des. temp: 480 C act. temp: 481 C t(AW) 60 sec t(U) 2.8 sec pres ramp: 3.8 sec des. press: 73 N act. press: 72 N t(F) 05:00 error code: 64

F

Figure F-57. Weld chart from a UF tool series The data transfer feature allows the inspector or installer to have back-up documentation on the welds conducted on the tool. Also, by reviewing the welds, it can also be identified if weld counts were reset during the installation, since the tool will record all welds. The procedures for transferring the data is explained individually in the tool’s operation manuals.

Step 7. Hanging Hanging any thermoplastic system is not that much different than hanging a metal system. Typically, the spacing between hangers is shorter due to the flexibility of plastic. In addition, the type of hanger is important. Hangers should be placed based on the spacing requirements provided in Tables F-7, F-8, and F-9. Since thermoplastic materials vary in strength and rigidity, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, the amount of hangers will generally be increased. Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical. In these cases, the hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation. When selecting hangers for a system, it is important to avoid using a hanger that will place a pinpoint load on the pipe when tightened. For example, a U-bolt hanger is not acceptable for high-purity thermoplastic piping systems. See Figure F-58.

F-30

Nominal Size (inches) 1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12

68° F 20° C

86° F 30° C

104° F 40° C

122° F 50° C

140° F 60° C

158° F 70° C

176° F 80° C

3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.5 8.5 9.5

2.5 3.0 3.0 3.5 4.0 4.5 5.0 5.0 6.0 7.0 7.5 8.5

2.5 2.5 3.0 3.0 4.0 4.0 4.0 5.0 6.0 6.0 7.0 8.0

2.0 2.5 3.0 3.0 3.5 4.0 4.0 4.0 5.0 6.0 6.5 7.0

2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.0 5.0 5.5 6.0 7.0

2.0 2.5 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 6.0 6.5

2.0 2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0

Table F-8. Polypropylene SDR 11 Support Spacing Recommendation (feet) Nominal Size (inches) 1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12 14 16 18

68° F 20° C

86° F 30° C

104° F 40° C

122° F 50° C

140° F 60° C

158° F 70° C

176° F 80° C

3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.5 8.5 9.5 10.0 10.5 11.5

2.5 3.0 3.0 3.5 4.0 4.5 5.0 5.0 6.0 7.0 7.5 8.5 8.5 9.5 10.0

2.5 2.5 3.0 3.0 4.0 4.0 4.0 5.0 6.0 6.0 7.0 8.0 8.0 8.5 9.0

2.0 2.5 3.0 3.0 3.5 4.0 4.0 4.0 5.0 6.0 6.5 7.0 7.5 8.0 8.5

2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.0 5.0 5.5 6.0 7.0 7.0 7.5 8.0

2.0 2.5 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 6.0 6.5 6.5 7.0 7.5

2.0 2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 6.5 7.0

Table F-9. E-CTFE Support Spacing Recommendation (feet) Nominal Size (inches)

68° F 20° C

248° F 140° C

1 2 3 4

3.60 5.00 5.75 6.00

2.50 3.00 3.75 4.00

Notes: 1. Supports must be spaced according to the highest possible temperature the pipes will encounter even if the extreme condition is only temporary. 2. Support spacing is based on a liquid with a specific gravity of 1.0. Spacing should be reduced by 10% for liquids having 1.5 specific gravity, 15% for 2.0 s.g., and 20% for 2.5 s.g. Pressure Point

Pressure Point

U-bolts not recommended

Recommended for high-purity systems Figure F-58. Selection of hangers for piping systems



HIGH-PURITY INSTALLATIONS INSTALLATION


Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps, as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp. This is a must for PVDF and E-CTFE systems, which are less tolerant to scratching. Valves in a pipe system can also add significant weight and stress to a pipe system. Valves, especially metal butterfly valves and heavy diaphragm valves, must be individually supported. For more details on hanging Asahi /America systems, consult Section C, Engineering Theory and Design Considerations.

Step 8. System Testing Prior to pressure testing, the system should be examined for the following items: 1. Pipe should be completed per drawing layout with all pipe and valve supports in place. 2. Pipe, valves, and equipment should be supported as specified, without any concentrated loads on system. 3. Pipe should be in good condition, void of any cracks, scratches, or deformation. 4. Pipe flanges should be properly aligned. All flange bolts should be checked for correct torques. 5. All joints should be reviewed for appropriate welding technique. Butt: To have two beads, 360° around the joint. Socket: To have two beads on the end of the fitting and on the outside of the pipe in contact, 360° around the joint. IR: Labels should identify weld certification by the print “welding OK.” Joints should have two beads 360° around the joint. Also, refer to manufacturer’s separate weld inspection criteria, supplied separately by Asahi /America. HPF: Conducted with balloon should be inspected for the fusion pin being popped out on all balloon joints.

may have decreased. If drop is less than 10 psi, pump the pressure back up. At this time, the system may be fully pressurized to desired test pressure. 3. If after one hour the pressure has decreased more than 10% and ambient conditions are steady, consider the test a failure. Note the 10% value may need to be greater for larger systems. Also note that Step 2 may need to be conducted several times if there are significant thermal changes. 4. If the pressure drops less than 10% after one hour, pump the pressure back up to the test pressure. This is normal due to creep. If after 2 or 3 hours, the pressure does not drop, consider the test a success. 5. Test is to be witnessed by the quality control engineer, and be certified by the contractor. 6. Obvious leaks can be found by emptying the system and placing a 10 psi charge of clean, dry nitrogen on the system. Each joint should then be individually checked using a soapy water solution or an ultrasonic leak detection gun. Leak detection guns are available from Asahi /America. Consult factory for usage of U.S. leak detection guns. Some limitations do apply.

Step 9. Repair Procedures If a leak is found or an addition is required to an existing system, there are several options on how to make the repair. In most systems, socket or butt fusion, there is a requirement for pipe movement when making a weld. To conduct a butt or IR weld, one side of the tool moves in order to accommodate the planer, the heating element, and the final joining force. In a repair procedure, the need for movement of the existing pipe makes for the simplest repair. In all cases, weld areas and pipe components must be cleaned as in the original installation.

Flexible Pipe System If the pipe is in an area where it can be moved, standard butt fusion or socket fusion equipment can be used. 1. Cut out the section in need of repair. It is best to conduct new tie-in welds on straight runs of pipe for easier alignment. 2. If several welds are required, prefab a spool piece on a bench and conduct only a few tie-in welds in the pipe rack.

If any deficiencies appear, the quality control engineer should provide directions/repair.

3. Attach the tool to the existing pipe and properly support the machine to avoid sagging or stressing the pipe.

Pressure Test

4. Conduct standard butt-fusion weld per operating procedures. It may be necessary to flex one end of the existing pipe out of the way.

Test fluid should be deionized water, with quality level set by the quality control engineer or system owner. In all cases, tests must be done hydrostatically. Air is not acceptable.

5. Conduct final weld using the flexible side of the pipe system in the moving clamp.

1. Filling the system: Open the valves and vents to purge the system of any air. Slowly inject the water into the system, making sure that air does not become trapped in the system. 2. Begin pressurizing the system in increments of 10 psi. Bring the system up to 100 psi and hold. Allow system to hold pressure for a minimum of two hours and up to a recommended 12 hours. Check pressure gauge after one hour. Due to natural creep effects in plastic piping, the pressure


L

Figure F-59. Remove damaged section


F-31

F

INSTALLATION PRACTICES First Tie In

HIGH-PURITY INSTALLATION

1. Remove the section to be repaired. 2. Weld flanges or unions on both ends of the existing piping. 3. Measure the distance from face to face and build a spool to fit into place. 4. Connect spool into place.

Figure F-60. Install new spool Second Tie In

L


Figure F-61. Butt weld spool to existing pipe line

Non-Flexible Pipe System Depending on the size and material, repairs can also be made to systems without any movement. For Purad systems in sizes 1/2"– 2", HPF welds can be conducted in place with minimal need for movement.

F

1. Remove the damaged section of piping. For easier alignment, it is best to conduct new tie-in welds on straight runs of pipe.

Slide into Postion

Figure F-63. Slide second coupling into place and conduct first weld at joint seam

2. If several welds are required, prefab a spool piece on a bench setup and conduct only a few tie-in welds in the pipe rack. 3. Using either the large or the small alignment rack, fix two wide clamps to the existing pipe line and to the new spool piece. Make sure all components are level and properly supported. 4. Plane the ends perfectly square. It is recommended to pre-plane both ends of the spool and both ends of the existing pipe line at this point. It is also necessary to slide the second HPF coupling onto the spool at this point to avoid difficulty of placing it on the pipe after one weld is complete.

HPF Coupling

L

Figure F-64. Conduct final weld


5. Slide the coupling into place using the third wide clamp and center the existing pipe in the clamp using the mechanical stop. Now bring the spool piece into the clamp until it is up tight against the existing pipe line.

L

6. Conduct the HPF weld per procedure for the equipment. 7. Measure the thickness of the coupling. Take half of the thickness and mark this distance from the end of the pipe. This mark identifies the location of the end of the coupling and helps to center the coupling on the two final components to be joined. Lock in place using the wide clamp.

Figure F-66. Weld flanges or unions into place

8. Conduct the final weld according to procedure. For systems in PP or larger diameter PVDF, HPF is not available. If there is no flex for movement of the existing pipe in the region of the damaged pipe, the repair can be done using flanges or unions.

F-32

L

Figure F-67. Place spool into place



CHEMICAL SINGLE WALL SYSTEMS

CHEMICAL SINGLE WALL SYSTEMS Installing any piping system properly requires preplanning. The installation is more than the welding of components. It requires the proper environment, material inventory, welding equipment, tools, and thorough training. This guide is to assist in the planning and installation of a chemical pipe system either in a pipe rack or trench. This guide is aimed at industrial applications and not high-purity installations. This guide will concentrate mainly on materials such as PVDF, polypropylene, and E-CTFE, as supplied by Asahi /America, Inc. The practices outlined in this guide are also applicable to other materials such as PVC and C-PVC, with the exception of joining techniques. Asahi /America’s recommended steps to plan and complete a successful installation follow. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Step 11.

Welding Environment Tool Selection Material Handling Training and Preparation Tool Commission and Daily Checks Pipe Cutting Weld Inspection Hanging Trenching and Burial System Testing Repair Procedures

INSTALLATION PRACTICES a shelter or tent should be constructed over equipment. In addition to rain, high winds and cold temperatures, below 40° F, will negatively influence the welding process. If these conditions are not avoidable, a heated tent structure is recommended. For specific recommendations by tool types, consult the Asahi /America Engineering Department. Table F-10. Sample Welding Data Pipe Size

A

B

C

(inches)

Heat Soak Time 8

Change Over Time 6

Cooling Time 240

1" Pro 150

When conducting field welds in a pipe rack or in a trench, it is important to have the location of the weld well planned. Vertical welds in any location will prove difficult to conduct and should be avoided. The field weld that connects up prefabricated spool pieces should be a pipe-to-pipe weld whenever possible. Pipe-to-pipe welds are easier to align and level, making the weld easier to conduct in possibly tight quarters. Table F-11 provides information on the various welding systems available. Table F-11. Equipment Selection Description

If possible, set up a welding area to build the spool pieces. The weld area should be situated in an area that has reduced exposure to wind, possible rain, and extreme cold temperatures. Building spool pieces inside a weld shop may prove advantageous. A fairly controlled environment and organized work space will improve efficiency and quality of the system to be installed. Not all welding can be conducted in a shop and eventually field welds will need to be done. Some systems will be installed completely outside, with all the welds perhaps conducted in place.

Polypropylene

PVDF

E-CTFE/Halar

Shop 4*

1/2"– 4" Pro 150 4" Pro 45

A A

1/2"–1" 11/2"– 4"

B A

1/2"– 4"

X

Shop 12

11/2"–8" Pro 150 10" Pro 150 12" Pro 150 4"–12" Pro 45

A B X A

11/2"–12"

A

11/2"– 6"

A

Field 6

11/4"–6" Pro 150

A

11/4"–6"

A

Does not apply

Field 12

3"–12" Pro 150 4"–12" Pro 45

A A

3"–12"

A

Does not apply

Field 20

8"–20" Pro 150 8"–20" Pro 45

A A

Does not apply

Does not apply

Socket 2 Hand Held

1/2"–11/4" Pro 150 11/2"–2" Pro 150

A B

1/2"–11/4" 11/2"–2"

A B

Does not apply

Step 1. Welding Environment Asahi/America does not set requirements for proper welding environments. It is necessary for the installer to choose the environment based on the installation type, timing, or quality goal. In most systems, pipe is either going into a pipe rack, beneath a floor or wall, or buried underground. In all these cases, conducting welds in the actual final location may not always be the most convenient location for welding. In fact, in most cases, it is preferable to prefabricate spool piece components and conduct final welds or hook-up in the pipe rack.

(time-sec)

Socket 4 Bench

1/2"– 4"

Pro 150

A

1/2"– 4"

A

Does not apply

UF 2000/1

1/2"–2"

Pro 150

C

1/2"–2"

C

1/2"– 2"

UF 2000/2

21/2"–10" Pro 150

C

21/2"–10"

C

21/2"–10"

C

SP 110

1/2"– 4"

C

1/2"– 4"

C

1/2"– 4"

C

C

21/2"–10"

C

21/2"–10"

C

1/2"–2"

A

Does not apply

Pro 150

SP 250

21/2"–10" Pro 150

HPF

Does not apply

Polymatic

1/2"–9"

A: B: C: X:

*

Pro 150

A

Does not apply

C

Does not apply

Recommended Will work, but better solution is available Recommended, special requirements apply, consult factory Not recommended Hand planer on this tool. For large amounts of welds 3" and 4", a larger tool with electric planer is more suitable

When welding outside, several factors have to be considered. It is always important not to weld in the rain. Rain will damage equipment and improperly influence the weld. For rainy days,



F-33

F



In all field welds, in the rack or in a trench, it is important to have ample room for welding equipment and to choose the proper welding equipment. In some underground installations, it may be necessary to increase the width of the trench in weld locations. Many underground systems are welded above ground and then lowered down into the trench to avoid placing equipment in narrow trenches. The same is true in crowded pipe racks. Many times it will prove more efficient to prefab spools and use flanges or unions to connect them together in the pipe rack.

Step 2. Tool Selection The selection of the type of welding method conducted on a single wall industrial piping project should be based on the following criteria: • Material • Sizes to be installed • Welding location • Type of installation • Available expertise

F

Figure F-69. Shop 12 (11/2" – 12")

For assembling industrial grade piping systems made from PVDF, PP, or E-CTFE, there are really three choices for assembly: butt fusion, socket fusion, and electro fusion. Each method has its advantages and disadvantages. A discussion on each method for assistance in choosing the best method for each project follows.

Butt Fusion During the butt-fusion process, components are forced against a flat heating element or plate to melt the ends for the fusion. Figures F-68, F-69 and F-70 show some of the systems available for this process.

Figure F-70. Field (3" – 12") Pipe

Heater

Pipe


Molten End

Heat Soak Time

Figure F-68. Shop 4 (1/2" – 4") Figure F-71. Butt-fusion welding process

F-34




The material is in contact with the heat source for a specified amount of time to allow the material time to soak in the heat and melt the pipe ends. At the end of the heat soak time, the heating plate is removed and the pipes are joined together at a force. Figure F-71 shows a brief detail of the process. The advantage of butt fusion is its weld strength. When properly conducted, it is a strong, reliable joint. Butt fusion can be done in any size range, reducing the training time at the job start-up. In addition, butt fusion is fairly weather tolerant. This does not mean it can be conducted in any environment, but it will work in conditions other methods will not.

Socket Fusion Socket fusion is the oldest method for assembling thermoplastic materials. Socket fusion is available for welding PVDF (SDR 21) and PP in sizes 1/2"– 4". Similar in nature to butt fusion, the material is in direct contact with the heat source. However, instead of melting the component ends, the pipe is forced inside a mandrel and the fitting is forced over a mandrel. After proper heat soak time has been accomplished, the two components are forced together until they bottom-out. Figure F-72 illustrates a brief outline of the process. Coupling Heater Inserts

Pipe

Heater

INSTALLATION PRACTICES Socket fusion is fairly tolerant to weather conditions and is simple to do. Untrained personnel can be trained in a short period of time to make consistent and reliable joints. Mechanically the welds are reliable, and fairly easy to inspect. Socket fusion is ideal for smaller systems and is quite simple and practical for welding 1/2"– 1". Systems consisting primarily of 3" and 4" are better suited for butt fusion, as the equipment is smaller and easier to use in tight locations.

Electro Fusion HPF is a portable, electro-fusion process for welding PVDF in sizes 1/2"– 2". HPF is the brand name for the PVDF equipment and provides the added benefit of a bead-free weld. In addition to HPF, standard electro-fusion welding for polypropylene and polyethylene are available as well. Contact Asahi /America for more information on equipment types. The HPF system for PVDF is ideal for welding in tight locations such as in pipe racks, walls, or under floors. The process works by placing the components to be welded in an electric socket fitting. The socket is electrified and the resistance of the wire heats the material and fuses it all together to make one component. Tools are supplied with computer control. Parameters are selected via a bar code system on each weld, making the process extremely reliable and exactly repeatable. Because the entire welding process takes place inside the socket, the required equipment to actually fuse the joint is small and compact.

HPF Coupling

PVDF Pipe


Figure F-73. HPF weld


Joining and Cooling



For conducting beadless fusion, HPF is provided with two options: with balloon and without. For beadless and seam free, weld balloons are available. This ensures a smooth weld and no crevice. Joints welded with balloon will have a small wave in the joint due to the weight of the coupling and the outward force of the inflated balloon. Sometimes it is not possible to place a balloon in the weld area and then be able to remove it after, such as in the case of a repair or addition. For this reason, HPF can also be conducted without a balloon. These joints will also be beadless, but will have a small seam around the joint. HPF is recommended for welding in or outside of a cleanroom environment. During the weld process, HPF is closed to the external environment, so issues of wind, temperature, and contamination are greatly reduced. HPF is the tool of choice for repairs or additions to an existing system. HPF is only available for PVDF in sizes 1/2"– 2".


F-35

F

INSTALLATION PRACTICES HPF systems for harsh chemical transport should be approved by Asahi /America and called out as the welding method when conducting a chemical resistance verification. Asahi /America has also introduced electro fusion in polypropylene (HDPE on special request) in 1/2"– 9". This new system works in a similar fashion to that of HPF, but does not provide a bead free and seamless weld. However, electro fusion does prove extremely convenient in tight locations.

PP Coupling

PP Pipe

Figure F-74. PP weld

F

Polypropylene electro-fusion couplings are significantly larger than that of HPF and do require extended leg fittings. All systems to be assembled using electro fusion must be approved by Asahi /America if they are to be used in a chemical application. The welding material should be called out at the time of a chemical resistance verification.

Step 3. Material Handling When pipe, fittings, and valves arrive on site, they should be inspected to ensure the proper components have arrived and no damage has occurred during shipment. Asahi /America goes to great lengths to ensure that pipe and fittings are properly packaged for shipment. If damage occurs, the freight company should be notified immediately. Preferable, pipe should be stored inside or in a trailer. Care should be taken to properly support pipe during storage. Use the hanging criteria for the proper support distance. Pipe can be stacked during storage. Heavier pipes of larger dimensions should be stored at the bottom. However, it may prove more practical to segregate by size for easier access during the project. Pipe should not be stacked above the recommended height of 4 feet. If material is stored outside, it is preferable to cover with a tarp in case of rain. PVDF is UV resistant, but polypropylene will degrade over time when exposed directly to UV. Depending on the size of the pipe and the wall thickness, it could cause physical damage that could reduce the allowable pressure rating. In all cases, the UV will cause a color change over time that may not be acceptable for aesthetic reasons. In general, it is recommended to cover polypropylene during storage. Fittings are best kept in their boxes or bags, as they are shipped in separate containers by size, style, and material. This will allow for simplified picking and inventory control throughout the project.

F-36


Step 4. Training and Preparation A chemical system is a critical utility within a plant’s operation. An unplanned shutdown can prove to be more costly than the piping construction itself. One bad weld can cause hours of repair and frustration, as well as significant lost revenue. For these reasons, it is critical to receive training at the time of job start-up and use certified personnel throughout the course of a project. Tool operation is only one of several factors in a thorough training course. Operators, inspectors, and managers need to understand the physical nature of the material: how to properly handle it, how to inspect welds, how to identify potential problems, how to properly maintain equipment, and finally, how best to tie into a line and test it. All of the above topics are discussed during Asahi /America’s certified training sessions. For the installation of a single wall pipe system, the following training sessions are available: • Tool Operator Training • Quality Control Inspection In addition to the above on-site training, Asahi /America also offers courses that are held at the corporate office for the following topics: • Certified Maintenance and Repair • Certified Trainer (prerequisites apply) Consult with Asahi /America’s Engineering Department for dates and availability of corporate programs. During the on-site training process, Asahi /America certified trainers will set recommendations for the class size based on the tool type. In general, groups of four are recommended for the welding operation portion of the training. Typically, two groups can be certified in one day on the welding portion of the seminar. On simple installations, it may be faster; and on more complex installations, it may be longer. To reduce distraction within the class, it is important that only personnel who will be conducting the weld operation during the project participate in the training. It is also recommended that if a third party QC is used, they also attend the full training course to fully understand the welding process and QC parameters.

Preparation To best use training time, preparation should be made prior to the trainers’ arrival on site. A recommended list of preparations follows. • Ensure that project material is on site. It is not critical to have all material, but enough to start the project. Once training is complete, it is practical for the trainer to oversee the beginning portion of the installation. Many times new questions and challenges arise once the actual installation starts. In addition, if there is a significant period of time between the training and actual installation,




operators may forget portions of the training or different operators may now be slated for the welding operation. Both scenarios require additional training. • Ensure required tools are on site. Do not open the tools until a certified trainer is present. If more tools are ordered during a project, this is no longer required as proper unpacking and set up of the equipment is covered in the training process.

INSTALLATION PRACTICES Step 6. Pipe Cutting Cutting plastic pipe can be handled in a variety of methods. In small dimensions, 1/2"– 4", roll wheel pipe cutters are commonly available and work well. These types of cutters are similar to a tube cutter, but only larger. If using a roll cutter on PP or PE, it is important to ensure the wheel has a larger radius than the wall thickness of the pipe so it will cut all the way through.

• Ensure that the correct power is available. Many pieces of equipment require 220 Volt single or three phase power supply. Consult with the factory or distributor at the time of tool ordering. • If possible, have a conference room with an overhead projector available for the classroom portion of the training. If this is not available, select an area where all personnel will be able to see and hear the trainer for this portion of the discussion. • Ensure that pipe samples are available for the training session. Asahi /America does not normally provide samples for the training. Formal training can be the key factor in starting a project off in the right direction. Take advantage of this service while on site. Asahi /America also offers field technicians for hire to oversee project welding and training for any specified amount of time. Contact Asahi /America for more information. This is a service many customers take advantage of to ensure a smooth, trouble-free installation.

Step 5. Tool Commission and Daily Checks Checking equipment and welding technique daily is recommended. This is particularly important on larger projects where there are many welders on site. This daily check will allow QA to ensure all welders are up to speed on tool operation, welding technique, and inspection. Most problems in the field occur due to improper usage of equipment, rather than equipment failure. During the initial training of the project, many welds are produced in the presence of a qualified trainer. These welds should be kept and used for the daily checks. Each welder should conduct one coupon test weld and submit it to QA. The coupons should be compared to initial samples. Inspection should include bead formation, sizing, and weld label.

Figure F-75. Roll cutter If you are not concerned about particle generation, then band saws, vertical or horizontal, will work very well for plastic. Since plastic pipes can have a very heavy wall thickness, it is important to travel slowly through with the band saw to avoid the blade from bending and creating an angled cut. For smaller pipe sizes, a circular blade chop saw will also provide neat and accurate cuts. If only manual saws are available, a hack saw will certainly cut through small dimensions, but avoid using a fine blade as it will take considerable time. In addition, reciprocating saws are generally not the best choice as the blades are only long enough to cut one wall at a time. If too fine of a blade is used, the material will become hot and can fuse itself back together partially behind the blade travel.

Step 7. Weld Inspection To ensure a safe and on-time system start-up, initiating a standard inspection process on each project is recommended. This quality assurance measure can be conducted by third party QC or can be done by each individual operator after each weld. A recommended inspection report for recording quality assurance on each weld is attached at the end of Section F. Use the recommendation of this weld inspection guide in conjunction with the equipment manual to achieve the best project results.

Conducting preventive maintenance to the equipment at the beginning of each day is required. The maintenance recommended varies on each weld tool type. Consult the Operation Manual for items to be checked daily. By keeping equipment in good operating condition and ensuring all operators are up to speed, it is less likely tool problems and welding errors will occur.



F-37

F



Butt Fusion

Socket Fusion

To inspect butt-fusion joints, the inspector should look for the following characteristics on each weld: • Welds should have two beads that are 360° around the pipe • Beads should be of consistent height and width • Beads should have a rounded shape • Beads should be free of burrs or foreign material • A bead on either side should not reduce greatly in width or disappear • Components welded should be properly aligned and cannot be misaligned by more than 10% of the wall thickness

With socket fusion, beads are also present on the outside that should be used for inspection. With a socket weld, it is important to ensure that the bead on the pipe and the bead on the fitting are in contact. If the two beads are not in contact, or the bead from the pipe is not up against the socket, the proper insertion depth has not occurred. If beads do not meet, the weld will not be full strength and should be rejected. With socket fusion weld inspection, look for the following items: • Bead formation on pipe in full contact with fitting 360° around the joint. • Consistent bead 360° around the joint. • Free of any burrs or foreign material. • Proper alignment. Pipe needs to be inserted straight into the fitting without angle.

Figure F-76 shows a detail of a standard butt-fusion bead formation.

Figure F- 77 is an example of acceptable and non-acceptable socket fusion joints. No Gap

F

Gap

No Gap

Figure F-76. Typical butt-fusion weld bead Butt-fusion beads will vary in size and a little in shape with different materials. In general, PP and HDPE will have larger bead formations in comparison to PVDF. With PP and HDPE, there will be a pronounced double-bead formation that will be simple to identify. With PVDF, there will also be a double-bead formation, but not as pronounced. The material will appear to flow more together, making what appears to be one single weld. However, upon examination you will always see the seam where the components were joined. In addition, when butt welding PVDF pipe to fittings, the fitting bead will be larger than the pipe bead. This is normal as the resin used to produce PVDF fittings flows at a higher rate when melted compared to the resin used to extrude pipes. Mechanically there will be no issues on strength of the joint, only the appearance of the weld. Since outside temperatures and conditions will have some effect on bead sizes, there is no formal specification for the size of the bead. Also, measuring each bead would be time consuming. During the training process, welding one of each size to use as a rough gauge for the project is recommended. These sample coupons can be referred to on a regular basis to check welding throughout the project. If bead formations do not meet the inspection criteria, they should be rejected. Consult the operation manual on each tool on how to correct the problem. If problems persist, contact Asahi /America for assistance. Many times these issues can be cleared up quickly over the phone, avoiding wasted time and material. Never continue welding if proper fusion cannot be accomplished. This will only add to problems at a later time.

F-38

Good Socket Weld

Bad Socket Weld

Figure F-77. Good and bad socket fusion welds

Electro Fusion HPF welds can be inspected, as well as data on each weld and stored in the memory if desired. This information can be printed any time on 81/2" by 11" paper. Consult the HPF Operation Manual for details on printing weld data. It is important to specify the need for data retrieval at the time of job start-up, as all HPF equipment is shipped with the memory function turned off. HPF is a non-bead forming weld process. The inspection on HPF is simplified since the socket coupling itself covers the weld. When welding with balloon, the indicator on the side of each fitting can identify proper fusion. The plastic indicator will push out from the HPF coupling due to the heat from the weld. This device, Figure F-78, much like a turkey timer, indicates that the fitting has been properly heated. When welding without balloon, the indicator will not necessarily push out. The HPF equipment shows the weld count on the screen of each weld. This number should be logged on the supplied charts. In addition, the data from each weld can be printed using a standard dot matrix printer. The tracking of the joint on the pipe, the log, and the tool printout allows quality assurance to track each weld to ensure welds in the system were conducted properly. In addition, the printout will indicate the method of welding on each joint, balloon or without balloon.




INSTALLATION PRACTICES Limitations of Inspection Following proper weld procedures, in conjunction with thorough inspection, will lead to a safe and reliable system. However, a weld cannot be 100% judged by viewing it after the fusion is complete. Bad welds with obvious problems can be identified, such as missing beads, small beads, and misalignment, but other problems may not be easily found. The cold weld is more difficult to identify, and virtually impossible to detect with the naked eye. Two cross-sectional views of a pipe wall that has been welded are shown in Figure F-79. Weld 1 is a good fusion joint, while Weld 2 is a cold weld. Notice in the cold weld there is very little material joined together in the pipe wall area. The molten material has been forced to the outer and inner bead and the unheated sections of the pipe have been forced together in the pipe wall region. In the proper Weld 1, you can see there is material joined together in the pipe wall, as well as in the inner and outer beads.

Figure F-78. HPF indicator Other techniques employed with HPF to ensure proper insertion depth is the marking of the depth. When setting a component into the clamp and centering it, mark the side of the component up tight against the clamp. This mark will allow inspectors to verify the pipe was properly installed into the clamp after the weld is completed. The distance of the mark to the side of the coupling will be identical for each dimensional size. Marks that are too close or too far to the coupling should be rejected. Most problems with HPF come from not carefully inserting the fitting and centering it into the coupling. Since the process is controlled with bar coding the parameters and computer control of the heating and cooling, the welding process itself is extremely reliable. The proper set up is the main variable that is the responsibility of the operator.

In the fusion process, it is possible to find tiny bubbles trapped in the welded region. This may be most noticeable with PVDF, for its clear nature allows it to be visible. These bubbles are a common occurrence in non-contact butt fusion, but can also be present in conventional butt-fusion systems. The bubbles are from one of two sources: either air has been trapped in the weld during the joining process, or small vacuums appear due to material shrinkage during the cooling down time. In either case, the bubbles are not an area of concern and there is no specification for the size of a bubble that would cause a joint failure. The combination of the welding parameters and the melt flow index of the Solef PVDF resin help to ensure against tiny bubbles affecting the quality of the joint.

Rev. EDG– 02/A

Weld 1– Standard IR joint

Weld 2 – Cold weld

Figure F-79. Cross-sectional view of pipe wall with weld

Bubbles in the Joint

ASAHI /AMERICA

F

The problem with inspecting a cold weld is that the outer bead is the same as a good joint. In Figure F-79, the top bead represents the outer look of the weld. It can be seen very clearly that both welds look the same according to the bead formation. Since the occurrence of a cold weld is difficult to find and inspect, it is important to use proper welding procedures when joining the material. The issue of inspecting and avoiding a cold weld is no different than a PVC joint that has not been primed prior to cementing. You cannot always tell after the weld is made, but if you correctly follow procedures it will not occur. Cold welds can be avoided with the following operating techniques on all butt fusion and socket fusion equipment. • Ensure proper heating element temperature throughout the project. • Use the correct welding parameters by pipe size, wall thickness, and material.


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INSTALLATION PRACTICES • Do not delay between removal of heating element and joining of material. • Do not slam material together after heating. Material should be joined quickly, but the pressure build up should be smooth and even. • Do not join components together above the joining force.

Step 8. Hanging Hanging any thermoplastic system is not that much different than hanging a metal system. Typically, the spacing between hangers is shorter due to the flexibility of plastic. In addition, the type of hanger is important. Hangers should be placed based on the spacing requirements provided in Tables F-12 thru F-14 . Since thermoplastics materials vary in strength and rigidity, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, the amount of hangers will generally be increased.

F

Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical. In these cases, the hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation. When selecting hangers for a system, it is important to avoid using a hanger that will place a pinpoint load on the pipe when tightened. For example, a U-bolt hanger is not recommended for thermoplastic piping systems. See Figures F-80 and F-81. Pressure Point

Pressure Point

Figure F-80. Effects of U-bolt on pipe – not recommended


Table F-12. PVDF Support Spacing Recommendation (feet) Nominal Size (inches) 1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12

68° F 20° C

86° F 30° C

104° F 40° C

122° F 50° C

140° F 60° C

158° F 70° C

176° F 80° C

3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.5 8.5 9.5

2.5 3.0 3.0 3.5 4.0 4.5 5.0 5.0 6.0 7.0 7.5 8.5

2.5 2.5 3.0 3.0 4.0 4.0 4.0 5.0 6.0 6.0 7.0 8.0

2.0 2.5 3.0 3.0 3.5 4.0 4.0 4.0 5.0 6.0 6.5 7.0

2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.0 5.0 5.5 6.0 7.0

2.0 2.5 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 6.0 6.5

2.0 2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0

Table F-13. Polypropylene SDR II Support Spacing Recommendation (ft) Nominal Size (inches) 1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12 14 16 18

68° F 20° C

86° F 30° C

104° F 40° C

122° F 50° C

140° F 60° C

158° F 70° C

176° F 80° C

3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 7.5 8.5 9.5 10.0 10.5 11.5

2.5 3.0 3.0 3.5 4.0 4.5 5.0 5.0 6.0 7.0 7.5 8.5 8.5 9.5 10.0

2.5 2.5 3.0 3.0 4.0 4.0 4.0 5.0 6.0 6.0 7.0 8.0 8.0 8.5 9.0

2.0 2.5 3.0 3.0 3.5 4.0 4.0 4.0 5.0 6.0 6.5 7.0 7.5 8.0 8.5

2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.0 5.0 5.5 6.0 7.0 7.0 7.5 8.0

2.0 2.5 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 6.0 6.5 6.5 7.0 7.5

2.0 2.0 2.5 3.0 3.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 6.5 7.0

Table F-14. E-CTFE Support Spacing Recommendation (feet) Nominal Size (inches)

68° F 20° C

248° F 140° C

1 2 3 4

3.60 5.00 5.75 6.00

2.50 3.00 3.75 4.00

Notes: 1. Supports must be spaced according to the highest possible temperature the pipes will encounter even if the extreme condition is only temporary. 2. Support spacing is based on a liquid with a specific gravity of 1.0. Spacing should be reduced by 10% for liquids having 1.5 specific gravity, 15% for 2.0 s.g., and 20% for 2.5 s.g.

Figure F-81. Recommended hanger

F-40




Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp. This is a must for PVDF and E-CTFE systems, which are less tolerant to scratching. For more details on hanging Asahi /America systems, consult Section C, Engineering Theory and Design Considerations.

Step 9. Trenching and Burial Proper trenching and burial of a pipe system requires engineering prior to an installation. Section C provides a comprehensive guide to burial calculations load tolerance of thermoplastic pipe. This information should be supplied and be specified prior to installation. Refer to Asahi /America’s manual for the burial calculations. For installation purposes, it is important to look at several factors as the installer of underground piping. • Soil conditions should match that of the specification and/or drawings. • Trenches should be dug according to plan. • Pipe should be surrounded by specified soil type and compaction. • Accommodations for welding in the trench should be made. • Safety issues of being in a trench should always be observed. For each underground installation, burial designs will specify depth of trench and width of trench. The wider the trench, the more load the pipe will see upon compaction. Therefore, it is important to follow trench design closely to avoid excess load on the pipe. In addition to the trench details, the type of soil becomes important. Different types of soils have differing densities and will create differing loads on the buried pipe. If the soil does not match that of the design, it needs to be rechecked or different fill may be required.



9"

Sand 95% Proctor

9"

Pea Gravel

6" 6"

6"

Figure F-82. Trench detail Welding in a trench should also be preplanned. It is common that all welding is done above ground, and then, the welded components are all lowered into the trench. In many instances it may be necessary to weld in the trench. For conducting welds in a trench it is important to allocate space for the machine as it will be wider than the pipe itself. Widening the trench may be required to accommodate the machine.

Step 10. System Testing Prior to pressure testing, the system shall be examined for the following items: 1. Pipe should be completed per drawing layout with all pipe and valve supports in place. 2. Pipe, valves, and equipment should be supported as specified, without any concentrated loads on system. 3. Pipe should be in good condition, void of any cracks, scratches, or deformation. 4. Pipe flanges should be properly aligned. All flange bolts should be checked for correct torques. 5. All joints should be reviewed for appropriate welding technique. See Weld Inspection, Step 7. If any deficiencies appear, the quality control engineer should provide directions/repair.

The surrounding material of the pipe is also important. Items such as large rocks may cause pinpoint loads on the pipe that could eventually damage the pipe. Figure F-82 depicts a recommended cross section of a trench and proper fill material and compaction.



F-41

F

INSTALLATION PRACTICES Pressure Test

Step 11. Repair Procedures

Test fluid should be water. In all cases, tests must be done hydrostatically. Air is not acceptable.

If a leak is found or an addition is required to an existing system, there are several options on how to make the repair. In most systems, socket or butt fusion, there is a requirement for pipe movement when making a weld. To conduct a butt or IR weld, one side of the tool moves in order to accommodate the planer, the heating element, and the final joining force. In a repair procedure, the need for movement of the existing pipe makes for the simplest repair.

1. Filling the system: Open the valves and vents to purge the system of any air. Slowly inject the water into the system, making sure that air does not become trapped in the system. 2. Begin pressurizing the system in increments of 10 psi. Bring the system up to the test pressure and hold. Allow system to hold pressure for a minimum of two hours and up to a recommended 12 hours. Check pressure gauge after one hour. Due to natural creep effects in plastic piping, the pressure may have decreased. If drop is less than 10 psi, pump the pressure back up. At this time, the system may be fully pressurized to desired test pressure. 3. If after one hour the pressure has decreased more than 10%, consider the test a failure. Note the 10% value may need to be greater for larger systems. Also, note that Step 2 may need to be conducted several times if there are significant thermal changes.

F


4. If the pressure drops less than 10% after one hour, pump the pressure back up to the test pressure. This is normal due to creep. If after two hours the pressure does not drop, consider the test a success. 5. Test is to be witnessed by the quality control engineer, and be certified by the contractor.

Flexible Pipe System If the pipe is in an area where it can be moved, standard butt fusion or socket fusion equipment can be used. 1. Cut out the section in need of repair. It is best to conduct new tie-in welds on straight runs of pipe for easier alignment. 2. If several welds are required, prefab a spool piece on a bench and conduct only a few tie-in welds in the pipe rack. 3. Attach the tool to the existing pipe and properly support the machine to avoid sagging or stressing the pipe. 4. Conduct standard butt-fusion weld per operating procedures. It may be necessary to flex the existing pipe out of the way of existing pipe. 5. Conduct final weld using the flexible side of the pipe system in the moving clamp.

6. Obvious leaks can be found by emptying the system and placing a 5 psi charge of clean, dry nitrogen on the system. Each joint should then be individually checked using a soapy water solution or an ultrasonic leak detection gun. Leak detection guns are available from Asahi /America. Consult factor for usage of U.S. leak detection guns. Some limitations do apply.

L


First Tie In

Figure F-85. Install new spool Second Tie In

Figure F-83. Ultrasonic leak detection gun L


F-42





Non-Flexible Pipe System Depending on the size and material, repairs can also be made to systems without any movement. For Purad PVDF systems in sizes 1/2"– 2", HPF welds can be conducted in place with minimal need for movement. In polypropylene in sizes 1/2"– 9", electro-fusion welds can be accomplished. 1. Remove the damaged section of piping. For easier alignment, conduct new tie-in welds on straight runs of pipe.

L


2. If several welds are required, prefab a spool piece on a bench setup and conduct only a few tie-in welds in the pipe rack. 3. Using either the large or the small alignment rack, fix two wide clamps to the existing pipe line and to the new spool piece. Make sure all components are level and properly supported. 4. Plane the ends perfectly square. It is recommended to preplane both ends of the spool and both ends of the existing pipe line at this point. It is also necessary to slide the second coupling onto the spool at this point to avoid difficulty of placing it on the pipe after one weld is complete. For polypropylene, planing is recommended but not required, as long as cuts are straight and square. 5. Slide the coupling into place using the third wide clamp and center the existing pipe in the clamp using the mechanical stop. Now bring the spool piece into the clamp until it is up tight against the existing pipe line. For polypropylene, only one clamp is necessary.

Slide to Position

HPF Coupling

Figure F-88. Slide second coupling into place and conduct first weld at joint seam

L

F

Figure F-89. Conduct final weld

6. Conduct the weld per procedure for the equipment. 7. Measure the thickness of the coupling. Take half of the thickness and mark this distance from the end of the pipe. This mark identifies the location of the end of the coupling and helps to center the coupling on the two final components to be joined. Lock in place using the wide clamp.8. Conduct the final weld according to procedure.



F-43



For systems where electro fusion is not available, and there is no flex for movement of the existing pipe in the region of the damaged pipe, the repair can be done using flanges or unions. 1. Remove the section to be repaired. 2. Weld flanges or unions on both ends of the existing piping. 3. Measure the distance from face to face and build a spool to fit into place. 4. Connect spool into place.


L

F

Figure F-91. Weld flanges or unions into place

L


F-44




DOUBLE WALL SYSTEMS

DOUBLE WALL SYSTEMS Installing any piping system properly requires preplanning. The installation is more than the welding of components. It requires the proper environment, material inventory, welding equipment, tools, and thorough training. This guide is to assist in the planning and installation of a double wall pipe system either in a pipe rack or trench. This guide will concentrate on Duo-Pro and Fluid-Lok systems, as produced and supplied by Asahi /America, Inc. Duo-Pro and Fluid-Lok systems are similar with only a few minor exceptions. Both systems are highly engineered systems, fabricated from single wall components to provide the widest variety of selection and performance for all circumstances. By the time a DuoPro system arrives on site, most of the engineering and design layout work should have been completed. Covered in this guide are the steps to plan and complete a successful installation. Step 1. Welding Environment Step 2. Tool Selection Step 3. Material Handling Step 4. Training and Preparation Step 5. Tool Commission and Daily Checks Step 6. Pipe Cutting Step 7. Weld Preparation Step 8. Weld Inspection Step 9. Hanging Step 10. Trenching and Burial Step 11. System Testing Step 12. Repair Procedures

Step 1. Welding Environment Asahi /America does not set requirements for proper welding environments. As the installer, it is necessary to choose the environment based on the installation type, timing or quality goal. In most systems, pipe is either going into a pipe rack, beneath a floor or wall, or buried underground. In all these cases, conducting welds in the actual final location may not always be the most convenient location for welding. In fact, in most cases, it is preferable to prefabricate spool piece components and conduct final welds or hook-up in the pipe rack. If possible, set up a welding area to build the spool pieces. The weld area should be situated in an area that has reduced exposure to wind, possible rain, and extreme cold temperatures. Building spool pieces inside a weld shop may prove advantageous. A fairly controlled environment and organized work space will improve efficiency and quality of the system to be installed.

When welding outside, several factors have to be considered. It is always important not to weld in the rain. Rain will damage equipment and improperly influence the weld. For rainy days, a shelter or tent should be constructed over equipment. In addition to rain, high winds and cold temperatures, below 40° F, will negatively influence the welding process. If these conditions are not avoidable, a heated tent structure is recommended. For specific recommendations by tool type, consult the Asahi /America Engineering Department. When conducting field welds in a pipe rack or in a trench, it is important to have the location of the weld well planned. Vertical welds in any location will prove difficult to conduct and should be avoided. The field weld that connects up prefabricated spool pieces should be a pipe-to-pipe weld whenever possible. Pipe-to-pipe welds are easier to align and level, making the weld easier to conduct in possibly tight quarters. In all field welds, in the rack or in a trench, it is important to have ample room for welding equipment and to choose the proper welding equipment. In some underground installations, it may be necessary to increase the width of the trench in weld locations. Many underground systems are welded above ground and then lowered down into the trench to avoid placing equipment in narrow trenches. The same is true in crowded pipe racks. Many times it will prove more efficient to prefab spools and use flanges or unions to connect them together in the pipe rack. Consult Asahi /America for the design and use of a double contained flange.

Step 2. Tool Selection The selection of the type of welding method conducted on a double wall industrial piping project should be based on the following criteria: • Material • Sizes to be installed • Welding location • Type of installation • Similar to dissimilar material • Available expertise For assembling double containment piping systems made from PVDF, PP, E-CTFE, and HDPE, there are many choices of equipment available, each having its advantages and disadvantages. On all Asahi /America’s standard double wall containment systems, butt fusion is the only joining system offered due to its ideal functionality in this application. Tables F-15 and F-16 contain data on available welding equipment. There is no one right piece of equipment that can handle all sizes and materials. It is absolutely critical to have the right equipment on site for proper installation.

Not all welding can be conducted in a shop and eventually field welds will need to be done. Some systems will be installed completely outside, with all the welds perhaps conducted in place.



F-45

F


DOUBLE WALL SYSTEMS

Table F-15. Equipment Selection: Simultaneous Fusion Description

Pro 150 x 150

Pro 150 x 45

Pro 45 x 45

PVDF x PVDF

Shop 4 Miniplast

1 x 3: 2 x 4: 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14: 12 x 16: — —

2 x 4: — 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14: 12 x 16: 14 x 18: 16 x 20:

2 x 4: — 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14: 12 x 16: 14 x 18: 16 x 20:

1 x 3: 2 x 4: 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: — — — — — — — —

Shop 12

Field 6

Field 12

Field 20

MacElroy 1-4

F MacElroy 2-8

MacElroy 4-12

MacElroy 6-18

MacElroy 8-24

A A A A B X A A A A A B B A A A A

X X X X X X X X X X X X X X X X X X X X

A A A B B A A A A A A B A A A A A A X X X X X X X X X X X X X X X X X X X X

A A A B B A A A A A B B A A A A A A X X X X X X X X X X X X X X X X X X X X

A A A A B B A A A A A

X X X X X X X X X X X X X X X X X X X X

HDPE SDR 11 x 11 1 x 3: 2 x 4: 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14: 12 x 16: — — 1x3 1x4 1.5 x 4 2x4 2x4 3x6 4x8 4x8 6 x 10 8 x 12 6 x 10 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 14 x 20 or 14 x 22 16 x 22 or 16 x 24 18 x 24

A A A A B X A A A A A B B A A A A

A A A A A A A A A A A A A A B B A A A A

HDPE SDR 11 x 17 1 x 3: 2 x 4: 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14 12 x 16: 14 x 18: 16 x 20: 1x3 1x4 1.5 x 4 2x4 2x4 3x6 4x8 4x8 6 x 10 8 x 12 6 x 10 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 14 x 20 or 14 x 22 16 x 22 or 16 x 24 18 x 24

A A A A B X A A A A A B B A A A A A A A A A A A A A A A A A A A A B B A A A A

HDPE SDR 17 x 17 1 x 3: 2 x 4: 2 x 4: 3 x 6: 4 x 8: 6 x 10: 2 x 4: 3 x 6: 3 x 6: 4 x 8: 6 x 10: 8 x 12: 4 x 8: 6 x 10: 8 x 12: 10 x 14: 12 x 16: 14 x 18: 16 x 20: — — — — — 3x6 4x8 4x8 6 x 10 8 x 12 6 x 10 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 8 x 12 10 x 14 or 10 x 16 12 x 16 or 12 x 18 14 x 20 or 14 x 22 16 x 22 or 16 x 24 18 x 24

A A A A B x A A A A A B B A A A A A A

A A A A A A A A A B B A A A A

A: Recommended. B: Will work, but a better choice is available. X: Not recommended.

Table F-16. Equipment Selection: Staggered Welding Description

Pro 150 x 150

Pro 150 x 45

Pro 45 x 45

PVDF x Pro 150

PVDF x Pro 45

PVDF x PVDF

1x4

Shop 4 Shop 10 Shop 4 Shop 10 Shop 10 Shop 10 Shop 10 carrier Field 12 containment Shop 10 carrier Field 12 containment Shop 10 carrier Field 12 containment


DNA

Shop 4 Shop 10 Shop 4 Shop 10 Shop 10 Shop 10 Shop 10 carrier Field Field12 containment Shop 10 carrier Field Field12 containment Shop 10 carrier Field Field12 containment

DNA


2x4 3x6 4x8 6 x 10

8 x 12

10 x 14

F-46

DNA DNA Shop 10 Shop 10 carrier Field 12 containment Shop 10 carrier Field 12 containment Shop 10 carrier Field 12 containment


Shop 4 Shop 10 Shop 10 Shop 10 Shop 10 carrier 12Field Field1212 containment Shop 10 carrier 12Field Field12 12 containment Shop 10 carrier 12Field Field1212 containment


DOUBLE WALL SYSTEMS


Step 3. Material Handling

Both of these can be conducted on site during the time of the start-up. The depth of training in a double containment piping system is based on the system type to be installed. Systems that require staggered fusion are more involved to install and may require the operation of different equipment.

When pipe, fittings, and fabrications arrive on site, they should be inspected to ensure the proper components have arrived and no damage has occurred during shipment. Asahi /America goes to great lengths to ensure that pipe and fittings are properly packaged for shipment. If damage occurs, the freight company should be notified immediately. Preferably, pipe should be stored inside or in a trailer. Care should be taken to properly support pipe during storage. Use the hanging criteria for the proper support distance. Pipe can be stacked during storage. Heavier pipes of larger dimensions should be stored at the bottom. However, it may prove more practical to segregate by size for easier access during the project. Pipe should not be stored above the recommended maximum height of 4 feet. If material is stored outside, it is preferable to cover with a tarp in case of rain. PVDF is UV resistant, but polypropylene will degrade over time when exposed directly to UV. Depending on the size of the pipe and the wall thickness, it could cause physical damage that could reduce the allowable pressure rating. In all cases, the UV will cause a color change over time that may not be acceptable for aesthetic reasons. In general, covering polypropylene during storage is recommended. Fittings are best kept in their boxes or bags, as they are shipped in separate containers by size, style, and material. This will allow for simplified picking and inventory control throughout the project.

Step 4. Training and Preparation A double containment system is a critical utility within a plant. It is often under flooring or underground where it is not easily accessible. In addition, double containment systems also are in overhead piping and provide additional needed safety for plant personnel from a leak in a hazardous chemical system. A repair to a system can prove difficult and costly. One bad weld can cause hours of repair and frustration, as well as lost revenue. For these reasons, it is critical to receive training at the time of job start-up and use certified personnel throughout the course of a project. Tool operation is only one of several factors in a thorough training course. Operators, inspectors, and managers need to understand the physical nature of the material, how to properly handle it, how to inspect welds, how to identify potential problems, how to properly maintain equipment and finally, how best to tie into a line and test it. During Asahi /America’s certified training sessions, all of the above topics are discussed. For the installation of a double containment system, the following training sessions are available: • Tool Operator Training • Quality Control Inspection


In addition to the above on-site training, Asahi /America also offers courses that are held at the corporate office for the following topics: • Certified Maintenance and Repair • Certified Trainer (prerequisites apply) Consult with Asahi /America’s Engineering Department for dates and availability of corporate programs. During the on-site training process, Asahi /America certified trainers will set recommendations for the class size based on the tool type. In general, groups of four are recommended for the welding operation portion of the training. Typically, two groups can be certified in one day on the welding portion of the seminar. On simple installations, it may be faster; and on more complex installations, it may be longer. To reduce the distraction within the class, it is important that only personnel who will be conducting the weld operation during the project participate in the training. It is also recommended that if a third party QC is to be used that they also attend the full training course to fully understand the welding process and QC parameters.

Preparation To best use training time, preparation should be made prior to the trainers’ arrival on site. A recommended list of preparations follows. • Ensure that project material is on site. It is not critical to have all material, but enough to start the project. Once training is complete, it is practical for the trainer to oversee the beginning portion of the installation. Many times new questions and challenges arise once the actual installation starts. In addition, if there is a significant period of time between the training and actual installation, operators may forget portions of the training or different operators may now be slated for the welding operation. Both scenarios require additional training. • Ensure required tools are on site. Do not open the tools until a certified trainer is present. If more tools are ordered during a project, this is no longer required as proper unpacking and set up of the equipment is covered in the training process. • Ensure that the correct power is available. Many pieces of equipment require 220 Volt single or three phase power supply. Consult with the factory or distributor at the time of tool ordering. • If possible, have a conference room with an overhead projector available for the classroom portion of the training. If this is not available, select an area where all personnel will be able to see and hear the trainer for this portion of the discussion.


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INSTALLATION PRACTICES • Ensure that pipe samples are available for the training session. Asahi /America does not normally provide samples for the training. • Ensure extra components such as welding rod, support discs, and hot air welders are ordered and available at the time of training. Such components.will be required throughout the project. Formal training can be the key factor in starting a project off in the right direction. Take advantage of this service while on site. Asahi /America also offers field technicians for hire to oversee project welding and training for any specified amount of time. Contact the Asahi /America Engineering Department for more information.

Step 5. Tool Commission and Daily Checks

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Checking equipment and welding technique daily is recommended. This is particularly important on larger projects where there are many welders on site. This daily check will allow QA to ensure all welders are up to speed on tool operation, welding technique, and inspection. Most problems in the field occur due to improper usage of equipment, rather than equipment failure.

DOUBLE WALL SYSTEMS

In most sizes, band saws, vertical or horizontal, will work very well for plastic. Since plastic pipes can have a very heavy wall thickness, it is important to travel slowly through the band saw to avoid the blade from bending and creating an angled cut. For smaller pipe sizes and Poly-Flo pipes up to 2 x 3, a circular blade chop saw will also provide neat and accurate cuts. A miter box chop saw is also very useful if angled welds are to be done in the field. If only manual saws are available, a hack saw will certainly cut through small dimensions, but avoid using a fine blade as it will take considerable time. In addition, reciprocating saws are generally not the best choice as the blades are only long enough to cut one wall at a time. If too fine of a blade is used, the material will become hot and can fuse itself back together partially behind the blade travel.

Step 7. Weld Preparation The type of material and system will dictate welding method and tool selection. One important factor in welding a Duo-Pro or Fluid-Lok system is the alignment of the support discs. To allow the pulling of cable, it is necessary to have the disc openings aligned at the pipe bottom. Welds

During the initial training of the project, many welds are produced in the presence of a qualified trainer. These welds should be kept and used for the daily checks. Each welder should conduct one coupon test weld and submit it to QA. The coupons should be compared to initial samples. Inspection should include bead formation, sizing, and weld label. Conducting preventive maintenance to the equipment at the beginning of each day is also required. The maintenance recommended varies on each weld tool type. Consult the Operation Manual for items to be checked daily. By keeping equipment in good operating condition and ensuring all operators are up to speed, tool problems or welding errors are less likely to occur.

Step 6. Pipe Cutting Cutting plastic pipe can be handled in a variety of methods. In small dimensions, 1/2" through 4", roll wheel pipe cutters are commonly available and work well. These types of cutters are similar to a tube cutter, but only larger. When using a roll cutter on PP or PE, it is important to ensure the wheel has a larger radius than the wall thickness of the pipe so it will cut all the way through. A roll cutter will only cut single wall pipe. It can be used to cut the inner and outer pipe separately, but if a pipe is already fabricated into a double contained configuration, a roll cutter cannot be used. Poly-Flo systems cannot be cut using a roll cutter.

F-48

Align cutouts at bottom of pipe

Figure F-93. Support disc alignment In a Poly-Flo system, it is important to rotate the pipe ribs. Since a Poly-Flo system cannot accommodate leak detection cable, rotating the ribs is recommended to allow a possible leak to make its path to the bottom annular space. The cold weld is more difficult to identify, and virtually impossible to detect with the naked eye. Two cross-sectional views of a pipe wall that has been welded are shown in Figure F-79. Weld 1 is a good fusion joint, while Weld 2 is a cold weld. Notice in the cold weld there is very little material joined together in the pipe wall area. The molten material has been forced to the outer and inner bead, and the unheated sections of the pipe have been forced together in the pipe wall region. In the proper Weld 1, you can see there is material joined together in the pipe wall, as well as in the inner and outer beads.




DOUBLE WALL SYSTEMS

Step 8. Weld Inspection To ensure a safe and on-time system start-up, initiating a standard inspection process is recommended on each project. This quality assurance measure can be conducted by a third party QC or can be done by each individual operator after each weld. A recommended inspection report for recording quality assurance on each weld is attached to the end of Section F. Use the recommendation of this weld inspection guide in conjunction with the equipment manual to achieve the best project results. To inspect butt-fusion joints, the inspector should look for the following characteristics on each weld. • Welds should have two beads that are 360° around the pipe. • Beads should be of consistent height and width. • Beads should have a rounded shape. • Beads should be free of burrs or foreign material. • A bead on either side should not reduce greatly in width or disappear. • Components welded should be properly aligned and cannot be misaligned by more than 10% of the wall thickness. When welding the inner and outer pipe and fitting simultaneously, the outer bead will provide an accurate depiction of the inner weld. If the outer pipe appears improperly aligned, the inner pipe will also be out of alignment. For simultaneous fusion, it is necessary to ensure the carrier component is flush in length with the containment component. Check on each part with a straight edge after the planing and prior to the heating step of welding. Other methods include marking the ends of the carrier in four locations 90° apart prior to planing. If planing on the containment pipe is complete and all the original marks on the carrier have been removed by the planer, then both parts are flush. Figure F-94 shows a detail of a standard butt-fusion bead formation. Butt Fusion Weld Beads Support Disk

Butt-fusion beads will vary in size and a little in shape with different materials. In general, PP and HDPE will have larger bead formations in comparison to PVDF. With PP and HDPE, there will be a pronounced double-bead formation that will be simple to identify. With PVDF, there will also be a double-bead formation, but not as pronounced. The material will appear to flow more together, making what appears to be one single weld. However, upon examination, you will always see the seam where the components were joined. In addition, when butt welding PVDF pipe to fittings, the fitting bead will be larger than the pipe bead. This is normal as the resin used to produce PVDF fittings flows at a higher rate when melted compared to the resin used to extrude pipes. Mechanically, there will be no issues on strength of the joint, only the appearance of the weld. Since outside temperatures and conditions will have some effect on bead sizes, there is no formal specification for the size of the bead. Also, measuring each bead would be time consuming. During the training process, welding one of each size to use as a rough gauge for the project may prove useful. These sample coupons can be referred to on a regular basis to check welding throughout the project. If bead formations do not meet the inspection criteria, they should be rejected. Consult the operation manual for each tool on how to correct the problem. If problems persist, contact Asahi /America for assistance. Many times these issues can be cleared up quickly over the phone, avoiding waste in time and material. Never continue welding if proper fusion cannot be accomplished. This will only add to problems at a later time.

Limitations of Inspection Following proper weld procedures in conjunction with a thorough inspection process will lead to a safe and reliable system. However, a weld cannot be 100% judged by viewing it after the fusion is complete. Bad welds with obvious problems can be identified, such as missing beads, small beads, and misalignment, but other problems may not be easily found. A cold weld occurs when an operator either maintains too high a force during the heat soak time or joins the material together at too high a force. Molten material is then pushed to the outer bead and cooler material is forced together inside the weld.

Figure F-94. Typical butt-fusion weld bead



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INSTALLATION PRACTICES The problem with inspecting a cold weld is the outer bead is the same as a good joint. Since the occurrence of a cold weld is difficult to find and inspect, it is important to use proper welding procedures when joining the material. The issue of inspecting and avoiding a cold weld is no different than a PVC joint that has not been primed prior to cementing. You cannot tell after the weld is made, but if you correctly follow procedures, it will not occur. Cold welds can be avoided with the following operating techniques on all butt fusion and socket fusion equipment.

DOUBLE WALL SYSTEMS

When selecting hangers for a system, it is important to avoid using a hanger that will place a pinpoint load on the pipe when tightened. For example, a U-bolt hanger is not acceptable for high-purity thermoplastic piping systems. See Figures F-95 and F-96. Pressure Point

• Ensure proper heating element temperature throughout the project. • Use the correct welding parameters by pipe size, wall thickness, and material. Pressure Point

• Do not delay between removal of heating element and joining of material. • Do not slam material together after heating. Material should be joined quickly, but the pressure build up should be smooth and even.

Figure F-95. Effects of U-bolt on pipe – not recommended

• Do not join components together above the joining force.

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Step 9. Hanging Hanging any thermoplastic double wall system is not that much different than hanging a metal system. Typically, the spacing between hangers is shorter due to the flexibility of plastic. In addition, the type of hanger is important. Hangers should be placed based on the spacing requirements provided in Appendix A. Since thermoplastic materials vary in strength and rigidity, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, the amount of hangers will generally be increased. Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical In these cases. The hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation.

F-50

Figure F-96. Recommended hanger Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps, as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp. This is a must for PVDF and E-CTFE systems, which are less tolerant to scratching.




DOUBLE WALL SYSTEMS

Step 10. Trenching and Burial Proper trenching and burial of a pipe system requires engineering prior to an installation. Asahi /America’s Engineering Manual (Section C) provides a comprehensive guide to burial calculations load tolerance of thermoplastic pipe. This information should be supplied and be specified prior to installation. Refer to Asahi /America’s manual for the burial calculations. For installation purposes, it is important to look at several factors as the installer of underground piping. • Soil conditions should match that of the specification and/or drawings. • Trenches should be dug according to plan. • Pipe should be surrounded by specified soil type and compaction. • Accommodations for welding in the trench should be made. • Safety issues of being in a trench should always be observed. For each underground installation, burial designs will specify depth of trench and width of trench. The wider the trench, the more load the pipe will see upon compaction. Therefore, it is important to follow trench design closely to avoid excess load on the pipe. In addition to the trench details, the type of soil becomes important. Different types of soils have differing densities and will create differing loads on the buried pipe. If the soil does not match that of the design, it needs to be rechecked or different top fill may be required. The surrounding material of the pipe is also important. Items such as large rocks may cause pinpoint loads on the pipe that could eventually damage the pipe. Figure F-97 depicts a recommended cross section of a trench and proper fill material and compaction.

Welding in a trench should also be preplanned. It is common that all welding is done above ground, and then, the welded components are all lowered into the trench. In many instances it may be necessary to weld in the trench. For conducting welds in a trench, it is important to allocate space for the machine as it will be wider than the pipe itself. Widening of the trench may be required to accommodate the machine.

Step 11. System Testing Procedures for testing installed sections of Duo-Pro systems must take into account factors affecting both carrier and containment pipes. Basic recommendations may be given, but a comprehensive testing program should be developed for each and every system design. The program should be developed based on the needs and characteristics of the particular system at hand. All pressure tests must be conducted prior to backfilling a buried system.

Carrier Pipe, Pressure System If the carrier piping is intended for pressure service greater than 10 feet of head, a hydrostatic pressure test must be conducted. In any hydrostatic pressure test, provisions must be made to vent all air out of the inner pipe. If necessary, special highpoint vents should be installed to bleed any trapped air. Air pockets can create a dangerous situation if a cold weld exists and is found during a test. Compressed air pockets can contribute to extensive propagation of fault lines when a failure occurs. Compressed air or gas should not be used for pressure testing of any carrier pipe in excess of 10 psi. Pressure tests should be conducted at a maximum of 150 percent of the operating pressure of the lowest rated component of the system.


9"

Sand 95% Proctor

9"

Pea Gravel

6" 6"

6"

Figure F-97. Trench detail



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INSTALLATION PRACTICES Filling the System The piping should be capped off at the end of the spool section to be tested and fitted with an adapter to allow tie-in for testing. All flanges in the vertical position should be left open at this point. Bleed off air through the relief valves. Introduce water very slowly into the system at the low point. In no instance should the water velocity exceed two feet per second. When the water fills all vertical risers, the flanges can be resealed. The relief valves should be left open until it is certain that all air is out of the system. The system can then be brought up to pressure through gradual steps using a hand pump or other similar equipment. Do not use city water pressure to accomplish this step if the water pressure in the city mains is greater than the pressure test to be conducted.

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Conducting the Test The test should be done in gradual steps of 10 psi for Pro 150/ PE 150, 5 psi for Pro 45 / PE 45, or 10 psi for PVDF until the desired pressure is achieved. There will be some gradual drop in pressure due to natural creep effects and elongation of the pipe wall. Also, there could be some drop occurring due to thermal expansion effects where there are sudden environmental temperature changes. After one hour, check the pressure gauge. If there is a decrease without an indication of leakage, pump the pressure back up to the test pressure. If the total pressure drops more than 10% after the second pressurization, the test can be considered a failed test. Check the system for leaks or other problems. Otherwise, continue the pressure test for a minimum of two hours up to a recommended duration of 12 hours or as required by local code requirements. Cyclic Hydrostatic Testing In critical applications, the inner piping should be tested hydrostatically for more than one cycle. To test for more than one cycle, do not empty the system and start all over. Instead, drop the system pressure down to below 5 psi, and then raise it back in gradual steps of 10 to 20 psi to the desired test pressure. Follow the same procedures as described above. Repeat this procedure for as many cycles as required up to a maximum recommendation of seven cycles.

DOUBLE WALL SYSTEMS

Carrier Pipe, Drainage Systems Inner piping that is intended for drainage service (10 feet of head or less) should be tested by implementing a 10-foot standing water test. A 10-foot standing water test consists of welding or attaching in some manner a 10-foot riser to the upstream (high end) of the system. It is not unusual that there are several high points (branch connections) in a system. It is important that every riser or branch connection be affixed with a 10-foot riser in order to ensure that every point in the system will see 10 feet of head. In fact, at the low point, the system will see a pressure equal to 10 feet of head plus the value of the elevation change. A maximum of 20 feet of head must not be exceeded in a drainage system. To consider a standing water test acceptable, the water level after 12 hours should be at a level equal to the level at the start of the test, minus normal evaporation and expansion due to temperature fluctuations. Compressed air or gas should not be used for pressure testing of any carrier pipe in excess of 10 psi.

Containment Pipe, Pressure Systems If outer piping is designed and required to withstand the same pressure as the inside piping, then a hydrostatic pressure test should be conducted for both inner and outer pipes. This is for situations where the inner pipe pressure is greater than 10 psi. It is important to remember that when the annular space is pressurized during this situation, two pipes are involved. A plastic pipe is always less capable of withstanding external pressure than internal pressure. The inner pipe should be kept full of water at a pressure equal to the pressure test of the outer pipe. Equal pressure on the carrier and containment is necessary for the following reasons: 1. To prevent possible collapse of the inner piping during the test. 2. Both the inner and outer piping will elongate equally, thus minimizing any differential stress or stress buildup between the two pipes. 3. In the event of a carrier failure, the containment piping must handle the same pressure as the carrier. The inner pipe will continue to pressurize the outer pipe until the two reach an equilibrium.

Note: Do not use fabricated drainage fittings in pressurized systems where a pressure over 10 feet of head is required. Use molded pressure fittings in these applications.

F-52




DOUBLE WALL SYSTEMS

Filling the System The outer piping can be filled after the inner test is conducted or at the same time as the inner pipe. The system should be filled in the exact same way as described for pressurized carrier pipe. Do not use city water pressure to accomplish this step if the water pressure in the city mains is greater than the pressure test to be conducted. In many cases, it is not an advantage to conduct a hydrostatic test on the annular space, as it is very difficult to dry the space after the test. An air test can be used as an alternative. The pressure should be no higher than 10 psi, and extra safety precautions must be made for surrounding personnel. In all cases, the ambient temperature should be above 32° F. The carrier pipe should also be filled with water and pressurized any time a test is conducted on the annular space.

Conducting the Test Testing is conducted on the containment in the same manner as the carrier. The test should be done in gradual steps of 10 psi for Pro 150/ PE 150, or 5 psi for Pro 45 / PE 45 until the desired test pressure is achieved. There will be some gradual drop in pressure due to natural creep effects and elongation of the pipe wall. Also, there could be some drop occurring due to thermal expansion effects where there are sudden ambient changes. After one hour, check the pressure gauge. If there is a decrease without an indication of leakage, pump the pressure back up to the test pressure. If the total pressure drops more than 10% after this second pressurization, the test can be considered a failed test. Check the system for leaks or other problems. In larger systems and pipelines exposed to large changes in temperature, it may take several tries to get the pressure to remain constant. Otherwise, continue the pressure test for a minimum of two hours up to a recommended duration of 12 hours. A cyclic hydrostatic test as described above for the inner pipes may be used where appropriate. Note: Do not use fabricated drainage fittings in pressurized systems where a pressure exceeding 10 feet of head is required. Use molded pressure fittings in these applications. Containment Pipe, Drainage Systems Outer piping that is intended for drainage capability (10 feet of head or less) or that is flowing open ended, should be tested by implementing a 10-foot standing water test. It should be noted that the carrier pipe pressure must be maintained equal to the outer pipe pressure at all points in order that the inner pipe does not collapse. Pro 45/ PE 45 inside carrier pipe is common in some large-diameter systems such as drainage mains. In order to test these systems, special consideration must be given to ensure that the inner pipe is kept under equal pressure with the outer pipe.


The standing water test should be conducted in the same manner as the inside pipes. A riser should be attached to every vertical riser equal to 10 feet, and the system filled with water. The level should be checked after 12-18 hours, and if no fluid has escaped (minus normal evaporative losses and expansion due to temperature fluctuation), the test should be considered successful. It should be noted that the total of the elevational change plus 10 feet should not exceed the sum of 20 feet. In order not to trap fluid in the annular space, a low-pressure compressed air or nitrogen test (≤10 psi) may be used. Note that if this type of test is used, the carrier inner pipe must be filled with fluid and kept to at least the level of the pressure in the annular space to prevent collapse. If this type of test is used, it is required to “soap” each joint thoroughly to check for visual leaks. In addition, the pressure gauge must also be checked after 2-12 hours for indication. Again, any time compressed air is used, extra safety precautions should be taken. Air tests should be done at 32° F or higher ambient temperature.

Annular Test, Drainage Systems The purpose of the annular test is to test both the carrier and containment simultaneously. For low-pressure drainage systems, an annular test can be conducted to reduce test time. This type of test can only be used on drainage systems using Pro 150 carrier. Cap off the carrier and containment pipe, and provide a pressure gauge on each. Using low-pressure compressed air (≤10 psi), charge the annular space. In a tight system, the containment gauge should read 10 psi (minus losses due to creep), and the carrier gauge should be zero. If there is a leak in the containment piping, the containment gauge will begin to drop. If, however, there is a leak in the carrier piping, the inner piping will become pressurized. See Figure F-98 for typical test results. Pressure should be maintained on the system for 2-12 hours to ensure against a possible slow leak.

10 0

0

10

(a) Leak Out of Containment Pipe

10 0

0

10

(b) Leak In to Carrier Pipe

Figure F-98. Annular pressure test leak indications


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INSTALLATION PRACTICES Drying the Annular Space If the annular space is contaminated with water due to the test procedures or other unforeseen events, it is essential that all moisture be removed thoroughly to minimize condensation that may cause false alarms in leak detection cables and low-point sensors. As discussed in Section C, Engineering Theory and Design Considerations, the installation of properly sized vents and drains will assist greatly with this process. It may be necessary to use Vortek blowers and/or clean dry air to remove all moisture completely. The greater the number of vents and drains, the higher the volume of air can be pushed through the system, thereby decreasing the drying time. As it is extremely difficult to remove moisture from the annular space, it may be appropriate to use compressed air (≤10 psi) for testing carrier and containment pipe where pressure requirements are low. Use of compressed air will not contaminate the annular space with moisture.

Locating a Leak

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In the event of a leak in the carrier, the pressure should be relieved and the water drained to prevent flooding of the annular space. To determine the location of the leak, Asahi/America has available ultrasonic leak detection guns, as shown in Figure F-99. The gun is capable of hearing disturbances in air flow (vibration) through the containment wall. To locate the leak, put a compressed air charge on the carrier piping (≤10 psi). Using the gun, walk the pipe line placing the gun extension against the containment wall. The compressed air escaping through a leak will be heard through the ear phones of the gun, thus locating the leak. In many situations, the time required to locate a leak on the carrier pipe using this technology is less than one hour.

DOUBLE WALL SYSTEMS

Step 12. Repair Procedures A properly designed, installed, and maintained double-containment piping system will provide years of reliable service. The system, however, should offer the means to perform a repair in the event of a mishap, and this repair should be of such quality that the operating parameters, pressure, temperature, and safety factors are not reduced. The Duo-Pro and Fluid-Lok systems offer this capability for all pressure ratings with minimum disruption to site conditions. The first step in a repair procedure is to isolate the leak source. The ease of finding a leak is determined by the leak detection method selected at the time of installation. The use of a leak detection cable will pinpoint the location of the leak to plus or minus three feet, and is possibly the most efficient system. The low-point sensors will identify a zone that has been contaminated. Further testing methods will be required to locate the actual leak source. Several methods are available for this, including the use of an ultrasonic test gun (Figure F-99), fiber optic cameras, and dye solutions. These methods, although more time consuming, are viable alternatives to leak detection cable. The second step in a repair procedure is to flush the carrier and containment pipes to remove any hazardous chemicals that will create safety concerns for the workers doing the repairs. The ability to flush the system is determined by the initial design. The installation of high-point vents and low-point drains in the containment pipe will provide a safe means to perform the flushing. Attempts to install high-point vents and lowpoint drains during repair are costly and potentially dangerous. To completely weld a system repair, the pipe must be flexible in movement in the axial direction. If movement is not present, then a double-wall flange repair may prove convenient. Doublewall flanges may have reduced pressure ratings. Consult factory prior to installation. The third step is to expose the damaged pipe and perform the repair procedure with one of the following methods.

Figure-99. Ultrasonic leak detection gun

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DOUBLE WALL SYSTEMS

Repairs to Systems without Flexibility

Repairs to Systems with Flexibility

Flanged Repairs (similar materials) Duo-Pro and Poly-Flo systems offer patented, double-wall flanges that permit the flow of fluids through the annular space, as shown in Figure F-100. (Consult factory for pressure rating.)

Butt-Fusion Repairs (similar materials) The second method of repair is performed without the use of flanges but instead, only with thermal butt fusion. The use of butt fusion, as the repair procedure requires a larger excavation due to the requirement that the pipe be able to move at least three inches to perform the weld.

Flat Face Flange

"O" Ring Flange

To perform the repair: 1. The damaged section of pipe is removed and the area cleared to allow the pipe to move in the radial direction. Note that only one end of the pipe needs this flexibility (Figure F-104). 3'- 6" Minimum

Figure F-100. Double-wall flange 1. The damaged section of pipe is removed first (Figure F-101). 3'- 6" Minimum

Damaged Section Removed

Figure F-104. Remove damaged section of pipe

F Figure F-101. Remove damaged section of pipe

2. The pipe in the ground is prepared for simultaneous fusion.

2. Plane ends and install supports discs. Next, weld two flanges onto the exposed pipe ends.

3. A spool of pipe is assembled and butt welded to the stationary pipe.

Weld

Weld

Support Disc

Support Disc "O" Ring Flange

"O" Ring Flange

Figure F-102. Install double-wall flanges

1st Weld Performed on Stationary Pipe

Figure F-105. Install new spool

3. A flanged spool piece is fabricated and installed.

2nd Weld Performed on Flexible Pipe

Figure F-106. Butt weld spool to remaining pipe 4. The second weld is then performed on the flexible side. Figure F-103. Install flanged spool

5. The system is then tested and returned to working order.

4. The system is then tested and returned to working order. For all repair methods, a minimum of 3'- 6" is required to facilitate use of welding equipment.



F-55

INSTALLATION PRACTICES The repair procedures described above are appropriate for Duo-Pro and Poly-Flo systems when the same material is used for the carrier and containment piping. To perform a repair on a system with a PVDF carrier and a polypropylene containment, the following steps should be followed.

Repairing PVDF Carrier/Polypropylene Containment (Duo-Pro only)

DOUBLE WALL SYSTEMS

4. The repair procedure is now the same as for similar materials, as described above. There are other repair options available that require the use of slip couplings, electro-fusion couplings, and use of hot-gas welding and extrusion welding. These repair options are adequate for drainage systems only and require well-trained technicians to perform the repair. Consult the Asahi /America Engineering Department for assistance.

Flanged Repairs (dissimilar materials) To perform the repair: 1. The damaged section of pipe is removed and prepared. 6"


F

Figure F-107. Remove damaged section of pipe 2. Polypropylene flanges are welded to the containment pipe.

Polypropylene Flange Welded to Containment Pipe

Figure F-108. Weld polypropylene flanges to pipe ends 3. PVDF flanges are bolted to the polypropylene flanges. Now both the inner and outer piping are similar material. PVDF Flange Bolted to Polypropylene Flange Pipe Ends Are Now Prepared for Simultaneous Welding

Figure F-109. Bolt polypropylene flanges to PVDF flanges

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POLY-FLO SYSTEMS

POLY-FLO SYSTEMS (DOUBLE WALL) Single Extrusion Poly-Flo System Installing any piping system properly requires preplanning. The installation is more than the welding of components. It requires the proper environment, material inventory, welding equipment, tools, and thorough training. This guide is to assist in the planning and installation of a Poly-Flo pipe system either in a pipe rack or trench. This guide will concentrate on the Poly-Flo system, as supplied by Asahi /America, Inc. The Poly-Flo system is similar to the Duo-Pro and Fluid-Lok systems, with only a few exceptions. The Poly-Flo system is a highly engineered system, manufactured from a single extrusion process, that will provide an economical and dependable performance for any double wall piping application. By the time a Poly-Flo system arrives on site, most of the engineering and design layout work should have been completed. Asahi /America’s recommendations for project management follow. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Step 11.


Step 1. Welding Environment Asahi /America does not set requirements for proper welding environments. As the installer, it is necessary to choose the environment based on the installation type, timing, or quality goal. In most systems, pipe is either going into a pipe rack, beneath a floor or wall, or buried underground. In all these cases, conducting welds in the actual final location may not always be the most convenient location for welding. In fact, in most cases, it is preferable to prefabricate spool piece components and conduct final welds or hook-up in the pipe rack. If possible, set up a welding area to build the spool pieces. The weld area should be situated in an area that has reduced exposure to wind, possible rain, and extremely cold temperatures. Building spool pieces inside a weld shop may prove advantageous. A fairly controlled environment and organized work space will improve efficiency and quality of the system to be installed.


Not all welding can be conducted in a shop and eventually field welds will need to be done. Some systems will be installed completely outside, with all the welds perhaps conducted in place. When welding outside, several factors have to be considered. It is always important not to weld in the rain. Rain will damage equipment and improperly influence the weld. For rainy days, a shelter or tent should be constructed over equipment. In addition to rain, high winds and cold temperatures, below 40° F, will negatively influence the welding process. If these conditions are not avoidable, a heat tent structure is recommended. For specific recommendations by tool type, consult the Asahi /America Engineering Department. When conducting field welds in a pipe rack or in a trench, it is important to have the location of the welding planned. Vertical welds in any location will prove more difficult to conduct and should be avoided. The field weld that connects up prefabricated spool pieces should be a pipe-to-pipe weld whenever possible. Pipe-to-pipe welds are easier to align and level, making the weld easier to conduct in possibly tight quarters. In all field welds, in the rack or in a trench, it is important to have ample room for welding equipment and to choose the proper welding equipment. In some underground installations, it may be necessary to increase the width of the trench in weld locations. Many underground systems are welded above ground and then lowered down into the trench to avoid placing equipment in narrow trenches. The same is true in crowded pipe racks. Many times it will prove more efficient to prefab spools and use flanges or unions to connect them together in the pipe rack. Consult Asahi /America for the design and use of a double contained flange.

Step 2. Tool Selection The selection of the type of welding method conducted on a single wall industrial piping project should be based on the following criteria: • Material • Sizes to be installed • Welding location • Type of installation • Available expertise For assembling Poly-Flo piping systems made from PVDF, PP, and HDPE, there are a few choices of equipment available, each having its advantages and disadvantages. On all of Asahi / America’s Poly-Flo containment systems, butt fusion is the only joining system offered. Table F-17 gives data on available welding equipment. There is no one right piece of equipment that can handle all sizes and materials. It is absolutely critical to have the right equipment on site for proper installation.


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INSTALLATION PRACTICES Table F-17. Equipment Selection for Poly-Flo (inches) Description Shop 4 Miniplast

1x3

2x3

X

X

Shop 10 and 12 Manual Field 6 Field 12

4x6

X

X

X

X X

X = Recommended

Step 3. Material Handling Shipping The normal method for transportation of Poly-Flo systems is by truck. The pipe is capped or polyethylene wrapped to protect the ends from damage. Unless sizes prohibit, fittings are boxed and palletized according to the order quantities. Prefabricated spools can often be shipped by flatbed for easier loading and unloading. On large pipe orders, pipe may be palletized and polyethylene wrapped upon request.

Handling and Unloading

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Before unloading the truck, a smooth rounded protecting strip should be placed at the end of the truck bed to protect the piping from sharp edges on the truck. The use of any device to remove the pipe that may cause scars, such as end hooks or cable slings, is not acceptable. The piping can be handled with fork lifts by placing the fork lift under the mid-point of the piping. If the piping is stacked on racks, care should be taken to stack the piping to reasonable heights. Stacking to excessive heights may cause the piping to become ovalized, if left in this condition for a long enough period of time. If the piping is placed on the ground, clear the area of any sharp rocks or objects before doing so, and observe maximum stacking heights.

POLY-FLO SYSTEMS

If the pipe is stacked during storage, the heavier pipes of larger dimensions should be stored at the bottom. It may, however, prove more practical to segregate the pipe by size for easier access during the project. Pipe should not be stored above the recommended maximum height of 4 feet. Fittings are best kept in their boxes or bags, as they are shipped in separate containers by size, style, and material. This will allow for simplified picking and inventory control throughout the project. Plastic piping should never be subjected to dragging over rugged terrain, as it is able to withstand little mechanical abuse compared to steel. Scarring, cutting, or scratching of the surface may cause a stress point that will lower the impact strength of the piping.

Receiving and Inspection Asahi /America piping systems are packaged carefully, inspected, and loaded according to the methods previously described prior to shipping. In addition, a detailed packing slip is included with each shipment, listing the quantities of each pipe and fitting and any Proweld equipment and valves. Back ordered items are also detailed on this packing slip, and are shipped immediately upon availability. The carrier assumes responsibility for delivering the product in the same condition in which it was loaded on the truck. When pipe, fittings and fabrications arrive on site they should be inspected to ensure the proper components have arrived and that no damage has occurred during shipment. Asahi / America goes to great lengths to ensure that pipe and fittings are properly packaged for shipment. If damage occurs, the freight company should be notified immediately.

To maintain the purity of the products prior to installation, PolyFlo pipe should be stored indoors in a site free from excessive dirt and dust. If the products are stored outdoors, they should be covered with a tarpaulin or other protective covering to avoid any possible damage from the weather. Poly-Flo black polypropylene, PVDF, and HDPE are resistant to almost all of the effects of weather. PVDF is completely unaffected by UV light. HDPE, with its black additive, is resistant to UV light, as is Poly-Flo black polypropylene.

Upon arrival at the job site, the following receiving procedure is recommended:

Care should be taken to properly support pipe during storage. When storing the piping in racks, close or continuous support should be provided by these racks to prevent permanent deflection of the piping. The piping should not be located near excessively warm areas such as boiler rooms or steam lines. In addition, if the piping is in an area subjected to temperature build-up due to the sun’s rays, adequate ventilation should be provided or an alternate site should be selected.

4. Count quantities of all items to see if they correspond with the packing slip. Report any discrepancies immediately.

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1. Check the overall condition of the shipment, paying particular attention to whether the product is neatly stacked and material has not shifted, bounced, etc. 2. If there is visible evidence that the shipment is in disarray, check each and every item for damage. 3. If items are damaged, do not discard. These items must be returned for replacement.

If piping sustains only minor damage, such as small cuts or gouges, this material may be used without any adverse effect on piping performance. Since Poly-Flo pipe are thermally butt fused, sections containing the minor imperfections can be cut out and the piping re-fused together.




POLY-FLO SYSTEMS

Step 4. Training and Preparation

Preparation

Training

To best use training time, preparation should be made prior to the trainers’ arrival on site. A recommended list of preparations follows.

A Poly-Flo system is a critical utility within a plant. It is often under flooring or underground where it is not easily accessible. In addition, Poly-Flo systems often are in overhead piping and provide additional needed safety for plant personnel from a leak in a hazardous chemical system. A repair to a system can prove difficult and costly. One bad weld can cause hours of repair and frustration, as well as significant lost revenue. For these reasons, it is critical to receive training at the time of job start-up and use certified personnel throughout the course of a project. Tool operation is only one of several factors in a thorough training course. Operators, inspectors, and managers need to understand the physical nature of the material: how to properly handle it, how to inspect welds, how to identify potential problems, how to properly maintain equipment, and finally, how best to tie into a line and test it. All of the above topics are discussed during Asahi /America’s certified training sessions. For the installation of a Poly-Flo system, the following training sessions are available: • Tool Operator Training • Quality Control Inspection Both of these can be conducted on site during the time of the start-up. The depth of training in a Poly-Flo piping system is based on the pipe size and location of the system to be installed. In addition to the above on-site training, Asahi /America also offers courses that are held at the corporate office for the following topics: • Certified Maintenance and Repair • Certified Trainer (prerequisites apply) Consult with Asahi /America’s Engineering Department for dates and availability of corporate programs. During the on-site training process, Asahi /America certified trainers will set recommendations for the class size based on the tool type. In general, groups of four are recommended for the welding operation portion of the training. Typically, two groups can be certified in one day on the welding portion of the seminar. On simple installations, it may be faster; and on more complex installations, it may be longer. To reduce the distraction within the class, it is important that only personnel who will be conducting the weld operation during the project participate in the training. It is also recommended that if a third party QC is used, they also attend the full training course to fully understand the welding process and QC parameters.


• Ensure that project material is on site. It is not critical to have all material, but enough to start the project. Once training is complete, it is practical for the trainer to oversee the beginning portion of the installation. Many times new questions and challenges arise once the actual installation starts. In addition, if there is a significant period of time between the training and actual installation, operators may forget portions of the training or different operators may now be slated for the welding operation. Both scenarios require additional training. • Ensure the required tools are on site. Do not open the tools until a certified trainer is present. If more tools are ordered during a project, this is no longer required as proper unpacking and set up of the equipment is covered in the training process. • Ensure that the correct power is available. Some pieces of equipment may require 220 Volt single or three phase power supply. Consult with the factory or distributor at the time of tool ordering. • If possible, have a conference room with an overhead projector available for the classroom portion of the training. If this is not available, select an area where all personnel will be able to see and hear the trainer for this portion of the discussion. • Ensure that pipe samples are available for the training session. Asahi /America does not normally provide samples for the training. Formal training can be the key factor in starting a project off in the right direction. Take advantage of this service while on site. Asahi /America also offers field technicians for hire to oversee project welding and training for any specified amount of time. Contact Asahi /America for more information.

Step 5. Tool Commission and Daily Checks Checking equipment and welding technique daily is recommended. This is particularly important on larger projects where there are many welders on site. This daily check will allow QA to ensure all welders are up to speed on tool operation, welding technique, and inspection. Most problems in the field occur due to improper usage of equipment, rather than equipment failure. During the initial training of the project, many welds are produced in the presence of a qualified trainer. These welds should be kept and used for the daily checks. Each welder should conduct one coupon test weld and submit it to QA. The coupons should be compared to initial samples. Inspection should include bead formation, sizing, and weld label.


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INSTALLATION PRACTICES Conducting preventive maintenance to the equipment at the beginning of each day is required. The maintenance recommended varies on each weld tool type. Consult the Operation Manual for items to be checked daily. By keeping equipment in good operating condition and ensuring all operators are up to speed, tool problems or welding errors are less likely to occur.

Step 6. Pipe Cutting Poly-Flo systems cannot be cut using a roll cutter. In most sizes, band saws, vertical or horizontal, will work very well for plastic. Since plastic pipes can have very heavy wall thickness, it is important to travel slowly through the band saw, so as to keep the blade from bending and creating an angled cut. For Poly-Flo pipes up to 2" x 3", a circular blade chop saw will also provide neat and accurate cuts. A miter box chop saw is also very useful if angled welds are to be done in the field.

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If only manual saws are available, a hack saw will certainly cut through small dimensions, but avoid using a fine blade, as it will take considerable time. In addition, reciprocating saws are generally not the best choice as the blades are generally only long enough to cut one wall at a time. If too fine a blade is used, the material will become quite hot and can fuse itself back together partially behind the blade travel. When using power saws to cut Poly-Flo pipe, be sure to use a deburring tool or small sharp knife to clean the ends of the inside diameter and outside diameter of both the inner and outer pipe walls. Also, be sure to deburr the ribs of the Poly-Flo pipe. This is done to ensure good pipe wall welds, as well as to ensure that there is no blockage of the annular space.

Step 7. Weld Inspection To ensure a safe and on-time system start-up, initiating a standard inspection process on each project is recommended. This quality assurance measure can be conducted by third party QC or can be done by each individual operator after each weld. A recommended inspection report for recording quality assurance on each weld is attached at the end of Section F. Use the recommendation of this weld inspection guide in conjunction with the equipment manual to achieve the best project results.

Butt Fusion To inspect butt-fusion joints, the inspector should look for the following characteristics on each weld. • Welds should have two beads that are 360° around the pipe. • Beads should be of consistent height and width. • Beads should have a rounded shape. • Beads should be free of burrs or foreign material. • A bead on either side should not reduce greatly in width or disappear.

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POLY-FLO SYSTEMS

• Components welded should be properly aligned and cannot be misaligned by more than 10% of the wall thickness. • Pipe ribs should always be offset, not lined up in a continuous way, so as to allow any leaking media to flow to the bottom of the pipe so that it can be detected by a leak detection system. When correctly welding the inner and outer pipe and fitting simultaneously, the outer bead will provide an accurate depiction of the inner weld. If the outer pipe appears to be improperly aligned, then the inner pipe will also be out of alignment. For simultaneous fusion, it is necessary to ensure that the carrier component is flush in length with the containment component. This can be checked on each part with a straight edge after the planing and prior to the heating step of welding. Other methods include marking the ends of the carrier in four locations, 90 degrees apart, prior to planing. If planing on the containment pipe is complete and all the original marks on the carrier have been removed by the planer, it is then known that both parts are flush. Butt-fusion beads will vary in size and a little in shape with different materials. In general, PP and HDPE will have larger bead formations in comparison to PVDF. With PP and HDPE, there will be a pronounced double-bead formation that will be simple to identify. With PVDF, there will also be a double bead formation, but not as pronounced, and the material will appear to flow more together, making what appears to be one single weld. However, upon examination, you will always see the seam where the components were joined. In addition, when welding PVDF pipe to fittings, the fitting bead will be larger than the pipe bead. This is normal, as the resin used to produce PVDF fittings flows at a higher rate when melted, as compared to the resin used to extrude pipes. Mechanically, there will not be any issues on strength of the joint, only the appearance of the weld. Since outside temperature and conditions will have some effect on bead sizes, there is no formal specification for the size of the bead. Also, measuring each bead would be time consuming. During the training process, welding one of each size to use as a rough gauge for the project is recommended. These sample coupons can be referred to on a regular basis to check welding throughout the project. If bead formations do not meet the inspection criteria, they should be rejected. Consult the operation manual on how to correct the problem for each tool. If problems keep occurring, contact Asahi /America for assistance. Many times these issues can be cleared up quickly over the phone, avoiding waste in time and material.




POLY-FLO SYSTEMS

Limitations of Inspection Following proper weld procedures, in conjunction with a thorough inspection process, will lead to a safe and reliable system. However, a weld cannot be 100% judged by viewing it after the fusion is complete. Bad welds with obvious problems can be identified, such as missing beads, small beads, and misalignment, but other problems may not be easily found. Cold welds occur when an operator either maintains too high a force during the heat soak time, or joins the material at too high a force. The resulting effect is that molten material is pushed to the outer bead, and cooler material is forced together. The problem with inspecting a cold weld is the outer bead is the same as a good joint. Since the occurrence of a cold weld is difficult to find and inspect, it is important to use proper welding procedures when joining the material. The issue of inspecting and avoiding a cold weld is no different than a PVC joint that has not been primed prior to cementing. You cannot tell after the weld is made, but if you correctly follow procedures, it will not occur. Cold welds can be avoided with the following operating techniques on all butt-fusion equipment: • Ensure proper heating element temperature throughout the project.

In designing above ground Poly-Flo systems, it is important to use adequate support spacings and reliable hangers. In a Poly-Flo system, support spacings are based on containment piping. The only difference between a double-containment and a single-wall system is the weight per foot will be less than that of the single-wall system when filled with fluid. Based on the carrier piping being filled with water and a maximum deflection of 0.1 inch between supports, Tables F-18 through F-21 will provide proper support spacings for Poly-Flo systems, by size and material, in inches. Table F-18. Poly-Flo Support Spacing Recommendations* (feet) Nominal Size (in)

BPP

PVDF

HDPE

1x2 2x3 4x6

5.4 6.5 9.3

5.5 6.7 NA

6.75 8.30 10.00

* Support spacing is based on a liquid with a specific gravity of 1.0. Correction factors must be used for denser fluids as follows: 0.50 for S.G.=1.25 0.85 for S.G.=1.50 0.75 for S.G.=1.75 0.70 for S.G.=2.00. Support spacing based on water at 68° F. Correction factors must be used for elevated temperatures. See Table F-19.

• Use the correct welding parameters by pipe size, wall thickness, and material. • Do not delay between removal of heating element and joining of material. • Do not slam material together after heating. Material should be joined quickly, but the pressure build up should be smooth and even. Do not join components together above the joining force. •. If joining force is exceeded during the weld, it is a bad weld. Do not try to back off of the pressure after the weld is made, as the exceeding force will have pushed the weld material out of the joint being made. This can cause a cold weld, resulting in a weakened joint.

Step 8. Hanging Hanging any Poly-Flo system is not that much different than hanging a metal system. Typically, the spacing between hangers is shorter due to the flexibility of plastic. In addition, the type of hanger is important. Hangers should be placed based on the spacing requirements provided in Tables F-18 thru F-21. Since thermoplastic materials vary in strength and rigidity, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, the amount of hangers will generally be increased. Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical. In these cases, the hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation.


Table F-19. Poly-Flo Support Spacing Recommendations* (in feet) for BPP with Temperature Correction Factors Included Nominal Size (in) 1x2 2x3 4x6

100° F 140° F 5.10 6.11 8.77

4.66 5.59 8.03

180° F 200° F 240° F 280° F 4.12 4.94 7.09

NA NA NA

NA NA NA

NA NA NA

Table F-20. Poly-Flo Support Spacing Recommendations* (in feet) for PVDF with Temperature Correction Factors Included Nominal Size (in) 100° F 140° F 1x2 2x3 4x6

4.68 5.67 8.08

3.91 4.73 6.75

180° F 200° F 240° F 280° F 3.52 4.27 6.08

2.75 3.33 4.75

1.65 2.00 2.85

NA NA NA

Table F-21. Poly-Flo Support Spacing Recommendations* (in feet) for HDPE with Temperature Correction Factors Included Nominal Size (in) 100° F 140° F 1x2 2x3 4x6

6.41 7.92 NA

5.81 7.17 NA

180° F 200° F 240° F 280° F NA NA NA


NA NA NA

NA NA NA

NA NA NA

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INSTALLATION PRACTICES When hanging a plastic system, it is important to use hangers that will not provide pinpoint loads or other unnecessary stresses on the pipe itself. In general, an adequate hanger or support will have a minimum surface area of one-inch wide supporting the pipe and shall be free of sharp edges and burrs that will abrade and/or cut the pipe. The support shall also provide for axial movement with no lateral movement allowed. Hangers that wrap around the pipe’s circumference uniformly or allow the pipe to rest without restraint are recommended. U-bolt style hangers are not allowed unless proper shields are used to prevent point loading. Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps, as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp.

POLY-FLO SYSTEMS


9"

Sand 95% Proctor

9"

Pea Gravel

6" 6"

6"

Figure F-110. Trench detail Welding in a trench should also be preplanned. It is common that all welding is done above ground, and then, the welded components are all lowered into the trench. In many instances, it may be necessary to weld in the trench. For conducting welds in a trench, it is important to allocate space for the machine, as it will be wider than the pipe itself. Widening the trench to accommodate the machine may be required.

Step 9. Trenching and Burial

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Proper trenching and burial of a pipe system requires engineering prior to an installation. Asahi /America’s Engineering Manual (Section C) provides a comprehensive guide to the burial calculations load tolerance of thermoplastic pipe. This information should be supplied and be specified prior to installation. Refer to Asahi /America’s manual for the burial calculations. For installation purposes, it is important to look at several factors as the installer of underground piping. • Soil conditions should match that of the specification and/or drawings. • Trenches should be dug according to plan. • Pipe should be surrounded by specified soil type and compaction. • Accommodations for welding in the trench should be made. • Safety issues of being in a trench should always be observed. For each underground installation, burial designs will specify depth of trench and width of trench. The wider the trench, the more load the pipe will see upon compaction. Therefore, it is important to follow trench design closely to avoid excess load on the pipe. In addition to the trench details, the type of soil becomes important. Different types of soils have different densities and will create varying loads on the buried pipe. If the soil does not match that of the design, it needs to be rechecked or a different top fill may be required. The surrounding material of the pipe is also important. Items such as large rocks may cause pinpoint loads on the pipe that could eventually damage the pipe. Figure F-110 depicts a recommended cross section of a trench and proper fill material and compaction.

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Trench Preparation and Considerations The recommended trench width can be found by adding one foot to the width of the pipe to be buried. Larger trench widths can be tolerated, but trench widths greater than the diameter plus two feet typically produce large loads on the pipe. For small diameter pipes (4" and less), smaller trench widths are suggested. The important point to remember is that the trench width at the top of the conduit is the dimension that determines the load on the pipe. Therefore, the sides of the trench can be sloped on an angle starting above this point to assist in minimizing soil loads in loose soil conditions (prior to compaction). If the trench widths described are to be exceeded, or if the pipe is installed in a compacted embankment, the embedment should be compacted to 2.5 pipe diameters from the pipe on both sides. If this distance is less than the distance to the trench walls, the embedment materials should be compacted all the way to the trench wall. When installing long lengths of piping underground, it may not be necessary to use elbows, as long as the minimum radius of bending for specific diameters and wall thickness are observed. If the soil is well compacted, thrust blocks are not required. However, if changes of directions are provided with tees or elbows, or if the soil is not very well compacted, thrust blocks should be provided. The size and type of thrust block is related to maximum system pressure, size of pipe, direction of change (vertical or horizontal), soil type, and type of fitting or bend. To determine thrust block area, a geotechnical engineer should be consulted, and soil bearing tests conducted if deemed necessary. If the bottom of the trench is below the water table, actions must be taken to adequately correct the situation. The use of well points or under-drains is suggested in this instance, at least until the pipe has been installed, and backfilling has




POLY-FLO SYSTEMS

proceeded to the point at which floatation can no longer occur. The water in the trench should be pumped out, and the bottom of the trench stabilized with the use of suitable foundation material, compacted to the density of the bedding material. For unstable trench bottoms, as in muddy or sandy soils, excavate to a depth 4" to 6" below trench bottom grade, backfill with a suitable foundation material, and compact to the density of the bedding material. Be sure to remove all rocks, boulders, or ledge at least 6" in any direction from the pipe. At anchors, valves, flanges, etc., independent support should be provided by the use of a reinforcing concrete pad poured underneath the pipe equivalent to five times the length of the flange, valve, or anchor. In addition, reinforcing rods should be provided to keep the appurtenance from shifting, thereby preventing shearing and bending stresses on the piping. It is strongly suggested that an elastomeric material be used to prevent stress concentration loading on the piping caused by the reinforcing rod.

Step 10. System Testing Procedures for testing installed sections of Poly-Flo systems must take into account factors affecting both carrier and containment pipes. Basic recommendations may be given, but a comprehensive testing program should be developed for each and every system design. The program should be developed based on the requirements and characteristics of the particular system at hand. Where possible, a test fixture can be used. These testing fixtures allow the testing of both the carrier and the annular spaces from one location with a minimum number of welds. Water should not be introduced into the annular space. Therefore, a low-pressure air test should be used to test the containment area. Under no circumstances should an air test exceed 10 psi. Any air test in excess of 10 psi is extremely dangerous, due to the compressibility of air and the large amount of potential energy that can be released in the event of a catastrophic failure. The carrier should be tested hydrostatically to no more than 1.5 times the maximum operating pressure of the lowest rated component in the system (never to exceed 150 psi). For all testing, the system must be thoroughly tied down to prevent shock-induced reactions or whipping. All personnel in the area must be kept clear and advised of the inherent dangers of pressure testing. All testing must be conducted prior to a buried system being backfilled.

Annular Test The system must be properly capped and the test fixture installed. The carrier pipe must, in all cases, be filled prior to any test on the annular space. This is done to ensure that the carrier pipe will not collapse during the test. Pressure gauges should have a small enough scale to be able to detect small changes in air pressure. Charge the annular space to no more


than 10 psi. Monitor the pressure gauge. There may be some initial decrease in pressure due to the creep properties of the plastic. Allow at least 30 minutes for the system to stabilize, then re-charge back up to 10 psi. This is considered the beginning of the test. Monitor the pressure for a minimum of 2 hours up to a maximum of 12 hours. If there is a pressure drop in excess of 10% of the beginning pressure, the test should be considered failed. If this occurs, continue to monitor the carrier gauge to determine if the leak is to atmosphere or into the carrier space.

Carrier Test If the carrier pipe is intended for pressure service, a hydrostatic pressure test must be used. In any hydrostatic pressure test, provisions must be made to vent all air out of the inner pipe. If necessary, special high-point vents should be used to bleed any trapped air. Air pockets can create a dangerous condition if a cold weld exists and fails during the test. Air pockets can cause rapid and extensive propagation of fault lines should a failure occur. Filling the system – Again, the piping must be properly capped and the test fixture installed. Water can then be introduced very slowly at the low point of the system. Under no circumstances should the velocity of the water exceed two feet per second, as water hammer can create extremely high surge pressures. The system can then be brought up to test pressure using a hand pump or similar equipment. Conducting the test – The system should be brought up to test pressure in gradual steps of no more than 10 psi. There may be some initial degradation of the pressure due to the creep properties of the plastic. Allow at least 30 minutes for the system to stabilize, then re-charge back up to test pressure. This is considered the beginning of the test. Monitor the pressure for a minimum of 2 hours up to a maximum of 12 hours. If there is a pressure drop in excess of 10% of the beginning pressure, the test should be considered failed. Locating a Leak In the event of a leak in the containment area, it may be possible to diagnose if the leak path is into the carrier or out to atmosphere by monitoring the gauge on the carrier for pressure build up. If the leak is out to atmosphere, the simplest way to locate the leak is by “soaping” the joints. If the leak is into the carrier, then an ultrasonic leak detection gun must be used as described below. In the event of a leak in the carrier, the pressure should be relieved and the water drained to prevent flooding of the annular space. If the annular space does become flooded, it may be necessary to dry it by purging with dry air or nitrogen (this depends on the type of leak detection used and the requirements of the system owner).


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INSTALLATION PRACTICES To determine the location of the leak, Asahi /America, Inc. has ultrasonic leak detection guns available. The gun is capable of hearing airflow through the containment pipe wall. To locate the leak, apply a compressed air charge of no more that 10 psi on the pipe. Using the gun, walk the pipe line placing the gun extension against the containment wall. The compressed air escaping through the leak path will be heard through the earphones of the gun, thus locating the leak. In many cases, the time required to locate a leak is less than one hour.

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POLY-FLO SYSTEMS

Repairs to Systems without Flexibility Flanged Repairs (similar materials) Poly-Flo systems offer patented, fully pressurized, double-wall flanges that permit the flow of fluids through the annular space, as shown in Figure F-111. (Consult factory for pressure rating.)

The customer should supply necessary reducer bushings and fittings. Provisions must be made to accommodate a pressure gauge, bleed valve, shutoff valve, and air/water connection on each end of the tee. The left side of the tee tests the carrier; the right side tests the containment.

Figure F-111. Poly-Flo double-wall flange assembly


1. The damaged section of pipe is removed first (Figure F-112).

A properly designed, installed, and maintained double-containment piping system will provide years of reliable service. The system, however, should offer the means to perform a repair in the event of a mishap, and this repair should be of such quality that the operating parameters (pressure, temperature) and safety factors are not reduced. The Poly-Flo system offers this capability for all pressure ratings with minimum disruption to site conditions. The first step in a repair procedure is to isolate the leak source. The ease of finding a leak is determined by the leak detection method selected at the time of installation. The use of a leak detection cable will pinpoint the location of the leak to plus or minus three feet, and is possibly the most efficient system. The low-point sensors will identify a zone that has been contaminated. Further testing methods will be required to determine the location of the actual leak source. Several methods are available for this, including the use of an ultrasonic test gun, fiber optic cameras, and dye solutions. These methods, although more time consuming, are viable alternatives to leak detection cable. The second step in a repair procedure is to flush the carrier and containment pipes to remove any hazardous chemicals that will create safety concerns for the workers doing the repairs. The ability to flush the system is determined by the initial design. The installation of high-point vents and low-point drains in the containment pipe will provide a safe means to perform the flushing. Attempts to install high-point vents and low-point drains during repair are costly and potentially dangerous. The third step is to expose the damaged pipe and perform the repair procedure with one of the following methods. The amount of pipe that needs to be exposed will depend on which repair method is chosen. A mechanical, flanged repair will take considerably less exposure of the damaged pipe than a thermal butt-fusion repair method.

F-64

3'- 6" (minimum)

Figure F-112. Remove damaged section of pipe 2. Plane ends. Next, weld two flanges onto the exposed pipe ends. Weld

Weld

"O" Ring Flange

"O" Ring Flange

Figure F-113. Install double-wall flanges 3. A flanged spool piece is fabricated and installed.

Flat Face Flange

Flat Face Flange

Figure F-114. Install flanged spool 4. The system is then tested and returned to working order.




POLY-FLO SYSTEMS

Repairs to Systems with Flexibility Butt-Fusion Repairs (similar materials) The second method of repair is performed without the use of flanges, but instead, only with thermal butt fusion. The use of butt fusion as the repair procedure requires a larger excavation due to the requirement that the pipe be able to move about one inch to perform the weld. To perform the repair: 1. The damaged section of pipe is removed and the area cleared to allow the pipe to move in the radial direction. Note that only one end of the pipe needs this flexibility (Figure F-115). 3'6" Minimum


F

Figure F-115. Remove damaged section of pipe 2. The pipe in the ground is prepared for simultaneous fusion. 3. A spool of pipe is assembled and butt welded to the stationary pipe.

1st Weld Performed on Stationary Pipe

Figure F-116. Install new spool 4. The second weld is then performed on the flexible side.

2nd Weld Performed on Flexible Pipe

Figure F-117. Butt weld spool to remaining pipe 5. The system is then tested and returned to working order.



F-65



F

F-66



COMPRESSED AIR PIPING SYSTEMS

COMPRESSED AIR PIPING SYSTEMS Installing any piping system properly requires preplanning. The installation is more than the welding of components. It requires the proper environment, material inventory, welding equipment, tools, and thorough training. This guide is to assist in the planning and installation of a compressed air/gas pipe system, either in a pipe rack or trench. This guide is aimed at industrial applications and not high-purity installations. For compressed air piping, Asahi /America recommends only the use of manufacturer approved materials for this application. In particular, the Air-Pro system from Asahi is the only system recommended for use in this application due to safety concerns. Air-Pro has been specifically designed and tested for the application of compressed air and gases. All other materials such as PVC, C-PVC, PVDF, and polypropylene are not recommended for compressed air and are not warranted by Asahi /America for that service. Asahi /America’s recommendations for project management follow. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Step 11.


Step 1. Welding Environment Asahi /America does not set requirements for proper welding environments. As the installer, it is necessary to choose the environment based on the installation type, timing, or quality goal. In most systems, pipe is either going into a pipe rack, beneath a floor or wall, or buried underground. In all these cases, conducting welds in the actual final location may not always be the most convenient location for welding. In fact, in most cases, it is preferable to prefabricate spool piece components and conduct final welds or hook-up in the pipe rack.

INSTALLATION PRACTICES Not all welding can be conducted in a shop and eventually field welds will need to be done. Some systems will be installed completely outside, with all the welds perhaps conducted in place. When welding outside, several factors have to be considered. It is always important not to weld in the rain. Rain will damage equipment and improperly influence the weld. For rainy days, a shelter or tent should be constructed over equipment. In addition to rain, high winds, and cold temperatures below 40° F, will negatively influence the welding process. If these conditions are not avoidable, a heated tent structure is advised. For specific recommendations by tool type, consult the Asahi /America Engineering Department. When conducting field welds in a pipe rack or in a trench, it is important to have the location of the welding planned. Vertical welds in any location will prove more difficult to conduct and should be avoided. The field weld that connects up prefabricated spool pieces should be a pipe-to-pipe weld whenever possible. Pipe-to-pipe welds are easier to align and level, making the weld easier to conduct in possibly tight quarters. In all field welds, in the rack or in a trench, it is important to have ample room for welding equipment and to choose the proper welding equipment. In some underground installations, it may be necessary to increase the width of the trench in weld locations. Many underground systems are welded above ground and then lowered down into the trench to avoid placing equipment in narrow trenches. The same is true in crowded pipe racks. Many times, it will prove more efficient to prefab spools and use flanges or unions to connect them together in the pipe rack. Consult Asahi /America for the use of double containment flanges.

Step 2. Tool Selection The selection of the type of welding method conducted on an Air-Pro piping project should be based on the following criteria: • Material • Sizes to be installed • Welding location • Type of installation • Number of welds • Available expertise

If possible, set up a welding area to build the spool pieces. The weld area should be situated in an area that has reduced exposure to wind, possible rain, and extremely cold temperatures. Building spool pieces inside a weld shop may prove advantageous. A fairly controlled environment and organized work space will improve efficiency and quality of the system to be installed.



F-67

F



Socket Fusion The majority of Air-Pro systems are 1/2" to 4". In these sizes, the weld method available is socket fusion. Asahi /America offers two styles of socket fusion equipment: a small hand-held tool capable of welding up to 2" and a larger bench style tool capable of welding up to 4". Figure F-118. shows a brief pictorial of the socket fusion method. For further explanation of the socket fusion method, see Socket Fusion Welding Methods in the beginning of Section F. Coupling Heater Inserts

Pipe

Figure F-119. 2" hand-held socket fusion heater

Heater

The hand-held tool also has the practical use of working in tight locations. Due to its compact size, it is recommended for use in pipe racks, trenches, etc. where larger bench style equipment may prove too bulky and cumbersome. The hand-held tool is also ideal for repairs and additions to existing systems.


Bench Socket Fusion The bench socket fusion machine is just that; it sits on a bench in order to be operated. The tool, depicted in Figure F-120, is provided with a heating element for the socket inserts to be attached. It also has a set of clamps and moving beds to force the pipe and fittings in and out of the heater inserts.

F


Joining and Cooling


Two Inch Hand-Held Socket Fusion Heater This tool, depicted in Figure F-119, is a hand-held heating plate that accepts two sizes of socket fusion heater inserts. The tool is ideal for welding smaller dimensions and works very well in sizes 1/2"–1". While the tool can hold inserts in 11/2"and 2", it does prove to be more difficult due to the heavy wall of Air-Pro, requiring more force from the operator to push the pipe and fittings into the heating inserts. For projects that are primarily 1" and below, the hand-held tool is recommended. If only a few welds in the larger dimensions are necessary, the project can be accomplished completely with the hand-held tool.

F-68

Figure F-120. Bench socket fusion heater The advantage of the bench tool is the ease of operation. Fixing pipe and fittings into the clamps provides good alignment. The gear operation greatly assists in providing the required force to heat and join the components. If a system is made up primarily of 11/2" and larger, the bench tool is recommended. In smaller systems that are prefabricated, the bench tool may also provide a higher quality system in terms of weld aesthetics and alignment.





The bench tool is ideal for welding on a bench top, where the tool remains stationary. However, the tool can be placed on rollers and easily moved around if required. In trench applications, where a lot of welding may be required of straight runs of pipe, the bench tool can still be used. Each site condition is different, so experimentation with keeping the tool on the bench, rollers, or placement close to the ground will help find the fastest installation for a project.

Table F-22. Butt-Fusion Equipment for Air-Pro Material

Butt Fusion

Butt fusion offers many advantages in an Air-Pro installation. When joining pipe to pipe, a coupling is not required. The two pipes are welded directly to each other. This reduces the amount of required fittings, as well as the amount of welds to be conducted. In the instance of Air-Pro being buried, the trench equipment proves ideal. It is designed to be pulled and dragged in a trench bottom. It is hydraulically operated, eliminating the need for bulk pull arms and gearing on equipment.

In the Air-Pro Compressed Air Piping system, the majority of systems are joined using socket fusion. However, larger systems in 6"–12" are available upon request. For these systems, butt fusion is the recommended welding method. Figure F-121. displays a brief pictorial of the butt-fusion welding method.

Pipe

Heater

Pipe

Size

Shop 10/12

Field 6

Field 12

6" 8" 10" 12"

A B X X

A X X X

A A A A

A = Recommended B = Recommended, but better choices are available X = Not recommended

In many systems below 6" that are primarily made of pipe, butt fusion is used. For these installations, it proves cost effective to reduce fittings and welds. This is highly recommended if the system is mostly straight runs of pipe. In 4" and below, Air-Pro is not available with butt-fusion fittings. Therefore, two types of welding equipment will be required on the job site to attach pipe and fittings.


Molten End

Step 3. Material Handling When pipe, fittings, and valves arrive on site, they should be inspected to ensure the proper components have arrived and that no damage has occurred during shipment. Asahi /America goes to great lengths to ensure that pipe and fittings are properly packaged for shipment. If damage occurs, the freight company should be notified immediately.

Heat Soak Time

Joining and Cooling

Figure F-121. Butt-fusion welding process Depending on the size to be joined, the style of butt-fusion equipment will vary from manual operation to hydraulic style equipment. For an Air-Pro System being joined using butt fusion, Table F-22 provides the recommended tool for the application.


Preferably, pipe should be stored inside or in a trailer. Care should be taken to properly support pipe during storage. Use the hanging criteria for the proper support distance. Pipe can be stacked during storage. Heavier pipes of larger dimensions should be stored at the bottom. However, it may prove more practical to segregate by size for easier access during the project. Pipe should not be stored above the recommended maximum height of 4 feet. If material is stored outside, it is preferable to cover with a tarp in case of rain. Fittings are best kept in their boxes or bags, as they are shipped in separate containers by size, style, and material. This will allow for simplified picking and inventory control throughout the project.


F-69

F

INSTALLATION PRACTICES Step 4. Training and Preparation

Step 5. Tool Commission and Daily Checks

An Air-Pro system is a straightforward installation and training requirements are minimal. Hand-held fusion can be learned in a period of one hour by most installers. Installations requiring bench style or butt-fusion equipment may require more training. In all cases, contact your distributor for proper training support prior to the job start, or even prior to ordering material. Training can then be planned and provided when the project is ready to begin.

Checking equipment and welding technique daily is recommended. This is particularly important on larger projects where there are many welders on site. This daily check will allow QA to ensure all welders are up to speed on tool operation, welding technique, and inspection. Most problems in the field occur due to improper usage of equipment rather than equipment failure.

Proper welding is critical in any piping system. An unplanned shutdown can prove to be more costly than the piping construction itself. One bad weld can cause hours of repair and frustration, as well as significant lost revenue. For these reasons, it is critical to ensure all installers are trained and approved to use the equipment. Untrained personnel will not speed up a project’s completion.

F


Tool operation is only one of several factors in a thorough training course. Operators, inspectors, and managers need to understand the physical nature of the material: how to properly handle it, how to inspect welds, how to identify potential problems, how to properly maintain equipment, and finally, how best to tie into a line and test it.

During the initial training of the project, many welds are produced in the presence of a qualified trainer. These welds should be kept and used for the daily checks. Each welder should conduct a one coupon test weld and submit it to QA. The coupons should be compared to initial samples. Inspection should include bead formation, sizing, and weld label. Conducting preventive maintenance to the equipment at the beginning of each day is required. The maintenance recommended varies on each weld tool type. Consult the Operation Manual for items to be checked daily. By keeping equipment in good operating condition and ensuring all operators are up to speed, it is less likely tool problems or welding errors will occur.

Step 6. Pipe Cutting Preparation To best use training time, preparation should be made prior to the trainers’ arrival on site. A recommended list of preparations follows. • Ensure that project material is on site. It is not critical to have all material, but enough to start the project. Once training is complete, it is practical for the trainer to oversee the beginning portion of the installation. Many times new questions and challenges arise once the actual installation starts. In addition, if there is a significant period of time between the training and actual installation, operators may forget portions of the training or different operators may now be slated for the welding operation. Both scenarios require additional training.

Cutting plastic pipe can be handled in a variety of methods. In small dimensions, 1/2" through 4", roll wheel pipe cutters are commonly available and work well. These types of cutters are similar to a tube cutter, but only larger. For an Air-Pro system using a roll cutter, it is important to ensure the wheel has a larger radius than the wall thickness of the pipe so it will cut all the way through.

• Ensure required tools are on site. Do not open the tools until a certified trainer is present. If more tools are ordered during a project, this is no longer required, as proper unpacking and set up of the equipment is covered in the training process. • Ensure that the correct power is available. Consult with the factory or distributor at the time of tool ordering. • Ensure that pipe samples are available for the training session. Asahi /America does not normally provide samples for the training. Formal training can be the key factor in starting a project off in the right direction. Take advantage of this service while on site. Asahi /America also offers field technicians for hire to oversee project welding and training for any specified amount of time. Contact Asahi /America for more information.

F-70

Figure F-122. Roll cutter If you are not concerned about particle generation, then band saws, vertical or horizontal, will work very well for plastic. Since plastic pipes can have a very heavy wall thickness, it is important to travel slowly through the band saw to avoid having the blade bend and create an angled cut. For smaller pipe sizes, a circular blade chop saw will provide neat and accurate cuts.




If only manual saws are available, a hack saw will certainly cut through small dimensions, but avoid using a fine blade as it will take considerable time. Reciprocating saws are generally acceptable as long as the blades are long enough to cross the entire diameter of the pipe. If too fine a blade is used, the material will become quite hot and can fuse itself back together partially behind the blade travel.

INSTALLATION PRACTICES If bead formations do not meet the inspection criteria, they should be rejected. Consult the operation manual for each tool on how to correct the problem. If problems persist, contact Asahi /America or your local distributor for assistance. Many times these issues can be cleared up quickly over the phone, avoiding waste in time and material. Never continue welding if proper fusion cannot be accomplished. This will only add to problems at a later time.

Step 7. Weld Inspection To ensure a safe and on time system start-up, initiating a standard inspection process on each project is recommended. This quality assurance measure can be conducted by third party QC or can be done by each individual operator after each weld. A recommended inspection report for recording quality assurance on each weld is attached at the end of this Section F. Use the recommendation of this weld inspection guide in conjunction with the equipment manual to achieve the best project results.

Butt Fusion To inspect butt-fusion joints, the inspector should look for the following characteristics on each weld. • Welds should have two beads that are 360° around the pipe. • Beads should be of consistent height and width. • Beads should have a rounded shape. • Beads should be free of burrs or foreign material. • A bead on either side should not reduce greatly in width or disappear. • Components welded should be properly aligned and cannot be misaligned by more than 10% of the wall thickness.

Socket Fusion With socket fusion, beads are also present on the outside that should be used for inspection. With a socket weld, it is important to ensure that the bead of the pipe and the bead on the fitting are in contact. If the two beads are not in contact, or the bead from the pipe is not up against the socket, the proper insertion depth has not occurred. If beads do not meet, the weld will not be full strength and should be rejected. With socket fusion weld inspection, look for the following items: • Bead formation on pipe in full contact with fitting 360° around the joint. • Consistent bead 360° around the joint. • Free of any burrs or foreign material. • Proper alignment. Pipe needs to be inserted straight into the fitting without angle. Figure F-124 shows an example of acceptable and nonacceptable socket fusion joints. Gap

No Gap

Figure 123 shows a detail of a standard butt-fusion bead formation.

Figure F-124 Good weld

Bad weld

Limitations of Inspection

Figure F-123. Typical butt-fusion weld bead Butt-fusion beads will vary in size depending on the outside temperature, the diameter welded, and the operator. With Air-Pro, there will be a pronounced double-bead formation that will be simple to identify. Since outside temperatures and conditions will have some effect on bead sizes, there is no formal specification for the size of the bead. Also, measuring each bead would be time consuming. During the training process, welding one of each size to use as a rough gauge for the project is recommended. These sample coupons can be referred to on a regular basis to check welding throughout the project.


Following proper weld procedures, in conjunction with thorough inspection, will lead to a safe and reliable system. However, a weld cannot be 100% judged by viewing it after the fusion is complete. Bad welds with obvious problems can be identified, such as missing beads, small beads, and misalignment, but other problems may not be easily found. The cold weld is more difficult to identify, and virtually impossible with the naked eye. In a cold weld there is very little material joined together in the pipe wall area. The molten material has been forced to the outer and inner bead, and the unheated sections of the pipe have been forced together in the pipe wall region. In a proper weld, there is material joined together in the pipe wall, as well as in the inner and outer beads.


F-71

F

INSTALLATION PRACTICES The problem with inspecting a cold weld is that the outer bead may be the same as a good joint. Since the occurrence of a cold weld is difficult to find and inspect, it is important to use proper welding procedures when joining the material. The issue of inspecting and avoiding a cold weld is no different than a PVC joint that has not been primed prior to cementing. You cannot tell after the weld is made, but if you correctly follow procedures, it will not occur. Cold welds can be avoided with the following operating techniques on all butt fusion and socket fusion equipment. • Ensure proper heating element temperature throughout the project. • Use the correct welding parameters by pipe size, wall thickness, and material. • Do not delay between removal of heating element and joining of material. • Do not slam material together after heating. Material should be joined quickly, but the pressure build up should be smooth and even. • Do not join components together above the joining force.

F

Step 8. Hanging Hanging any thermoplastic system is not that much different than hanging a metal system. Typically, the spacing between hangers is shorter due to the flexibility of plastic. In addition, the type of hanger is important. Hangers should be placed based on the spacing requirements provided in Appendix A. Since thermoplastic materials vary in strength and rigidity, it is important to select hanging distances based on the material you are hanging. Also, operating conditions must be considered. If the pipe is operated at a higher temperature, the amount of hangers will generally be increased. Finally, if the system is exposed to thermal cycling, the placement of hangers, guides, and anchors is critical In these cases. The hanger locations should be identified by the system engineer and laid out to allow for expansion and contraction of the pipe over its life of operation.

F-72


When selecting hangers for a system, it is important to avoid using a hanger that will place a pinpoint load on the pipe when tightened. For example, a U-Bolt hanger is not ideal for hanging thermoplastic piping systems. While Air-Pro is most likely the most tolerant system to mishandling, improper hanging, scratching, and impacts, it is still best to avoid poor metal hangers when possible. Figure F-125 depicts the negative effect of a U-bolt hanger on a system. Pressure Point

Pressure Point

Figure F-125. Effects of U-bolt on pipe Hangers that secure the pipe 360° around the pipe are preferred. Thermoplastic clamps are also recommended over metal clamps as they are less likely to scratch the pipe in the event of movement. If metal clamps are specified for the project, they should be inspected for rough edges that could damage the pipe. Ideally, if a metal clamp is being used, an elastomeric material should be used in between the pipe and the clamp.





Step 9. Trenching and Burial

Step 10. System Testing

Proper trenching and burial of a pipe system requires engineering prior to an installation. Asahi /America’s Engineering Manual (Section C) provides a comprehensive guide to the burial calculations load tolerance of thermoplastic pipe. This information should be supplied and be specified prior to installation. Refer to Asahi /America’s manual for the burial calculations.

Prior to pressure testing, the system should be examined for the following items:

For installation purposes, it is important to look at several factors as the installer of underground piping. • Soil conditions should match that of the specification and/or drawings. • Trenches should be dug according to plan. • Pipe should be surrounded by specified soil type and compaction. • Accommodations for welding in the trench should be made. • Safety issues of being in a trench should be checked.

3. Pipe should be in good condition, void of any cracks, scratches, or deformation.

1. Pipe should be completed per drawing layout with all pipe and valve supports in place. 2. Pipe, valves, and equipment should be supported as specified, without any concentrated loads on system.

4. Pipe flanges should be properly aligned. All flange bolts should be checked for correct torques. 5. All joints should be reviewed for appropriate welding technique. See weld inspection procedure above. If any deficiencies appear, the quality control engineer should provide directions/repair.

Pressure Test For each underground installation, burial designs will specify depth of trench and width of trench. The wider the trench, the more load the pipe will see upon compaction. Therefore, it is important to follow trench design closely to avoid excess load on the pipe. In addition to the trench details, the type of soil becomes important. Different types of soils have different densities and will create varying loads on the buried pipe. If the soil does not match that of the design, it needs to be rechecked or different top fill may be required.

The Air-Pro system can be tested using compressed air.

The surrounding material of the pipe is also important. Items such as large rocks may cause pinpoint loads on the pipe that could eventually damage the pipe. Figure F-126 depicts a recommended cross section of a trench and proper fill material and compaction.

2. If after one hour the pressure has decreased more than 10%, consider the test a failure. Note the 10% value may need to be greater for larger systems. Also, note that Step 2 may need to be conducted several times if there are significant thermal changes in the environment.

1. Begin pressurizing the system in increments of 10 psi. Bring the system up to 100 psi and hold. Allow system to hold pressure for a minimum of two hours and up to a recommended 12 hours. Check pressure gauge after one hour. Due to natural creep effects in plastic piping, the pressure may have decreased. If drop is less than 10 psi, pump the pressure back up. At this time, the system may be fully pressurized to desired test pressure.

3. Test is to be witnessed by quality control engineer, and certified by the contractor. Pipe Depth Backfill 85% Proctor

9"

Sand 95% Proctor

9"

Pea Gravel

4. Obvious leaks can be found by checking each joint individually using a soapy water solution or an ultrasonic leak detection gun. Leak detection guns are available from Asahi /America. Consult factory for usage of U.S. leak detection guns. Some limitations do apply.

6" 6"

6"

Figure F-126. Trench detail Welding in a trench should also be preplanned. It is common that all welding is done above ground, and then, the welded components are all lowered into the trench. In many instances, it may be necessary to weld in the trench. For conducting welds in a trench, it is important to allocate space for the machine as it will be wider than the pipe itself. Widening the trench to accommodate the machine may be required. Figure F-129. Ultrasonic leak detection gun ASAHI /AMERICA Rev. EDG– 02/A


F-73

F




Non-Flexible Pipe System

If a leak is found or an addition is required to an existing system, there are several options on how to make the repair. In most systems, socket or butt fusion, there is a requirement for pipe movement when making a weld. To conduct a butt weld, one side of the tool moves in order to accommodate the planer, the heating element, and the final joining force. In a repair procedure, the need for movement of the existing pipe makes for the simplest repair.

Depending on the size and material, repairs can also be made to systems without any movement. If there is no flex for movement of the existing pipe in the region of the damaged pipe, the repair can be done using flanges or true union ball valves. 1. Remove the section to be repaired. 2. Weld flanges or unions on both ends of the existing piping. 3. Measure the distance from face to face and build a spool to fit into place.

Flexible Pipe System If the pipe is in an area where it can be moved, standard butt fusion or socket fusion equipment can be used.

4. Connect spool into place.

1. Cut out the section in need of repair. It is best to conduct new tie-in welds on straight runs of pipe for easier alignment. 2. If several welds are required, prefab a spool piece on a bench and conduct only a few tie-in welds in the pipe rack. 3. Attach the tool to the existing pipe and properly support the machine to avoid sagging on stressing the pipe.

F

4. Conduct standard butt-fusion weld per operating procedures. It may be necessary to flex one end of the pipe out of the way of existing pipe.


5. Conduct final weld using the flexible side of the pipe system in the moving clamp.

L

L

Figure F-132. Weld flanges or unions into place Figure F-128. Remove damaged section

First Tie In

L

Figure F-129. Install new spool


Second Tie In

L


F-74



HIGH-PURITY WELD INSPECTION TABLE Project Name Date:

Company:

Page:

Affix Weld Label or fill in

Welder:

Joint Number: Material:

OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:


Welder:


OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:


Welder:


OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:


Welder:

Joint Number: Material: Serial Number:


OD:

Wall Thk:

QC: Drawing Number:


F-75

WELD INSPECTION TABLE Project Name Date:

Company:

Page:


Welder: OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:

Joint Number:

Welder:

Material:

OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:

Joint Number:

Welder:

Material:

OD:

Wall Thk:

QC:

Serial Number:

Drawing Number:

Joint Number:

Welder:

Material:

OD:

Wall Thk:

Serial Number:

F-76


QC: Drawing Number:


Section G VALVES Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . .G-2 Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . .G-3 Butterfly Valves . . . . . . . . . . . . . . . . . . . . .G-3 Diaphragm Valves . . . . . . . . . . . . . . . . . . .G-4 Gate Valves . . . . . . . . . . . . . . . . . . . . . . . . .G-4



G-1

VALVES INTRODUCTION An important part of any piping system is the selection of valves. Valve components determine a system's ability to control flow, pressure, and the distribution of media. The type and size of valves selected greatly impact a system’s functionality. Selection criteria should include, as a minimum, valve size, quality, material of construction, Cv, control characteristic, and performance requirement. Other selection criteria may include production methods, design, actuators, accessories, and options. As with metal valves, thermoplastic valves come in a variety of sizes and configurations. Asahi /America is proud to offer the widest combination available. From 1/4" PVC ball valves to 24" PP butterfly valves, we are able to offer the right valve for the right application. The following section is designed to assist you in selecting the proper valve among our many choices. In order to determine which valve is best for your application, an understanding of each individual's features and benefits is required. Additional assistance, should it be required, is available from our knowledgeable and experienced staff of valve technicians and engineers.

INTRODUCTION

A valve with linear trim can be used for accurate flow control applications. Small movements in a valve's travel will correspond in small movements in rate of flow or pressure drop. Equal Percent Valves with equal percentage flow characteristics exhibit equal increments of valve travel and produce equal percentage changes in the existing flow. When the valve is near a closed position and the flow is low, the change in flow is minimal. With a high flow, the change in flow will be high. Equal percentage is generally used for pressure control, and also where minimal pressure drop is available at the valve or when the system has a varying pressure drop. Quick Opening Valves with quick opening characteristics near maximum Cv have relatively little travel. Quick opening valves are generally used for On/Off applications only. They inherently display poor flow control characteristics because initial small movements in valve travel equal large movements in Cv. Shortly after the initial open position, large movements in travel result in small movements in a valve’s Cv. Table G-1.

Flow Control Characteristics

Flow Capacity

Control Characteristics A valve’s control characteristic is another important selection criteria. A valve’s control characteristic can usually be sorted into the following three categories:

100 Quick Opening Cv (percent)

G

A valve's flow capacity is often expressed in terms of Cv. Cv is defined as the amount of gallons per minute that can flow through a valve with a 1 psi pressure drop. A valve with a Cv of 100, for example, would experience 1 psi of pressure drop at 100 gpm. Thus in systems with limited amounts of beginning pressure, such as thermoplastic systems, Cv is a useful tool in determining proper valve capacity. Valves with low Cv would result in high pressure drops to the point of restricting a system's ability to distribute its flow media.

80 60

Linear

40 Equal Percentage 20 0

0

10

20

30 40 50 60 70 Valve Opening (percent)

80

90

100

Linear A valve with linear control will have its percent of full Cv corresponding to its percent of full open. In other words, valves that are physically opened 25%, are operating close to or at 25% of rated Cv. A valve with a Cv of 100 at 25% open is expected to be operating at a Cv of 25.

G-2



VALVES

VALVE TYPES

BALL VALVES

BUTTERFLY VALVES

Ball valves are one of the most common thermoplastic valves and are characterized as quick opening with positive, quick shutoff capabilities. Ball valves use an internal ball with flow through port. The valve is shut as the internal ball is rotated so the flow port faces against the valve body. Used primarily for on-off applications, ball valves are generally limited in plastics to line sizes 4" and below with some availability in full port 6" sizes. Excellent shut off is achieved with ball valves, but flow control should not be expected. Media with high concentrations of suspended particles should be avoided. The particles have a tendency to become lodged in between the ball and valve body, greatly reducing the life expectancy and functionality of the valve.

Butterfly valves are another common type of thermoplastic valve. Butterfly valves generally use discs, which rotate on a center axis 90° from full open to full close. The thermoplastic disc uses interference fit against the valve body, usually with elastomer seal or gasket, to achieve bubble tight shut off. Butterfly valves have application flexibility. They are available in sizes from 11/2" to 36", with a variety of options for actuation, stem extensions, and bolting configuration. Butterfly valves also have better flow control than ball valves with equal percent characteristics, but should be limited to applications not requiring high precision control. These valves are also more tolerant to suspended particles with the exception of long, hair-like strands, which can hang up around the center axis.

G Figure G-1. Ball valve

Valve Rating Pressure Drop: Controllability: On-Off: Characteristic: Movement:

Very Low Poor Excellent Quick Opening 90 Degree

Figure G-2. Butterfly valve



Low Fair Excellent Equal Percent 90 Degree


G-3

VALVES

VALVE TYPES

DIAPHRAGM VALVES

GATE VALVES

Diaphragm valves have a flexible diaphragm, which is compressed against a sealing surface. A compressor, generally actuated by circular motion, compresses the diaphragm. Flow is directed up against the diaphragm and back down the sealing surface. Characterized by linear control, diaphragm valves are excellent for throttling and semi-precise flow control applications; especially in smaller sizes.

Gate valves use a vertical plug, which is inserted into the flow path and seals the valve shut. Unlike diaphragm valves, the plug is generally of solid construction and completely lifts out of the flow path when opened. Gate valves are ideal for applications where lines may need “snakes” to remove debris. Gate valves have excellent shut-off capabilities with high tolerances for suspended particles. Gate valves have poor control abilities and are generally used for on-off applications.

Figure G-3. Diaphragm valve

Valve Rating

Figure G-4. Gate valve

Pressure Drop: Controllability: On-Off: Characteristic: Movement:

G

G-4

Medium Good Good Linear Linear


Low Poor Good Quick Opening Linear



Appendix A SYSTEM TABLES

Contents Physical Properties . . . . . . . . . . . . . . .App. A-2

Pro 150 . . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-8

Pressure Ratings . . . . . . . . . . . . . . . . . . . . . . .App. A-2

Pro 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-9

PVDF 150 (SDR 33), PVDF 230 (SDR 21) App. A-2

PVDF . . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-10

PP 45 (SDR 32.5), PP 150 (SDR 11),

. . .App. A-2

Poly-Flo . . . . . . . . . . . . . . . . . . . . . . . . .App. A-11

and (SDR 32.5), PE 80 (SDR 11) . . . . . . .App. A-2

Eq. Length of Fittings: Single & Double Wall . .App. A-12

Air-Pro/PE 100 (SDR 7) . . . . . . . . . . . . . .App. A-2

Proline and Duo-Pro, Poly-Flo, Air-Pro .App. A-12

Halar/E-CTFE . . . . . . . . . . . . . . . . . . . . . .App. A-2

Dimensional Pipe Data . . . . . . . . . . .App. A-13

External Support Spacing: Single Wall Pipe . .App. A-3

Pro 150, Pro 90, . . . . . . . . . . . . . . . . . .App. A-13

Pro 150, Pro 45, Purad PVDF, . . . . . . . . .App. A-3

Pro 45, PVDF, Poly-Flo . . . . . . . . . . . . .App. A-14

Air-Pro . . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-4

HDPE . . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-15

External Support Spacing: Double Wall Pipe .App. A-4

Air-Pro . . . . . . . . . . . . . . . . . . . . . . . . . .App. A-16

Duo-Pro, Fluid-Lok, Poly-Flo, . . . . . . . . .App. A-4

Annular Spacing: Duo-Pro . . . . . . . . . . . .App. A-16/17

Internal Support Spacing: Double Wall Pipe .App. A-5 Duo-Pro, Fluid-Lok . . . . . . . . . . . . . . . . .App. A-5

Vacuum Rating . . . . . . . . . . . . . . . . . .App. A-17 Heat Loss per Linear Foot . . . . . . . .App. A-18

Long-Term Modulus of Elasticity . . . . . . . . . .App. A-5

Purad PVDF . . . . . . . . . . . . . . . . . . . . . . . . .App. A-18

PP, PVDF, E-CTFE, HDPE . . . . . . . . . . . .App. A-5

Proline Pro 150 . . . . . . . . . . . . . . . . . . . . . . .App. A-19

Bending Radius . . . . . . . . . . . . . . . . . . . . . . .App. A-6

Proline Pro 45 . . . . . . . . . . . . . . . . . . . . . . . .App. A-20

Single Wall, Double Wall . . . . . . . . . . . . .App. A-6

Spiral Factor/Pitch . . . . . . . . . . . . . . . . . . . .App. A-20

Burial Data . . . . . . . . . . . . . . . . . . . . .. . App. A-7

Valve Heat Loss Factor . . . . . . . . . . .App. A-20 Heat Gain per Linear Foot . . . . . . . . .App. A-21

Max. Allowable Soil Load: . . . . . . . . . . . . . . .App. A-7 Pro 150, Pro 45, PVDF, Duo-Pro . . . . . . .App. A-7 Max. Allowable Soil Load: Double Wall Pipe .App. A-7 Fluid-Lok, Poly-Flo

. . . . . . . . . . . . . . . .App. A-7

Fluid Dynamics . . . . . . . . . . . . . . . . . . .App. A-8

Pro 150 in Still Air . . . . . . . . . . . . . . . . . .App. A-21/25 Pro 150 in Moving Air . . . . . . . . . . . . . . .App. A-26/30 Pro 45 in Still Air . . . . . . . . . . . . . . . . . . .App. A-31/34 Pro 45 in Moving Air . . . . . . . . . . . . . . . .App. A-35/37

Pressure Drop Versus Flow: Single Wall Pipe .App. A-8



App. A-1

APPENDIX A

PRESSURE RATINGS

Table App. A-1 Permissible Operating Pressures for Purad PVDF Pipe and Fittings (bar) 1 Year PVDF 150 SDR 33

Temperature (° C)

PVDF 230 SDR 21

13 10 9 7 6 5 4.5 4 3.5 3 2.8 2.5 2

20 30 40 50 60 70 80 90 100 110 120 130 140

5 Years PVDF 150 SDR 33

20 16 14 12 10 9 7 6.5 6 5 4.5 4 3.5

10 Years PVDF 230 SDR 21

12 10 9 7 6 5 4.5 4 3 3 2.5 2 1.5

PVDF 150 SDR 33

18 15 14 11 9 8 7 6 5 4.5 4 3.5 3

20 Years

PVDF 230 SDR 21

11 9 9 6 5 4.5 4 3.5 3 2.5 2 1.5 1.3

18 15 14 10 9 7 6 5.5 5 4.5 4 3.5 3

50 Years

PVDF 150 SDR 33

PVDF 230 SDR 21

PVDF 150 SDR 33

PVDF 230 SDR 21

11 9 9 6 5 4 3.5 3 2.5 2.3 2 1.5 1.3

17 14 14 10 8 7 6 5 4.5 4 3.5 3 2.5

10 8 9 6 5 4 3.5 3 2.5 1.8 1.7 1.5 1

16 13 14 9 8 7 6 5 4 3.5 3 2.5 2

Table App. A-2 Permissible Operating Pressures for Polypropylene Proline Pro 150 and Proline Pro 45 (psi) 1 Year Temperature (° C)

Pro 45 SDR 32.5

20 30 40 50 60 70 80 95

5 Years Pro 150 SDR 11

58 49 45 36 30 26 20 13

Pro 45 SDR 32.5

180 154 133 113 96 78 61 41

52 46 41 34 26 20 15 10

10 Years

Pro 150 SDR 11

Pro 45 SDR 32.5

168 145 125 104 81 61 46 32

53 46 41 32 24 18 13 8

25 Years

Pro 150 SDR 11 165 141 122 99 75 55 41 26

Pro 45 SDR 32.5

50 Years

Pro 150 SDR 11

51 45 36 29 21 15 12 —

Pro 45 SDR 32.5

156 136 113 90 64 46 38 —

45 44 35 26 18 15 — —

Pro 150 SDR 11 150 133 104 70 55 46 — —

Table App. A-3 Permissible Operating Pressures for HDPE Pipe (psi) Temperature Hydrostatic Design Basis (° F) (psi)

A

50 60 73.4 80 90 100 110 120 130 140

Pipe Standard Dimension Radio (SDR) SDR 32.5

SDR 26

58 55 51 48 44 40 36 32 28 25

73 69 64 60 56 50 45 40 36 32

1820 1730 1600 1520 1390 1260 1130 1000 900 800

Table App. A-4. Air-Pro Pressure Rating Correction (PE 100 SDR 7) Temperature °F 68 86 104 140

°C 20 30 40 60

Correction Factor 1.00 0.88 0.79 0.65

For a given operating temperature, multiply the norminal pressure rating by the correction factor to determine the maximum rated operating pressure.

App. A-2

SDR 21

SDR 19

90 86 80 76 70 63 57 50 45 40

100 96 90 85 77 70 63 56 50 45

SDR 17 113 108 100 95 87 79 71 63 56 50

SDR 15.5

SDR 13.5

125 119 110 105 96 87 78 69 62 55

145 138 128 122 111 101 90 80 72 64

SDR 11

SDR 9.3

SDR 7.0

180 170 160 150 140 125 113 100 90 80

215 207 190 182 167 150 135 120 108 96

303 288 267 253 232 210 188 167 150 133

Table App. A-5. Halar/E-CTFE Pressure Rating Correction Temperature °F 68 83 104 121 140 158

°C 20 30 40 50 60 70

Correction Factor 1.00 0.90 0.82 0.73 0.65 0.54

Temperature °F 176 194 212 256 292 340

°C 80 90 100 125 150 170

Correction Factor 0.39 0.27 0.20 0.10 * *

* Drainage pressure only.



APPENDIX A

SUPPORT SPACINGS

Table App. A-6. Proline Pro 150 Support Spacing Nominal Diameter (inches) 1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12 14 16 18

68° F/ 20° C

86° F/ 30° C

3 3 3.5 4 4.5 5 5.5 6 7 7.5 8.5 9.5 10 10.5 11.5

2.5 3 3 3.5 4 4.5 5 5 6 7 7.5 8.5 8.5 9.5 10

104° F/ 40° C

122° F/ 50° C

140° F/ 60° C

2.5 2.5 3 3 4 4 4 5 6 6 7 8 8 8.5 9

2 2.5 3 3 3.5 4 4 4 5 6 6.5 7 7.5 8 8.5

2 2.5 3 3 3 3.5 4 4 5 5.5 6 7 7 7.5 8

Table App. A-7. Proline Pro 45 Support Spacing Nominal Diameter (inches) 2 21/2 4 6 8 10 12 14 16 18 20 24

68° F/ 20° C

86° F/ 30° C

2.5 2.75 3.5 4 4 4.5 5 5.5 6 6.5 6.5 7.5

2.25 2.5 2.75 3.5 4 4 4.5 4.5 5 5.5 6 6.5

104° F/ 40° C 2.25 2.25 2.75 3.5 3.5 4 4.5 4.5 4.5 5 5 5.5

1/2 3/4

1 11/2 2 21/2 3 4 6 8 10 12

158° F/ 70° C 2 2.5 2.5 3 3 3 3.5 4 4.5 5 6 6.5 6.5 7 7.5

176° F/ 80° C 2 2 2.5 3 3 3 3.5 4 4.5 5 5.5 6 6.5 6.5 7

(feet)*

122° F/ 50° C

140° F/ 60° C

158° F/ 70° C

176° F/ 80° C

2 2.25 2.25 2.75 3.5 3.5 4 4 4 4.5 4.5 4.5

1.5 2 2.25 2.75 3 3.5 4 4 4 4.5 4.5 4.5

1.5 1.5 2.25 2.5 2.75 3.5 3.5 3.5 4 4 4.5 4.5

1.5 1.5 2.25 2.5 2.75 3 3.5 3.5 3.5 4 4 4

Table App. A-8. Purad PVDF Support Spacing Nominal Diameter (inches)

(feet)*

(feet)*

68° F/ 20° C

86° F/ 30° C

104° F/ 40° C

122° F/ 50° C

140° F/ 60° C

3 3 3.5 4 4.5 5 5.5 6 7 7.5 8.5 9.5

2.5 3 3 3.5 4 4.5 5 5 6 7 7.5 8.5

2.5 2.5 3 3 4 4 4 5 6 6 7 8

2 2.5 3 3 3.5 4 4 4 5 6 6.5 7

2 2.5 3 3 3 3.5 4 4 5 5.5 6 7

A 158° F/ 70° C 2 2.5 2.5 3 3 3 3.5 4 4.5 5 6 6.5

176° F/ 80° C 2 2 2.5 3 3 3 3.5 4 4.5 5 5.5 6

* Above values are based on water with specific gravity = 1.0. Correction factors must be used for denser fluids as follows: 0.90 for S.G. = 1.5, 0.85 for S.G. = 2.0, 0.80 and for S.G. = 2.5.



App. A-3

APPENDIX A

SUPPORT SPACINGS

Table App. A-9. Air-Pro Support Spacing (feet) Nominal Diameter (inches) 1/2 3/4

1 11/4 11/2 2 3

68° F/ 20° C

104° F/ 40° C

2.8 3.2 3.6 4.1 4.5 5.1 8.4

2.6 2.9 3.3 3.6 4.1 4.6 8.15

Table App. A-10. Double Containment External Support Spacing (inches)* Containment Size (nom inches) 3 4 6 8 10 12 14 16 18 20 24

*

Duo-Pro PRO 150 72 96 108 112 118 125 137 150 NA NA NA

PR0 45 NA 70 80 86 98 110 125 140 148 148 170

HDPE / Fluid-Lok PVDF

SDR 11

SDR 17

SDR 32

124 130 144 157 165 165 NA NA NA NA NA

55 60 70 80 90 100 107 115 122 130 NA

48 55 68 79 87 94 100 106 112 117 125

10 20 35 48 58 65 70 77 80 85 93

Support spacing is based on S.G. of 1.0. Corrections factors must be used for denser fluids as follows: 0.90 for S.G.=1.5, 0.85 for S.G.=2.0 and 0.80 for S.G.=2.5. Support spacing based on water at 68° F. Corrections factors must be used for elevated temperatures. Refer to Table A-13.

A Table App. A-11 Poly-Flo External Support Spacing (inches)* Size 1x2 2x3 4x6 6x8

*

App. A-4

BPP 65 78 112 121

PVDF 66 80 114 124

HDPE 81 100 NA NA

Support spacing is based on S.G. of 1.0. Correction factors must be used for denser fluids as follows: 0.90 for S.G. =1.25, 0.85 for S.G. =1.50, 0.75 for S.G. =1.75, 0.70 for S.G. =2.00. Support spacing based on water at 68° F. Corrections factors must be used for elevated temperatures. Refer to Table App. A-13.



APPENDIX A

PHYSICAL PROPERTIES

Table App. A-12. Double Containment Internal Support Spider Clip Spacing (inches)* Duo-Pro

HDPE / Fluid-Lok

Carrier Size (nom in)

Pro 150

Pro 45

PVDF

Halar®

SDR11

SDR17

SDR32

1 2 3 4 6 8 10 12 14 16 18 20

42 54 66 72 84 90 102 114 120 126 138 NA

NA NA NA 42 48 48 54 60 66 72 78 78

42 54 66 72 84 90 102 114 NA NA NA NA

44 59 69 72 NA NA NA NA NA NA NA NA

30 42 48 54 66 78 84 96 102 108 114 120

NA 36 42 48 60 72 78 84 90 96 102 108

NA NA 36 42 54 60 66 72 78 84 90 96

* Support spacing based on water at 68° F. Correction factors must be used for elevated temperatures. Refer to Table App. A-13.

Table App. A-13. Double Containment Support Spacing Temperature Correction Factors for Duo-Pro and Fluid-Lok Temperature (° F) 73 100 140 180 200 240 280

PP

PVDF

Halar®

1.00 0.94 0.86 0.76 NA NA NA

1.00 0.85 0.71 0.64 0.50 0.30 NA

1.00 0.85 0.71 0.64 0.50 0.30 0.20

HDPE 1.00 0.95 0.86 NA NA NA NA

A Table App. A-14. Long-Term Modulus of Elasticity (psi) Temperature (° F)

PP

PVDF

Halar®

HDPE

73

26,100

98,000

88,000

30,000

100

21,025

87,000

78,300

—

140

16,025

54,000

48,600

—*

180

10,000

40,000

36,000

NA

200

NA

31,000

28,000

NA

240

NA

25,000

22,500

NA

280

NA

17,000

15,000

NA

*

* For conservative estimate use value @ 73° F.



App. A-5

APPENDIX A

BENDING RADIUS

Table App. A-15. Allowable Bending Radius-Proline Polypropylene (inches) Proline Pro 150 (SDR 11)

20° C (68° F) 30 x Outside Diameter

0° C (32° F) 75 x Outside Diameter

Pro 90 (SDR 17)

30 x Outside Diameter


Pro 45 (SDR 33)



Table App. A-16. Allowable Bending Radius-Double Wall (inches) Size 1x3

PRO 150 x 45 NA

PRO 150 x 150 608

PRO 45 x 45 NA

PVDF x PVDF 669

PVDF x PRO 150 608

PVDF X PRO 45 NA

2x4

744

744

NA

818

744

744

3x6

1081

1081

1081

1198

1081

1081

4x8

1352

1352

1352

1186

1352

1352

6 x 10

1691

1691

1691

1858

1691

1691

8 x 12

2131

2131

2131

2342

2131

2131

10 x 14

2402

2402

2402

NA

NA

NA

12 x 16

2707

2707

2707

NA

NA

NA

14 x 18

3045

NA

3045

NA

NA

NA

16 x 20

3384

NA

3384

NA

NA

NA

18 x 24

4262

NA

4262

NA

NA

NA

20 x 24

4262

NA

4262

NA

NA

NA

A

App. A-6



APPENDIX A

BURIAL DATA Table App. A-17. Max Allowable Soil Load for PP, PVDF, and Duo-Pro* (lbs per linear ft) Size

Soil Modulus (E')

Material Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 PVDF Pro 150 Pro 45 Pro 150 Pro 45 Pro 150 Pro 45 Pro 45 Pro 45

2

2.5

3

4

6

8

10

12

14 16 18 20 24

200 psi 749 138 386 897 165 245 1047 196 270 1272 243 341 1870 349 484 2319 435 599 2913 546 754 3657 687 948 4106 776 4625 870 5219 981 1088 1376

400 psi 847 251 495 1015 300 379 1189 358 432 1445 440 538 2121 637 772 2633 795 959 3305 996 1204 4151 1254 1515 4664 1415 5254 1591 4926 1792 1989 2511

700 psi 995 422 659 1191 502 581 1400 601 675 1704 737 835 2497 1069 1204 3104 1336 1499 3894 1671 1880 4894 2105 2367 5501 2375 6197 2673 6987 3008 3341 4213

1000 psi 1144 592 824 1367 704 782 1612 844 918 1963 1034 1132 2874 1500 1635 3576 1876 2040 4483 2346 2555 4636 2957 3218 6338 3334 7140 3754 8047 4225 4693 5914

Table App. A-18. Maximum Allowable Soil Load for Fluid-Lok Double Containment HDPE Pipe Max Burial Depth, ft in dry soil of 100 lbs/cu ft SDR

Soil Modulus, psi* 1000 2000 3000

Max Deflection, % after installation

Max External Pressure, psi 1000

Soil Modulus, psi* 2000 3000

1000

A

Soil Modulus, psi* 2000 3000

32.5 26.0 21.0 19.0 17.0 15.5 13.5 11.0 9.3 8.3

25 33 46 52 61 56 49 39 33 30

32 45 61 69 121 112 98 78 68 61

37 52 71 81 181 168 147 117 101 89

17 23 32 36 42 39 34 27 23 21

22 31 42 48 84 78 68 54 47 42

26 36 49 56 126 117 102 81 70 62

1.7 2.3 3.2 3.6 4.2 3.9 3.4 2.7 2.3 2.1

0.9 1.2 1.6 1.8 2.1 2.0 1.7 1.4 1.2 1.1

0.6 0.8 1.1 1.2 1.4 1.3 1.1 0.9 0.8 0.7

7.3

26

52

79

18

36

55

1.8

0.9

0.6

Table App. A-19. Maximum Allowable Soil Load for Poly-Flo Pipe (lbs per linear ft) Soil Modulus (E') Size

200 (psi)

400 (psi)

700 (psi)

1000 (psi)

1x2 2x3 4x6

399 749 1047

449 847 1189

524 995 1400

599 1144 1612



App. A-7

A

App. A-8

3.42

4.79

5.64 10.84

8.18 20.21

11.70 39.12

5

7

10

V

1

5.51 2.72

2.95 1.95

0.54 0.78

0.15 0.39

P

9.73 14.72 11.70 20.63

25

30

11/4 P

11/2 P

9.96

P

1.84

1.22

1.00

0.81

0.63

P

0.77 0.03

0.69 0.02

0.62 0.02

0.69 0.02

0.98 0.03

0.89 0.03

0.79 0.02

6.93 1.20 7.69 1.46 9.23 2.04 10.80 2.75

500

600

700

5.39 0.75

4.62 0.57

3.85 0.40

10 P

P.O. Box 653 • 35 Green Street, Malden, MA 02148 • Tel: (800) 343-3618, (781) 321-5409 Fax: (800) 426-7058 • Internet: http://www.asahi-america.com • Email: [email protected] 9.84 1.78

V = Velocity of water in ft/s; P = Pressure drop in psi/100 ft of pipe based upon the Hazen and Williams method, using C = 150 in Equation C-20.

7500

12.60 2.17

6.30 0.60

5.67 0.49

8.85 1.45

4.41 0.31

3.78 0.23

3.15 0.16

9.92

7.93

3.97

3.57

3.17

2.78

2.38

1.98

1.78

1.07

0.70

0.19

0.16

0.13

0.10

0.07

0.05

0.04

2.52 0.11 1.59 0.03 2.84 0.14

900

5000

P

2.21 0.09 1.39 0.03

1000

2500

12

1.89 0.08 1.19 0.02

5.04 0.40

2000

V

1.58 0.05 0.99 0.01

1.26 0.03

1.10 0.02

0.95 0.02

0.79 0.01

V

7.87 1.17

6.89 0.92

5.90 0.69

4.92 0.49

4.43 0.40

3.94 0.32

3.44 0.26

2.95 0.19

2.46 0.13

3.08 0.27 1.97 0.09

2.69 0.21 1.72 0.07

6.16 0.97

800

P

2.31 0.18 1.48 0.05

450

11.40 4.64

350

8

0.59 0.01

V

1.92 0.11 1.23 0.04

1.54 0.07

1.39 0.06

1.23 0.05

1.08 0.04

400

9.75 3.50

8.13 2.49

6.50 1.65

5.69 1.29

4.88 0.07

4.08 0.89

3.25 0.46

2.93 0.38

2.60 0.30

300

9.31

9.72 6.64

6

0.54 0.01

V

0.18 0.92 0.03

2.28 0.24

1.95

0.47 1.63 0.13

0.34 1.48 0.10

0.28 1.30 0.08

7.29 3.43

12.20

0.05

0.03

0.02

0.01

P

0.23 1.14 0.06

0.17 0.98

0.13 0.81

8.51 4.39

250

4

0.06 0.49

V

0.10 0.65

8.08 2.58

4.86

4.38

3.89

3.40

2.92

2.43

2.19

1.94

1.70

1.46

1.22

0.97

0.73

0.03

0.34 0.02 0.49

200

10.60 6.33

150

3

0.24 0.01

V

175

12.50 10.50 8.79 4.52

125

6.97 7.03 2.99

5.73 6.33 2.46

8.96

90

100

3.60 4.92 1.54

2.71 4.22 1.16 4.61 5.62 1.97

8.31 5.98

1.93 3.52 0.83

1.59 3.18 0.68

1.27 2.81 0.55

0.10 2.48 0.43

0.75 2.11 0.32

0.54 1.76 0.23

0.36 1.41 0.15

0.21 1.05 0.09

7.97

9.48

60

5.93 4.98

0.49 0.02

0.35 0.01

P

1.01 0.70 0.04

0.05

0.03

21/2 V

80

7.90

50

4.88 4.48

3.92 3.98

3.07 3.49

2.30 2.99

1.64 2.49

1.09 1.99

0.64 1.49

0.30 1.00

0.70

P

11.10 11.10 6.97

11.00 14.16 7.11

45

2

0.50

V

70

9.78 11.38 6.32

40

8.89 5.53

6.68 4.74

4.77 3.95

3.15 3.16

1.85 2.37

0.87 1.58

1.11 0.10

0.79 0.08

0.32 0.02

V

8.57

7.34

6.12

4.90

3.67

2.45

1.71 0.45

1.22 0.24

0.49 0.04

0.24 0.01

V

35

9.74

7.78

20

5.72

10.30 22.59 5.64

2.70

1.39

0.75

0.14

0.04

P

15

6.85 10.66 3.89

1.37

1.99

2.34

2

0.68

0.55

3/4

V

P

1/2

1.17

V

1

Flow Rate (gpm)

Table App. A-20. Proline Pro 150 Velocities and Pressure Drops

0.02

0.02

7.80 0.59

6.24 0.39

3.12 0.11

2.81 0.09

2.50 0.07

2.19 0.06

1.87 0.04

1.56 0.03

1.40 0.03

1.25

1.09

P

0.01

14

0.94

V

16 P

12.30 1.20

6.15 0.33

4.82 0.22

2.46 0.06

2.21 0.05

1.97 0.04

1.72 0.03

1.48 0.02

1.23 0.02

1.11 0.01

V

18 P

14.60 1.43

9.72 0.68

4.86 0.19

3.89 0.13

1.94 0.03

1.75 0.03

1.55 0.02

1.36 0.02

1.17 0.01

V

APPENDIX A FLUID DYNAMICS

ASAHI /AMERICA

Rev. EDG– 02/A

Rev. EDG– 02/A

0.01

0.03

0.05

0.38

0.53

0.76

7

10

ASAHI /AMERICA

2.93

3.56

5.38

6.80

7.55

9.44

90

100

125

5.34

4.80

4.27 1.53

1.26

1.03

0.79

11.17

450


4

0.75 1.05 1.40 1.79 2.23 2.71

7.02 8.19 9.36 10.53 11.70

0.50

0.39

0.29

0.21

5.85

2.93

1.29

0.14

0.62

2.34

0.86

0.11

5.27

2.05

0.67

0.08 0.08

3.84

1.76

0.50

0.04

4.68

1.46

0.36

0.03

3.09

1.17

0.24

0.03

3.51

1.05

0.19

0.02

4.10

0.94

0.16

0.01

P

1.81

0.82

6

2.42

0.70

0.12

V

0.09

0.06

0.05

0.04

0.03

0.03

0.02

0.01

P

2.47

14.96

0.56

0.45

0.36

0.26

0.19

0.16

0.13

0.10

0.07

0.05

0.03

0.03

0.03

0.01

P

0.68

7

7.48

6.73

5.98

5.24

4.49

3.74

3.37

2.99

2.62

2.24

1.87

1.50

1.31

1.12

0.93

V

10

1.11 1.68

11.96

0.31

0.26

0.20

0.15

0.12

0.09

0.07

0.06

0.04

0.03

0.02

0.02

0.01

P

9.58

4.79

4.31

3.83

3.35

2.87

2.40

2.16

1.92

1.68

1.44

1.20

0.96

0.84

V

12

7.54

6.03

3.02

2.71

2.41

2.11

1.81

1.51

1.36

1.21

1.06

V

0.55

0.36

0.10

0.08

0.08

0.05

0.04

0.03

0.02

0.02

0.01

P

14

0.31 1.10

11.88

0.20

0.06

0.05

0.04

0.03

0.02

0.02

P

5.94

4.75

2.38

2.14

1.90

1.66

1.43

1.19

1.07

V

16

0.61 0.30

14.00

0.17

0.11

0.03

0.03

0.02

0.02

0.01

P

9.35

4.67

3.74

1.87

1.68

1.50

1.31

1.12

V


10,000

7,500

5,000

2,500

2,000

1,000

900

800

700

600

500

9.93

400

7.44 8.68

4.78

11.08

300

6.20

4.96

4.34

3.72

3.10

2.48

2.23

1.99

1.74

1.49

1.24

1.12

0.99

0.87

0.74

0.62

0.50

V

350

3.41

9.24

1.76

1.33

0.94

0.62

0.52

0.41

0.32

0.24

0.17

0.14

0.11

0.09

0.08

0.05

0.03

0.02

0.01

P

250

3

2.26

6.47

5.54

4.62

3.69

3.33

2.96

2.59

2.22

1.84

1.66

1.48

1.29

1.11

0.92

0.74

0.55

0.37

V

7.39

5.53

2.35

6.04

80

3.74

0.59

10.68

1.84

5.29

70

3.20

0.42

200

1.38

4.53

60

2.67

0.35

4.31

0.99

3.78

50

2.40

0.28

9.35

0.81

3.40

45

2.14

0.22

175

0.65

3.02

40

1.87

0.16

3.24

0.51

2.64

35

1.60

0.12

8.01

0.38

2.27

30

1.34

0.08

0.05

0.02

0.01

150

0.27

1.89

25

1.07

0.80

0.53

P

2.34

0.18

1.51

20

21/2

0.37

V

6.68

0.10

1.13

15

5

P

2

V

Flow Rate (gpm)

Table App. A-21. Proline Pro 45 Velocities and Pressure Drops 18

0.74 1.26

11.00

0.35

0.10

0.06

0.02

0.01

P

14.80

7.39

3.69

2.96

1.48

1.30

V

20

12.00

8.97

5.98

2.99

2.39

1.20

V

0.75

0.44

0.21

0.06

0.04

0.01

P

24

7.55

5.66

3.77

1.89

1.51

V

0.24

0.14

0.07

0.02

0.01

P

FLUID DYNAMICS

APPENDIX A

A

App. A-9

A

App. A-10

0.38

1.01

2.02

5.06

7.09

10.13

1

2

5

7

10 0.02



1.97

15.10

5000

0.10

0.08

0.06

0.05

0.03

0.03

0.02

0.02

0.01

P

0.36

3.02

2.71

2.41

2.11

1.81

1.51

1.36

1.21

1.06

12

1.97

1.68

1.11

0.31

0.26

0.20

0.16

0.12

0.08

0.07

V

6.03

12.00

9.58

4.79

4.31

3.83

3.35

2.87

2.40

2.16

0.06

0.04

0.03

0.02

0.01

P

7.54

3.29

10

1.92

1.68

1.44

1.20

0.96

V

2500

15.00

0.60

2000

2.23

10.50

900

5.98

0.47

0.91

1.79

9.36

800

5.24

0.35

0.25

7.48

1.40

8.19

700

4.49

3.74

0.20

0.16

0.13

0.10

0.07

0.04

0.03

0.03

0.02

0.01

P

1000

1.05

7.02

600

8

0.75

0.75

5.85

500

3.37

2.99

2.62

2.24

1.87

1.50

1.31

1.12

0.93

0.75

V

6.73

0.61

5.27

0.39

0.29

0.21

0.14

0.10

0.08

0.06

0.04

0.03

0.03

0.02

0.02

P

450

6

0.49

4.10

3.51

2.93

2.34

2.05

1.76

1.46

1.17

1.05

0.94

0.82

0.70

V

4.68

3.84

11.20

400

1.81

0.85

0.50

0.36

0.24

0.19

0.16

0.12

0.09

0.06

0.05

0.04

0.03

0.03

0.02

0.01

P

3.09

4

9.93

6.20

4.34

3.72

3.10

2.48

2.23

1.99

1.74

1.49

1.24

1.12

0.99

0.87

0.74

0.62

0.50

V

350

9.06

2.10

1.58

1.13

0.74

0.61

0.49

0.39

0.29

0.21

0.17

0.14

0.11

0.08

0.06

0.04

0.02

0.01

P

2.41

11.90

7.94

6.95

5.96

4.96

3.57

3.18

2.78

2.38

1.99

1.79

1.59

1.39

1.19

0.99

0.79

0.6 0

0.4 0

3

7.44

5.60

4.37

3.29

2.35

1.55

1.28

1.03

0.80

0.60

0.43

0.36

0.29

0.22

0.17

0.12

0.08

0.05

V

300

250

9.40 10.70

200

6.71

5.37

4.83

4.30

3.76

3.22

2.69

2.42

2.15

1.88

1.61

1.34

1.07

0.81

0.54

P

0.01

21/2

0.38

V

175

6.38

4.22

3.47

2.79

2.18

1.64

1.17

0.96

0.78

0.60

0.45

0.32

0.21

0.13

0.06

0.03

0.02

P

8.06

125

2

150

8.10 10.13

100

6.48

5.67

4.86

4.05

3.65

3.24

2.84

2.43

2.03

1.62

1.22

0.81

0.57

0.41

7.29

9.60

7.49

5.63

4.02

3.31

2.66

2.08

1.46

1.11

0.74

0.43

0.20

0.10

0.06

V

90

10.80

80

6.73 9.42

10.62

50

6.06

5.38

70

12.20

9.56

45 8.08

8.06 10.00

8.50

40

4.71

4.04

3.37

2.69

2.02

1.35

0.94

0.67

P 0.01

11/2

0.27

V

60

6.30

7.43

35

3.37

2.24

1.31

0.62

0.32

0.17

0.03

4.73

16.50

10.70

30

5.31

4.25

3.19

2.12

1.49

1.06

0.42

P 0.01

11/4

0.21

V

6.37

11.80

8.88

4.57

2.16

1.11

0.60

0.11

0.03

P

25

26.10

5.33

3.55

2.49

1.78

0.71

1

7.79

11.70

20

7.24

3.74

2.01

0.37

0.36

V

7.10

8.76

5.84

4.09

2.92

1.17

0.1

P

15.30

3/4

0.58

V

15

26.80

13.80

7.42

1.36

P

1/2

V

Flow Rate (gpm)

Table App. A-22. Purad PVDF Velocities and Pressure Drops

APPENDIX A FLUID DYNAMICS

ASAHI /AMERICA

Rev. EDG– 02/A

APPENDIX A

FLUID DYNAMICS

Table App. A-23. Poly-Flo Friction Losses and Pressure Drops (per 100 ft of pipe)* 1x2 Flow (gpm)

Friction Loss (ft of water)

1 2 3 5 7 10 15 20 25 35 50 75 100 150 250 500 750 1000 1250 1500

0.10 0.37 0.78 2.00 3.73 7.21 15.29 26.04 39.37 73.42 142.14

2x3

Pressure Drop (psi)


0.04 0.16 0.34 0.87 1.61 3.12 6.62 11.27 17.04 37.78 61.53

0.13 0.25 0.54 0.92 1.38 2.58 4.99 10.58 18.03 38.20 98.38

4x6

Pressure Drop (psi)

0.06 0.11 0.23 0.40 0.60 1.12 2.16 4.58 7.80 16.54 42.59


Pressure Drop (psi)

0.05 0.09 0.17 0.36 0.62 1.31 3.37 12.18 25.82 43.98 66.49 93.20

0.02 0.04 0.07 0.16 0.27 0.57 1.46 5.27 11.18 19.04 28.78 40.34

*Note: Units shown are for specific gravities of working fluids less than or equal to 1.0. Correction factors for more dense fluids are as follows: 0.90 for SG = 1.25, 0.85 for SG = 1.50, 0.75 for SG = 1.75, 0.70 for SG = 2.00.

Table App. A-24. Poly-Flo Pressure Drops (per 100 ft of pipe)

1 x 2 Inch Pipe

50 40 30 20 10 0

10 20 30 40 FLOW RATE (gal/min)


50

40 30 20 10 0

A

50 PRESSURE DROP (psi)

PRESSURE DROP (psi)

PRESSURE DROP (psi)

60

0

4 x 6 Inch Pipe

2 x 3 Inch Pipe 50

70

0

50 100 150 200 FLOW RATE (gal/min)

250

40 30 20 10 0

0

400 800 1200 FLOW RATE (gal/min)


1600

App. A-11

APPENDIX A

FLUID DYNAMICS

Table App. A-25. Equivalent Lengths for Proline and Duo-Pro Fittings (for friction loss in ft) Carrier Size (nom in) 1/2 3/4

1 11/4 11/2 2 21/2 3 4 6 8 10 12 14 16 18 20 24

Concentric Reduction = D2 /D1*

90° Elbow

45° Elbow

Tee

1.50 2.00 2.75 3.50 4.25 5.50 7.00 8.00 11.00 16.00 20.00 25.00 32.00 25.00 30.00 32.50 35.00 40.00

0.80 1.00 1.25 1.70 2.00 2.50 3.00 3.80 5.00 7.50 10.00 12.50 15.00 12.00 15.00 16.00 17.00 20.00

3.25 4.00 6.00 8.00 9.00 12.00 14.00 17.00 21.00 34.00 44.00 55.00 58.00 80.00 90.00 100.00 110.00 140.00

1/4

3/4

1/2

1.0

0.6

4.0 5.0 7.0 10.0 12.5 15.0

1.5 2.0 2.5 3.0 4.0 6.0 8.0 10.0 12.0

4.0 6.0 7.0

20.0

16.0

9.0

2.5

1.2

2.5

Concentric Reduction = D1/D2** 1/4

1/ 2

3/4

4.0 1.5 2.0 3.0

2.00 1.00 1.50 1.75 2.20 2.50 3.50

1.33

5.00 7.00 10.00 12.50

2.00

4.0 6.0 7.0 8.0 12.0

0.50

1.00

4.00

7.00

* D2 = larger diameter portion, which is shown in size column. ** D1= smaller diameter portion, which is shown in size column.

Table App. A-26. Equivalent Lengths for Poly-Flo Fittings (for friction loss in ft) Equivalent Length (feet) Description

1x2

2x3

4x6

90° Elbow 90° Elbow, Long Sweep 45° Elbow Tee, Side Outlet Tee, Straight Flow

5.0 N/A 1.7 4.0 1.5

10.0 8.6 4.3 8.0 3.0

N/A 12.4 6.2 16.0 6.0

A Table App. A-27. Equivalent Lengths for Air-Pro Fittings (for friction loss in ft-in) Nominal Diameter (in.) Description Socket 45° Elbow 90° Elbow Tee Reducer

App. A-12

1/2

0'-8" 0'-8" 1'-4" 2'-7" 0'-11"

3/4

0'-8" 0'-11" 2'-4" 4'-7" 1'-4"

1

11/4

11/2

2

3

0'-11" 1'-4" 3'-4" 6'-3" 1'-8"

1'-4" 2'-0" 4'-3" 7'-10" 2'-0"

1'-8" 3'-0" 5'-11" 9'-2" 2'-4"

2'-0" 4'-0" 7'-6" 12'-5" 3'-0"

3'-7" 7'-6" 14'-9" 24'-7" 6'-10"



APPENDIX A

DIMENSIONAL PIPE DATA

Table App. A-28. Proline Pro 150 (SDR 11) Metric Pipe Dimensional Size (nom in) 1/2 3/4

1 11/4 11/2 2 21/2 3 4 6 8 10 12 14 16 18 20

Outer Diameter (mm) 20 25 32 40 50 63 75 90 110 160 200 250 315 355 400 450 500

Inner Diameter

(in) 0.79 0.98 1.26 1.57 1.97 2.48 2.95 3.54 4.33 6.30 7.87 9.84 12.40 13.98 15.75 17.72 19.69

(ft) 0.066 0.082 0.105 0.131 0.164 0.207 0.246 0.295 0.361 0.525 0.656 0.820 1.033 1.165 1.312 1.476 1.640

Wall Thick

Internal Area

(in)

(ft)

(in)

(in2)

0.59 0.77 1.02 1.28 1.61 2.02 2.41 2.90 3.54 5.15 6.44 8.05 10.14 11.43 12.88 14.49 16.10

0.049 0.064 0.085 0.107 0.134 0.169 0.201 0.241 0.295 0.429 0.537 0.671 0.845 0.953 1.073 1.207 1.342

0.098 0.106 0.118 0.146 0.181 0.228 0.272 0.323 0.394 0.575 0.717 0.898 1.130 1.272 1.433 1.614 1.791

0.274 0.468 0.823 1.294 2.026 3.216 4.560 6.594 9.861 20.83 32.58 50.86 80.78 102.7 130.3 164.9 203.6

(ft2) 0.0019 0.0032 0.0057 0.0090 0.0141 0.0223 0.0317 0.0458 0.0685 0.1446 0.2263 0.3532 0.5610 0.7129 0.9051 1.1449 1.4142

Cross Section

Moment of Inertia

Section Modulus

MidRadius

Polypro Weight

(in2)

(in4)

(in3)

(in)

(lbs/lin ft)

(ft)

0.213 0.293 0.424 0.654 1.017 1.615 2.288 3.266 4.869 10.34 16.11 25.22 40.01 50.76 64.45 81.66 100.7

0.0129 0.0287 0.0698 0.1687 0.4103 1.0346 2.0771 4.2770 9.5290 42.769 104.21 254.82 641.82 1034.3 1667.4 2673.1 4070.7

0.033 0.058 0.111 0.214 0.417 0.834 1.407 2.414 4.401 13.58 26.47 51.78 103.5 148.0 211.8 301.8 413.6

0.344 0.439 0.571 0.715 0.894 1.126 1.341 1.610 1.969 2.862 3.579 4.472 5.636 6.352 7.157 8.051 8.947

0.094 0.127 0.181 0.275 0.429 0.671 0.939 1.341 2.012 4.293 6.64 10.40 16.50 20.93 26.63 33.67 41.59

2.474 3.092 3.958 4.947 6.184 7.792 9.276 11.13 13.61 19.79 24.74 30.92 38.96 43.91 49.47 55.66 61.84

Circum

Table App. A-29. Proline Pro 90 (SDR 17) Metric Pipe Dimensional Size (nom in) 11/2 2 21/2 3 4 6 8 10 12 14 16 18 20 22 24

Outer Diameter

Inner Diameter

(mm)

(in)

(ft)

50 63 75 90 110 160 200 250 315 355 400 450 500 560 630

1.97 2.48 2.95 3.54 4.33 6.30 7.87 9.84 12.40 13.98 15.75 17.72 19.69 22.05 24.80

0.164 0.207 0.246 0.295 0.361 0.525 0.656 0.820 1.033 1.165 1.312 1.476 1.640 1.837 2.067


(in) 1.74 2.20 2.61 3.14 3.83 5.58 6.98 8.72 10.99 12.39 13.96 15.71 17.46 19.55 21.99

Wall Thick

Internal Area

(ft)

(in)

(in2)

0.145 0.183 0.218 0.262 0.320 0.465 0.581 0.727 0.916 1.033 1.163 1.309 1.455 1.629 1.833

0.114 0.142 0.169 0.201 0.248 0.358 0.449 0.559 0.705 0.791 0.894 1.004 1.114 1.248 1.406

2.378 3.790 5.367 7.752 11.55 24.48 38.23 59.78 94.9 120.6 153.1 193.8 239.3 300.2 379.9

(ft2) 0.017 0.026 0.037 0.054 0.080 0.170 0.265 0.415 0.659 0.838 1.063 1.346 1.662 2.085 2.638

Cross Moment Section MidSection of Inertia Modulus Radius (in2)

(in4)

0.665 1.041 1.480 2.108 3.181 6.687 10.47 16.30 25.90 32.78 41.71 52.71 65.00 81.55 103.3

0.287 0.714 1.439 2.955 6.653 29.61 72.42 176.3 444.5 714.9 1154.0 1847.0 2812.0 4426.0 7095.0

(in3)

(in)

0.292 0.927 0.576 1.169 0.975 1.392 1.668 1.671 3.072 2.041 9.401 2.970 18.39 3.713 35.82 4.642 71.68 5.848 102.3 6.593 146.6 7.427 208.5 8.356 285.7 9.285 401.5 10.400 572.1 11.700


Polypro Weight (lbs/lin ft) 0.282 O.443 0.630 0.872 1.341 2.817 4.360 6.774 10.73 13.62 17.24 21.80 26.90 33.74 42.73

Circum (ft) 6.184 7.792 9.276 11.13 13.61 19.79 24.74 30.92 38.96 43.91 49.47 55.66 61.84 69.26 77.92

App. A-13

A

APPENDIX A


Table App. A-30. Proline Pro 45 (SDR 32.5) Metric Pipe Dimensional Size (nom in) 2 21/2 3 4 6 8 10 12 14 16 18 20 22 24

Outer Diameter (mm) 63 75 90 110 160 200 250 315 355 400 450 500 560 630

(in) 2.48 2.95 3.54 4.33 6.30 7.87 9.84 12.40 13.98 15.75 17.72 19.69 22.05 24.80

Inner Diameter

(ft) 0.207 0.246 0.295 0.361 0.525 0.656 0.820 1.033 1.165 1.312 1.476 1.640 1.837 2.067

(in) 2.32 2.76 3.32 4.06 5.91 7.39 9.23 11.63 13.10 14.77 16.61 18.46 20.68 23.26

(ft) 0.194 0.230 0.277 0.338 0.492 0.615 0.769 0.969 1.092 1.231 1.385 1.539 1.723 1.938

Wall Thick (in) 0.079 0.094 0.110 0.138 0.197 0.244 0.307 0.386 0.437 0.488 0.551 0.610 0.685 0.772

Internal Area (in2) 4.238 5.999 8.672 12.92 27.39 42.84 66.89 106.2 134.8 171.4 216.8 267.8 335.8 424.9

(ft2) 0.029 0.042 0.060 0.090 0.190 0.298 0.464 0.738 0.936 1.190 1.506 1.860 2.332 2.951

Cross Moment Section MidSection of Inertia Modulus Radius (in2) 0.594 0.848 1.189 1.815 3.774 5.851 9.199 14.560 18.590 23.400 29.720 36.570 45.970 58.260

Polypro Weight

Circum

(lbs/lin ft) 0.262 0.369 0.510 0.805 1.610 2.482 3.823 6.104 7.780 9.793 12.340 15.230 19.120 24.210

(ft) 7.792 9.276 11.130 13.610 19.790 24.740 30.920 38.960 43.910 49.470 55.660 61.840 69.260 77.920

Cross Moment Section MidSection of Inertia Modulus Radius

PVDF Weight

Circum

(lbs/lin ft) 0.141 0.181 0.295 0.369 0.570 0.731 1.040 0.993 1.476 3.045 4.823 7.438 16.500

(ft) 2.474 3.092 3.958 4.947 6.184 7.792 9.276 11.130 13.610 19.790 24.740 30.920 38.960

(in4) 0.429 0.867 1.753 3.993 17.58 42.62 104.70 263.10 426.40 681.90 1096.00 1665.00 2625.00 4210.00

(in3) 0.346 0.588 0.990 1.844 5.583 10.83 21.27 42.43 61.01 86.61 123.70 169.20 238.10 339.50

(in) 1.201 1.429 1.717 2.096 3.051 3.815 4.768 6.008 6.770 7.630 8.583 9.537 10.680 12.020

Table App. A-31. Purad PVDF Metric Pipe Dimensional Data Size (nom in) 1/2 3/4 1 11/4 11/2 2 21/2 3 4 6 8 10 12

Pressure Rating (psi) 230 230 230 230 230 230 230 150 150 150 150 150 150

Outer Diameter (mm) 20 25 32 40 50 63 75 90 110 160 200 250 315

(in) 0.79 0.98 1.26 1.57 1.97 2.48 2.95 3.54 4.33 6.30 7.87 9.84 12.40

(ft) 0.066 0.082 0.105 0.131 0.164 0.207 0.246 0.295 0.361 0.525 0.656 0.820 1.033

Inner Diameter (in) 0.64 0.83 1.07 1.39 1.73 2.24 2.67 3.32 4.06 5.91 7.39 9.24 11.64

(ft) 0.053 0.070 0.089 0.115 0.144 0.187 0.222 0.277 0.339 0.493 0.615 0.770 0.970

Wall Thick (in) .075 .075 .094 .094 .114 .118 .142 .110 .134 .193 .244 .303 .382

Internal Area (in2) 0.319 0.547 0.901 1.508 2.357 3.955 5.596 8.672 12.970 27.460 42.840 67.000 106.370

(ft2) 0.0022 0.0038 0.0063 0.0105 0.0164 0.0275 0.0389 0.0602 0.0900 0.1907 0.2975 0.4653 0.7387

(in2) 0.167 0.214 0.346 0.439 0.687 0.877 1.252 1.189 1.765 3.701 5.851 9.085 14.420

(in4) 0.0107 0.0222 0.0591 0.1209 0.2951 0.6129 1.2394 1.7534 3.8897 17.266 42.621 103.450 260.680

(in3) 0.027 0.045 0.094 0.153 0.300 0.494 0.840 0.990 1.796 5.482 10.830 21.020 42.040

(in) 0.356 0.455 0.583 0.740 0.925 1.181 1.406 1.717 2.098 3.053 3.815 4.770 6.010

* For dimensions on other sizes, Asahi/America dimensional guides.

A Table App. A-32. Poly-Flo Pipe Dimensional Data Size (nom in) 1x2 2x3 4x6 6x8

Outer Pipe OD ID (in) (in) 1.950 1.75 3.035 2.79 6.080 5.68 8.000 7.44

App. A-14

Inner Pipe OD ID (in) (in) 1.220 1.02 2.280 2.03 4.560 4.16 6.000 5.44

Wall Thick (in) 0.100 0.125 0.200 0.280

Internal Area (in2) 0.817 3.237 13.590 23.240

Cross Moment Polypro PVDF HDPE Section of Inertia Weight Weight Weight Circum (in2) (in4) (lbs/lin ft) (lbs/lin ft) (lbs/lin ft) (ft) 0.933 0.305 0.65 1.2 0.65 6.126 1.989 1.705 1.00 1.9 1.00 9.535 6.434 22.510 2.80 NA 2.80 19.100 11.820 71.280 7.00 NA 7.00 25.130



Rev. EDG– 02/A

ASAHI /AMERICA


Min Wall (in) .150 .188 .237 .271 .339 .500 .643 .795 .946 1.018 1.232 1.536 1.821 2.000

Weight (lb/ft) .18 .29 .46 .60 .94 2.05 3.39 5.17 7.33 8.49 12.43 19.32 27.16 32.76

267 psi SDR 7 Min Wall (in) .117 .146 .184 .211 .264 .389 .500 .618 .736 .792 .958 1.194 1.417 1.556 1.778 2.000 2.222 2.389 2.444 2.667 Weight (lb/ft) .15 .23 .37 .48 .76 1.66 2.74 4.18 5.93 6.86 10.05 15.61 21.97 26.50 34.60 43.79 54.05 62.47 65.40 77.85

200 psi SDR 9 Min Wall (in) .095 .120 .151 .173 .216 .318 .409 .506 .602 .648 .784 .977 1.159 1.273 1.455 1.636 1.818 1.955 2.000 2.182 2.364 2.545 2.727 Weight (lb/ft) .12* .19* .31* .41* .64* 1.39* 2.29* 3.51 4.97* 5.75 8.42* 13.09* 18.41* 22.20* 29.00* 36.69* 45.30* 52.37 54.82* 65.24* 76.57 88.78 101.92

160 psi SDR 11 Weight (lb/ft)

.176 .53 .259 1.15 .333 1.90 .412 2.91 .491 4.13 .528 4.78 .639 7.00 .796 10.87 .944 15.29 1.037 18.44 1.185 24.09 1.333 30.48 1.481 37.63 1.593 43.51 1.630 45.56 1.778 54.21 1.926 63.62 2.074 73.78 2.222 84.69 2.333 93.35 2.370 96.35 2.519 108.81 2.667 121.98

Min Wall (in)

130 psi SDR 13.5 Weight (lb/ft)

.153 .47 .226 1.02 .290 1.68* .359 2.57 .427 3.63 .460 4.21 .556 6.16 .694 9.58 .823 13.48* .903 16.24 1.032 21.21 1.161 26.84* 1.290 33.14 1.387 38.30 1.419 40.10 1.548 47.72 1.677 56.00 1.806 64.95 1.935 74.56 2.032 82.20 2.065 84.87 2.194 95.81 2.323 107.41

Min Wall (in)

110 psi SDR 15.5 Weight (lb/ft)

.140 .43 .206 .93* .265 1.54* .327 2.35 .390 3.34* .420 3.86 .507 5.65* .632 8.78* .750 12.36* .824 14.91* .941 19.46* 1.059 24.64* 1.176 30.41* 1.265 35.16 1.294 36.80 1.412 43.81* 1.529 51.39 1.647 59.62* 1.765 68.45 1.853 75.45 1.882 77.86 2.000 87.91 2.118 98.57 2.316 117.88

Min Wall (in)

100 psi SDR 17

.184 .237 .293 .348 .375 .454 .566 .671 .737 .842 .947 1.053 1.132 1.158 1.263 1.368 1.474 1.579 1.658 1.684 1.789 1.895 2.072 2.211 2.487

Min Wall (in)

.84 1.39 2.12 3.01 3.48 5.10 7.92 11.14 13.43 17.54 22.19 27.42 31.68 33.16 39.46 46.30 53.73 61.67 67.98 70.15 79.17 88.81 106.18 120.89 152.94

Weight (lb/ft)

89 psi SDR 19

.167 .214 .265 .315 .340 .411 .512 .607 .667 .762 .857 .952 1.024 1.048 1.143 1.238 1.333 1.429 1.500 1.524 1.619 1.714 1.875 2.000 2.250

Min Wall (in)

.77 1.26 1.93 2.73* 3.16 4.64* 7.21* 10.13* 12.22 15.96* 20.19 24.93 28.82 30.18 35.91* 42.14 48.86 56.12* 61.85 63.84 72.06 80.78* 96.64 109.97 139.16

Weight (lb/ft)

80 psi SDR 21

.135 .173 .214 .255 .274 .332 .413 .490 .538 .615 .692 .769 .827 .846 .923 1.000 1.077 1.154 1.211 1.231 1.308 1.385 1.514 1.615 1.817 2.077

.62 1.03 1.57 2.23* 2.58* 3.79* 5.87* 8.26* 9.96* 13.01* 16.47* 20.34* 23.51 24.61* 29.30* 34.39 39.88 45.78 50.44 52.10 58.81 65.94* 78.83 89.71* 113.53* 148.33*

Weight (lb/ft)

65 psi SDR 26 Min Wall (in)

* Denotes standard sizes. ** Pipe sizes are identified by IPS (iron pipe size) diameters which designate the nominal diameter for 12" IPS and smaller pipe, and outside diameter for 14" IPS and larger pipe. *** Pressure ratings are for water at 73.4° F and HDB hoop stress of 1,600 psi.

Pressure*** Rating O.D. IPS** Size Pipe (in) Size 3/4" 1.050 1" 1.315 11/4" 1.660 11/2" 1.900 2" 2.375 3" 3.500 4" 4.500 5" 5.563 6" 6.625 7" 7.125 8" 8.625 10" 10.750 12" 12.750 14" 14.000 16" 16.000 18" 18.000 20" 20.000 211/2" 21.500 22" 22.000 24" 24.000 26" 26.000 28" 28.000 30" 30.000 800 mm 31.496 32" 32.000 34" 34.000 36" 36.000 1000 mm 39.370 42" 42.000 1200 mm 47.244 54" 54.000

Table App. A-33. IPS HDPE Pipe Dimensional Data

.108 .138 .171 .204 .219 .265 .331 .392 .431 .492 .554 .615 .662 .677 .738 .800 .862 .923 .969 .985 1.046 1.108 1.211 1.292 1.454 1.662

Min Wall (in)

.50 .83 1.27 1.80* 2.08 3.05* 4.75* 6.67* 8.05 10.50 13.30 16.41* 18.98 19.86* 23.62* 27.74* 32.19* 36.93* 40.71 42.04* 47.43 53.20* 63.69 72.37* 91.62* 119.70*

Weight (lb/ft)

50 psi SDR 32.5


APPENDIX A

App. A-15

A

APPENDIX A


Table App. A-34. Air-Pro (PE 100, SDR 7) Pipe Dimensional Data Size (nom in) 1/2 3/4 1 11/4 11/2 2 21/2 3 4

Wall Outer Diameter Thickness

Weight

(mm) 20 25 32 40 50 63 75 90 110

(lbs/ft) 0.64 0.83 1.07 1.39 1.73 2.24 2.67 3.32 4.06

(in) 0.79 0.98 1.26 1.57 1.97 2.48 2.95 3.54 4.33

(inches) 0.066 0.082 0.105 0.131 0.164 0.207 0.246 0.295 0.361

Table App. A-35. Annular Space for Duo-Pro Polypropylene x Polypropylene Assemblies (inches) Nominal Size (inches) 1x3

A

App. A-16

Carrier Presure Rating

Containment Wall Thickness

Annular Space

SDR-11

SDR-11

(inches) 0.82

2x4

SDR-11

SDR-11

0.53

2x4

SDR-11

SDR-32

0.79

3x6

SDR-11

SDR-11

0.80

3x6

SDR-11

SDR-32

1.18

4x8

SDR-11

SDR-11

1.05

4x8

SDR-11

SDR-32

1.53

4x8

SDR-32

SDR-32

1.53

6 x 10

SDR-11

SDR-11

0.88

6 x 10

SDR-11

SDR-32

1.47

6 x 10

SDR-32

SDR-32

1.47

8 x 12

SDR-11

SDR-11

1.14

8 x 12

SDR-11

SDR-32

1.88

8 x 12

SDR-32

SDR-32

1.88

10 x 14

SDR-11

SDR-11

0.80

10 x 14

SDR-11

SDR-32

1.63

10 x 14

SDR-32

SDR-32

1.63

12 x 16

SDR-11

SDR-11

1.05

12 x 16

SDR-11

SDR-32

1.19

12 x 16

SDR-32

SDR-32

1.19

14 x 18

SDR-11

SDR-32

1.32

14 x 18

SDR-32

SDR-32

1.32

16 x 20

SDR-11

SDR-32

1.36

16 x 20

SDR-32

SDR-32

1.36

16 x 20

SDR-32

SDR-32

2.77



APPENDIX A

VACUUM RATING

Table App. A-36. Annular Space for Duo-Pro PVDF Carrier Pipe Assemblies (inches) Nominal Size

Carrier Presure Rating

(inches) 1x3

(psi) 230

1x2 2x4

Containment Wall Thickness*

Annular Space

SDR-11

(inches) 0.82

230

SDR-32

1.03

230

SDR-11

0.53

2x4

230

SDR-32

0.79

3x6

150

SDR-11

0.80

3x6

150

SDR-32

1.18

4x8

150

SDR-11

1.05

4x8

150

SDR-32

1.53

6 x 10

150

SDR-11

0.88

6 x 10

150

SDR-32

1.47

8 x 12

150

SDR-11

1.14

8 x 12

150

SDR-32

1.88

10 x 14

150

SDR-11

0.80

10 x 14

150

SDR-32

1.63

12 x 16

150

SDR-11

1.05

12 x 16

150

SDR-32

1.19

* For PVDF containment , sizes 3"-12" are SDR 32. For Poly-Pro containment, sizes 3"-18" can be SDR 11 (Pro 150), and sizes 4"-16" can be SDR 32 (Pro 45)

Table App. A-37. Collapse Pressures Pro 150 (SDR 11)

Pro 45 (SDR 32.5)

Pro 30 (SDR 41)

HDPE 150 (SDR 11)

PVDF

° F /° C

(psi)

° F /° C

(psi)

° F /° C

(psi)

° F /° C

(psi)

° F /° C

(psi)

68/20 83/30 104/40 140/60 176/80 200/93.3 —

32.3 28.9 25.5 18.7 — — —

68/21 83/31 104/41 140/61 176/81 200/93.4 —

1.2 1.1 1.0 0.7 — — —

68/22 83/32 104/42 140/62 176/82 200/93.5 248/120

0.73 0.66 0.58 0.44 0.29 0.21 —

68/23 83/33 104/43 140t63 176/83 200/93.6 248/121

28.5 24.0 19.7 — — — —

68/24 83/34 104/44 140/64 176/84 200/93.7 248/122

17.4 34.0 7.3 3.6 2.9 2.6 2.5

Full vacuum = 14.7 psi, values greater are considered full vacuum.



App. A-17

A

APPENDIX A

HEAT LOSS

Table App. A-38. PVDF Pipe Heat Loss in Watts per Linear Foot n.l.t.

∆T

0.375

0.5

0.75

1

1.25

0.5

50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200

1.98 2.96 3.95 4.94 5.93 6.92 7.90 1.37 2.05 2.73 3.42 4.10 4.79 5.47 1.13 1.70 2.26 2.83 3.39 3.96 4.52 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.92 1.37 1.83 2.29 2.75 3.20 3.66 0.85 1.28 1.71 2.14 2.56 2.99 3.42 0.77 1.16 1.54 1.93 2.31 2.70 3.08

2.26 3.39 4.52 5.66 6.79 7.92 9.05 1.54 2.3 3.07 3.84 4.61 5.37 6.14 1.26 1.88 2.51 3.14 3.77 4.39 5.02 1.10 1.65 2.20 2.75 3.30 3.86 4.41 1.00 1.50 2.00 2.50 3.01 3.51 4.01 0.93 1.40 1.86 2.33 2.79 3.26 3.72 0.84 1.25 1.67 2.09 2.51 2.92 3.34

2.64 3.97 5.29 6.61 7.93 9.25 10.58 1.75 2.63 3.5 4.38 5.25 6.13 7.00 1.41 2.12 2.82 3.53 4.23 4.94 5.65 1.23 1.84 2.45 3.07 3.68 4.29 4.91 1.11 1.66 2.22 2.77 3.33 3.88 4.43 1.02 1.54 2.05 2.56 3.07 3.59 4.10 0.91 1.37 1.82 2.28 2.74 3.19 3.65

3.13 4.70 6.27 7.83 9.40 10.97 12.54 2.03 3.05 4.06 5.08 6.09 7.11 8.12 1.61 2.42 3.23 4.04 4.84 5.65 6.46 1.39 2.08 2.78 3.47 4.17 4.86 5.56 1.25 1.87 2.49 3.11 3.74 4.36 4.98 1.14 1.72 2.29 2.86 3.43 4.01 4.58 1.01 1.52 2.02 2.53 3.03 3.54 4.04

3.75 5.62 7.49 9.36 11.24 13.11 14.98 2.37 3.55 4.74 5.92 7.11 8.29 9.48 1.85 2.78 3.71 4.64 5.56 6.49 7.42 1.58 2.37 3.16 3.95 4.74 5.53 6.32 1.40 2.11 2.81 3.51 4.21 4.92 5.62 1.28 1.92 2.57 3.21 3.85 4.49 5.13 1.12 1.68 2.24 2.81 3.37 3.93 4.49

1.0

1.5

2.0

2.5

3.0

A 4.0

Nominal Diameter of Pipe In Inches 1.5 2 2.5 3 4.41 6.61 8.82 11.02 13.23 15.43 17.64 2.74 4.12 5.49 6.86 8.23 9.6 10.98 2.12 3.18 4.24 5.30 6.37 7.43 8.49 1.79 2.69 3.58 4.48 5.37 6.27 7.16 1.58 2.37 3.16 3.95 4.74 5.53 6.32 1.44 2.15 2.87 3.59 4.31 5.03 5.74 1.24 1.87 2.49 3.11 3.73 4.36 4.98

5.33 8.00 10.67 13.33 16.00 18.67 21.34 3.25 4.88 6.50 8.13 9.76 11.38 13.01 2.48 3.72 4.96 6.20 7.44 8.68 9.92 2.07 3.10 4.14 5.17 6.21 7.24 8.28 1.81 2.72 3.62 4.53 5.44 6.34 7.25 1.63 2.45 3.27 4.09 4.9 5.72 6.54 1.40 2.10 2.81 3.51 4.21 4.91 5.61

6.29 9.43 12.58 15.72 18.86 22.01 25.15 3.75 5.63 7.51 9.39 11.26 13.14 15.02 2.82 4.24 5.65 7.06 8.47 9.89 11.3 2.34 3.50 4.67 5.84 7.01 8.17 9.34 2.03 3.05 4.06 5.08 6.09 7.11 8.12 1.82 2.73 3.64 4.55 5.46 6.38 7.29 1.55 2.32 3.10 3.87 4.65 5.42 6.20

7.31 10.97 14.62 18.28 21.94 25.60 29.26 4.32 6.48 8.64 10.80 12.96 15.12 17.28 3.22 4.83 6.44 8.05 9.66 11.27 12.88 2.64 3.96 5.28 6.6 7.92 9.25 10.57 2.28 3.42 4.57 5.71 6.85 7.99 9.13 2.04 3.06 4.07 5.09 6.11 7.13 8.15 1.72 2.58 3.44 4.30 5.15 6.01 6.87

4

6

8

10

12

8.58 12.87 17.16 21.46 25.75 30.04 34.33 5.04 7.56 10.08 12.60 15.11 17.63 20.15 3.72 5.59 7.45 9.31 11.17 13.04 14.90 3.03 4.55 6.07 7.59 9.10 10.62 12.14 2.61 3.91 5.21 6.51 7.82 9.12 10.42 2.31 3.47 4.62 5.78 6.94 8.09 9.25 1.93 2.90 3.87 4.83 5.80 6.77 7.74

11.62 17.43 23.24 29.05 34.86 40.68 46.49 6.78 10.17 13.56 16.96 20.35 23.74 27.13 4.95 7.43 9.91 12.38 14.86 17.34 19.82 3.99 5.98 7.98 9.97 11.96 13.96 15.95 3.39 5.08 6.78 8.47 10.17 11.86 13.55 2.98 4.47 5.96 7.45 8.94 10.43 11.91 2.45 3.68 4.90 6.13 7.35 8.58 9.81

13.92 20.80 27.85 34.80 41.78 48.70 55.71 8.14 12.21 16.27 20.30 24.41 28.40 32.55 5.90 8.87 11.83 14.79 17.75 20.70 23.60 4.74 7.10 9.47 11.84 14.21 16.58 18.94 4.00 6.00 8.00 10.00 12.01 14.01 16.01 3.50 5.25 7.00 8.75 10.50 12.25 14.00 2.86 4.28 5.71 7.14 8.57 9.99 11.42

16.57 24.85 33.14 41.43 49.72 58.01 66.30 9.75 14.62 19.50 24.37 29.25 34.13 39.00 7.07 10.61 14.15 17.68 21.22 24.76 28.29 5.64 8.46 11.28 14.10 16.92 19.74 22.56 4.75 7.12 9.49 11.87 14.24 16.61 18.98 4.13 6.20 8.27 10.33 12.40 14.47 16.53 3.35 5.02 6.69 8.36 10.04 11.71 13.38

19.78 29.67 39.57 49.46 59.36 69.25 79.15 11.76 17.64 23.53 29.41 35.29 41.17 47.06 8.53 12.80 17.07 21.34 25.60 29.87 34.14 6.79 10.18 13.58 16.97 20.36 23.76 27.15 5.69 8.54 11.38 14.23 17.08 19.92 22.77 4.94 7.41 9.88 12.35 14.82 17.29 19.76 3.97 5.95 7.94 9.92 11.91 13.89 15.88

n.i.t. = nominal insulation thickness of foamed elastomer in inches; ∆T = temperature difference between cold fluid and desired maintenance in °F; body of table is in watts per linear foot of pipe. Heat loss values are calculated using Equation C-67). Values are for moving air at 20 mph velocity, assuming no outer cladding.

App. A-18



APPENDIX A

HEAT LOSS

Table App. A-39. Proline Pro 150 Pipe Heat Loss in Watts per Linear Foot n.l.t.

∆T

0.375

0.5

0.75

1

1.25

0.5

50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150

1.99 2.98 3.97 4.97 5.96 1.37 2.06 2.74 3.43 4.12 1.13 1.70 2.27 2.84 3.40 1.00 1.50 2.01 2.51 3.01 0.92 1.38 1.83 2.29 2.75 0.86 1.28 1.71 2.14 2.57 0.77 1.16 1.55 1.93 2.32

2.28 3.42 4.56 5.70 6.84 1.54 2.32 3.09 3.86 4.63 1.26 1.89 2.52 3.15 3.78 1.11 1.66 2.21 2.76 3.32 1.01 1.51 2.01 2.51 3.02 0.93 1.40 1.87 2.33 2.80 0.84 1.26 1.67 2.09 2.51

2.65 3.97 5.30 6.62 7.94 1.75 2.63 3.50 4.38 5.26 1.41 2.12 2.83 3.53 4.24 1.23 1.84 2.46 3.07 3.68 1.11 1.66 2.22 2.77 3.33 1.03 1.54 2.05 2.56 3.08 0.91 1.37 1.83 2.28 2.74

3.17 4.76 6.34 7.93 9.52 2.05 3.07 4.09 5.12 6.14 1.62 2.44 3.25 4.06 4.87 1.40 2.10 2.79 3.49 4.19 1.25 1.88 2.50 3.13 3.76 1.15 1.72 2.30 2.88 3.45 1.01 1.52 2.03 2.54 3.04

3.73 5.60 7.47 9.33 11.20 2.36 3.55 4.73 5.91 7.09 1.85 2.78 3.70 4.63 5.56 1.58 2.37 3.15 3.94 4.73 1.40 2.10 2.81 3.51 4.21 1.28 1.92 2.56 3.20 3.85 1.12 1.68 2.24 2.80 3.36

1.0

1.5

2.0

2.5

3.0

4.0

Nominal Diameter of Pipe In Inches 1.5 2 2.5 3 4 4.37 6.55 8.74 10.92 13.11 2.73 4.09 5.46 6.82 8.19 2.11 3.17 4.23 5.28 6.34 1.78 2.68 3.57 4.46 5.35 1.58 2.36 3.15 3.94 4.73 1.43 2.15 2.86 3.58 4.29 1.24 1.86 2.48 3.10 3.72

5.17 7.76 10.35 12.94 15.53 3.19 4.79 6.39 7.98 9.58 2.44 3.67 4.89 6.11 7.33 2.04 3.07 4.09 5.11 6.13 1.79 2.69 3.59 4.48 5.38 1.62 2.43 3.24 4.05 4.86 1.39 2.09 2.78 3.48 4.17

5.88 8.82 11.77 14.71 17.65 3.61 5.41 7.21 9.01 10.82 2.74 4.11 5.48 6.85 8.22 2.28 3.42 4.55 5.69 6.83 1.99 2.98 3.97 4.97 5.96 1.79 2.68 3.57 4.47 5.36 1.52 2.29 3.05 3.81 4.57

6.75 10.12 13.50 16.87 20.25 4.12 6.17 8.23 10.29 12.35 3.10 4.66 6.21 7.76 9.31 2.56 3.85 5.13 6.41 7.69 2.22 3.34 4.45 5.56 6.67 1.99 2.99 3.98 4.98 5.97 1.69 2.53 3.37 4.21 5.06

7.84 11.76 15.68 19.59 23.51 4.77 7.16 9.54 11.93 14.32 3.58 5.37 7.15 8.94 10.73 2.94 4.40 5.87 7.34 8.81 2.53 3.80 5.07 6.33 7.60 2.25 3.38 4.51 5.64 6.76 1.89 2.84 3.79 4.73 5.68

6

8

10

12

14

16

18

10.26 15.39 20.52 25.66 30.79 6.30 9.44 12.59 15.74 18.89 4.69 7.03 9.38 11.72 14.07 3.81 5.72 7.63 9.54 11.44 3.26 4.89 6.53 8.16 9.79 2.88 4.32 5.76 7.20 8.64 2.38 3.58 4.77 5.96 7.15

12.01 18.02 24.02 30.03 36.04 7.44 11.17 14.89 18.61 22.33 5.54 8.31 11.08 13.85 16.62 4.49 6.74 8.98 11.23 13.48 3.83 5.74 7.65 9.57 11.48 3.37 5.05 6.73 8.41 10.10 2.76 4.15 5.53 6.91 8.29

13.94 20.91 27.88 34.85 41.82 8.77 13.16 17.55 21.94 26.33 6.55 9.82 13.09 16.36 19.64 5.30 7.95 10.60 13.25 15.90 4.50 6.75 9.01 11.26 13.51 3.95 5.92 7.89 9.87 11.84 3.22 4.83 6.45 8.06 9.67

16.14 24.22 32.29 40.37 48.44 10.37 15.56 20.75 25.93 31.12 7.78 11.67 15.56 19.45 23.34 6.3 9.45 12.6 15.75 18.9 5.35 8.02 10.69 13.36 16.04 4.68 7.01 9.35 11.69 14.03 3.8 5.7 7.6 9.49 11.39

17.36 26.05 34.73 43.42 52.10 11.29 16.94 22.59 28.24 33.88 8.50 12.75 17.00 21.25 25.51 6.89 10.34 13.79 17.24 20.68 5.85 8.77 11.70 14.62 17.54 5.11 7.67 10.22 12.78 15.34 4.14 6.21 8.29 10.36 12.43

18.61 27.91 37.22 46.52 55.93 12.26 18.40 24.53 30.66 36.8 9.28 13.91 18.55 23.19 27.83 7.54 11.30 15.07 18.84 22.61 6.39 9.59 12.79 15.99 19.18 5.59 8.38 11.18 13.97 16.76 4.52 6.78 9.04 11.30 13.57

19.85 29.78 39.71 49.64 59.57 13.28 19.92 26.56 33.20 39.84 10.10 15.15 20.20 25.25 30.30 8.22 12.33 16.44 20.55 24.67 6.98 10.47 13.96 17.46 20.95 6.10 9.15 12.20 15.20 18.31 4.93 7.40 9.87 12.33 14.80


A



App. A-19

APPENDIX A

HEAT LOSS

Table App. A-40. Proline Pro 45 Pipe Heat Loss in Watts per Linear Foot n.l.t.

∆T

2

2.5

3

4

0.5

50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150 50 75 100 125 150

5.61 8.42 11.22 14.03 16.83 3.35 5.03 6.71 8.38 10.06 2.54 3.81 5.07 6.34 7.61 2.11 3.16 4.22 5.27 6.33 1.84 2.76 3.69 4.61 5.53 1.66 2.49 3.32 4.15 4.98 1.42 2.13 2.84 3.55 4.26

6.45 9.68 12.90 16.13 19.36 3.81 5.72 7.62 9.53 11.44 2.86 4.29 5.71 7.14 8.57 2.36 3.54 4.72 5.89 7.07 2.05 3.07 4.10 5.12 6.14 1.84 2.75 3.67 4.59 5.51 1.56 2.34 3.12 3.90 4.68

7.50 11.25 15.01 18.76 22.51 4.38 6.58 8.77 10.96 13.16 3.26 4.88 6.51 8.14 9.77 2.67 4.00 5.33 6.67 8.00 2.30 3.45 4.60 5.75 6.90 2.05 3.08 4.10 5.13 6.15 1.73 2.59 3.46 4.32 5.19

8.85 13.28 17.71 22.14 26.56 5.13 7.70 10.26 12.83 15.39 3.77 5.66 7.55 9.44 11.33 3.07 4.60 6.14 7.67 9.20 2.63 3.95 5.26 6.58 7.89 2.33 3.50 4.66 5.83 7.00 1.95 2.92 3.89 4.87 5.84

1.0

1.5

2.0

2.5

3.0

4.0

Nominal Diameter of Pipe In Inches 6 8 10 12 12.11 18.17 24.23 30.29 36.35 6.95 10.42 13.90 17.37 20.85 5.04 7.56 10.08 12.60 15.13 4.04 6.07 8.09 10.11 12.13 3.43 5.14 6.86 8.57 10.29 3.01 4.52 6.02 7.53 9.03 2.47 3.71 4.95 6.18 7.42

14.63 21.95 29.26 36.58 43.90 8.37 12-56 16.75 20.94 25.12 6.04 9.06 12.08 15.10 18.12 4.81 7.22 9.63 12.04 14.44 4.06 6.09 8.12 10.15 12.17 3.54 5.31 7.09 8.86 10.63 2.88 4.33 5.77 7.21 8.65

17.59 26.38 35.18 43.98 52.78 10.09 15.14 20.19 25.24 30.28 7.25 10.88 14.51 18.13 21.76 5.75 8.63 11.51 14.39 17.26 4.83 7.24 9.65 12.07 14.48 4.19 6.29 8.39 10.48 12.58 3.38 5.08 6.77 8.46 10.16

21.25 31.87 42.50 53.13 63.76 12.27 18.40 24.53 30.67 36.80 8.80 13.19 17.59 21.99 26.39 6.95 10.43 13.91 17.38 20.86 5.80 8.71 11.61 14.52 17.42 5.03 7.54 10.05 12.56 15.08 4.02 6.04 8.05 10.06 12.08

14

16

18

20

24

23.38 35.07 46.76 58.45 70.15 13.56 20.34 27.13 33.91 40.69 9.73 14.59 19.45 24.32 29.18 7.68 11.52 15.36 19.20 23.04 16.40 9.60 12.81 16.01 19.21 5.53 8.30 11.06 13.83 16.59 4.41 6.62 8.83 11.04 13.24

25.72 38.59 51.45 64.32 77.19 15.00 22.50 30.00 37.51 45.01 10.76 16.14 21.52 26.90 32.28 8.49 12.73 16.97 21.22 25.46 7.07 10.60 14.13 17.67 21.20 6.09 9.14 12.19 15.24 18.28 4.85 7.27 9.70 12.12 14.54

28.16 42.25 56.34 70.43 84.52 16.54 24.81 33.09 41.36 49.63 11.88 17.82 23.76 29.70 35.65 9.37 14.05 18.73 23.42 28.10 7.79 11.69 15.58 19.48 23.37 6.71 10.07 13.42 16.78 20.13 5.32 7.99 10.65 13.31 15.97

30.55 45.83 61.12 76.40 91.69 18.06 27.10 36.13 45.16 54.20 12.99 19.49 25.98 32.48 38.98 10.24 15.36 20.48 25.60 30.72 8.51 12.77 17.02 21.28 25.53 7.32 10.99 14.65 18.31 21.97 5.80 8.70 11.59 14.49 17.39

36.15 54.23 72.31 90.39 108.48 21.78 32.68 43.57 54.47 65.36 15.75 23.63 31.51 39.38 47.26 12.43 18.65 24.86 31.08 37.30 10.33 15.49 20.66 25.82 30.99 8.88 13.31 17.75 22.19 26.63 7.00 10.50 14.00 17.50 21.00


A Table App. A-41. Spiral Factor/Pitch Pipe Size

Table App. A-42. Valve Heat Loss Factor

Spiral Factor (feet of auto-tractor per feet of pipe)

(ips)

1.1

1.2

1.3

1.4

1.5

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 6.0 8.0

NR NR 17 20 24 28 31 35 39 46 59

NR NR NR 14 17 19 21 24 26 31 41

NR NR NR NR 13 15 17 19 21 25 33

NR NR NR NR NR 13 14 16 18 21 28

NR NR NR NR NR NR NR 14 15 18 24

Valve Type

Std 90

Gate Butterfly Ball Globe

4.3 2.3 2.6 3.9

For Example: Heat loss for a 2" gate valve is 4.3 times the heat loss for one foot of pipe of the same size and insulation.

Note: 1 inch = 2.54 cm

App. A-20



APPENDIX A

HEAT GAIN

Table App. A-43. Heat Gain Values for Pro150 in Still Air Conditions Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 255 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55

Pipe Size = 0.5", O.D. = 0.79" Ambient Temperature (F) 90 85 80



Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 15.8 11.7 9.5 8.2 7.3 6.6 6.1 5.4 4.9 4.5 4.0 3.7 14.4 10.7 8.7 7.4 6.6 6.0 5.5 4.9 4.4 4.1 3.6 3.3 12.9 9.6 7.8 6.7 5.9 5.4 5.0 4.4 4.0 3.7 3.3 3.0 11.5 8.5 6.9 5.9 5.3 4.8 4.4 3.9 3.5 3.3 2.9 2.7 10.1 7.5 6.1 5.2 4.6 4.2 3.9 3.4 3.1 2.9 2.6 2.3

42.3 63.1 72.4 77.3 80.3 82.3 83.6 85.4 86.4 87.2 88 88.5 46.5 65.4 73.9 78.5 81.2 83 84.3 85.8 86.8 87.4 88.2 88.6 51 68 75.6 79.6 82.1 83.7 84.8 86.2 87.1 87.7 88.4 88.8 55.2 70.5 77.2 80.9 82.9 84.4 85.4 86.7 87.5 87.9 88.6 88.9 59.5 72.8 78.7 81.9 83.9 85.1 85.9 87.1 87.8 88.2 88.7 89.1

14.4 10.7 8.7 7.4 6.6 6 5.5 4.9 4.4 4.1 3.6 3.3 12.9 9.6 7.8 6.7 5.9 5.4 5 4.4 4 3.7 3.3 3 11.5 8.5 6.9 5.9 5.3 4.8 4.4 3.9 3.5 3.3 2.9 2.7 10.1 7.5 6.1 5.2 4.6 4.2 3.9 3.4 3.1 2.9 2.6 2.3 8.6 6.4 5.2 4.5 4 3.6 3.3 2.9 2.7 2.5 2.2 2

41.5 60.4 68.9 73.5 76.2 78 79.3 80.8 81.8 82.4 83.2 83.6 46 63 70.6 74.6 77.1 78.7 79.8 81.2 82.1 82.7 83.4 83.8 50.2 65.5 72.2 75.9 77.9 79.4 80.4 81.7 82.5 82.9 83.6 83.9 54.5 67.8 73.7 76.9 78.9 80.1 80.9 82.1 82.8 83.2 83.7 84.1 59 70.3 75.4 78 79.7 80.8 81.6 82.5 83 83.4 83.9 84.2

12.9 9.6 7.8 6.7 5.9 5.4 5 4.4 4 3.7 3.3 3 11.5 8.5 6.9 5.9 5.3 4.8 4.4 3.9 3.5 3.3 2.9 2.7 10.1 7.5 6.1 5.2 4.6 4.2 3.9 3.4 3.1 2.9 2.6 2.3 8.6 6.4 5.2 4.5 4 3.6 3.3 2.9 2.7 2.5 2.2 2 7.2 5.3 4.3 3.7 3.3 3 2.8 2.4 2.2 2.1 1.8 1.7

41 58 65.6 69.6 72.1 73.7 74.8 76.2 77.1 77.7 78.4 78.8 45.2 60.5 67.2 70.9 72.9 74.4 75.4 76.7 77.5 77.9 78.6 78.9 49.5 62.8 68.7 71.9 73.9 75.1 75.9 77.1 77.8 78.2 78.7 79.1 54 65.3 70.4 73 74.7 75.8 76.6 77.5 78 78.4 78.9 79.2 58.2 67.8 72 74.3 75.6 76.5 77.1 77.9 78.4 78.7 79.1 79.3

19.5 14 11.2 9.5 8.4 7.6 6.9 6.1 5.5 5 4.4 4 17.7 12.7 10.2 8.6 7.6 6.9 6.3 5.5 5 4.6 4 3.7 15.9 11.4 9.2 7.8 6.9 6.2 5.7 5 4.5 4.1 3.6 3.3 14.2 10.2 8.1 6.9 6.1 5.5 5.1 4.4 4 3.7 3.2 2.9 12.4 8.9 7.1 6 5.3 4.8 4.4 3.9 3.5 3.2 2.8 2.6

42.5 62.8 71.9 76.9 79.9 81.9 83.4 85.1 86.2 87 87.9 88.4 46.9 65.4 73.5 78.1 80.8 82.6 83.9 85.6 86.6 87.2 88.1 88.5 51.3 67.9 75.2 79.2 81.7 83.4 84.5 86 86.9 87.5 88.3 88.7 55.4 70.2 76.9 80.5 82.6 84.1 85.1 86.5 87.3 87.8 88.5 88.8 59.8 72.7 78.5 81.7 83.6 84.9 85.8 86.9 87.6 88.1 88.7 89

17.7 12.7 10.2 8.6 7.6 6.9 6.3 5.5 5.0 4.6 4.0 3.7 15.9 11.4 9.2 7.8 6.9 6.2 5.7 5.0 4.5 4.1 3.6 3.3 14.2 10.2 8.1 6.9 6.1 5.5 5.1 4.4 4 3.7 3.2 2.9 12.4 8.9 7.1 6 5.3 4.8 4.4 3.9 3.5 3.2 2.8 2.6 10.6 7.6 6.1 5.2 4.6 4.1 3.8 3.3 3.0 2.8 2.4 2.2

41.9 60.4 68.5 73.1 75.8 77.6 78.9 80.6 81.6 82.2 83.1 83.5 46.3 62.9 70.2 74.2 76.7 78.4 79.5 81 81.9 82.5 83.3 83.7 50.4 65.2 71.9 75.5 77.6 79.1 80.1 81.5 82.3 82.8 83.5 83.8 54.8 67.7 73.5 76.7 78.6 79.9 80.8 81.9 82.6 83.1 83.7 84 59.2 70.2 75.2 77.8 79.5 80.6 81.3 82.4 82.9 83.3 83.8 84.1

15.9 11.4 9.2 7.8 6.9 6.2 5.7 6 4.5 4.1 3.6 3.3 14.2 10.2 8.1 6.9 6.1 5.5 5.1 4.4 4 3.7 3.2 2.9 12.4 8.9 7.1 6 5.3 4.8 4.4 3.9 3.5 3.2 2.8 2.6 10.6 7.6 6.1 5.2 4.6 4.1 3.8 3.3 3 2.8 2.4 2.2 8.9 6.4 5.1 4.3 3.8 3.4 3.2 2.8 2.5 2.3 2 1.8

41.3 57.9 65.2 69.2 71.7 73.4 74.5 76 76.9 77.5 78.3 78.7 45.4 60.2 66.9 70.5 72.6 74.1 75.1 76.5 77.3 77.8 78.5 78.8 49.8 62.7 68.5 71.7 73.6 74.9 75.8 76.9 77.6 78.1 78.7 79 54.2 65.2 70.2 72.8 74.5 75.6 76.3 77.4 77.9 78.3 78.8 79.1 58.3 67.6 71.8 74.1 75.4 76.4 76.9 77.8 78.3 78.6 79 79.3

24.7 17.2 13.6 11.4 10 8.9 8.2 7.1 6.3 5.8 5 4.6 22.5 15.7 12.3 10.4 9.1 8.1 7.4 6.4 5.7 5.3 4.6 4.1 20.2 14.1 11.1 9.3 8.2 7.3 6.7 5.8 5.2 4.7 4.1 3.7 18 12.5 9.9 8.3 7.2 6.5 5.9 5.1 4.6 4.2 3.7 3.3 15.7 11 8.6 7.3 6.3 5.7 5.2 4.5 4 3.7 3.2 2.9

43.2 62.8 71.6 76.5 79.4 81.5 82.9 84.8 86 86.7 87.7 88.2 47.4 65.2 73.3 77.6 80.4 82.3 83.6 85.3 86.4 87 87.9 88.4 51.7 67.7 74.9 79 81.3 83.1 84.2 85.8 86.7 87.4 88.1 88.6 55.9 70.2 76.6 80.1 82.4 83.8 84.9 86.3 87.1 87.6 88.3 88.7 60.3 72.6 78.3 81.3 83.3 84.6 85.5 86.7 87.5 87.9 88.5 88.9

22.5 15.7 12.3 10.4 9.1 8.1 7.4 6.4 5.7 5.3 4.6 4.1 20.2 14.1 11.1 9.3 8.2 7.3 6.7 5.8 5.2 4.7 4.1 3.7 18 12.5 9.9 8.3 7.2 6.5 5.9 5.1 4.6 4.2 3.7 3.3 15.7 11 8.6 7.3 6.3 5.7 5.2 4.5 4 3.7 3.2 2.9 13.5 9.4 7.4 6.2 5.4 4.9 4.5 3.9 3.4 3.2 2.8 2.5

42.4 60.2 68.3 72.6 75.4 77.3 78.6 80.3 81.4 82 82.9 83.4 46.7 62.7 69.9 74 76.3 78.1 79.2 80.8 81.7 82.4 83.1 83.6 50.9 65.2 71.6 75.1 77.4 78.8 79.9 81.3 82.1 82.6 83.3 83.7 55.3 67.6 73.3 76.3 78.3 79.6 80.5 81.7 82.5 82.9 83.5 83.9 59.4 70.1 75 77.6 79.3 80.3 81.1 82.1 82.8 83.2 83.7 84

20.2 14.1 11.1 9.3 8.2 7.3 6.7 5.8 5.2 4.7 4.1 3.7 18 12.5 9.9 8.3 7.2 6.5 5.9 5.1 4.6 4.2 3.7 3.3 15.7 11 8.6 7.3 6.3 5.7 5.2 4.5 4 3.7 3.2 2.9 13.5 9.4 7.4 6.2 5.4 4.9 4.5 3.9 3.4 3.2 2.8 2.5 11.2 7.8 6.2 5.2 4.5 4.1 3.7 3.2 2.9 2.6 2.3 2.1

41.7 57.7 64.9 69 71.3 73.1 74.2 75.8 76.7 77.4 78.1 78.6 45.9 60.2 66.6 70.1 72.4 73.8 74.9 76.3 77.1 77.6 78.3 78.7 50.3 62.6 68.3 71.3 73.3 74.6 75.5 76.7 77.5 77.9 78.5 78.9 54.4 65.1 70 72.6 74.3 75.3 76.1 77.1 77.8 78.2 78.7 79 58.8 67.7 71.6 73.8 75.2 76.1 76.8 77.7 78.2 78.5 79 79.2

Fluid Temp = temperature of the chilled water (F). Heat Gain (Btu per linear foot of pipe) calculated from Equation C-67.



App. A-21

A

APPENDIX A

HEAT GAIN

Table App A-43. Heat Gain Values for Pro150 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 so 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55




Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 30.1 20.7 16.1 13.5 11.7 10.4 9.5 8.1 7.2 6.6 5.7 5.1 27.4 18.8 14.7 12.2 10.6 9.5 8.6 7.4 6.6 6 5.2 4.6 24.6 16.9 13.2 11 9.6 8.5 7.7 6.6 5.9 5.4 4.7 4.2 21.9 15 11.7 9.8 8.5 7.6 6.9 5.9 5.3 4.8 4.1 3.7 19.2 13.2 10.3 8.6 7.4 6.6 6 5.2 4.6 4.2 3.6 3.2

44.5 63 71.5 76.2 79.2 81.2 82.6 84.6 85.8 86.6 87.6 88.1 48.6 65.5 73.1 77.5 80.2 82 83.3 85.1 86.1 86.9 87.8 88.3 52.8 68 74.8 78.7 81.1 82.8 84 85.6 86.5 87.2 88 88.5 56.9 70.4 76.6 80 82.1 83.6 84.7 86.1 86.9 87.5 88.2 88.7 61 72.8 78.2 81.2 83.2 84.4 85.3 86.5 87.3 87.8 88.5 88.8

27.4 18.8 14.7 12.2 10.6 9.5 8.6 7.4 6.6 6 5.2 4.6 24.6 16.9 13.2 11 9.6 8.5 7.7 6.6 5.9 5.4 4.7 4.2 21.9 15 11.7 9.8 8.5 7.6 6.9 5.9 5.3 4.8 4.1 3.7 19.2 13.2 10.3 8.6 7.4 6.6 6 5.2 4.6 4.2 3.6 3.2 16.4 11.3 8.8 7.3 6.4 5.7 5.2 4.4 3.9 3.6 3.1 2.8

43.6 60.5 68.1 72.5 75.2 77 78.3 80.1 81.1 81.9 82.8 83.3 47.8 63 69.8 73.7 76.1 77.8 79 80.6 81.5 82.2 83 83.5 51.9 65.4 71.6 75 77.1 78.6 79.7 81.1 81.9 82.5 83.2 83.7 56 67.8 73.2 76.2 78.2 79.4 80.3 81.5 82.3 82.8 83.5 83.8 60.2 70.3 74.9 77.5 79.1 80.2 81 82.1 82.7 83.1 83.7 84

24.6 16.9 13.2 11 9.6 8.5 7.7 6.6 5.9 5.4 4.7 4.2 21.9 15 11.7 9.8 8.5 7.6 6.9 5.9 5.3 4.8 4.1 3.7 19.2 13.2 10.3 8.6 7.4 6.6 6 5.2 4.6 4.2 3.6 3.2 16.4 11.3 8.8 7.3 6.4 5.7 5.2 4.4 3.9 3.6 3.1 2.8 13.7 9.4 7.3 6.1 5.3 4.7 4.3 3.7 3. 3 2.6 2.3

42.8 58 64.8 68.7 71.1 72.8 74 75.6 76.5 77.2 78 78.5 46.9 60.4 66.6 70 72.1 73.6 74.7 76.1 76.9 77.5 78.2 78.7 51 62.8 68.2 71.2 73.2 74.4 75.3 76.5 77.3 77.8 78.5 78.8 55.2 65.3 69.9 72.5 74.1 75.2 76 77.1 77.7 78.1 78.7 79 59.3 67.7 71.6 73.7 75.1 76 76.7 77.5 78.1 78.4 78.9 79.2

35.8 24.5 19 15.8 13.6 12.1 11 9.4 8.3 7.5 6.4 5.7 32.6 22.3 17.3 14.4 12.4 11 10 8.5 7.5 6.8 5.8 5.2 29.3 20.1 15.6 12.9 11.2 9.9 9 7.7 6.8 6.1 5.3 4.7 26.1 17.8 13.8 11.5 9.9 8.8 8 6.8 6 5.4 4.7 4.2 22.8 15.6 12.1 10 8.7 7.7 7 6 5.3 4.8 4.1 3.6

46.6 63.7 71.6 76.1 79.1 81 82.4 84.3 85.6 86.4 87.4 88 50.5 66 73.3 77.4 80 81.8 83.1 84.9 86 86.7 87.7 88.2 54.5 68.4 74.9 78.7 81 82.7 83.8 85.4 86.4 87.1 87.9 88.4 58.4 70.9 76.7 79.9 82 83.5 84.5 85.9 86.8 87.4 88.1 88.6 62.4 73.2 78.3 81.2 83 84.3 85.2 86.4 87.2 87.7 88.4 88.8

32.6 22.3 17.3 14.4 12.4 11 10 8.5 7.5 6.8 5.8 5.2 29.3 20.1 15.6 12.9 11.2 9.9 9 7.7 6.8 6.1 5.3 4.7 26.1 17.8 13.8 11.5 9.9 8.8 8 6.8 6 5.4 4.7 4.2 22.8 15.6 12.1 10 8.7 7.7 7 6 5.3 4.8 4.1 3.6 19.5 13.4 10.4 8.6 7.4 6.6 6 5.1 4.5 4.1 3.5 3.1

45.5 61 68.3 72.4 75 76.8 78.1 79.9 81 81.7 82.7 83.2 49.5 63.4 69.9 73.7 76 77.7 78.8 80.4 81.4 82.1 82.9 83.4 53.4 65.9 71.7 74.9 77 78.5 79.5 80.9 81.8 82.4 83.1 83.6 57.4 68.2 73.3 76.2 78 79.3 80.2 81.4 82.2 82.7 83.4 83.8 61.4 70.6 74.9 77.5 79.1 80.1 80.9 81.9 82.6 83 83.6 83.9

29.3 20.1 15.6 12.9 11.2 9.9 9 7.7 6.8 6.1 5.3 4.7 26.1 17.8 13.8 11.5 9.9 8.8 8 6.8 6 5.4 4.7 4.2 22.8 15.6 12.1 10 8.7 7.7 7 6 5.3 4.8 4.1 3.6 19.5 13.4 10.4 8.6 7.4 6.6 6 5.1 4.5 4.1 3.5 3.1 16.3 11.1 8.7 7.2 6.2 5.5 5 4.3 3.8 3.4 2.9 2.6

44.5 58.4 64.9 68.7 71 72.7 73.8 75.4 76.4 77.1 77.9 78.4 48.4 60.9 66.7 69.9 72 73.5 74.5 75.9 76.8 77.4 78.1 78.6 52.4 63.2 68.3 71.2 73 74.3 75.2 76.4 77.2 77.7 78.4 78.8 56.4 65.6 69.9 72.5 74.1 75.1 75.9 76.9 77.6 78 78.6 78.9 60.2 68.1 71.6 73.7 75 75.9 76.6 77.4 78 78.4 78.8 79.1

42.8 29.3 22.7 18.8 16.1 14.3 12.9 10.9 9.6 8.6 7.3 6.5 38.9 26.6 20.6 17.1 14.7 13 11.7 9.9 8.7 7.9 6.7 5.9 35 24 18.6 15.4 13.2 11.7 10.5 8.9 7.8 7.1 6 5.3 31.1 21.3 16.5 13.6 11.7 10.4 9.4 7.9 7 6.3 5.3 4.7 27.2 18.6 14.4 11.9 10.3 9.1 8.2 6.9 6.1 5.5 4.7 4.1

48.8 64.4 71.8 76.1 79 80.8 82.3 84.2 85.4 86.3 87.3 87.9 52.6 66.7 73.5 77.4 79.9 81.7 83 84.7 85.8 86.6 87.5 88.1 56.3 69 75.1 78.6 80.9 82.5 83.7 85.3 86.3 86.9 87.8 88.3 60.1 71.4 76.8 79.9 82 83.3 84.4 85.8 86.6 87.3 88 88.5 63.8 73.7 78.5 81.2 82.9 84.2 85.1 86.3 87.1 87.6 88.3 88.7

38.9 26.6 20.6 17.1 14.7 13 11.7 9.9 8.7 7.9 6.7 5.9 35 24 18.6 15.4 13.2 11.7 10.5 8.9 7.8 7.1 6 5.3 31.1 21.3 16.5 13.6 11.7 10.4 9.4 7.9 7 6.3 5.3 4.7 27.2 18.6 14.4 11.9 10.3 9.1 8.2 6.9 6.1 5.5 4.7 4.1 23.3 16 12.4 10.2 8.8 7.8 7 6 5.2 4.7 4 3.5

47.6 61.7 68.5 72.4 74.9 76.7 78 79.7 80.8 81.6 82.5 83.1 51.3 64 70.1 73.6 75.9 77.5 78.7 80.3 81.3 81.9 82.8 83.3 55.1 66.4 71.8 74.9 77 78.3 79.4 80.8 81.6 82.3 83 83.5 58.8 68.7 73.5 76.2 77.9 79.2 80.1 81.3 82.1 82.6 83.3 83.7 62.6 71 75.1 77.5 79 80 80.8 81.8 82.5 83 83.5 83.9

35 24 18.6 15.4 13.2 11.7 10.5 8.9 7.8 7.1 6 5.3 31.1 21.3 16.5 13.6 11.7 10.4 9.4 7.9 7 6.3 5.3 4.7 27.2 18.6 14.4 11.9 10.3 9.1 8.2 6.9 6.1 5.5 4.7 4.1 23.3 16 12.4 10.2 8.8 7.8 7 6 5.2 4.7 4 3.5 19.4 13.3 10.3 8.5 7.3 6.5 5.9 5 4.4 3.9 3.3 3

46.3 59 65.1 68.6 70.9 72.5 73.7 75.3 76.3 76.9 77.8 78.3 50.1 61.4 66.8 69.9 72 73.3 74.4 75.8 76.6 77.3 78 78.5 53.8 63.7 68.5 71.2 72.9 74.2 75.1 76.3 77.1 77.6 78.3 78.7 57.6 66 70.1 72.5 74 75 75.8 76.8 77.5 78 78.5 78.9 61.3 68.4 71.7 73.7 75 75.8 76.5 77.3 77.9 78.3 78.8 79


App. A-22



APPENDIX A

HEAT GAIN

Table App A-43. Heat Gain Values for Pro150 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 so 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55




Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 55.3 38.4 29.8 24.6 21.1 18.6 16.7 14 12.2 10.9 9.2 8.1 50.2 34.9 27.1 22.4 19.2 16.9 15.2 12.8 11.1 9.9 8.4 7.3 45.2 31.4 24.4 20.1 17.3 15.2 13.7 11.5 10 9 7.5 6.6 40.2 27.9 21.7 I7.9 15.3 13.5 12.1 10.2 8.9 8 6.7 5.9 35.2 24.4 19 15.7 13.4 11.8 10.6 8.9 7.8 7 5.8 5.1

52.7 65.8 72.4 76.3 78.9 80.7 82.1 84 65.2 86 67.1 87.7 56.1 68 74 77.5 79.9 81.6 82.8 84.5 85.6 86.4 87.3 88 59.5 70.2 75.6 78.8 80.9 82.4 83.5 85 86 86.7 87.6 88.2 62.9 72.4 77.2 80 82 83.3 84.3 85.6 86.5 87.1 87.9 88.4 66.3 74.6 78.8 81.3 83 84.1 85 86.2 86.9 87.4 88.2 88.6

50.2 34.9 27.1 22.4 19.2 16.9 15.2 12.8 11.1 9.9 8.4 7.3 45.2 31.4 24.4 20.1 17.3 15.2 13.7 11.5 10 9 7.5 6.6 40.2 27.9 21.7 17.9 15.3 13.5 12.1 10.2 8.9 8 6.7 5.9 35.2 24.4 19 15.7 13.4 11.8 10.6 8.9 7.8 7 5.8 5.1 30.1 20.9 16.3 13.4 11.5 10.1 9.1 7.7 6.7 6 5 1 4.4

51.1 63 69 72.5 74.9 76.6 77.8 79.5 80.6 81.4 82.3 83 54.5 65.2 70.6 73.8 75.9 77.4 78.5 80 81 81.7 82.6 83.2 57.9 67.4 72.2 75 77 78.3 79.3 80.6 81.5 82.1 82.9 83.4 61.3 69.6 73.8 76.3 78 79.1 80 81.2 81.9 82.4 83.2 83.6 64.7 71.8 75.4 77.5 79 80 80.7 81.7 82.4 82.8 83.4 83.8

45.2 31.4 24.4 20.1 17.3 15.2 13.7 11.5 10 9 7.5 6.6 40.2 27.9 21.7 17.9 15.3 13.5 12.1 10.2 8.9 8 6.7 5.9 35.2 24.4 19 15.7 13.4 11.8 10.6 8.9 7.8 7 5.8 5.1 30.1 20.9 16.3 13.4 11.5 10.1 9.1 7.7 6.7 6 5 4.4 25.1 17.4 13.5 11.2 9.6 8.5 7.6 6.4 5.6 5 4.2 3.7

49.5 60.2 65.6 68.8 70.9 72.4 73.5 75 76 76.7 77.6 78.2 52.9 62.4 67.2 70 72 73.3 74.3 75.6 76.5 77.1 77.9 78.4 56.3 64.6 68.8 71.3 73 74.1 75 76.2 76.9 77.4 78.2 78.6 59.7 66.8 70.4 72.5 74 75 75.7 76.7 77.4 77.8 78.4 78.8 63.1 69 72 73.8 75 75.8 76.4 77.2 77.8 78.2 78.7 79

63.1 44.4 34.7 28.7 24.6 21.6 19.4 16.3 14.1 12.6 10.5 9.2 57.4 40.4 31.5 26 22.3 19.7 17.6 14.8 12.8 11.4 9.6 8.3 51.7 36.3 28.4 23.4 20.1 17.7 15.9 13.3 11.6 10.3 8.6 7.5 45.9 32.3 25.2 20.8 17.9 15.7 14.1 11.8 10.3 9.2 7.6 6.7 40.2 28.3 22.1 18.2 15.6 13.8 12.4 10.3 9 8 6.7 1 5.8

55.2 66.9 72.8 76.5 79 80.8 82.1 83.9 85.1 85.9 87 87.6 58.4 68.9 74.4 77.8 80 81.6 82.8 84.4 85.5 86.3 87.2 87.9 61.5 71.1 76 79 81 82.4 83.5 85 85.9 86.6 87.5 88.1 64.7 73.2 77.5 80.2 82 83.3 84.2 85.5 86.4 87 87.8 88.3 67.8 75.2 79.1 81.4 83 84.1 84.9 86.1 86.9 87.4 88.1 88.5

57.4 40.4 31.5 26 22.3 19.7 17.6 14.8 12.8 11.4 9.6 8.3 51.7 36.3 28.4 23.4 20.1 17.7 15.9 13.3 11.6 10.3 8.6 7.5 45.9 32.3 25.2 20.8 17.9 15.7 14.1 11.8 10.3 9.2 7.6 6.7 40.2 28.3 22.1 18.2 15.6 13.8 12.4 10.3 981.9 882.4 6.7 5.8 34.4 24.2 18.9 15.6 13.4 11.8 10.6 8.9 7.7 6.9 5.7 5.1

53.4 63.9 69.4 72.8 75 76.6 77.8 79.4 80.5 81.3 82.2 82.9 56.5 66.1 71 74 76 77.4 78.5 80 80.9 81.6 82.5 83.1 59.7 68.2 72.5 75.2 77 78.3 79.2 80.5 81.4 82 82.8 83.3 62.8 70.2 74.1 76.4 78 79.1 79.9 81.1 7.7 6.9 83.1 83.5 66 72.4 75.7 77.7 79 80 80.7 81.6 82.3 82.8 83.4 83.7

51.7 36.3 28.4 23.4 20.1 17.7 15.9 13.3 11.6 10.3 8.6 7.5 45.9 32.3 25.2 20.8 17.9 15.7 14.1 11.8 10.3 9.2 7.6 6.7 40.2 28.3 22.1 18.2 15.6 13.8 12.4 10.3 9 8 6.7 5.8 34.4 24.2 18.9 15.6 13.4 11.8 10.6 8.9 77.3 77.8 5.7 5 28.7 20.2 15.8 13 11.2 9.8 8.8 7.4 6.4 5.7 4.8 1 4.2

51.5 61.1 66 69 71 72.4 73.5 75 75.9 76.6 77.5 78.1 54.7 63.2 67.5 70.2 72 73.3 74.2 75.5 76.4 77 77.8 78.3 57.8 65.2 69.1 71.4 73 74.1 74.9 76.1 76.9 77.4 78.1 78.5 61 67.4 70.7 72.7 74 75 75.7 76.6 13.5 12 78.4 78.7 64.2 69.5 72.2 73.9 75 75.8 76.4 77.2 77.8 78.1 78.6 78.9

78.5 60.2 57.2 69.1 45.3 74.1 37.7 77.2 32.5 79.4 28.6 80.9 25.7 82.1 21.5 83.8 18.6 84.9 16.5 85.8 13.6 86.8 11.8 87.5 71.3 62.9 52 71 41.2 75.5 34.3 78.4 29.5 80.3 26 81.8 23.4 82.8 19.5 84.4 16.9 85.4 15 86.1 12.4 87.1 10.7 87.7 64.2 65.6 46.8 72.9 37.1 77 30.9 79.5 26.6 81.3 23.4 82.6 21 83.6 17.6 84.9 15.2 85.9 13.5 86.5 11.2 87.4 9.6 88 57.1 68.3 41.6 74.8 32.9 78.4 27.4 80.7 23.6 82.3 20.8 83.4 18.7 84.3 15.6 85.5 86.3 11.8 86.9 10.5 9.9 87.7 8.6 88.2 49.9 71.1 36.4 76.7 28.8 79.9 24 81.9 20.7 83.2 18.2 84.2 16.3 85 13.7 86.1 11.8 86.8 10.5 87.3 8.7 88 1 7.5 1 88.4

71.3 52 41.2 34.3 29.5 26 23.4 19.5 16.9 15 12.4 10.7 64.2 46.8 37.1 30.9 26.6 23.4 21 17.6 15.2 13.5 11.2 9.6 57.1 41.6 32.9 27.4 23.6 20.8 18.7 15.6 13.5 12 9.9 8.6 49.9 36.4 28.8 24 20.7 18.2 16.3 13.7 81.8 82.3 8.7 7.5 42.8 31.2 24.7 20.6 17.7 15.6 14 11.7 10.1 9 7.4 1 6.4

57.9 66 70.5 73.4 75.3 76.8 77.8 79.4 80.4 81.1 82.1 82.7 60.6 67.9 72 74.5 76.3 77.6 78.6 79.9 80.9 81.5 82.4 83 63.3 69.8 73.4 75.7 77.3 78.4 79.3 80.5 81.3 81.9 82.7 83.2 66.1 71.7 74.9 76.9 78.2 79.2 80 81.1 10.1 9 83 83.4 68.8 73.6 76.3 78 79.2 80.1 80.7 81.6 82.3 82.7 83.3 1 83.6

64.2 46.8 37.1 30.9 26.6 23.4 21 17.6 15.2 13.5 11.2 9.6 57.1 41.6 32.9 27.4 23.6 20.8 18.7 15.6 13.5 12 9.9 8.6 49.9 36.4 28.8 24 20.7 18.2 16.3 13.7 11.8 10.5 8.7 7.5 42.8 31.2 24.7 20.6 17.7 15.6 14 11.7 77.3 77.7 7.4 6.4 35.7 26 20.6 17.2 14.8 13 11.7 9.8 8.4 7.5 6.2 1 5.4

55.6 62.9 67 69.5 71.3 72.6 73.6 74.9 75.9 76.5 77.4 78 58.3 64.8 68.4 70.7 72.3 73.4 74.3 75.5 76.3 76.9 77.7 78.2 61.1 66.7 69.9 71.9 73.2 74.2 75 76.1 76.8 77.3 78 78.4 63.8 68.6 71.3 73 74.2 75.1 75.7 76.6

78.3 78.6 66.5 70.5 72.8 74.2 75.2 75.9 76.4 77.2 77.7 78.1 78.6 1 78.9




App. A-23

A

APPENDIX A

HEAT GAIN

Table App A-43. Heat Gain Values for Pro150 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 155

Pipe Size = 8", O.D. = 7.87" Ambient Temperature (F) 90 85 80



Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 88.2 65.8 52.8 44.3 38.3 33.9 30.4 25.4 22 19.5 16 13.8 80.2 59.9 48 40.3 34.8 30.8 27.6 23.1 20 17.7 14.6 12.5 72.2 53.9 43.2 36.3 31.4 27.7 24.9 20.8 18 15.9 13.1 11.3 64.2 47.9 38.4 32.2 27.9 24.6 22.1 18.5 16 14.2 11.7 10 56.1 41.9 33.6 28.2 24.4 21.5 19.3 16.2 14 12.4 10.2 8.8

63.2 70.7 74.9 77.7 79.7 81.1 82.3 83.9 84.9 85.7 86.8 87.4 65.7 72.4 76.3 78.8 80.6 81.9 83 84.4 85.4 86.1 87.1 87.7 68.1 74.2 77.7 79.9 81.5 82.7 83.7 85 85.9 86.5 87.4 87.9 70.5 75.9 79 81.1 82.5 83.6 84.4 85.5 86.3 86.9 87.6 88.1 73 77.7 80.4 82.2 83.4 84.4 85.1 86.1 86.8 87.3 87.9 88.4

80.2 59.9 48 40.3 34.8 30.8 27.6 23.1 20 17.7 14.6 12.5 72.2 53.9 43.2 36.3 31.4 27.7 24.9 20.8 18 15.9 13.1 11.3 64.2 47.9 38.4 32.2 27.9 24.6 22.1 18.5 16 14.2 11.7 10 56.1 41.9 33.6 28.2 24.4 21.5 19.3 16.2 14 12.4 10.2 8.8 48.1 35.9 28.8 24.2 20.9 18.5 16.6 13.9 12 10.6 8.8 7.5

60.7 67.4 71.3 73.8 75.6 76.9 78 79.4 80.4 81.1 82.1 82.7 63.1 69.2 72.7 74.9 76.5 77.7 78.7 80 80.9 81.5 82.4 82.9 65.5 70.9 74 76.1 77.5 78.6 79.4 80.5 81.3 81.9 82.6 83.1 68 72.7 75.4 77.2 78.4 79.4 80.1 81.1 81.8 82.3 82.9 83.4 70.4 74.4 76.8 78.3 79.4 80.2 80.8 81.6 82.2 82.7 83.2 83.6

72.2 53.9 43.2 36.3 31.4 27.7 24.9 20.8 18 15.9 13.1 11.3 64.2 47.9 38.4 32.2 27.9 24.6 22.1 18.5 16 14.2 11.7 10 56.1 41.9 33.6 28.2 24.4 21.5 19.3 16.2 14 12.4 10.2 8.8 48.1 35.9 28.8 24.2 20.9 18.5 16.6 13.9 12 10.6 8.8 7.5 40.1 29.9 24 20.1 17.4 15.4 13.8 11.6 10 8.9 7.3 6.3

58.1 64.2 67.7 69.9 71.5 72.7 73.7 75 75.9 76.5 77.4 77.9 60.5 65.9 69 71.1 72.5 73.6 74.4 75.5 76.3 76.9 77.6 78.1 63 67.7 70.4 72.2 73.4 74.4 75.1 76.1 76.8 77.3 77.9 78.4 65.4 69.4 71.8 73.3 74.4 75.2 75.8 76.6 77.2 77.7 78.2 78.6 67.8 71.2 73.2 74.4 75.3 76 76.5 77.2 77.7 78 78.5 78.8

97.6 74.8 61 51.6 44.9 39.8 35.8 30 26 23 18.9 16.2 88.8 68 55.4 46.9 40.8 36.2 32.6 27.3 23.6 20.9 17.2 14.8 79.9 61.2 49.9 42.2 36.7 32.6 29.3 24.6 21.3 18.8 15.5 13.3 71 54.4 44.3 37.5 32.6 28.9 26.1 21.8 18.9 16.7 13.8 11.8 62.1 47.6 38.8 32.8 28.6 25.3 22.8 19.1 16.5 14.7 12 10.3

66.3 72.3 75.9 78.4 80.1 81.4 82.5 84 85 85.7 86.7 87.4 68.5 73.9 77.2 79.4 81 82.2 83.1 84.5 85.4 86.1 87 87.6 70.6 75.5 78.5 80.5 81.9 83 83.8 85 85.9 86.5 87.3 87.9 72.8 77.1 79.8 81.5 82.8 83.8 84.5 85.6 86.3 86.9 87.6 88.1 74.9 78.7 81 82.6 83.7 84.6 85.2 86.1 86.8 87.3 87.9 88.3

88.8 68 55.4 46.9 40.8 36.2 32.6 27.3 23.6 20.9 17.2 14.8 79.9 61.2 49.9 42.2 36.7 32.6 29.3 24.6 21.3 18.8 15.5 13.3 71 54.4 44.3 37.5 32.6 28.9 26.1 21.8 18.9 16.7 13.8 11.8 62.1 47.6 38.8 32.8 28.6 25.3 22.8 19.1 16.5 14.7 12 10.3 53.3 40.8 33.3 28.1 24.5 21.7 19.5 16.4 14.2 12.6 10.3 18.9

63.5 68.9 72.2 74.4 76 77.2 78.1 79.5 80.4 81.1 82 82.6 65.6 70.5 73.5 75.5 76.9 78 78.8 80 80.9 81.5 82.3 82.9 67.8 72.1 74.8 76.5 77.8 78.8 79.5 80.6 81.3 81.9 82.6 83.1 69.9 73.7 76 77.6 78.7 79.6 80.2 81.1 81.8 82.3 82.9 83.3 72.1 75.3 77.3 78.7 79.6 80.3 80.9 81.7 82.3 82.7 83.2 83.6

79.9 61.2 49.9 42.2 36.7 32.6 29.3 24.6 21.3 18.8 15.5 13.3 71 54.4 44.3 37.5 32.6 28.9 26.1 21.8 18.9 16.7 13.8 11.8 62.1 47.6 38.8 32.8 28.6 25.3 22.8 19.1 16.5 14.7 12 10.3 53.3 40.8 33.3 28.1 24.5 21.7 19.5 16.4 14.2 12.6 10.3 8.9 44.4 34 27.7 23.5 20.4 18.1 16.3 13.7 11.8 10.5 8.6 7.4

60.6 65.5 68.5 70.5 71.9 73 73.8 75 75.9 76.5 77.3 77.9 62.8 67.1 69.8 71.5 72.8 73.8 74.5 75.6 76.3 76.9 77.6 78.1 64.9 68.7 71 72.6 73.7 74.6 75.2 76.1 76.8 77.3 77.9 78.3 67.1 70.3 72.3 73.7 74.6 75.3 75.9 76.7 77.3 77.7 78.2 78.6 69.2 72 73.6 74.7 75.5 76.1 76.6 77.2 77.7 78 78.5 78.81

107.3 84.6 70.1 60 52.5 46.8 42.3 35.6 30.9 27.4 22.5 19.3 97.5 76.9 63.7 54.5 47.8 42.6 38.5 32.4 28.1 24.9 20.5 17.5 87.8 69.2 57.3 49.1 43 38.3 34.6 29.1 25.3 22.4 18.4 15.8 78 61.5 51 43.6 38.2 34.1 30.8 25.9 22.5 19.9 16.4 14 68.3 53.8 44.6 38.2 33.4 29.8 26.9 22.7 19.7 17.4 14.3 12.3

69.3 74 77 79.1 80.6 81.8 82.7 84.1 85 85.8 86.7 87.4 71.2 75.5 78.2 80.1 81.5 82.5 83.4 84.6 85.5 86.1 87 87.6 73.1 76.9 79.4 81.1 82.3 83.3 84.1 85.2 85.9 86.5 87.3 87.8 75 78.4 80.6 82.1 83.2 84 84.7 85.7 86.4 86.9 87.6 88.1 76.9 79.8 81.7 83.1 84 84.8 85.4 86.2 86.8 87.3 87.9 88.31

97.5 76.9 63.7 54.5 47.8 42.6 38.5 32.4 28.1 24.9 20.5 17.5 87.8 69.2 57.3 49.1 43 38.3 34.6 29.1 25.3 22.4 18.4 15.8 78 61.5 51 43.6 38.2 34.1 30.8 25.9 22.5 19.9 16.4 14 68.3 53.8 44.6 38.2 33.4 29.8 26.9 22.7 19.7 17.4 14.3 12.3 58.5 46.1 38.2 32.7 28.7 25.5 23.1 19.4 16.9 14.9 12.3 10.5

66.2 70.5 73.2 75.1 76.5 77.5 78.4 79.6 80.5 81.1 82 82.6 68.1 71.9 74.4 76.1 77.3 78.3 79.1 80.2 80.9 81.5 82.3 82.8 70 73.4 75.6 77.1 78.2 79 79.7 80.7 81.4 81.9 82.6 83.1 71.9 74.8 76.7 78.1 79 79.8 80.4 81.2 81.8 82.3 82.9 83.3 73.7 76.3 77.9 79.1 79.9 80.5 81 81.8 82.3 82.7 83.2 83.6

87.8 69.2 57.3 49.1 43 38.3 34.6 29.1 25.3 22.4 18.4 15.8 78 61.5 51 43.6 38.2 34.1 30.8 25.9 22.5 19.9 16.4 14 68.3 53.8 44.6 38.2 33.4 29.8 26.9 22.7 19.7 17.4 14.3 12.3 58.5 46.1 38.2 32.7 28.7 25.5 23.1 19.4 16.9 14.9 12.3 10.5 48.8 38.5 31.9 27.3 23.9 21.3 19.2 16.2 14 12.5 10.2 8.8

63.1 66.9 69.4 71.1 72.3 73.3 74.1 75.2 75.9 76.5 77.3 77.8 65 68.4 70.6 72.1 73.2 74 74.7 75.7 76.4 76.9 77.6 78.1 66.9 69.8 71.7 73.1 74 74.8 75.4 76.2 76.8 77.3 77.9 78.3 68.7 71.3 72.9 74.1 74.9 75.5 76 76.8 77.3 77.7 78.2 78.6 70.6 72.7 74.1 75 75.7 76.3 76.7 77.3 77.8 78.1 78.5 78.8


App. A-24



APPENDIX A

HEAT GAIN

Table App. A-43. Heat Gain Values for Pro 150 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 155





70.9 75.0 77.6 79.5 80.9 82.0 82.9 84.2 85.1 85.8 86.7 87.3 72.6 76.3 78.8 80.5 81.8 82.8 83.6 84.7 85.6 86.2 87.0 87.6 74.3 77.7 79.9 81.4 82.6 83.5 84.2 85.2 86.0 86.6 87.3 87.8 76.1 79.0 81.0 82.4 83.4 84.2 84.8 85.8 86.4 86.9 87.6 88.1 77.8 80.4 82.1 83.3 84.2 84.9 85.5 86.3 86.9 87.3 87.9 88.3

101.9 81.6 68.2 58.7 51.7 46.2 41.8 35.3 30.7 27.2 22.4 19.2 91.8 73.4 61.4 52.9 46.5 41.6 37.7 31.8 27.6 24.5 20.2 17.3 81.6 65.3 54.6 47.0 41.3 37.0 33.5 28.3 24.6 21.8 17.9 15.3 71.4 57.1 47.7 41.1 36.2 32.3 29.3 24.7 21.5 19.1 15.7 13.4 61.2 49.0 40.9 35.2 31.0 27.7 25.1 21.2 18.4 16.3 13.4 11.5

67.6 71.3 73.8 75.5 76.8 77.8 78.6 79.7 80.6 81.2 82.0 82.6 69.3 72.7 74.9 76.4 77.6 78.5 79.2 80.2 81.0 81.6 82.3 82.8 71.1 74.0 76.0 77.4 78.4 79.2 79.8 80.8 81.4 81.9 82.6 83.1 72.8 75.4 77.1 78.3 79.2 79.9 80.5 81.3 81.9 82.3 82.9 83.3 74.5 76.8 78.3 79.3 80.1 80.7 81.1 81.8 82.3 82.7 83.2 83.6

91.8 73.4 61.4 52.9 46.5 41.6 37.7 31.8 27.6 24.5 20.2 17.3 81.6 65.3 54.6 47.0 41.3 37.0 33.5 28.3 24.6 21.8 17.9 15.3 71.4 57.1 47.7 41.1 36.2 32.3 29.3 24.7 21.5 19.1 15.7 13.4 61.2 49.0 40.9 35.2 31.0 27.7 25.1 21.2 18.4 16.3 13.4 11.5 51.0 40.8 34.1 29.4 25.8 23.1 20.9 17.7 15.4 13.6 11.2 9.6

64.3 67.7 69.9 71.4 72.6 73.5 74.2 75.2 76.0 76.6 77.3 77.8 66.1 69.0 71.0 72.4 73.4 74.2 74.8 75.8 76.4 76.9 77.6 78.1 67.8 70.4 72.1 73.3 74.2 74.9 75.5 76.3 76.9 77.3 77.9 78.3 69.5 71.8 73.3 74.3 75.1 75.7 76.1 76.8 77.3 77.7 78.2 78.6 71.3 73.2 74.4 75.2 75.9 76.4 76.8 77.4 77.8 78.1 78.5 78.8

116.7 94.8 80.0 69.3 61.3 55.0 49.9 42.3 36.8 32.7 26.9 23.1 106.1 86.2 72.7 63.0 55.7 50.0 45.4 38.5 33.5 29.8 24.5 21.0 95.5 77.5 65.4 56.7 50.1 45.0 40.9 34.6 30.1 26.8 22.0 18.9 84.9 68.9 58.2 50.4 44.6 40.0 36.3 30.8 26.8 23.8 19.6 16.8 74.3 60.3 50.9 44.1 39.0 35.0 31.8 26.9 23.4 20.8 17.1 14.7

72.3 75.9 78.2 80.0 81.3 82.3 83.1 84.3 85.2 85.8 86.7 87.3 73.9 77.1 79.3 80.9 82.1 83.0 83.7 84.8 85.6 86.2 87.0 87.6 75.5 78.4 80.4 81.8 82.9 83.7 84.3 85.3 86.1 86.6 87.3 87.8 77.1 79.7 81.4 82.7 83.6 84.4 85.0 85.9 86.5 87.0 87.6 88.1 78.7 81 82.5 83.6 84.4 85.1 85.6 86.4 86.9 87.4 87.9 88.3

106.1 86.2 72.7 63.0 55.7 50.0 46.4 38.5 33.5 29.8 24.5 21.0 95.5 77.5 65.4 56.7 50.1 45.0 40.9 34.6 30.1 26.8 22 18.9 84.9 68.9 58.2 50.4 44.6 40.0 36.3 30.8 26.8 23.8 19.6 16.8 74.3 60.3 50.9 44.1 39.0 35.0 31.8 26.9 23.4 20.8 17.1 14.7 63.7 51.7 43.6 37.8 33.4 30.0 27.2 23.1 20.1 17.9 14.7 12.6

68.9 72.1 74.3 75.9 77.1 78.0 78.7 79.8 80.6 81.2 82.0 82.6 70.5 73.4 75.4 76.8 77.9 78.7 79.3 80.3 81.1 81.6 82.3 82.8 72.1 74.7 76.4 77.7 78.6 79.4 80.0 80.9 81.5 82 82.6 83.1 73.7 76.0 77.5 78.6 79.4 80.1 80.6 81.4 81.9 82.4 82.9 83.3 75.3 77.3 78.6 79.5 80.2 80.8 81.2 81.9 82.4 82.7 83.2 83.6

95.5 77.5 65.4 56.7 50.1 45.0 40.9 34.6 30.1 26.8 22.0 18.9 84.9 68.9 58.2 50.4 44.6 40.0 36.3 30.8 26.8 23.8 19.6 16.8 74.3 60.3 50.9 44.1 39.0 35.0 31.8 26.9 23.4 20.8 17.1 14.7 63.7 51.7 43.6 37.8 33.4 30.0 27.2 23.1 20.1 17.9 14.7 12.6 53.1 43.1 36.4 31.5 27.9 25.0 22.7 19.2 16.7 14.9 12.2 10.5

65.5 68.4 70.4 71.8 72.9 73.7 74.3 75.3 76.1 76.6 77.3 77.8 67.1 69.7 71.4 72.7 73.6 74.4 75.0 75.9 76.5 77.0 77.6 78.1 68.7 71.0 72.5 73.6 74.4 75.1 75.6 76.4 76.9 77.4 77.9 78.3 70.3 72.3 73.6 74.5 75.2 75.8 76.2 76.9 77.4 77.7 78.2 78.6 72.0 73.6 74.7 75.4 76.0 76.5 76.9 77.4 77.8 78.1 78.5 78.8

120.9 99.6 84.9 74.1 65.8 59.3 54.0 45.9 40.1 35.7 29.4 25.2 109.9 90.6 77.2 67.3 59.8 53.9 49.1 41.8 36.5 32.4 26.7 22.9 98.9 81.5 69.5 60.6 53.8 48.5 44.2 37.6 32.8 29.2 24.1 20.6 88.0 72.5 61.7 53.9 47.9 43.1 39.3 33.4 29.2 25.9 21.4 18.3 77.0 63.4 54.0 47.1 41.9 37.7 34.3 29.2 25.5 22.7 18.7 16.1

73.7 76.8 78.9 80.4 81.6 82.5 83.3 84.4 85.3 85.9 86.8 87.4 75.2 78.0 79.9 81.3 82.4 83.2 83.9 84.9 85.7 86.3 87.1 87.6 76.7 79.2 80.9 82.2 83.1 83.9 84.5 85.4 86.1 86.6 87.4 87.8 78.1 80.4 81.9 83.0 83.9 84.6 85.1 86.0 86.6 87.0 87.6 88.1 79.6 81.6 82.9 83.9 84.7 85.3 85.7 86.5 87.0 87.4 87.9 88.3

109.9 90.6 77.2 67.3 59.8 53.9 49.1 41.8 36.5 32.4 26.7 22.9 98.9 81.5 69.5 60.6 53.8 48.5 44.2 37.6 32.8 29.2 24.1 20.6 88.0 72.5 61.7 53.9 47.9 43.1 39.3 33.4 29.2 25.9 21.4 18.3 77.0 63.4 54.0 47.1 41.9 37.7 34.3 29.2 25.5 22.7 18.7 16.0 66.0 54.3 46.3 40.4 35.9 32.3 29.4 25.1 21.9 19.5 16.0 13.7

70.2 73.0 74.9 76.3 77.4 78.2 78.9 79.9 80.7 81.3 82.1 82.6 71.7 74.2 75.9 77.2 78.1 78.9 79.5 80.4 81.1 81.6 82.4 82.8 73.1 75.4 76.9 78.0 78.9 79.6 80.1 81.0 81.6 82.0 82.6 83.1 74.6 76.6 77.9 78.9 79.7 80.3 80.7 81.5 82.0 82.4 82.9 83.3 76.1 77.8 78.9 79.8 80.4 80.9 81.3 82.0 82.4 82.8 83.2 83.6

98.9 81.5 69.5 60.6 53.8 48.5 44.2 37.6 32.8 29.2 24.1 20.6 88.0 72.5 61.7 53.9 47.9 43.1 39.3 33.4 29.2 25.9 21.4 18.3 77.0 63.4 54.0 47.1 41.9 37.7 34.3 29.2 25.5 22.7 18.7 16.0 66.0 54.3 46.3 40.4 35.9 32.3 29.4 25.1 21.9 19.5 16.0 13.7 55.0 45.3 38.6 33.7 29.9 26.9 24.5 20.9 18.2 16.2 13.4 11.5

66.7 69.2 70.9 72.2 73.1 73.9 74.5 75.4 76.1 76.6 77.4 77.8 68.1 70.4 71.9 73.0 73.9 74.6 75.1 76.0 76.6 77.0 77.6 78.1 69.6 71.6 72.9 73.9 74.7 75.3 75.7 76.5 77.0 77.4 77.9 78.3 71.1 72.8 73.9 74.8 75.4 75.9 76.3 77.0 77.4 77.8 78.2 78.6 72.6 74.0 74.9 75.6 76.2 76.6 77.0 77.5 77.9 78.1 78.5 78.8




App. A-25

A

APPENDIX A

HEAT GAIN

Table App. A-44. Heat Gain Values for Pro 150 in Moving Air Conditions Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55


Pipe Size =0.75", O.D. = 0.98" Ambient Temperature (F) 90 85 80



54.8 78.8 83.8 85.9 87.0 87.7 88.1 88.7 89.0 89.2 89.5 89.6 58.0 79.8 84.4 86.3 87.3 87.9 88.3 88.8 89.1 89.3 89.5 89.6 61.2 80.9 85.0 86.7 87.6 88.1 88.5 88.9 89.2 89.4 89.5 89.7 64.4 81.9 85.5 87.0 87.8 88.3 88.7 89.0 89.3 89.4 89.6 89.7 67.6 82.9 86.1 87.4 88.1 88.5 88.8 89.2 89.4 89.5 89.7 89.7

39.7 16.6 11.3 8.9 7.6 6.7 6.1 5.2 4.7 4.3 3.7 3.4 35.7 14.9 10.2 8.1 6.8 6.0 5.4 4.7 4.2 3.8 3.4 3.1 31.8 13.3 9.1 7.2 6.1 5.4 4.8 4.2 3.7 3.4 3.0 2.7 27.8 11.6 7.9 6.3 5.3 4.7 4.2 3.6 3.3 3.0 2.6 2.4 23.8 10.0 6.8 5.4 4.5 4.0 3.6 3.1 2.8 2.6 2.2 2.0

53 74.8 79.4 81.3 82.3 82.9 83.3 83.8 84.1 84.3 84.5 84.6 56.2 75.9 80.0 81.7 82.6 83.1 83.5 83.9 84.2 84.4 84.5 84.7 59.4 76.9 80.5 82.0 82.8 83.3 83.7 84.0 84.3 84.4 84.6 84.7 62.6 77.9 81.1 82.4 83.1 83.5 83.8 84.2 84.4 84.5 84.7 84.7 65.8 78.9 81.6 82.8 83.4 83.8 84.0 84.3 84.5 84.6 84.7 84.8

35.7 14.9 10.2 8.1 6.8 6.0 5.4 4.7 4.2 3.8 3.4 3.1 31.8 13.3 9.1 7.2 6.1 5.4 4.8 4.2 3.7 3.4 3.0 2.7 27.8 11.6 7.9 6.3 5.3 4.7 4.2 3.6 3.3 3.0 2.6 2.4 23.8 10.0 6.8 5.4 4.5 4.0 3.6 3.1 2.8 2.6 2.2 2.0 19.8 8.3 5.7 4.5 3.8 3.3 3.0 2.6 2.3 2.1 1.9 1.7

51.2 70.9 75.0 76.7 77.6 78.1 78.5 78.9 79.2 79.4 79.5 79.7 54.4 71.9 75.5 77.0 77.8 78.3 78.7 79.0 79.3 79.4 79.6 79.7 57.6 72.9 76.1 77.4 78.1 78.5 78.8 79.2 79.4 79.5 79.7 79.7 60.8 73.9 76.6 77.8 78.4 78.8 79.0 79.3 79.5 79.6 79.7 79.8 64.0 74.9 77.2 78.1 78.6 79.0 79.2 79.4 79.6 79.6 79.7 79.8

53.0 21.9 14.7 11.5 9.7 8.5 7.6 6.5 5.8 5.3 4.6 4.1 48.2 19.9 13.4 10.5 8.8 7.7 6.9 5.9 5.2 4.8 4.2 3.8 43.4 17.9 12.1 9.4 7.9 6.9 6.2 5.3 4.7 4.3 3.7 3.4 38.6 15.9 10.7 8.4 7.0 6.2 5.5 4.7 4.2 3.8 3.3 3.0 33.7 13.9 9.4 7.3 6.2 5.4 4.9 4.1 3.7 3.3 2.9 2.6

55.6 78.7 83.7 85.8 86.9 87.6 88.0 88.6 88.9 89.2 89.4 89.6 58.7 79.7 84.2 86.1 87.2 87.8 88.2 88.7 89.0 89.2 89.5 89.6 61.8 80.7 84.8 86.5 87.5 88.0 88.4 88.9 89.1 89.3 89.5 89.6 64.9 81.8 85.4 86.9 87.7 88.2 88.6 89.0 89.2 89.4 89.6 89.7 68.1 82.8 86.0 87.3 88.0 88.5 88.7 89.1 89.3 89.5 89.6 89.7

48.2 19.9 13.4 10.5 8.8 7.7 6.9 5.9 5.2 4.8 4.2 3.8 43.4 17.9 12.1 9.4 7.9 6.9 6.2 5.3 4.7 4.3 3.7 3.4 38.6 15.9 10.7 8.4 7.0 6.2 5.5 4.7 4.2 3.8 3.3 3.0 33.7 13.9 9.4 7.3 6.2 5.4 4.9 4.1 3.7 3.3 2.9 2.6 28.9 11.9 8.0 6.3 5.3 4.6 4.2 3.5 3.1 2.9 2.5 2.3

53.7 74.7 79.2 81.1 82.2 82.8 83.2 83.7 84.0 84.2 84.5 84.6 56.8 75.7 79.8 81.5 82.5 83.0 83.4 83.9 84.1 84.3 84.5 84.6 59.9 76.8 80.4 81.9 82.7 83.2 83.6 84 84.2 84.4 84.6 84.7 63.1 77.8 81.0 82.3 83.0 83.5 83.7 84.1 84.3 84.5 84.6 84.7 66.2 78.8 81.6 82.7 83.3 83.7 83.9 84.3 84.4 84.5 84.7 84.8

43.4 17.9 12.1 9.4 7.9 6.9 6.2 5.3 4.7 4.3 3.7 3.4 38.6 15.9 10.7 8.4 7.0 6.2 5.5 4.7 4.2 3.8 3.3 3.0 33.7 13.9 9.4 7.3 6.2 5.4 4.9 4.1 3.7 3.3 2.9 2.6 28.9 11.9 8.0 6.3 5.3 4.6 4.2 3.5 3.1 2.9 2.5 2.3 24.1 9.9 6.7 5.2 4.4 3.9 3.5 3.0 2.6 2.4 2.1 1.9

51.8 70.7 74.8 76.5 77.5 78.0 78.4 78.9 79.1 79.3 79.5 79.6 54.9 71.8 75.4 76.9 77.7 78.2 78.6 79.0 79.2 79.4 79.6 79.7 58.1 72.8 76.0 77.3 78.0 78.5 78.7 79.1 79.3 79.5 79.6 79.7 61.2 73.8 76.6 77.7 78.3 78.7 78.9 79.3 79.4 79.5 79.7 79.8 64.3 74.9 77.1 78.1 78.6 78.9 79.1 79.4 79.5 79.6 79.7 79.8

65.8 27.1 18.0 13.9 11.6 10.1 9.0 7.6 6.7 6.0 5.2 4.7 59.9 24.6 16.4 12.7 10.5 9.2 8.2 6.9 6.1 5.5 4.7 4.2 53.9 22.1 14.7 11.4 9.5 8.2 7.4 6.2 5.5 4.9 4.3 3.8 47.9 19.7 13.1 10.1 8.4 7.3 6.5 5.5 4.9 4.4 3.8 3.4 41.9 17.2 11.5 8.9 7.4 6.4 5.7 4.8 4.3 3.8 3.3 3.0

56.8 78.6 83.5 B5.6 86.7 87.4 87.9 88.5 88.9 89.1 89.4 89.5 59.7 79.6 84.1 86.0 87.0 87.7 88.1 88.7 89.0 89.2 89.4 89.6 62.8 80.7 84.7 86.4 87.3 87.9 88.3 88.8 89.1 89.3 89.5 89.6 65.8 81.7 85.3 86.8 87.6 88.1 88.5 88.9 89.2 89.3 89.5 89.7 66.8 82.7 85.8 87.2 87.9 88.4 88.7 89.1 89.3 89.4 89.6 89.7

59.9 24.6 16.4 12.7 10.5 9.2 8.2 6.9 6.1 5.5 4.7 4.2 53.9 22.1 14.7 11.4 9.5 8.2 7.4 6.2 5.5 4.9 4.3 3.8 47.9 19.7 13.1 10.1 8.4 7.3 6.5 5.5 4.9 4.4 3.8 3.4 41.9 17.2 11.5 8.9 7.4 6.4 5.7 4.8 4.3 3.8 3.3 3.0 35.9 14.8 9.8 7.6 6.3 5.5 4.9 4.1 3.6 3.3 2.8 2.5

54.7 74.6 79.1 81.0 82.0 82.7 83.1 83.7 84.0 84.2 84.4 84.6 57.8 75.7 79.7 81.4 82.3 82.9 83.3 83.8 84.1 84.3 84.5 84.6 60.8 76.7 80.3 81.8 82.6 83.1 83.5 83.9 84.2 84.3 84.5 84.7 63.8 77.7 80.8 82.2 82.9 83.4 83.7 84.1 84.3 84.4 84.6 84.7 66.9 78.8 81.5 82.6 83.2 83.6 83.9 84.2 84.4 84.5 84.7 84.7

53.9 22.1 14.7 11.4 9.5 8.2 7.4 6.2 5.5 4.9 4.3 3.8 47.9 19.7 13.1 10.1 8.4 7.3 6.5 5.5 4.9 4.4 3.8 3.4 41.9 17.2 11.5 8.9 7.4 6.4 5.7 4.8 4.3 3.8 3.3 3.0 35.9 14.8 9.8 7.6 6.3 5.5 4.9 4.1 3.6 3.3 2.8 2.5 29.9 12.3 8.2 6.3 5.3 4.6 4.1 3.4 3.0 2.7 2.4 2.1

52.8 70.7 74.7 76.4 77.3 77.9 78.3 78.8 79.1 79.3 79.5 79.6 55.8 71.7 75.3 76.8 77.6 78.1 78.5 78.9 79.2 79.3 79.5 79.7 58.8 72.7 75.8 77.2 77.9 78.4 78.7 79.1 79.3 79.4 79.6 79.7 61.9 73.8 76.5 77.6 78.2 78.6 78.9 79.2 79.4 79.5 79.7 79.7 64.9 74.8 77.0 78.0 78.5 78.8 79.1 79.3 79.5 79.6 79.7 79.8


App. A-26



APPENDIX A

HEAT GAIN

Table App. A-44. Heat Gain Values for Pro 150 in Moving Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55




Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 76.6 32.3 21.4 16.5 13.6 11.8 10.5 8.8 7.7 6.9 5.9 5.2 69.6 29.4 19.5 15 .0 12.4 10.7 9.5 8.0 7.0 6.3 5.3 4.8 62.6 26.4 17.5 13.5 11.2 9.7 8.6 7.2 6.3 5.6 4.8 4.3 55.7 23.5 15.6 12.0 9.9 8.6 7.6 6.4 5.6 5.0 4.3 3.8 48.7 20.6 13.6 10.5 8.7 7.5 6.7 5.6 4.9 4.4 3.7 3.3

59.1 78.8 83.5 85.5 86.6 87.3 87.8 88.4 88.8 89.0 89.3 89.5 62.0 79.8 84.0 85.9 86.9 87.6 88.0 88.6 88.9 89.1 89.4 89.5 64.8 80.8 84.6 86.3 87.2 87.8 88.2 88.7 89.0 89.2 89.5 89.6 67.6 81.8 85.2 86.7 87.6 88.1 88.4 88.9 89.1 89.3 89.5 89.6 70.4 82.8 85.8 87.1 87.9 88.3 88.6 89.0 89.2 89.4 89.6 89.7

69.6 29.4 19.5 15.0 12.4 10.7 9.5 8.0 7.0 6.3 5.3 4.8 62.6 26.4 17.5 13.5 11.2 9.7 8.6 7.2 6.3 5.6 4.8 4.3 55.7 23.5 15.6 12.0 9.9 8.6 7.6 6.4 5.6 5.0 4.3 3.8 48.7 20.6 13.6 10.5 8.7 7.5 6.7 5.6 4.9 4.4 3.7 3.3 41.8 17.6 11.7 9.0 7.4 6.4 5.7 4.8 4.2 3.8 3.2 2.9

57.0 74.8 79.0 80.9 81.9 82.6 83.0 83.6 83.9 84.1 84.4 84.5 59.8 75.8 79.6 81.3 82.2 82.8 83.2 83.7 84.0 84.2 84.5 84.6 62.6 76.8 80.2 81.7 82.6 83.1 83.4 83.9 84.1 84.3 84.5 84.6 65.4 77.8 80.8 82.1 82.9 83.3 83.6 84.0 84.2 84.4 84.6 84.7 68.2 78.9 81.4 82.5 83.2 83.6 83.8 84.1 84.3 84.5 84.6 84.7

62.6 26.4 17.5 13.5 11.2 9.7 8.6 7.2 6.3 5.6 4.8 4.3 55.7 23.5 15.6 12.0 9.9 8.6 7.6 6.4 5.6 5.0 4.3 3.8 48.7 20.6 13.6 10.5 8.7 7.5 6.7 5.6 4.9 4.4 3.7 3.3 41.8 17.6 11.7 9.0 7.4 6.4 5.7 4.8 4.2 3.8 3.2 2.9 34.8 14.7 9.7 7.5 6.2 5.4 4.8 4.0 3.5 3.1 2.7 2.4

54.8 70.8 74.6 76.3 77.2 77.8 78.2 78.7 79.0 79.2 79.5 79.6 57.6 71.8 75.2 76.7 77.6 78.1 78.4 78.9 79.1 79.3 79.5 79.6 60.4 72.8 75.8 77.1 77.9 78.3 78.6 79.0 79.2 79.4 79.6 79.7 63.2 73.9 76.4 77.5 78.2 78.6 78.8 79.1 79.3 79.5 79.6 79.7 66.0 74.9 77.0 78.0 78.5 78.8 79.0 79.3 79.5 79.6 79.7 79.8

85.1 37.8 25.2 19.4 16.0 13.8 12.2 10.1 8.8 7.9 6.6 5.9 77.4 34.4 22.9 17.6 14.5 12.5 11.1 9.2 8.0 7.1 6.0 5.3 69.6 30.9 20.6 15.8 13.1 11.3 10.0 8.3 7.2 6.4 5.4 4.8 61.9 27.5 18.3 14.1 11.6 10.0 8.9 7.4 6.4 5.7 4.8 4.3 54.2 24.1 16.0 12.3 10.2 8.8 7.8 6.4 5.6 5.0 4.2 3.7

62.5 79.2 83.5 85.5 86.6 87.3 87.8 88.4 88.7 89.0 89.3 89.5 65.0 80.1 84.1 85.9 86.9 87.5 88.0 88.5 88.9 89.1 89.4 89.5 67.5 81.1 84.7 86.3 87.2 87.8 88.2 88.7 89.0 89.2 89.4 89.6 70.0 82.1 85.3 86.7 87.5 88.0 88.4 88.8 89.1 89.3 89.5 89.6 72.5 83.1 85.9 87.1 87.8 88.3 88.6 89.0 89.2 89.4 89.6 89.71

77.4 34.4 22.9 17.6 14.5 12.5 11.1 9.2 8.0 7.1 6.0 5.3 69.6 30.9 20.6 15.8 13.1 11.3 10.0 8.3 7.2 6.4 5.4 4.8 61.9 27.5 18.3 14.1 11.6 10.0 8.9 7.4 6.4 5.7 4.8 4.3 54.2 24.1 16.0 12.3 10.2 8.8 7.8 6.4 5.6 5.0 4.2 3.7 46.4 20.6 13.8 10.6 8.7 7.5 6.7 5.5 4.8 4.3 3.6 3.2

60.0 75.1 79.1 80.9 81.9 82.5 83.0 83.5 83.9 84.1 84.4 84.5 62.5 76.1 79.7 81.3 82.2 82.8 83.2 83.7 84.0 84.2 84.4 84.6 65.0 77.1 80.3 81.7 82.5 83.0 83.4 83.8 84.1 84.3 84.5 84.6 67.5 78.1 80.9 82.1 82.8 83.3 83.6 84.0 84.2 84.4 84.6 84.7 70.0 79.1 81.4 82.5 83.1 83.5 83.8 84.1 84.3 84.4 84.6 84.7

69.6 30.9 20.6 15.8 13.1 11.3 10.0 8.3 7.2 6.4 5.4 4.8 61.9 27.5 18.3 14.1 11.6 10.0 8.9 7.4 6.4 5.7 4.8 4.3 54.2 24.1 16.0 12.3 10.2 8.8 7.8 6.4 5.6 5.0 4.2 3.7 46.4 20.6 13.8 10.6 8.7 7.5 6.7 5.5 4.8 4.3 3.6 3.2 38.7 17.2 11.5 8.8 7.3 6.3 5.5 4.6 4.0 3.6 3.0 2.7

57.5 71.1 74.7 76.3 77.2 77.8 78.2 78.7 79.0 79.2 79.4 79.6 60.0 72.1 75.3 76.7 77.5 78.0 78.4 78.8 79.1 79.3 79.5 79.6 62.5 73.1 75.9 77.1 77.8 78.3 78.6 79.0 79.2 79.4 79.6 79.7 65.0 74.1 76.4 77.5 78.1 78.5 78.8 79.1 79.3 79.4 79.6 79.7 67.5 75.1 77.0 77.9 78.4 78.8 79.0 79.3 79.4 79.5 79.7 79.8

94.8 44.5 30.0 23.0 18.9 16.3 14.4 11.8 10.2 9.1 7.6 6.7 86.2 40.5 27.2 20.9 17.2 14.8 13.1 10.8 9.3 8.3 6.9 6.1 77.6 36.4 24.5 18.8 15.5 13.3 11.8 9.7 8.4 7.4 6.2 5.5 69.0 32.4 21.8 16.7 13.8 11.8 10.4 8.6 7.4 6.6 5.5 4.9 60.3 28.3 19.1 14.6 12.1 10.4 9.1 7.5 6.5 5.8 4.9 4.3

65.7 79.6 83.6 85.5 86.5 87.2 87.7 88.3 88.7 88.9 89.3 89.4 67.9 80.6 84.2 85.9 86.9 87.5 87.9 88.5 88.8 89.0 89.3 89.5 70.1 81.5 84.8 86.3 87.2 87.7 88.1 88.6 88.9 89.1 89.4 89.5 72.3 82.4 85.3 86.7 87.5 88.0 88.3 88.8 89.1 89.2 89.5 89.6 74.5 83.4 85.9 87.1 87.8 88.2 88.5 88.9 89.2 89.3 89.5 89.6

86.2 40.5 27.2 20.9 17.2 14.8 13.1 10.8 9.3 8.3 6.9 6.1 77.6 36.4 24.5 18.8 15.5 13.3 11.8 9.7 8.4 7.4 6.2 5.5 69.0 32.4 21.8 16.7 13.8 11.8 10.4 8.6 7.4 6.6 5.5 4.9 60.3 28.3 19.1 14.6 12.1 10.4 9.1 7.5 6.5 5.8 4.9 4.3 51.7 24.3 16.3 12.6 10.3 8.9 7.8 6.5 5.6 5.0 4.2 3.7

62.9 75.6 79.2 80.9 81.9 82.5 82.9 83.5 83.8 84.0 84.3 84.5 65.1 76.5 79.8 81.3 82.2 82.7 83.1 83.6 83.9 84.1 84.4 84.5 67.3 77.4 80.3 81.7 82.5 83.0 83.3 83.8 84.1 84.2 84.5 84.6 69.5 78.4 80.9 82.1 82.8 83.2 83.5 83.9 84.2 84.3 84.5 84.6 71.7 79.3 81.5 82.5 83.1 83.5 83.8 84.1 84.3 84.4 84.6 84.7

77.6 36.4 24.5 18.8 15.5 13.3 11.8 9.7 8.4 7.4 6.2 5.5 69.0 32.4 21.8 16.7 13.8 11.8 10.4 8.6 7.4 6.6 5.5 4.9 60.3 28.3 19.1 14.6 12.1 10.4 9.1 7.5 6.5 5.8 4.9 4.3 51.7 24.3 16.3 12.6 10.3 8.9 7.8 6.5 5.6 5.0 4.2 3.7 43.1 20.2 13.6 10.5 8.6 7.4 6.5 5.4 4.6 4.1 3.5 3.0

60.1 71.5 74.8 76.3 77.2 77.7 78.1 78.6 78.9 79.1 79.4 79.5 62.3 72.4 75.3 76.7 77.5 78.0 78.3 78.8 79.1 79.2 79.5 79.6 64.5 73.4 75.9 77.1 77.8 78.2 78.5 78.9 79.2 79.3 79.5 79.6 66.7 74.3 76.5 77.5 78.1 78.5 78.8 79.1 79.3 79.4 79.6 79.7 68.9 75.3 77.1 77.9 78.4 78.7 79.0 79.2 79.4 79.5 79.7 79.7




App. A-27

A

APPENDIX A

HEAT GAIN

Table App. A-44. Heat Gain Values for Pro 150 in Moving Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





70.2 80.5 83.9 85.5 86.5 87.2 87.6 88.2 88.6 88.9 89.2 89.4 72.0 81.3 84.4 85.9 86.8 87.4 87.9 88.4 88.7 89.0 89.3 89.4 73.8 82.2 85.0 86.3 87.2 87.7 88.1 88.6 88.9 89.1 89.3 89.5 75.6 83.1 85.5 86.8 87.5 88.0 88.3 88.7 89.0 89.2 89.4 89.6 77.4 84.0 86.1 87.2 87.8 88.2 88.5 88.9 89.1 89.3 89.5 89.6

99.9 51.5 35.4 27.3 22.5 19.3 17.0 13.9 11.9 10.5 8.7 7.5 89.9 46.3 31.9 24.6 20.3 17.4 15.3 12.5 10.7 9.5 7.8 6.8 79.9 41.2 28.3 21.9 18.0 15.4 13.6 11.1 9.5 8.4 7.0 6.0 69.9 36.0 24.8 19.1 15.8 13.5 11.9 9.7 8.3 7.4 6.1 5.3 59.9 30.9 21.2 16.4 13.5 11.6 10.2 8.3 7.1 6.3 5.2 4.5

67.0 76.3 79.4 80.9 81.8 82.4 82.9 83.4 83.7 84.0 84.3 84.4 68.8 77.2 80.0 81.3 82.2 82.7 83.1 83.6 83.9 84.1 84.3 84.5 70.6 78.1 80.5 81.8 82.5 83.0 83.3 83.7 84.0 84.2 84.4 84.6 72.4 79.0 81.1 82.2 82.8 83.2 83.5 83.9 84.1 84.3 84.5 84.6 74.2 79.8 81.7 82.6 83.1 83.5 83.7 84.0 84.3 84.4 84.6 84.7

89.9 46.3 31.9 24.6 20.3 17.4 15.3 12.5 10.7 9.5 7.8 6.8 79.9 41.2 28.3 21.9 18.0 15.4 13.6 11.1 9.5 8.4 7.0 6.0 69.9 36.0 24.8 19.1 15.8 13.5 11.9 9.7 8.3 7.4 6.1 5.3 59.9 30.9 21.2 16.4 13.5 11.6 10.2 8.3 7.1 6.3 5.2 4.5 49.9 25.7 17.7 13.7 11.3 9.6 8.5 6.9 5.9 5.3 4.3 3.8

63.8 72.2 75. 76.3 77.2 77.7 78.1 78.6 78.9 79.1 79.3 79.5 65.6 73.1 75.5 76.8 77.5 78.0 78.3 78.7 79.0 79.2 79.4 79.6 67.4 74.0 76.1 77.2 77.8 78.2 78.5 78.9 79.1 79.3 79.5 79.6 69.2 74.8 76.7 77.6 78.1 78.5 78.7 79.0 79.3 79.4 79.6 79.7 71.0 75.7 7.2 78.0 78.4 78.7 78.9 79.2 79.4 79.5 79.6 79.7

117.8 64.3 44.9 34.9 28.8 24.7 21.7 17.7 15.1 13.3 10.9 9.5 107.1 58.4 40.8 31.7 26.2 22.4 19.7 16.1 13.7 12.1 10.0 8.6 96.4 52.6 36.7 28.6 23.6 20.2 17.8 14.5 12.4 10.9 9.0 7.7 85.7 46.7 32.7 25.4 21.0 18.0 15.8 12.9 11.0 9.7 8.0 6.9 75.0 40.9 28.6 22.2 18.3 15.7 13.8 11.3 9.6 8.5 7.0 6.0

72.7 81.1 84.1 85.6 86.6 87.2 87.6 88.2 88.6 88.8 89.2 89.4 74.3 81.9 84.6 86.0 86.9 87.4 87.8 88.4 88.7 88.9 89.2 89.4 75.8 82.7 85.2 86.4 87.2 87.7 88.1 88.5 88.8 89.1 89.3 89.5 77.4 83.5 85.7 86.8 87.5 87.9 88.3 88.7 89.0 89.2 89.4 89.5 79.0 84.3 86.2 87.2 87.8 88.2 88.5 88.9 89.1 89.3 89.5 89.6

107.1 58.4 40.8 31.7 26.2 22.4 19.7 16.1 13.7 12.1 10.0 8.6 96.4 52.6 36.7 28.6 23.6 20.2 17.8 14.5 12.4 10.9 9.0 7.7 85.7 46.7 32.7 25.4 21.0 18.0 15.8 12.9 11.0 9.7 8.0 6.9 75.0 40.9 28.6 22.2 18.3 15.7 13.8 11.3 9.6 8.5 7.0 6.0 64.3 35.1 24.5 19.0 15.7 13.5 11.8 9.7 8.2 7.3 6.0 5.2

69.3 76.9 79.6 81.0 81.9 82.4 82.8 83.4 83.7 83.9 84.2 84.4 70.8 77.7 80.2 81.4 82.2 82.7 83.1 83.5 83.8 84.1 84.3 84.5 72.4 78.5 80.7 81.8 82.5 82.9 83.3 83.7 84.0 84.2 84.4 84.5 74.6 79.3 81.2 82.2 82.8 83.2 83.5 83.9 84.1 84.3 84.5 84.6 75.5 80.1 81.8 82.6 83.1 83.5 83.7 84 84.2 84.4 84.5 84.6

96.4 52.6 36.7 28.6 23.6 20.2 17.8 14.5 12.4 10.9 9.0 7.7 85.7 46.7 32.7 25.4 21.0 18.0 15.8 12.9 11.0 9.7 8.0 6.9 75.0 40.9 28.6 22.2 18.3 15.7 13.8 11.3 9.6 8.5 7.0 6.0 4.3 35.1 24.5 19.0 15.7 13.5 11.8 9.7 8.2 7.3 6.0 5.2 53.6 29.2 20.4 15.9 13.1 11.2 9.9 8.0 6.9 6.1 5.0 4.3

65.8 72.7 75.2 76.4 77.2 77.7 78.1 78.5 78.8 79.1 79.3 79.5 67.4 73.5 75.7 76.8 77.5 77.9 78.3 78.7 79.0 79.2 79.4 79.5 69.0 74.3 76.2 77.2 77.8 78.2 78.5 78.9 79.1 79.3 79.5 79.6 70.5 75.1 76.8 77.6 78.1 78.5 78.7 79.0 79.2 79.4 79.5 79.6 72.1 75.9 77.3 78.0 78.4 78.7 78.9 79.2 79.4 79.5 79.6 79.7

130.2 79.2 57.5 45.5 37.9 32.6 28.7 23.4 19.9 17.5 14.2 12.2 118.3 72.0 52.3 41.4 34.4 29.6 26.1 21.3 18.1 15.9 12.9 11.1 106.5 64.8 47.1 37.2 31.0 26.7 23.5 19.1 16.3 14.3 11.6 10.0 94.7 57.6 41.8 33.1 27.5 23.7 20.9 17.0 14.5 12.7 10.3 8.9 82.8 50.4 36.6 29.0 24.1 20.7 18.3 14.9 12.7 11.1 9.1 7.8

76.8 82.3 84.6 85.9 86.7 87.2 87.7 88.2 88.6 88.8 89.1 89.3 78.0 83.0 85.1 86.3 87.0 87.5 87.9 88.4 88.7 88.9 89.2 69.4 79.2 83.7 85.6 86.6 87.3 87.7 88.1 88.5 88.8 89.0 89.3 89.4 80.4 84.4 86.1 87.0 87.6 88.0 88.3 88.7 88.9 89.1 89.4 89.5 81.6 85.1 86.6 87.4 87.9 88.3 88.5 88.9 89.1 89.2 89.4 89.6

118.3 72.0 52.3 41.4 34.4 29.6 26.1 21.3 18.1 15.9 12.9 11.1 106.5 64.8 47.1 37.2 31.0 26.7 23.5 19.1 16.3 14.3 11.6 10.0 94.7 57.6 41.8 33.1 27.5 23.7 20.9 17.0 14.5 12.7 10.3 8.9 82.8 50.4 36.6 29.0 24.1 20.7 18.3 14.9 12.7 11.1 9.1 7.8 71.0 43.2 31.4 24.8 20.7 17.8 15.7 12.8 10.9 9.5 7.8 6.6

73.0 78.0 80.1 81.3 82.0 82.5 82.9 83.4 83.7 83.9 84.2 84.4 74.2 78.7 80.6 81.6 82.3 82.7 83.1 83.5 83.8 84.0 84.3 84.4 75.4 79.4 81.1 82.0 82.6 83.0 83.3 83.7 83.9 84.1 84.4 84.5 76.6 80.1 81.6 82.4 82.9 83.3 83.5 83.9 84.1 84.2 84.4 84.6 77.8 80.8 82.1 82.8 83.2 83.5 83.7 84.0 84.2 84.3 84.5 84.6

106.5 64.8 47.1 37.2 31.0 26.7 23.5 19.1 16.3 14.3 11.6 10.0 94.7 57.6 41.8 33.1 27.5 23.7 20.9 17.0 14.5 12.7 10.3 8.9 82.8 50.4 36.6 29.0 24.1 20.7 18.3 14.9 12.7 11.1 9.1 7.8 71.0 43.2 31.4 24.8 20.7 17.8 15.7 12.8 10.9 9.5 7.8 6.6 59.2 36.0 26.1 20.7 17.2 14.8 13.0 10.6 9.1 7.9 6.5 5.5

69.2 73.7 75.6 76.6 77.3 77.7 78.1 78.5 78.8 79.0 79.3 79.4 70.4 74.4 76.1 77.0 77.6 78.0 78.3 78.7 78.9 79.1 79.4 79.5 71.6 75.1 76.6 77.4 77.9 78.3 78.5 78.9 79.1 79.2 79.4 79.6 72.8 75.8 77.1 77.8 78.2 78.5 78.7 79.0 79.2 79.3 79.5 79.6 74.0 76.5 77.6 78.1 78.5 78.8 78.9 79.2 79.3 79.5 79.6 79.7


App. A-28



APPENDIX A

HEAT GAIN


35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





78.9 83.0 85.0 86.1 86.8 87.3 87.7 88.2 88.6 88.8 89.1 89.3 79.9 83.7 85.4 86.4 87.1 87.6 87.9 88.4 88.7 88.9 89.2 89.4 80.9 84.3 85.9 86.8 87.4 87.8 88.1 88.5 88.8 89.0 89.3 89.4 81.9 84.9 86.3 87.2 87.7 88.1 88.3 88.7 89.0 89.1 89.3 89.5 82.9 85.6 86.8 87.5 88.0 88.3 88.5 88.9 89.1 89.2 89.4 89.5

124.7 80.7 60.1 48.2 40.4 34.9 30.8 25.2 21.4 18.8 15.2 13.0 112.2 72.6 54.1 43.4 36.3 31.4 27.7 22.7 19.3 16.9 13.7 11.7 99.7 64.5 48.1 38.5 32.3 27.9 24.7 20.1 17.1 15.0 12.2 10.4 87.3 56.5 42.1 33.7 28.3 24.4 21.6 17.6 15.0 13.1 10.7 9.1 74.8 48.4 36.1 28.9 24.2 20.9 18.5 15.1 12.9 11.3 9.1 7.8

74.9 78.7 80.4 81.4 82.1 82.6 82.9 83.4 83.7 83.9 84.2 84.4 75.9 79.3 80.9 81.8 82.4 82.8 83.1 83.5 83.8 84.0 84.3 84.4 76.9 79.9 81.3 82.2 82.7 83.1 83.3 83.7 84.0 84.1 84.3 84.5 77.9 80.6 81.8 82.5 83.0 83.3 83.5 83.9 84.1 84.2 84.4 84.5 78.9 81.2 82.3 82.9 83.3 83.5 83.7 84.0 84.2 84.3 84.5 84.6

112.2 72.6 54.1 43.4 36.3 31.4 27.7 22.7 19.3 16.9 13.7 11.7 99.7 64.5 48.1 38.5 32.3 27.9 24.7 20.1 17.1 15.0 12.2 10.4 87.3 56.5 42.1 33.7 28.3 24.4 21.6 17.6 15.0 13.1 10.7 9.1 74.8 48.4 36.1 28.9 24.2 20.9 18.5 15.1 12.9 11.3 9.1 7.8 62.3 40.3 30.1 24.1 20.2 17.4 15.4 12.6 10.7 9.4 7.6 6.5

70.9 74.3 75.9 76.8 77.4 77.8 78.1 78.5 78.8 79.0 79.3 79.4 71.9 74.9 76.3 77.2 77.7 78.1 78.3 78.7 79.0 79.1 79.3 79.5 72.9 75.6 76.8 77.5 78.0 78.3 78.5 78.9 79.1 79.2 79.4 79.5 73.9 76.2 77.3 77.9 78.3 78.5 78.7 79.0 79.2 79.3 79.5 79.6 75.0 76.8 77.7 78.2 78.6 78.8 79.0 79.2 79.3 79.4 79.6 79.7

142.7 98.0 75.0 61.1 51.7 44.9 39.8 32.7 27.9 24.4 19.8 16.8 129.7 89.1 68.2 55.5 47.0 40.8 36.2 29.7 25.3 22.2 18.0 15.3 116.7 80.2 61.4 50.0 42.3 36.8 32.6 26.7 22.8 20.0 16.2 13.8 103.8 71.3 54.6 44.4 37.6 32.7 29.0 23.8 20.3 17.8 14.4 12.2 90.8 62.4 47.8 38.9 32.9 28.6 25.4 20.8 17.7 15.5 12.6 10.7

80.8 83.8 85.4 86.3 87.0 87.4 87.8 88.2 88.6 88.8 89.1 89.3 81.6 84.4 85.8 86.7 87.2 87.7 88.0 88.4 88.7 88.9 89.2 89.3 82.4 84.9 86.2 87.0 87.5 87.9 88.2 88.6 88.8 89.0 89.3 89.4 83.3 85.5 86.6 87.3 87.8 88.1 88.4 88.7 89.0 89.1 89.3 89.5 84.1 86.1 87.1 87.7 88.1 88.4 88.6 88.9 89.1 89.2 89.4 89.5

129.7 89.1 68.2 55.5 47.0 40.8 36.2 29.7 25.3 22.2 18.0 15.3 116.7 80.2 61.4 50.0 42.3 36.8 32.6 26.7 22.8 20.0 16.2 13.8 103.8 71.3 54.6 44.4 37.6 32.7 29.0 23.8 20.3 17.8 14.4 12.2 90.8 62.4 47.8 38.9 32.9 28.6 25.4 20.8 17.7 15.5 12.6 10.7 77.8 53.4 40.9 33.3 28.2 24.5 21.7 17.8 15.2 13.3 10.8 9.2

76.6 79.4 80.8 81.7 82.2 82.7 83.0 83.4 83.7 83.9 84.2 84.3 77.4 79.9 81.2 82.0 82.5 82.9 83.2 83.6 83.8 84.0 84.3 84.4 78.3 80.5 81.6 82.3 82.8 83.1 83.4 83.7 84.0 84.1 84.3 84.5 79.1 81.1 82.1 82.7 83.1 83.4 83.6 83.9 84.1 84.2 84.4 84.5 80.0 81.6 82.5 83.0 83.3 83.6 83.8 84.0 84.2 84.3 84.5 84.6

116.7 80.2 61.4 50.0 42.3 36.8 32.6 26.7 22.8 20.0 16.2 13.8 103.8 71.3 54.6 44.4 37.6 32.7 29.0 23.8 20.3 17.8 14.4 12.2 90.8 62.4 47.8 38.9 32.9 28.6 25.4 20.8 17.7 15.5 12.6 10.7 77.8 53.4 40.9 33.3 28.2 24.5 21.7 17.8 15.2 13.3 10.8 9.2 64.9 44.5 34.1 27.8 23.5 20.4 18.1 14.9 12.7 11.1 9.0 7.6

72.4 74.9 76.2 77.0 77.5 77.9 78.2 78.6 78.8 79.0 79.3 79.4 73.3 75.5 76.6 77.3 77.8 78.1 78.4 78.7 79.0 79.1 79.3 79.5 74.1 76.1 77.1 77.7 78.1 78.4 78.6 78.9 79.1 79.2 79.4 79.5 75.0 76.6 77.5 78.0 78.3 78.6 78.8 79.0 79.2 79.3 79.5 79.6 75.8 77.2 77.9 78.3 78.6 78.8 79.0 79.2 79.3 79.4 79.6 79.7

148.0 107.5 84.7 70.1 60.0 52.6 46.9 38.7 33.1 29.0 23.5 20.0 134.6 97.7 77.0 63.8 54.6 47.8 42.6 35.2 30.1 26.4 21.4 18.2 121.1 87.9 69.3 57.4 49.1 43.0 38.3 31.6 27.1 23.8 19.3 16.3 107.7 78.2 61.6 51.0 43.7 38.2 34.1 28.1 24.1 21.1 17.1 14.5 94.2 68.4 53.9 44.6 38.2 33.5 29.8 24.6 21.1 18.5 15.0 12.7

82.4 84.6 85.8 86.6 87.1 87.5 87.9 88.3 88.6 88.8 89.1 89.3 83.1 85.1 86.2 86.9 87.4 87.8 88.0 88.4 88.7 B8.9 89.2 89.3 83.8 85.6 86.6 87.2 87.7 88.0 88.2 88.6 88.8 89.0 89.3 89.4 84.5 86.1 87.0 87.5 87.9 88.2 88.4 88.8 89.0 89.1 89.3 89.5 85.2 86.6 87.3 87.8 88.2 88.4 88.6 88.9 89.1 89.2 89.4 89.5

134.6 97.7 77.0 63.8 54.6 47.8 42.6 35.2 30.1 26.4 21.4 18.2 121.1 87.9 69.3 57.4 49.1 43.0 38.3 31.6 27.1 23.8 19.3 16.3 107.7 78.2 61.6 51.0 43.7 38.2 34.1 28.1 24.1 21.1 17.1 14.5 94.2 68.4 53.9 44.6 38.2 33.5 29.8 24.6 21.1 18.5 15.0 12.7 80.7 58.6 46.2 38.3 32.7 28.7 25.6 21.1 18.0 15.8 12.8 10.9

78.1 80.1 81.2 81.9 82.4 82.8 83.0 83.4 83.7 83.9 84.2 84.3 78.8 80.6 81.6 82.2 82.7 83.0 83.2 83.6 83.8 84.0 84.3 84.4 79.5 81.1 82.0 82.5 82.9 83.2 83.4 83.8 84.0 84.1 84.3 84.5 80.2 81.6 82.3 82.8 83.2 83.4 83.6 83.9 84.1 84.2 84.4 84.5 80.9 82.1 82.7 83.1 83.4 83.7 83.8 84.1 84.2 84.3 94.5 84.6

121.1 87.9 69.3 57.4 49.1 43.0 38.3 31.6 27.1 23.8 19.3 16.3 107.7 78.2 61.6 51.0 43.7 38.2 34.1 28.1 24.1 21.1 17.1 14.5 94.2 68.4 53.9 44.6 38.2 33.5 29.8 24.6 21.1 18.5 15.0 12.7 80.7 58.6 46.2 38.3 32.7 28.7 25.6 21.1 18.0 15.8 12.8 10.9 67.3 48.9 38.5 31.9 27.3 23.9 21.3 17.6 15.0 13.2 10.7 9.1

73.8 75.6 76.6 77.2 77.7 78.0 78.2 78.6 78.8 79 79.3 79.4 74.5 76.1 77.0 77.5 77.9 78.2 78.4 78.8 79.0 79.1 79.3 79.5 75.2 76.6 77.3 77.8 78.2 78.4 78.6 78.9 79.1 79.2 79.4 79.5 75.9 77.1 77.7 78.1 78.4 78.7 78.8 79.1 79.2 79.3 79.5 79.6 76.5 77.5 78.1 78.5 78.7 78.9 79.0 79.2 79.4 79.5 79.6 79.7




App. A-29

A

APPENDIX A

HEAT GAIN

Table App. A-44. Heat Gain Values for Pro 150 in Moving Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55




Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 150.6 112.3 89.8 75.1 64.6 56.0 50.8 42.1 36.1 31.7 25.8 21.9 136.9 102.1 81.7 68.3 58.8 51.7 46.2 38.3 32.9 28.9 23.4 19.9 123.2 91.9 73.5 61.4 52.9 46.5 41.6 34.5 29.6 26 21.1 17.9 109.5 81.7 65.3 54.6 47.0 41.4 37.0 30.6 26.3 23.1 18.7 15.9 95.8 71.5 57.2 47.8 41.1 36.2 32.4 26.8 23.0 20.2 16.4 13.9

83.1 85.0 86.1 86.8 87.3 87.6 87.9 88.3 88.6 88.8 89.1 89.3 83.8 85.4 86.4 87 87.5 87.8 88.1 88.5 88.7 88.9 89.2 89.3 84.4 85.9 86.8 87.3 87.8 88.1 88.3 88.6 88.9 89.0 89.3 89.4 85.0 86.3 87.1 87.6 88.0 88.3 88.5 88.8 89.0 89.1 89.3 89.5 85.6 86.8 87.5 87.9 88.3 88.5 88.7 88.9 89.1 89.2 89.4 89.5

136.9 102.1 81.7 68.3 58.8 51.7 46.2 38.3 32.9 28.9 23.4 19.9 123.2 91.9 73.5 61.4 52.9 46.5 41.6 34.5 29.6 26.0 21.1 17.9 109.5 81.7 65.3 54.6 47.0 41.4 37.0 30.6 26.3 23.1 18.7 15.9 95.8 71.5 57.2 47.8 41.1 36.2 32.4 26.8 23.0 20.2 16.4 13.9 82.1 61.3 49.0 41.0 35.3 31.0 27.7 23.0 19.7 17.3 14.1 11.9

78.8 80.4 81.4 82.0 82.5 82.8 83.1 83.5 83.7 83.9 84.2 84.3 79.4 80.9 81.8 82.3 82.8 83.1 83.3 83.6 83.9 84.0 84.3 84.4 80.0 81.3 82.1 82.6 83.0 83.3 83.5 83.8 84.0 84.1 84.3 84.5 80.6 81.8 82.5 82.9 83.3 83.5 83.7 83.9 84.1 84.2 84.4 84.5 81.3 82.3 82.8 83.2 83.5 83.7 83.9 84.1 84.2 84.4 84.5 84.6

123.2 91.9 73.5 61.4 52.9 46.5 41.6 34.5 29.6 26.0 21.1 17.9 109.5 81.7 65.3 54.6 47.0 41.4 37.0 30.6 26.3 23.1 18.7 15.9 95.8 71.5 57.2 47.8 41.1 36.2 32.4 26.8 23.0 20.2 16.4 13.9 82.1 61.3 49.0 41.0 35.3 31.0 27.7 23.0 19.7 17.3 14.1 11.9 68.5 51.0 40.8 34.1 29.4 25.8 23.1 19.2 16.4 14.4 11.7 9.9

74.4 75.9 76.8 77.3 77.8 78.1 78.3 78.6 78.9 79.0 79.3 79.4 75.0 76.3 77.1 77.6 78.0 78.3 78.5 78.8 79.0 79.1 79.3 79.5 75.6 76.8 77.5 77.9 78.3 78.5 78.7 78.9 79.1 79.2 79.4 79.5 76.3 77.3 77.8 78.2 78.5 78.7 78.9 79.1 79.2 79.4 79.5 79.6 76.9 77.7 78.2 78.5 78.8 78.9 79.1 79.2 79.4 79.5 79.6 79.7

152.7 116.8 94.8 80.0 69.3 61.3 55.0 45.8 39.4 34.7 28.2 23.9 138.9 106.2 86.2 72.7 63.0 55.7 50.0 41.6 35.8 31.5 25.6 21.7 125.0 95.6 77.6 65.5 56.7 50.1 45.0 37.5 32.2 28.4 23.0 19.6 111.1 85.0 69.0 58.2 50.4 44.6 40.0 33.3 28.6 25.2 20.5 17.4 97.2 74.3 60.4 50.9 44.1 39.0 35.0 29.1 25.1 22.1 17.9 15.2

83.8 85.4 86.3 86.9 87.4 87.7 88.0 88.4 88.6 88.8 89.1 89.3 84.4 85.8 86.6 87.2 87.6 87.9 88.2 88.5 88.8 88.9 89.2 89.3 84.9 86.2 87.0 87.5 87.8 88.1 88.3 88.7 88.9 89 89.3 89.4 85.5 86.6 87.3 87.8 88.1 88.3 88.5 88.8 89.0 89.1 89.3 89.5 86.1 87.0 87.6 88.0 88.3 88.5 88.7 89.0 89.1 89.2 89.4 89.51

138.9 106.2 86.2 72.7 63.0 55.7 50.0 41.6 35.8 31.5 25.6 21.7 125.0 95.6 77.6 65.5 56.7 50.1 45.0 37.5 32.2 28.4 23.0 19.6 111.1 85.0 69.0 58.2 50.4 44.6 40.0 33.3 28.6 25.2 20.5 17.4 97.2 74.3 60.4 50.9 44.1 39.0 35.0 29.1 25.1 22.1 17.9 15.2 83.3 63.7 51.7 43.6 37.8 33.4 30.0 25.0 21.5 18.9 15.4 13.0

79.4 80.8 81.6 82.2 82.6 82.9 83.2 83.5 83.8 83.9 84.2 84.3 79.9 81.2 82.0 82.5 82.8 83.1 83.3 83.7 83.9 84.0 84.3 84.4 80.5 81.6 82.3 82.8 83.1 83.3 83.5 83.8 84.0 84.1 84.3 84.5 81.1 82.0 82.6 83.0 83.3 83.5 83.7 84.0 84.1 84.2 84.4 84.5 81.6 82.5 83.0 83.3 83.6 83.7 83.9 84.1 84.3 84.4 84.5 84.6

125.0 95.6 77.6 65.5 56.7 50.1 45.0 37.5 32.2 28.4 23.0 19.6 111.1 85.0 69.0 58.2 50.4 44.6 40.0 33.3 28.6 25.2 20.5 17.4 97.2 74.3 60.4 50.9 44.1 39.0 35.0 29.1 25.1 22.1 17.9 15.2 83.3 63.7 51.7 43.6 37.8 33.4 30.0 25.0 21.5 18.9 15.4 13.0 69.4 53.1 43.1 36.4 31.5 27.9 25.0 20.8 17.9 15.8 12.8 10.9

74.9 76.2 77.0 77.5 77.8 78.1 78.3 78.7 78.9 79.0 79.3 79.4 75.5 76.6 77.3 77.8 78.1 78.3 78.5 78.8 79.0 79.1 79.3 79.5 76.1 77.0 77.6 78.0 78.3 78.5 78.7 79.0 79.1 79.2 79.4 79.5 76.6 77.5 78.0 78.3 78.6 78.7 78.9 79.1 79.3 79.4 79.5 79.6 77.2 77.9 78.3 78.6 78.8 79.0 79.1 79.3 79.4 79.5 79.6 79.7

154.5 121.0 99.7 84.9 74.1 65.8 59.3 49.6 42.8 37.7 30.7 26.1 140.5 110.0 90.6 77.2 67.3 59.8 53.9 45.1 38.9 34.3 27.9 23.7 126.4 99.0 81.5 69.5 60.6 53.8 48.5 40.6 35.0 30.9 25.2 21.4 112.4 88.0 72.5 61.8 53.9 47.9 43.1 36.1 31.1 27.5 22.4 19.0 98.3 77.0 63.4 54.0 47.1 41.9 37.7 31.6 27.2 24.0 19.6 16.6

84.4 85.7 86.5 87.1 87.5 87.8 88.0 88.4 88.7 88.8 89.1 89.3 85.0 86.1 86.8 87.3 87.7 88.0 88.2 88.5 88.8 88.9 89.2 89.3 85.5 86.5 87.2 87.6 87.9 88.2 88.4 88.7 88.9 89.1 89.3 89.4 86.0 86.9 87.5 87.9 88.2 88.4 88.6 88.8 89.0 89.2 89.3 89.5 86.5 87.3 87.8 88.1 88.4 88.6 88.8 89.0 89.1 89.3 89.4 89.5

140.5 110.0 90.6 77.2 67.3 59.8 53.9 45.1 38.9 34.3 27.9 23.7 126.4 99.0 81.5 69.5 60.6 53.8 48.5 40.6 35.0 30.9 25.2 21.4 112.4 88.0 72.5 61 .8 53.9 47.9 43.1 36.1 31.1 27.5 22.4 19.0 98.3 77.0 63.4 54.0 47.1 41.9 37.7 31.6 27.2 24.0 19.6 16.6 84.3 66.0 54.4 46.3 40.4 35.9 32.3 27.1 23.3 20.6 16.8 14.2

80.0 81.1 81.8 82.3 82.7 83.0 83.2 83.5 83.8 83.9 84.2 84.3 80.5 81.5 82.2 82.6 82.9 83.2 83.4 83.7 83.9 94.1 84.3 84.4 81.0 81.9 82.5 82.9 83.2 83.4 83.6 83.8 84.0 84.2 84.3 84.5 81.5 82.3 82.8 83.1 83.4 83.6 83.8 84.0 84.1 84.3 84.4 84.5 82.0 82.7 83.1 83.4 83.6 83.8 83.9 84.1 84.3 84.4 84.5 84.6

126.4 99.0 81.5 69.5 60.6 53.8 48.5 40.6 35.0 30.9 25.2 21.4 112.4 88.0 72.5 61.8 53.9 47.9 43.1 36.1 31.1 27.5 22.4 19.0 98.3 77.0 63.4 54.0 47.1 41.9 37.7 31.6 27.2 24.0 19.6 16.6 84.3 66.0 54.4 46.3 40.4 35.9 32.3 27.1 23.3 20.6 16.8 14.2 70.2 55.0 45.3 38.6 33.7 29.9 26.9 22.5 19.5 17.2 14.0 11.9

75.5 76.5 77.2 77.6 77.9 78.2 78.4 78.7 78.9 79.1 79.3 79.4 76.0 76.9 77.5 77.9 78.2 78.4 78.6 78.8 79.0 79.2 79.3 79.5 76.5 77.3 77.8 78.1 78.4 78.6 78.8 79.0 79.1 79.3 79.4 79.5 77.0 77.7 78.1 78.4 78.6 78.8 78.9 79.1 79.3 79.4 79.5 79.6 77.5 78.1 78.4 78.7 78.9 79.0 79.1 79.3 79.4 79.5 79.6 79.7


App. A-30



APPENDIX A

HEAT GAIN

Table App. A-45. Heat Gain Values for Pro 45 in Still Air Conditions Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





40.3 61.0 70.0 75.0 78.1 80.3 81.8 83.9 85.2 86.1 87.2 87.9 44.9 63.6 71.8 76.4 79.2 81.2 82.6 84.5 85.6 86.5 87.5 88.1 49.4 66.2 73.7 77.7 80.3 82.1 83.3 85.0 86.1 86.8 87.7 88.2 53.9 68.9 75.4 79.1 81.4 83.0 84.1 85.6 86.5 87.2 88.0 88.4 58.4 71.5 77.3 80.5 82.5 83.9 84.8 86.1 87.0 87.5 88.2 88.6

46.9 30.2 22.7 18.4 15.7 13.8 12.3 10.4 9.1 8.1 6.9 6.1 42.2 27.2 20.4 16.6 14.1 12.4 11.1 9.3 8.2 7.3 6.2 5.5 37.5 24.1 18.2 14.8 12.6 11.0 9.9 8.3 7.3 6.5 5.5 4.9 32.8 21.1 15.9 12.9 11.0 9.6 8.6 7.3 6.3 5.7 4.8 4.3 28.1 18.1 13.6 11.1 9.4 8.3 7.4 6.2 5.4 4.9 4.1 3.6

39.9 58.6 66.8 71.4 74.2 76.2 77.6 79.5 80.6 81.5 82.5 83.1 44.4 61.2 68.7 72.7 75.3 77.1 78.3 80.0 81.1 61.8 82.7 83.2 48.9 63.9 70.4 74.1 76.4 78.0 79.1 80.6 81.5 82.2 83.0 83.4 53.4 66.5 72.3 75.5 77.5 78.9 79.8 81.1 82.0 82.5 83.2 83.6 58.0 69.2 74.1 76.8 78.6 79.7 80.6 81.7 82.4 82.9 83.5 83.9

42.2 27.2 20.4 16.6 14.1 12.4 11.1 9.3 8.2 7.3 6.2 5.5 37.5 24.1 18.2 14.8 12.6 11.0 9.9 8.3 7.3 6.5 5.5 4.9 32.8 21.1 15.9 12.9 11.0 9.6 8.6 7.3 6.3 5.7 4.8 4.3 28.1 18.1 13.6 11.1 9.4 8.3 7.4 6.2 5.4 4.9 4.1 3.6 23.5 15.1 11.3 9.2 7.8 6.9 6.2 5.2 4.5 4.1 3.4 3.0

39.4 56.2 63.7 67.7 70.3 72.1 73.3 75.0 76.1 76.8 77.7 78.2 43.9 58.9 65.4 69.1 71.4 73.0 74.1 75.6 76.5 77.2 78.0 78.4 48.4 61.5 67.3 70.5 72.5 73.9 74.8 76.1 77.0 77.5 78.2 78.6 53.0 64.2 69.1 71.8 73.6 74.7 75.6 76.7 77.4 77.9 78.5 78.9 57.4 66.8 70.9 73.2 74.6 75.6 76.3 77.2 77.8 78.2 78.7 79.0

70.8 45.3 33.8 27.3 23.0 20.1 17.9 14.9 12.9 11.4 9.5 8.3 64.4 41.2 30.7 24.8 20.9 18.3 16.3 13.5 11.7 10.4 8.7 7.6 58.0 37.0 27.6 22.3 18.8 16.4 14.6 12.2 10.5 9.4 7.8 6.8 51.5 32.9 24.6 19.8 16.8 14.6 13.0 10.8 9.4 8.3 6.9 6.1 45.1 28.8 21.5 17.3 14.7 12.8 11.4 9.5 8.2 7.3 6.1 5.3

42.3 61.5 70.0 74.8 77.9 80.0 81.5 83.6 84.9 85.8 87.0 87.7 46.6 64.0 71.9 76.2 79.0 80.9 82.3 84.2 85.4 86.2 87.2 87.9 50.9 66.7 73.7 77.6 80.1 81.8 83.1 84.7 85.8 86.6 87.5 88.1 55.3 69.3 75.5 79.0 81.2 82.7 83.8 85.3 86.3 87.0 87.8 88.3 59.6 71.9 77.3 80.4 82.3 83.6 84.6 85.9 86.8 87.3 88.1 88.5

64.4 41.2 30.7 24.8 20.9 18.3 16.3 13.5 11.7 10.4 8.7 7.6 58.0 37.0 27.6 22.3 18.8 16.4 14.6 12.2 10.5 9.4 7.8 6.8 51.5 32.9 24.6 19.8 16.8 14.6 13 10.8 9.4 8.3 6.9 6.1 45.1 28.8 21.5 17.3 14.7 12.8 11.4 9.5 8.2 7.3 6.1 5.3 38.6 24.7 18.4 14.9 12.6 11 9.8 8.1 7 6.2 5.2 4.5

41.6 59.0 66.9 71.2 74.0 75.9 77.3 79.2 80.4 81.2 82.2 82.9 45.9 61.7 68.7 72.6 75.1 76.8 78.1 79.7 80.8 81.6 82.5 83.1 50.3 64.3 70.5 74.0 76.2 77.7 78.8 80.3 81.3 82.0 82.8 83.3 54.6 66.9 72.3 75.4 77.3 78.6 79.6 80.9 81.8 82.3 83.1 83.5 59.0 69.4 74.1 76.7 78.4 79.5 80.4 81.5 82.2 82.7 83.4 83.7

58.0 37.0 27.6 22.3 18.8 16.4 14.6 12.2 10.5 9.4 7.8 6.8 51.5 32.9 24.6 19.8 16.8 14.6 13.0 10.8 9.4 8.3 6.9 6.1 45.1 28.8 21.5 17.3 14.7 12.8 11.4 9.5 8.2 7.3 6.1 5.3 38.6 24.7 18.4 14.9 12.6 11.0 9.8 8.1 7.0 6.2 5.2 4.5 32.2 20.6 15.4 12.4 10.5 9.1 8.1 6.8 5.8 5.2 4.3 3.8

40.9 56.7 63.7 67.6 70.1 71.8 73.1 74.7 75.8 76.6 77.5 78.1 45.3 59.3 65.5 69.0 71.2 72.7 73.8 75.3 76.3 77.0 77.8 78.3 49.6 61.9 67.3 70.4 72.3 73.6 74.6 75.9 76.8 77.3 78.1 78.5 54.0 64.4 69.1 71.7 73.4 74.5 75.4 76.5 77.2 77.7 78.4 78.7 58.3 67.0 70.9 73.1 74.5 75.5 76.2 77.1 77.7 78.1 78.6 78.6

83.8 53.8 40.1 32.3 27.2 23.6 21.0 17.4 15.0 13.2 11.0 9.5 76.2 48.9 36.4 29.3 24.7 21.5 19.1 15.8 13.6 12.0 10.0 8.6 68.6 44.0 32.8 26.4 22.2 19.3 17.2 14.2 12.2 10.8 9.0 7.8 61.0 39.1 29.2 23.5 19.8 17.2 15.3 12.6 10.9 9.6 8.0 6.9 53.3 34.2 25.5 20.5 17.3 15.0 13.4 11.0 9.5 8.4 7.0 6.0

43.8 62.0 70.2 74.8 77.8 79.9 81.4 83.4 84.8 85.7 86.8 87.6 48 64.5 72.0 76.2 78.9 80.8 82.2 84.0 85.2 86.1 87.1 87.8 52.2 67.1 73.8 77.6 80.1 81.7 83.0 84.6 85.7 86.5 87.4 88.0 56.4 69.6 75.6 79.0 81.1 82.6 83.7 85.2 86.2 86.9 87.7 88.2 60.6 72.2 77.4 80.4 82.3 83.6 84.5 85.9 86.7 87.3 88.0 88.5

76.2 48.9 36.4 29.3 24.7 21.5 19.1 15.8 13.6 12.0 10.0 8.6 68.6 44.0 32.8 26.4 22.2 19.3 17.2 14.2 12.2 10.8 9.0 7.8 61.0 39.1 29.2 23.5 19.8 17.2 15.3 12.6 10.9 9.6 8.0 6.9 53.3 34.2 25.5 20.5 17.3 15.0 13.4 11.0 9.5 8.4 7.0 6.0 45.7 29.3 21.9 17.6 14.8 12.9 11.5 9.5 8.2 7.2 6.0 5.2

43.0 59.5 67.0 71.2 73.9 75.8 77.2 79.0 80.2 81.1 82.1 82.8 47.2 62.1 68.8 72.6 75.1 76.7 78.0 79.6 80.7 81.5 82.4 83.0 51.4 64.6 70.6 74.0 76.1 77.6 78.7 80.2 81.2 81.9 82.7 83.2 55.6 67.2 72.4 75.4 77.3 78.6 79.5 80.9 81.7 82.3 83.0 83.5 59.8 69.7 74.2 76.7 78.4 79.5 80.3 81.4 82.1 82.7 83.3 83.7

68.6 44.0 32.8 26.4 22.2 19.3 17.2 14.2 12.2 10.8 9.0 7.8 61.0 39.1 29.2 23.5 19.8 17.2 15.3 12.6 10.9 9.6 8.0 6.9 53.3 34.2 25.5 20.5 17.3 15.0 13.4 11.0 9.5 8.4 7.0 6.0 45.7 29.3 21.9 17.6 14.8 12.9 11.5 9.5 8.2 7.2 6.0 5.2 38.1 24.4 18.2 14.7 12.4 10.7 9.5 7.9 6.8 6.0 5.0 4.4

42.2 57.1 63.8 67.6 70.1 71.7 73.0 74.6 75.7 76.5 77.4 78.0 46.4 59.6 65.6 69.0 71.1 72.6 73.7 75.2 76.2 76.9 77.7 78.2 50.6 62.2 67.4 70.4 72.3 73.6 74.5 75.9 76.7 77.3 78.0 78.5 54.8 64.7 69.2 71.7 73.4 74.5 75.3 76.4 77.1 77.7 78.3 78.7 59.0 67.3 71.0 73.1 74.4 75.4 76.1 77.0 77.6 78.0 78.6 78.9




App. A-31

A

APPENDIX A

HEAT GAIN

Table App. A-45. Heat Gain Values for Pro 45 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





46.7 63.0 70.6 74.9 77.8 79.8 81.2 83.2 64.5 85.6 86.7 87.4 60.7 65.5 72.3 76.3 78.9 80.7 82.0 83.9 85.1 85.9 87.0 87.6 54.6 67.9 74.1 77.7 80.0 81.6 82.8 84.5 85.5 86.3 87.3 87.9 58.5 70.4 75.9 79.0 81.1 82.6 83.6 85.1 86.0 86.7 87.6 88.1 62.5 72.8 77.6 80.4 82.2 83.5 84.4 85.7 86.5 87.1 87.9 88.3

103.6 67.2 50.2 40.4 33.9 29.4 26.0 21.3 18.2 16.0 13.1 11.2 93.3 60.5 45.2 36.3 30.5 26.4 23.4 19.2 16.4 14.4 11.8 10.1 82.9 53.8 40.2 32.3 27.1 23.5 20.8 17.1 14.6 12.8 10.5 9.0 72.5 47.1 35.2 28.3 23.7 20.6 18.2 14.9 12.8 11.2 9.2 7.9 62.2 40.3 30.1 24.2 20.4 17.6 15.6 12.8 10.9 9.6 7.9 6.7

45.7 60.5 67.3 71.3 73.9 75.7 70.7 78.9 80.1 80.9 82.0 82.6 49.6 62.9 69.1 72.7 75.0 76.6 77.8 79.5 80.5 81.3 82.3 82.9 63.5 65.4 70.9 74.0 76.1 77.6 78.6 80.1 81.0 81.7 82.6 83.1 57.5 67.8 72.6 75.4 77.2 78.5 79.4 80.7 81.5 82.1 82.9 63.3 61.4 70.3 74.4 76.8 78.3 79.4 80.2 81.3 82.0 82.5 83.2 83.6

93.3 60.5 45.2 36.3 30.5 26.4 23.4 19.2 16.4 14.4 11.8 10.1 82.9 53.8 40.2 32.3 27.1 23.5 20.8 17.1 14.6 12.8 10.5 9.0 72.5 47.1 35.2 28.3 23.7 20.6 18.2 14.9 12.8 11.2 9.2 7.9 62.2 40.3 30.1 24.2 20.4 17.6 15.6 12.8 10.9 9.6 7.9 6.7 51.8 33.6 25.1 20.2 17.0 14.7 13.0 10.7 9.1 8.0 6.6 5.6

44.6 57.9 64.1 67.7 70.0 71.6 72.8 74.5 75.5 76.3 77.3 77.9 48.5 60.4 65.9 69.0 71.1 72.6 73.6 75.1 76.0 76.7 77.6 78.1 52.5 62.8 67.6 70.4 72.2 73.5 74.4 75.7 76.5 77.1 77.9 78.3 56.4 65.3 69.4 71.8 73.3 74.4 75.2 76.3 77.0 77.5 78.2 78.6 60.3 67.7 71.2 73.2 74.4 75.3 76.0 76.9 77.5 77.9 78.5 78.6

135.7 89.1 66.8 53.8 45.2 39.1 34.6 28.3 24.1 21.1 17.1 14.6 123.4 81.0 60.8 48.9 41.1 35.6 31.4 25.7 21.9 19.2 15.6 13.3 111.0 72.9 54.7 44.0 37.0 32.0 28.3 23.1 19.7 17.3 14.0 11.9 98.7 64.8 48.6 39.1 32.9 28.4 25.1 20.6 17.5 15.3 12.5 10.6 86.4 56.7 42.5 34.2 28.8 24.9 22.0 16.0 15.3 13.4 10.9 9.3

48.8 63.8 70.9 75.1 77.6 79.8 81.2 83.2 84.5 85.4 86.6 87.3 52.6 66.2 72.7 76.5 78.9 80.7 82 81.8 65.0 85.8 86.9 87.5 56.3 68.6 74.4 77.8 80.0 81.6 82.8 84.4 85.5 66.2 87.2 87.8 60.1 70.9 76.1 79.2 81.1 82.6 83.6 85.0 86.0 86.6 87.5 88.0 63.8 73.3 77.9 80.5 82.2 83.5 84.4 85.6 86.5 87.1 87.8 88.3

123.4 81.0 60.8 48.9 41.1 35.6 31.4 25.7 21.9 19.2 15.6 13.3 111.0 72.9 54.7 44.0 37.0 32.0 28.3 23.1 19.7 17.3 14.0 11.9 98.7 64.8 48.6 39.1 32.9 28.4 25.1 20.6 17.5 15.3 12.5 10.6 86.4 56.7 42.5 34.2 28.8 24.9 22.0 18.0 15.3 13.4 10.9 9.3 74 48.6 36.5 29.3 24.6 21.3 18.9 15.4 13.1 11.5 9.3 8.0

47.6 61.2 67.7 71.5 73.9 75.7 77.0 78.8 80.0 80.8 81.9 82.5 51.3 63.6 69.4 72.8 75.3 76.6 77.8 79.4 80.5 81.2 82.2 82.8 56.1 65.9 71.1 74.2 76.1 77.6 78.6 80.0 81.0 81.6 82.5 83.0 58.8 68.3 72.9 75.5 77.2 78.5 79.4 80.6 81.5 82.1 82.8 83.3 62.6 70.7 74.6 78.9 78.4 79.4 80.2 81.3 82.0 82.5 83.1 83.5

111.0 72.9 54.7 44.0 37.0 32.0 28.3 23.1 19.7 17.3 14.0 11.9 98.7 64.8 48.6 39.1 2.9 28.4 25.1 20.6 17.5 15.3 12.5 10.6 86.4 56.7 42.5 34.2 28.8 24.9 22.0 18.0 15.3 13.4 10.9 9.3 74.0 48.6 36.5 29.3 24.6 21.3 18.9 15.4 13.1 11.5 9.3 8.0 61.7 40.5 30.4 24.4 20.5 17.8 15.7 12.9 10.9 9.6 7.8 6.6

46.3 58.6 64.4 67.8 70.0 71.6 72.8 74.4 75.5 76.2 77.2 77.8 50.1 60.9 66.1 69.2 71.1 72.6 73.6 75.0 76.0 76.6 77.5 78.0 53.8 63.3 67.9 70.5 72.2 73.5 74.4 75.6 76.5 77.1 77.8 78.3 57.6 65.7 69.6 71.9 73.4 74.4 75.2 76.3 77.0 77.5 78.1 78.5 61.3 68.1 71.3 73.2 74.5 75.3 76.0 76.9 77.5 77.9 78.4 78.8

159.3 106.5 80.4 64.9 54.6 47.3 41.8 34.1 29.0 25.3 20.5 17.4 144.9 96.8 73.1 59.0 49.6 43.0 38.0 31.0 26.4 23.0 18.6 15.8 130.4 87.1 65.8 53.1 44.7 38.7 34.2 27.9 23.7 20.7 16.7 14.2 115.9 77.4 58.5 47.2 39.7 34.4 30.4 24.8 21.1 18.4 14.9 12.6 101.4 67.7 51.2 41.3 34.7 30.1 28.6 21.7 18.4 16.1 13.0 11.0

51.4 64.8 71.4 75.4 78.0 79.8 81.2 83.1 84.4 85.3 86.5 87.2 54.8 67.1 73.1 76.7 79.1 80.7 82 83.7 84.9 85.7 86.8 87.5 58.4 69.4 74.8 78.0 80.2 81.7 82.8 84.4 85.4 86.2 87.1 87.7 61.9 71.7 76.5 79.4 81.3 82.6 83.6 85.0 85.9 86.6 87.4 88.0 65.4 74.0 78.2 80.7 82.4 83.5 84.4 85.6 86.4 87.0 87.8 88.2

144.9 96.8 73.1 59.0 49.6 43.0 38.0 31.0 26.4 23.0 18.6 15.8 130.4 87.1 65.8 53.1 44.7 38.7 34.2 27.9 23.7 20.7 16.7 14.2 115.9 77.4 58.5 47.2 39.7 34.4 30.4 24.8 21.1 18.4 14.9 12.6 101.4 67.7 51.2 41.3 34.7 30.1 26.6 21.7 18.4 16.1 13.0 11.0 86.9 58.1 43.9 35.4 29.8 25.8 22.8 18.6 15.8 13.8 11.2 9.5

49.8 62.1 68.1 71.7 74.1 75.7 77.0 78.7 79.9 80.7 81.8 82.5 53.4 64.4 69.8 73.0 75.2 76.7 77.8 79.4 80.4 81.2 82.1 82.7 56.9 06.7 71.5 74.4 76.3 77.6 78.6 80.0 80.9 81.6 82.4 83.0 60.4 89.0 73.2 75.7 77.4 78.5 79.4 80.6 81.4 82.0 82.8 83.2 63.9 71.3 74.9 77.0 78.4 79.4 00.2 81.2 81.9 82.4 83.1 83.5

130.4 87.1 65.8 53.1 44.7 38.7 34.2 27.9 23.7 20.7 16.7 14.2 115.9 77.4 58.5 47.2 39.7 34.4 30.4 24.8 21.1 18.4 14.9 12.6 101.4 67.7 51.2 41.3 34.7 30.1 26.6 21.7 18.4 16.1 13.0 11.0 86.9 58.1 43.9 35.4 29.8 25.8 22.8 18.6 15.8 13.8 11.2 9.5 72.4 48.4 36.5 29.5 24.8 21.5 19.0 15.5 13.2 11.5 9.3 7.9

48.4 59.4 64.8 68.0 70.2 71.7 72.8 74.4 75.4 76.2 77.1 77.7 51.9 61.7 66.5 69.4 71.3 72.6 73.6 75.0 75.9 76.6 77.4 78.0 55.4 64.0 68.2 70.7 72.4 73.5 74.4 75.6 76.4 77.0 77.8 78.2 58.9 66.3 69.9 72.0 73.4 74.4 75.2 76.2 76.9 77.4 78.1 78.5 62.4 68.5 71.6 73.3 74.5 75.4 76.0 76.9 77.4 77.9 78.4 78.7


App. A-32



APPENDIX A

HEAT GAIN

Table App. A-45. Heat Gain Values for Pro 45 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 040 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 250 2.5 055 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 4O 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55





54.1 66 72 75.7 78.2 79.9 81.3 83.1 84.4 85.2 86.4 87.1 57.3 68.2 73.7 77.0 79.3 80.9 82.1 83.7 84.9 85.7 86.7 87.4 60.6 70.4 75.3 78.3 80.3 81.8 82.9 84.4 85.4 86.1 87.1 87.7 63.9 72.5 77.0 79.6 81.4 82.7 83.6 85.0 85.9 86.5 87.4 87.9 67.1 74.7 78.6 80.9 82.5 83.6 84.4 85.6 86.4 87.0 87.7 88.2

169.6 115. 7 88.2 71.5 60.3 52.3 46.2 37.7 32.0 27.9 22.5 19.0 152.6 104.1 79.4 64.4 54.3 47.0 41.6 33.9 28.8 25.1 20.2 17.1 135.7 92.5 70.5 57.2 48.2 41.8 37.0 30.2 25.6 22.3 18.0 15.2 118.7 81.0 61.7 50.1 42.2 36.6 32.4 26.4 22.4 19.6 15.7 13.3 101.8 69.4 52.9 42.9 36.2 31.4 27.7 22.6 19.2 16.8 13.5 11.4

52.3 63.2 68.7 72.0 74.3 75.9 77.1 78.7 79.9 80.7 81.7 82.4 55.6 65.4 70.3 73.3 75.3 76.8 77.9 79.4 80.4 81.1 82.1 82.7 58.9 67.5 72.0 74.6 76.4 77.7 78.6 80.0 80.9 81.5 82.4 82.9 62.1 69.7 73.6 75.9 77.5 78.6 79.4 80.6 81.4 82.0 82.7 83.2 65.4 71.9 75.2 77.2 78.6 79.5 80.2 81.3 81.9 82.4 83.0 83.4

152.6 104.1 79.4 64.4 54.3 47.0 41.6 33.9 28.8 25.1 20.2 17.1 135.7 92.5 70.5 57.2 48.2 41.8 37.0 30.2 25.6 22.3 18.0 15.2 118.7 81.0 61.7 50.1 42.2 36.6 32.4 26.4 22.4 19.6 15.7 13.3 101.8 69.4 52.9 42.9 36.2 31.4 27.7 22.6 19.2 16.8 13.5 11.4 84.8 57.8 44.1 35.8 30.2 26.1 23.1 18.9 16.0 14.0 11.2 9.5

50.6 60.4 65.3 68.3 70.3 71.8 72.9 74.4 75.4 76.1 77.1 77.7 53.9 62.5 67.0 69.6 71.4 72.7 73.6 75.0 75.9 76.5 77.4 77.9 57.1 64.7 68.6 70.9 72.5 73.6 74.4 75.6 76.4 77.0 77.7 78.2 60.4 66.9 70.2 72.2 73.6 74.5 75.2 76.3 76.9 77.4 78.0 78.4 63.7 69.1 71.8 73.5 74.6 75.4 76.0 76.9 77.4 77.8 78.4 78.7

201.1 138.9 106.6 86.7 73.3 63.6 56.2 45.9 39.0 34.0 27.3 23.0 182.8 126.3 96.9 78.8 66.6 57.8 51.1 41.7 35.4 30.9 24.8 20.9 164.5 113.7 87.2 70.9 59.9 52.0 46.0 37.6 31.9 27.8 22.3 18.8 146.2 101.0 77.5 63.0 53.3 46.2 40.9 33.4 28.3 24.7 19.8 16.7 128.0 88.4 67.8 55.2 46.6 40.4 35.8 29.2 24.8 21.6 17.4 14.6

55.7 66.7 72.4 75.9 78.3 80.0 81.3 83.1 84.4 85.2 86.4 87.1 58.8 68.8 74.0 77.2 79.4 80.9 82.1 83.8 84.9 85.7 86.7 87.4 61.9 70.9 75.6 78.5 80.5 81.8 82.9 84.4 85.4 86.1 87.0 87.6 65.0 73.1 77.2 79.8 81.5 82.8 83.7 85.0 85.9 86.5 87.4 87.9 68.1 75.2 78.8 81.1 82.6 83.7 84.5 85.6 86.4 87.0 87.7 88.2

182.8 126.3 96.9 78.8 66.6 57.8 51.1 41.7 35.4 30.9 24.8 20.9 164.5 113.7 87.2 70.9 59.9 52.0 46.0 37.6 31.9 27.8 22.3 18.8 146.2 101.0 77.5 63.0 53.3 46.2 40.9 33.4 28.3 24.7 19.8 16.7 128.0 88.4 67.8 55.2 46.6 40.4 35.8 29.2 24.8 21.6 17.4 14.6 109.7 75.8 58.1 47.3 40.0 34.7 30.7 25.0 21.3 18.5 14.9 12.5

53.8 63.8 69.0 72.2 74.4 75.9 77.1 78.8 79.9 80.7 81.7 82.4 56.9 65.9 70.6 73.5 75.5 76.8 77.9 79.4 80.4 81.1 82.0 82.6 60.0 68.1 72.2 74.8 76.5 77.8 78.7 80.0 80.9 81.5 82.4 82.9 63.1 70.2 73.8 76.1 77.6 78.7 79.5 80.6 81.4 82.0 82.7 83.2 66.3 72.3 75.4 77.3 78.6 79.6 80.3 81.3 81.9 82.4 83.0 83.4

164.5 113.7 87.2 70.9 59.9 52.0 46.0 37.6 31.9 27.8 22.3 18.8 146.2 101.0 77.5 63.0 53.3 46.2 40.9 33.4 28.3 24.7 19.8 16.7 128.0 88.4 67.8 55.2 46.6 40.4 35.8 29.2 24.8 21.6 17.4 14.6 109.7 75.8 58.1 47.3 40.0 34.7 30.7 25.0 21.3 18.5 14.9 12.5 91.4 63.1 48.4 39.4 33.3 28.9 25.6 20.9 17.7 15.4 12.4 10.5

51.9 60.9 65.6 68.5 70.5 71.8 72.9 74.4 75.4 76.1 77.0 77.6 55.0 63.1 67.2 69.8 71.5 72.8 73.7 75.0 75.9 76.5 77.4 77.9 58.1 65.2 68.8 71.1 72.6 73.7 74.5 75.6 76.4 77.0 77.7 78.2 61.3 67.3 70.4 72.3 73.6 74.6 75.3 76.3 76.9 77.4 78.0 78.4 64.4 69.4 72.0 73.6 74.7 75.5 76.1 76.9 77.4 77.8 78.4 78.7

217.1 151.8 117.1 95.6 80.9 70.3 62.2 50.8 43.1 37.6 30.2 25.4 197.3 138.0 106.4 86.9 73.6 63.9 56.6 46.2 39.2 34.2 27.4 23.1 177.6 124.2 95.8 78.2 66.2 57.5 50.9 41.6 35.3 30.8 24.7 20.8 157.9 110.4 85.1 69.5 58.8 51.1 45.3 37.0 31.4 27.4 21.9 18.5 138.1 96.6 74.5 60.8 51.5 44.7 39.6 32.3 27.5 23.9 19.2 16.2

57.1 67.4 72.8 76.2 78.5 80.1 81.4 83.2 84.4 85.2 86.3 87.1 60.1 69.4 74.4 77.4 79.5 81.0 82.2 83.8 84.9 85.6 86.7 87.3 63.1 71.5 75.9 78.7 80.6 81.9 83.0 84.4 85.4 86.1 87.0 87.6 66.1 73.5 77.5 79.9 81.6 82.8 83.7 85.0 85.9 86.5 87.4 87.9 69.1 75.6 79.1 81.2 82.7 83.7 84.5 85.7 86.4 87.0 87.7 88.1

197.3 138.0 106.4 86.9 73.6 63.9 56.6 46.2 39.2 34.2 27.4 23.1 177.6 124.2 95.8 78.2 66.2 57.5 50.9 41.6 35.3 30.8 24.7 20.8 157.9 110.4 85.1 69.5 58.8 51.1 45.3 37.0 31.4 27.4 21.9 18.5 138.1 96.6 74.5 60.8 51.5 44.7 39.6 32.3 27.5 23.9 19.2 16.2 118.4 82.8 63.9 52.1 44.1 38.3 33.9 27.7 23.5 20.5 16.5 13.8

55.1 64.4 69.4 72.4 74.5 76.0 77.2 78.8 79.9 80.6 81.7 82.3 58.1 66.5 70.9 73.7 75.6 76.9 78.0 79.4 80.4 81.1 82.0 82.6 61.1 68.5 72.5 74.9 76.6 77.8 78.7 80.0 80.9 81.5 82.4 82.9 64.1 70.6 74.1 76.2 77.7 78.7 79.5 80.7 81.4 82.0 82.7 83.1 67.1 72.6 75.6 77.5 78.7 79.6 80.3 81.3 81.9 82.4 83.0 83.4

177.6 124.2 95.8 78.2 66.2 57.5 50.9 41.6 35.3 30.8 24.7 20.8 157.9 110.4 85.1 69.5 58.8 51.1 45.3 37.0 31.4 27.4 21.9 18.5 138.1 96.6 74.5 60.8 51.5 44.7 39.6 32.3 27.5 23.9 19.2 16.2 118.4 82.8 63.9 52.1 44.1 38.3 33.9 27.7 23.5 20.5 16.5 13.8 98.7 69.0 53.2 43.4 36.8 31.9 28.3 23.1 19.6 17.1 13.7 11.5

53.1 61.5 65.9 68.7 70.6 71.9 73.0 74.4 75.4 76.1 77.0 77.6 56.1 63.5 67.5 69.9 71.6 72.8 73.7 75.0 75.9 76.5 77.4 77.9 59.1 65.6 69.1 71.2 72.7 73.7 74.5 75.7 76.4 77.0 77.7 78.1 62.1 67.6 70.6 72.5 73.7 74.6 75.3 76.3 76.9 77.4 78.0 78.4 65.0 69.7 72.2 73.7 74.8 75.5 76.1 76.9 77.4 77.8 78.3 78.7




App. A-33

A

APPENDIX A

HEAT GAIN

Table App. A-45. Heat Gain Values for Pro 45 in Still Air Conditions (continued) Nominal Fluid Insulation Temp Thichness (F) (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





58.7 68.1 73.2 76.5 78.7 80.3 81.5 83.2 84.4 85.2 86.3 87.1 61.6 70.1 74.8 77.7 79.7 81.1 82.2 83.8 84.9 85.6 86.7 87.3 64.4 72.1 76.3 78.9 80.7 82.0 83.0 84.4 85.4 86.1 87.0 87.6 67.3 74.1 77.8 80.2 81.7 82.9 83.8 85.1 85.9 86.5 87.3 87.9 70.1 76.1 79.3 81.4 82.8 83.8 84.6 85.7 86.4 87.0 87.7 88.1

211.0 149.6 116.3 95.3 80.9 70.4 62.4 51.0 43.3 37.8 30.3 25.4 189.9 134.7 104.6 85.8 72.8 63.4 56.2 45.9 39.0 34.0 27.2 22.9 168.8 119.7 93.0 76.2 64.7 56.3 49.9 40.8 34.7 30.2 24.2 20.4 147.7 104.7 81.4 66.7 56.6 49.3 43.7 35.7 30.3 26.4 21.2 17.8 126.6 89.8 69.8 57.2 48.5 42.2 37.4 30.6 26.0 22.7 18.2 15.3

56.6 65.1 69.8 72.7 74.7 76.1 77.2 78.8 79.9 80.6 81.7 82.3 59.4 67.1 71.3 73.9 75.7 77.0 78.0 79.4 80.4 81.1 82.0 82.6 62.3 69.1 72.8 75.2 76.7 77.9 78.8 80.1 80.9 81.5 82.3 82.9 65.1 71.1 74.3 76.4 77.8 78.8 79.6 80.7 81.4 82.0 82.7 83.1 67.9 73.1 75.9 77.6 78.8 79.7 80.4 81.3 81.9 82.4 83.0 83.4

189.9 134.7 104.6 85.8 72.8 63.4 56.2 45.9 39.0 34.0 27.2 22.9 168.8 119.7 93.0 76.2 64.7 56.3 49.9 40.8 34.7 30.2 24.2 20.4 147.7 104.7 81.4 66.7 56.6 49.3 43.7 35.7 30.3 26.4 21.2 17.8 126.6 89.8 69.8 57.2 48.5 42.2 37.4 30.6 26.0 22.7 18.2 15.3 105.5 74.8 58.1 47.6 40.5 35.2 31.2 25.5 21.7 18.9 15.1 12.7

54.4 62.1 66.3 68.9 70.7 72.0 73.0 74.4 75.4 76.1 77.0 77.6 57.3 64.1 67.8 70.2 71.7 72.9 73.8 75.1 75.9 76.5 77.3 77.9 60.1 66.1 69.3 71.4 72.8 73.8 74.6 75.7 76.4 77.0 77.7 78.1 62.9 68.1 70.9 72.6 73.8 74.7 75.4 76.3 76.9 77.4 78.0 78.4 65.8 70.1 72.4 73.8 74.8 75.6 76.1 76.9 77.4 77.8 78.3 78.7

246.6 177.0 138.4 113.9 96.9 84.5 75.0 61.4 52.1 45.4 36.4 30.6 224.2 160.9 125.8 103.5 88.1 76.8 68.1 55.8 47.4 41.3 33.1 27.8 201.8 144.8 113.2 93.2 79.3 69.1 61.3 50.2 42.7 37.2 29.8 25.0 179.3 128.7 100.6 82.8 70.5 61.4 54.5 44.6 37.9 33.1 26.5 22.2 156.9 112.6 88.1 72.5 61.7 53.7 47.7 39.1 33.2 28.9 23.2 19.5

60.1 68.8 73.6 76.7 78.8 80.4 81.6 83.2 84.4 85.2 86.3 87.0 62.8 70.7 75.1 77.9 79.8 81.2 82.3 83.9 84.9 85.7 86.7 87.3 65.5 72.7 76.6 79.1 80.8 82.1 83.1 84.5 85.4 86.1 87.0 87.6 68.3 74.6 78.1 80.3 81.9 83.0 83.9 85.1 85.9 86.5 87.3 87.9 71.0 76.5 79.6 81.5 82.9 83.9 84.6 85.7 86.4 87.0 87.7 88.1

224.2 160.9 125.8 103.5 88.1 76.8 68.1 55.8 47.4 41.3 33.1 27.8 201.8 144.8 113.2 93.2 79.3 69.1 61.3 50.2 42.7 37.2 29.8 25.0 179.3 128.7 100.6 82.8 70.5 61.4 54.5 44.6 37.9 33.1 26.5 22.2 156.9 112.6 88.1 72.5 61.7 53.7 47.7 39.1 33.2 28.9 23.2 19.5 134.5 96.5 75.5 62.1 52.9 46.1 40.9 33.5 28.4 24.8 19.9 16.7

57.8 65.7 70.1 72.9 74.8 76.2 77.3 78.9 79.9 80.7 81.7 82.3 60.5 67.7 71.6 74.1 75.8 77.1 78.1 79.5 80.4 81.1 82.0 82.6 63.3 69.6 73.1 75.3 76.9 78.0 78.9 80.1 80.9 81.5 82.3 82.9 66.0 71.5 74.6 76.5 77.9 78.9 79.6 80.7 81.4 82.0 82.7 83.1 68.7 73.4 76.1 77.7 78.9 79.7 80.4 81.3 81.9 82.4 83.0 83.4

201.8 144.8 113.2 93.2 79.3 69.1 61.3 50.2 42.7 37.2 29.8 25.0 179.3 128.7 100.6 82.8 70.5 61.4 54.5 44.6 37.9 33.1 26.5 22.2 156.9 112.6 88.1 72.5 61.7 53.7 47.7 39.1 33.2 28.9 23.2 19.5 134.5 96.5 75.5 62.1 52.9 46.1 40.9 33.5 28.4 24.8 19.9 16.7 112.1 80.4 62.9 51.8 44.0 38.4 34.1 27.9 23.7 20.7 16.5 13.9

55.5 62.7 66.6 69.1 70.8 72.1 73.1 74.5 75.4 76.1 77.0 77.6 58.3 64.6 68.1 70.3 71.9 73.0 73.9 75.1 75.9 76.5 77.3 77.9 61.0 66.5 69.6 71.5 72.9 73.9 74.6 75.7 76.4 77.0 77.7 78.1 63.7 68.4 71.1 72.7 73.9 74.7 75.4 76.3 76.9 77.4 78.0 78.4 66.4 70.4 72.6 73.9 74.9 75.6 76.2 76.9 77.5 77.8 78.3 78.7

276.4 204.5 162.6 135.2 115.8 101.4 90.3 74.3 63.3 55.2 44.2 37.1 251.3 185.9 147.8 122.9 105.3 92.2 82.1 67.5 57.5 50.2 40.2 33.7 226.2 167.3 133.0 110.6 94.8 83.0 73.9 60.8 51.8 45.2 36.2 30.4 201.0 148.7 118.2 98.3 84.2 73.8 65.7 54.0 46.0 40.1 32.2 27.0 175.9 130.1 103.5 86.0 73.7 64.6 57.5 47.3 40.3 35.1 28.2 23.6

63.4 70.5 74.7 77.4 79.3 80.7 81.8 83.4 84.5 85.3 86.3 87.0 65.8 72.3 76.1 78.5 80.3 81.6 82.5 84.0 85.0 85.7 86.7 87.3 68.2 74.1 77.5 79.7 81.2 82.4 83.3 84.6 85.5 86.1 87.0 87.6 70.7 75.8 78.8 80.8 82.2 83.2 84.0 85.2 86.0 86.6 87.3 87.8 73.1 77.6 80.2 82.0 83.2 84.1 84.8 85.8 86.5 87.0 87.7 88.1

251.3 185.9 147.8 122.9 105.3 92.2 82.1 67.5 57.5 50.2 40.2 33.7 226.2 167.3 133.0 110.6 94.8 83.0 73.9 60.8 51.8 45.2 36.2 30.4 201.0 148.7 118.2 98.3 84.2 73.8 65.7 54.0 46.0 40.1 32.2 27.0 175.9 130.1 103.5 86.0 73.7 64.6 57.5 47.3 40.3 35.1 28.2 23.6 150.8 111.5 88.7 73.7 63.2 55.3 49.3 40.5 34.5 30.1 24.1 20.2

60.8 67.3 71.1 73.5 75.3 76.6 77.5 79.0 80.0 80.7 81.7 82.3 63.2 69.1 72.5 74.7 76.2 77.4 78.3 79.6 80.5 81.1 82.0 82.6 65.7 70.8 73.8 75.8 77.2 78.2 79.0 80.2 81.0 81.6 82.3 82.8 68.1 72.6 75.2 77.0 78.2 79.1 79.8 80.8 81.5 82.0 82.7 83.1 70.5 74.4 76.6 78.1 79.2 79.9 80.5 81.4 82.0 82.4 83.0 83.4

226.2 167.3 133.0 110.6 94.8 83.0 73.9 60.8 51.8 45.2 36.2 30.4 201.0 148.7 118.2 98.3 84.2 73.8 65.7 54.0 46.0 40.1 32.2 27.0 175.9 130.1 103.5 86.0 73.7 64.6 57.5 47.3 40.3 35.1 28.2 23.6 150.8 111.5 88.7 73.7 63.2 55.3 49.3 40.5 34.5 30.1 24.1 20.2 125.6 92.9 73.9 61.4 52.6 46.1 41.1 33.8 28.8 25.1 20.1 16.9

58.2 64.1 67.5 69.7 71.2 72.4 73.3 74.6 75.5 76.1 77.0 77.6 60.7 65.8 68.8 70.8 72.2 73.2 74.0 75.2 76.0 76.6 77.3 77.8 63.1 67.6 70.2 72.0 73.2 74.1 74.8 75.8 76.5 77.0 77.7 78.1 65.5 69.4 71.6 73.1 74.2 74.9 75.5 76.4 77 77.4 78 78.4 67.9 71.1 73 74.3 75.1 75.8 76.3 77 77.5 77.8 78.3 78.6


App. A-34



APPENDIX A

HEAT GAIN

Table App. A-46. Heat Gain Values for Pro 45 in Moving Air Conditions Nominal Fluid Insulation Temp Thichness (F) (inches) 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55

Pipe Size = 2", O.D. = 2.48 Ambient Temperature (F) 90 85 80



Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Heat Surface Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp Gain Temp 152.7 54.1 34.0 25.4 20.5 17.4 15.2 12.4 10.7 9.4 7.9 6.9 138.8 49.2 30.9 23 18.6 15.8 13.9 11.3 9.7 8.6 7.1 6.3 125.0 44.3 27.8 20.7 16.8 14.2 12.5 10.2 8.7 7.7 6.4 5.6 111.1 39.4 24.7 18.4 14.9 12.7 11.1 9.0 7.7 6.9 5.7 5.0 97.2 34.5 21.7 16.1 13.0 11.1 9.7 7.9 6.8 6.0 5.0 4.4

50.8 77.4 82.7 85.0 86.2 87.0 87.6 88.2 88.6 88.9 89.2 89.4 54.4 78.5 83.4 85.5 86.6 87.3 87.8 88.4 88.8 89.0 89.3 89.5 57.9 79.7 84.1 85.9 86.9 87.6 88.0 88.6 88.9 89.1 89.4 89.5 61.5 80.8 84.7 86.4 87.3 87.8 88.2 88.7 89.0 89.2 89.4 89.6 65.0 82.0 85.4 86.8 87.6 88.1 88.4 88.9 89.1 89.3 89.5 89.6

138.8 49.2 30.9 23.0 18.6 15.8 13.9 11.3 9.7 8.6 7.1 6.3 125.0 44.3 27.8 20.7 16.8 14.2 12.5 10.2 8.7 7.7 6.4 5.6 111.1 39.4 24.7 18.4 14.9 12.7 11.1 9.0 7.7 6.9 5.7 5.0 97.2 34.5 21.7 16.1 13.0 11.1 9.7 7.9 6.8 6.0 5.0 4.4 83.3 29.5 18.6 13.8 11.2 9.5 8.3 6.8 5.8 5.1 4.3 3.8

49.4 73.5 78.4 80.5 81.6 82.3 82.8 83.4 83.8 84.0 84.3 84.5 52.9 74.7 79.1 80.9 81.9 82.6 83.0 83.6 83.9 84.1 84.4 84.5 56.5 75.8 79.7 81.4 82.3 82.8 83.2 83.7 84.0 84.2 84.4 84.6 60.0 77.0 80.4 81.8 82.6 83.1 83.4 83.9 84.1 84.3 84.5 84.6 63.6 78.1 81.0 82.3 83.0 83.4 83.7 84.0 84.3 84.4 84.6 84.7

125.0 44.3 27.8 20.7 16.8 14.2 12.5 10.2 8.7 7.7 6.4 5.6 111.1 39.4 24.7 18.4 14.9 12.7 11.1 9.0 7.7 6.9 5.7 5.0 97.2 34.5 21.7 16.1 13.0 11.1 9.7 7.9 6.8 6.0 5.0 4.4 83.3 29.5 18.6 13.8 11.2 9.5 8.3 6.8 5.8 5.1 4.3 3.8 69.4 24.6 15.5 11.5 9.3 7.9 6.9 5.6 4.8 4.3 3.6 3.1

47.9 69.7 74.1 75.9 76.9 77.6 78.0 78.6 78.9 79.1 79.4 79.5 51.5 70.8 74.7 76.4 77.3 77.8 78.2 78.7 79.0 79.2 79.4 79.6 55.0 72.0 75.4 76.8 77.6 78.1 78.4 78.9 79.1 79.3 79.5 79.6 58.6 73.1 76.0 77.3 78.0 78.4 78.7 79.0 79.3 79.4 79.6 79.7 62.2 74.3 76.7 77.7 78.3 78.7 78.9 79.2 79.4 79.5 79.6 79.7

195.1 73.1 46.1 34.2 27.5 23.2 20.2 16.2 13.8 12.1 9.9 8.6 177.3 66.4 41.9 31.1 25.0 21.1 18.3 14.8 12.5 11.0 9.0 7.8 159.6 59.8 37.7 28.0 22.5 19.0 16.5 13.3 11.3 9.9 8.1 7.0 141.9 53.1 33.5 24.8 20.0 16.8 14.7 11.8 10.0 8.8 7.2 6.2 124.1 46.5 29.3 21.7 17.5 14.7 12.8 10.3 8.8 7.7 6.3 5.5

54.9 77.7 82.7 84.9 86.1 86.9 87.4 88.1 88.5 88.8 89.2 89.4 58.1 78.8 83.4 85.4 86.5 87.2 87.7 88.3 88.7 88.9 89.2 89.4 61.3 80.0 84.1 85.8 86.8 87.5 87.9 88.5 88.8 89.0 89.3 89.5 64.5 81.1 84.7 86.3 87.2 87.8 88.1 88.6 88.9 89.1 89.4 89.5 67.7 82.2 85.4 86.8 87.5 88.0 88.4 88.8 89.1 89.3 89.5 89.6

177.3 66.4 41.9 31.1 25.0 21.1 18.3 14.8 12.5 11.0 9.0 7.8 159.6 59.8 37.7 28.0 22.5 19.0 16.5 13.3 11.3 9.9 8.1 7.0 141.9 53.1 33.5 24.8 20.0 16.8 14.7 11.8 10.0 8.8 7.2 6.2 124.1 46.5 29.3 21.7 17.5 14.7 12.8 10.3 8.8 7.7 6.3 5.5 106.4 39.9 25.1 18.6 15.0 12.6 11.0 8.9 7.5 6.6 5.4 4.7

53.1 73.8 78.4 80.4 81.5 82.2 82.7 83.3 83.7 83.9 84.2 84.4 56.3 75.0 79.1 80.8 81.8 82.5 82.9 83.5 83.8 84.0 84.3 84.5 59.5 76.1 79.7 81.3 82.2 82.8 83.1 83.6 83.9 84.1 84.4 84.5 62.7 77.2 80.4 81.8 82.5 83.0 83.4 83.8 84.1 84.3 84.5 84.6 65.9 78.3 81.0 82.2 82.9 83.3 83.6 84.0 84.2 84.4 84.5 84.6

159.6 59.8 37.7 28.0 22.5 19.0 16.5 13.3 11.3 9.9 8.1 7.0 141.9 53.1 33.5 24.8 20.0 16.8 14.7 11.8 10.0 8.8 7.2 6.2 124.1 46.5 29.3 21.7 17.5 14.7 12.8 10.3 8.8 7.7 6.3 5.5 106.4 39.9 25.1 18.6 15.0 12.6 11.0 8.9 7.5 6.6 5.4 4.7 88.7 33.2 20.9 15.5 12.5 10.5 9.2 7.4 6.3 5.5 4.5 3.9

51.3 70.0 74.1 75.8 76.8 77.5 77.9 78.5 78.8 79.0 79.3 79.5 54.5 71.1 74.7 76.3 77.2 77.8 78.1 78.6 78.9 79.1 79.4 79.5 57.7 72.2 75.4 76.8 77.5 78 78.4 78.8 79.1 79.3 79.5 79.6 60.9 73.3 76 77.2 77.9 78.3 78.6 79 79.2 79.4 79.5 79.6 64.0 74.4 76.7 77.7 78.2 78.6 78.8 79.1 79.3 79.5 79.6 79.7

218.4 85.8 54.5 40.4 32.5 27.3 23.7 19.0 16.1 14.0 11.4 9.8 198.5 78.0 49.5 36.8 29.5 24.8 21.6 17.3 14.6 12.8 10.4 8.9 178.7 70.2 44.6 33.1 26.6 22.4 19.4 15.6 13.2 11.5 9.4 8.0 158.8 62.4 39.6 29.4 23.6 19.9 17.3 13.8 11.7 10.2 8.3 7.1 139.0 54.6 34.7 25.7 20.7 17.4 15.1 12.1 10.2 8.9 7.3 6.2

57.9 78.1 82.8 84.9 86.1 86.9 87.4 88.1 88.5 88.8 89.1 89.3 60.8 79.2 83.5 85.4 86.5 87.2 87.6 88.3 86.6 88.9 89.2 89.4 63.7 80.2 84.1 85.9 86.8 87.4 87.9 88.4 88.8 89.0 89.3 89.5 66.7 81.3 84.8 86.3 87.2 87.7 88.1 88.6 88.9 89.1 89.4 89.5 69.6 82.4 85.4 86.8 87.5 88.0 88.4 88.8 89.0 89.2 89.4 89.6

198.5 78.0 49.5 36.8 29.5 24.8 21.6 17.3 14.6 12.8 10.4 8.9 178.7 70.2 44.6 33.1 26.6 22.4 19.4 15.6 13.2 11.5 9.4 8.0 158.8 62.4 39.6 29.4 23.6 19.9 17.3 13.8 11.7 10.2 8.3 7.1 139.0 54.6 34.7 25.7 20.7 17.4 15.1 12.1 10.2 8.9 7.3 6.2 119.1 46.8 29.7 22.1 17.7 14.9 12.9 10.4 8.8 7.7 6.2 5.4

55.8 74.2 78.5 80.4 81.5 82.2 82.6 83.3 83.6 83.9 84.2 84.4 58.7 75.2 79.1 80.9 81.8 82.4 82.9 83.4 83.8 84.0 84.3 84.5 61.7 76.3 79.8 81.3 82.2 82.7 83.1 83.6 83.9 84.1 84.4 84.5 64.6 77.4 80.4 81.8 82.5 83.0 83.4 83.8 84.0 84.2 84.4 84.6 67.5 78.5 81.1 82.2 82.9 83.3 83.6 84.0 84.2 84.3 84.5 84.6

178.7 70.2 44.6 33.1 26.6 22.4 19.4 15.6 13.2 11.5 9.4 8.0 158.8 62.4 39.6 29.4 23.6 19.9 17.3 13.8 11.7 10.2 8.3 7.1 139.0 54.6 34.7 25.7 20.7 17.4 15.1 12.1 10.2 8.9 7.3 6.2 119.1 46.8 29.7 22.1 17.7 14.9 12.9 10.4 8.8 7.7 6.2 5.4 99.3 39.0 24.8 18.4 14.8 12.4 10.8 8.6 7.3 6.4 5.2 4.5

53.7 70.2 74.1 75.9 76.8 77.4 77.9 78.4 78.8 79.0 79.3 79.5 56.7 71.3 74.8 76.3 77.2 77.7 78.1 78.6 78.9 79.1 79.4 79.5 59.6 72.4 75.4 76.8 77.5 78.0 78.4 78.8 79.0 79.2 79.4 79.6 62.5 73.5 76.1 77.2 77.9 78.3 78.6 79.0 79.2 79.3 79.5 79.6 65.4 74.6 76.7 77.7 78.2 78.6 78.8 79.1 79.3 79.4 79.6 79.7




App. A-35

A

APPENDIX A

HEAT GAIN

Table App. A-46. Heat Gain Values for Pro 45 in Moving Air Conditions (continued) Nominal Fluid Insulation Temp (F) Thichness (inches)

A

0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5 0 0.125 0.25 0.375 0.5 0.625 0.75 1 1.25 1.5 2 2.5

35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





46.7 62.0 70.6 74.9 77.8 79.8 81.2 83.2 84.5 85.5 86.7 87.4 50.7 65.5 72.3 76.3 78.9 80.7 82.0 83.9 85.1 85.9 87.0 87.6 54.6 67.9 74.1 77.7 80.0 81.6 82.8 84.5 85.5 86.3 87.3 87.9 58.5 70.4 75.9 79.0 81.1 82.6 83.6 85.1 86.0 86.7 87.6 88.1 62.5 72.8 77.6 80.4 82.2 83.5 84.4 85.7 86.5 87.1 87.9 88.3

103.6 67.2 50.2 40.4 33.9 29.4 26.0 21.3 18.2 16.0 13.1 11.2 93.3 60.5 45.2 36.3 30.5 26.4 23.4 19.2 16.4 14.4 11.8 10.1 82.9 53.8 40.2 32.3 27.1 23.5 20.8 17.1 14.6 12.8 10.5 9.0 72.5 47.1 35.2 28.3 23.7 20.6 18.2 14.9 12.8 11.2 9.2 7.9 62.2 40.3 30.1 24.2 20.4 17.6 15.6 12.8 10.9 9.6 7.9 6.7

45.7 60.5 67.3 71.3 73.9 75.7 77.0 78.9 80.1 80.0 82.0 82.6 49.6 62.9 69.1 72.7 75.0 76.6 77.8 79.5 80.5 81.3 82.3 82.9 53.5 65.4 70.9 74.0 76.1 77.6 78.6 80.1 81.0 81.7 82.6 83.1 57.5 67.8 72.6 75.4 77.2 78.5 79.4 80.7 81.5 82.1 82.9 83.3 61.4 70.3 74.4 76.8 78.3 79.4 80.2 81.3 82.0 82.5 83.2 83.6

93.3 60.5 45.2 36.3 30.5 26.4 23.4 19.2 16.4 14.4 11.8 10.1 82.9 53.8 40.2 32.3 27.1 23.5 20.8 17.1 14.6 12.8 10.5 9.0 72.5 47.1 35.2 28.3 23.7 20.6 18.2 14.9 12.8 11.2 9.2 7.9 62.2 40.3 30.1 24.2 20.4 17.6 15.6 12.8 10.9 9.6 7.9 6.7 51.8 33.6 25.1 20.2 17.0 14.7 13.0 10.7 9.1 8.0 6.6 5.6

44.6 57.9 64.1 67.7 70.0 71.6 72.8 74.5 75.5 76.3 77.3 77.9 48.5 60.4 65.9 69.0 71.1 72.6 73.6 75.1 76.0 76.7 77.6 78.1 52.5 62.8 67.6 70.4 72.2 73.5 74.4 75.7 76.5 77.1 77.9 78.3 56.4 65.3 69.4 71.8 73.3 74.4 75.2 76.3 77.0 77.5 78.2 78.6 60.3 67.7 71.2 73.2 74.4 75.3 76.0 76.9 77.5 77.9 78.5 78.8

300.9 137.0 89.6 67.1 53.9 45.3 39.2 31.1 26.0 22.5 18.0 15.1 273.6 124.5 81.5 61.0 49.0 41.2 35.6 28.3 23.6 20.5 16.3 13.8 246.2 112.1 73.3 54.9 44.1 37.1 32.1 25.5 21.3 18.4 14.7 12.4 218.9 99.6 65.2 48.8 39.2 32.9 28.5 22.6 18.9 16.4 13.1 11.0 191.5 87.2 57.0 42.7 34.3 28.8 24.9 19.8 16.6 14.3 11.4 9.6

65.7 79.3 83.2 85.0 86.1 86.8 87.3 88.0 88.4 88.7 89.0 89.3 67.9 80.2 83.8 85.5 86.5 87.1 87.6 88.2 88.6 88.8 89.1 89.3 70.1 81.2 84.4 85.9 86.8 87.4 87.8 88.4 88.7 88.9 89.2 89.4 72.3 82.2 85.0 86.4 87.2 87.7 88.1 88.5 88.8 89.0 89.3 89.5 74.5 83.2 85.7 86.8 87.5 88.0 88.3 88.7 89.0 89.2 89.4 89.5

273.6 124.5 81.5 61.0 49.0 41.2 35.6 28.3 23.6 20.5 16.3 13.8 246.2 112.1 73.3 54.9 44.1 37.1 32.1 25.5 21.3 18.4 14.7 12.4 218.9 99.6 65.2 48.8 39.2 32.9 28.5 22.6 18.9 16.4 13.1 11.0 191.5 87.2 57.0 42.7 34.3 28.8 24.9 19.8 16.6 14.3 11.4 9.6 164.1 74.7 48.9 36.6 29.4 24.7 21.4 17.0 14.2 12.3 9.8 8.3

62.9 75.2 78.8 80.5 81.5 82.1 82.6 83.2 83.6 83.8 84.1 84.3 65.1 76.2 79.4 80.9 81.8 82.4 82.8 83.4 83.7 83.9 84.2 84.4 67.3 77.2 80.0 81.4 82.2 82.7 83.1 83.5 83.8 84.0 84.3 84.5 69.5 78.2 80.7 81.8 82.5 83.0 83.3 83.7 84.0 84.2 84.4 84.5 71.7 79.1 81.3 82.3 82.9 83.3 83.5 83.9 84.1 84.3 84.5 84.6

246.2 112.1 73.3 54.9 44.1 37.1 32.1 25.5 21.3 18.4 14.7 12.4 218.9 99.6 65.2 48.8 39.2 32.9 28.5 22.6 18.9 16.4 13.1 11.0 191.5 87.2 57.0 42.7 34.3 28.8 24.9 19.8 16.6 14.3 11.4 9.6 164.1 74.7 48.9 36.6 29.4 24.7 21.4 17.0 14.2 12.3 9.8 8.3 136.8 62.3 40.7 30.5 24.5 20.6 17.8 14.1 11.8 10.2 8.2 6.9

60.1 71.2 74.4 75.9 76.8 77.4 77.8 78.4 78.7 78.9 79.2 79.4 62.3 72.2 75.0 76.4 77.2 77.7 78.1 78.5 78.8 79.0 79.3 79.5 64.5 73.2 75.7 76.8 77.5 78.0 78.3 78.7 79.0 79.2 79.4 79.5 66.7 74.1 76.3 77.3 77.9 78.3 78.5 78.9 79.1 79.3 79.5 79.6 68.9 75.1 76.9 77.7 78.2 78.6 78.8 79.1 79.3 79.4 79.6 79.7

328.9 160.3 106.9 80.6 65.0 54.7 47.3 37.5 31.3 27.0 21.5 18.0 299.0 145.7 97.1 73.3 59.1 49.7 43.0 34.1 28.5 24.6 19.5 16.4 269.1 131.2 87.4 66.0 53.2 44.7 38.7 30.7 25.6 22.1 17.6 14.7 239.2 116.6 77.7 58.6 47.3 39.8 34.4 27.3 22.8 19.7 15.6 13.1 209.3 102.0 68.0 51.3 41.4 34.8 30.1 23.9 19.9 17.2 13.7 11.5

68.7 79.9 83.4 85.2 86.2 86.9 87.3 88.0 88.4 88.7 89.0 89.2 70.7 80.8 84.0 85.6 86.5 87.1 87.6 88.2 88.5 88.8 89.1 89.3 72.6 81.7 84.6 86.0 86.9 87.4 87.8 88.3 88.7 88.9 89.2 89.4 74.5 82.6 85.2 86.5 87.2 87.7 88.1 88.5 88.8 89.0 89.3 89.4 76.5 83.6 85.8 86.9 87.6 88.0 88.3 88.7 89.0 89.1 89.4 89.5

299.0 145.7 97.1 73.3 59.1 49.7 43.0 34.1 28.5 24.6 19.5 16.4 269.1 131.2 87.4 66.0 53.2 44.7 38.7 30.7 25.6 22.1 17.6 14.7 239.2 116.6 77.7 58.6 47.3 39.8 34.4 27.3 22.8 19.7 15.6 13.1 209.3 102.0 68.0 51.3 41.4 34.8 30.1 23.9 19.9 17.2 13.7 11.5 179.4 87.4 58.3 44.0 35.5 29.8 25.8 20.5 17.1 14.7 11.7 9.8

65.7 75.8 79.0 80.6 81.5 82.1 82.6 83.2 83.5 83.8 84.1 84.3 67.6 76.7 79.6 81.0 81.9 82.4 82.8 83.3 83.7 83.9 84.2 84.4 69.5 77.6 80.2 81.5 82.2 82.7 83.1 83.5 83.8 84.0 84.3 84.4 71.5 78.6 80.8 81.9 82.6 83.0 83.3 83.7 84.0 84.1 84.4 84.5 73.4 79.5 81.4 82.4 82.9 83.3 83.6 83.9 84.1 84.3 84.5 84.6

269.1 131.2 87.4 66.0 53.2 44.7 38.7 30.7 25.6 22.1 17.6 14.7 239.2 116.6 77.7 58.6 47.3 39.8 34.4 27.3 22.8 19.7 15.6 13.1 209.3 102.0 68.0 51.3 41.4 34.8 30.1 23.9 19.9 17.2 13.7 11.5 179.4 87.4 58.3 44.0 35.5 29.8 25.8 20.5 17.1 14.7 11.7 9.8 149.5 72.9 48.6 36.6 29.6 24.9 21.5 17.1 14.2 12.3 9.8 8.2

62.6 71.7 74.6 76.0 76.9 77.4 77.8 78.3 78.7 78.9 79.2 79.4 64.5 72.6 75.2 76.5 77.2 77.7 78.1 78.5 78.8 79.0 79.3 79.4 66.5 73.6 75.8 76.9 77.6 78.0 78.3 78.7 79.0 79.1 79.4 79.5 68.4 74.5 76.4 77.4 77.9 78.3 78.6 78.9 79.1 79.3 79.5 79.6 70.3 75.4 77.0 77.8 78.3 78.6 78.8 79.1 79.3 79.4 79.5 79.6


App. A-36



APPENDIX A

HEAT GAIN


35 35 35 35 35 35 35 35 35 35 35 35 40 40 40 40 40 40 40 40 40 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50 50 50 50 55 55 55 55 55 55 55 55 55 55 55 55





71.6 80.6 83.7 85.3 86.3 86.9 87.4 88.0 88.4 88.6 89.0 89.2 73.3 81.4 84.3 85.7 86.6 87.2 87.6 88.2 88.5 88.8 89.1 89.3 75.0 82.3 84.9 86.2 86.9 87.5 87.8 88.3 88.7 88.9 89.2 89.4 76.6 83.2 85.4 86.6 87.3 87.7 88.1 88.5 88.8 89.0 89.3 89.4 78.3 84.0 86.0 87.0 87.6 88.0 88.3 88.7 89.0 89.1 89.4 89.5

325.4 170.2 115.9 88.3 71.6 60.4 52.3 41.5 34.6 29.8 23.6 19.7 292.9 153.2 104.3 79.5 64.4 54.3 47.1 37.4 31.2 26.8 21.2 17.7 260.3 136.1 92.7 70.7 57.3 48.3 41.8 33.2 27.7 23.9 18.9 15.8 227.8 119.1 81.2 61.8 50.1 42.3 36.6 29.1 24.2 20.9 16.5 13.8 195.3 102.1 69.6 53.0 43.0 36.2 31.4 24.9 20.8 17.9 14.2 11.8

68.3 76.4 79.3 80.7 81.6 82.2 82.6 83.2 83.5 83.8 84.1 84.3 70.0 77.3 79.9 81.2 81.9 82.5 82.8 83.3 83.7 83.9 84.2 84.4 71.6 78.2 80.4 81.6 82.3 82.7 83.1 83.5 83.8 84.0 84.3 84.4 73.3 79.0 81.0 82.0 82.6 83.0 83.3 83.7 84.0 84.1 84.4 84.5 75.0 79.9 81.6 82.4 83.0 83.3 83.6 83.9 84.1 84.3 84.4 84.6

292.9 153.2 104.3 79.5 64.4 54.3 47.1 37.4 31.2 26.8 21.2 17.7 260.3 136.1 92.7 70.7 57.3 48.3 41.8 33.2 27.7 23.9 18.9 15.8 227.8 119.1 81.2 61.8 50.1 42.3 36.6 29.1 24.2 20.9 16.5 13.8 195.3 102.1 69.6 53.0 43.0 36.2 31.4 24.9 20.8 17.9 14.2 11.8 162.7 85.1 58.0 44.2 35.8 30.2 26.2 20.8 17.3 14.9 11.8 9.9

65.0 72.3 74.9 76.2 76.9 77.5 77.8 78.3 78.7 78.9 79.2 79.4 66.6 73.2 75.4 76.6 77.3 77.7 78.1 78.5 78.8 79.0 79.3 79.4 68.3 74.0 76.0 77.0 77.6 78.0 78.3 78.7 79.0 79.1 79.4 79.5 70.0 74.9 76.6 77.4 78.0 78.3 78.6 78.9 79.1 79.3 79.4 79.6 71.6 75.7 77.1 77.9 78.3 78.6 78.8 79.1 79.3 79.4 79.5 79.6

370.9 201.6 139.1 106.7 86.8 73.3 63.6 50.5 42.1 36.3 28.7 23.9 337.2 183.2 126.5 97.0 78.9 66.6 57.8 45.9 38.3 33.0 26.1 21.7 303.5 164.9 113.8 87.3 71.0 60.0 52.0 41.3 34.5 29.7 23.5 19.6 269.8 146.6 101.2 77.6 63.1 53.3 46.3 36.8 30.6 26.4 20.9 17.4 236.0 128.3 88.5 67.9 55.2 46.6 40.5 32.2 26.8 23.1 18.2 15.2

73.1 81.0 83.9 85.4 86.3 86.9 87.4 88.0 88.4 88.6 89.0 89.2 74.6 81.8 84.4 85.8 86.6 87.2 87.6 88.2 88.5 88.8 89.1 89.3 76.2 82.6 85.0 86.2 87.0 87.5 87.9 88.4 88.7 88.9 89.2 89.3 77.7 83.4 85.6 86.6 87.3 87.8 88.1 88.5 88.8 89.0 89.3 89.4 79.3 84.3 86.1 87.1 87.7 88.1 88.3 88.7 89.0 89.1 89.4 89.5

337.2 183.2 126.5 97.0 78.9 66.6 57.8 45.9 38.3 33.0 26.1 21.7 303.5 164.9 113.8 87.3 71.0 60.0 52.0 41.3 34.5 29.7 23.5 19.6 269.8 146.6 101.2 77.6 63.1 53.3 46.3 36.8 30.6 26.4 20.9 17.4 236.0 128.3 88.5 67.9 55.2 46.6 40.5 32.2 26.8 23.1 18.2 15.2 202.3 109.9 75.9 58.2 47.3 40.0 34.7 27.6 23.0 19.8 15.6 13.0

69.6 76.8 79.4 80.8 81.6 82.2 82.6 83.2 83.5 83.8 84.1 84.3 71.2 77.6 80.0 81.2 82.0 82.5 82.9 83.4 83.7 83.9 84.2 84.3 72.7 78.4 80.6 81.6 82.3 82.8 83.1 83.5 83.8 84.0 84.3 84.4 74.3 79.3 81.0 82.1 82.7 83.1 83.3 83.7 84.0 84.1 84.4 84.5 75.8 80.1 81.7 82.5 83.0 83.3 83.6 83.9 84.1 84.3 84.4 84.6

303.5 164.9 113.8 87.3 71.0 60.0 52.0 41.3 34.5 29.7 23.5 19.6 269.8 146.6 101.2 77.6 63.1 53.3 46.3 36.8 30.6 26.4 20.9 17.4 236.0 128.3 88.5 67.9 55.2 46.6 40.5 32.2 26.8 23.1 18.2 15.2 202.3 109.9 75.9 58.2 47.3 40.0 34.7 27.6 23.0 19.8 15.6 13.0 168.6 91.6 63.2 48.5 39.4 33.3 28.9 23.0 19.2 16.5 13.0 10.9

66.2 72.6 75.0 76.2 77.0 77.5 77.9 78.4 78.7 78.9 79.2 79.3 67.7 73.4 75.6 76.6 77.3 77.8 78.1 78.5 78.8 79.0 79.3 79.4 69.3 74.3 76.1 77.1 77.7 78.1 78.3 78.7 79 79.1 79.4 79.5 70.8 75.1 76.7 77.5 78.0 78.3 78.6 78.9 79.1 79.3 79.4 79.6 72.3 75.9 77.2 77.9 78.3 78.6 78.8 79.1 79.3 79.4 79.5 79.6

386.7 217.4 151.9 117.2 95.6 80.9 70.3 55.9 46.7 40.2 31.7 26.4 351.5 197.6 138.1 106.5 86.9 73.6 63.9 50.8 42.4 36.5 28.8 24.0 316.4 177.9 124.3 95.9 78.2 66.2 57.5 45.8 38.2 32.9 25.9 21.6 281.2 158.1 110.5 85.2 69.5 58.9 51.1 40.7 33.9 29.2 23.1 19.2 246.1 138.3 96.7 74.6 60.8 51.5 44.7 35.6 29.7 25.6 20.2 16.8

74.4 81.3 84.0 85.5 86.4 87.0 87.4 88.0 88.4 88.6 89.0 89.2 75.8 82.1 84.6 85.9 86.7 87.2 87.6 88.2 88.5 88.8 89.1 89.3 77.2 82.9 85.1 86.3 87.0 87.5 87.9 88.4 88.7 88.9 89.2 89.3 78.6 83.7 85.7 86.7 87.4 87.8 88.1 88.5 88.8 89.0 89.3 89.4 80.1 84.5 86.2 87.1 87.7 88.1 88.4 88.7 89.0 89.1 89.3 89.5

351.5 197.6 138.1 106.5 86.9 73.6 63.9 50.8 42.4 36.5 28.8 24.0 316.4 177.9 124.3 95.9 78.2 66.2 57.5 45.8 38.2 32.9 25.9 21.6 281.2 158.1 110.5 85.2 69.5 58.9 51.1 40.7 33.9 29.2 23.1 19.2 246.1 138.3 96.7 74.6 60.8 51.5 44.7 35.6 29.7 25.6 20.2 16.8 210.9 118.6 82.9 63.9 52.2 44.2 38.4 30.5 25.4 21.9 17.3 14.4

70.8 77.1 79.6 80.9 81.7 82.2 82.6 83.2 83.5 83.8 84.1 84.3 72.2 77.9 80.1 81.3 82.0 82.5 82.9 83.4 83.7 83.9 84.2 84.3 73.6 78.7 80.7 81.7 82.4 82.8 83.1 83.5 83.8 84.0 84.3 84.4 75.1 79.5 81.2 82.1 82.7 83.1 83.4 83.7 84.0 84.1 84.3 84.5 76.5 80.3 81.8 82.5 83.0 83.3 83.6 83.9 84.1 84.3 84.4 84.6

316.4 177.9 124.3 95.9 78.2 66.2 57.5 45.8 38.2 32.9 25.9 21.6 281.2 158.1 110.5 85.2 69.5 58.9 51.1 40.7 33.9 29.2 23.1 19.2 246.1 138.3 96.7 74.6 60.8 51.5 44.7 35.6 29.7 25.6 20.2 16.8 210.9 118.6 82.9 63.9 52.2 44.2 38.4 30.5 25.4 21.9 17.3 14.4 175.8 98.8 69.0 53.3 43.5 36.8 32.0 25.4 21.2 18.3 14.4 12.0

67.2 72.9 75.1 76.3 77.0 77.5 77.9 78.4 78.7 78.9 79.2 79.3 68.6 73.7 75.7 76.7 77.4 77.8 78.1 78.5 78.8 79.0 79.3 79.4 70.1 74.5 76.2 77.1 77.7 78.1 78.4 78.7 79.0 79.1 79.3 79.5 71.5 75.3 76.8 77.5 78.0 78.3 78.6 78.9 79.1 79.3 79.4 79.6 72.9 76.1 77.3 77.9 78.3 78.6 78.8 79.1 79.3 79.4 79.5 79.6




App. A-37

A

APPENDIX A


A

App. A-38



Appendix B GENERAL ENGINEERING TABLES Contents Prism Load Values . . . . . . . . . . . . . . . .App. B-2 Marston Soil Load Values . . . . . . . . .. . App. B-3 E’ Modulus . . . . . . . . . . . . . . . . . . . . .App. B-11 Bedding Constant . . . . . . . . . . . . . . .App. B-11



App. B-1

APPENDIX B

BURIAL DATA

Table B-1. Prism Load Values for Asahi/Americ Pipe Height Soil Wt Nom. O.D. 0.50 (feet) (lb/ft3) Act. O.D. 0.79

B

0.75 0.98

1 1.26

1.25 1.58

1.5 1.97

2 2.48

2.5 2.95

3 3.54

4 4.33

6 6.29

8 7.87

10 9.84

12 12.4

14 13.98

16 15.75

18 17.72

20 19.69

24 24.8

3 3 3 3 3

100 110 120 125 130

19.8 21.7 23.7 24.7 25.7

24.5 27.0 29.4 30.6 31.9

31.5 34.7 37.8 39.4 41.0

39.5 43.5 47.4 49.4 51.4

49.3 54.2 59.1 61.6 64.0

62.0 68.2 74.4 77.5 80.6

73.7 81.1 88.5 92.2 95.9

88.5 97.4 106.2 110.6 115.1

108.3 119.1 129.9 135.3 140.7

157.3 173.0 188.7 196.6 204.4

1 96.8 216.4 236.1 245.9 255.8

246.0 270.6 295.2 307.5 319.8

310.0 341.0 372.0 387.5 403.0

349.5 384.5 419.4 436.9 454.4

393.8 433.1 472.5 492.2 511.9

443 487.3 531.6 553.8 575.9

492.2 541.5 590.7 615.3 639.9

620.0 682.0 744.0 775.0 806.0

4 4 4 4 4

100 110 120 125 130

26.3 29.0 31.6 32.9 34.2

32.7 35.9 39.2 40.8 42.5

42.0 46.2 50.4 52.5 54.6

52.7 57.9 63.2 65.8 68.5

65.7 72.2 78.8 82.1 85.4

82.7 90.9 99.2 103.3 107.5

98.3 108.2 118.0 122.9 127.8

118.0 129.8 141.6 147.5 153.4

144.3 158.8 173.2 180.4 187.6

209.7 230.6 251.6 262.1 272.6

262.3 288.6 314.8 327.9 341.0

328.0 360.8 393.6 410.0 426.4

413.3 454.7 496.0 516.7 537.3

466.0 512.6 559.2 582.5 605.8

525.0 577.5 630.0 656.3 682.5

590.7 649.7 708.8 736.3 767.9

656.3 722.0 787.6 820.4 853.2

826.7 909.3 992.0 1033.3 1074.7

5 5 5 5 5

100 110 120 125 130

32.9 36.2 39.5 41.1 42.8

40.8 44.9 49.0 51.0 53.1

52.5 57.8 63.0 65.6 68.3

65.8 72.4 79.0 82.3 85.6

82.1 90.3 98.5 102.6 106.7

103.3 113.7 124.0 129.2 134.3

122.9 135.2 147.5 153.6 159.8

147.5 162.3 177.0 184.4 191.8

180.4 198.5 216.5 225.5 234.5

262.1 288.3 314.5 327.6 340.7

327.9 360.7 393.5 409.9 426.3

410.0 451.0 492.0 512.5 533.0

516.7 568.3 620.0 645.8 671.7

582.5 640.8 699.0 728.1 757.3

656.3 721.9 787.5 820.3 853.1

738.3 812.2 886.0 922.9 959.8

820.4 902.5 984.5 1025.5 1066.5

1033.3 1136.7 1240.0 1291.7 1343.3

6 6 6 6 6

100 110 120 125 130

39.5 43.4 47.4 49.4 51.3

49.0 53.9 58.8 61.2 63.7

63.0 69.3 75.6 78.8 81.9

79.0 86.9 94.8 98.7 102.7

98.5 108.3 118.2 123.1 128.0

124.0 136.4 148.8 155.0 161.2

147.5 162.2 177.0 184.4 191.7

177.0 194.7 212.4 221.3 230.1

216.5 238.1 259.8 270.6 281.4

314.5 345.9 377.4 393.1 408.8

393.5 432.8 472.2 491.9 511.5

492.0 541.2 590.4 615.0 639.6

620.0 682.0 744.0 775.0 806.0

699.0 787.5 886.0 768.9 866.3 974.6 838.8 945.0 1063.2 873.8 984.4 1107.5 908.7 1023.8 1151.8

984.5 1082.9 1181.4 1230.6 1279.8

1240.0 1364.0 1488.0 1550.0 1612.0

7 7 7 7 7

100 110 120 125 130

46.1 50.7 55.3 57.6 59.9

57.2 62.9 68.6 71.5 74.3

73.5 80.9 88.2 91.9 95.6

92.2 101.4 110.6 115.2 119.8

114.9 126.4 137.9 143.6 149.4

144.7 159.1 173.6 180.8 188.1

172.1 189.3 206.5 215.1 223.7

206.5 227.2 247.8 258.1 268.5

252.6 277.8 303.1 315.7 328.4

366.9 403.6 440.3 458.6 477.0

459.1 505.0 550.9 573.9 596.8

574.0 631.4 688.8 717.5 746.2

723.3 795.7 868.0 904.2 940.3

815.5 897.1 978.6 1019.4 1060.2

918.8 1010.6 1102.5 1148.4 1194.4

1033.7 1137.0 1240.4 1292.1 1343.8

1148.6 1263.4 1378.3 1435.7 1493.2

1446.7 1591.3 1736.0 1808.3 1880.7

8 8 8 8 8

100 110 120 125 130

52.7 57.9 63.2 65.8 68.5

65.3 71.9 78.4 81.7 84.9

84.0 92.4 100.8 105.0 109.2

105.3 115.9 126.4 131.7 136.9

131.3 144.5 157.6 164.2 170.7

165.3 181.9 198.4 206.7 214.9

196.7 216.3 236.0 245.8 255.7

236.0 259.6 283.2 295.0 306.8

288.7 317.5 346.4 360.8 375.3

419.3 461.3 503.2 524.2 545.1

524.7 577.1 629.6 655.8 682.1

656.0 826.7 721.6 909.3 787.2 992.0 820.0 1033.3 852.8 1074.7

932.0 1025.2 1118.4 1165.0 1211.6

1050.0 1155.0 1260.0 1312.5 1365.0

1181.3 1299.5 1417.6 1476.7 1535.7

1312.7 1443.9 1575.2 1640.8 1706.5

1653.3 1818.7 1984.0 2066.7 2149.3

9 9 9 9 9

100 110 120 125 130

59.2 65.2 71.1 74.1 77.0

73.5 80.8 88.2 91.9 95.5

94.5 104.0 113.4 118.1 122.9

118.5 130.3 142.2 148.1 154.0

147.7 182.5 177.3 184.7 192.1

186.0 204.6 223.2 232.5 241.8

221.2 243.4 265.5 276.6 287.6

265.5 292.1 318.6 331.9 345.2

324.7 357.2 369.7 405.9 422.2

471.7 518.9 566.1 589.7 613.3

590.2 649.3 708.3 737.8 767.3

738.0 811.8 885.6 922.5 959.4

930.0 1023.0 1116.0 1162.5 1209.0

1048.5 1153.4 1258.2 1310.6 1363.1

1181.3 1299.4 1417.5 1476.6 1535.6

1329.0 1461.9 1594.8 1661.2 1727.7

1476.7 1624.4 1772.1 845.9 1919.8

1860.0 2046.0 2232.0 2325.0 2418.0

10 10 10 10 10

100 110 120 125 130

65.8 72.4 79.0 82.3 85.6

81.7 89.8 98.0 102.1 106.2

105.0 115.5 126.0 131.3 136.5

131.7 144.8 158.0 164.6 171.2

164.2 180.6 197.0 205.2 213.4

206.7 227.3 248.0 258.3 268.7

245.8 270.4 295.0 307.3 319.6

295.0 324.5 354.0 368.8 333.5

360.8 396.9 433.0 451.0 469.1

524.2 576.6 629.0 655.2 681.4

655.8 820.0 1033.3 721.4 902.0 1136.7 787.0 984.0 1240.0 819.8 1025.0 1291.7 852.6 1066.0 1343.3

1165.0 1281.5 1398.0 1458.3 1514.5

1312.5 1443.8 1575.0 1640.6 1706.3

1476.7 1624.3 1772.0 1845.8 1919.7

1640.8 1804.9 1969.0 2051.0 2133.1

2066.7 2273.3 2480.0 2583.3 2686.7

15 15 15 15 15

100 110 120 125 130

98.7 108.6 118.5 123.4 128.4

122.5 134.7 147.0 153.1 159.2

157.5 173.3 189.0 198.9 204.8

197.5 217.2 237.0 246.9 256.7

246.2 270.9 295.5 307.8 320.1

310.0 341.0 372.0 387.5 403.0

368.7 405.6 442.5 460.9 479.4

442.5 486.8 531.0 553.1 575.3

541.2 786.2 595.4 864.9 649.5 943.5 676.6 982.8 703.6 1022.1

983.7 1082.1 1180.5 1229.7 1278.9

1230.0 1353.0 1478.0 1537.5 1599.0

1550.0 1705.0 1860.0 1937.5 2015.0

1747.5 1922.3 2097.0 2184.4 2271.8

1968.8 2165.6 2362.5 2460.9 2559.4

2215.0 2436.5 2658.0 2768.7 2879.5

2461.2 2707.4 2953.5 3076.6 3199.6

3100.0 3410.0 3720.0 3875.0 4030.0

20 20 20 20 20

100 110 120 125 130

131.7 144.8 158.0 164.6 171.2

163.3 179.7 196.0 204.2 212.3

210.0 231.0 252.0 262.5 273.0

263.3 289.7 316.0 329.2 342.3

328.3 361.2 394.0 410.4 426.8

413.3 454.7 496.0 516.7 537.3

491.7 540.8 590.0 614.6 639.2

590.0 649.0 708.0 737.5 767.0

721.7 793.8 866.0 902.1 938.2

1048.3 1153.2 1258.0 1310.4 1362.8

1311.7 1442.8 1574.0 1639.6 1705.2

1640.0 1804.0 1968.0 2050.0 2132.0

2066.7 2273.3 2480.0 2583.3 2686.7

2330.0 2563.0 2796.0 2912.5 3029.0

2625.0 2887.5 3150.0 3281.3 3412.5

2953.3 3248.7 3544.0 3691.7 3839.3

3281.7 3609.8 3938.0 4102.1 4266.2

4133.3 4546.7 4960.0 5166.7 5373.3

30 30 30 30 30

100 110 120 125 130

197.5 217.2 237.0 246.9 256.7

245.0 269.5 294.0 306.2 318.5

315.0 346.5 378.0 393.8 409.5

395.0 434.5 474.0 493.7 513.5

492.5 541.7 591.0 615.6 640.2

620.0 682.0 744.0 775.0 806.0

737.5 885.0 1082.5 1572.5 811.2 973.5 1190.7 1729.7 885.0 1062.0 1299.0 1887.0 921.9 1106.3 1353.1 1965.6 958.7 1150.5 1407.2 2044.2

1967.5 2164.2 2361.0 2459.4 2557.7

2460.0 2706.0 2952.0 3075.0 3198.0

3100.0 3410.0 3720.0 3875.0 4030.0

3495.0 3844.5 4194.0 4368.8 4543.5

3937.5 4331.3 4725.0 4921.9 511 8.8

4430.0 4873.0 5316.0 5537.5 5759.0

4922.5 5414.7 5907.0 8153.1 6399.2

6200.0 6820.0 7440.0 7750.0 8060.0

50 50 50 50 50

100 110 120 125 130

329.2 362.1 395.0 411.5 427.9

408.3 449.2 490.0 510.4 530.8

525.0 577.5 630.0 656.3 682.5

658.3 820.8 1033.3 724.2 902.9 1136.7 790.0 985.0 1240.0 822.9 1026.0 1291.7 855.8 1067.1 1343.3

3279.2 3607.1 3935.0 4099.0 4262.9

4100.0 4510.0 4920.0 5125.0 5330.0

5166.7 5683.3 6200.0 6458.3 6716.7

5825.0 6407.5 6990.0 7281.3 7572.5

6562.5 7218.8 7875.0 8203.1 8531.3

7383.3 8204.2 10333.3 8121.7 9024.6 11366.7 8860.0 9845.0 12400.0 9229.2 10255.2 12916.7 9598.3 10665.4 13433.3

B-2

1229.2 1352.1 1475.0 1536.5 1597.9

1475.0 1622.5 1770.0 1843.8 1917.5

1804.2 1964.6 2165.0 2255.2 2345.4

2620.8 2882.9 3145.0 3276.0 3407.1



APPENDIX B

BURIAL DATA

Table B-2. Marston Soil Load Values for Asahi/America Pipe

Depth 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

Soil Type granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay

Soil Wgt

Nominal Piping Diameter = 0.5 Inches Width of Trench in Feet 0.5 0.75 1 2 3 4 5

Nominal Piping Diameter = 0.75 Inches Width of Trench in Feet 0.5 0.75 1 2 3 4 5

100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

7.6 9.4 11.1 12.3 14.5 8.2 10.1 12 14 16 8.4 10.7 12.6 15.2 17.1 8.6 10.9 13 15.6 18 8.6 10.9 13 16 19 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3 8.6 10.9 13 16 19.3

9.4 11.7 13.7 15.3 18 10.2 12.6 14.9 17.4 19.9 10.4 13.3 15.7 18.9 21.2 10.6 13.5 16.2 19.4 22.3 10.6 13.5 16.2 19.9 23.6 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9 10.6 13.5 16.2 19.9 23.9

10.1 11.9 14.2 15.4 17.3 11.4 13.6 16 17.9 19.9 11.8 14.7 17.2 19.7 22.8 12.3 15.2 18.1 21 23.7 12.6 16 19.6 23.1 26 12.8 16.3 19.6 23.5 28.6 12.8 16.3 19.6 24.1 28.9 12.8 16.3 19.6 24.1 28.9 12.8 16.3 19.6 24.1 28.9 12.8 16.3 19.6 24.1 28.9 12.8 16.3 19.6 24.1 28.9 12.8 16.3 19.6 24.1 28.9

11.8 13.8 15.8 17.3 18.8 13.5 15.9 18.2 20.6 23.1 14.8 17.7 20.9 23 25.7 15.1 18.8 22.1 24.7 29.1 16.5 20.3 24.1 28 32.5 16.8 21 25.3 30.4 34.2 17.1 21.7 26.1 31.7 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5

15.8 17.4 19.7 20.6 22.3 18.4 21 23.7 26.3 28.2 22.4 24.6 27.6 29.6 32.5 23 27.5 31.6 34.6 37.7 27 31.9 36.3 41.1 46.2 29.6 35.5 41.9 46.1 51.3 32.3 39.8 47.4 54.3 64.2 33.6 42 50.6 60.9 68.5 34.2 43.4 51.3 62.5 73.6 34.2 43.4 52.1 63.4 75.3 34.2 43.4 52.1 64.2 77 34.2 43.4 52.1 64.2 77

16.2 18.5 20.4 22.2 23.6 19.7 21.7 28.4 29.6 30.8 24.7 28.2 30.8 34.6 34.7 27.6 31.5 35.5 39.5 43.6 31.6 38 42.7 44.4 51.3 36.5 43.4 51 54.3 59 44.4 48.9 64 69.1 77 47.4 58.7 68.7 79 91.1 49.4 60.8 72.3 86.4 100.1 50.4 63 75.8 91.3 102.7 51.3 65.2 78.2 93.8 114.2 51.3 65.2 78.2 96.3 115.5

17.1 18.8 21.2 23 24.3 21.6 24 27.2 29.6 31.5 25 29 31.6 36.2 39.4 31.6 34.8 39.5 41.1 44.5 36.9 42 47.4 52.7 58.2 44.8 49.2 55.3 59.2 65 51.3 63.7 72.7 79 85.6 59.2 71 83.7 92.2 102.7 61.9 75.3 88.5 102 118.1 64.5 79.7 94.8 108.6 128.4 67.1 84 101.1 121.8 136.9 68.5 86.9 102.7 126.7 147.2

17.4 19.2 21.7 23 24.8 22.4 25 27.6 30 32.1 27 30.8 34 36.8 39.4 29 32.6 37.5 41.1 44.9 39.5 43.4 49.4 53.5 59.9 46.1 52.5 59.2 65 72.7 51 67 79 86.4 94.1 67.5 81.5 90.8 102.9 115.5 74.1 88.7 104.7 115.2 128.4 77.4 94.1 110.6 125.5 145.5 82.3 101.4 120.5 144 162.6 83.9 105 126.4 152.2 171.2

12.6 14.8 17.6 19.1 21.5 14.1 16.8 19.8 22.2 24.7 14.7 18.2 21.3 24.5 28.3 15.3 18.9 22.4 26 29.5 15.6 19.9 24.3 28.7 32.2 15.9 20.2 24.3 29.1 35.4 15.9 20.2 24.3 29.9 35.8 15.9 20.2 24.3 29.9 35.8 15.9 20.2 24.3 29.9 35.8 15.9 20.2 24.3 29.9 35.8 15.9 20.2 24.3 29.9 35.8 15.9 20.2 24.3 29.9 35.8

14.7 17.1 19.6 21.4 23.4 16.7 19.8 22.5 25.5 28.7 18.4 22 26 28.6 31.9 18.8 23.4 27.4 30.6 36.1 20.4 25.2 29.9 34.7 40.3 20.8 26.1 31.4 37.8 42.5 21.2 27 32.3 39.3 47.8 21.2 27 32.3 39.8 47.8 21.2 27 32.3 39.8 47.8 21.2 27 32.3 39.8 47.8 21.2 27 32.3 39.8 47.8 21.2 27 32.3 39.8 47.8

19.6 21.6 24.5 25.5 27.6 22.9 26.1 29.4 32.7 35 27.8 30.5 34.3 36.7 40.3 28.6 34.1 39.2 42.9 46.7 33.5 39.5 45.1 51 57.3 36.8 44 51.9 57.2 63.7 40 49.4 58.8 67.4 79.6 41.7 52.1 62.7 75.5 84.9 42.5 53.9 63.7 77.6 91.3 42.5 53.9 64.7 78.6 93.4 42.5 53.9 64.7 79.6 95.6 42.5 53.9 64.7 79.6 95.6

20.1 22.9 25.3 27.6 29.3 24.5 27 35.3 36.8 38.2 30.6 35 38.2 42.9 43 34.3 39.1 44.1 49 54.1 39.2 47.2 52.9 55.1 63.7 45.3 53.9 63.2 67.4 73.3 55.1 60.6 79.4 85.7 95.6 58.8 72.8 85.3 98 113.1 61.3 75.5 89.7 107.2 124.2 62.5 78.2 94.1 113.3 127.4 63.7 80.9 97 116.4 141.7 63.7 80.9 97 119.4 143.3

21.2 23.4 26.3 28.6 30.2 26.8 29.8 33.7 36.7 39.1 31 35.9 39.2 44.9 48.8 39.2 43.1 49 51 55.2 45.7 52.1 58.8 65.3 72.2 55.5 61.1 68.6 73.5 80.7 63.7 79.1 90.2 98 106.2 73.5 88 103.9 114.3 127.4 76.8 93.4 109.8 126.6 146.5 80 98.8 117.6 134.8 159.3 83.3 104.2 125.4 151.1 169.9 84.9 107.8 127.4 157.2 182.6

21.6 23.8 27 28.6 30.8 27.8 31 34.3 37.3 39.8 33.5 38.2 42.1 45.7 48.8 35.9 40.4 46.6 51 55.7 49 53.9 61.3 66.4 74.3 57.2 65.1 73.5 80.6 90.2 63.3 83.1 98 107.2 116.8 83.7 101.1 112.7 127.6 143.3 91.9 110 129.9 142.9 159.3 96 116.8 137.2 155.7 180.5 102.1 125.8 149.5 178.6 201.7 104.1 130.3 156.8 188.9 212.3

Depth (of burial) is in feet; Soil Wgt (weight) is in lbs/ft3; values in the body of the table are in lbs of soil load per linear foot (lbs/linear ft).



App. B-3

B

APPENDIX B

BURIAL DATA

Table B-2. Marston Soil Load Values for Asahi/America Pipe (continued)

B

Depth

Soil Type

Soil Wgt

3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay

100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Diameter = 1 Inches Width of Trench in Feet 0.5 0.75 1 2 3 4 12.1 15 17.6 19.7 23.2 13.1 16.2 19.2 22.3 25.6 13.4 17 20.2 24.3 27.3 13.7 17.3 20.8 24.9 28.7 13.7 17.3 20.8 25.6 30.4 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7 13.7 17.3 20.8 25.6 30.7

16.1 19.1 22.7 24.6 27.6 18.1 21.7 25.5 28.5 31.7 18.9 23.4 27.4 31.5 36.3 19.7 24.3 28.8 33.5 37.9 20.1 25.6 31.2 36.9 41.5 20.5 26 31.2 37.4 45.6 20.5 26 31.2 38.4 46.1 20.5 26 31.2 38.4 46.1 20.5 26 31.2 38.4 46.1 20.5 26 31.2 38.4 46.1 20.5 26 31.2 38.4 46.1 20.5 26 31.2 38.4 46.1

18.9 21.9 25.2 27.6 30 21.5 25.4 29 32.8 36.9 23.6 28.3 33.4 36.8 41 24.2 30 35.3 39.4 46.4 26.3 32.3 38.4 44.6 51.9 26.8 33.5 40.3 48.6 54.6 27.3 34.7 41.6 50.5 61.4 27.3 34.7 41.6 51.2 61.4 27.3 34.7 41.6 51.2 61.4 27.3 34.7 41.6 51.2 61.4 27.3 34.7 41.6 51.2 61.4 27.3 34.7 41.6 51.2 61.4

25.2 27.7 31.5 32.8 35.5 29.4 33.5 37.8 42 45 35.7 39.3 44.1 47.3 51.9 36.8 43.9 50.4 55.1 60.1 43.1 50.8 58 65.6 73.7 47.3 56.6 66.8 73.5 81.9 51.5 63.5 75.6 86.6 102.4 53.6 67 80.6 97.1 109.2 54.6 69.3 81.9 99.8 117.4 54.6 69.3 83.2 101.1 120.1 54.6 69.3 83.2 102.4 122.9 54.6 69.3 83.2 102.4 122.9

25.8 29.5 32.5 35.4 37.7 31.5 34.7 45.4 47.3 49.1 39.4 45 49.1 55.1 55.3 44.1 50.2 56.7 63 69.6 50.4 60.6 68 70.9 81.9 58.3 69.3 81.3 86.6 94.2 70.9 78 102.1 110.3 122.9 75.6 93.6 109.6 126 145.4 78.8 97 115.3 137.8 159.7 80.3 100.5 121 145.7 163.8 81.9 104 124.7 149.6 182.2 81.9 104 124.7 153.6 184.3

27.3 30 33.8 36.8 38.8 34.4 38.3 43.3 47.3 50.2 39.9 46.2 50.4 57.8 62.8 50.4 55.4 63 65.6 71 58.8 67 75.6 84 92.8 71.4 78.5 88.2 94.5 103.7 81.9 101.6 115.9 126 136.5 94.5 113.2 133.6 147 163.8 98.7 120.1 141.1 162.8 188.4 102.9 127.1 151.2 173.3 204.8 107.1 134 161.3 194.3 218.4 109.2 138.6 163.8 202.1 234.8

5 27.8 30.6 34.7 36.8 39.6 35.7 39.8 44.1 47.9 51.2 43.1 49.1 54.2 58.7 62.8 46.2 52 59.9 65.6 71.7 63 69.3 78.8 85.3 95.6 73.5 83.7 94.5 103.7 116 81.4 106.8 126 137.8 150.2 107.6 129.9 144.9 164.1 184.3 118.1 141.5 167 183.8 204.8 123.4 150.2 176.4 200.2 232.1 131.3 161.7 192.2 229.7 259.4 133.9 167.5 201.6 242.8 273

Nominal Piping Diameter = 1.25 Inches Width of Trench in Feet 0.5 0.75 1 2 3 4 5 15.1 18.8 22.1 24.7 29.1 16.5 20.3 24.1 28 32.1 16.8 21.4 25.3 30.4 34.2 17.1 21.7 26.1 31.3 35.9 17.1 21.7 26.1 32.1 38.1 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5 17.1 21.7 26.1 32.1 38.5

20.2 23.9 28.4 30.9 34.7 22.7 27.2 32 35.8 39.8 23.7 29.3 34.4 39.5 45.6 24.7 30.4 36.1 42 47.5 25.2 32 39.1 46.3 52 25.7 32.6 39.1 46.9 57.1 25.7 32.6 39.1 48.1 57.8 25.7 32.6 39.1 48.1 57.8 25.7 32.6 39.1 48.1 57.8 25.7 32.6 39.1 48.1 57.8 25.7 32.6 39.1 48.1 57.8 25.7 32.6 39.1 48.1 57.8

23.7 27.5 31.6 34.6 37.7 27 31.9 36.3 41.1 46.2 29.6 35.5 41.9 46.1 51.4 30.3 37.7 44.2 49.4 58.2 32.9 40.6 48.2 56 65 33.6 42 50.6 60.9 68.5 34.2 43.5 52.1 63.4 77 34.2 43.5 52.1 64.2 77 34.2 43.5 52.1 64.2 77 34.2 43.5 52.1 64.2 77 34.2 43.5 52.1 64.2 77 34.2 43.5 52.1 64.2 77

31.6 34.8 39.5 41.1 44.5 36.9 42 47.4 52.7 56.5 44.8 49.2 55.3 59.3 65 46.1 55 63.2 69.1 75.3 54 63.7 72.7 82.3 92.4 59.3 71 83.7 92.2 102.7 64.5 79.7 94.8 108.6 128.4 67.2 84 101.1 121.8 136.9 68.5 86.9 102.7 125.1 147.2 68.5 86.9 104.3 126.7 150.6 68.5 86.9 104.3 128.4 154.1 68.5 86.9 104.3 128.4 154.1

32.4 36.9 40.8 44.4 47.2 39.5 43.5 56.9 59.3 61.6 49.4 56.5 61.6 69.1 69.3 55.3 63 71.1 79 87.3 63.2 76 85.3 88.9 102.7 73.1 86.9 101.9 108.6 118.1 88.9 97.8 128 138.3 154.1 94.8 117.3 137.5 158 182.3 98.8 121.7 144.6 172.8 200.3 100.7 126 151.7 182.7 205.4 102.7 130.4 156.4 187.6 228.5 102.7 130.4 156.4 192.6 231.1

34.2 37.7 42.3 46.1 48.6 43.2 48.1 54.4 59.3 63 50 57.9 63.2 72.4 78.7 63.2 69.5 79 82.3 89 73.7 84 94.8 105.3 116.4 89.5 98.5 110.6 118.5 130.1 102.7 127.5 145.4 158 171.2 118.5 141.9 167.5 184.3 205.4 123.8 150.6 177 204.1 236.2 129 159.3 189.6 217.3 256.8 134.3 168 202.2 243.6 273.9 136.9 173.8 205.4 253.5 294.4

34.9 38.4 43.5 46.1 49.6 44.8 50 55.3 60.1 64.2 54 61.6 67.9 73.7 78.7 57.9 65.2 75.1 82.3 89.9 79 86.9 98.8 107 119.8 92.2 105 118.5 130 145.5 102 134 158 172.8 188.3 135 162.9 181.7 205.7 231.1 148.1 177.4 209.4 230.4 256.8 154.7 188.3 221.2 251 291 164.6 202.8 241 288 325.2 167.9 210 252.8 304.5 342.3


App. B-4



APPENDIX B

BURIAL DATA


Depth

Soil Type

Soil Wgt

3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay satu rated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay satu rated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granu lar w/o cohesion sand and gravel saturated top soil dry clay saturated clav

100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Diameter = 1.5 Inches Width of Trench in Feet 0.5 0.75 1 2 3 4 5 18.9 23.5 27.6 30.8 36.3 20.5 25.3 30 34.9 40 20.9 26.6 31.5 38 42.7 21.3 27.1 32.5 39 44.8 21.3 27.1 32.5 40 47.5 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48 21.3 27.1 32.5 40 48

25.2 29.8 35.5 38.5 43.2 28.3 33.9 39.9 44.6 49.6 29.6 36.6 42.8 49.3 56.8 30.8 37.9 45.1 52.3 59.2 31.4 40 48.8 57.7 64.8 32 40.6 48.8 58.5 71.2 32 40.6 48.8 60 72 32 40.6 48.8 60 72 32 40.6 48.8 60 72 32 40.6 48.8 60 72 32 40.6 48.8 60 72 32 40.6 48.8 60 72

29.6 34.3 39.4 43.1 47 33.7 39.7 45.3 51.3 57.6 36.9 44.2 52.2 57.5 64 37.8 47 55.2 61.6 72.6 41 50.6 60.1 69.8 81.1 41.9 52.4 63 75.9 85.4 42.7 54.2 65 79 96 42.7 54.2 65 80 96 42.7 54.2 65 80 96 42.7 54.2 65 80 96 42.7 54.2 65 80 96 42.7 54.2 65 80 96

39.4 43.3 49.3 51.3 55.5 46 52.4 59.1 65.7 70.4 55.8 61.4 69 73.9 81.1 57.5 68.6 78.8 86.2 93.9 67.3 79.5 90.6 102.6 115.2 73.9 88.5 104.4 114.9 128.1 80.4 99.3 118.2 135.4 160.1 83.7 104.7 126.1 151.9 170.7 85.4 108.4 128.1 156 183.5 85.4 108.4 130 158 187.8 85.4 108.4 130 160.1 192.1 85.4 108.4 130 160.1 192.1

40.4 42.7 46 47 50.8 52.8 55.4 57.5 58.9 60.6 49.3 53.8 54.2 60 70.9 67.8 73.9 73.9 76.8 78.5 61.6 62.4 70.4 72.2 76.8 78.8 86.2 90.3 86.4 98.2 69 78.8 78.6 86.7 88.7 98.5 98.5 102.6 108.8 111 78.8 91.9 94.8 104.7 106.4 118.2 110.8 131.3 128.1 145.1 91.1 111.6 108.4 122.8 127.1 137.9 135.4 147.8 147.3 162.2 110.8 128.1 121.9 158.9 159.6 181.2 172.4 197 192.1 213.4 118.2 147.8 146.3 177 171.4 208.8 197 229.8 227.3 256.1 123.1 154.3 151.7 187.8 180.3 220.6 215.5 254.5 249.7 294.5 125.6 160.9 157.1 198.6 189.1 236.4 227.8 270.9 256.1 320.1 128.1 167.5 162.5 209.5 195 252.2 233.9 303.7 284.9 341.5 128.1 170.7 162.5 216.7 195 256 1 240.1 316 288.1 367.1

43.5 47.9 54.2 57.5 61.9 55.8 62.3 69 74.9 80 67.3 76.7 84.7 91.8 98.2 72.2 81.3 93.6 102.6 112 98.5 108.4 123.1 133.4 149.4 114.9 130.9 147.8 162.1 181.4 127.2 167 197 215.5 234.8 168.3 203.2 226.6 256.5 288.1 184.7 221.2 261 287.3 320.1 192.9 234.8 275.8 312.9 362.8 205.2 252.8 300.4 359.1 405.5 209.3 261.8 315.2 379.6 426.8

Nominal Piping Diameter = 2 Inches Width of Trench in Feet 0.75 1 2 3 4 5 31.8 37.5 44.6 48.4 54.4 35.7 42.6 50.2 56.2 62.5 37.2 46 53.9 62 71.5 38.8 47.7 56.7 65.9 74.6 39.5 50.3 61.4 72.7 81.6 40.3 51.2 61.4 73.6 89.7 40.3 51.2 61.4 75.6 90.7 40.3 51.2 61.4 75.6 90.7 40.3 51.2 61.4 75.6 90.7 40.3 51.2 61.4 75.6 90.7 40.3 51.2 61.4 75.6 90.7 40.3 51.2 61.4 75.6 90.7

37.2 43.2 49.6 54.3 59.1 42.4 50 57 64.6 72.5 46.5 55.7 65.7 72.3 80.6 47.5 59.1 69.4 77.5 91.3 51.7 63.7 75.6 87.8 102.1 52.7 65.9 79.4 95.6 107.5 53.7 68.2 81.8 99.5 120.9 53.7 68.2 81.8 100.8 120.9 53.7 68.2 81.8 100.8 120.9 53.7 68.2 81.8 100.8 120.9 53.7 68.2 81.8 100.8 120.9 53.7 68.2 81.8 100.8 120.9

49.6 54.6 62 64.6 69.9 57.9 65.9 74.4 82.7 88.7 70.3 77.3 86.8 93 102.1 72.3 86.4 99.2 108.5 118.2 84.7 100 114.1 129.2 145.1 93 111.4 131.4 144.7 161.2 101.3 125 148.8 170.5 201.5 105.4 131.9 158.7 191.2 214.9 107.5 136.4 161.2 196.3 231.1 107.5 136.4 163.7 198.9 236.4 107.5 136.4 163.7 201.5 241.8 107.5 136.4 163.7 201.5 241.8

50.8 58 64 69.8 74.2 62 68.2 89.3 93 96.7 77.5 88.7 96.7 108.5 108.8 86.8 98.9 111.6 124 137 99.2 119.4 133.9 139.5 161.2 114.7 136.4 160 170.5 185.4 139.5 153.5 200.9 217 241.8 148.8 184.1 215.8 248 286.1 155 191 226.9 271.3 314.3 158.1 197.8 238.1 286.8 322.4 161.2 204.6 245.5 294.5 358.7 161.2 204.6 245.5 302.3 362.7

53.7 59.1 66.5 72.3 76.3 67.8 75.5 85.3 93 98.9 78.5 90.9 99.2 113.7 123.6 99.2 109.1 124 129.2 139.7 115.7 131.9 148.8 165.3 182.7 140.5 154.6 173.6 186 204.2 161.2 200.1 228.2 248 268.7 186 222.8 262.9 289.3 322.4 194.3 236.4 277.8 320.3 370.8 202.5 250.1 297.6 341 403 210.8 263.7 317.4 382.3 429.9 214.9 272.8 322.4 397.8 462.1

54.8 60.2 68.2 72.3 77.9 70.3 78.4 86.8 94.3 100.8 84.7 96.6 106.6 115.6 123.6 90.9 102.3 117.8 129.2 141.1 124 136.4 155 167.9 188.1 144.7 164.8 186 204.1 228.4 160.2 210.3 248 271.3 295.5 211.8 255.8 285.2 322.9 362.7 232.5 278.5 328.6 361.7 403 242.8 295.5 347.2 394 456.7 258.3 318.3 378.2 452.1 510.5 263.5 329.6 396.8 477.9 537.3




App. B-5

B

APPENDIX B

BURIAL DATA


Depth

B

3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

Soil Type granular w/o cohesion sand and gravel saturated top soil dry clay satu rated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay granular w/o cohesion sand and gravel saturated top soil dry clay saturated clay

Soil Wgt

Nominal Piping Diameter = 2.5 Inches Width of Trench in Feet 0.75 1 2 3 4 5

Nominal Piping Diameter = 3 Inches Width of Trench in Feet 0.75 1 2 3 4 5

100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

37.8 44.6 53.1 57.6 64.7 42.4 50.7 59.7 66.8 74.3 44.2 54.8 64.2 73.7 85.1 46.1 56.8 67.5 78.4 88.7 47 59.8 73 86.4 97.1 47.9 60.8 73 87.6 106.7 47.9 60.8 73 89.9 107.9 47.9 60.8 73 89.9 107.9 47.9 60.8 73 89.9 107.9 47.9 60.8 73 89.9 107.9 47.9 60.8 73 89.9 107.9 47.9 60.8 73 89.9 107.9

45.4 53.5 63.7 69.1 77.7 50.9 60.8 71.7 80.2 89.2 53.1 65.7 77 88.5 102.1 55.3 68.1 81 94 106.4 56.4 71.8 87.6 103.7 116.5 57.5 73 87.6 105.1 128 57.5 73 87.6 107.9 129.4 57.5 73 87.6 107.9 129.4 57.5 73 87.6 107.9 129.4 57.5 73 87.6 107.9 129.4 57.5 73 87.6 107.9 129.4 57.5 73 87.6 107.9 129.4

44.2 51.4 59 64.5 70.3 50.4 59.5 67.9 76.8 86.3 55.3 66.3 78.2 86 95.9 56.5 70.3 82.6 92.2 108.7 61.5 75.7 90 104.5 121.4 62.7 78.4 94.4 113.7 127.8 63.9 81.1 97.4 118.3 143.8 63.9 81.1 97.4 119.8 143.8 63.9 81.1 97.4 119.8 143.8 63.9 81.1 97.4 119.8 143.8 63.9 81.1 97.4 119.8 143.8 63.9 81.1 97.4 119.8 143.8

59 4.9 73.8 76.8 83.1 68.8 78.4 S8.5 98.3 105.5 83.6 91.9 103.3 110.6 121.4 86 102.8 118 129.1 140.6 100.8 119 135.7 153.6 172.6 110.6 132.5 156.4 172.1 191.8 120.5 148.7 177 202.8 239.7 125.4 156.8 188.8 227.4 255.7 127.8 162.3 191.8 233.5 274.8 127.8 162.3 194.7 236.6 281.2 127.8 162.3 194.7 239.7 287.6 127.8 162.3 194.7 239.7 287.6

60.5 69 76.1 83 88.2 73.7 81.1 106.2 110.6 115.1 92.2 105.5 115.1 129.1 129.4 103.3 117.6 132.8 147.5 163 118 142 159.3 165.9 191.8 136.4 162.3 190.3 202.8 220.5 165.9 182.5 239 258.1 287.6 177 219 256.7 295 340.4 184.4 227.2 269.9 322.7 373.9 188.1 235.3 283.2 341.1 383.5 191.8 243.4 292.1 350.3 426.6 191.8 243.4 292.1 359.5 431.4

63.9 70.3 79.1 86 90.8 80.6 89.8 101.5 110.6 117.6 93.4 108.2 118 135.2 147 118 129.8 147.5 153.6 166.2 137.7 156.8 177 196.7 217.3 167.2 183.9 206.5 221.3 242.9 191.8 238 271.4 295 319.6 221.3 265 312.7 344.2 383.5 231.1 281.2 330.4 381 441 240.9 297.5 354 405.6 479.4 250.8 313.7 377.6 454.8 511.3 255.7 324.5 383.5 473.2 549.7

65.1 71.7 81.1 86 92.7 83.6 93.3 103.3 112.2 119.8 100.8 114.9 126.9 137.5 147 108.2 121.7 140.1 153.6 167.8 147.5 162.3 184.4 199.7 223.7 172.1 196.1 221.3 242.8 271.6 190.5 250.1 295 322.7 351.5 252 304.2 339.3 384.1 431.4 276.6 331.3 390.9 430.2 479.4 288.9 351.5 413 468.6 543.3 307.3 378.6 449.9 537.8 607.2 313.4 392.1 472 568.5 639.2

53.1 61.7 70.8 77.4 84.4 60.5 71.4 81.4 92.2 103.5 66.4 79.5 93.8 103.3 115.1 67.9 84.4 99.1 110.6 130.4 73.8 90.9 108 125.4 145.7 75.2 94.1 113.3 136.4 153.4 76.7 97.4 116.8 142 172.6 76.7 97.4 116.8 143.8 172.6 76.7 97.4 116.8 143.8 172.6 76.7 97.4 116.8 143.8 172.6 76.7 97.4 116.8 143.8 172.6 76.7 97.4 116.8 143.8 172.6

70.8 77.9 88.5 92.2 99.7 82.6 94.1 106.2 118 126.6 100.3 110.3 123.9 132.8 145.7 103.3 123.3 141.6 154.9 168.7 121 142.8 162.8 184.4 207.1 132.8 159 187.6 206.5 230.1 144.6 178.5 212.4 243.4 287.6 150.5 188.2 226.6 272.9 306.8 153.4 194.7 230.1 280.3 329.8 153.4 194.7 233.6 283.9 337.5 153.4 194.7 233.6 287.6 345.2 153.4 194.7 233.6 287.6 345.2

72.6 82.7 91.3 99.6 105.8 88.5 97.4 127.4 132.8 138.1 110.6 126.6 138.1 154.9 155.3 123.9 141.2 159.3 177 195.6 141.6 170.4 191.2 199.1 230.1 163.7 194.7 228.3 243.4 264.6 199.1 219 286.7 309.8 345.2 212.4 262.8 308 354 408.4 221.3 272.6 323.9 387.2 448.7 225.7 282.3 339.8 409.3 460.2 230.1 292.1 350.5 420.4 512 230.1 292.1 350.5 431.4 517.7

76.7 84.4 94.9 103.3 108.9 96.8 107.7 121.8 132.8 141.1 112.1 129.8 141.6 162.3 176.4 141.6 155.8 177 184.4 199.4 165.2 188.2 212.4 236 260.8 200.6 220.7 247.8 265.5 291.5 230.1 285.6 325.7 354 383.5 265.5 318 375.2 413 460.2 277.3 337.5 396.5 457.3 529.2 289.1 357 424.8 486.8 575.3 300.9 376.4 453.1 545.8 613.6 306.8 389.4 460.2 567.9 659.6

78.2 86 97.4 103.3 111.2 100.3 112 123.9 134.6 143.8 121 137.9 152.2 165 176.4 129.8 146 168.2 184.4 201.3 177 194.7 221.3 239.7 268.5 206.5 235.3 265.5 291.3 326 228.6 300.2 354 387.2 421.9 302.4 365.1 407.1 460.9 517.7 331.9 397.5 469.1 516.3 575.3 346.6 421.9 495.6 562.3 652 368.8 454.3 539.9 645.3 728.7 376.1 470.5 566.4 682.2 767


App. B-6



APPENDIX B

BURIAL DATA


Depth 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

Soil Wgt


100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Diameter = 4 Inches Width of Trench in Feet 0.75 1 2 3 4 5 55.5 65.5 77.9 84.6 95.0 62.2 74.4 87.7 98.1 109.1 64.9 80.4 94.2 108.3 124.9 67.7 83.4 99.0 115.0 130.2 69.0 87.8 107.2 126.9 142.5 70.4 89.3 107.2 128.5 156.6 70.4 89.3 107.2 131.9 158.3 70.4 89.3 107.2 131.9 158.3 70.4 89.3 107.2 131.9 158.3 70.4 89.3 107.2 131.9 158.3 70.4 89.3 107.2 131.9 158.3 70.4 89.3 107.2 131.9 158.3

64.9 75.4 86.6 94.7 103.2 74.0 87.3 99.6 112.8 126.7 81.2 97.2 114.7 126.3 140.7 83.0 103.2 121.2 135.3 159.5 90.2 111.1 132.1 153.4 178.3 92.0 115.1 138.6 166.9 187.6 93.8 119.1 142.9 173.7 211.1 93.8 119.1 142.9 175.9 211.1 93.8 119.1 142.9 175.9 211.1 93.8 119.1 142.9 175.9 211.1 93.8 119.1 142.9 175.9 211.1 93.8 119.1 142.9 175.9 211.1

86.6 95.3 108.3 112.8 122.0 101.0 115.1 129.9 144.3 154.8 122.7 135.0 151.6 162.4 178.3 126.3 150.8 173.2 189.4 206.4 147.9 174.6 199.2 225.5 253.3 162.4 194.5 229.5 252.6 281.5 176.8 218.3 259.8 297.7 351.8 184.0 230.2 277.1 333.8 375.3 187.6 238.2 281.5 342.8 403.4 187.6 238.2 285.8 347.3 412.8 187.6 238.2 285.8 351.8 422.2 187.6 238.2 285.8 351.8 422.2

88.8 101.2 111.7 121.8 129.5 108.3 119.1 155.9 162.4 168.9 135.3 154.8 168.9 189.4 190.0 151.6 172.7 194.9 216.5 239.2 173.2 208.4 233.8 243.6 281.5 200.3 238.2 279.3 297.7 323.7 243.6 267.9 350.7 378.9 422.2 259.8 321.5 376.7 433.0 499.6 270.6 333.4 396.2 473.6 548.8 276.0 345.3 415.7 500.7 562.9 281.5 357.2 428.7 514.2 626.2 281.5 357.2 428.7 527.7 633.3

93.8 103.2 116.0 126.3 133.2 118.4 131.8 149.0 162.4 172.6 137.1 158.8 173.2 198.5 215.8 173.2 190.5 216.5 225.5 243.9 202.1 230.2 259.8 288.7 319.0 245.4 269.9 303.1 324.8 356.5 281.5 349.3 398.4 433.0 469.1 324.8 389.0 459.0 505.2 562.9 339.2 412.8 485.0 559.3 647.3 353.6 436.6 519.6 595.4 703.6 368.1 460.4 554.2 667.5 750.5 375.3 476.3 562.9 694.6 806.8

95.6 105.2 119.1 126.3 136.0 122.7 136.9 151.6 164.6 175.9 147.9 168.7 186.2 201.8 215.8 158.8 178.6 205.7 225.5 246.3 216.5 238.2 270.6 293.2 328.4 252.6 287.8 324.8 356.3 398.7 279.6 367.1 433.0 473.6 516.0 369.9 446.5 498.0 563.8 633.3 405.9 486.2 573.7 631.5 703.6 424.0 516.0 606.2 687.8 797.4 451.0 555.7 660.3 789.3 891.3 460.1 575.5 692.8 834.4 938.2

Nominal Piping Diameter = 6 Inches Width of Trench in Feet 1 2 3 4 5 94.4 109.6 125.8 137.6 149.9 107.5 126.8 144.7 163.8 184.0 117.9 141.3 166.7 183.5 204.4 120.6 149.9 176.1 196.6 231.7 131.0 161.4 191.8 222.8 258.9 133.7 167.2 201.3 242.4 272.6 136.3 173.0 207.6 252.3 306.6 136.3 173.0 207.6 255.5 306.6 136.3 173.0 207.6 255.5 306.6 136.3 173.0 207.6 255.5 306.6 136.3 173.0 207.6 255.5 306.6 136.3 173.0 207.6 255.5 306.6

125.8 138.4 157.3 163.8 177.2 146.8 167.2 188.7 209.7 224.9 178.2 196.0 220.2 235.9 258.9 183.5 219.1 251.6 275.2 299.8 214.9 253.7 289.3 327.6 368.0 235.9 282.5 333.4 366.9 408.9 256.8 317.1 377.4 432.4 511.1 267.3 334.4 402.6 484.9 545.1 272.6 346.0 408.9 498.0 586.0 272.6 346.0 415.1 504.5 599.6 272.6 346.0 415.1 511.1 613.3 272.6 346.0 415.1 511.1 613.3

128.9 147.0 162.3 176.9 188.1 157.3 173.0 226.4 235.9 245.3 196.6 224.9 245.3 275.2 276.0 220.2 250.8 283.1 314.5 347.5 251.6 302.7 339.7 353.8 408.8 290.9 346.0 405.7 432.4 470.2 353.8 389.2 509.5 550.4 613.3 377.4 467.0 547.2 629.0 725.7 393.1 484.3 575.5 688.0 797.3 401.0 501.6 603.8 727.3 817.7 408.8 518.9 622.7 746.9 909.7 408.8 518.9 622.7 766.6 919.9

136.3 149.9 168.6 183.5 193.5 171.9 191.4 216.4 235.9 250.8 199.2 230.6 251.6 288.3 313.5 251.6 276.8 314.5 327.6 354.3 293.5 334.4 377.4 419.3 463.4 356.4 392.1 440.3 471.8 517.9 408.9 507.4 578.7 629.0 681.4 471.8 565.1 666.7 733.8 817.7 492.7 599.6 704.5 812.5 940.4 513.7 634.2 754.8 864.9 1022.1 534.7 668.8 805.1 969.7 1090.3 545.1 691.9 817.7 1009.0 1172.0

138.9 152.8 173.0 183.5 197.6 178.2 198.9 220.2 239.2 255.5 214.9 245.0 270.5 293.2 313.5 230.6 259.5 298.8 327.6 357.7 314.5 346.0 393.1 425.9 477.0 366.9 418.0 471.8 517.6 579.2 406.2 533.3 629.0 688.0 749.6 537.3 648.7 723.4 819.0 919.9 589.7 706.3 833.4 917.3 1022.1 615.9 749.6 880.6 999.2 1158.4 655.2 807.2 959.2 1146.6 1294.7 668.3 836.0 1006.4 1212.1 1362.8




App. B-7

B

APPENDIX B

BURIAL DATA


Depth

B

3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50


Soil Wgt 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Diameter = 8 Inches Width of Trench in Feet 1 2 3 4 5 118.1 137.1 157.4 172.2 187.6 134.4 158.7 181.0 204.9 230.2 147.6 176.7 208.6 229.5 255.8 150.8 187.6 220.4 245.9 289.9 164.0 202.0 240.0 278.7 324.0 167.2 209.2 251.8 303.3 341.0 170.5 216.4 259.7 315.6 383.7 170.5 216.4 259.7 319.7 383.7 170.5 216.4 259.7 319.7 383.7 170.5 216.4 259.7 319.7 383.7 170.5 216.4 259.7 319.7 383.7 170.5 216.4 259.7 319.7 383.7

157.4 173.1 196.8 204.9 221.7 183.6 209.2 236.1 262.3 281.4 223.0 245.3 275.5 295.1 324.0 229.5 274.1 314.8 344.3 375.1 268.9 317.4 362.0 409.9 460.4 295.1 353.5 417.1 459.1 511.6 321.4 396.8 472.2 541.1 639.4 334.5 418.4 503.7 606.6 682.1 341.0 432.9 511.6 623.0 733.2 341.0 432.9 519.4 631.2 750.3 341.0 432.9 519.4 639.4 767.3 341.0 432.9 519.4 639.4 767.3

161.3 184.0 203.0 221.3 235.3 196.8 216.4 283.3 295.1 306.9 245.9 281.4 306.9 344.3 345.3 275.5 313.8 354.2 393.5 434.8 314.8 378.7 425.0 442.7 511.6 364.0 432.8 507.6 541.1 588.3 442.7 487.0 637.5 688.6 767.3 472.2 584.3 684.7 787.0 908.0 491.9 606.0 720.1 860.8 997.5 501.7 627.6 755.5 910.0 1023.1 511.6 649.3 779.1 934.6 1138.2 511.6 649.3 779.1 959.2 1151.0

170.5 187.6 210.9 229.5 242.1 215.1 239.5 270.7 295.1 313.8 249.2 288.6 314.8 360.7 392.2 314.8 346.3 393.5 409.9 443.3 367.3 418.4 472.2 524.7 579.8 446.0 490.6 550.9 590.3 648.0 511.6 634.8 724.0 787.0 852.6 590.3 707.0 834.2 918.2 1023.1 616.5 750.3 881.4 1016.5 1176.6 642.7 793.6 944.4 1082.1 1278.9 669.0 836.8 1007.4 1213.3 1364.1 682.1 865.7 1023.1 1262.5 1466.4

173.8 191.2 216.4 229.5 247.2 223.0 248.9 275.5 299.2 319.7 268.9 306.6 338.4 366.9 392.2 288.6 324.6 373.8 409.9 447.6 393.5 432.9 491.9 532.9 596.8 459.1 523.0 590.3 647.6 724.7 508.3 667.3 787.0 860.8 937.8 672.2 811.6 905.1 1024.7 1151.0 737.8 883.7 1042.8 1147.7 1278.9 770.6 937.8 1101.8 1250.2 1449.4 819.8 1010.0 1200.2 1434.6 1619.9 836.2 1046.1 1259.2 1516.6 1705.2

Nominal Piping Diameter = 10 Inches Width of Trench in Feet 2 3 4 5 196.8 216.5 246.0 256.3 277.2 229.6 261.6 295.2 328.0 351.8 278.8 306.7 344.4 369.0 405.1 287.0 342.8 393.6 430.5 469.0 336.2 396.9 452.6 512.5 575.6 369.0 442.0 521.5 574.0 639.6 401.8 496.1 590.4 676.5 799.5 418.2 523.2 629.8 758.5 852.8 426.4 541.2 639.6 779.0 916.8 426.4 541.2 649.4 789.3 938.1 426.4 541.2 649.4 799.5 959.4 426.4 541.2 649.4 799.5 959.4

201.7 230.0 253.9 276.8 294.2 246.0 270.6 354.2 369.0 383.8 307.5 351.8 383.8 430.5 431.7 344.4 392.4 442.8 492.0 543.7 393.6 473.6 531.4 553.5 639.6 455.1 541.2 634.7 676.5 735.5 553.5 608.9 797.0 861.0 959.4 590.4 730.6 856.1 984.0 1135.3 615.0 757.7 900.4 1076.3 1247.2 627.3 784.7 944.6 1137.8 1279.2 639.6 811.8 974.2 1168.5 1423.1 639.6 811.8 974.2 119.3 1439.1

213.2 234.5 263.7 287.0 302.7 269.0 299.5 338.5 369.0 392.3 311.6 360.8 393.6 451.0 490.4 393.6 433.0 492.0 512.5 554.3 459.2 523.2 590.4 656.0 724.9 557.6 613.4 688.8 738.0 810.2 639.6 793.8 905.3 984.0 1066.0 738.0 884.0 1043.0 1148.0 1279.2 770.8 938.1 1102.1 1271.0 1471.1 803.6 992.2 1180.8 1353.0 1599.0 836.4 1046.3 1259.5 1517.0 1705.6 852.8 1082.4 1279.2 1578.5 1833.5

217.3 239.0 270.6 287.0 309.1 278.8 311.2 344.4 374.1 399.8 336.2 383.4 423.1 458.7 490.4 360.8 405.9 467.4 512.5 559.7 492.0 541.2 615.0 666.3 746.2 574.0 654.0 738.0 809.8 906.1 635.5 834.4 984.0 1076.3 1172.6 840.5 1014.8 1131.6 1281.3 1439.1 922.5 1105.0 1303.8 1435.0 1599.0 963.5 1172.6 1377.6 1563.1 1812.2 1025.0 1262.8 1500.6 1793.8 2025.4 1045.5 1307.9 1574.4 1896.3 2132.0


App. B-8



APPENDIX B

BURIAL DATA


Depth 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50

Soil Type granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay granular w/o cohesion sand & gravel saturated top soil dry clay saturated clay


Soil Wgt 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Diameter = 12 Inches Width of Trench in Feet 2 3 4 5 248 272.8 310 322.9 349.3 289.3 329.6 372 413.3 443.3 351.3 386.5 434 465 510.5 361.7 431.9 496 542.5 591.1 423.7 500.1 570.4 645.8 725.4 465 557 657.2 723.3 806 506.3 625.2 744 852.5 1007.5 527 659.3 793.6 955.8 1074.7 537.3 682 806 981.7 1155.3 537.3 682 818.4 994.6 1182.1 537.3 682 818.4 1007.5 1209 537.3 682 818.4 1007.5 1209

254.2 289.8 319.9 348.7 370.8 310 341 446.4 465 483.6 387.5 443.3 483.6 542.5 544.1 434 494.4 558 620 685.1 496 596.7 669.6 697.5 806 573.5 682 799.8 852.5 926.9 697.5 767.2 1004.4 1085 1209 744 920.7 1078.8 1240 1430.7 775 954.8 1134.6 1356.2 1571.7 790.5 988.9 1190.4 1433.7 1612 806 1023 1227.6 1472.5 1793.4 806 1023 1227.6 1511.2 1813.5

268.7 295.5 332.3 361.7 381.5 338.9 377.4 426.6 465 494.3 392.7 454.7 496 568.3 617.9 496 545.6 620 645.8 698.5 578.7 659.3 744 826.7 913.5 702.7 772.9 868 930 1020.9 806 1000.3 1140.8 1240 1343.3 930 1113.9 1314.4 1446.7 1612 971.3 1182.1 1388.8 1601.7 1853.8 1012.7 1250.3 1488 1705 2015 1054 1318.5 1587.2 1911.7 2149.3 1074.7 1364 1612 1989.2 2310.5

273.8 301.2 341 361.7 389.6 351.3 392.1 434 471.5 503.8 423.7 483.1 533.2 578 617.9 454.7 511.5 589 645.8 705.3 620 682 775 839.6 940.3 723.3 824.1 930 1020.4 1141.8 800.8 1051.4 1240 1356.3 1477.7 1059.2 1278.8 1426 1614.6 1813.5 1162.5 1392.4 1643 1808.3 2015 1214.2 1477.7 1736 1969.8 2283.7 1291.7 1591.3 1891 2260.4 2552.3 1317.5 1648.2 1984 2389.6 2686.7

Nominal Piping Diameter = 14 Inches Width of Trench in Feet 2 3 4 5 279.6 307.6 349.5 364.1 393.8 326.2 371.6 419.4 466 499.8 396.1 435.7 489.3 524.3 575.5 407.8 487 559.2 611.6 666.4 477.7 563.9 643.1 728.1 817.8 524.3 627.9 740.9 815.5 908.7 570.9 704.8 838.8 961.1 1135.9 594.2 743.3 894.7 1077.6 1211.6 605.8 768.9 908.7 1106.8 1302.5 605.8 768.9 922.7 1121.3 1332.8 605.8 768.9 922.7 1135.9 1363.1 605.8 768.9 922.7 1135.9 1363.1

286.6 326.8 360.7 393.2 418 349.5 384.5 503.3 524.3 545.2 436.9 499.8 545.2 611.6 613.4 489.3 557.5 629.1 699 772.4 559.2 672.8 754.9 786.4 908.7 646.6 768.9 901.7 961.1 1045 786.4 865 1132.4 1223.3 1363.1 838.8 1038 1216.3 1398 1612.9 873.8 1076.5 1279.2 1529.1 1772 891.2 1114.9 1342.1 1616.4 1817.4 908.7 1153.4 1384 1660.1 2021.9 908.7 1153.4 1384 1703.8 2044.6

302.9 333.2 374.7 407.8 430.1 382.1 425.5 480.9 524.3 557.3 442.7 512.6 559.2 640.8 696.7 559.2 615.1 699 728.1 787.5 652.4 743.3 838.8 932 1029.9 792.2 871.4 978.6 1048.5 1151 908.7 1127.7 1286.2 1398 1514.5 1048.5 1255.9 1481.9 1631 1817.4 1095.1 1332.8 1565.8 1805.8 2090 1141.7 1409.7 1677.6 1922.3 2271.8 1188.3 1486.5 1789.4 2155.3 2423.2 1211.6 1537.8 1817.4 2242.6 2604.9

308.7 339.6 384.5 407.8 439.2 396.1 442.1 489.3 531.5 567.9 477.7 544.6 601.1 651.7 696.7 512.6 576.7 664.1 728.1 795.1 699 768.9 873.8 946.6 1060.2 815.5 929.1 1048.5 1150.4 1287.3 902.9 1185.4 1398 1529.1 1666 1194.1 1441.7 1607.7 1820.3 2044.6 1310.6 1569.8 1852.4 2038.8 2271.8 1368.9 1666 1957.2 2220.8 2574.7 1456.3 1794.1 2132 2548.4 2877.6 1485.4 1858.2 2236.8 2694.1 3029

Nominal Piping Diameter = 16 Inches Width of Trench in Feet 2 3 4 5 315 346.5 393.8 410.2 443.6 367.5 418.7 472.5 525 563.1 446.3 490.9 551.3 590.6 648.4 459.4 548.6 630 689.1 750.8 538.1 635.3 724.5 820.3 921.4 590.6 707.4 834.8 918.8 1023.8 643.1 794.1 945 1082.8 1279.7 669.4 837.4 1008 1214.1 1365 682.5 866.3 1023.8 1246.9 1467.4 682.5 866.3 1039.5 1263.3 1501.5 682.5 866.3 1039.5 1279.7 1535.6 682.5 866.3 1039.5 1279.7 1535.6


322.9 368.2 406.4 443 470.9 393.8 433.1 567 590.6 614.3 492.2 563.1 614.3 689.1 691 551.3 628 708.8 787.5 870.2 630 758 850.5 885.9 1023.8 728.4 866.3 1015.9 1082.8 1177.3 885.9 974.5 1275.8 1378.1 1535.6 945 1169.4 1370.3 1575 1817.2 984.4 1212.8 1441.1 1722.7 1996.3 1004.1 1256.1 1512 1821.1 2047.5 1023.8 1299.4 1559.3' 1870.3 2277.8 1023.8 1299.4 1559.3 1919.5 2303.4

341.3 375.4 422.1 459.4 484.6 430.5 479.3 541.8 590.6 627.9 498.8 577.5 630 721.9 784.9 630 693 787.5 820.3 887.3 735 837.4 945 1050 1160.3 892.5 981.8 1102.5 1181.3 1296.8 1023.8 1270.5 1449 1575 1706.3 1181.3 1414.9 1669.5 1837.5 2047.5 1233.8 1501.5 1764 2034.4 2354.6 1286.3 1588.1 1890 2165.6 2559.4 1338.8 1674.8 2016 2428.1 2730 1365 1732.5 2047.5 2526.6 2934.8

347.8 382.6 433.1 459.4 494.8 446.3 498.1 551.3 598.8 639.8 538.1 613.6 677.3 734.2 784.9 577.5 649.7 748.1 820.3 895.8 787.5 866.3 984.4 1066.4 1194.4 918.8 1046.7 1181.3 1296.1 1450.3 1017.2 1335.5 1575 1722.7 1876.9 1345.3 1624.2 1811.3 2050.8 2303.4 1476.6 1768.6 2086.9 2296.9 2559.4 1542.2 1876.9 2205 2502 2900.6 1640.6 2021.3 2401.9 2871.1 3241.9 1673.4 2093.4 2520 3035.2 3412.5

App. B-9

B

APPENDIX B

BURIAL DATA


Depth

B

3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 8 8 8 8 8 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 25 25 25 25 25 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50


Soil Wgt 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130 100 110 120 125 130

Nominal Piping Dia = 18" Width of Trench in Feet 2 3 4 5 354.4 389.8 443.0 461.5 499.1 413.5 471.1 531.6 590.7 633.5 502.1 552.3 620.2 664.5 729.5 516.8 617.2 708.8 775.3 844.7 605.4 714.7 815.1 922.9 1036.6 664.5 795.9 939.2 1033.7 1151.8 723.6 893.4 1063.2 1218.3 1439.8 753.1 942.1 1134.1 1365.9 1535.7 767.9 974.6 1151.8 1402.8 1650.9 767.9 974.6 1169.5 1421.3 1689.3 767.9 974.6 1169.5 1439.8 1727.7 767.9 974.6 1169.5 1439.8 1727.7

363.3 414.2 457.2 498.4 529.8 443.0 487.3 637.9 664.5 691.1 553.8 633.5 691.1 775.3 777.5 620.2 706.6 797.4 886.0 979.0 708.8 852.8 956.9 996.8 1151.8 819.6 974.6 1142.9 1218.3 1324.6 996.8 1096.4 1435.3 1550.5 1727.7 1063.2 1315.7 1541.6 1772.0 2044.4 1107.5 1364.4 1621.4 1938.1 2246.0 1129.7 1413.2 1701.1 2048.9 2303.6 1151.8 1461.9 1754.3 2104.3 2562.8 1151.8 1461.9 1754.3 2159.6 2591.6

383.9 422.3 474.9 516.8 545.2 484.3 539.3 609.6 664.5 706.4 561.1 649.7 708.8 812.2 883.0 708.8 779.7 886.0 922.9 998.2 826.9 942.1 1063.2 1181.3 1305.4 1004.1 1104.5 1240.4 1329.0 1458.9 1151.8 1429.4 1630.2 1772.0 1919.7 1329.0 1591.8 1878.3 2067.3 2303.6 1388.1 1689.3 1984.6 2288.8 2649.1 1447.1 1786.8 2126.4 2436.5 2879.5 1506.2 1884.2 2268.2 2731.8 3071.5 1535.7 1949.2 2303.6 2842.6 3301.8

391.3 430.4 487.3 516.8 556.7 502.1 560.4 620.2 673.7 719.9 605.4 690.3 762.0 826.0 883.0 649.7 731.0 841.7 922.9 1007.8 886.0 974.6 1107.5 1199.8 1343.8 1033.7 1177.6 1329.0 1458.2 1631.7 1144.4 1502.5 1772.0 1938.1 2111.6 1513.6 1827.4 2037.8 2307.3 2591.6 1661.3 1989.8 2347.9 2584.2 2879.5 1735.1 2111.6 2480.8 2814.9 3263.4 1845.8 2274.1 2702.3 3230.2 3647.4 1882.8 2355.3 2835.2 3414.8 3839.3

Nominal Piping Dia = 20" Nominal Piping Dia = 24" Width of Trench in Feet Width of Trench in Feet 3 4 5 3 4 5 403.6 460.3 508.0 553.8 588.7 492.2 541.5 708.8 738.4 767.9 615.3 703.9 767.9 861.4 863.9 689.1 785.1 886.1 984.5 1087.9 787.6 947.6 1063.3 1107.6 1279.9 910.7 1083.0 1270.0 1353.7 1471.8 1107.6 1218.3 1594.9 1722.9 1919.8 1181.4 1462.0 1713.0 1969.0 2271.7 1230.6 1516.1 1801.6 2153.6 2495.7 1255.2 1570.3 1890.2 2276.7 2559.7 1279.9 1624.4 1949.3 2338.2 2847.7 1279.9 1624.4 1949.3 2399.7 2879.7

426.6 469.3 527.7 574.3 605.8 538.2 599.2 677.3 738.4 785.0 623.5 722.0 787.6 902.5 981.2 787.6 866.4 984.5 1025.5 1109.2 918.9 1046.9 1181.4 1312.7 1450.5 1115.8 1227.3 1378.3 1476.8 1621.1 1279.9 1588.3 1811.5 1969.0 2133.1 1476.8 1768.8 2087.1 2297.2 2559.7 1542.4 1877.1 2205.3 2543.3 2943.7 1608.0 1985.4 2362.8 2707.4 3199.6 1673.7 2093.7 2520.3 3035.5 3412.9 1706.5 2165.9 2559.7 3158.6 3668.9

434.8 478.3 541.5 574.3 618.6 557.9 622.7 689.2 748.6 799.9 672.7 767.1 846.7 917.8 981.2 722.0 812.2 935.3 1025.5 1119.9 984.5 1083.0 1230.6 1333.2 1493.2 1148.6 1308.6 1476.8 1620.3 1813.1 1271.6 1669.5 1969.0 2153.6 2346.4 1681.9 2030.5 2264.4 2563.8 2879.7 1845.9 2211.0 2608.9 2871.5 3199.6 1928.0 2346.4 2756.6 3127.8 3626.2 2051.0 2526.9 3002.7 3589.3 4052.9 2092.1 2617.1 3150.4 3794.4 4266.2

508.4 579.7 639.8 697.5 741.5 620.0 682.0 892.8 930.0 967.2 775.0 886.6 967.2 1085.0 1088.1 868.0 988.9 1116.0 1240.0 1370.2 992.0 1193.5 1339.2 1395.0 1612.0 1147.0 1364.0 1599.6 1705.0 1853.8 1395.0 1534.5 2008.8 2170.0 2418.0 1488.0 1841.4 2157.6 2480.0 2861.3 1550.0 1909.6 2269.2 2712.5 3143.4 1581.0 1977.8 2380.8 2867.5 3224.0 1612.0 2046.0 2455.2 2945.0 3586.7 1612.0 2046.0 2455.2 3022.5 3627.0

537.3 591.1 664.6 723.3 763.0 677.9 754.7 853.1 930.0 988.7 785.3 909.3 992.0 1136.7 1235.9 992.0 1091.2 1240.0 1291.7 1397.1 1157.3 1318.5 1488.0 1653.3 1826.9 1405.3 1545.9 1736.0 1860.0 2041.9 1612.0 2000.5 2281.6 2480.0 2686.7 1860.0 2227.9 2628.8 2893.3 3224.0 1942.7 2364.3 2777.6 3203.3 3707.6 2025.3 2500.7 2976.0 3410.0 4030.0 2108.0 2637.1 3174.4 3823.3 4298.7 2149.3 2728.0 3224.0 3978.3 4621.1

547.7 602.4 682.0 723.3 779.1 702.7 784.3 868.0 942.9 1007.5 847.3 966.2 1066.4 1156.0 1235.9 909.3 1023.0 1178.0 1291.7 1410.5 1240.0 1364.0 1550.0 1679.2 1880.7 1446.7 1648.2 1860.0 2040.8 2283.7 1601.7 2102.8 2480.0 2712.5 2955.3 2118.3 2557.5 2852.0 3229.2 3627.0 2325.0 2784.8 3286.0 3616.7 4030.0 2428.3 2955.3 3472.0 3939.6 4567.3 2583.3 3182.7 3782.0 4520.8 5104.7 2635.0 3296.3 3968.0 4779.2 5373.3


App. B-10



APPENDIX B

BURIAL DATA

Table B-3. Average Values of Modulus of Soil Reaction, E' (for initial flexible pipe deflection) E' for Degree of Compaction of Bedding, (in pounds per square inch)

Soil type-pipe bedding material

Dumped D umped (2)

(Unified Classification System)

(1) Fine-grained Soils (LL > 50)b Soils with medium to high plasticity CH, MH, CH - MH Fine-grained Soils (LL < 50) Soils with medium to no plasticity CL, ML, ML- CL, with less than 25% coarse-grained particles Fine-grained Soils (LL < 50) Soils with medium to no plasticity CL, ML, ML,CL, with more than 25% coarse-grained particles Coarse-grained Soils with Fines GM, GC, SM, SCc contains more than 12% fines Coarse-grained Soils with Little or No Fines CW, CP, SW, SPc contains less than 12% fines Crushed Rock Accuracy in Terms of Percentage Deflectiond

Slight, <85% Proctor, <40% Relative Density (3)

Moderate, 85%-90% Proctor, 40%-70% Relative Density (4)

High, >95% Proctor, >70% (5)

No data available; consult a competent soils engineer; otherwise use E' = 0 50

200

400

1,000

100

400

1,000

2,000

200

1,000

2,000

3,000

1,000 ±2

3,000 ±2

3,000

3,000 ±1

±0.5

a ASTM

Designation D-2487, USBR Designation E-3. = Liquid limit. c Or any borderline soil beginning with one of these symbols (i.e., GM-GC, GC-SC). d For ±1 % accuracy and predicted deflection of 3%, actual deflection would be between 2% and 4%. b LL

Note: Values applicable only for fills less than 50 ft (15m). Table does not include any safety factor. For use in predicting initial deflections only, appropriate Deflection Lag Factor must be applied for long-term deflections. If bedding falls on the borderline between two compaction categories, select lower E' value or average the two values. Percentage Proctor based on laboratory maximum dry density from test standards using about 12,500 ft-lb/cu ft (598,000 J/m3) (ASTM D-698, AASHO T-99, USBR Designation E-1 1). 1 psi = 6.9 kN/M2. Source: “Soil Reaction for Buried Flexible Pipe” by Amster K. Howard, U.S. Bureau of Reclamation, Denver, Colorado. Reprinted with permission from American Society of Civil Engineers’ Journal of Geotechnical Engineering Division. January 1977, PP. 33-43.

Table B-4. Values of Bedding Constant, K Bedding Angle (degrees)

K

0 30 45 60 90 120 180

0.110 0.108 0.105 0.102 0.096 0.090 0.083



B

App. B-11

APPENDIX B


B

App. B-12



Appendix C CONVERSION TABLES Contents General Conversion Tables . . . . . . . . . . . . . . . . . . . . . . .C-2 Volumetric Flow Rate Conversion Tables . . . . . . . . . . . .C-8 Pressure Conversion Tables . . . . . . . . . . . . . . . . . . . . . .C-9 Viscosity Conversion Tables . . . . . . . . . . . . . . . . . . . . .C-10 Force Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . .C-10 Heat Transfer Coefficient Conversion Tables . . . . . . .C-11 Thermal Conductivity Coefficient Conversion Table . .C-11 Various Values of the Ideal Gas Law Constant . . . . . .C-11

C



App. C-1

APPENDIX C To Convert From

C

App. C-2

GENERAL CONVERSION TABLES

Multiply By

To Obtain

Acres

43,560

Square feet

Acres

4074

Square meters

Acres

0.001563

Square miles

Acre-feet

1233

Cubic meters

Ampere-hours (absolute)

3600

Coulombs (absolute)

Angstrom units

3.937 x 10-9

Inches

Angstrom units

1 x 10-10

Meters

Angstrom units

1 x 10-4

Microns

Atmospheres

760

Millimeters of mercury at 32° F 106

Atmospheres

1.0133 x

Atmospheres

101,325

Newtons per square meter

Atmospheres

33.90

Feet of water at 39.1° F

Atmospheres

1033.3

Grams per square centimeter

Atmospheres

29.921

Inches of mercury at 32° F

Atmospheres

2116.3

Pounds per square foot

Atmospheres

14.696

Pounds per square inch

Bags (cement)

94

Pounds (cement)

Barrels (cement)

376

Pounds (cement)

Barrels (oil)

0.15899

Cubic meters

Barrels (oil)

42

Gallons

Barrels (U.S. liquid)

0.11924

Cubic meters


31.5

Gallons

Barrels per day

0.02917

Gallons per minute

Bars

0.9869

Atmospheres

Bars

1 x 105


Bars

14.504


Bars

0.98

Kilogram force per square centimeter

Board feet

1112

Cubic feet

Boiler horsepower

33,480

Btu per hour

Boiler horsepower

9.803

Kilowatts

Btu

252

Calories (gram)

Btu

0.55556

Centigrade heat units (chu or pcu)

Btu

777.9

Foot-pounds

Btu

3.929 x 10-4

Horsepower-hours

Btu

1055.1

Joules

Btu

10.41

Liter-atmospheres

Btu

6.88 x 10-5

Pounds carbon to CO2

Btu

0.001036

Pounds water evaporated from and at 212° F

Btu

0.3676

Cubic foot-atmospheres 10-4

Dynes per square centimeter

Btu

2.930 x

Btu per cu ft

37,260

Joules per cubic meter

Btu per hour

0.29307

Wafts

Btu per min

0.02357

Horsepower

Btu per lb

2326

Joules per kilogram

Btu per lb per ° F

1

Calories per gram per degree centigrade

Kilowatt-hours



APPENDIX C


To Convert From

Multiply By

To Obtain

Btu per lb per ° F

4186.8

Joules per kilogram per degree Kelvin

Btu per sec

1054.4

Watts

Btu per sq ft per hour

3.1546

Joules per square meter per second

Btu per sq ft per min

0.1758

Kilowatts per square foot

Btu per sq ft per sec for a temp 1.2405

Calories, gram (15° C), per sq cm per sec

gradient of 1° F per in

for a temperature gradient of 1° C per cm

Btu (60° F) per° F

453.6

Calories per degree centigrade

Bushels (U.S. dry)

1.2444

Cubic feet

Bushels (U.S. dry)

0.03524 10-3

Cubic meters

Calories, gram

3.968 x

Calories, gram

3.087

Calories, gram

4.1868

Joules

Calories, gram

4.130 x 10-2

Liter-atmospheres

Calories, gram

1.5591 x 10-6

Horsepower-hours

Btu Foot-pounds

Calories, gram, per gram per °C 4186.8

Joules per kilogram per degree Kelvin

Calories, kilogram

0.0011626

Kilowatt-hours

Calories, kilogram per sec

4.185

Kilowatts

Candle power (spherical)

12.556

Lumens

Carats (metric)

0.2

Grams

Centigrade heat units

1.8

Btu

Centimeters

1 x 108

Angstrom units

Centimeters

0.03281

Feet

Centimeters

0.3937

Inches

Centimeters

0.01

Meters

Centimeters

10,000

Microns

Cm of mercury at 0° C

0.013158

Atmospheres


0.4460



1333.2



27.845



0.19337


Cm per sec

1.9685

Feet per minute

Cm of water at 4° C

98.064


Centistokes

I x 10-6

Square meters per second

Circular mils

5.067 x 10-6

Square centimeters

Circular mils

7.854 x 10-7

Square inches

Circular mils

0.7854

Square mils

Cords

128

Cubic feet

Cubic cm

3.532 x 10-5

Cubic feet

Cubic cm

2.6417 x 10-4

Gallons

Cubic cm

0.03381

Ounces (U.S. fluid)

Cubic cm

0.0010567

Quarts (U.S. fluid)

Cubic feet

0.8036

Bushels (U.S.)

Cubic feet

28,317

Cubic centimeters

Cubic feet

0.0005787

Cubic inches

Cubic feet

0.028317

Cubic meters



C

App. C-3

APPENDIX C

C

App. C-4


To Convert From

Multiply By

To Obtain

Cubic feet

0.03704

Cubic yards

Cubic feet

7.481

Gallons

Cubic feet

28.316

Liters

Cubic foot-atmospheres

2116.3

Foot-pounds


28.316

Liter-atmospheres

Cubic feet of water (60° F)

62.37

Pounds

Cubic feet per min

472.0

Cubic centimeters per second

Cubic feet per min

0.1247

Gallons per second

Cubic feet per sec

448.8

Gallons per minute

Cubic feet per sec

0.64632

Million gallons per day

Cubic inches

1.6387 x 10-5

Cubic meters

Cubic yards

0.76456

Cubic meters

Curies

2.2 x 1012

Disintegrations per minute

Curies

1.1 x 1012

Coulombs per minute

Degrees

0.017453

Radians

Drams (apothecaries or troy)

3.888

Grams

Drams (avoir dupois)

1.7719

Grams

Dynes

1 x 10-5

Newtons

Ergs

1 x 10-7

Joules

Faradays

96,500

Coulombs (abs)

Fathoms

6

Feet

Feet

0.3048

Meters

Feet per min

0.5080

Centimeters per second

Feet per min

0.011364

Miles per hour

Feet per (sec)2

0.3048

Meters per (sec)2


2989


Foot-poundals

3.995 x 10-5

Btu

Foot-poundals

0.04214

Joules

Foot-poundals

4.159 x 10-4

Liter-atmospheres

Foot-pounds

0.0012856

Btu

Foot-pounds

0.3239

Calories, gram

Foot-pounds

32.174

Foot-poundals 10-7

Foot-pounds

5.051 x

Foot-pounds

3.766 x 10-7

Kilowatt-hours

Foot-pounds

0.013381

Liter-atmospheres

Foot-pounds force

1.3558

Joules

Foot-pounds per sec

0.0018182

Horsepower

Horsepower-hours

Foot-pounds per sec

0.0013558

Kilowatts

Furlongs

0.125

Miles

Gallons (U.S. liquid)

0.03175


Gallons

0.003785

Cubic meters

Gallons

0.13368

Cubic feet

Gallons

0.8327

Gallons (Imperial)

Gallons

3.785

Liters

Gallons

128

Ounces (U.S. fluid)



APPENDIX C


To Convert From

Multiply By

To Obtain

Gallons per min

8.021

Cubic feet per hour

Gallons per min

0.002228

Cubic feet per second

Gallons per min

227.1

Liters per hour

Gallons per min

3.785

Liters per minute

Grains

0.06480

Grams

Grains

1/7000

Pounds

Grains per cu ft

2.2884

Grams per cubic meter

Grains per gallon

17.118

Parts per million

Grams

0.5644

Drams (avoir dupois)

Grams

0.2572

Drams (troy)

Grams

15.432

Grains

Grams

0.001

Kilograms

Grams

0.0022046

Pounds (avoir dupois)

Grams

0.002679

Pounds (troy)

Grams per cu cm

62.43

Pounds per cubic foot

Grams per cu cm

8.345

Pounds per gallon

Grams per liter

58.42

Grains per gallon

Grams per liter

0.0624

Pounds per cubic foot

Grams per sq cm

2.0482


Grams per sq cm

0.014223


Hectares

2.471

Acres

Hectares

10,000

Square meters

Horsepower (British)

42.42

Btu per minute


2545

Btu per hour


33,000

Foot-pounds per minute


550

Foot-pounds per second


745.7

Wafts


1.0139

Horsepower (metric)


0.175

Pounds carbon to CO2 per hour


2.64

Pounds water evaporated per hour at 212° F

Horsepower (metric)

542.47

Foot-pounds per second

Horsepower (metric)

7.5

Kilogram-meters per second

Hours (mean solar)

3600

Seconds

Inches

0.0254

Meters


13.61968

Inches of water


3376.9


Inches of water at 60° F

248.84


Joules (absolute)

9.480 x 10-4

Btu (mean)

Joules (absolute)

0.2389

Calories, gram (mean)

Joules (absolute)

0.3485


Joules (absolute)

0.7376

Foot-pounds

Joules (absolute)

2.7778 x 10-7

Kilowatt-hours

Joules (absolute)

0.009869

Liter-atmospheres

Kilocalories

4186.8

Joules

Kilograms

2.2046




C

App. C-5

APPENDIX C

C

App. C-6


To Convert From

Multiply By

To Obtain

Kilograms force

9.807

Newtons

Kilograms per sq cm

14.223


Kilograms per sq cm

1.02

Bars

Kilowatt-hours

3414

Btu

Kilowatt-hours

2.6552 x 106

Foot-pounds

Kilowatts

1.3410

Horsepower

Knots (international)

0.5144

Meters per second

Knots (nautical mph)

1.1516

Miles per hour

Lamberts

2.054

Candles per square inch

Liter-atmospheres

0.03532


Liter-atmospheres

74.74

Foot-pounds

Liters

0.03532

Cubic feet

Liters

0.001

Cubic meters

Liters

0.26418

Gallons

Lumens

0.001496

Watts

Micromicrons

1 x 10-6

Microns

Microns

1 x 104

Angstrom units

Microns

1 x 10-6

Meters

Miles (nautical)

6080

Feet

Miles (nautical)

1.1516

Miles (U.S. statute)

Miles

5280

Feet

Miles

1609.3

Meters

Miles per hour

1.4667

Feet per second

Miles per hour

0.4470

Meters per second

Milliliters

1

Cubic centimeters

Millimeters

0.001

Meters

Millimeters of Hg at 0° C

133.32


Millimicrons

0.001

Microns

Mils

0.001

Inches

Mils

2.54 x 10-5

Meters

Minims (U.S.)

0.06161

Cubic centimeters

Minutes (angle)

2.909 x 10-4

Radians

Minutes (mean solar)

60

Seconds

Newtons

0.10197

Kilograms

Newtons

0.22481

Pounds force

N/m2

0.10197

Kilogram force per square meter

N/mm2

10.1968

Kilogram force per square cm

Ounces (avoir dupois)

0.02835

Kilograms

Ounces (avoir dupois)

0.9115

ounces (troy) 10-5

Cubic meters

Ounces (U.S. fluid)

2.957 x

Ounces (troy)

1.000

Ounces (apothecaries')

Pints (U.S. liquid)

4.732 x 10-4

Cubic meters

Poundals

0.13826

Newtons


7000

Grains


0.45359

Kilograms



APPENDIX C


To Convert From

Multiply By

To Obtain


1.2153

Pounds (troy)

Pounds per cu ft

0.016018

Grams per cubic centimeter

Pounds per cu ft

16.018

Kilograms per cubic meter

Pounds per sq ft

4.725 x 10-4

Atmospheres

Pounds per sq ft

4.882

Kilograms per square meter

Pounds per sq in

0.06805

Atmospheres

Pounds per sq in

0.07031

Kilograms per square cm

Pounds per sq in

6894.8


Pounds force

4.4482

Newtons

Pounds force per sq ft

47.88


0.379

Horsepower-hours

Pounds water evaporated from and at 212° F Pound-centigrade units (pcu)

Btu 10-4

Quarts (U.S. liquid)

9.464 x

Radians

57.30

Revolutions per min

0.10472

Cubic meters Degrees

10-6

Radians per second

Seconds (angle)

4.848 x

Slugs

1

Slugs

14.594

Kilograms

Slugs

32.17

Pounds

Radians Gee pounds

Square cm

0.0010764

Square feet

Square feet

0-.0929

Square meters

Square feet per hr

2.581 x 10-5

Square meters per sec

Square inches

6.452

Square centimeters

Square inches

6.452 x 10-4

Square meters

Square inches

645.2

Square millimeters

Square yards

0.8361

Square meters

Stokes

1 x 10-4

Square meters per sec

Tons (long)

1016

Kilograms

Tons (long)

2240

Pounds

Tons (metric)

1000

Kilograms

Tons (metric)

2204.6

Pounds

Tons (metric)

1.1023

Tons (short)

Tons (short)

907.18

Kilograms

Tons (short)

2000

Pounds

Tons (refrigeration)

12,000

Btu per hour

Tons (British shipping)

42.00

Cubic feet

Tons (U.S. shipping)

40.00

Cubic feet

Torr (mm mercury, 0° C)

133.32


Wafts

3.413

Btu per hour

Wafts

1

Joules per second

Wafts

0.10197

Kilogram-meters per sec

Waft-hours

3600

Joules

Yards

0.9144

Meters


1.8


C

App. C-7

APPENDIX C

CONVERSION TABLES

VOLUMETRIC FLOW RATE CONVERSION TABLE Multiply by Table Values to Convert to These Units To Convert From:

m3/s

dm3/s

ft3/d

ft3/hr

ft3/min

ft3/s

m3/s dm3/s ft3/d ft3/hr ft3/min ft3/s U.K. gal/hr U.S. gal/hr U.K. gal/min U.S. gal/min bbl/d bbl/hr

1 10-3 3.277 x 10-7 7.866 x 10-6 4.719 x 10-4 2.832 x 10-2 1.263 x 10-6 1.052 x 10-6 7.577 x 10-5 6.309 x 10-5 1.840 x 10-6 4.416 x 10-5

103 1 3.277413 x 10-4 7.865791 x 10-3 4.719474 x 10-1 2.831685 x 101 1.262803 x 10-3 1.051503 x 10-3 7.576820 x 10-2 6.309020 x 10-2 1.840131 x 10-3 4.416314 x 10-2

3.05119 x 106 3.05119 x 103 1 24 1.4400 x 103 8.6400 x 104 2.6717 3.20856 1.6030 x 102 1.9253 x 102 5.615 1.3476 x 102

1.2713 x 105 1.2713 x 102 4.1667 x 10-2 1 60 3600 1.1132 x 10-1 1.3369 x 10-1 6.6793 8.0220 2.3396 x 10-1 5.615

2.1189 x 103 2.1189 6.9444 x 10-4 1.6667 x 10-2 1 60 1.8554 x 10-3 2.2282 x 10-3 1.1132 x 10-1 1.337 x 10-1 3.899 x 10-3 9.358 x 10-2

3.5315 x 101 3.5315 x 10 -2 1.15741 x 10-5 2.7778 x 10-4 1.6667 x 10-4 1 3.0923 x 10-5 3.7136 x 10-5 1.8554 x 10-3 2.228 x 10-3 6.499 x 10-5 1.5597 x 10-3

To Convert From:

U.K. gal/hr

U.S. gal/hr

U.K. gal/min

U.S. gal/min

bbl/d

bbl/hr

m3/s dm3/s ft3/d ft3/hr ft3/min ft3/s U.K. gal/hr U.S. gal/hr U.K. gal/min U.S. gal/min bbl/d bbl/hr

7.9189 x 105 7.9189 x 102 3.7429 x 10-1 8.9831 5.3897 x 102 3.234 x 104 1 1.20094 60 7.2056 x 101 2.1017 5.044 x 101

9.5102 x 105 9.5102 x 102 3.1167 x 10-1 7.48 4.488 x 102 2.693 x 104 8.327 x 10-1 1 4.9961 x 101 60 1.750 42

1.3198 x 104 1.3198 x 101 6.2383 x 10-3 1.4972 x 10-1 8.983 5.3897 x 102 1.667 x 10-2 2.00157 x 10-2 1 1.20094 3.503 x 10-2 8.407 x 10-1

1.5850 x 104 1.5850 x 101 5.1940 x 10-3 1.2466 x 10-1 7.48 4.488 x 102 1.3878 x 10-2 1.667 x 10-2 8.3268 x 10-1 1 2.917 x 10-2 7.000 x 10-1

5.4344 x 105 5.4344 x 102 1.781 x 10-1 4.274 2.565 x 102 1.539 x 104 4.758 x 10-1 5.714 x 10-1 2.855 x 101 3.428 x 101 1 24

2.2643 x 104 2.2643 x 101 7.421 x 10-3 1.781 x 10-1 1.069 x 101 6.411 x 102 1.983 x 10-2 2.381 x 10-2 1.189 1.429 4.1667 x 10-2 1

C

App. C-8



APPENDIX C

CONVERSION TABLES

VOLUMETRIC FLOW RATE CONVERSION TABLE Multiply by Table Values to Convert to These Units To Convert From:

g/cm-s2 (dyne/cm2)

kg/m-s2 (N/m2)

lbm/ft-s2 (poundal/ft2)

lbf/ft2

g/cm-s-2 (dyne/cm2) kg/m-s2 (N/m2) lbm /ft-s2 (poundal/ft2) lbf/ft2 lbf/in2 Atmospheres (atm) mm Hg in. Hg bar Pa kPa

1 10 1.4882 x 101 4.7880 x 102 6.8947 x 104 1.0133 x 105 1.332 x 103 3.3864 x 104 103 10-2 10

10-1 1 1.4882 4.7880 x 101 6.8947 x 103 1.0133 x 105 1.332 x 102 3.3864 x 103 102 10-3 1

6.7197 x 10-2 6.7197 x 10-1 1 32.1740 4.6330 x 103 6.8087 x 104 8.9588 x 101 2.2756 x 103 6.720 x 104 6.720 x 10-1 6.720 x 102

2.0886 x 10-3 2.0886 x 10-2 3.1081 x 10-2 1 144 2.1162 x 103 2.7845 7.0727 x 101 2.088 x 103 2.089 x 10-2 2.089 x 101

lbf/in2 (psi)

Atmospheres (atm)

mm Hg

in. Hg

1.4504 x 10-5 1.4504 x 10-4 2.1584 x 10-4 6.9444 x 10-3 1 14.696 1.9337 x 10-2 4.9116 x 10-1 1.450 x 10-3 1.450 x 10-4 1.450 x 10-3

9.8692 x 10-7 9.8692 x 10-6 1.4687 x 10-5 4.7254 x 10-4 6.8046 x 10-2 1 1.3158 x 10-3 3.3421 x 10-2 9.869 x 10-1 9.869 x 10-6 9.869 x 10-3

7.5006 x 10-4 7.5006 x 10-3 1.1162 x 10-2 3.5913 x 10-1 5.1715 x 101 760 1 25.400 7.5006 x 102 7.5006 x 10-3 7.5006

2.9530 x 10-5 2.9530 x 10-5 2.9530 x 10-4 1.4139 x 10-2 2.0360 29.921 3.9370 x 10-2 1 2.953 x 101 2.953 x 10-4 2.953 x 10-1

bar

Pa

kPa

10-3 10-2 1.488 x 10-5 4.78803 x 10-4 6.89476 x 102 1.01325 1.33322 x 10-3 3.38638 x 10-2 1 10-5 10-2

102 1.000-3 1.488 4.78803 x 101 6.89476 x 103 1.01325 x 105 1.33322 x 102 3.38638 x 103 105 1 103

10-1 1.000 1.488 x 10-3 4.78803 x 10-2 6.89476 1.01325 X 102 1 .33322 x 10-1 3.38638 100 10-3 1

To Convert From: g/cm-s-2 (dyne/cm2) kg/m-s2 (N/m2) lbm /ft-s2 (poundal/ft2) lbf/ft2 lbf/in2 Atmospheres (atm) mm Hg in. Hg bar Pa kPa

To Convert From: g/cm-s-2 (dyne/cm2) kg/m-s2 (N/m2) lbm /ft-s2 (poundal/ft2) lbf/ft2 lbf/in2 Atmospheres (atm) mm Hg in. Hg bar Pa kPa

C



App. C-9

APPENDIX C

CONVERSION TABLES

VISCOSITY CONVERSION TABLE Multiply by Table Values to Convert to These Units To Convert From:

g-cm-1-s-1 (poise)

kg-m-1-s-1

lbm-ft-1-s-1

lbf-s-ft-2

lbf-s-in-2

g-cm-1-s-1 (poise) kg-m-1-s-1 lbm-ft-1-s-1 lbf-s-ft-2 lbf-s-in-2 centipoise lbm-ft-1-hr-1 kgf-s-m-2 mPa-s

1 10 1.4882 x 101 4.7880 x 102 6.895 x 104 10-2 4.1338 x 10-3 9.806 x 101 10-2

10-1 1 1.4882 4.7880 x 101 6.895 x 103 10-3 4.1338 x 10-4 9.806 10-3

6.7197 x 10-2 6.7197 x 10-1 1 32.1740 4.633 x 103 6.7197 x 10-4 2.7778 x 10-4 6.589 6.719 x 10-4

2.0886 x 10-3 2.0886 x 10-2 3.1081 x 10-2 1 144 2.0886 x 10-5 8.6336 x 10-6 2.048 x 10-1 2.089 x 10-5

1.4504 x 10-5 1.4504 x 10-4 2.1584 x 10-4 6.9444 x 10-3 1 1.4503 x 10-7 5.995 x 10-2 1.4223 x 10-3 1.4504 x 10-7

To Convert From:

centipoise

lbm-ft-1-hr-1

kgf-s-m-2

mPa-s

g-cm-1-s-1 (poise) kg-m-1-s-1 lbm-ft-1-s-1 lbf-s-ft-2 lbf-s-in-2 centipoise lbm-ft-1-hr-1 kgf-s-m-2 mPa-s

102 103 1.4882 x 103 4.7880 x 104 6.895 x 106 1 4.1338 x 10-1 2 9.806 x 103 1

2.4191 x 102 2.4191 x 103 3600 1.1583 x 105 1.668 x 101 2.4191 1 2.372 x 104 2.419

1.0198 x 10-2 1.020 x 10-1 1.518 x 10-1 4.883 7.0309 x 102 1.0198 x 10-4 4.216 x 10-5 1 1.0197 x 10-4

102 103 1.4882 x 103 4.78803 x 104 6.89476 x 106 1 4.1338 x 10-1 9.80665 x 103 1

FORCE CONVERSION TABLE Multiply by Table Values to Convert to These Units To Convert From: g-cm-s-2 (dyne) kg-m-s-2 (N) lbm-ft-s-2 (poundal) lbf U.K. ton f U.S. ton f

g-cm-s-2 (dyne)

kg-m-s-2 (N)

lbm-ft-s-2 (poundal)

U.K.

U.S.

lbf

ton f

ton f

1 105 1.3826 x 104 4.4482 x 105 9.964 x 102 8.896 x 102

10-5 1 1.3826 x 10-1 4.4482 9.964 x 10-3 8.896 x 10-3

7.2330 x 10-5 7.2330 1 32.1740 7.207 x 10-2 6.435 x 10-2

2.2481 x 10-6 2.2481 x 10-1 3.1081 x 10-2 1 2.240 x 10-3 2.000 x 10-3

1.004 x 10-3 100.4 1.388 x 101 4.464 x 102 1 0.8929

1.124 x 10-3 112.4 1.554 x 101 5.00 x 102 1.120 1

C

App. C-10



APPENDIX C

CONVERSION TABLES

HEAT TRANSFER COEFFICIENT CONVERSION TABLE To Convert From:

Multiply By

pcu/(hr) (ft2) (° C) kg-cal/(hr) (m2) (° C) g-cal/(sec) (cm2) (° C) watts/(cm2) (° C) watts/(in2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) kg-cal/(hr) (m2) (° C) watts/(m2) (° C)

To Obtain Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) Btu/(hr) (ft2) (° F) pcu/(hr) (ft2) (° C) kg-cal/(hr) (m2) (° C) g-cal/(sec) (cm2) (° C) watts/(cm2) (° C) watts/(in2) (° F) hp/(ft2) (° F) joules/(sec) (m2) (° C) joules/(sec) (m2) (° C) joules/(sec) (m2) (° C)

1 0.2048 7380 1760 490 .1 4.88 0.0001355 0.000568 0.00204 0.000394 5.678 1.163 1.0

THERMAL CONDUCTIVITY COEFFICIENT CONVERSION TABLE To Convert From:

Multiply By

g-cal/(sec) (cm2) (° C/cm) watts/(cm2) (° C/cm) g-cal/(sec) (cm2) (° C/cm) Btu/(hr) (ft2) (° F/ft) Btu/(hr) (ft2) (° F/ft)

To Obtain Btu/(hr) (ft2) (° F/in) Btu/(hr) (ft2) (° F/in) Btu/(hr) (ft2) (° F/in) joules/(sec) (m) (° C) joules/(sec) (m) (° C)

2903.0 694.0 0.8064 1.731 1.163

VARIOUS VALUES OF THE IDEAL GAS LAW CONSTANT Temperature Scale Rankine

Kelvin


Pressure Units

Volume Units

Weight Units

Energy Units

— — — atm in. Hg mm. Hg lb/in2abs lb/ft2abs — — — atm atm mm Hg bar kg/cm2 atm mm Hg —

— — — ft3 ft3 ft3 ft3 ft3 — — — cm3 liters liters liters liters ft3 ft3 —

lb-moles lb-moles lb-moles lb-moles lb-moles lb-moles lb-moles lb-moles g-moles g-moles g-moles g-moles g-moles g-moles g-moles g-moles lb-moles lb-moles lb-moles

Btu hp-hr kw-hr atm-ft3 in. Hg-ft3 mm. Hg-ft3 (lb) (ft3)/in2 ft-lb calories joules (abs) joules (int) atm-cm3 atm-liters mm Hg-liters bar-liters kg/(cm2) (liters) atm-ft3 mm Hg-ft3 chu or pcu


R 1.9872 0.0007805 0.0005819 0.7302 21.85 555.0 10.73 1545.0 1.9872 8.3144 8.3130 82.057 0.08205 62.361 0.08314 0.08478 1.314 998.9 1.9872

App. C-11

C

APPENDIX C

CONVERSION TABLES


C

App. C-12



Appendix D BIBLIOGRAPHY



App. D-1

BIBLIOGRAPHY ASPE Data Book 1983-1984, Volume 1, Fundamentals of Plumbing Design. American Society of Plumbing Engineers, Sherman Oaks, CA (1983)

REFERENCES

Howard, A.K. Laboratory Load Tests on Buried Flexible Pipe, Journal AWWA, (October 1972)

ASPE Data Book 1981-1982, Volume 11, Special Plumbing System Designs. American Society of Plumbing Engineers, Sherman Oaks, CA (1989)

Howard, Amster K. Modulus of Soil Reaction (E') Values for Buried Flexible Pipe, Journal of the Geotechnical Engineering Division, ASCE, Vol. 103, No. GT, Proceedings Paper 12700 (Jan.1977)

Annual Book of ASTM Standards, Volume 8.04, Plastic Pipe and Building Products. Philadelphia, PA (1986)

Karassik, Igor J., William C. Krutzsch, Warren H. Fraser and Joseph P. Messina. Pump Handbook, 2nd Ed. (1986)

Asahi/America’s Proline Systems Engineering Design Guide (1990)

Kent, George R. Preliminary Pipeline Sizing. Chemical Engineering Magazine (Sept. 25, 1978) (p. 17)

Austin, George T. Shreve's Chemical Process Industries. 5th Edition, McGraw-Hill, New York, NY (1984)

Kern, Robert (Hoffmann-LaRoche, Inc.) How To Compute Pipe Size. Chemical Engineering Magazine (Jan. 6, 1975) (p. 19)

Balzhiser, R.E., M.R. Samuels, and J.D. Eliassen. Chemical Engineering Thermodynamics. Prentice-Hall (1972)

Kern, Robert (Hoffmann-LaRoche, Inc.) How To Design Piping For Pump-Suction Conditions. Chemical Engineering Magazine (April 28, 1975) (p. 25)

Barnard, R.E. Design and Deflection Control of Buried Steel Pipe Supporting Earth and Live Loads. American Society for Testing and Materials, Proc. 57 (1957) Baumeister, T., and L. Marks. Standard Handbook for Mechanical Engineers, 8th Ed., McGraw-Hill (1978)

Kern, Robert (Hoffmann-LaRoche, Inc.) How To Size Piping For Pump-Discharge Conditions. Chemical Engineering Magazine (May 26, 1975) (p. 32) Kern, Robert (Hoffmann-LaRoche, Inc.) Pump Piping Design. Chemical Engineering Magazine (Oct. 11, 1971) (p. 40)

Calculation and Shortcut Deskbook. Chemical Engineering Chimes, A.R. Fast Way To Choose Pipe Diameters. Weehawken, NJ (p. 70) Chemical Plant and Petroleum Refinery Piping, ANSI/ASME B31.3. The American Society of Mechanical Engineers, New York, NY (1999) Cheremisinoff, Nicholas P. Fluid Flow Pocket Handbook. Houston, TX (1984) Cheremisinoff, Nicholas P. Heat Transfer Pocket Handbook. Houston, TX (1984) Design and Construction of Sanitary and Storm Sewers. ASME Manual and Report on Engineering Practice. No. 37. (WPCF Manual of Practice No. 9). American Society of Civil Engineers and the Water Pollution Control Federation, New York, NY (1974)

D

Kerr, S.L. Surges in Pipelines — Oil and Water. Trans. ASME, 72:667 (1950) Kerr, S.L. Water Hammer—A Problem in Engineering Design. Consulting Engineer (May 1958) Kerr, S.L. Water Hammer Control. Journal AWWA, 43:985 (Dec. 1951) King, Reno C. and Sabin Crocker. Piping Handbook, 5th Edition, McGraw-Hill Book Co. (1973) LaLonde, William S., Jr., and William J. Stack-Staikidis Professional Engineers’ Examination Questions and Answers. 4th Edition (1984) Liu, Henry. Manning's Coefficient for Smooth Pipes. ASCE Journal of Sanitary Engineer. Div. Proc. 98SA2,353 (1972)

Flow of Fluids Through Valves, Fittings and Pipe. Technical Paper No. 410, 21st Printing, Crane Co., Chicago, IL (1982)

Managing Corrosion With Plastics. Volume IV, National Association of Corrosion Engineers, Houston, TX (1979)

Handbook of PVC Pipe Design and Construction. Uni-Bell Plastic Pipe Association, Dallas, TX (1979)

Mruk, Stanley A. Thermoplastics Piping: A Review. (p. 3)

Handbook of Steel Drainage and Highway Construction Products. American Iron and Steel Institute, Donnelley and Sons Co. (1971)

App. D-2

Rubens, A.C. Designing RTRP Systems Utilizing Published Engineering Data. (p. 30) Managing Corrosion With Plastics. Volume V, National Association of Corrosion Engineers, Houston, TX (1983)



BIBLIOGRAPHY

REFERENCES

Clark, Clayton F. The Use of Large Diameter Polyolefin Pipe in Corrosion Resistant Applications. (p. 15) Dicks, M., K. Graf, R.H. Nurse. Evaluation of the Chemical Resistance of Polyethylene and Polypropylene Materials for Piping and Other Engineering Applications. (p. 24) Hall, Rowland. Design and Installation of Above Ground Thermoplastic Piping Systems. (p. 133) Schlanger, L.M., E.R. Baumgaertner, W.A. Miller Fluorplastics. (p. 98) Marston, Anson and A.0. Anderson. The Theory of Loads on Pipes in Ditches and Tests of Cement and Clay Drain Tile and Sewer Pipe. Bul. 31, Iowa Engineering Experiment Station, Ames, IA (1913) Means Mechanical Cost Data. 7th Annual Edition, Robert Snow Means Co., Kingston, MA (1983) Modern Plastics Encyclopedia. Issued annually by Modern Plastics. McGraw-Hill, New York, NY (1985 Edition) Page, John S. and James G. Nation. Estimator’s Piping Man Hour Manual. 3rd Edition, Gulf Publishing, Houston, TX (1979) Perry, Robert H., and Cecil H. Chilton. Chemical Engineers Handbook. 6th Edition (1984) Peters, M., and K. Timmerhaus. Plant Design and Economics for Chemical Engineers. 3rd Edition, McGraw-Hill (1980) Poly (Vinyl Chloride) (PVC) Plastic Piping Design and Installation. PPI Technical Report PPI-TR13. Plastics Pipe Institute, New York, NY (Aug. 1973) 1994 Power Piping, ANSI/ASME B31.1. 1999 Edition, The American Society of Mechanical Engineers, New York, NY Prabhudesai, Rajaram K., and Dilip K. Das. Chemical Engineering for Professional Engineers’ Examinations. (1984) Plastics Piping Manual. Plastics Pipe Institute, New York, NY (1976) Reinhart, Frank W. Long-Term Hydrostatic Strengths of Thermoplastic Pipe. Proceedings — 4th American Gas Association Plastic Pipe Symposium, Arlington, VA (1973) Robinson, Randall N. Chemical Engineering Review Manual. 3rd Edition, San Carlos, CA (1984) Schweitzer, Philip A. Corrosion and Corrosion Protection Handbook. Fairfield, NJ (1983)


Simpson, Larry L. and Martin L. Weirick (Union Carbide Corp.) Designing Plant Piping. Chemical Engineering Magazine (April 3, 1978) (p. 3) Sommers, K.Criteria, Tools And Practices For High Purity Water Distribution Systems. Tall Oaks Publishing, Inc. Ultra Pure Water Magazine (May/June 2000) Spangler, M.G. The Structural Design of Flexible Pipe Culverts. Bulletin 153, Iowa Engineering Experiment Station, Ames, IA (1941) Spangler, M.G., and R.L. Handy Soil Engineering. Intext Educational Publ., New York, NY (1973) Standard Method for Classification of Soils for Engineering Purposes. ASTM D2487. American Society for Testing and Materials, Philadelphia, PA Standard Method of Test for Relative Density of Cohesionless Soils. ASTM D2049. American Society for Testing and Materials, Philadelphia, PA Standard Method of Test for Density of Soil in Place by the Rubber-Balloon Method. ASTM D2167. American Society for Testing and Materials, Philadelphia, PA Standard Method of Test for Density of Soil in Place by the Sand-Cone Method. ASTM D1556. American Society for Testing and Materials, Philadelphia, PA Standard Practice for Description of Soils (Visual-Manual) Procedure. ASTM D2488. American Society for Testing and Materials, Philadelphia, PA Standard Recommended Practice for Underground Installation of Flexible Thermoplastic Sewer Pipe. ASTM D2321. American Society for Testing and Materials, Philadelphia, PA Standard Recommended Practice for Underground Installation of Thermoplastic Pressure Piping. ASTM D2774. American Society for Testing and Materials, Philadelphia, PA Thermal Expansion and Contraction of Plastic Pipe. PPI Technical Report, PPI-TR21. Plastics Pipe Institute, New York, NY (Sept. 1973) Timoshenko, S. and D.H. Young. Elements of Strength of Materials. 4th Edition, Van Nostrand Co., Princeton, NJ, p. 111, p. 139. Timoshenko, S.P. Theory of Elastic Stability. 2nd Edition, McGraw-Hill, (1961) Timoshenko, S.P. Strength of Materials, Part II — Advanced Theory and Problems. Van Nostrand Co, Princeton, NJ (1968) pp. 187-190.


App. D-3

D

BIBLIOGRAPHY

REFERENCES

Tuthill, Arthur H. Installed Cost of Corrosion — Resistant Piping, Part I. Chemical Engineering Magazine (March 31, 1986) (p. 113) Tuthill, Arthur H. Installed Cost of Corrosion-Resistant Piping, Part Il. Chemical Engineering Magazine (March 31, 1986) (p. 125) Watkins, R.K. and A.P. Moser. Response of Corrugated Steel Pipe to External Soil Pressures. Highway Research Record 373 (1971) pp. 88-112 Watkins, R.K., A.P. Moser and R.R. Bishop. Structural Response of Buried PVC Pipe. Modern Plastics (Nov. 1973) pp. 88-90 Watkins, RK, and A.B. Smith. Ring Deflection of Buried Pipe. Journal AWWA, Vol. 59, No. 3 (March 1967) Watkins, R.K., and M.G. Spangler. Some Characteristics of the Modulus of Passive Resistance of Soil — A Study in Similitude. Watkins, R.K. Design of Buried, Pressurized Flexible Pipe. ASCE National Transportation Engineering Meeting in Boston, MA. Appendix C (July 1970) Water Flow Characteristics of Thermoplastic Pipe. PPI Technical Report, PPI-TR14. Plastics Pipe Institute, New York, NY (1971) Williams, D.J. Polymer Science and Engineering. Prentice-Hall, (1971) Yamartino, J. Installed Cost of Corrosion-Resistant Piping 1978. Chemical Engineering Magazine (Nov. 20, 1978)

D

App. D-4



INDEX E INDEX



Index E-1

INDEX A Access tee: D-20 Air-Pro: D-28 Annular space: D-19, D-20, App. A-16 to A-17 B Backfilling: C-26, C-27 Ball valves: G-3 Bead formations: F-26 Bedding constant: App. B-11 Bending: C-28 Bending radius: App. A-6 Bernoulli equation: C-7 Burial: C-23, C-24, C-25 Butt fusion: F-5, F-6, F-34, F-38, F-69, D-6, D-8 Butterfly valves: F-2, G-3 C Cable leak detection: D-19 Cavitation: C-8 Change in direction: C-13, C-14, C-18, C-19 Chemical reaction: E-4 Chemical resistance: E-2, E-7 Chlorinated hydrocarbon: F-3 Chlorine: F-3 Cleanroom: F-20 Combined stress: C-11, C-16 Compartments: D-19 Compound pipe sizing: C-8 Compressed air: F-67, C-10 Compressed air system: D-27 Compressible fluids: C-10 Compressor: D-29 Concentration: E-3 Conversion tables: App. C-2 to C-11 CPVC: A-3 D Darcy: C-6 Darcy Method: C-5 dead leg: D-3, D-4 Diaphragm valves: G-4 Dimensional: App. A-13 to A-15 Dogbone: D-14 Double Contained Valves: D-15 Drain: C-9 Duo-Pro: C-16, D-12 E E' modulus: C-24, App. B-11 E-CTFE: A-3 Earth loads: C-23 Electro fusion: F-35, F-38 Electro-conductive polypropylene: B-3 End load: C-11, C-16 EPA requirements: D-10, D-16 Equal percent: G-2 Equivalent lengths: App. A-12

Expansion loop: C-12, C-13, C-18, C-14 Expansion offsets: C-12, C-18 Extrusion welding: F-16, D-25 F Fabrication: D-24 Flange: F-2 Flexible bellows: C-12, C-18 Flexible design: C-19, C-20 Flexible system design: C-12 Flow capacity: G-2 Flow rate: D-5 Fluid dynamics: C-4 Fluid-lok: C-16, D-13 Force transfer coupling: C-17 Free hand: F-15 Friction losses: App. A-11 G Gate valves: G-4 Gooseneck: C-10 H H20 highway loading: C-24 Halar: A-3 Hand-held welding: F-14 Hanging: C-21 Hazen and Williams method: C-6 HDB: C-3 Heat gain: App. A-21 to A-37 Heat loss: App. A-18 to A-20 Heat tracing: C-29, C-30, C-31 High-purity system design: D-2 High-speed welding: F-15 Hot air: D-25 Hot DI: D-3 HPF: F-20, F-23, F-27, F-35 HPF fusion: F-13 Hydrostatic design basis: C-3 I Inspection: F-39, F-49, F-60, F-71 Inspection Labels: F-26 instrumentation fittings: D-4 insulation: C-29, C-31 IR fusion: F-12, D-6, D-9 J Jumper cable: D-21 L Leak detection: F-9, D-10, D-18 Leak detection cable: C-25 Leak detectors: D-14 Light trap: D-5 Live load: C-24 Low point: D-18 low point sensors: D-19

E Index E-2



INDEX M Manning equation: C-9 Martson soil load: C-24, App. B-3 to B-10 Modulus of elasticity: App. A-5 Monitoring flow: D-5 Moody friction factor: C-5 N Net positive suction head: C-8 Non-compressible fluids: C-4 O Offset: C-13, C-19 Operating pressures: App. A-2 Ozone: D-5 P Packaging: F-24 PE: A-3 PE100: B-4 PE80: B-4 PFA: F-28 Pipe pistons: C-12, C-18 Plasticization: E-4 Poly-flo: F-57, D-12 Polyethylene: B-4 polypropylene: B-2 PolyPure: F-25 Polyvinylidene Fluoride: B-5 PP: A-3 PPH-s: B-3 PPR-el: B-3 PPR-s-el: B-3 Pressure drop: C-6, C-7, C-10, App. A-8 to A-10 Pressure loss: C-5 Pressure test: F-31 Prism load: C-23, App. B-2 Product pipe: D-11 Pull Port Tee: D-20 Purad: A-4, F-20, F-24, B-5 Pure water system: D-2 PVC: A-3 PVDF: A-3, B-5, D-2 Q Quick opening: G-2 R Repair: F-42, F-54, F-55, F-64, F-74 Resistivity probe: D-4 Restraint: C-12 Restraint design: C-17 Restraint dogbone: D-16 Restraint fitting: D-8 Restraint shoulders: C-17 Reynolds’ number: C-4, C-5, D-3

S Schedule ratings: C-2 SDR: C-2 Self-extinguishing polypropylene: B-3 Sensor cable: D-21 Side-wall fusion: F-14 Simultaneous butt-fusion: F-6 Snaking: C-27 Socket fusion: F-4, F-35, F-38, F-68, D-6, D-8 Soil load: App. A-7 Solef: A-4 Solvation effect: E-4 SP series: F-22 Spider clip: D-12 Sprinkler systems: D-23 Staggered butt-fusion: F-10, C-20 Standard dimensional ratio: C-2 Stress cracking: E-4, E-5 Support discs: D-12, D-20 Support Spacing: App. A-3 to A-5 T T-valves: D-4 Tack welding: F-15 Temperature: E-3 Terminal velocity: C-9 Testing: F-31, F-41, F-51, F-52, F-53, F-63, F-73 Thermal conductivity: C-29 Thermal design: C-29 Thermal expansion: C-11, C-15, C-20 Thermal stress: C-11, C-16 Threading: F-2 Tool selection: F-34, F-45 Torque: F-2 Training: F-36, F-47, F-59, F-70 Trench: C-26 U U-bolt hanger: C-21 Ultraviolet: D-5 UV: F-3, D-8, D-17, D-24, D-29 UV sterilizing lamps: D-5 V Velocity: C-4. App. A-8 to A-10 Vent piping: C-9 Ventilation: D-23, D-24 Visual inspection: D-21 Vortex meters: D-5 Vortex principal: D-5 W Waste: C-9 Weatherability: F-3, D-17 Weld inspection: F-37

E ASAHI /AMERICA Rev. EDG– 02/A


Index E-3

WARRANTY Warranty; Limitation on Liability. Asahi/America, Inc., ("Seller") warrants, to the original Buyer only, that all products delivered hereunder shall be free from defects in design and manufacture for a period of one year from the date of delivery, provided that such products are installed, used, operated, adjusted and serviced only in a proper and appropriate manner and in strict accordance with any instructions relating thereto furnished to Buyer by Seller. In no event shall the foregoing warranty extend to any products in any way caused or allowed to be, or installed , operated or used in such a manner as to be, subject or exposed to conditions of misuse, abuse or accident. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. NO WARRANTY OF MERCHANTABILITY, NO IMPLIED WARRANTY OF FITNESS FOR ANY PARTICULAR PURPOSE, AND NO IMPLIED WARRANTY ARISING BY USAGE OF TRADE, COURSE OF DEALING OR COURSE OF PERFORMANCE IS GIVEN BY SELLER OR SHALL ARISE BY OR IN CONNECTION WITH THIS SALE AND/OR THE SELLER'S AND/OR BUYER'S CONDUCT IN RELATION THERETO OR TO EACH OTHER, AND IN NO EVENT SHALL SELLER BE LIABLE ON ANY SUCH WARRANTY WITH RESPECT TO ANY PRODUCT. Liability of the Seller under or in connection with this sale and/or the foregoing warranty shall be limited, at the sole option of the Seller, to one repair of, replacement of, or a refund of the purchase price of any products or part thereof (a), with respect to which Seller receives, promptly after Buyer's discovery of any alleged defect and prior to the expiration of the one-year warranty period as provided above, notice from Buyer or Buyer's claim defect and (b) which shall be returned to Seller by Buyer, as provided herein, promptly after Buyer's discovery of such alleged defect and which shall be determined by the Seller to have proven defective within the one-year warranty period provided above; failure by Buyer to notify Seller and return such products to Seller after Buyer's discovery of such alleged defect shall constitute a waiver by Buyer of any an all claims of any kind with respect thereto. Any products returned by Buyer to Seller under the foregoing terms shall be returned to Seller's place of business freight prepaid, accompanied or preceded by Buyer's particularized statement of the claimed defect. The risk of loss and freight charges to and from Seller in connection with any returned products shall be borne by Buyer; but Seller shall bear such additional freight charges arising in connection with any such returned products ultimately determined by Seller to be defective under the terms of the foregoing warranty, the cost of repair or replacement (if any) of such products, and the risk of loss or damage which such products are in Seller's possession at its place of business. The foregoing remedy shall constitute the sole and exclusive remedy of the Buyer under or in connection with this sale and/or warranty of the Seller. Except as specifically provided herein, Seller shall not be responsible or liable for any costs, expenses or damages of Buyer in connection with any removal, repair or replacement (including any attempts or actions relating thereto) of any allegedly defective products, and no charge of setoff of any kind of Buyer relating thereto shall be made against the Seller without prior and specific written approval of Seller. IN NO EVENT SHALL SELLER BE RESPONSIBLE OR LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING IN ANY WAY IN CONNECTION WITH ANY PRODUCTS OR THIS SALE. The agreement of Seller to sell its products is expressly conditioned upon the Buyer's assent to, and Seller agrees to sell its products only upon, all terms and conditions set forth above and on the face hereof. Buyer's acceptance of any products provided under this sale shall constitute such assent.

PO Box 653 • 35 Green Street, Malden, MA 02148 • Tel: (800) 343-3618, (781) 321-5409 Fax: (800) 426-7058 • Internet: http://www.asahi-america.com • Email: [email protected]

ASAHI/AMERICA REV. EDG-02/A

Piping Engineering Design Guide

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