ThermoPlastic
ThermoPlastic
Chemtrol® has over 45 years of experience in industrial thermoplastics, offering reliable products for demanding environments. The manual includes guides on chemical compatibility, valve design, and fittings, available on their website.
- PVC: Conforms to ASTM D1784, used for its high physical properties and chemical resistance, with a maximum service temperature of 140°F.
- CPVC: Similar to PVC but with a higher service temperature of 210°F, suitable for hot corrosive liquids.
- PVDF: Offers high chemical resistance and a service temperature of 280°F, ideal for handling halogens.
- PP: Known for versatile chemical resistance, suitable for drainage of mixed industrial chemicals.
- FKM, EPDM, PTFE, CR: Various elastomers and polymers with specific chemical resistances and applications.
The manual provides detailed ASTM test results for specific gravity, water absorption, tensile strength, and other mechanical and thermal properties of thermoplastic materials.
Numerous ASTM standards are referenced, ensuring quality and performance in industrial applications.
Includes dimensions, pressure and temperature ratings, flow and friction loss charts, and guidelines for managing thermal expansion and pipe support spacing.
Covers storage, handling, joining methods, and specific instructions for solvent cement joining, thermo-seal socket fusion, and flanged joints. Also addresses ultraviolet radiation and underground installation considerations.
Details specifications for various pipe and fitting materials, including PVC, CPVC, PP, and PVDF, as well as valves like Tru-Bloc® and butterfly valves.
Information on product warranties is provided, emphasizing the importance of following guidelines to ensure product integrity and safety.
- ASTM D2837: Describes the procedure for obtaining the Hydrostatic Design Basis for thermoplastic pipe materials.
- ASTM D2657: Covers the procedure for heat-fusion bonding of polyolefin materials.
- ASTM D3222: Details the polymerization method and physical properties of PVDF Fluoroplastic Materials.
- ANSI/ASME B1.20.1: Specifies dimensions and tolerance for tapered pipe threads.
- ASME B16.5: Sets standards for bolt holes, bolt circles, and dimensions for steel 150# flanges.
- NSF/ANSI 14: Applies to thermoplastic and thermoset plastic piping system components.
- NSF/ANSI 61: Establishes minimum health effects requirements for chemical contaminants in drinking water systems.
This document provides detailed specifications on flow capacity and friction loss for Schedule 40 and Schedule 80 thermoplastic pipes.
It is crucial not to use or test the products with compressed air or other gases.
Hydraulic shock refers to the pressure rise in a piping system when the liquid is started or stopped quickly.
The document provides a formula to calculate the maximum surge pressure in a piping system.
All materials expand or contract with temperature changes.
Pipes should be independently anchored to prevent stress from thermal expansion or contraction.
Flexibility in piping systems can be achieved through directional changes or loops.
Proper support spacing is crucial to prevent excessive bending stress.
Thermoplastic pipes can be joined using solvent welding or socket fusion.
Do not use or test products with compressed air or gases.
This document discusses various methods for joining thermoplastic piping.
Solvent welding is a cost-effective method for joining pipes made from materials like PVC, CPVC, and ABS.
Thermo-fusion involves melting the surfaces of the pipe and fitting using electrically heated anvils before joining them.
Threaded joints are used for emergency repairs and systems requiring occasional disassembly.
Flanges and pipe unions are mechanical joining methods that allow for easy disassembly and maintenance.
Before joining, inspect pipes and fittings for defects and clean surfaces thoroughly.
For PVC and CPVC pressure piping systems, select appropriate solvent cements and primers.
Manage solvent cement and primer to minimize evaporation and maintain freshness.
The document outlines drying times for PVC and CPVC pipes based on nominal pipe size and surface temperature.
Key instructions include cleaning and preparing pipes and fittings, using proper applicators, and maintaining wet beads during joint insertion.
In hot weather, increased crew size and shading of materials are recommended to prevent rapid solvent evaporation.
The document emphasizes the reliability of chemical fusion joining for thermoplastic piping.
Estimates for the number of joints per container size are provided.
Instructions for socket heat fusion joints include preparation of components and selection of appropriate tools.
The SSJK – 3"–4" Joining Kit is designed for socket fusion connections of large pipes.
The Model 3500 and 3600 Socket Fusion Tools are manually operated machines for joining pipes ranging from 1⁄2" to 6".
Heating Anvils are coated with PTFE to prevent plastic retention.
Proper alignment and depth are crucial for successful joints.
Heating Anvils should be checked for proper fit.
- Thermo-Fusion Socket Heating Times: Heating times vary by pipe size and material.
- Equipment: Includes pipe cutting and beveling tools, hand-held heat-tools, depth gauges, pipe clamps with inserts, heating anvils, timers, thermal blankets, auxiliary handles, hex-key wrenches, thermostat adjustment tools, and cleaning supplies.
- Preparation: Select appropriate inserts for pipe clamps based on pipe size.
- Joining Mechanics: Involves a two-person team where one handles the pipe and the other the socket connection.
- Safety: Avoid using compressed air or gases with these products to prevent injury or damage.
- Use a fusion joining machine for pipes 3" and larger for better precision and ease.
- Maintain clean heating anvils to ensure quality joints and prevent residue buildup.
- Follow prescribed heating times and temperatures strictly to avoid joint failure.
- Do not use or test products with compressed air or gases.
- Molten plastic can cause severe burns; handle with care.
The Bench-Mount Joining Machine is designed for prefabrication, featuring a temperature-controlled heat-plate that can be repositioned to avoid interference during operation.
- Machine Base: Made of aluminum for rigidity and lightweight movement.
- Steel Rods: Serve as machine ways, providing stability.
- Pipe and Fitting Sleds: Move precisely on the machine ways through bushings.
- Rack and Pinion: Facilitates in-and-out movement of sleds.
- Hand-Wheel: Allows operator to move sleds together or apart.
- Depth Gauge Stroke-Limiter: Ensures correct pipe projection measurement.
- Joint Insertion Stroke-Limiter: Adjusts for different pipe sizes, ensuring proper joint insertion.
- Knob Handle: Locks the pipe sled in place.
Clamping Vises Features
- Vise Bases: Ensure precise alignment in longitudinal and horizontal planes.
- Vice Holder-Blocks: Form the Fitting and Pipe Vises, ensuring equal radii grasping.
- Prismatic Clamping Jaws: Align fittings and pipes, handling various sizes.
- Handles: Used to adjust Holder-Blocks via Lead-Screw.
- Electronic Temperature Controller: Maintains precise heat-plate temperature.
Machine Setup and Operation
Before using the machine, operators must be familiar with the detailed instructions.
The joining process involves a two-person crew: the operator and an assistant.
This section emphasizes the importance of perfect alignment in pipe and fitting joints using a Bench-Mount Machine.
After heating, the operator must quickly retract the heated product and prepare for fusion.
The document outlines testing procedures for socket fusion joints, recommending hydro-testing over air or gas due to safety concerns.
Guidelines for making good socket fusion joints include operating at the correct temperature, beveling the pipe, and ensuring clean heating tools.
This section covers the use of flanges in process lines, specifying gasket requirements and installation tips.
Hot gas welding is recommended for minor leaks.
- Preparation: Clean the weld area of dust, dirt, and moisture.
- Filler Rod Selection: Determine the correct filler rod length by wrapping it around the pipe.
- Welding Temperatures: Adjust temperatures based on material.
- Welding Process: Preheat surfaces until tacky, then apply filler rod with slight pressure while maintaining even heat.
- Multiple Passes: For large diameter pipes, multiple weld passes may be required.
- Quality Indicators: Proper welds show small flow lines or waves.
- Scope: Covers threading of IPS Schedule 80 or heavier thermoplastic pipe using NPT threads.
- Equipment: Requires pipe dies, vise, threading machine, lubricant, and PTFE tape.
- Procedure: Use a tapered plug to prevent pipe distortion.
- Testing: Pressure test systems up to 100% of hydrostatic pressure rating.
- PVC and CPVC: UV radiation causes degradation, embrittlement, and loss of strength.
- Polypropylene and Polyethylene: Rapidly degraded by UV exposure.
- PVDF: Transparent to UV and not degraded by sunlight.
- Painting: Use water-based acrylic paint for UV protection and color coding.
- Scope: Designed for industrial, pressure-rated fluid-handling systems at temperatures up to 140°F.
- Materials: Made from PVC compound meeting ASTM D1784 standards.
- Dimensions/Design: Conforms to ASTM D2467 for socket and threaded connections.
- Pressure Ratings: Socket fittings rated as per ASTM D1785.
- Markings: Must include manufacturer’s name, material designation, ASTM number, and NSF certification.
- Scope: Suitable for systems up to 210°F.
- Materials: CPVC materials conform to ASTM D1784.
- Dimensions/Design: Socket and threaded connections as per ASTM F439.
- Pressure Ratings: Socket fittings rated as per ASTM F441.
- Markings: Must include manufacturer’s name, material designation, ASTM number, and NSF certification.
- Scope: For applications up to 180°F.
- Materials: Black and Chem-Pure® PP materials conform to ASTM D4101 standards.
- Dimensions/Design: Heat-fusion welding compatible.
- Pressure Ratings: Heat-fusion joints rated up to 410 psi for 1/2" size at 73°F.
- Markings: Must include manufacturer’s name, nominal size, and material designation.
- Scope: For systems up to 280°F.
- Materials: Red and natural PVDF conform to ASTM D3222 standards.
- Dimensions/Design: Heat-fusion welding compatible.
- Pressure Ratings: Heat-fusion joints rated up to 580 psi for 1/2" size at 73°F.
- Markings: Must include manufacturer’s name, nominal size, and material designation.
- Products should not be used or tested with compressed air or gases to avoid personal injury or property damage.
The document outlines the specifications for various types of valves, including Tru-Bloc® ball valves, ball check and foot valves, and butterfly valves made from materials such as PVC, CPVC, PP, and PVDF.
These valves are available in sizes ranging from 1/2" to 6" and are made from PVC and CPVC materials.
These valves are intended for use in systems where long-term resistance to corrosion is crucial.
The document specifies the requirements for wafer-style butterfly valves made from PVC and CPVC.
The valves are constructed from materials that meet specific ASTM classifications.
All valves must be clearly marked with the manufacturer's name, nominal size, material designation, and country of manufacture.
The installation and operation of the valves must follow the manufacturer's printed instructions.
The document includes a warning against using or testing the products with compressed air or other gases.
The document outlines the design and specifications for various types of valves including globe design, Y-pattern, angle valves, needle valves, and Chemcock valves.
Valves must be clearly marked with the manufacturer's details and certification marks for potable water conveyance.
A critical warning is provided against using or testing the products with compressed air or gases.
Chemtrol offers a one-year limited warranty against defects in materials and workmanship.
Products are sold through select distributors knowledgeable in plastic applications.
Chemtrol, a brand of NIBCO INC., emphasizes innovation and service in thermoplastics for industrial piping applications.
Catalog excerpts
Chemtrol® Thermoplastic Flow Solutions Thermoplastic Piping Technical Manual ® PVC, CPVC, PP, PVDF Chemtrol® is a brand of
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® ® Contents Introduction www.chemtrol.com 1 Materials Materials Physical Properties of Thermoplastic Piping Materials 1 Standards Engineering Data 3 4 5 6 Dimensions and Reference Data – Schedule 80 Pipe and Fittings Dimensions and Reference Data – Pipe Threads and Flanges Metric Conversion Tables 1 2 4 Engineering Design 7 Pressure and Temperature Ratings of Chemtrol® Products Pressure Ratings/Pressure Losses Flow and Friction Loss Chart for Schedule 40 Flow and Friction Loss Chart for Schedule 80 Hydraulic Shock/Surge Wave Method Expansion and Thermal Contraction of Plastic Pipe Managing...
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® Introduction Introduction to Chemtrol® With more than 45 years of experience in industrial thermoplastics, Chemtrol offers dependable products that work in the most demanding environments. For specific recommendations of chemical compatibility, see the Chemtrol Chemical Resistance Guide. For a wide variety of thermoplastic valves of superior design and quality, see the Chemtrol Valve Guide. For the best thermoplastic fittings and flanges available for industrial use, refer to the Chemtrol Fitting Guide. These publications are available for download on www.nibco.com/chemtrol in PDF format....
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® ® Materials www.chemtrol.com Physical Properties of Thermoplastic Piping Materials ASTM Test Methods Properties Material PVC 12454-B CPVC 23447-B 1.38 1.50 1.76 .905 .05 .05 .04 .02 7,300 7,200 6,000 4,600 4.2 3.7 2.1 2.0 Flexural Strength psi 14,500 15,600 9,700 7,000 Izod Impact Strength @ 73° F (Notched) 1.1 2.0 3.8 .8 Coefficient of Thermal Expansion in/in/° F x 10–5 3.0 3.8 7.9 5.0 Thermal Conductivity BTU/HR/Sq. Ft./° F/in 1.2 .95 .79 1.2 D648 Heat Distortion Temp. ° F @ 66 psi NA NA 284 195 D648 Heat Distortion Temp. ° F @ 264 psi 163 212 194 140 Resistance to Heat ° F at Continuous...
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® Standards ® www.chemtrol.com Many commercial, industrial, and governmental standards or specifications are available to assist the design engineer in specifying plastic piping systems. Standards most frequently referred to and most commonly called out in plastic piping specifications are ASTM Standards. These standards also often form the basis of other standards in existence. Below is a list and description of those standards most typically applied to industrial plastic piping. ASTM D2657 This standard covers the procedure for heat-fusion bonding of polyolefin materials. ASTM D1784 (American...
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® ® Engineering Data www.chemtrol.com ressure Conversion Factors P Metric Equivalent Charts Metric Equivalent Charts Linear Conversion Table From Fractional Inches to Millimeters inches mm inches mm 1/64 .016 .397 33/64 .516 13.097 1/32 .031 .794 17/32 .531 13.494 3/64 .047 1.191 35/64 .547 13.891 1/16 .063 1.588 9/16 .563 14.288 5/64 .078 1.984 37/64 .578 14.684 3/32 .094 2.381 19/32 .594 15.081 7/64 .109 2.778 39/64 .609 15.478 1/8 .125 3.175 5/8 .625 15.875 9/64 .141 3.572 41/64 .641 16.272 5/32 .156 3.969 21/32 .656 16.669 11/64 .172 4.366 43/64 .672 17.066 3/16 .188 4.763 11/16 .688 17.463...
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® Engineering Design Metric Equivalent of Chemtrol® Products Pressure Ratings Charts The pressure carrying capability of any pipe at a given temperature is a function of the material strength from which the pipe is made and the geometry of the pipe as defined by its diameter and wall thickness. The following expression, commonly known as the ISO equation, is used in thermoplastic pipe specifications to relate these factors: P = 2S / (Do /t –1) where: P S Do t = maximum pressure rating, psi = maximum hydraulic design stress (max. working strength), psi = average outside pipe diameter, in. =...
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® ® Introduction Design Engineering www.chemtrol.com Pressure Ratings of Chemtrol® Products Chemtrol Products in Vacuum or Collapse Loading Situations Thermoplastic pipe is often used in applications where the pressure on the outside of the pipe exceeds the pressure inside. Suction or vacuum lines and buried pipe are examples of this type of service. As a matter of practical application, gauges indicate the pressure differential above or below atmospheric pressure. However, scientists and engineers frequently express pressure on an absolute scale where zero equals a theoretically perfect vacuum...
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® Engineering Design ® www.chemtrol.com Hydraulic Shock Hydraulic shock is the term used to describe the momentary pressure rise in a piping system which results when the liquid is started or stopped quickly. This pressure rise is caused by the momentum of the fluid; therefore, the pressure rise increases with the velocity of the liquid, the length of the system from the fluid source, or with an increase in the speed with which it is started or stopped. Examples of situations where hydraulic shock can occur are valves which are opened or closed quickly or pumps which start with an empty discharge...
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® ® Engineering Design Expansion and Thermal Contraction of Plastic Pipe Calculating Dimensional Change All materials undergo dimensional change as a result of temperature variation above or below the installation temperature. The extent of expansion or contraction is dependent upon the coefficient of linear expansion for the piping material. These coefficients are listed below for the essential industrial plastic piping materials in the more conventional form of inches of dimensional change, per ° F of temperature change, per inch of length. They are also presented in a more convenient form...
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® Engineering Design ® www.chemtrol.com Managing Expansion/Contraction in System Design Stresses and forces which result from thermal expansion and contraction can be reduced or eliminated by providing for flexibility in the piping system through frequent changes in direction or introduction of loops as graphically depicted on this page. Normally, piping systems are designed with sufficient directional changes, which provide inherent flexibility, to compensate for expansion and contraction. To determine if adequate flexibility exists in leg (R) (see Fig. 1) to accommodate the expected expansion...
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