POLYSTARTM ADVANCED POLYPROPYLENE PIPING SYSTEM CATALOG. PolystarPipe.com

Transcription

1 POLYSTARTM ADVANCED POLYPROPYLENE PIPING SYSTEM CATALOG PolystarPipe.com

2 IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION Reaing & Unerstaning the Manual! WARNING TO AVOID DEATH, SERIOUS PERSONAL INJURY, PROPERTY DAMAGE, OR DAMAGE TO THE EQUIPMENT: Rea all prouct manuals an all prouct labels BEFORE using this prouct an follow all safety an use information. Learn how to properly an safely use the equipment. Do not let anyone use the equipment without instruction. Keep prouct manuals available for easy access by all users. Replace missing, amage, or illegible prouct manuals an prouct labels. Replacement Manuals are available at: Unerstaning Safety Information!! DANGER This is a safety-alert symbol. The safety alert symbol is shown alone or use with a signal wor (DANGER, WARNING, or CAUTION), a pictorial an/or a safety message to ientify hazars. When you see this symbol alone or with a signal wor on your equipment or in this Manual, be alert to the potential for eath or serious personal injury.! CAUTION NOTICE This symbol ientifies hazars which, if not avoie, coul result in minor or moerate injury. This symbol ientifies practices, actions, or failure to act which coul result in property amage or amage to the equipment. This pictorial alerts you to the nee to rea the manual.! WARNING This symbol ientifies hazars which, if not avoie, will result in eath or serious injury. 2

3 TABLE OF CONTENTS 1.0 Introuction an Overview 1.1 Introucing Polystar 1.2 System Highlights 1.3 Prouct Stanars an Quality Control 1.4 Summary of Major Moels 2.0 Material Properties an Dimensional Data 2.1 Material Properties for Polystar PP-RCT Material 2.2 Pressure Ratings for Polystar Pipe 2.3 Recommene Specifications for Polystar 2.4 Chemical Resistance for Polystar PP-RCT Material 2.5 Pipe Dimensional Data 2.6 Fittings Dimensional Data 3.0 System Sizing an Engineering Consierations 3.1 Flow Rate, Velocity, an Hea Loss (Pressure Drop) Data 3.2 Support Spacing for Polystar Pipes 3.3 Anchoring Polystar Pipes 3.4 Thermal Expansion an Contraction 3.5 Expansion/Contraction Compensation Guielines 4.0 Thermoynamic Consierations 4.1 Heat Gain/Loss v. Temperature for Polystar Piping Systems 4.2 Insulation Thickness v. Heat Loss 4.3 Freeze Protection for Polystar Piping 5.0 Installation Requirements an Proceures 5.1 Transportation, Delivery & Storage 5.2 Socket Fusion Proceure Using Han-Hel Polywelers 5.3 Socket Fusion Proceure Using Moel 7125 Bench Socket Fusion Tools 5.4 Butt Fusion Proceure Using Manual Track Butt Fusion Tools 5.5 Electrofusion Proceure Using Beat-TR Electrofusion Processors 5.6 Sale Fusion Proceure Using Han-Hel Polywelers 5.7 Repair Proceures Using Han Hel Polywelers 6.0 Aitional Consierations 6.1 Testing Recommenations 6.2 Flushing an Grouning Recommenations Glossary of Terms Inex 3

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5 SECTION ONE 1.0 Introuction an Overview 1.1 Introucing Polystar 1.2 System Highlights 1.3 Prouct Stanars an Quality Control 1.4 Summary of Major Moels POLYSTARTM PolystarPipe.com 5

6 1.1 INTRODUCING POLYSTAR INTRODUCING THE POLYSTAR PP-RCT PIPING SYSTEM FROM ORION We are please to introuce Polystar, the worl s most avance polypropylene piping system. Polystar is the first complete piping system manufacture entirely with a β-nucleate polypropylene ranom copolymer referre to as PP-RCT. The β-nucleation process creates an enhance crystalline structure that gives Polystar piping higher strength at elevate temperatures. Polystar is initially available in three classifications, two of which are reinforce with our unique Fibercore Reinforcement Technology for applications with thermal expansion an contraction. All Polystar piping an fittings are manufacture from the same resin an pigmente with a base color of steel grey (similar to RAL 7042) to architecturally blen into builing settings. The piping classification is inicate with co-extrue color striping. The PP-RCT use in the Polystar piping system has a unique crystal structure. In comparison to stanar PP-R, which isplays only alpha (α) crystals, the crystal structure of β-ppr inclues a high egree of β-crystals an a lesser extent of α-crystals. The resulting fine crystal structure an homogeneous crystallite size istribution positively affects the mechanical characteristics of Polystar s raw material. PRODUCED TO THE HIGHEST WORLDWIDE STANDARDS Polystar Piping System components are manufacture for Orion to the highest-quality stanars by its partner Baenninger, Inc. Components are mae in Baenninger s state-of-the-art facilities in Germany. Piping is extrue in uniquely esigne equipment for this purpose. As a result of this joint cooperation, Baenninger's equipment is capable of extruing piping with up to seven layers through 24 (630mm) sizes. Avance injection-moling capabilities allow Baenninger to prouce injection-mole fittings up to 24 (630mm) size. This makes Polystar the most complete an highest quality PP piping system available. Plain En Fittings in sizes 6 (160mm) through 24 (630mm) are injection- mole at facilities in Reiskirchen, Germany. Polystar is initially available in three classifications: CT- Re, CT-White, an CT-Blue. CT-Re is reinforce with the Fibercore mile layer an is the highest pressure-rate piping in the line, making it the perfect choice for hot potable water piping systems an other applications with emaning pressure requirements at elevate temperatures. CT-White, also reinforce with Fibercore, is esigne with a thinner wall than CT-Re to make it an economical choice for above groun hyronic heating, chille water lines, an other HVAC applications. The thir type of piping, CT-Blue, is extrue with straight PP-RCT material for applications where thermal expansion an contraction issues are not a concern. Socket Fusion Fittings in sizes ⅜ (16 mm) through 4 (125mm) an pipe from sizes ⅜ (16 mm) through 24 (630 mm) are prouce in facilities in Staβfurt, Germany. *Polystar, CT-Re, CT-White, CT-Blue, CT-Lavener, Grey Pigmente PP Piping with Re Stripes, Grey Pigmente PP Piping with White Stripes, Grey Pigmente PP Piping with Blue Stripes, an Fibercore Reinforcement Technology are traemarks of Orion Enterprises, Inc., a Watts Water Technologies company. 6

7 POLYSTAR CT-WHITE Polystar CT-White piping is an extrue pressure piping series esigne for a wie variety of commercial an inustrial applications. The piping is extrue with our Fibercore mile-layer reinforcement technology, which strengthens, stiffens, an as imensional stability to the pipe. The CT-White s superior resistance to chemicals an temperatures make it ieal for conveying water in all types of HVAC applications. It is also an excellent choice for conveying a wie variety of chemicals for inustrial process piping applications. Avantages of CT-White Piping: Permanent leak-tight joints Fast, repeatable weling with easy-to-use tools Highly resistant to a wie range of chemicals an aggressive water (See Section 2.4) Excellent flow characteristics an low pressure rop Thermal properties reuce insulation thicknesses Low flame an smoke ratings 100% Recyclable POLYSTAR CT-BLUE 5 Polystar CT-Blue piping is an extrue pressure piping series esigne for a wie variety of commercial an inustrial applications. The piping is extrue as a monolithic single layer without any central reinforcement, making it an economical choice for applications where temperatures remain constant. The CT-Blue s superior resistance to chemicals an temperatures makes it ieal for conveying water in all kins of services, incluing potable water. It is also an excellent choice for conveying a wie variety of chemicals for inustrial process piping applications. Avantages of CT-Blue Piping: Completely hygienic Rate for potable water service (future) Permanent leak-tight joints Fast, repeatable weling with easy-to-use tools Highly resistant to a wie range of chemicals an aggressive water (See Section 2.4) Excellent flow characteristics an low pressure rop Highly insulating to reuce insulation thicknesses Very low soun transmission rates Low flame an smoke ratings Long lasting an resistant to traitional corrosion 5 100% Recyclable POLYSTAR CT-RED Polystar CT-Re piping is an extrue pressure piping series which can be use in a variety of high temperature applications. The piping is extrue with Fibercore milelayer reinforcement technology which strengthens, stiffens, an as imensional stability to the pipe. The CT-Re s superior resistance to chemicals an temperatures makes it ieal for conveying hot water in all types of commercial, inustrial, an resiential applications. It also makes an excellent choice for conveying a wie variety of chemicals for inustrial process piping applications. Avantages of CT-Re Piping: Completely hygienic Rate for hot potable water service (future) Permanent leak-tight joints Fast, repeatable weling with easy-to-use tools Highly resistant to a wie range of chemicals an aggressive water (See Section 2.4) Excellent flow characteristics an low pressure rop Very low soun transmission rates Highly insulating to reuce insulation thicknesses Low flame an smoke ratings Long lasting an resistant to traitional corrosion 5 100% Recyclable APPLICATIONS FOR POLYSTAR USE: Hot an Col Potable Water Cooling Tower Water Supply/Return/Recirculation Chille Water Distribution Propylene an Ethylene Glycol Distribution Hyronic Heating Distribution Plant Water Distribution Chemical Process Piping Fire Sprinkler Piping Recycle, Reclaime, an Rainwater Retention Applications Compresse Air 1.2 SYSTEM HIGHLIGHTS 7

8 1.3 PRODUCT STANDARDS AND QUALITY CONTROL PRODUCT STANDARDS AND LISTING INFORMATION Polystar piping systems are manufacture in accorance with a variety of national an international stanars. These stanars are summarize as follows: ASTM F2389 Stanar Specification for Pressurerate polypropylene (PP) Piping Systems This stanar is the key stanar for the Unite States which etails all of the requirements for pressure piping systems manufacture from Polypropylene materials, incluing PP-RCT materials. CSA B Polypropylene (PP-R) pipe an fittings for pressure applications This stanar is the key stanar for Canaa which etails all of the requirements for pressure piping systems manufacture from Polypropylene materials, incluing PP-RCT materials. CSA B214 Installation Coe for hyronic heating systems Canaian Coe for Hyronic heating applications. DIN 8077 Polypropylene (PP) pipes PP-H, PP-B, PP-R, PP-RCT Dimensions German Stanar which covers polypropylene piping systems such as Polystar. ISO 9080 Plastics piping an ucting systems -- Determination of the long-term hyrostatic strength of thermoplastics materials in pipe form by extrapolation International stanar reference in ASTM F2389 use to etermine hyrostatic strength basis for Polystar piping in orer to etermine pressure ratings. ASTM D2837 Stanar Test Metho for Obtaining Hyrostatic Design Basis for Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Proucts The ASTM stanar which is similar to ISO ASTM F2023 Stanar Test Metho for Evaluating the Oxiative Resistance of Crosslinke Polyethylene (PEX) Tubing an Systems to Hot Chlorinate Water The stanar chlorine test which is reference in ASTM F2389 for which PP materials such as Polystar have to be teste to. NSF Stanar 14 Plastics Piping System Components an Relate Materials NSF 14 establishes minimum physical, performance, health effects, quality assurance, marking, an recor keeping requirements for plastic piping components an relate materials. NSF-61 Drinking Water System Components Inicates the prouct is certifie to NSF/ANSI 61 for potable water contact. NSF PW - Inicates the prouct is certifie to NSF 61 along with one or more stanars that woul aress structural aspect of the prouct (e.g. ASTM F2389, CSA B137.11). NSF-rfh - Proucts meet all applicable performance requirements for a pressure rate floor heating application specifie in NSF/ANSI Stanar 14. No health effects evaluation is require. NSF-rw - Proucts meeting the applicable performance stanars for reclaime water applications as require by NSF/ANSI Stanar 14, incluing a hyrostatic esign basis (HDB). No health effects evaluation is require. NSF-51 Foo Equipment Materials Plastics, materials, an components use in foo equipment the stanar for which Polystar materials have to be teste for use in Foo Equipment or for contact with foo. ASTM F2023 Stanar Test Metho for Evaluating the Oxiative Resistance of Crosslinke Polyethylene (PEX) Tubing an Systems to Hot Chlorinate Water The stanar chlorine test which is reference in ASTM F2389 for which PP materials such as Polystar have to be teste to. ASTM D 635 Stanar test metho for rate of burning an/or extent an time of burning of plastics in a horizontal position. 8

9 LISTING APPROVAL AND QUALITY CONTROL Polystar proucts are manufacture in accorance with the following approvals an quality systems. 1.3 PRODUCT STANDARDS AND QUALITY CONTROL 9

10 1.4 SUMMARY OF MAJOR MODELS CT-RED PIPE SF LONG RADIUS 90 ELBOW CT-WHITE PIPE SF STREET 45 ELBOW CT-BLUE PIPE SF 45 ELBOW CT-BLUE COILS 45 ELBOW PLAIN END SF STREET 90 ELBOW SF 90 ELBOW 90 ELBOW PLAIN END SF TEE TEE PLAIN END SF 90 ELBOW - FNPT SF RED TEE SF CROSS SF MANIFOLD SF CROSSOVER SF RED COUPLING SF 90 ELBOW - MNPT PIPE SUPPORT STUB FLANGE PLAIN END REDUCER PLAIN END CAP PLAIN END 10

11 SF COUPLING SF STUB FLANGE ELECTROFUSION COUPLING SF CAP STREET 90 ELBOW - FNPT SF WYE SF TEE - FNPT SF RED WELDING SADDLE 1. 4 SUMMARY OF MAJOR MODELS SF TEE- MNPT ALL PLASTIC UNION FEMALE NPT LF ADPTR MALE NPT LEAD FREE ADPTR SF REDUCING SADDLES MNPT SF 90 WINGED EL FNPT SF SO90 WINGED EL - FNPT SF TEE GAUGE CONNECTION ALL PLASTIC BALL VALVE THREE-WAY BALL VALVE SPRING CHECK VALVE SWING CHECK VALVE ALL-PLASTIC BUTTERFLY VALVE DIAPHRAGM VALVE FLANGED DIAPHRAGM VALVE UNION DIAPHRAGM VALVE Note: Aitional Moels Available. 11

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13 SECTION TWO 2.0 Material Properties an Dimensional Data 2.1 Material Properties for Polystar PP-RCT Material 2.2 Pressure Ratings for Polystar Pipe 2.3 Recommene Specifications for Polystar 2.4 Chemical Resistance for Polystar PP-RCT Material 2.5 Pipe Dimensional Data 2.6 Fittings Dimensional Data POLYSTARTM PolystarPipe.com 13

14 2.1 MATERIAL PROPERTIES FOR POLYSTAR PP-RCT MATERIAL PROPERTIES MATERIAL PROPERTIES FOR POLYSTAR PP-RCT MATERIAL STANDARD CRITERIA PP-RCT VALUE UNIT Melting Inex MFR 190/5 ISO / R E-0.3 lb /10 minutes Melting MFR 230/2.16 ISO / R E E-03 lb /10 minutes Density ISO / R lb/ft 3 Melting Range Polarization Microscope F Yiel Stress ISO / R527 3,600 PSI Tensile Strength Fee Spee 6,500 PSI Yiel ISO % Bening 3.5% ISO 178 3,300 PSI Moulus Of Elasticity ISO ,500 PSI Mechanical properties following impact bening 32 C DIN 8078 No Fracture Expansion Coefficient VDE 0304 Part 1 & / F Thermal 68 F DIN BTU/(hr-ft 2 - F/in) Charpy Impact, Notche ISO ft-lb/in 2 Specific 68 F Aiabatic Calorimeter 0.48 BTU/(lb- F) Absolute Roughness E-05 ft 14

15 POLYSTAR CT-RED Temperature 1/2" 3/4" 1" PRESSURE v. TEMPERATURE 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" (20 mm) (25 mm) (32 mm) (40 mm) (50 mm) (63 mm) (75 mm) (90 mm) (110 mm) (125 mm) (160 mm) (200 mm) (250 mm) DR 7.4 DR 7.4 DR 9 DR 9 DR 9 DR 9 DR 9 DR 9 DR 9 DR 9 DR 11 DR 11 DR F (23 C)* F (60 C)* F (82 C)* F (99 C)** POLYSTAR CT-WHITE 1/2" 3/4" 1" PSI PRESSURE v. TEMPERATURE 1 1/4" For Pressure Ratings above 10" (250mm) iameter size, contact the Orion Technical Department. 1 1/2" 2" 2 1/2" 3" 3 1/2" (20 mm) (25 mm) (32 mm) (40 mm) (50 mm) (63 mm) (75 mm) (90 mm) (110 mm) (125 mm) (160 mm) (200 mm) (250 mm) DR 7.4 DR 7.4 DR 9 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 17 DR 17 DR 17 4" 4" 6" 6" 8" 8" 10" 10" 2.2 PRESSURE RATINGS FOR POLYSTAR PIPE Temperature PSI 73 F (23 C)* F (60 C)* F (82 C)* F (99 C)** For Pressure Ratings above 10" (250mm) iameter size, contact the Orion Technical Department. PRESSURE v. TEMPERATURE POLYSTAR CT-BLUE Temperature 1/2" (20 mm) 3/4" (25 mm) 1" 1 1/4" (32 mm) (40 mm) 1 1/2" (50 mm) 2" (63 mm) 2 1/2" (75 mm) 3" 3 1/2" 4" 6" 8" 10" (90 mm) (110 mm) (125 mm) (160 mm) (200 mm) (250 mm) DR 9 DR 9 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 DR 11 PSI 73 F (23 C)* F (60 C)* F (82 C)* F (99 C)** * Pressure rating evaluate up to 50 years **Pressure rating evaluate up to 10 years Pressure ratings evelope with a 1.5 safety factor For Pressure Ratings above 10" (250mm) iameter size, contact the Orion Technical Department. 15

16 2.2 PRESSURE RATINGS FOR POLYSTAR PIPE Hoop Stress (psi) 10,000 1,000 Hoop Stress v. Time For Polystar Polypropylene Reference Curves for PP-RCT Material Class ReferenceCurves for PP-R (EN ISO ; DIN 8078) 203 F 230 F 68 F 158 F years ,000 10, ,000 1,000,000 Time (Hours) Hoop Stress v. Time For Polystar Polypropylene 100 Reference Curves for PP-RCT Material Class ReferenceCurves for PP-R (EN ISO ; DIN 8078) Hoop Stress (MPa) C 70 C 95 C 110 C years ,000 10, ,000 1,000,000 Time (Hours) 16

17 SHORT FORM SPECIFICATION FOR POLYSTAR CT-WHITE PIPING SYTEMS Pipe an fittings shall be manufacture from a PP- RCT resin meeting the short-term properties an longterm strength requirements of ASTM F 2389, an shall be provie by Orion. All hot water pipe shall be mae in a three layer extrusion process an shall contain a fiberglass-reinforce mile layer (Fibercore ) to restrict thermal expansion. Fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F Fittings for sizes 4 nominal (125mm) an below shall be of the socket fusion type an shall be injection mole. Fittings for sizes 6 nominal (160mm) an above shall be of the plain en type an shall be injection mole, except where a mole fitting is unavailable. All pipe an fittings shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B Piping systems in nominal sizes 4 inch (125mm) an below shall be joine by socket fusion (ASTM D2657) with fiel tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joine either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleane, isinfecte an teste in accorance with Orion s recommenations an the requirements of the authority having jurisiction. SHORT FORM SPECIFICATION FOR POLYSTAR CT-RED PIPING SYTEMS Pipe an fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F 2389, an shall be provie by Orion. All hot water pipe shall be mae in a three layer extrusion process an shall contain a fiberglassreinforce mile layer (Fibercore ) to restrict thermal expansion. Fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F Fittings for sizes 4 nominal (125mm) an below shall be of the socket fusion type an shall be injection mole. Fittings for sizes 6 nominal (160mm) an above shall be of the plain en type an shall be injection mole, except where a mole fitting is unavailable. All pipe an fittings shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B Piping systems in nominal sizes 4 inch (125mm) an below shall be joine by socket fusion (ASTM D2657) with fiel tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joine either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleane, isinfecte an teste in accorance with Orion s recommenations an the requirements of the authority having jurisiction. SHORT FORM SPECIFICATION FOR POLYSTAR CT-BLUE PIPING SYTEMS Pipe an fittings shall be manufacture from a PP- RCT resin meeting the short-term properties an longterm strength requirements of ASTM F 2389, an shall be provie by Orion. All pipe shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B Fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F Fittings for sizes 4 nominal (125mm) an below shall be of the socket fusion type an shall be injection mole. Fittings for sizes 6 nominal (160mm) an above shall be of the plain en type an shall be injection mole, except where a mole fitting is unavailable. All pipe an fittings shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B Piping systems in nominal sizes 4 inch (125mm) an below shall be joine by socket fusion (ASTM D2657) with fiel tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joine either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleane, isinfecte an teste in accorance with Orion s recommenations an the requirements of the authority having jurisiction. 2.3 RECOMMENDED SPECIFICATIONS FOR POLYSTAR 17

18 2.3 RECOMMENDED SPECIFICATIONS FOR POLYSTAR RECOMMENDED SPECIFICATION FOR POLYSTAR PIPING SYSTEMS FOR FACILITY WATER AND PROCESS WATER APPLICATIONS PART 1 GENERAL 1.01 SUMMARY A. This Section specifies the water istribution piping system, incluing col, hot an re-circulate hot water piping, fittings, valves an specialties within the facility REFERENCE DOCUMENTS A. ASTM F Stanar Specification for Pressure-rate Polypropylene (PP) Piping Systems B. CSA B Polypropylene (PP-R) Pipe an Fittings for Pressure Applications C. NSF/ANSI 14 Plastic Piping System Components an Relate Materials 1.03 QUALITY ASSURANCE Material shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B an manufacturer s specifications. PART 2 PRODUCTS 2.01 PIPE AND PIPING PRODUCTS A. Pipe shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F The pipe shall contain no rework or recycle materials. All hot water pipe shall be mae in a three layer extrusion process an shall contain a fiberglass-reinforce mile layer (Fibercore ) to restrict thermal expansion. All pipe shall comply with the rate pressure requirements of ASTM F All pipe shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B B. Pipe shall be Polystar CT-Blue, Polystar CT-Re or Polystar CT-White as provie by Orion. Piping specifications an orering information are available at FITTINGS A. Fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F The fittings shall contain no rework or recycle materials. All fittings shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B All fittings shall be injection mole. Fabricate fittings are not allowe, except where a mole fitting is unavailable. B. Fittings for sizes 4 nominal (125mm) an below shall be of the socket fusion type an shall be injection mole. C. Fittings for sizes 6 nominal (160mm) an above shall be of the plain en type an shall be injection mole, except where a mole fitting is unavailable VALVES A. Valves shall be manufacture in accorance with the manufacturer s specifications. B. All Ball Valves, Multiport Ball Valves, Diaphragm Valves, Butterfly Valves, Spring Check Valves an Swing Check Valves shall be Polystar Valves, except where valves are not offere by Orion SMOKE AND FIRE RATINGS A. Where inicate on the rawings that a Plenumrate Piping System is require, the piping shall be protecte with a suitable fire protective insulation, as recommene by Orion UV PROTECTION A. For pipe that will be expose to irect UV light for more than 30 ays, it shall be provie with a Factory applie, UV-resistant coating or alternative UV protection. PART 3 - EXECUTION 3.01 FUSION WELDING OF JOINTS A. Fittings in sizes 4 nominal (125mm) an below shall be joine using heat element socket fusion in accorance with ASTM D2657. B. Pipe in sizes 4 nominal (125mm) an below shall be joine using either heat element socket fusion in accorance with ASTM D2657 using mole couplings, or may alternatively be joine by the electrofusion metho using Polystar Electrofusion Couplings in accorance with ASTM F1290. C. Pipe an Fittings in sizes 6 inch nominal (160mm) an above may be joine by either heat element butt fusion in accorance with ASTM D2657, or may be joine by the electrofusion metho using Polystar Electrofusion Couplings in accorance with ASTM F1290. D. Pipe joining equipment shall be limite to Polystar Equipment as supplie by Orion, or shall be approve by Orion for use with Polystar materials. E. Joint preparation, setting an alignment, fusion process, cooling times an working pressure shall be in accorance with the pipe an fitting manufacturer s specifications. 18

19 3.02 PIPING INSTALLATIONS A. Install hangers, supports, guies an anchors at intervals specifie in the applicable Plumbing Coe an as recommene by pipe manufacturer. B. Support vertical piping at each floor penetration an as specifie in the applicable Plumbing Coe using suitable riser clamps. C. Fire stopping shall be compatible with the Polystar Piping an meet the requirements of ASTM E 814 or ULC S115, Fire Tests of Through Penetration Firestops. Pipe insulations or fire resistive coating shall be remove where the pipe passes through fire stop an, if require by the firestop manufacturer, for 3 beyon the firestop outsie of the fire barrier. D. Piping shall be protecte from excessive heat generate from pumps operating at shut-off conitions. Where the possibility exists that the pump will eahea (i.e. operate with no flow), a suitable temperature relief valve shall be provie, or other comparable level of protection, set to a maximum temperature of 185 F. E. If heat tracing is specifie for the piping, this shoul be limite to the use of self-regulating type to ensure the surface temperature of the pipe an fittings will not excee 70 C (158 F) INSPECTING AND CLEANING A. The pipes shoul be flushe with col water after completing the installation. Inspect an test piping systems in accorance with the recommenations an requirments of authorities having jurisiction an as specifie by the piping system manufacturer. B. Clean an isinfect water istribution piping in accorance with the requirements of the authority having jurisiction TESTING A. Upon completion of the piping installation, the piping shall be teste using either a hyrostatic pressure test to 150% of the esign pressure of the system for a minimum of one hour, or using a pneumatic test with compresse air or inert gas to 110% of the esign pressure for a minimum of one hour, in accorance with the proceures, guielines an recommenations of Orion an in accorance with the requirements of the authority having local jurisiction. The contractor shall take into account all necessary safety precautions an shall follow proceures an guielines to insure that the testing is carrie out in a safe manner. RECOMMENDED SPECIFICATIONS FOR POLYSTAR PIPING SYSTEMS FOR HYDRONIC HEATING APPLICATIONS PART 1 GENERAL 1.01 SUMMARY A. This Section specifies the hyronic piping system, incluing piping, fittings, valves an specialties within the builing REFERENCE DOCUMENTS A. ASTM F Stanar Specification for Pressure-rate Polypropylene (PP) Piping Systems B. CSA B Polypropylene (PP-R) Pipe an Fittings for Pressure 21 Applications C. NSF/ANSI 14 Plastic Piping System Components an Relate Materials 1.03 QUALITY ASSURANCE A. Material shall be certifie by NSF International as complying with NSF 14-Hyronic, an ASTM F 2389 or CSA B B. Material shall comply with manufacturer s specifications. C. Special Engineere proucts shall be certifie by NSF International as complying with NSF 14-Hyronic. PART 2 PRODUCTS 2.01 PIPE AND PIPING PRODUCTS A. Pipe shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F 2389 or CSA B The pipe shall contain no rework or recycle materials. All pipe shall be mae in a three layer extrusion process. All hot water pipe shall be mae in a three layer extrusion process an shall contain a fiberglass-reinforce mile layer (Fibercore ) to restrict thermal expansion. All pipe shall comply with the rate pressure requirements of ASTM F All pipe shall be certifie by NSF International as complying with NSF 14, NSF 61, an ASTM F 2389 or CSA B B. Pipe shall be Polystar CT-White as provie by Orion Piping specifications an orering information are available at FITTINGS A. Fittings shall be manufacture from a PP-RCT resin meeting the short-term properties an long-term strength requirements of ASTM F The fittings shall contain no rework or recycle materials. All fittings shall be certifie by NSF International as complying 2.3 RECOMMENDED SPECIFICATIONS FOR POLYSTAR 19

20 2.3 RECOMMENDED SPECIFICATIONS FOR POLYSTAR with NSF 14, NSF 61, an ASTM F 2389 or CSA B All fittings shall be injection mole, except where a mole fitting is unavailable. B. Fittings for sizes 4 nominal (125mm) an below shall be of the socket fusion type an shall be injection mole. C. Fittings for sizes 6 nominal (160mm) an above shall be of the plain en type an shall be injection mole, except where a mole fitting is unavailable VALVES A. Valves shall be manufacture in accorance with the manufacturer s specifications. B. All Ball Valves, Multiport Ball Valves, Diaphragm Valves, Butterfly Valves, Spring Check Valves an Swing Check Valves shall be Polystar Valves, except where valves are not offere by Orion SMOKE AND FIRE RATINGS A. Where inicate on the rawings that a Plenumrate Piping System is require, the piping shall be protecte with a suitable fire protective insulation, as recommene by Orion UV PROTECTION A. For pipe that will be expose to irect UV light for more than 30 ays, it shall be provie with a Factory applie, UV-resistant coating or alternative UV protection. PART 3 - EXECUTION 3.01 FUSION WELDING OF JOINTS A. Fittings in sizes 4 nominal (125mm) an below shall be joine using heat element socket fusion in accorance with ASTM D2657. B. Pipe in sizes 4 nominal (125mm) an below shall be joine using either heat element socket fusion in accorance with ASTM D2657 using mole couplings, or may alternatively be joine by the electrofusion metho using Polystar Electrofusion Couplings in accorance with ASTM F1290. C. Pipe an Fittings in sizes 6 inch nominal (160mm) an above may be joine by either heat element butt fusion in accorance with ASTM D2657, or may be joine by the electrofusion metho using Polystar Electrofusion Couplings in accorance with ASTM F1290. D. Pipe joining equipment shall be limite to Polystar Equipment as supplie by Orion, or shall be approve by Orion for use with Polystar materials. E. Joint preparation, setting, alignment, fusion process, cooling times an working pressure shall be in accorance with the manufacturer s specifications PIPING INSTALLATIONS A. Install hangers, supports, guies an anchors at intervals specifie in the applicable Plumbing Coe an as recommene by pipe manufacturer. B. Support vertical piping at each floor penetration an as specifie in the applicable Plumbing Coe using suitable riser clamps. C. Fire stopping shall be compatible with the Polystar Piping an meet the requirements of ASTM E 814 or ULC S115, Fire Tests of Through Penetration Firestops. Pipe insulations or fire resistive coating shall be remove where the pipe passes through fire stop an, if require by the firestop manufacturer, for 3 beyon the firestop outsie of the fire barrier. D. Piping shall be protecte from excessive heat generate from pumps operating at shut-off conitions. Where the possibility exists that the pump will eahea (i.e. operate with no flow), a suitable temperature relief valve shall be provie, or other comparable level of protection, set to a maximum temperature of 185 F. E. If heat tracing is specifie for the piping, this shoul be limite to the use of self-regulating type to ensure the surface temperature of the pipe an fittings will not excee 70 C (158 F) INSPECTING AND CLEANING A. The pipes shoul be flushe with col water after completing the installation. Inspect an test piping systems in accorance with the recommenations an requirments of authorities having jurisiction an as specifie by the piping system manufacturer. B. Clean an isinfect water istribution piping in accorance with the requirements of the authority having jurisiction TESTING A. Upon completion of the piping installation, the piping shall be teste using either a hyrostatic pressure test to 150% of the esign pressure of the system for a minimum of one hour, or using a pneumatic test with compresse air or inert gas to 110% of the esign pressure for a minimum of one hour, in accorance with the proceures, guielines an recommenations of Orion an in accorance with the requirements of the authority having local jurisiction. The contractor shall take into account all necessary safety precautions an shall follow proceures an guielines to insure that the testing is carrie out in a safe manner. 20

21 CHEMICAL RESISTANCE Orion s Polystar piping systems are useful for a wie variety of process piping applications. Before etermining the suitability of a Polystar piping system for conveying chemicals of any type uner pressure, it is important to verify that the material is suitable for use an that the piping system will be capable of withstaning the chemicals uner the concurrent pressure an temperature an other loas uner which it will operate. The chemical resistance tables provie in this section provie a general guieline for etermining the suitability of Polystar PP-RCT piping systems. However, chemical resistance is epenent on a great number of specific factors, which inclue more than the concentration of the chemicals an the temperatures to which they are to be hanle. Other factors inclue, but are not limite to the concurrent temperature, pressure, an other internal an external loas impose on the system, the uration of application (i.e. continuous vs. intermittent), steay vs. cyclic loaing, consieration of other chemicals which may be mixe together with the chemical uner question, an the esign coes to which the system is being implemente (e.g. ANSI/ASME B31.3 Coe). While these charts may serve as a general guieline for the etermination of resistance, it is recommene to contact the factory for further guiance for any chemical application of Polystar. The final etermination will be the responsibility of the engineer in responsible charge of the project or other representative of the owner.! CAUTION Prior to consiering Polystar for any chemical application, consult the factory for a full recommenation base on the complete conitions of the application. Do not rely solely on the recommenations shown in the charts as suitability is base on aitional factors incluing but not limite to pressure, temperature, uration an whether there are any mixtures of chemicals involve. NOTICE When consiering the installation of Polystar PP-RCT materials that are connecte to an existing copper piping system, o not install the PP-RCT materials in applications involving elevate temperatures with aggressive water applications if the velocity of the water in the copper piping excees 10 ft/secon. This can result in the release of copper ions which can result in potential stress cracking in PP piping. 2.4 CHEMICAL RESISTANCE FOR POLYSTAR PP-RCT MATERIAL! WARNING Accoring to the ANSI/ASME B31.3 Process Piping Coe, thermoplastic piping shoul not be use in flammable flui service above groun, in nominal sizes above 1 inch (32 mm). With sizes 1 inch an below, seconary containment shoul be provie. Consult the factory prior to use in any flammable flui services. NOTICE Prior to using Polystar in water applications involving elevate temperatures an with high resiual chlorine content, consult the factory as to the suitability of the Polystar materials for the intene application 21

22 2.4 CHEMICAL RESISTANCE FOR POLYSTAR PP-RCT MATERIAL Legen for Chemical Resistance Charts VL = 10% concentration by weight, L = > 10% concentration by weight, GL = saturate (aqueous) 68 F, TR = pure solution, + = resistant, = limite resistance (consult factory), - = not resistant TEMPERATURE CHEMICAL Conc. % 68 F 140 F 212 F Acetic aci (glacial acetic aci) TR + - Acetic aci, hyr Acetic aci anhyrie TR + Acetone TR + + Alum GL + + Alum of all kins, hyr. all + + Ammonia, gaseous TR + + Ammonia, hyr. conc. + + Ammonium acetate GL + + Ammonium carbonate GL + + Ammonium chlorie GL + + Ammonium nitrate GL Ammonium phosphate Gl Ammonium sulphate GL Amylalcohol, pure TR Aniline TR Antifreezing solution (motor vehicles) H Barium salts GL Battery aci Typical + + Benzalehye GL + + Benzene TR - - Benzine H - - Benzoic aci GL + + Bichromate of potash GL + + Bleaching solution 20 - Borax L + + Boric aci GL Bromine, liqui TR Bromine, vapours all - - Bromine water GL - - Butyl acetate TR - - Calcium chlorie GL Calcium nitrate CL + + Carbon Tetrachlorie TR Carbonum isulphie TR Caustic potash solution Caustic soa solution up to Chlor, liqui TR

23 TEMPERATURE CHEMICAL Conc. % 68 F 140 F 212 F Chlorie of lime all + + Chlorine, gaseous wet Chlorine water GL - - Chlorobenzene TR Chloroform TR - - Chlorosulphonic aci TR Chromic sulphuric aci Mixe Citric aci, hyr. VL Coconut oil TR + Corn oil TR + Cresol Cyclohexane TR + Cyclohexanol TR + Cyclohexanone TR - - Dekahyronaphtaline TR - - Detergent VL + + Dibutyl phthalate TR - - Diesel oil H + Diethylether TR + 1,4-Dioxane TR Ether Ethyl acetate TR + - Ethyl benzene TR - - Ethyl chlorie TR Formalehye, hyr Formic aci Fruit juices TR Fuel oil TR + Glycerine TR Heptane TR + - Hexane TR + Hyrochloric aci, hyr. up to Hyrofluoric aci solution Hyrogen chlorie, gaseous TR + + Hyrogen peroxie, hyr Hyrogen sulphie TR + + Iso-octane TR + - Joine solution TR + Lactic aci CHEMICAL RESISTANCE FOR POLYSTAR PP-RCT MATERIAL 23

24 2.4 CHEMICAL RESISTANCE FOR POLYSTAR PP-RCT MATERIAL TEMPERATURE CHEMICAL Conc. % 68 F 140 F 212 F LANOLIN TR + Linsee oil TR Magnesium salts GL + + Menthol TR + Mercury TR + + Mercury salts GL + + Methanol TR + + Methyl ethyl ketone TR + Methylene chlorie TR - - Milk TR Motor oil (motor vehicles) TR + Nickle salts, hyr. GL + + Nitric aci, hyr Oleic aci GL + - Oleum TR Olive oil TR + + Oxalic gl + + Ozone 0,5 ppm + Paraffin TR + + Paraffin oil TR + - Peanut oil TR + + Peppermint oil TR + Perchlorethylene Petroleum TR + Petroleum ether TR + Petroleum jelly TR + Phenol (hyr. phase) Phosphoric aci Photographic eveloper TR + + Pine neele oil TR + Potassium carbonate (Potash) GL + + Potassium chlorate GL + + Potassium chlorie GL + + Potassium hyroxie Potassium ioie GL + + Potassium nitrate, hyr. GL + + Potassium permanganate GL + - Potassium persulphate GL + + Propane, gaseous TR + Pyriine TR Sea water TR Silicone oil TR

25 TEMPERATURE CHEMICAL Conc. % 68 F 140 F 212 F Silver salts GL + + Soium carbonate Soium carbonate (soa) Soium chlorate GL + + Soium chlorie VL Soium chlorite, hyr Soium hyrochlorite, hy Soium nitrate GL + + Soium nitrite GL + + Soium phosphate GL Soium sulphate GL + + Soium sulphie GL + + Soium sulphite Soium thiosulphate GL + + Soybean oil TR + Stannous chlorie GL + + Starch solution, hyr. all + + Succinic aci, hyr. GL + + Sugar syrup TR + + Sulphur ioxie TR + + Sulphuric aci, hyr. 80-TR Tartaric aci, hyr Tetrachloroethane TR - - Tetrachloroethylene (Perchlorethylen) TR Tetrahyrofurane TR - - Tetrahyronaphtalene (Tetralin) TR Toluene TR - - Transformer oil TR - Trichloroethylene TR Tricresyl phosohate TR + Trioctyl phosohate TR + Turpentine oil TR Turpentine substitute TR + - Urea, hyr. GL + + Vinegar TR Water TR Wine TR + + Xylene TR - - Zinc salts, hyr. GL CHEMICAL RESISTANCE FOR POLYSTAR PP-RCT MATERIAL 25

26 2.5 PIPE DIMENSIONAL DATA Legen for Dimensional Data Charts: nom = nominal iameter in = actual outsie iameter in millimeters DN = nominal iameter in mm accoring to ISO 1 = actual insie iameter in, 1 (flanges) = outsie iameter of stub flange face in 2, 4, 5 = actual outsie iameter of fitting hub in L, L 1 = centerline to en in z, z 1 = centerline to en of water way (excluing socket) in s = wall thickness in SW, SW 1 = imensions of mole nut size in mm H, h, SD, R, R p, = other, miscellaneous in Larger sizes are available for pipes an fittings. For imensional information on larger sizes contact Orion's Technical Services Department. PIPE CT-WHITE nom SDR mm DN mm 1 s ½ ¾ ¼ ½ ½ ½

27 PIPE CT-RED nom SDR mm DN mm i s ½ ¾ ¼ ½ ½ ½ PIPE DIMENSIONAL DATA PIPE CT-BLUE nom SDR mm DN mm i s ½ ¾ ¼ ½ ½ ½

28 2.6 FITTINGS DIMENSIONAL DATA 90 ELBOW SOCKET FUSION LONG RADIUS nom mm 2 L z ⅜ ½ ¾ ¼ ELBOW SOCKET FUSION STREET nom mm 2 L z z1 ½ ¾ ELBOW SOCKET FUSION nom mm 2 L z ⅜ ½ ¾ ¼ ½ ½ ½

29 45 ELBOW PLAIN END nom mm s L z FITTINGS DIMENSIONAL DATA 90 ELBOW SOCKET FUSION STREET nom mm 2 L z z1 ⅜ ½ ¾ ¼

30 2.6 FITTINGS DIMENSIONAL DATA 90 ELBOW SOCKET FUSION nom mm 2 L z ⅜ ½ ¾ ¼ ½ ½ ½ ELBOW PLAIN END nom mm s L z

31 SOCKET FUSION TEES nom mm 2 L z ⅜ ½ ¾ ¼ ½ ½ ½ FITTINGS DIMENSIONAL DATA TEES/ REDUCING TEES PLAIN END nom mm 1 nom 1 mm s s1 L L1 z z ½ ½

32 2.6 FITTINGS DIMENSIONAL DATA nom SOCKET FUSION REDUCING TEES 1 nom 2 nom mm 1 mm 2 mm 4 5 L L1 z z1 ½ ⅜ ½ ½ ¾ ½ ¾ ⅜ ¾ ¾ ½ ½ ¾ ½ ¾ ¾ ¾ ½ ½ ½ ½ ¾ ½ ¾ ¾ ¾ ¾ ¼ ½ 1¼ ¼ ¾ 1¼ ¼ ¼ 1 1¼ ½ ½ 1½ ½ ¾ 1½ ½ 1 1½ ½ 1¼ 1½ ½ ¾ ¼ 1½ ¼ ½ ½ ½ 2½ ½ ¾ 2½ ½ 1 2½ ½ 1¼ 2½ ½ 1½ 2½ ½ 2 2½ ½ ½ 2 3½ ½ 2½ 3½ ½ 3 3½ ½ ½

33 SOCKET FUSION CROSSES nom mm L z ½ ¾ ¼ ½ FITTINGS DIMENSIONAL DATA SOCKET FUSION HEADERS nom mm 1 nom 1 mm x4 branches t t1 L L1 L2 L3 ¾ 25 ⅜ ½ ¾ ¼ 40 ¾ SOCKET FUSION CROSSOVER nom mm SD H Z L ½ ¾

34 2.6 FITTINGS DIMENSIONAL DATA SOCKET FUSION REDUCING BUSHINGS nom mm 1 nom 1 mm 2 L z ½ 20 ⅜ ¾ 25 ⅜ ¾ 25 ½ ½ ¾ ¼ 40 ½ ¼ 40 ¾ ¼ ½ 50 ½ ½ 50 ¾ ½ ½ 50 1¼ ½ ¾ ¼ ½ ½ 75 1½ ½ ½ ½ ½ 110 2½ ½ SOCKET FUSION STUB FLANGE ADAPTERS nom mm 2 D1 L z h 1½ ½ ½

35 CONCENTRIC REDUCERS PLAIN END nom mm 1 nom 1 1 mm s s1 L L1 z ½ ½ FITTINGS DIMENSIONAL DATA SOCKET FUSION COUPLINGS nom mm 2 nom L mm z ⅜ ½ ¾ ¼ ½ ½ ½

36 2.6 FITTINGS DIMENSIONAL DATA ELECTRO- FUSION COUPLINGS nom mm h mm L ½ ¾ ¼ ½ ½ ½ SOCKET FUSION CAP nom mm 2 L ⅜ ½ ¾ ¼ ½ ½ ½

37 CAPS PLAIN END nom mm s L L FITTINGS DIMENSIONAL DATA SOCKET FUSION 45 LATERAL WYE nom mm L z z1 z ¼ ½ STUB FLANGE ADAPTERS PLAIN END nom mm s h 1 4 z L

38 2.6 FITTINGS DIMENSIONAL DATA WELDING SADDLES WITH SOCKET FUSION OUTLETS nom mm 1 nom 1 mm h 3 90 ½ ¾ ¼ ½ 110 ½ ½ 110 ¾ ½ 110 1¼ ½ 110 1½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ ½ ¾ ¼ ½ *Note: Smaller sizes are available for 1-1/4" (40mm) through 2-1/2" (75mm) mains. Reucing sales mole with integral male an female threae aapters with lea free brass inserts. are also available Sales with 1 inch (32mm) sizes are uner evelopment. SW 38

39 LEAD FREE* BRASS UNIONS nom mm L z SW mm ⅜ ½ ¾ ¼ ½ ½ SW 1 mm *The wette surface of this prouct contacte by consumable water contains less than 0.25% of lea by weight. 2.6 FITTINGS DIMENSIONAL DATA LEAD FREE* BRASS FEMALE ADAPTERS NPT nom mm Rp 2 D1 L z ⅜ 16 ½ ½ 20 ½ ½ 20 ¾ ¾ 25 ½ ¾ 25 ¾ ¾ ¼ ¼ 40 1¼ ½ 50 1¼ ½ 50 1½ ½ 75 2½ ½ SW *The wette surface of this prouct contacte by consumable water contains less than 0.25% of lea by weight. 39

40 2.6 FITTINGS DIMENSIONAL DATA LEAD FREE* BRASS MALE ADAPTERS nom mm R 2 D1 L z ⅜ 16 ½ ½ 20 ½ ½ 20 ¾ ¾ 25 ½ ¾ 25 ¾ ¾ ¼ ¼ 40 1¼ ½ 50 1¼ ½ 50 1½ ½ 75 2½ ½ SW mm *The wette surface of this prouct contacte by consumable water contains less than 0.25% of lea by weight. ALL PLASTIC UNIONS nom mm DN mm G L I l1 z D ½ ¾ ¼ ½ ¼ ½ ¼ ¾

41 PIPE BRACKET (For Non- Insulate Pipe) nom mm Size Hanger Ro *Bolt Size ½ ⅜ ¾ ⅜ ⅜ 1¼ ⅜ 1½ ⅜ ⅜ 2½ ⅜ ⅜ 3½ ⅜ ½ ½ ½ ½ ½ ½ *Hanger Ros are not inclue with pipe bracket. Note: Pipe brackets for insulate piping are available, contact manufacturer. 2.6 FITTINGS DIMENSIONAL DATA SEMI-TUBE SUPPORT nom mm S ⅜-¾ ¼ ½ ½ ½ Semi tube length is for all sizes. 41

42 42

43 SECTION THREE 3.0 System Sizing an Engineering Consierations 3.1 Flow Rate, Velocity, an Hea Loss (Pressure Drop) Data 3.2 Support Spacing for Polystar Pipes 3.3 Anchoring Polystar Pipes 3.4 Thermal Expansion an Contraction 3.5 Expansion/Contraction Compensation Guielines POLYSTARTM PolystarPipe.com 43

44 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA Pipe iameter is a critical factor in properly esigning the polystar pipe system. Polystar pipe systems are recommene to maintain an average flow velocity of 8 fps to provie energy efficient pumping, control of noise generation, an to ampen the affects of water hammer on the piping system. Once pipe sizes have been etermine for the system the following equations can be use to etermine the system pressure rop, an to select pump motor horsepower. When etermining frictional pressure loss across a system it is recommene that a 20% safety factor be use to account for aging of pipe, non-smooth wels, an manufacturing tolerances. DARCY METHOD h f = Friction loss from flow in the pipe/fittings, (ft) L = Length of pipe an/or equivalent length of pipe fitting (ft) D = Insie iameter of pipe, (ft) V = Average flow velocity within pipe, (ft/s) g = , Gravitational constant, (ft/s 2 ) f = Friction factor є = E-05, Absolute roughness of polypropylene pipe, (feet) μ = Absolute viscosity of liqui in pipe, (lb Mass /ft-s) ν= Kinematic viscosity of flui of liqui in pipe, (ft 2 /s) Re = Reynols number ρ = Density of liqui in pipe, (lb Mass /ft 3 ) Q = Volumetric flow, (gpm) C = Valve manufacturer's flow coefficient The Darcy-Weisbach equation can be use to etermine the friction loss for Polystar piping systems. It can be use to etermine the system's friction loss across pipe, fittings, an valves. Reynols Number The Reynols number allows the friction factor to be etermine. Depening on how large or small the Reynols number will etermine which equation shoul be use to calculate the friction factor. For Reynols Numbers <2000, the flow conition is consiere to be a laminar flow conition. For a laminar flow conition use the following equation to calculate the friction factor. For Reynols Numbers >4000, the flow conition is consiere to be a turbulent flow conition. For turbulent flow conitions use the Colebrook equation to calculate the friction factor. Colebrook Equation RRRR = ρρ DD VV μμ ff = 64 RRRR A Mooy Diagram can be use to etermine the friction factor as well. It can be use to etermine the friction factor in laminar flow conitions, transitional flow conitions, or turbulent flow conitions. To use the Mooy Diagram first calculate the Reynols number, an a relative roughness number. Use these numbers with the Mooy Diagram to etermine the friction factor. An equation for relative roughness is shown below. = VV DD vv 1 ff = 2 llllll 10 є 3.7DD RRRR ff RRRRRRRRRRRRRRRR RRRRRRRRhnnnnnnnn = εε DD Darcy-Weisbach Equation h ff = ff LL DD VV 2 2 gg In orer to calcuate the friction loss using the Darcy- Weisbach equation one must first calculate the Reynols number, which can be calculate with one of the below equations. FRICTION HEAD LOSS ACROSS PIPE Measure the evelope length of pipe, the length of pipe in the system containing the same pipe iameter an same average flow velocity. Insert this length along with the average flow velocity an pipe iameter into the Darcy-Weisbach equation to calculate the frictional hea loss of the pipe. 44

45 h ff = ff LL DD VV 2 2 gg where L = L Develope Length FRICTIONAL HEAD LOSS ACROSS A FITTING Select the fitting's equivalent pipe length from the fitting table an use this length in the Darcy-Weisbach Equation to etermine the frictional hea loss across the fitting. h ff = ff LL DD VV 2 2 gg where L = L Fitting Equiv Length If the pipe an fitting have ientical sizes an flow, the equivalent lenght of the fitting an the evelope length of the pipe can be summe together as a combine equivalent length which can be use to etermine the frictional hea loss across the combine length of pipe. h ff = ff LL DD VV 2 2 gg L = L Develope Length + L Fitting Equiv Length FRICTIONAL HEAD LOSS ACROSS A VALVE Valves are provie with a K-factor which have the following L/D, friction factor relationship. The K-factor may very epening on the valve position for most valves. Select the higher K value which applies to the system operation to be conservative. Use the pipe iameter, K-factor an friction factor to calculate the equivalent length across the valve. Insert the equivalent length of the valve into the Darcy-Weisbach equation to calculate the frictional hea loss across the valve. h ff = ff LL DD VV 2 2 gg where L = L Valve Equiv Length = (D K)/f Some valve manufacturers will provie a flow coefficient rather than a K-factor for the valve. The flow coefficient of a valve is efine to have a value of 1.0 when water at 60 F flows through the valve with a flow of 1 gpm, creating a pressure rop of 1 psi across the valve. To etermine the pressure rop across the valve insert the ensity of the chemical flowing through the valve, the volumetric flow rate, an the manufacturer's flow coefficient. The pressure rop will be provie in psi, not in feet of water column. QQ = 7.9 CC PP = ρρ CCheeeeeeeeeeee 62.4 PP ρρ CCheeeeeeeeeeee QQ CC 2 HAZEN & WILLIAMS METHOD The Hazen & Williams equation can be use for water at 60 F or any other flui having a kinematic viscosity of ft 2 /s. As water temperature varies from 32 F to 212 F the friction can vary as much as 40%, therefore one shoul use caution in using this equation. D = Insie iameter of pipe, () Q = Volumetric pipe flow, (gpm) C = 150, Flow coefficient for polypropylene pipe H f = Friction hea, (ft of water/100 ft of pipe) HH ff = CC 1.85 QQ 1.85 DD FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA LL DD = KK ff 45

46 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA PUMP/MOTOR H Total = Total hea, (ft) h f = Frictional hea loss, (ft) h Elevation = Elevation change, (ft) m = Mass flow rate, (lbmass/minute) HH TTTTTTTTTT = h ff + h EEEEEEEEEEEEEEEEEE Hyraulic Horse Power Pump Brake Horse Power KW Input To Motor HHHHHH HHPP = mm HH TTTTTTTTTT 33,000 PPPPPPPP BBBBBBBBBB HHHH = KKKK iiiiiiiiii tttt mmmmmmmmmm = HHHHHH HHHH PPPPPPPP EEEEEEEEEEEEEEEEEEEE PPPPPPPP BBBBBBBB HHHH MMMMMMMMMM EEEEEEEEEEEEEEEEEEEE CONVERTING FROM FEET OF HEAD TO PSI A column of water is 2.31 feet high is equal to 1 psi at 65 F. LLLLLLLLLLLL HHHHHHHH iiii ffffffff oooo wwwwwwwwrr = SSSSSSSSSSSSSSSS GGGGGGGGGGGGGG = ρρ CCheeeeeeeeeeee ρρ WWWWWWWWWW = pppppp 2.31 SSSSSSSSSSSSSSSS GGGGGGGGGGGGGG ρρ CCheeeeeeeeeeee 62.4 llll MMMMMMMM ffff 3 1 pppppp = 2.31 llllllllllll heeeeee iiii ffffffff oooo wwwwwwwwww cccccccccc 46

47 HEADLOSS - CT RED PIPE HEADLOSS - CT-WHITE PIPE 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 47

48 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA HEADLOSS - CT-BLUE PIPE CT-RED PRESSURE LOSS v. FLOW (½" THRU 1") 48

49 CT-RED PRESSURE LOSS v. FLOW (1¼" THRU 2") CT-RED PRESSURE LOSS v. FLOW (2" THRU 4") 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 49

50 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA CT-RED PRESSURE LOSS v. FLOW (4" THRU 10") CT-WHITE PRESSURE LOSS v. FLOW (½" THRU 1") 50

51 CT-WHITE PRESSURE LOSS v. FLOW (1¼" THRU 2") CT-WHITE PRESSURE LOSS v. FLOW (2" THRU 4") 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 51

52 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA CT-WHITE PRESSURE LOSS v. FLOW (4" THRU 10") CT-BLUE PRESSURE LOSS v. FLOW (½" THRU 1") 52

53 CT-BLUE PRESSURE LOSS v. FLOW (1¼" THRU 2") CT-BLUE PRESSURE LOSS v. FLOW (2" THRU 4") 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 53

54 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA CT-BLUE PRESSURE LOSS v. FLOW (4" THRU 12") 54

55 1/2" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 1/2 Inch Pipe SDR 7.4, 0.78 inch OD, 0.57 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 1/2 Inch Pipe SDR 7.4, 0.78 inch OD, 0.57 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 1/2 Inch Pipe SDR 9, 0.78 inch OD, 0.61 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

56 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 3/4" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 3/4 Inch Pipe SDR 7.4, 0.98 inch OD, 0.71 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 3/4 Inch Pipe SDR 7.4, 0.98 inch OD, 0.71 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 3/4 Inch Pipe SDR 9, 0.98 inch OD, 0.76 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

57 1" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 1 Inch Pipe SDR 9, 1.26 inch OD, 0.98 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 1 Inch Pipe SDR 9, 1.26 inch OD, 0.98 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 1 Inch Pipe SDR 11, 1.26 inch OD, 1.03 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

58 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 1¼" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 1¼ Inch Pipe SDR 11, 1.57 inch OD, 1.28 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 1¼ Inch Pipe SDR 9, 1.57 inch OD, 1.22 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 1¼ Inch Pipe SDR 11, 1.57 inch OD, 1.28 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

59 1½" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 1½ Inch Pipe SDR 11, 1.97 inch OD, 1.61 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 1½ Inch Pipe SDR 9, 1.97 inch OD, 1.51 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 1½ Inch Pipe SDR 11, 1.97 inch OD, 1.61 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

60 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 2" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 2 Inch Pipe SDR 11, 2.48 inch OD, 2.02 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 2 Inch Pipe SDR 9, 2.48 inch OD, 1.92 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 2 Inch Pipe SDR 11, 2.48 inch OD, 2.02 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

61 2½" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 2½ Inch Pipe SDR 11, 2.95 inch OD, 2.43 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 2½ Inch Pipe SDR 9, 2.95 inch OD, 2.29 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 2½ Inch Pipe SDR 11, 2.95 inch OD, 2.43 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

62 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 3" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 3 Inch Pipe SDR 11, 3.54 inch OD, 2.90 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 3 Inch Pipe SDR 9, 3.54 inch OD, 2.75 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 3 Inch Pipe SDR 11, 3.54 inch OD, 2.90 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

63 3½" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 3½ Inch Pipe SDR 11, 4.33 inch OD, 3.54 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 3½ Inch Pipe SDR 9, 4.33 inch OD, 3.36 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 3½ Inch Pipe SDR 11, 4.33 inch OD, 3.54 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

64 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 4" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 4 Inch Pipe SDR 11, 4.92 inch OD, 4.02 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 4 Inch Pipe SDR 9, 4.92 inch OD, 3.82 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 4 Inch Pipe SDR 11, 4.92 inch OD, 4.02 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

65 6" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 6 Inch Pipe SDR 17, 6.29 inch OD, 5.55 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 6 Inch Pipe SDR 11, 6.29 inch OD, 5.15 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 6 Inch Pipe SDR 11, 6.29 inch OD, 5.15 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 65

66 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 8" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 8 Inch Pipe SDR 17, 7.89 inch OD, 6.94 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 8 Inch Pipe SDR 11, 7.89 inch OD, 6.44 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 8 Inch Pipe SDR 11, 7.89 inch OD, 6.44 inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

67 10" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) 10 Inch Pipe SDR 17, 9.85 inch OD, 8.68 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Re (Fibercore Reinforce) 10 Inch Pipe SDR 11, 9.85 inch OD, 8.06 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 10 Inch Pipe SDR 11, 9.85 inch OD, 8.06 inch ID Velocity (ft per sec) Healoss (ft per 100 ft) FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA

68 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 12" Flow (gal per min) VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER Polystar CT-White (Fibercore Reinforce) Polystar CT-Re (Fibercore Reinforce) 12 Inch Pipe 12 Inch Pipe Velocity (ft per sec) Healoss (ft per 100 ft) Velocity (ft per sec) Healoss (ft per 100 ft) Polystar CT-Blue 12 Inch Pipe SDR 11, inch OD, inch ID Velocity (ft per sec) Healoss (ft per 100 ft)

69 ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Socket Tee Through main ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm EQUIVALENT LENGTHS OF FITTINGS (ft.) Tee Through branch ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Tee Conjunction of flow ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Tee Counter current flow separation ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Tee Counter current flow conjunction ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Reucer By 1 imension ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 3" 90 mm 2.5 3" 90 mm 2.5 3" 90 mm " 90 mm 7.9 3" 90 mm " 90 mm " 90 mm 3.9 3½" 110 mm 3.0 3½" 110 mm 3.0 3½" 110 mm ½" 110 mm 9.6 3½" 110 mm ½" 110 mm ½" 110 mm 4.8 4" 125 mm 4.2 4" 125 mm 4.2 4" 125 mm " 125 mm " 125 mm " 125 mm " 125 mm 6.7 6" 200 mm 5.4 6" 200 mm " 200 mm " 200 mm " 200 mm " 200 mm 8.6 8" 200mm 6.7 8" 200mm " 200mm " 200mm " 200mm " 200mm " 250 mm " 250 mm " 250 mm " 250 mm " 250 mm " 250 mm " 315 mm " 315 mm " 315 mm " 315 mm " 315 mm " 315 mm " 355 mm " 355 mm " 355 mm " 355 mm " 355 mm " 355 mm

70 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA Reucer By 2 imensions ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Reucer By 3 imensions ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm EQUIVALENT LENGTHS OF FITTINGS (ft.) Reucer By 4 imensions ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Reucer By 5 imensions ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Reucer By 6 imensions ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Cross Separation of flow ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm Cross Conjunction of flow ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm " 125 mm 8.4 4" 125 mm " 125 mm " 125 mm " 125 mm " 160 mm " 200 mm " 160 mm " 160 mm " 160 mm " 200mm " 200mm " 200mm " 200mm " 200mm " 250 mm " 250 mm " 250 mm " 250 mm " 250 mm " 315 mm " 315 mm " 315 mm " 315 mm " 315 mm " 355 mm " 355 mm " 355 mm " 355 mm " 355 mm

71 Elbow 90 Elbow 90 Street ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm EQUIVALENT LENGTHS OF FITTINGS (ft.) Elbow 45 Elbow 45 Street ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm Aapter Female threa ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm Aapter Male threa ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm Elbow Female threa ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA 3½" 110 mm 9.0 3½" 110 mm 4.8 3½" 110 mm 8.4 4" 125 mm " 125 mm 6.7 6" 160 mm " 200 mm 8.6 8" 200mm " 200mm " 250 mm " 250 mm " 315 mm " 315 mm " 355 mm " 355 mm

72 3.1 FLOW RATE, VELOCITY, AND HEAD LOSS (PRESSURE DROP) DATA Elbow Male threa ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm Tee Female threa ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm EQUIVALENT LENGTHS OF FITTINGS (ft.) Tee Male threa ⅜" 16 mm ½" 20 mm 3.9 Sale Reucer Through main ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Sale Reucer Through branch ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm Sale Reucer Combination of flow ⅜" 16 mm ½" 20 mm ¾" 25 mm 1" 32 mm 1¼" 40 mm 1½" 50 mm 2" 63 mm 2½" 75 mm 3" 90 mm 3½" 110 mm " 125 mm 4.2 4" 125 mm 8.4 4" 125 mm " 160 mm 5.4 6" 160 mm " 160 mm " 200 mm 6.7 8" 200 mm " 200 mm " 250 mm " 250 mm " 250 mm " 315 mm " 315 mm " 315 mm " 355 mm " 355 mm " 355 mm

73 Pipe Size OD Inch Support Spans for Polystar CT-Re Pipe Spans Length in Temperatures ( F) /2 inch /4 inch inch /4 inch /2 inc inch /2 inch inch /2 inch inch inch inch inch SUPPORT SPACING FOR POLYSTAR PIPES 12 inch Consult Factory Support Spans for Polystar CT-White Pipes Pipe Size OD Inch Spans Length in Temperatures ( F) /2 inch /4 inch inch /4 inch /2 inc inch /2 inch inch /2 inch inch inch inch inch >10 inch Consult Factory 73

74 3.2 SUPPORT SPACING FOR POLYSTAR PIPES Pipe Size OD Inch Support Spans for Polystar CT-Blue Pipes Spans Length in Temperatures ( F) /2 inch /4 inch inch /4 inch /2 inc inch /2 inch inch /2 inch inch inch inch >8 inch Consult Factory * Consult support span requirements of local builing coe for minimum requirements. EXAMPLES OF COMMERCIALLY AVAILABLE ALTERNATIVE SUPPORTS AND CLAMPS FOR POLYSTAR PIPES (Other than Polystar Pipe Brackets) Ajustable Steel Clevis Ajustable Steel Ban Hanger Offset J-Hook Vee Bottom Clevis Hanger Pipe Alignment Guie Hanger Steel Pipe Clamp Steel Double Bolt Pipe Clamp Pipe Stanchion Sale Pipe Sale Support Ajustable Roller Hanger 74

75 ANCHORING POLYSTAR PIPES 3.3 ANCHORING POLYSTAR PIPES 75

76 3.4 THERMAL EXPANSION AND CONTRACTION THERMAL EXPANSION AND CONTRACTION Thermal expansion an contraction can be calculate using the equations below. α CT-Blue = 1.00E-03 Coeffient of linear expansion, (in/ft-f) α CT-White = 2.33E-04 Coeffient of linear expansion, (in/ft-f) α CT-Re = 2.33E-04 Coeffient of linear expansion, (in/ft-f) Linear Expansion L () EXPANSION OF CT-BLUE PIPE T = Temperature change, (F) L Pipe Length = Length of pipe, (ft) L = Change in length o to thermal expansion, (in.) LL = LL PPPPPPPP LLLLLLLLLL h TT Temperature Diff T (F) 200 ft 150 ft 100 ft 80 ft 60 ft 40 ft 20 ft 10 ft EXPANSION OF CT-WHITE/CT-RED PIPE 76

77 Pipe Diameter inch OD mm Linear Expansion, L, () ½ ¾ ¼ ½ ½ ½ L s, Length Of Bening Shank, () 3.5 EXPANSION/CONTRACTION COMPENSATION GUIDELINES EXPANSION/CONTRACTION COMPENSATION GUIDELINES Absorbing Linear Expansion With Expansion Loops Thermal eformation from linear expansion can be absorbe by changing the irection of the pipe through aing 90 egree elbows to absorb pipe expansion, or by installing expansion loops. Absorbing Linear Expansion With 90 Elbows C Material constant L = Linear Expansion, a function of pipe length an temperature change, () OD Pipe = Pipe OD, (mm) L S = Require length of the bening shank, (ft) LL SS = CC OOOO PPPPPPPP LL BS = Minimum Safety Distance, () L = Linear Expansion, a function of pipe length an temperature change, () Bmin = With of bening shank, () 8 Minimum Bmin () BB mmmmmm = 2 LL + BBBB 77

78 78

79 SECTION FOUR 4.0 Thermoynamic Consierations 4.1 Heat Gain/Loss vs. Temperature for Polystar Piping 4.2 Insulation Thickness vs. Heat Loss 4.3 Freeze Protection for Polystar Piping POLYSTARTM PolystarPipe.com 79

80 4.1 HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING Bare Polystar pipe material is consiere to have excellent insulation characteristics with its low thermal conuctivity value. Competing metal pipe such as copper, steel, an stainless steel are all consiere poor insulators. Actually the metal pipe material is consiere a conuctor of heat. Comparing the heat loss/gain charts of bare Polystar pipe to the heat loss/gain chart of metal pipe it is easy to see the thermal avantages which Polystar pipe provies. With a 50 F elta temperature ifference across the pipe, the heat loss/gain of the metal pipe is huge compare to that which is lost or gaine by Polystar pipe. There are two terms use to escribe the heat loss within a pipe, these are K-Factor an R-Value. The K-Factor is also known as thermal conuctivity. The thermal conuctivity of a material is base on the number of BTUs per hour which passes through a one inch thick by one square foot section of material, with a 1 F temperature ifference between the two surfaces. The lower the K-Factor the more suitable the material is for insulation. Typical pipe insulation is in the range of BTU/hr-ft- 75 F. The K-Factor of steel is 31 BTU/hr-ft- 75 F. The K-Factor of copper is 227 BTU/hr-ft- 75 F. These are all quite high when compare to Polystar pipe, which has K-Factor of BTU/hr-ft- 68 F. The National Commercial & Inustrial Insulation Stanars Manual efines R-Value as A measure of the ability to retar heat flow rather than transmit heat. With R-Value, the better insulator is the material which has the highest R-Value. For flat insulation geometry the relation between R-Value an K-Factor is shown in the first equation below. For cylinrical pipe geometry equivalent thickness, use the equation shown in the mile box belowto etermine the R-Value since the outer surface area of insulation is proportionately greater than the inner surface area. The equivalent thickness is the insulation thickness of a flat surface which woul equal the heat flux at the outer surface of a cylinrical geometry. The relationship between R-Value an K-Factor for pipe insulation is in the equation shown on the bottom below. The Table on page 80 isplays the R-Values for Polystar Pipe at 68 F. R-Value Equations RR VVVVVVVVVV = RR VVVVVVVVVV = TThiiiiiiiiiiiiii (iiiiiiheeee) kk ffffffffffff (BBBBBB iiiiiih/(hrr ffff 2 FF) EEEEEEEEEEEEEEEEEEEE TThiiiiiiiiiiiiii (iiiiiiheeee) kk ffffffffffff (BBBBBB iiiiiih/(hrr ffff 2 FF) r 2 = Outer Raius, r 1 = Inner Raius EEEEEEEEEEEEEEEEEEEE TThiiiiiiiiiiiiii = rr 2 xx ln rr 2 rr 1 A B A. Less insulation than steel, in many applications, results in installe cost savings. B. The same amount of insulation applie to Polystar as steel pipe results in energy savings. 80

81 Heat Loss, (BTU/Hr-Ft), 50 F Delta, Pipe With No Insulation Heat Loss (BTU/Hr-Ft), 50 F Delta, Pipe With No Insulation 4.1 HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING 81

82 4.1 HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING R-Value (US) Polystar SDR 7.4 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) R-Value ((hr ft2 F) / BTU) Polystar SDR 9 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) R-Value ((hr ft2 F) / BTU) Polystar SDR 11 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) R-Value ((hr ft2 F) / BTU) Polystar SDR 17 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) R-Value ((hr ft2 F) / BTU)

83 Below are three charts which isplay the heat gain/loss (BTU/hr-ft) through the pipe wall versus elta temperature ( F). These charts analyze the heat gain/loss through the CT-Re Heat Loss/Gain v. Temperature pipe. The outoor heat transfer coefficient is assume to be 2.0 BTU/hr-ft 2 - F. The insie heat transfer coefficients is not inclue in the calculation. 4.1 HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING CT-White Heat Loss/Gain v. Temperature 83

84 4.1 HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPING CT-Blue Heat Loss/Gain v. Temperature Polystar has excellent heat transfer characteristics that can reuce the insulation require to maintain a require flui temperature or to prevent sweating in col temperature applications. However, it is important to always verify the actual amount of insulation require base on the specific insulation being use. Contact the Orion technical epartment for assistance in etermining the actual insulation require for any Polystar application. 84

85 INSULATION THICKNESS V. HEAT LOSS There is a efinite thermal efficiency avantage associate with using Polystar pipe to that of using of metal pipe. The charts below isplay this as they compare the heat loss an heat gain through the Polystar pipe, an compare the Polystar pipe s heat loss an heat gain to those associate with the metal pipe. See the six charts below. The pipe insulation thickness is inicate in the chart heaing of each chart. Calculations are base on close cell foam insulation with a thermal conuctivity of 0.25 (BTU-in/hr-ft2-F). Three ifferent insulation thicknesses were evaluate. These insulation thicknesses inclue ½, 1, an 1½. A temperature ifference of 50 F is use in the calculations. This temperature ifferential was chosen to represent a heat-loss conition with hot water at 120 F an a room temperature at 70 F, or heat-gain conition of 50 F water pipe, which is locate outoors in a 100 F ambient temperature conition. Raiation an inner pipe heat film resistance is not inclue in the calculation. Below is a calculation which be can be use to estimate heat losses for other conitions. Thermal Conuctivities k Polystar Pipe = Thermal conuctivity of Polystar pipe, (BTU/hr-ft-F) k copper = 227 Thermal conuctivity of copper pipe, (BTU/hr-ft-F) k steel = 31 Thermal conuctivity of steel, (BTU/hr-ft-F) k Ins = Thermal conuctivity of close cell foam insulation, (BTU/hr-ft-F), 1/4" up to 1" of insulation k Ins = Thermal conuctivity of close cell foam insulation, (BTU/hr-ft-F), 1 1/2" up to 2" of insulation Temperature Delta T = 50 Temperature ifferential beteen 120 F water an 70 F room temperature, (F) Temperature ifferential beteen 50 F water an 100 F ambient temperature, (F) Heat Transfer Coefficient h O = 1.6 BTU/hr-ft 2 -F Air heat transfer coefficient = 2 (BTU/hr-ft 2 - F) at Avg temp = 100 F, Pipe Wall Temp = 80 F, Winspee = 5 mph Air heat transfer coefficient = 4.51 (BTU/hr-ft 2 - F) at Avg temp = 100 F, Pipe Wall Temp = 80 F, Winspee = 20 mph This heat transfer coefficient is epenent on the average temperature, pipe wall temperature, pipe outer iameter, an win spee. It typically has a value ranging from 0.5 to 4 (BTU/hr-ft 2 - F). It is calculate by using the Zukauskas Equation. First calculate the Nusselt number for the conition. The Nusselt number is then use to calculate the outoor heat transfer coefficient. Calculate/Determine Values R Pipe =Thermal resistance of pipe wall, (hr ft F/BTU) R Ins = Thermal resistance of pipe insulation, (hr ft F/BTU) R O = Thermal resistance of outer air, (hr F/BTU) R Total = Total thermal resistance of pipe an pipe insulation, (hr ft F/BTU) q Pipe = Heatloss through a non-insulate pipe/ pipe length, (BTU/hr-ft) q Total = Total heatloss through an insulate pipe/ pipe length, (BTU/hr-ft) rr PPPPPPPP,oo ln rr PPPPPPPP, ii RR PPPPPPPP = 2ππkk PPPPPPPP rr IIIIII,oo ln rr PPPPPPPP, oo RR IIIIII = RR OO = 2ππkk IIIIII 1 2ππrr OO h OO LL RR TTTTTTTTTT = RR PPPPPPPP + RR IIIIII + RR OO qq TT PPPPPPPP = RR PPPPPPPP qq TT TTTTTTTTTT = RR TTTTTTTTTT 4.2 INSULATION THICKNESS V. HEAT LOSS 85

86 4.2 INSULATION THICKNESS V. HEAT LOSS Heat Loss (BTU/Hr-Ft), 50 F Delta, 0.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F Heat Loss (BTU/Hr-Ft), 50 F Delta, 0.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 86

87 Heat Gain (BTU/Hr-Ft), 50 F Delta, 0.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 4.2 INSULATION THICKNESS V. HEAT LOSS Heat Loss (BTU/Hr-Ft), 50 F Delta, 1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 87

88 4.2 INSULATION THICKNESS V. HEAT LOSS Heat Loss (BTU/Hr-Ft), 50 F Delta, 1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F Heat Gain (BTU/Hr-Ft), 50 F Delta, 1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 88

89 Heat Loss (BTU/Hr-Ft), 50 F Delta, 1.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 4.2 INSULATION THICKNESS V. HEAT LOSS Heat Loss (BTU/Hr-Ft), 50 F Delta, 1.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 89

90 4.2 INSULATION THICKNESS V. HEAT LOSS Heat Loss (BTU/Hr-Ft), 50 F Delta, 1.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F 90

91 FREEZE PROTECTION FOR POLYSTAR PIPING All non-heat trace pipe place in freezing conitions will freeze in time no matter how much or what type of insulation is use. All piping which coul be expose to freezing conitions shoul be heat trace or burie below frost epth elevations. The calculation below can be use to etermine the amount of time for water in a stagnant pipe to freeze in freezing conitions. It shoul be note that in orer to avoi pipe amage, pipe shoul not be expose to the freezing conition for longer than t Liqui, the time calculate to lower the liqui in the pipe to 32 F. Water requires 144 BTU/lb of heat to be release to the environment before it turns to ice. This heat loss is calle the latent heat of fusion. The calculate time for the release of the latent D 3 heat of fusion is t Fusion. The overall time for the water in the pipe to freeze completely, t Total, is estimate by aing t Liqui an t Fusion. Pipe amage occurs ue to the excessive water pressure buil up, cause by the expansion of ice crystals, therefore it is important to avoi allowing pipe to be expose to freezing conitions past time t Liqui. The tables shown on page 93 can be reference to etermine the amount of time a pipe can be expose in freezing conitions. These tables are base on stagnant flow within the pipe, 0 F ambient temperature, an initial 68 F water temperature, no pipe insulation, a pipe thermal conuctivity of (BTU inch/(hr- F-ft 2 ), an outsie air velocity of 5 mph, an the outer pipe heat transfer coefficient etermine using the Zukauskas Equation. 4.3 FREEZE PROTECTION FOR POLYSTAR PIPING D 2 D 1 INSULATION PIPE WALL LIQUID Design Parameters For Water ρ w = 62.4 Density of water, (lb/ft3) Cp Water = 1 Specific heat of water, (BTU/lb F) h FS = 144 Latent heat of fusion of water, (BTU/lb) Temperatures T Initial = 68 Initial temperature of water in pipe (F) T Outsie Air = 0 Ambient temperature, wall temperature (F) T Freezing = 32 Final temperature water in pipe (F) T Average = 34 (F) Pipe Dimensions Thickness Ins = 0 Pipe insulation thickness, () L = 100 Length of pipe, (ft) Thermal Conuctivities kpipe = ((BTU in)/(hr ft2 F)) k Ins = ((BTU in)/(hr ft2 F)) 91

92 4.3 FREEZE PROTECTION FOR POLYSTAR PIPING Properties Of Outoor Air (Base on TAverage) Cp Air = Specific heat of air, (BTU/lb Avg Temp μ Air = Dynamic viscosity of air, (lb/hr Avg Temp k Air = Thermal conuctivity of air, ((BTU)/(hr ft Avg Temp Properties Of Outoor Air (Base on T Wall) Cp Air = Specific heat of air, (BTU/lb Wall Temp μ Air = Dynamic viscosity of air, (lb/hr Wall Temp k Air = Thermal conuctivity of air, ((BTU)/(hr ft Wall Temp υ Air = Kinematic viscosity of air, Avg Temp Win Spee = 5 mph V Air = 26,400 Air velocity base on win spee, (ft/hr) Calculate/Determine Values C = Parameters for Zukauskas Equation D out = Outer iameter use in outoor heat coefficient, (ft) h O = Outoor heat transfer coefficient, ((BTU)/(hr ft2 F) Nu= Nullset Number Re = Reynols Number Pr = Prantl Number R Pipe = Thermal resistance of pipe wall, (hr F/BTU) R Ins = Thermal resistance of pipe insulation, (hr F/BTU) R O = Thermal resistance of outer film, (h F/BTU) R T = Combine thermal resistance of pipe wall, insulation, an exterior air film (hr F/BTU) M = Mass of liqui water in the pipe, (lb) m = Parameters for Zukauskas Equation n = Parameters for Zukauskas Equation t Liqui = time to lower the liqui in the pipe to 32 F, (hr) t Fusion = time to the heat of fusion to be release from the water, (hr) t Total = time to freeze water in the pipe, (hr) V Air = Air velocity base on win spee, (ft/hr) q = Heat loss to cool the liqui to a freezing temperature, (BTU/hr) q Pipe Loss = Heat loss from the pipe uner ambient conitions, (BTU/hr) M = Mass of water in the pipe, (lb) Calculating Outsie Heat Transfer Coefficient Zukauskas Equation NNNN = h OODD OO kk AAAAAA All flui properties are epenent on the average temperature, except for P rs. P rs is evaluate at the cyliner wall. = CC(RRRR) mm PPPP nn PPPP.25 PPPP ss Re C m , , ,000-1,000, Pr Less than Greater than Parameters for Zukauskas Equation NNNN = h OODD OO kk AAAAAA PPPP = CC PPμμ kk AAAAAA RRRR = VV AAAAAA DD OOOOOOOOOO υυ AAAAAA n = CC(RRRR) mm PPPP nn PPPP.25 PPPP ss 92

93 Thermal Resistance From Pipe Wall Thermal Resistance From Pipe Insulation Thermal Resistance From Outoor Heat Transfer Coefficient Combine Thermal Resistance RR PPPPPPPP = ln rr 2 rr1 2ππLLLL PPPPPPPP x 12 RR IIIIII = ln rr 3 rr2 2ππLLLL IIIIII x 12 RR OO = 1 2ππrr OO h OO LL RR TT = RR PPPPPPPP + RR IIIIII + RR OO Heat Loss From The Pipe Uner Ambient Conitions qq PPPPPPPP LLLLLLLL = (TT IIIIIIIIIIIIII TT OOOOOOOOOOOOOO AAAAAA ) RR TT Time To Cool A Liqui To Freezing Temperature tt LLLLLLLLLLLL = MMCC pp TT IIIIIIIIIIIIII TT FFFFFFFFFFFFFFFF qq PPPPPPPP LLLLLLLL Time For The Heat Of Fusion To Be Release From The Water Total Time To Freeze Pipe tt FFFFFFFFFFFF = h FFFFMM qq PPPPPPPP LLLLLLLL tt TTTTTTTTTT = tt LLLLLLLLLLLL + tt FFFFFFFFFFFF 4.3 FREEZE PROTECTION FOR POLYSTAR PIPING Positioning of Self Regulating Heating Cables for 1 Cable Positioning of Self Regulating Heating Cables for 2 Cables Apply Tape Across Heating Cable Attachment of Tapes to Secure Self Regulating Heating Cables 93

94 4.3 FREEZE PROTECTION FOR POLYSTAR PIPING TIME TO FREEZE CHARTS Polystar piping systems may be installe in applications an conitions where freezing may occur. Generally, when water freezes in Polystar piping, it will not cause problems for the piping materials. This is largely ue to the uctile nature of the thermoplastic piping which allows it to be very forgiving an to stretch with volumetric expansion of water ue to freezing occurs. However, regarless of whether pipe becomes amage, freezing will result in a blockage in the system, which is a problem if water must be conveye through the system uring these freezing perios. The accompanying tables provie ata as to how long it takes for water which is stagnant to freeze in various Polystar pipes. While this ata may allow the user to unerstan if freezing may occur in their specific application, we recommen that if there is any question as to the possibility of freezing that freeze protection methos be applie to the Polystar piping system. Freeze protection methos inclue the use of anti-freeze (glycerin or glycol; polypropylene is not affecte by these freeze protection solvents) or the use of self-regulating heating cables. Another measure that can be use is to insure that there is always minimum constant flow even uring a power outage, which will assist in the prevention against freezing. Regarless of the metho chosen, all proucts must be use in accorance with the freeze protection system manufacturer s recommenations, the prouct listings, an in compliance with all applicable local coes. When using any type of external heat source applie to the piping, such self-regulating heating cables, the prouct must be suitable for use with plastic piping. The self-regulating heat cables use shoul have their set temperature at low levels to insure against overheating. Consult Orion s technical epartment for specific recommenations for use of self-regulating heat tracing cables as the means for freeze protection when this metho is to be use. Installation by the Spiraling Metho Installation on Flanges Installation on Elbows Installation at Supports 94

95 TIME TO FREEZE SDR 7.4 PIPE Polystar SDR 7.4 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) t Liqui, (hr) t Fusion, (hr) t Total, (hr) TIME TO FREEZE SDR 9 PIPE Polystar SDR 9 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) FREEZE PROTECTION FOR POLYSTAR PIPING t Liqui, (hr) t Fusion, (hr) t Total, (hr) TIME TO FREEZE SDR 11 PIPE Polystar SDR 11 inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ OD, Pipe (mm) ID, Pipe (mm) t Liqui, (hr) t Fusion, (hr) t Total, (hr) Freezing times inicate in tables 4.3.1, 4.3.2, an are base on a stagnant flow conition with 0 F ambient temperature, an initial 68F water temperature within the pipe, no pipe insulation aroun the pipe, a pipe thermal conuctivity of (BTU inch/(hr- F-ft 2 ), an outsie air velocity of 5 mph, an the outer pipe heat transfer coefficient base on the Zukauskas Equation. Preventing Surface Conensation On Polystar Piping Conensation forms on the exterior pipe wall once the pipe surface wall reaches the ew point temperature. For assistance in etermining whether insulation is require to prevent conensation, contact the Orion Engineering Department for aitional information. 95

96 96

97 SECTION FIVE 5.0 Installation Requirements an Proceures 5.1 Transportation, Delivery & Storage 5.2 Socket Fusion Proceure Using Han-Hel Polywelers 5.3 Socket Fusion Proceure Using Moel 7125 Bench Socket Fusion Tools 5.4 Butt Fusion Proceure using Manual Track Butt Fusion Tools 5.5 Electrofusion Proceure using Beat-TR Electrofusion Processors 5.6 Sale Fusion Proceure using Han-Hel Polywelers 5.7 Repair Proceures Using Han Hel Polywelers POLYSTARTM PolystarPipe.com 97

98 5.1 TRANSPORTATION, DELIVERY & STORAGE TRANSPORTATION, DELIVERY & STORAGE WRONG PREVENT IMPACTS (especially against pipe ens) PREVENT EXCESSIVE LOADS PREVENT WRONG LYING PIPES CORRECT A soli, flat, an level base for the pipe must be provie avoi a eformation of the pipes while in transport an storage. If the pipes are not store properly, or are stacke to excessive heights, it can lea to excessive ovalization or bowing of the pipes. Transport an storage Polystar pipes may be store outsie at any temperature if protecte from UV light. It is preferable to store pipes insie whenever possible. The pipes are shippe with a black protective outer poly bag. However, sometimes the protective bags may become rippe or torn uring shipping an therefore sections of the pipe may become expose. When storing outsie, the pipes shoul be inspecte to insure that they are thoroughly covere an protecte fom the effects of UV light. Maximum outoor storage time is 30 ays if remove from factory-supplie UV-protecte bags or for portions of pipe that are expose ue to rips an tears in the bags. Outoor installation UV raiation has an effect on polymeric plastic proucts. Protect pipes against weathering an UV raiation to prevent amage. In applications where the installe pipe will be expose to UV-raiation (such as rooftop or other outoor applications), it is recommene that stanar Polystar Piping (e.g. CT-White or CT-Blue) be provie with UV protection. The piping can be protecte by a number of methos, incluing priming with Rust-Oleum Plastic Primer Spray or by priming an painting painting using Rust-Oleum Plastic Primer an Specialty Plastic Spray. Alternatively, the piping can be protecte by use of protective tapes or can be covere with insulation or insulation jacketing. At temperatures below 32 F (0 C), the piping has less uctility an it is more susceptible to amage by impact (especially against pipe ens), excessive loas, crushing or bening. Hanle pipes with care at low temperatures. 98

99 SOCKET FUSION PROCEDURE USING HAND-HELD POLYWELDERS Preparations Cut pipes square into sections. Thoroughly clean both joint faces, the pipe en an fitting socket, with alcohol an lintfree cloth or absorbent paper. Mark bushing epth on the pipe. Bring the heating element of a suitable polyweler to 500 F (260 C). Check the temperature settings before starting the weling process. Temperature tolerance for the polyweler is ± 18 F (10 C). The temperature of the heating element of a suitable polyweler must be checke perioically by the installer a suitable measuring evice. Do not start heating the joint parts before the heating temperature reaches 500 F. The manrel an bushing must be clean an have to be purifie before each following weling process. Before using a suitable polyweler rea the User Manual carefully. Overview Polystar piping an fittings in sizes 4 inch (125mm) an uner are primarily joine by socket fusion weling. In the socket weling proceure, the pipes an fittings are connecte using heat fusion by overlapping the parts lengthwise. The heating of the pipe ens an fitting sockets is mae using a heating element of a suitable polyweler with fitte bushings. After the correct weling temperature has been reache, the joining can procee. The pipe an fitting socket iameters, as well as the respective heating bushings, are matche to buil up the necessary pressure uring the joining process. The heating element of a suitable polyweler is electrically heate. Push the pipe an fitting quickly an axially up to the stop of the manrel an the marke insertion epth respectively an keep them fast without twisting. The heating of the joint faces is one accoring to the table on the next page. At the en of the heating perio pull the pipe an the fitting from the heating element of the suitable polyweler an join them immeiately axially aligne an without torsion. Min the correct insertion epth (see table, Page 98). The pipe must be pushe in up to the marke insertion epth of the bush bottom. Fix the two joint parts again for the uration of the heating perio. Do not expose the wele joint to mechanical stress before the expiration of the cooling perio (see table, Page 99).! PP-RCT pipes an fittings are to be use only as part of the entire system. CT-Blue, CT-White an CT-Re are to be use only with steel gray PP-RCT fittings.! CAUTION Do not expose the wele joint to mechanical stress before the cooling perio is over! WARNING Do not use Polystar proucts to convey potable water except for those liste to NSF-PW! Consult the factory for assistance to etermine which Polystar Proucts carry this rating. 1. Measure an cut pipe with suitable pipe cutters to the correct length. Pipe must be cut with a 90 square cut. 5.2 SOCKET FUSION PROCEDURE USING HAND-HELD POLYWELDERS 99

100 5.2 SOCKET FUSION PROCEDURE USING HAND-HELD POLYWELDERS SOCKET FUSION INSERTION DEPTH 0 mm Bush Depth = Insertion Depth ½ " ¾ " ¼ " 1½ " 2½ " 3½ ! CAUTION Before using a suitable pipe cutter rea the owner's manual carefully.! WARNING Before using a suitable polyweler rea the Owner's manual carefully. 4. The pipe an the fitting are to be remove from the suitable polyweler. 2. Mark the bush epth on the weling istance to the en of the pipe. 5. Insert the pipe in the axial irection. During joining o not turn the pipe en aroun its axis in the socket. 3. Push the pipe en an the fitting socket to the heating element of a suitable Polyweler in axial irection. Heat pipe an fitting socket simultaneously. 100

101 a b c MANDREL COUPLING HEATING ELEMENT Figures a, b an c schematically show the 3 stages of the weling process: a = Weling preparation b = Heating Phase c = Wele joint BUSHING PP-RCT PIPE Stanar values for socket fusion weling at room temperature of aroun 68 F (20 C). If room temperature is below +41 F (5 C), the heating phase shoul be increase by up to 100%. Directly after the cooling time the fuse joints can be immeiately pressure teste. SOCKET FUSION PARAMETERS PIPE HEATING CHANGE FIXED TOTAL OUTSIDE PHASE OVER COOLING COOLING DIAMETER TIME IN MM SEC. SEC. SEC. MIN. 16 (⅜") (½") (¾") (1") 8 40 (1¼") (1½") (2") 75 (2½") 90 (3") 110 (3½") 125 (4") Definitions for Table Above: Heating Phase: Amount of time in which the manrel an bushing is require to heat the pipe an socket. Changeover: Amount of time in which the pipe has to be pushe into the socket following the heat soak. Fixe Cooling Time: The time in which the pipe/fitting must remain in the bench top fusion machine before it can be remove. Total Cooling Time: The time in which the joint nees to cool before pressure testing is allowe. 5.2 SOCKET FUSION PROCEDURE USING HAND-HELD POLYWELDERS 101

102 5.3 SOCKET FUSION PROCEDURE USING MODEL 7125 BENCH SOCKET FUSION TOOLS SOCKET FUSION PROCEDURE USING MODEL 7125 BENCH SOCKET FUSION TOOLS Weling: Switch on the suitable socket weling machine polyweler for bench an the energy control lamp turns on. The temperature control lamp goes off after reaching the operating temperature of 500 F (260 C). Temperature Tolerance for the heating element is ± 18 F (10 C). The first weling shoul take place within 5 minutes after the weling temperature has been reache. Split apart the machine slies an close own the heating element. Slowly move the machine slies by turning the han wheel. Align the heating element so that the pipe an the fitting fit properly into the weling tools. Move the slies with steay forwar motion up to the point until the stop has been reache. The heating timer of the joint surfaces starts only after the stop has been reache. After completion of the heating time the slies will be split an the heating unit must be brought into a rest position as fast as possible Move the machine slies with the han wheel with a steay forwar motion up to the stroke en so that the precise jointing epth between the pipe an the fitting is reache. The weling jointing may be remove from the clamping jaws only after cooling own. Unscrew the clamping jaw with the hanle lock an take off the wele unit.! WARNING Before using a suitable polyweler benchtop socket weling machine rea the Owner's manual carefully. 1. Pipes are measure an cut with suitable pipe cutters to the require length. Cutting shoul be perpenicular to the pipe axis (90 ). 2. Place an aust the fitting in the clamping jaw an ajust the stop to hol the fitting. Set the heating element in the holer. Mount the suitable weling tools (bushings an manrels) an install the clamping jaws. Plug in the heating iron an verify iron temperature before weling. Allow heating iron, manrel an bushing to cool before changing to a new size. 3. Lay the pipe axially to the fitting an position it so that it is situate frontally to the fitting. 102

103 4. Move the machine slies with the hanle lock to set the heating element into the center between pipe an fitting. 5. Move the machine slies with the hanle lock, warm up the pipe an the fitting in the weling tools. 7. After the warming time bon the pipe an the fitting. 8. Move the machine slies up to the stroke en.! CAUTION Watch your fingers an hans! Safety gloves require! Eye protection require! Machine is HOT! 5.3 SOCKET FUSION PROCEDURE USING MODEL 7125 BENCH SOCKET FUSION TOOLS 6. Move the machine slies with the hanle lock an remove the heating element. 103

104 5.4 BUTT FUSION PROCEDURE USING MANUAL TRACK BUTT FUSION TOOLS BUTT FUSION PROCEDURE USING MANUAL TRACK BUTT FUSION TOOLS Weling Proceure During butt weling with heating elements the areas to be joine are fitte with pressure at the location of the heating element (ajusting with merging pressure) until the specifie bea height is reache. Continue heating up to the weling temperature with reuce pressure (14.5 ± 1.5 psi) then, after removing the heating element, join the pieces with merging pressure (Aaption). 1. Before using a suitable butt weling machine rea its Owner's manual thoroughly. 3. The spigots of the fittings an the pipe ens have to be plane by a suitable electrical planing tool. Ensure that the spigots of the fittings an the pipe ens are always plane before every weling. 4. During butt weling with heating elements the areas to be joine are heate up to the weling temperature by means of the heating element an compresse after the heating element has been remove. Heating temperature 410 F (210 C) ± 18 F (10 C). 2. Cut the pipes with a suitable pipe saw to the require length.! CAUTION Watch your fingers an hans! Safety gloves require! Eye protection require! Machine is HOT! 5. After a ouble bea has been forme, the weling is uniform which inicates a successful wel. NOTICE Consult Orion for proper pressure gauge settings an time requirements for the six phases of the Butt Fusion process. These parameters vary from one machine manufacturer to another. Some original equipment manufacturers' ata may be inaccurate, consult with Orion. 104

105 ELECTROFUSION PROCEDURE USING BEAT-TR ELECTROFUSION PROCESSORS Preparing The Weling Surfaces Cut the PP-RCT pipe ens rectangularly to the pipe axis with a suitable pipe cutter. Remove any chips on the outer surface oxie layer with a suitable scraper an purify with a non-fuzzing (lint-free), absorbent cloth an cleaning agent. The preferre cleaning agent is 99% Isopropyl Alcohol.! WARNING Before using a suitable pipe cutter rea the Owner's manual carefully. 1. Cut the pipe perpenicularly with a suitable pipe cutter. 3. For imensions bigger than 3" (O.D.) we recommen using a peeling tool similar to the one shown above for removing the outsie oxie layer.! WARNING Before using a suitable scraper or peeling tool rea the Owner's manual carefully. 4. Clean the joint surfaces with a purifying agent (e.g. 99% isopropyl alcohol). 5.5 ELECTROFUSION PROCEDURE USING BEAT-TR ELECTROFUSION PROCESSORS 2. Remove the outsie oxie layer using a suitable scraper. 105

106 5.5 ELECTROFUSION PROCEDURE USING BEAT-TR ELECTROFUSION PROCESSORS Mounting Of The Electrofusion Weling Sockets Mark the socket epth on the pipe. After having finishe all preparatory work, take the electrofusion socket out of its packaging; o not touch the inner surfaces of the socket. Then push the socket slowly onto the pipe to the marke position. 5. Mark up the bushing epth. 6 Push in the electrofusion couplings up to the marke position on the pipe. Connecting The Fusion Processor Leas Position the electrofusion couplings in a way offering the easiest connection of the cor plugs to the contact bushes. Having checke that the require generator voltage is available, switch on the Beat-TR evice an connect the cor plugs on to the contact bushings. Set the iameter of the pipes to be connecte by using the bar coe reaer an scanning the bar coe on the coupling (or by manually entering the correct information using the manual moe). Then start the weling process by pressing the enter button on the machine. The Beat- TR electrofusion processor automatically controls the require weling time controls the voltage necessary for the fusion, an isplays a wel number when complete. 8. Plug in the cable pins in the contact bushings of a suitable electrofusion processor.! WARNING Before using a suitable aligning tool rea the owner's manual carefully.! CAUTION Watch your fingers an hans! Safety gloves require! Eye protection require! 7. Align the pipes an the electrofusion socket by using a suitable aligning tool. 106

107 9. The weling ata can be seen on the barcoe label of the socket. The ata can be rea by a barcoe reaer which shoul be part of a suitable electrofusion machine. 10. Start the weling evice from the switch. Cooling Time Observe the require cooling time if a cooling time is inicate on the bar coe. All imensions of electrofusion couplings contain a bar coe showing weling time, working voltage an in some instances a cooling time Repair Work With The Electrofusion Couplings Remove the efective pipe by cutting a rectangular section of at least 3-4 times the socket length to its axis. Fit the new pipe piece into the gap an prepare the ens of the ol pipe an new pipe piece as escribe before. Unpack two electrofusion couplings an push them completely over the two ens of the new pipe piece. Now fit in the new pipe piece an move the sockets to the marks on the ol pipe.! WARNING Before using a suitable electrofusion machine rea the Owner's manual carefully. 5.5 ELECTROFUSION PROCEDURE USING BEAT-TR ELECTROFUSION PROCESSORS 107

108 5.6 SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS Aitional Extension Of Existing Pipe Systems: Direct connection of existing consumer pipe to a utility line. Alternative to T-pieces. Weling Preparations: Heat up the heating unit to 500 F (260 C). Check the preset temperature prior to the weling process. Temperature Tolerance ± 18 F (10 C). The weling elements must be clean an shoul be cleane prior to every weling process. 1. Drilling through the pipe wall. This task shall be carrie out with an electric rill technically suitable for this task, thereby utilizing a suitable borer.! WARNING Before using an electric rill technically suitable for this task rea the manual of the respective electric rill carefully.! WARNING Before using a suitable weling sale tool for polyweler rea the owner's manual carefully. 2. Push in the heat nozzle of a suitable weling sale tool in the rill as well as the connecting piece of the weling sale in the heating socket of a suitable polyweler. The heating time for all imensions is about 30 secons. After a cooling time of about 10 minutes the fuse joint can be operate uner pressure. The appropriate branch connections will be assemble through socket fusion weling or by using female or male aapters with the weling sale. 3. Push the connecting piece of the weling sale quickly into the heate bore hole. Push the fitting for about 15 secons onto the pipe. After a cooling time of about 10 minutes the fuse joint can be operate uner pressure. The appropriate branch connections will be assemble through socket fusion weling or by using female or male aapters with the weling sale.! WARNING Before using a suitable polyweler rea the owner's manual carefully. 108

109 REPAIR PROCEDURES USING HAND-HELD POLYWELDERS Application Area: Repairing pipes amage by rills. Preparations: Empty an uncover the amage pipe. Select a suitable polyweler an a suitable weling tool, clean it before every weling process. Install the weling tools accoring to the instructions in the manual of the resp. weling tools. Preheat the heating unit to 500 F (260 C) ± 18 F (10 C).. Check the temperature before the weling process. Selection of weling elements: Suitable repairing-set: =7 mm (0.28") For Weling of holes up to 0.24" Suitable repairing-set: =11 mm (0.43") For Weling of holes up to 0.39" Mark the egree of the insertion epth (wall thickness) on the repairing plug. Fix istance tool accoring to the wall thickness of the pipe an tighten the screw.! WARNING Before using a suitable weling tool for polyweler rea the Owner's manual carefully. 2. Remove the weling evice an insert the repairing plug precisely without twisting it. 5.6 SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS 1. Pre-heat the borehole an the weling plugs with the repairing-set for 15 secons.! WARNING Before using a suitable polyweler or a suitable repairing-set for a polyweler rea the Owner's manual carefully. 3. After a cooling time of approx. 5 minutes, remove the protruing en of the repairing plug. Prevent amage to the pipe ens. At temperatures lower than 32 F, pipes are less flexible an more prone to breakage. Prevent impacts (especially against pipe ens), excessive loas, crushing or bening. Hanle pipes with care at low temperatures. UV raiation can have an impact on polymeric plastic proucts. Protect pipes against weathering an UV raiation to prevent amages. Use plastic bags or carboar boxes, that are inclue in the elivery. 109

110 5.6 SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS () Nominal Socket Weling Outlet Size & Require Drill Bit Size** WELDING SADDLES W/ SOCKET WELDING OUTLETS* (D) Nominal Sale Range (Base On OD Of Pipe Main)** Pipe Main 1 1 /4" - 2" (40 mm - 63 mm) Pipe Main 2 1 /2" - 4" (75 mm mm) Pipe Main 3 1 /2" - 4" (110 mm mm) Pipe Main 4" (63 mm) Pipe Main 6" - 10" (160 mm mm) Pipe Main 12" - 24" (315 mm mm) ½" (20 mm)*** X X X X ¾" (25 mm) X X X X 1 1 /4" (40 mm) X X X 1½" (50 mm) X X X 2" (60 mm) X X X * To perform a sale fusion, the proper sale, rill bit, an sale fusion bushing must be use. For example, to install a sale with ½" socket outlet connection into a 4" pipe. Drill a hole using a ¾" Polystar rill bit (part number ). Then use the bushing stampe with (B-R 2½"- 4") x ½" (part number ) to heat soak the sale area of the pipe an the sale itself (part number ). Weling Sales W/ Socket Weling Outlet Part Numbers D () Nominal Socket Weling Outlet Size of the Branch (D) Nominal Sale Range (Base On OD Of Pipe Main)** Pipe Main 1 1 /4" - 2" (40 mm - 63 mm) Pipe Main 2 1 /2" - 4" (75 mm mm) Pipe Main 3 1 /2" - 4" (110 mm mm) Pipe Main 4" (63 mm) Pipe Main 6" - 10" (160 mm mm) Pipe Main 12" - 24" (315 mm mm) ½" (20 mm)*** ¾" (25 mm) /4" (40 mm) ½" (50 mm) " (60 mm) ** Weling sales are available in the marke nominal sale ranges / nominal socket weling outlet sizes. ***For sales with the ½" socket outlet use a ¾" Polystar rill bit, otherwise match the rill bit with the socket outlet size. 110

111 SADDLES BUSHING PART NUMBERS () Nominal Socket Weling Outlet Size of the Branch (D) Nominal Sale Range (Base On OD Of Pipe Main)** Pipe Main 1 1 /4" - 2" (40 mm - 63 mm) Pipe Main 2 1 /2" - 4" (75 mm mm) Pipe Main 3 1 /2" - 4" (110 mm mm) Pipe Main 4" (63 mm) Pipe Main 6" - 10" (160 mm mm) Pipe Main 12" - 24" (315 mm mm) ½" (20 mm)*** ¾" (25 mm) 1 1 /4" (40 mm) ½" (50 mm) " (60 mm) DRILL BIT PART NUMBERS () Nominal Socket Weling Outlet Size of the Branch (D) Nominal Sale Range (Base On OD Of Pipe Main)** Pipe Main 1 1 /4" - 2" (40 mm - 63 mm) Pipe Main 2 1 /2" - 4" (75 mm mm) Pipe Main 3 1 /2" - 4" (110 mm mm) Pipe Main 4" (63 mm) Pipe Main 6" - 10" (160 mm mm) Pipe Main 12" - 24" (315 mm mm) 5.6 SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS ½" (20 mm)*** ¾" (25 mm) /4" (40 mm) ½" (50 mm) " (60 mm) ***For sales with the ½" socket outlet use a ¾" Polystar rill bit, otherwise match the rill bit with the socket outlet size. 111

112 112

113 SECTION SIX 6.0 Aitional Consierations 6.1 Testing Recommenations 6.2 Flushing an Grouning Recommenations POLYSTARTM PolystarPipe.com 113

114 6.1 TESTING RECOMMENDATIONS PRESSURE TESTING RECOMMENDATIONS A pressure test shoul be performe following the complete installation of the piping system. This test shoul be performe in accorance within these recommenations an within requirements of the local builing, an/or local plumbing coes. Water, air, or a mix of the two may be use to perform the pressure test. Pressure testing shoul be performe while the system is fully accessible to allow the contractor to access leaking joints. Polystar piping may be pressure teste as soon as the last joint mae in the piping system has ha the chance to cool to room temperature. We recommen that a preliminary low pressure air test, a static test an a cyclic test be performe uring testing. The pressure gauge use to conuct the pressure tests shoul be calibrate to ±0.5 psi. Hyrostatic Test If a hyrostatic pressure test is to be performe as the static an cyclic tests, the system shoul be teste to 1.5 times the esign pressure of the system, or 150 psi, whichever is higher. Testing to a pressure of less than 150 psi may not reveal all improperly wele joints. Further, for hot water pipes, testing to 1.5 times esign pressure may not aequately be representative of the concurrent effects of pressure an temperature. For these reasons a minimum test pressure of 150 psi shoul be use, however the maximum test pressure shoul be limite so as not to excee the ultimate rating of any element in the piping system. If any elements installe in the piping system have a rate pressure lower than 150 psi (e.g. valves mae by Orion or by others, gauges, other appurtenances by others, etc.) we recommen that these elements be isolate from the rest of the system, so that all Polystar elements can be teste to a minimum of 150 psi. Pneumatic Test As an alternative to a hyrostatic test, the installing contractor may elect to conuct a pneumatic test using compresse air or inert gas. The installing contractor may elect to o a pneumatic air test, but in oing so will be oing this test at their own risk. Contractors shoul recognize that a compresse air test presents some inherent angers. In such, cases, the contractor shoul take all necessary an reasonable precautions to limit the risk that is inherent in testing any piping material with compresse air. PP-RCT materials are uctile at normal temperatures an will not fail in the compresse air system in the same manner as non-uctile thermoplastics such as PVC as CPVC (i.e. by shattering into sharp fragments). Nonetheless, testing with compresse air presents angers ue to the suen an violent release of store energy. This type of failure can occur from a faile wel or an over-pressurization of a piping component. When energy is release from the piping system in this manner uner-supporte an non-restraine pipe sections can whip out of position an ben pipe hanger supports or amage other equipment, piping components can be launche through the air, an excessive noise can be generate. These are the risks which the contractor must use caution against when testing any compresse air system for the first time, no matter what type of piping material is use. While we prefer a hyrostatic test or a combine hyrostatic-pneumatic test be performe as to the pneumatic test, we also recommen Polystar pipe for a compresse air system. It is completely compatible with air within a compresse air system. Oil fille air compressors will mist oil into the piping system. This oil breaks own the chemical joint an cause stress fractures in the PVC/CPVC material. Polystar is uninfluence by the presence of this oily mist, making it a safe piping material for compresse air systems. For an alternative pneumatic test, the system shoul be teste to 1.1 times the esign pressure of the system, or 150 psi, whichever is higher. If the installing contractor elects to conuct the pneumatic test at their own risk, the contractor shoul take certain precautions, incluing but not limite to: (a) proviing reunant pressure regulators at the source of the air, testing an calibrating pressure regulators to insure that they are in safe working conition an set to the maximum test pressure (two or more regulators shoul be use in case of the failure of the primary regulator), (b) visually inspecting the piping system prior to testing to verify that all joints have been complete an that the piping system is thoroughly an aequately supporte an anchore in accorance with the recommenations of this manual an the authority having local jurisiction, (c) removing all persons from the areas of the piping to be teste that are not require to be present in orer to conuct or witness the tests, an () proviing all appropriate safety equipment an clothing/ gear to protect workers who are associate with the test, 114

115 (e) prior to conucting the high pressure test, completion of a low pressure test, i.e. first testing to 5 psi (0.3 bar); see below for escription of a low air pressure air test, (f) the low air pressure test shoul be conucte in stages by slowly raising the pressure in increments of 15 psi at a time allowing the system sufficient time to stabilize until raising the pressure to the next level, an (g) upon completion of the pressure test, the pressure shoul be immeiately release in a controlle an safe manner. The foregoing recommenations are provie strictly for guiance. The ecision to test with air, an the obligation to insure that such a test if performe is one in a safe manner, is strictly the responsibility of the contractor an Orion oes not assume or accept any liability with respect to the performance of air testing by the contractor. In extremely col temperatures (e.g. when the temperature is below 20 F) testing with air shoul be avoie entirely as the uctility of the materials will be substantially lessene, thereby increasing the chance of brittle failure. Combine Hyrostatic-Pneumatic Test A combine hyrostatic-pneumatic test can be conucte, whereby the piping system is fille completely an thoroughly with water, an compresse air is use as the means to pressurize the water. Thus an air compressor is use in lieu of a pump. This is consiere to be the same as a hyrostatic test, an as such, the pressure requirements woul be the same as those escribe on page 110 in the hyrostatic test proceure. However, when conucting this type of test, care shoul be taken to insure that all of the compresse air equipment which is use to generate the pneumatic pressure (e.g. generators, air compressor, tanks, valves, hoses, etc.) is hanle in a safe manner, with all the necessary safety precautions taken. Preliminary Low Pressure Air Test Prior to conucting the static pressure test, a preliminary low pressure air test ( 5 psi // 0.3 bar) is recommene regarless of whether a hyrostatic pressure test, pneumatic pressure test, or a combine hyrostaticpneumatic pressure test is performe. This test will help to prevent against unnecessary loss of water in the event there are joints in system which are not fully fuse/tightene, an it is a test which is require by the pneumatic test proceure as a safety precaution. When conucting the test, the contractor shoul take all reasonable precautions. In particular, the contractor shoul be sure to provie reunant pressure regulators at the source, verify that the regulators have been teste an calibrate, an insure they have been set to the maximum test pressure of 5 psi // 0.3 bar (two or more regulators shoul be use in case of the failure of the primary regulator). Once the system is fille an pressurize to a maximum pressure of 5 psi // 0.3 bar, all joints shoul be soape an visually inspecte for leaks. PP-RCT materials are not susceptible to stress cracking from orinary ishwashing soaps as is the case with CPVC, an in some cases PVC, an as such the use of ishwashing soaps as a means to ientify small leaks by the appearance of bubbles is a useful visual inspection means. Once a preliminary low air pressure leak test has been complete, the contractor may commence with the static pressure test. If a hyrostatic test or combine hyrostatic-pneumatic test is to be conucte, care must be taken to insure that all entraine air is release from all localize high points in the system. The system shoul be esigne so as to allow air to be release from any an all high points in the system. Air that is entrappe will become pressurize an will present angers in the local area where it is entraine. The suen opening or closing of a valve or the starting of a pump uring the test can lea to a shock wave, which can instantaneously over-pressurize a pocket of trappe air an cause a pipe to burst. As such, care must be taken to insure that all entraine/entrappe air must be release from the system at all localize high points before a hyrostatic test or a combine hyrostatic-pneumatic test is conucte. Primary Static Leak Test When performing the primary static leak test, the material properties of Polystar PP-RCT will cause the pipe to expan. Pipe expansion is cause by the molecules stretching uner the strain from the internal pressure within the pipe (this is true regarless of whether or not there is a temperature change). Pipe expansion will lea to a reuction in the internal pressure reaing within the piping system even when there are no leaks within the system. Changes in temperature can also effect the pipe s internal pressure. The coefficient of thermal expansion of Polystar PP-RCT material will lea to linear expansion an in turn a rop in test pressure. A temperature change of 20 F correspons to a pressure ifference of 7.5 to TESTING RECOMMENDATIONS 115

116 6.1 TESTING RECOMMENDATIONS psi ( 0.5 to 1 bar) pressure. If possible, allow for the temperature between the pipes an the test meium to reach equilibrium before reaing the pressure gauge. If necessary, the tester may re-pressurize the system until the system pressure stabilizes at the establishe test pressure, which is 1.5 times the esign pressure or 150 psi (which-ever is greater) in the case where the hyrostatic test or combine pneumatic-hyrostatic test is performe, or 1.1 times the esign pressure or 150 psi (which-ever is greater) in the case where the pneumatic test is performe. No matter which test is chosen o not to excee the lowest pressure rate element in the piping system. Once the system is stable, the test shoul then be carrie out for 60 minutes. The system must not lose more than 7.5 psi (0.5 bar) pressure in that time, this woul inicate the system has a leak. If any leakage appears, stop the test an repair the leaks before proceeing. Cyclic Test Following a successful completion of the static test, a cyclic test shoul also be conucte. For the cyclic test, monitor the system for at least 2 hours after the completion of the static test, making sure that the piping system oes not lose more than 3 psi (0.2 bar) pressure in that time. The cyclic test can then be conucte by first bringing the pressure own to 0 psi (0 bar). Then, re-pressurize the system to the establishe test pressure (which-ever is greater 1.5 times the esign pressure or 150 psi for hyrostatic testing or combine hyrostatic-pneumatic testing, or which- ever is greater, 1.1 times the esign pressure or 150 psi, for pneumatic testing). No matter which test is chosen o not to excee the lowest pressure rate element in the piping system. After holing the elevate pressure for 2 minutes with no pressure eviation, bring the system pressure own to 10% of the full test pressure. After holing this pressure with no pressure eviation for 2 more minutes, bring the system back to 0 an repeat this process 3 more times, with a final interval of 5 minutes. This cycling of pressure will ensure that all the fuse connections are properly installe. A recor of the pressure test must be prepare an signe by the owner s representative an installing contractor stating place, contractor information, an ate. A system can be teste in phases provie that every heat-fuse connection is eventually teste an that the tests are properly ocumente upon completion. A test recor template may be obtaine by contacting Orion customer service. The testing recommene here by Orion oes not supersee or replace regulations or requirements of the local coe authority having jurisiction as well as all national an local regulations (e.g. OSHA requirements). A copy of the complete an signe test recor shoul be sent by mail or fax to Orion at the contact information provie on the back cover of this ocument. An electronic version of the test recor may alternatively be e to the company to: support@polystarpipe.com! WARNING Testing with compresse air presents inherent angers ue to the store energy which if suenly release can lea to serious injury. Although PP-RCT materials are uctile materials at temperatures above 20 F (-7 C), an o not present the same anger of brittle failure as amorphous materials such as PVC an CPVC, serious injury can result from parts that can become airborne if isloge an ue to whipping an movement of materials that are not tie own properly. The ecision to test Polystar materials with compresse air may be one so at the sole ecision of the installing contractor. Orion oes not accept any liability for the ecision to test by air by the installing contractor.! CAUTION When testing Polystar proucts, it is important to make sure that all proper safety equipment, calibrate measuring instruments, clothing, an gear shoul be provie in orer to assist in protecting personnel involve in testing. 116

117 FLUSHING REQUIREMENT All water systems, regarless of the material of construction, shoul be flushe thoroughly after their installation. Piping must be flushe clean of irt, ebris an impurities in orer to insure the cleanliness of the inner surface of the pipe which will in turn help to provie protection of the water quality. It also must be one in orer to avoi corrosion amage to ownstream metallic piping components an equipment, to avoi malfunctions of pumps, heaters an other equipment. These requirements can be met by flushing the system with water, or by flushing the system with a mixture of air an water. The flushing metho an the flushing meium to be use may be etermine by local coes, engineering specifications, or by the mechanical equipment use. In lieu of other requirements, potable water woul be the typical meium use for flushing Polystar piping systems. GROUNDING The majority of builing coes in North America require that grouning be provie for conuctive components insie the structure. It is important to note that Polystar pipes o not act as a conuctor, but rather are ielectric an as such Polystar cannot be use to provie grouning. Therefore, if grouning is require, an alternative groun system or grouning metho must be installe. In these situations, please contact the Orion factory for our specific recommenations for grouning base on the requirements of the specific application. While we will provie recommenations for proviing grouning, the grouning system shoul be approve an inspecte by a qualifie electrician. 6.2 FLUSHING AND GROUNDING 117

118 GLOSSARY GLOSSARY Bench Top Socket Fusion Tool A mechanical evice esigne to act as a clamping system, as well as assist an installer with moving the pipe an fitting uring the fusion process. It is also esigne to assist with the control of the concentricity of the socket fusion wel, an to provie epth of insertion control. It is esigne to enable a heating iron to be mounte an controlle so as to allow the concentricity an epth of insertion to be controlle. Butt Fusion Also referre to as heat element butt heat fusion, it references a connection where the face of one pipe (or the face/en of plain en fittings) is heat fuse irectly to the face of another pipe. This process is available for use on sizes above 4 for all Polystar piping systems. Extrusion The process by which Polystar PP-RCT pipes are manufacture. The PP-RCT material is supplie from a hopper, melte an then force by means of a screw through a ie-hea an sizing sleeve in a single layer (CT- Blue ), two layers (CT-Lavener ) or three layers (CT- Re, CT-White ) an coole in long tanks, forming the Polystar pipes. Fibercore Technology A proprietary technology exclusive to Polystar systems whereby a PP-RCT an fiberglass matrix/blen is coextrue as a mile layer in a triple extrusion process. The Fibercore technology results in a mile layer in which the insie an outsie iameter of the ring is very uniformly controlle, thereby assuring consistent physical properties at any point along the length of the extrue pipe. The Fibercore mile layer is not secure to the ajoining layers by ahesive, but rather the material bons irectly to the ajoining PP-RCT layers, an thus forming a homogeneous bon. Fusion Outlet (Reucing Sale Fitting) A special fitting esigne to fuse irectly onto the sie of a pipe to form a reucing branch into the sie of a larger pipe, without having to purchase an install a mole tee. Since the outlets are joine by heat fusion, the resulting construction is a fully pressure rate connection. Heat Fusion Also referre to as heat weling or heat boning, it escribes the process of heating two similar thermoplastic materials forcing them together uner pressure, an allowing the materials to cool an recrystallize into a homogenous part an thereby creating a strong bon between the once separate materials. This process usually results in a strength in the bone (fuse) area which is greater than the corresponing separate pieces ue to the increase mass in the immeiate area of the bon. Injection Moling The process through which Polystar fittings are manufacture. Molten PP-RCT material is injecte into mols uner pressure, followe immeiately by cooling, creating strong fittings with no mechanical weaknesses. Linear Thermal Expansion an Contraction The growth/shrinkage in a pipe that occurs when the material changes temperature. It shoul be note that linear expansion can also occur ue to initial pressurization of PP-RCT materials. Polypropylene Ranom Copolymer (PP-R) A type of copolymer polypropylene material where the orientation of the monomers is attache in a ranom manner throughout the chain in each molecule. The resulting physical properties of the polymer typically exhibit very high impact strength, elongation an general forgiveness compare to other forms of polypropylene. Polystar The traename for a family of piping systems manufacture from a highly crystalline form of copolymer polypropylene (PP-RCT). The piping systems are manufacture in accorance with ASTM F2389 an CSA B It is offere in several ifferent classes of piping, some which are coextrue with a Fibercore mile layer. 118

119 Polystar CT-Blue A polypropylene pressure piping system esigne for (col) potable an foo-grae applications, as well as non-potable water applications an process piping. It is ientifie by its steel-grey color with externally extrue blue stripes. It is extrue as a monolithic material (without a Fibercore mile reinforcement layer). The pipe an fittings are joine using heat fusion. Polystar CT-Lavener A special formulation of Polystar piping systems with an extrue outer layer pigmente in purple color. This pipe is manufacture for use in rainwater an reclaime water. This system is istinguishe by the light purple color of the pipe, as require by the governing stanars for this class of water piping. Polystar CT-Re A polypropylene pressure piping system esigne for hot potable an foo-grae applications. It is ientifie by its steel-grey color with externally extrue re stripes. It is extrue with Fibercore mile reinforcement technology which assists to restrain the piping from linear expansion an contraction. The pipe an fittings are joine using heat fusion. Polystar CT-White A polypropylene pressure piping system esigne for heating an cooling as well as process piping applications. It is ientifie by its steel-grey color with externally extrue white stripes. It is extrue with Fibercore mile reinforcement technology which assists to restrain the piping from linear expansion an contraction. The pipe an fittings are joine using heat fusion. PP-RCT Material The basic material use in all of Polystar polypropylene piping systems. This resin is manufacture to result in highly crystalline formations of beta-crystalline arrangements of the ranom copolymer molecules. This results in a material which exhibits higher strength, especially at elevate temperatures, as well as an extremely smooth bore in an extrue pipe. Socket Fusion Also referre to as heat element socket fusion, this escribes a heat-fusion connection using weling heas an special fittings. The insie of the fitting is fuse to the outsie of the pipe by means of matching heating manrels an bushings, forming a quick an simple leakproof connection. This process is available for application with Polystar on sizes from nominal 4 (125 mm) an smaller. Transition, Flange A flange connection using a polypropylene stub flange, a loose glass fille polypropylene encapsulate steel backing ring, an a gasket that can be attache to a same size flange of any other piping material with matching hole pattern an flange size. In Polystar materials, the flanges are stanarly available as ANSI/ASME B psi hole patterns an imensions. Transition, Threae Aapter A special fitting machine from brass which is insert injection mole into the polypropylene. The insert is threae for use with any other type of threae connection. In Polystar, the threae transitions are available in lea-free brass only (less than 0.25% by weight lea content) an are available in NPT threas. Weling Heas Teflon-coate aluminum marels/bushings esigne to match specific sizes of pipe an fittings. The weling heas are engineere for irect insertion over the pipe an an into the socket hubs of fittings an couplings. The parts are esigne for full insertion to the specifie epth of the sockets in each given size. Weling Iron A heating tool mae with an aluminum heating surface that is controlle by an engineere heating element an electronic thermostatic temperature controls. The surface of the evice is esigne to heat weling heas to the proper weling temperature (in the case of socket fusion) an shoul never be in irect contact with the material being wele. GLOSSARY 119

120 INDEX INDEX Accessories 40, 41 Anchoring 75 Applications 9 Chemical Resistance Couplings 40, 41 Dimensional Data Equivalent Lengths Fibercore Technology 8 Fittings Flanges 34, 37 Flow Rates Freeze Protection Friction Loss 44-45, Fusion Butt Fusion 104 Electrofusion Reucing Sale Fusion 108 Repair Fusion 109 Socket Fusion , Weling Sales Hanger Spacing hangers Hea Loss 47-48, Heat Loss Hoop Stress 16 Impact 14 Insulation Linear expansion Material Properties 14 Moels, Summary of Mounting evices 40,41 Pipe Friction 44, 45 PP-RCT Polystar CT-Blue 8, 9, 10, 17, 18, 27, 48, 52-53, 55-68, 74, 76, 84, 87, 88, 90, 98, 99, 119 Polystar CT-Lavener 119 Polystar CT-Re 8, 9, 10, 17, 18, 27, 47-50, 55-68, 73, 76, 83, 87, 89, 99, 119 Polystar CT-White 8,9 10, 17-19, 26, 47, 50-52, 54, 55-68, 73, 76, 83, , 93, 94, 99, 119 Pressure Loss Presure Rating 15 Pump Information 46 Quality Control 8 Specifications - Facility Water an Process Water Applications 18 - Hyronic Heating 18 - Short Form Specifications 17 Support Spacing Support Types Sweating 96 Testing Material testing 14 Pressure testing Threae connections Tools Socket Fusion , Butt Fusion 104 Electrofusion Transitions Flanges 34, 37 Threae UV protection 98 Valves 11 Velocity Warranty

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122 TM POLYSTAR For aitional information visit our website at PolystarPipe.com A Watts Water Technologies Company C-OR-Polystar 1340 USA: Tel: (913) Fax: (800) Canaa: (905) Fax: (905) Baenninger, Inc.