POLYSTAR - Watts Watermedia.wattswater.com/C-OR-Polystar.pdf · 4.1 Heat Gain/Loss v. Temperature...

POLYSTARTM

PolystarPipe.com

ADVANCED POLYPROPYLENE PIPING SYSTEM | CATALOG

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IMPORTANT SAFETY INFORMATION

Understanding Safety Information

This is a safety-alert symbol. The safety alert symbol is shown alone or used with a signal word (DANGER, WARNING, or CAUTION), a pictorial and/or a safety message to identify hazards.

When you see this symbol alone or with a signal word on your equipment or in this Manual, be alert to the potential for death or serious personal injury.

This symbol identifies hazards which, if not avoided, will result in death or serious injury.

• Read all product manuals and all product labels BEFORE using this product and follow all safety and use information.

• Learn how to properly and safely use the equipment.

• Do not let anyone use the equipment without instruction.

• Keep product manuals available for easy access by all users.

• Replace missing, damaged, or illegible product manuals and product labels.

• Replacement Manuals are available at: www.PolystarPipe.com.

WARNING!

CAUTION!

NOTICE

DANGER!

!

WARNING!TO AVOID DEATH, SERIOUS PERSONAL INJURY, PROPERTY DAMAGE, OR DAMAGE TO THE EQUIPMENT:

Reading & Understanding the Manual

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This symbol identifies hazards which, if not avoided, could result in minor or moderate injury.

This symbol identifies practices, actions, or failure to act which could result in property damage or damage to the equipment.

This pictorial alerts you to the need to read the manual.

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1.0 Introduction and Overview1.1 Introducing Polystar1.2 System Highlights 1.3 Product Standards and Quality Control1.4 Summary of Major Models

2.0 Material Properties and Dimensional Data2.1 Material Properties for Polystar PP-RCT Material2.2 Pressure Ratings for Polystar Pipe2.3 Recommended Specifications for Polystar2.4 Chemical Resistance for Polystar PP-RCT Material2.5 Pipe Dimensional Data2.6 Fittings Dimensional Data

3.0 System Sizing and Engineering Considerations3.1 Flow Rate, Velocity, and Head Loss (Pressure Drop) Data3.2 Support Spacing for Polystar Pipes3.3 Anchoring Polystar Pipes3.4 Thermal Expansion and Contraction3.5 Expansion/Contraction Compensation Guidelines

4.0 Thermodynamic Considerations4.1 Heat Gain/Loss v. Temperature for Polystar Piping Systems4.2 Insulation Thickness v. Heat Loss 4.3 Freeze Protection for Polystar Piping

5.0 Installation Requirements and Procedures5.1 Transportation, Delivery & Storage5.2 Socket Fusion Procedure Using Hand-Held Polywelders5.3 Socket Fusion Procedure Using Model 7125 Bench Socket Fusion Tools5.4 Butt Fusion Procedure Using Manual Track Butt Fusion Tools5.5 Electrofusion Procedure Using Beat-TR Electrofusion Processors 5.6 Saddle Fusion Procedure Using Hand-Held Polywelders5.7 Repair Procedures Using Hand Held Polywelders

6.0 Additional Considerations6.1 Testing Recommendations6.2 Flushing and Grounding Recommendations

Glossary of Terms

Index

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1.0 Introduction and Overview

1.1 Introducing Polystar

1.2 System Highlights

1.3 Product Standards and Quality Control

1.4 Summary of Major Models

SECT

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POLYSTARTM

PolystarPipe.com

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INTRODUCING THE POLYSTAR™ PP-RCT PIPING SYSTEM FROM ORIONWe are pleased to introduce Polystar, the world’s most advanced polypropylene piping system. Polystar is the first complete piping system manufactured entirely with a β-nucleated polypropylene random copolymer referred to as PP-RCT. The β-nucleation process creates an enhanced crystalline structure that gives Polystar piping higher strength at elevated temperatures.

Polystar is initially available in three classifications, two of which are reinforced with our unique Fibercore™ Reinforcement Technology for applications with thermal expansion and contraction. All Polystar piping and fittings are manufactured from the same resin and pigmented with a base color of steel grey (similar to RAL 7042) to architecturally blend into building settings. The piping classification is indicated with co-extruded color striping.

The PP-RCT used in the Polystar piping system has a unique crystal structure. In comparison to standard PP-R, which displays only alpha (α) crystals, the crystal structure of β-PPR includes a high degree of β-crystals and a lesser extent of α-crystals. The resulting fine crystal structure and homogeneous crystallite size distribution positively affects the mechanical characteristics of Polystar’s raw material.

Polystar is initially available in three classifications: CT-Red™, CT-White™, and CT-Blue™. CT-Red is reinforced with the Fibercore middle layer and is the highest pressure-rated piping in the line, making it the perfect choice for hot potable water piping systems and other applications with demanding pressure requirements at elevated temperatures. CT-White™, also reinforced with Fibercore, is designed with a thinner wall than CT-Red to make it an economical choice for above ground hydronic heating, chilled water lines, and other HVAC applications. The third type of piping, CT-Blue, is extruded with straight PP-RCT material for applications where thermal expansion and contraction issues are not a concern.

PRODUCED TO THE HIGHEST WORLDWIDE STANDARDS …Polystar Piping System components are manufactured for Orion to the highest-quality standards by its partner Baenninger, Inc. Components are made in Baenninger’s state-of-the-art facilities in Germany. Piping is extruded in uniquely designed equipment for this purpose. As a result of this joint cooperation, Baenninger's equipment is capable of extruding piping with up to seven layers through 24” (630mm) sizes. Advanced injection-molding capabilities allow Baenninger to produce injection-molded fittings up to 24” (630mm) size. This makes Polystar the most complete and highest quality PP piping system available.

Plain End Fittings in sizes 6” (160mm) through 24” (630mm) are injection- molded at facilities in Reiskirchen, Germany.

Socket Fusion Fittings in sizes ⅜” (16 mm) through 4” (125mm) and pipe from sizes ⅜”” (16 mm) through 24” (630 mm) are

produced in facilities in Staβfurt, Germany.

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*Polystar, CT-Red, CT-White, CT-Blue, CT-Lavender, Grey Pigmented PP Piping with Red Stripes, Grey Pigmented PP Piping with White Stripes, Grey Pigmented PP Piping with Blue Stripes, and Fibercore™ Reinforcement Technology are trademarks of Orion Enterprises, Inc., a Watts Water Technologies company.

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1.2 | SYSTEM

HIGHLIGHTSPOLYSTAR CT-WHITEPolystar CT-White piping is an extruded pressure piping series designed for a wide variety of commercial and industrial applications. The piping is extruded with our Fibercore middle-layer reinforcement technology, which strengthens, stiffens, and adds dimensional stability to the pipe. The CT-White’s superior resistance to chemicals and temperatures make it ideal for conveying water in all types of HVAC applications. It is also an excellent choice for conveying a wide variety of chemicals for industrial process piping applications.

Advantages of CT-White Piping:

• Permanent leak-tight joints

• Fast, repeatable welding with easy-to-use tools

• Highly resistant to a wide range of chemicals and aggressive water (See Section 2.4)

• Excellent flow characteristics and low pressure drop

• Thermal properties reduce insulation thicknesses

• Low flame and smoke ratings

• 100% Recyclable 5

POLYSTAR CT-BLUEPolystar CT-Blue piping is an extruded pressure piping series designed for a wide variety of commercial and industrial applications. The piping is extruded 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 and temperatures makes it ideal for conveying water in all kinds of services, including potable water. It is also an excellent choice for conveying a wide variety of chemicals for industrial process piping applications.

Advantages of CT-Blue Piping:

• Completely hygienic

• Rated for potable water service (future)





• Highly insulating to reduce insulation thicknesses

• Very low sound transmission rates


• Long lasting and resistant to traditional corrosion


POLYSTAR CT-REDPolystar CT-Red piping is an extruded pressure piping series which can be used in a variety of high temperature applications. The piping is extruded with Fibercore middle-layer reinforcement technology which strengthens, stiffens, and adds dimensional stability to the pipe. The CT-Red’s superior resistance to chemicals and temperatures makes it ideal for conveying hot water in all types of commercial, industrial, and residential applications. It also makes an excellent choice for conveying a wide variety of chemicals for industrial process piping applications.

Advantages of CT-Red Piping:• Completely hygienic

• Rated for hot potable water service (future)





• Very low sound transmission rates

• Highly insulating to reduce insulation thicknesses


• Long lasting and resistant to traditional corrosion


APPLICATIONS FOR POLYSTAR USE:• Hot and Cold Potable Water

• Cooling Tower Water Supply/Return/Recirculation

• Chilled Water Distribution

• Propylene and Ethylene Glycol Distribution

• Hydronic Heating Distribution

• Plant Water Distribution

• Chemical Process Piping

• Fire Sprinkler Piping

• Recycled, Reclaimed, and Rainwater Retention Applications

• Compressed Air

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PRODUCT STANDARDS AND LISTING INFORMATIONPolystar piping systems are manufactured in accordance with a variety of national and international standards. These standards are summarized as follows:

• ASTM F2389 “Standard Specification for Pressure-rated polypropylene (PP) Piping Systems” – This standard is the key standard for the United States which details all of the requirements for pressure piping systems manufactured from Polypropylene materials, including PP-RCT materials.

• CSA B137.11 “Polypropylene (PP-R) pipe and fittings for pressure applications” – This standard is the key standard for Canada which details all of the requirements for pressure piping systems manufactured from Polypropylene materials, including PP-RCT materials.

• CSA B214 – “Installation Code for hydronic heating systems” – Canadian Code for Hydronic heating applications.

• DIN 8077 – “Polypropylene (PP) pipes – PP-H, PP-B, PP-R, PP-RCT – Dimensions” – German Standard which covers polypropylene piping systems such as Polystar.

• ISO 9080 “Plastics piping and ducting systems -- Determination of the long-term hydrostatic strength of thermoplastics materials in pipe form by extrapolation” – International standard referenced in ASTM F2389 used to determine hydrostatic strength basis for Polystar piping in order to determine pressure ratings.

• ASTM D2837 – “Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products” – The ASTM standard which is similar to ISO 9080.

• ASTM F2023 – “Standard Test Method for Evaluating the Oxidative Resistance of Crosslinked Polyethylene (PEX) Tubing and Systems to Hot Chlorinated Water” – The standard chlorine test which is referenced in ASTM F2389 for which PP materials such as Polystar have to be tested to.

• NSF Standard 14 – “Plastics Piping System Components and Related Materials” – NSF 14 establishes minimum physical, performance, health effects, quality assurance, marking, and record keeping requirements for plastic piping components and related materials.

• NSF-61 – “Drinking Water System Components” – Indicates the product is certified to NSF/ANSI 61 for potable water contact.

• NSF PW - Indicates the product is certified to NSF 61 along with one or more standards that would address structural aspect of the product (e.g. ASTM F2389, CSA B137.11).

• NSF-rfh - Products meet all applicable performance requirements for a pressure rated floor heating application specified in NSF/ANSI Standard 14. No health effects evaluation is required.

• NSF-rw - Products meeting the applicable performance standards for reclaimed water applications as required by NSF/ANSI Standard 14, including a hydrostatic design basis (HDB). No health effects evaluation is required.

• NSF-51 – “Food Equipment Materials Plastics, materials, and components used in food equipment” – the standard for which Polystar materials have to be tested for use in Food Equipment or for contact with food.

• ASTM F2023 – “Standard Test Method for Evaluating the Oxidative Resistance of Crosslinked Polyethylene (PEX) Tubing and Systems to Hot Chlorinated Water” – The standard chlorine test which is referenced in ASTM F2389 for which PP materials such as Polystar have to be tested to.

• ASTM D 635 “Standard test method for rate of burning and/or extent and time of burning of plastics in a horizontal position.”

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LISTING APPROVAL AND QUALITY CONTROLPolystar products are manufactured in accordance with the following approvals and quality systems.

1.3 | PRODUCT STANDARDS AND Q

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SF LONG RADIUS 90° ELBOW SF STREET 45° ELBOW

CT-WHITE™ PIPECT-RED™ PIPE

SF 45° ELBOW 45° ELBOW PLAIN END

CT-BLUE™ PIPE CT-BLUE COILS

SF STREET 90° ELBOW SF 90° ELBOW 90° ELBOW PLAIN END SF TEE

TEE PLAIN END

SF MANIFOLD

SF 90° ELBOW - FNPT SF RED TEE SF CROSS

PIPE SUPPORT

SF CROSSOVER

STUB FLANGE PLAIN END

SF RED COUPLING

REDUCER PLAIN END

SF 90° ELBOW - MNPT

CAP PLAIN END

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SF COUPLING SF STUB FLANGE ELECTROFUSION COUPLING SF CAP

STREET 90° ELBOW - FNPT SF WYE SF TEE - FNPT SF RED WELDING SADDLE

SF TEE- MNPT

ALL PLASTIC BALL VALVE

ALL PLASTIC UNION

THREE-WAY BALL VALVE

FEMALE NPT LF ADPTR

SPRING CHECK VALVE

MALE NPT LEAD FREE ADPTR

SWING CHECK VALVE

SF REDUCING SADDLES MNPT

ALL-PLASTIC BUTTERFLY VALVE

SF 90° WINGED EL FNPT

DIAPHRAGM VALVE

SF SO90° WINGED EL - FNPT

FLANGED DIAPHRAGM VALVE

SF TEE GAUGE CONNECTION

UNION DIAPHRAGM VALVE

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Note: Additional Models Available.

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2.0 Material Properties and Dimensional Data2.1 Material Properties for Polystar PP-RCT Material

2.2 Pressure Ratings for Polystar Pipe

2.3 Recommended Specifications for Polystar

2.4 Chemical Resistance for Polystar PP-RCT Material

2.5 Pipe Dimensional Data

2.6 Fittings Dimensional DataSECT

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MATERIAL PROPERTIES FOR POLYSTAR PP-RCT MATERIAL

PROPERTIES STANDARD CRITERIA PP-RCT VALUE UNIT

Melting Index MFR 190/5 ISO / R 1133 1.1 E-0.3 lb /10 minutes

Melting MFR 230/2.16 ISO / R 1133 5.3 E-03 - 7.9 E-03 lb /10 minutes

Density ISO / R 1183 56.5 lb/ft3

Melting Range Polarization Microscope 284-302 F

Yield Stress ISO / R527 3,600 PSI

Tensile Strength Feed Speed 6,500 PSI

Elongation @ Yield ISO 527-2 10 %

Bending Stress @ 3.5% ISO 178 3,300 PSI

Modulus Of Elasticity ISO 178 130,500 PSI

Mechanical properties following impact bending

test @ 32°CDIN 8078 No Fracture - - -

Expansion Coefficient VDE 0304 Part 1 & 4 0.00027 1/°F

Thermal Conductivity @ 68°F

DIN 52612 1.67 BTU/(hr-ft2-°F/in)

Charpy Impact, Notched ISO 179 19 ft-lb/in2

Specific Heat @ 68°F Adiabatic Calorimeter 0.48 BTU/(lb-°F)

Absolute Roughness - - - 2.29659E-05 ft

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PRESSURE v. TEMPERATURE

POLYSTAR CT-RED

1/2" (20 mm)

3/4" (25 mm)

1" (32 mm)

1 1/4"

(40 mm)

1 1/2" (50 mm)

2"(63 mm)

2 1/2"

(75 mm)

3" (90 mm)

3 1/2" (110 mm)

4" (125 mm)

6" (160 mm)

8" (200 mm)

10" (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 11

Temperature PSI

73°F (23°C)* 350 350 280 280 280 280 280 280 280 280 220 220 220

140°F (60°C)* 183 183 145 145 145 145 145 145 145 145 115 115 115

180°F (82°C)* 120 120 100 100 100 100 100 100 100 100 78 78 78

210°F (99°C)** 77 77 58 58 58 58 58 58 58 58 43 43 43


POLYSTAR CT-WHITE

1/2" (20 mm)

3/4" (25 mm)

1" (32 mm)

1 1/4"

(40 mm)

1 1/2" (50 mm)

2"(63 mm)

2 1/2"

(75 mm)

3" (90 mm)

3 1/2" (110 mm)

4" (125 mm)

6" (160 mm)

8" (200 mm)

10" (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

Temperature PSI

73°F (23°C)* 350 350 280 220 220 220 220 220 220 220 139 139 139

140°F (60°C)* 183 183 145 115 115 115 115 115 115 115 71 71 71

180°F (82°C)* 120 120 100 78 78 78 78 78 78 78 50 50 50

210°F (99°C)** 77 77 58 43 43 43 43 43 43 43 22 22 22


POLYSTAR CT-BLUE

1/2" (20 mm)

3/4" (25 mm)

1" (32 mm)

1 1/4"

(40 mm)

1 1/2" (50 mm)

2"(63 mm)

2 1/2"

(75 mm)

3" (90 mm)

3 1/2" (110 mm)

4" (125 mm)

6" (160 mm)

8" (200 mm)

10" (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

Temperature PSI

73°F (23°C)* 280 280 220 220 220 220 220 220 220 220 220 220 220

140°F (60°C)* 145 145 115 115 115 115 115 115 115 115 115 115 115

180°F (82°C)* 100 100 78 78 78 78 78 78 78 78 78 78 78

210°F (99°C)** 58 58 43 43 43 43 43 43 43 43 43 43 43

2.2 | PRESSURE RATINGS FOR PO

LYSTAR PIPE

For Pressure Ratings above 10" (250mm) diameter size, contact the Orion Technical Department.



* Pressure rating evaluated up to 50 years**Pressure rating evaluated up to 10 yearsPressure ratings developed with a 1.5 safety factor

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Hoop

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psi)

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Hoop Stress v. Time For Polystar Polypropylene

158 F

203 F230 F

68 F

1 5 10 50 years

Reference Curves for PP-RCT Material Class

Reference Curves for PP-R (EN ISO 115874; DIN 8078)

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1 10 100 1,000 10,000 100,000 1,000,000

Hoop

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Time (Hours)

Hoop Stress v. Time For Polystar Polypropylene

70 C

95 C

110 C

20 C

Reference Curves for PP-RCT Material Class

Reference Curves for PP-R (EN ISO 115874; DIN 8078)

50 years1051

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2.3 | RECOM

MENDED SPECIFICATIO

NS FOR PO

LYSTARSHORT FORM SPECIFICATION FOR POLYSTAR CT-WHITE™ PIPING SYTEMSPipe and fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389, and shall be provided by Orion. All hot water pipe shall be made in a three layer extrusion process and shall contain a fiberglass-reinforced middle layer (Fibercore™) to restrict thermal expansion. Fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. Fittings for sizes 4” nominal (125mm) and below shall be of the socket fusion type and shall be injection molded. Fittings for sizes 6” nominal (160mm) and above shall be of the plain end type and shall be injection molded, except where a molded fitting is unavailable. All pipe and fittings shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. Piping systems in nominal sizes 4 inch (125mm) and below shall be joined by socket fusion (ASTM D2657) with field tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joined either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleaned, disinfected and tested in accordance with Orion’s recommendations and the requirements of the authority having jurisdiction.

SHORT FORM SPECIFICATION FOR POLYSTAR CT-RED™ PIPING SYTEMSPipe and fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389, and shall be provided by Orion. All hot water pipe shall be made in a three layer extrusion process and shall contain a fiberglass-reinforced middle layer (Fibercore™) to restrict thermal expansion. Fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. Fittings for sizes 4” nominal (125mm) and below shall be of the socket fusion type and shall be injection molded. Fittings for sizes 6”

nominal (160mm) and above shall be of the plain end type and shall be injection molded, except where a molded fitting is unavailable. All pipe and fittings shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. Piping systems in nominal sizes 4 inch (125mm) and below shall be joined by socket fusion (ASTM D2657) with field tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joined either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleaned, disinfected and tested in accordance with Orion’s recommendations and the requirements of the authority having jurisdiction.

SHORT FORM SPECIFICATION FOR POLYSTAR CT-BLUE™ PIPING SYTEMSPipe and fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389, and shall be provided by Orion. All pipe shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. Fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. Fittings for sizes 4” nominal (125mm) and below shall be of the socket fusion type and shall be injection molded. Fittings for sizes 6” nominal (160mm) and above shall be of the plain end type and shall be injection molded, except where a molded fitting is unavailable. All pipe and fittings shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. Piping systems in nominal sizes 4 inch (125mm) and below shall be joined by socket fusion (ASTM D2657) with field tie-ins permissible by electrofusion (ASTM F1290) using Polystar Electrofusion Couplings. Piping systems above nominal 4 inch (125mm) shall be joined either by butt fusion (ASTM D2657) or electrofusion (ASTM F1290) using the appropriate Polystar couplings. Upon completion of the piping, the system shall be cleaned, disinfected and tested in accordance with Orion’s recommendations and the requirements of the authority having jurisdiction.

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RECOMMENDED SPECIFICATION FOR POLYSTAR PIPING SYSTEMS FOR FACILITY WATER AND PROCESS WATER APPLICATIONSPART 1 – GENERAL

1.01 SUMMARY

A. This Section specifies the water distribution piping system, including cold, hot and re-circulated hot water piping, fittings, valves and specialties within the facility.

1.02 REFERENCE DOCUMENTS

A. ASTM F 2389-10 - Standard Specification for Pressure-rated Polypropylene (PP) Piping Systems

B. CSA B137.11 - Polypropylene (PP-R) Pipe and Fittings for Pressure Applications

C. NSF/ANSI 14 – Plastic Piping System Components and Related Materials

1.03 QUALITY ASSURANCE

Material shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11 and manufacturer’s specifications.

PART 2 – PRODUCTS

2.01 PIPE AND PIPING PRODUCTS

A. Pipe shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. The pipe shall contain no rework or recycled materials. All hot water pipe shall be made in a three layer extrusion process and shall contain a fiberglass-reinforced middle layer (Fibercore™) to restrict thermal expansion. All pipe shall comply with the rated pressure requirements of ASTM F 2389. All pipe shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11.

B. Pipe shall be Polystar CT-Blue™, Polystar CT-Red™ or Polystar CT-White™ as provided by Orion. Piping specifications and ordering information are available at www.polystarpipe.com.

2.02 FITTINGS

A. Fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. The fittings shall contain no rework or recycled materials. All fittings shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. All fittings shall be injection molded.

Fabricated fittings are not allowed, except where a molded fitting is unavailable.

B. Fittings for sizes 4” nominal (125mm) and below shall be of the socket fusion type and shall be injection molded.

C. Fittings for sizes 6” nominal (160mm) and above shall be of the plain end type and shall be injection molded, except where a molded fitting is unavailable.

2.03 VALVES

A. Valves shall be manufactured in accordance with the manufacturer’s specifications.

B. All Ball Valves, Multiport Ball Valves, Diaphragm Valves, Butterfly Valves, Spring Check Valves and Swing Check Valves shall be Polystar Valves, except where valves are not offered by Orion.

2.04 SMOKE AND FIRE RATINGS

A. Where indicated on the drawings that a Plenum-rated Piping System is required, the piping shall be protected with a suitable fire protective insulation, as recommended by Orion.

2.05 UV PROTECTION

A. For pipe that will be exposed to direct UV light for more than 30 days, it shall be provided with a Factory applied, UV-resistant coating or alternative UV protection.

PART 3 - EXECUTION

3.01 FUSION WELDING OF JOINTS

A. Fittings in sizes 4” nominal (125mm) and below shall be joined using heat element socket fusion in accordance with ASTM D2657.

B. Pipe in sizes 4” nominal (125mm) and below shall be joined using either heat element socket fusion in accordance with ASTM D2657 using molded couplings, or may alternatively be joined by the electrofusion method using Polystar Electrofusion Couplings in accordance with ASTM F1290.

C. Pipe and Fittings in sizes 6 inch nominal (160mm) and above may be joined by either heat element butt fusion in accordance with ASTM D2657, or may be joined by the electrofusion method using Polystar™ Electrofusion Couplings in accordance with ASTM F1290.

D. Pipe joining equipment shall be limited to Polystar™ Equipment as supplied by Orion, or shall be approved by Orion for use with Polystar™ materials.

E. Joint preparation, setting and alignment, fusion process, cooling times and working pressure shall be in accordance with the pipe and fitting manufacturer’s specifications.

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3.02 PIPING INSTALLATIONS

A. Install hangers, supports, guides and anchors at intervals specified in the applicable Plumbing Code and as recommended by pipe manufacturer.

B. Support vertical piping at each floor penetration and as specified in the applicable Plumbing Code using suitable riser clamps .

C. Fire stopping shall be compatible with the Polystar™ Piping and meet the requirements of ASTM E 814 or ULC S115 , “Fire Tests of Through Penetration Firestops”. Pipe insulations or fire resistive coating shall be removed where the pipe passes through fire stop and, if required by the firestop manufacturer, for 3 inches beyond the firestop outside of the fire barrier.

D. Piping shall be protected from excessive heat generated from pumps operating at shut-off conditions. Where the possibility exists that the pump will dead-head (i.e. operate with no flow), a suitable temperature relief valve shall be provided, or other comparable level of protection, set to a maximum temperature of 185°F.

E. If heat tracing is specified for the piping, this should be limited to the use of self-regulating type to ensure the surface temperature of the pipe and fittings will not exceed 70°C (158°F).

3.03 INSPECTING AND CLEANING

A. The pipes should be flushed with cold water after completing the installation. Inspect and test piping systems in accordance with the recommendations and requirments of authorities having jurisdiction and as specified by the piping system manufacturer.

B. Clean and disinfect water distribution piping in accordance with the requirements of the authority having jurisdiction.

3.04 TESTING

A. Upon completion of the piping installation, the piping shall be tested using either a hydrostatic pressure test to 150% of the design pressure of the system for a minimum of one hour, or using a pneumatic test with compressed air or inert gas to 110% of the design pressure for a minimum of one hour, in accordance with the procedures, guidelines and recommendations of Orion and in accordance with the requirements of the authority having local jurisdiction. The contractor shall take into account all necessary safety precautions and shall follow procedures and guidelines to insure that the testing is carried out in a safe manner.

RECOMMENDED SPECIFICATIONS FOR POLYSTAR PIPING SYSTEMS FOR HYDRONIC HEATING APPLICATIONSPART 1 – GENERAL

1.01 SUMMARY

A. This Section specifies the hydronic piping system, including piping, fittings, valves and specialties within the building.

1.02 REFERENCE DOCUMENTS

A. ASTM F 2389-07 - Standard Specification for Pressure-rated Polypropylene (PP) Piping Systems

B. CSA B137.11 - Polypropylene (PP-R) Pipe and Fittings for Pressure 21 Applications

C. NSF/ANSI 14 – Plastic Piping System Components and Related Materials

1.03 QUALITY ASSURANCE

A. Material shall be certified by NSF International as complying with NSF 14-Hydronic, and ASTM F 2389 or CSA B137.11.

B. Material shall comply with manufacturer’s specifications.

C. Special Engineered products shall be certified by NSF International as complying with NSF 14-Hydronic.

PART 2 – PRODUCTS

2.01 PIPE AND PIPING PRODUCTS

A. Pipe shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389 or CSA B137.11. The pipe shall contain no rework or recycled materials. All pipe shall be made in a three layer extrusion process. All hot water pipe shall be made in a three layer extrusion process and shall contain a fiberglass-reinforced middle layer (Fibercore™) to restrict thermal expansion. All pipe shall comply with the rated pressure requirements of ASTM F 2389. All pipe shall be certified by NSF International as complying with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11.

B. Pipe shall be Polystar CT-White™ as provided by Orion Piping specifications and ordering information are available at www.polystarpipe.com.

2.02 FITTINGS

A. Fittings shall be manufactured from a PP-RCT resin meeting the short-term properties and long-term strength requirements of ASTM F 2389. The fittings shall contain no rework or recycled materials. All fittings shall be certified by NSF International as complying

2.3 | RECOM

MENDED SPECIFICATIO

NS FOR PO

LYSTAR

20

with NSF 14, NSF 61, and ASTM F 2389 or CSA B137.11. All fittings shall be injection molded, except where a molded fitting is unavailable.

B. Fittings for sizes 4” nominal (125mm) and below shall be of the socket fusion type and shall be injection molded.

C. Fittings for sizes 6” nominal (160mm) and above shall be of the plain end type and shall be injection molded, except where a molded fitting is unavailable.

2.03 VALVES

A. Valves shall be manufactured in accordance with the manufacturer’s specifications.

B. All Ball Valves, Multiport Ball Valves, Diaphragm Valves, Butterfly Valves, Spring Check Valves and Swing Check Valves shall be Polystar Valves, except where valves are not offered by Orion.

2.04 SMOKE AND FIRE RATINGS

A. Where indicated on the drawings that a Plenum-rated Piping System is required, the piping shall be protected with a suitable fire protective insulation, as recommended by Orion.

2.05 UV PROTECTION

A. For pipe that will be exposed to direct UV light for more than 30 days, it shall be provided with a Factory applied, UV-resistant coating or alternative UV protection.

PART 3 - EXECUTION

3.01 FUSION WELDING OF JOINTS

A. Fittings in sizes 4” nominal (125mm) and below shall be joined using heat element socket fusion in accordance with ASTM D2657.

B. Pipe in sizes 4” nominal (125mm) and below shall be joined using either heat element socket fusion in accordance with ASTM D2657 using molded couplings, or may alternatively be joined by the electrofusion method using Polystar Electrofusion Couplings in accordance with ASTM F1290.

C. Pipe and Fittings in sizes 6 inch nominal (160mm) and above may be joined by either heat element butt fusion in accordance with ASTM D2657, or may be joined by the electrofusion method using Polystar™ Electrofusion Couplings in accordance with ASTM F1290.

D. Pipe joining equipment shall be limited to Polystar™ Equipment as supplied by Orion, or shall be approved by Orion for use with Polystar™ materials.

E. Joint preparation, setting, alignment, fusion process, cooling times and working pressure shall be in accordance with the manufacturer’s specifications.

3.02 PIPING INSTALLATIONS

A. Install hangers, supports, guides and anchors at intervals specified in the applicable Plumbing Code and as recommended by pipe manufacturer.

B. Support vertical piping at each floor penetration and as specified in the applicable Plumbing Code using suitable riser clamps .

C. Fire stopping shall be compatible with the Polystar™ Piping and meet the requirements of ASTM E 814 or ULC S115 , “Fire Tests of Through Penetration Firestops”. Pipe insulations or fire resistive coating shall be removed where the pipe passes through fire stop and, if required by the firestop manufacturer, for 3 inches beyond the firestop outside of the fire barrier.

D. Piping shall be protected from excessive heat generated from pumps operating at shut-off conditions. Where the possibility exists that the pump will dead-head (i.e. operate with no flow), a suitable temperature relief valve shall be provided, or other comparable level of protection, set to a maximum temperature of 185°F.

E. If heat tracing is specified for the piping, this should be limited to the use of self-regulating type to ensure the surface temperature of the pipe and fittings will not exceed 70°C (158°F).

3.03 INSPECTING AND CLEANING

A. The pipes should be flushed with cold water after completing the installation. Inspect and test piping systems in accordance with the recommendations and requirments of authorities having jurisdiction and as specified by the piping system manufacturer.

B. Clean and disinfect water distribution piping in accordance with the requirements of the authority having jurisdiction.

3.04 TESTING

A. Upon completion of the piping installation, the piping shall be tested using either a hydrostatic pressure test to 150% of the design pressure of the system for a minimum of one hour, or using a pneumatic test with compressed air or inert gas to 110% of the design pressure for a minimum of one hour, in accordance with the procedures, guidelines and recommendations of Orion and in accordance with the requirements of the authority having local jurisdiction. The contractor shall take into account all necessary safety precautions and shall follow procedures and guidelines to insure that the testing is carried out in a safe manner.

2.3

| REC

OM

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STAR

21

2.4 | CHEMICAL RESISTANCE FO

R POLYSTAR PP-RCT M

ATERIALCHEMICAL RESISTANCEOrion’s Polystar piping systems are useful for a wide variety of process piping applications. Before determining the suitability of a Polystar piping system for conveying chemicals of any type under pressure, it is important to verify that the material is suitable for use and that the piping system will be capable of withstanding the chemicals under the concurrent pressure and temperature and other loads under which it will operate. The chemical resistance tables provided in this section provide a general guideline for determining the suitability of Polystar PP-RCT piping systems. However, chemical resistance is dependent on a great number of specific factors, which include more than the concentration of the chemicals and the temperatures to which they are to be handled. Other factors include, but are not limited to the concurrent temperature, pressure, and other internal and external loads imposed on the system, the duration of application (i.e. continuous vs. intermittent), steady vs. cyclic loading, consideration of other chemicals which may be mixed together with the chemical under question, and the design codes to which the system is being implemented (e.g. ANSI/ASME B31.3 Code). While these charts may serve as a general guideline for the determination of resistance, it is recommended to contact the factory for further guidance for any chemical application of Polystar. The final determination will be the responsibility of the engineer in responsible charge of the project or other representative of the owner.

WARNING!According to the ANSI/ASME B31.3 Process Piping Code, thermoplas-tic piping should not be used in flammable fluid service above ground, in nominal sizes above 1 inch (32 mm). With sizes 1 inch and below, secondary containment should be provided. Consult the factory prior to use in any flam-mable fluid services.

CAUTION!

Prior to considering Polystar for any chemical application, consult the factory for a full recommen-dation based on the complete conditions of the application. Do not rely solely on the recommen-dations shown in the charts as suitability is based on additional factors including but not limited to pressure, temperature, duration and whether there are any mix-tures of chemicals involved.

NOTICE

When considering the installa-tion of Polystar PP-RCT materials that are connected to an exist-ing copper piping system, do not install the PP-RCT materials in applications involving elevated temperatures with aggressive water applications if the velocity of the water in the copper piping exceeds 10 ft/second. This can result in the release of copper ions which can result in potential stress cracking in PP piping.

Prior to using Polystar in water applications involving elevated temperatures and with high re-sidual chlorine content, consult the factory as to the suitability of the Polystar materials for the intended application

NOTICE

22

TEMPERATURECHEMICAL Conc. % 68°F 140°F 212°F

Acetic acid (glacial acetic acid) TR + • -

Acetic acid, hydr. 50 + + •

Acetic acid anhydride TR +

Acetone TR + +

Alum GL + +

Alum of all kinds, hydr. all + +

Ammonia, gaseous TR + +

Ammonia, hydr. conc. + +

Ammonium acetate GL + +

Ammonium carbonate GL + +

Ammonium chloride GL + +

Ammonium nitrate GL + + +

Ammonium phosphate Gl + + +

Ammonium sulphate GL + + +

Amylalcohol, pure TR + + +

Aniline TR • •

Antifreezing solution (motor vehicles) H + + +

Barium salts GL + + +

Battery acid Typical + +

Benzaldehyde GL + +

Benzene TR • - -

Benzine H • - -

Benzoic acid GL + +

Bichromate of potash GL + +

Bleaching solution 20 • • -

Borax L + +

Boric acid GL + + +

Bromine, liquid TR - - -

Bromine, vapours all • - -

Bromine water GL • - -

Butyl acetate TR • - -

Calcium chloride GL + + +

Calcium nitrate CL + +

Carbon Tetrachloride TR - - -

Carbonum disulphide TR - - -

Caustic potash solution 50 + + +

Caustic soda solution up to 60 + + +

Chlor, liquid TR - - -

2.4

| CHE

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AL R

ESIS

TANC

E FO

R PO

LYST

AR P

P-RC

T M

ATER

IAL

VL = ≤ 10% concentration by weight, L = > 10% concentration by weight, GL = saturated (aqueous) solution @ 68°F, TR = pure solution,

+ = resistant, • = limited resistance (consult factory), - = not resistant

Legend for Chemical Resistance Charts

23

TEMPERATURE

CHEMICAL Conc. % 68°F 140°F 212°FChloride of lime all + +

Chlorine, gaseous wet 1 - - -

Chlorine water GL • - -

Chlorobenzene TR •

Chloroform TR • - -

Chlorosulphonic acid TR - - -

Chromic sulphuric acid Mixed - - -

Citric acid, hydr. VL + + +

Coconut oil TR +

Corn oil TR + •

Cresol 90 + +

Cyclohexane TR +

Cyclohexanol TR + •

Cyclohexanone TR • - -

Dekahydronaphtaline TR • - -

Detergent VL + +

Dibutyl phthalate TR • - -

Diesel oil H + •

Diethylether TR + •

1,4-Dioxane TR • •

Ether

Ethyl acetate TR + • -

Ethyl benzene TR • - -

Ethyl chloride TR - - -

Formaldehyde, hydr. 40 + +

Formic acid 100 + •

85 + • -

10 + + •

Fruit juices TR + + +

Fuel oil TR + •

Glycerine TR + + +

Heptane TR + • -

Hexane TR + •

Hydrochloric acid, hydr. up to 20 + +

20 - 36 + •

Hydrofluoric acid solution 40 + +

Hydrogen chloride, gaseous TR + +

Hydrogen peroxide, hydr. 30 + •

Hydrogen sulphide TR + +

Iso-octane TR + • -

Jodine solution TR + •

Lactic acid 90 + +


R POLYSTAR PP-RCT M

ATERIAL

24

TEMPERATURE

CHEMICAL Conc. % 68°F 140°F 212°FLANOLIN® TR + •

Linseed oil TR + + +

Magnesium salts GL + +

Menthol TR + •

Mercury TR + +

Mercury salts GL + +

Methanol TR + +

Methyl ethyl ketone TR + •

Methylene chloride TR • - -

Milk TR + + +

Motor oil (motor vehicles) TR + •

Nickle salts, hydr. GL + +

Nitric acid, hydr. 10 + • -

Oleic acid 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 (hydr. phase) 5 + +

Phosphoric acid 85 + + +

Photographic developer TR + +

Pine needle oil TR + •

Potassium carbonate (Potash) GL + +

Potassium chlorate GL + +

Potassium chloride GL + +

Potassium hydroxide 50 + + +

Potassium iodide GL + +

Potassium nitrate, hydr. GL + +

Potassium permanganate GL + -Potassium persulphate GL + +

Propane, gaseous TR + •

Pyridine TR • •

Sea water TR + + +

Silicone oil TR + + +

2.4

| CHE

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25

TEMPERATURE

CHEMICAL Conc. % 68°F 140°F 212°FSilver salts GL + +

Sodium carbonate 50 + + •

Sodium carbonate (soda) 50 + + •

Sodium chlorate GL + +

Sodium chloride VL + + +

Sodium chlorite, hydr. 2 - 20 + • -

Sodium hydrochlorite, hyd. 10 +

Sodium nitrate GL + +

Sodium nitrite GL + +

Sodium phosphate GL + + +

Sodium sulphate GL + +

Sodium sulphide GL + +

Sodium sulphite 40 + + +

Sodium thiosulphate GL + +

Soybean oil TR + •

Stannous chloride GL + +

Starch solution, hydr. all + +

Succinic acid, hydr. GL + +

Sugar syrup TR + +

Sulphur dioxide TR + +

Sulphuric acid, hydr. 80-TR • -

10 - 80 + +

10 + + +

Tartaric acid, hydr. 10 + +

Tetrachloroethane TR • - -

Tetrachloroethylene (Perchlorethylen) TR • •

Tetrahydrofurane TR • - -

Tetrahydronaphtalene (Tetralin) TR - - -

Toluene TR • - -

Transformer oil TR • -

Trichloroethylene TR - - -

Tricresyl phosohate TR + •

Trioctyl phosohate TR +

Turpentine oil TR - - -

Turpentine substitute TR + • -

Urea, hydr. GL + +

Vinegar TR + + +

Water TR + + +

Wine TR + +

Xylene TR • - -

Zinc salts, hydr. GL + +


R POLYSTAR PP-RCT M

ATERIAL

26

2.5

| PIP

E DI

MEN

SIO

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DATA

dnom SDR d

inchesd

mmDNmm

d1inches

sinches

½” 7.4 0.79 20 15 0.57 0.11¾” 7.9 0.98 25 20 0.71 0.141” 9 1.26 32 25 0.95 0.14

1¼” 11 1.57 40 32 1.28 0.151½” 11 1.97 50 40 1.61 0.182” 11 2.48 63 50 2.02 0.23

2½” 11 2.95 75 --- 2.42 0.273” 11 3.54 90 65 2.90 0.32

3½” 11 4.33 110 80 3.54 0.394” 11 4.92 125 100 4.02 0.456” 17 6.30 160 125 5.55 0.378” 17 7.87 200 160 6.94 0.4710” 17 9.84 250 200 8.68 0.58

PIPECT-WHITE

d nom = nominal diameter in inches

d = actual outside diameter in millimeters

DN = nominal diameter in mm according to ISO

d1 = actual inside diameter in inches

d, d1 (flanges) = outside diameter of stub flange

face in inches

d2, d

4, d

5 = actual outside diameter of fitting hub

in inches

L, L1 = centerline to end in inches

z, z1 = centerline to end of water way (excluding

socket) in inches

s = wall thickness in inches

SW, SW1 = dimensions of molded nut size in mm

H, h, SD, R, Rp, = other, miscellaneous in inches

Legend for Dimensional Data Charts:

Larger sizes are available for pipes and fittings. For dimensional information on larger sizes contact Orion's Technical Services Department.

27

2.5 | PIPE DIMENSIO

NAL DATA

dnom SDR d

inchesd

mmDNmm

diinches

sinches

½” 7.4 0.79 20 15 0.57 0.11¾” 7.4 0.98 25 20 0.71 0.141” 9 1.26 32 25 0.98 0.14

1¼” 9 1.57 40 32 1.22 0.181½” 9 1.97 50 40 1.51 0.222” 9 2.48 63 50 1.92 0.28

2½” 9 2.95 75 --- 2.29 0.333” 9 3.54 90 65 2.75 0.40

3½” 9 4.33 110 80 3.36 0.484” 9 4.92 125 100 3.82 0.556” 11 6.30 160 125 5.15 0.578” 11 7.87 200 160 6.44 0.7210” 11 9.84 250 200 8.06 0.89

PIPECT-RED

dnom SDR d

inchesd

mmDNmm

diinches

sinches

½” 9 0.79 20 15 0.61 0.09¾” 9 0.98 25 20 0.76 0.111” 11 1.26 32 25 1.03 0.11

1¼” 11 1.57 40 32 1.28 0.151½” 11 1.97 50 40 1.61 0.182” 11 2.48 63 50 2.02 0.23

2½” 11 2.95 75 --- 2.42 0.273” 11 3.54 90 65 2.90 0.32

3½” 11 4.33 110 80 3.54 0.394” 11 4.92 125 100 4.02 0.456” 11 6.30 160 125 5.15 0.578” 11 7.87 200 160 6.44 0.72

10” 11 9.84 250 200 8.06 0.8912” 11 12.40 315 250 10.15 1.1314” 11 13.98 355 --- 11.44 1.2716” 11 15.75 400 --- 12.89 1.43

PIPECT-BLUE

28

2.6

| FI

TTIN

GS D

IMEN

SIO

NAL

DATA

dnom

dmm

d2inches

Linches

zinches

⅜ 16 0.91 1.42 1.30½ 20 1.10 2.20 1.65¾ 25 1.34 2.72 2.091 32 1.65 3.39 2.68

1¼ 40 2.05 4.17 3.39

90° ELBOW SOCKET FUSION

LONG RADIUS

dnom

dmm

d2inches

Linches

zinches

z1inches

½ 20 1.14 0.79 0.20 1.10¾ 25 1.34 0.87 0.24 1.341 32 1.69 1.02 0.31 1.54

45° ELBOW SOCKET FUSIONSTREET


dnom

dmm

d2inches

Linches

zinches

⅜ 16 0.91 0.75 0.24½ 20 1.14 0.83 0.24¾ 25 1.34 0.94 0.311 32 1.69 1.10 0.39

1¼ 40 2.05 1.26 0.431½ 50 2.56 1.46 0.512 63 3.23 1.73 0.63

2½ 75 3.90 1.97 0.793 90 4.72 2.28 0.98

3½ 110 5.83 2.72 1.264 125 6.50 3.03 1.46

29

dnom

dinches

dmm

sinches

Linches

zinches

6 6.30 160 0.57 4.45 6.658 7.87 200 0.72 5.00 7.9110 9.84 250 0.89 6.10 8.5412 12.40 315 1.13 6.34 11.0214 13.98 355 1.27 6.69 12.6016 15.75 400 - - - - - - - - -

45° ELBOW PLAIN END

dnom

dmm

d2inches

Linches

zinches

z1inches

⅜ 16 0.94 0.87 0.35 0.98½ 20 1.14 1.06 0.47 1.42¾ 25 1.34 1.18 0.55 1.611 32 1.69 1.42 0.71 1.89

1¼ 40 2.05 1.65 0.83 2.17

90° ELBOW SOCKET FUSIONSTREET

2.6 | FITTINGS DIMENSIO

NAL DATA

30

dnom

dinches

dmm

sinches

Linches

zinches

6 6.30 160 0.57 4.61 8.278 7.87 200 0.72 5.04 9.8410 9.84 250 0.89 7.09 12.0912 12.40 315 1.13 7.56 15.4714 13.98 355 1.27 6.69 16.1816 15.75 400 - - - - - - - - -

90° ELBOW PLAIN END

dnom

dmm

d2inches

Linches

zinches

⅜ 16 1.02 0.94 0.43½ 20 1.14 1.10 0.51¾ 25 1.34 1.26 0.631 32 1.69 1.50 0.79

1¼ 40 2.05 1.73 0.911½ 50 2.56 2.05 1.102 63 3.31 2.44 1.34

2½ 75 3.98 2.80 1.613 90 4.72 3.27 1.97

3½ 110 5.83 3.90 2.444 125 6.50 4.88 3.31


2.6

| FI

TTIN

GS D

IMEN

SIO

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DATA

31

dnom

dmm

d2inches

Linches

zinches

⅜ 16 0.91 0.94 0.43½ 20 1.14 1.10 0.51¾ 25 1.34 1.26 0.631 32 1.69 1.50 0.79

1¼ 40 2.05 1.73 0.911½ 50 2.56 2.05 1.102 63 3.31 2.44 1.34

2½ 75 3.94 2.80 1.613 90 4.72 3.27 1.97

3½ 110 5.83 3.90 2.444 125 6.50 4.88 3.31

SOCKET FUSIONTEES

dnom

dinches

dmm

d1nom

d1mm

sinches

s1inches

Linches

L1inches

zinches

z1inches

6 6.30 160 --- --- 0.57 --- 4.88 --- 8.86 ---6 6.30 160 3 90 0.57 0.32 4.37 3.31 8.35 7.486 6.30 160 3½ 110 0.57 0.39 4.37 3.66 8.35 7.768 7.87 200 --- --- 0.72 --- 5.00 --- 9.88 ---8 7.87 200 3 90 0.72 0.32 5.04 3.46 10.16 8.398 7.87 200 3½ 110 0.72 0.39 5.04 3.86 10.16 8.828 7.87 200 4 125 0.72 0.45 5.04 4.09 10.16 8.908 7.87 200 6 160 0.72 0.57 5.04 4.41 10.16 9.5310 9.84 250 --- --- 0.89 --- 5.83 --- 12.36 ---12 12.40 315 --- --- 1.13 --- 6.50 --- 13.86 ---14 13.98 355 --- --- 1.27 --- 6.69 --- 15.43 ---

TEES/REDUCING

TEESPLAIN END


NAL DATA

32

SOCKET FUSION

REDUCING TEES

dnom

d1nom

d2 nom

d mm

d1mm

d2mm

d4inches

d5inches

Linches

L1inches

zinches

z1inches

½ ⅜ ½ 20 16 20 1.14 1.14 1.10 1.10 0.51 0.59½ ¾ ½ 20 25 20 1.34 1.34 1.26 1.26 0.71 0.63¾ ⅜ ¾ 25 16 25 1.34 1.14 1.26 1.26 0.63 0.75¾ ½ ½ 25 20 20 1.34 1.34 1.26 1.26 0.63 0.71¾ ½ ¾ 25 20 25 1.34 1.14 1.26 1.26 0.63 0.67¾ ¾ ½ 25 25 20 1.34 1.34 1.26 1.26 0.63 0.631 ½ ½ 32 20 20 1.69 1.34 1.46 1.50 0.71 0.871 ½ ¾ 32 20 25 1.69 1.34 1.46 1.50 0.71 0.911 ½ 1 32 20 32 1.69 1.14 1.50 1.42 0.79 0.831 ¾ 1 32 25 32 1.69 1.34 1.46 1.50 0.71 0.871 ¾ ¾ 32 25 25 1.69 1.34 1.46 1.50 0.71 0.871 ¾ 1 32 25 32 1.69 1.34 1.50 1.42 0.79 0.79

1¼ ½ 1¼ 40 20 40 2.05 1.69 1.73 1.54 0.94 0.941¼ ¾ 1¼ 40 25 40 2.05 1.69 1.73 1.57 0.91 0.941¼ 1 1 40 32 32 2.05 1.69 1.69 1.73 0.83 0.941¼ 1 1¼ 40 32 40 2.05 1.69 1.73 1.57 0.91 0.871½ ½ 1½ 50 20 50 2.56 1.69 2.05 1.81 1.10 1.221½ ¾ 1½ 50 25 50 2.56 1.69 2.05 1.81 1.10 1.181½ 1 1½ 50 32 50 2.56 1.69 2.05 1.81 1.10 1.101½ 1¼ 1½ 50 40 50 3.34 3.34 2.44 2.44 1.54 1.382 ½ 2 63 20 63 3.34 1.69 2.44 2.44 1.38 1.892 ¾ 2 63 25 63 3.34 1.69 2.44 2.44 1.38 1.812 1 2 63 32 63 3.34 1.69 2.44 2.44 1.38 1.732 1¼ 1½ 63 40 50 3.34 3.34 2.44 2.44 1.54 1.382 1¼ 2 63 40 63 3.34 3.34 2.44 2.44 1.38 1.652 1½ 2 63 50 63 3.34 3.34 2.44 2.44 1.38 1.54

2½ ½ 2½ 75 20 75 3.94 2.80 2.80 2.80 1.61 2.242½ ¾ 2½ 75 25 75 3.94 2.80 2.80 2.80 1.61 2.172½ 1 2½ 75 32 75 3.94 2.80 2.80 2.80 1.61 2.092½ 1¼ 2½ 75 40 75 3.94 2.56 2.80 2.80 1.61 2.012½ 1½ 2½ 75 50 75 3.94 2.56 2.80 2.80 1.61 1.892½ 2 2½ 75 63 75 3.94 3.98 2.80 2.80 1.61 1.733 2 3 90 63 90 4.72 3.35 3.27 3.27 1.97 2.173 2½ 3 90 75 90 4.72 3.94 3.27 3.27 1.97 2.09

3½ 2 3½ 110 63 110 5.83 3.35 3.90 3.90 2.44 2.803½ 2½ 3½ 110 75 110 5.83 3.94 3.90 3.90 2.44 2.723½ 3 3½ 110 90 110 5.83 4.72 3.90 3.90 2.44 2.604 2½ 4 125 75 125 6.50 3.94 4.88 4.09 3.31 2.914 3 4 125 90 125 6.50 4.72 4.88 4.17 3.31 2.874 3½ 4 125 110 125 6.50 5.83 4.88 4.33 3.31 3.43

2.6

| FI

TTIN

GS D

IMEN

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DATA

33

dnom

dmm

d1nom

d1mm

x4branches

tinches

t1inches

Linches

L1inches

L2inches

L3inches

¾ 25 ⅜ 16 4 0.63 0.51 9.33 1.02 1.46 1.261 32 ½ 20 4 0.71 0.57 9.76 1.18 1.69 1.461 32 ¾ 25 4 0.71 0.63 9.92 1.38 1.69 1.61

1¼ 40 ¾ 25 4 0.81 0.63 9.92 1.50 1.69 1.61

SOCKET FUSION

HEADERS

dnom

dmm

Linches

zinches

½ 20 2.01 1.42¾ 25 2.28 1.691 32 3.07 1.34

1¼ 40 3.70 1.651½ 50 4.41 2.602 63 5.43 3.31

SOCKETFUSION

CROSSES


NAL DATA

dnom

dmm

SDinches

Hinches

Zinches

Linches

½ 20 0.57 1.77 5.16 6.30¾ 25 0.63 2.17 6.61 7.871 32 1.02 2.76 8.03 9.45

SOCKET FUSION

CROSSOVER

34

SOCKET FUSION

REDUCINGBUSHINGS

dnom

dmm

d1nom

d1mm

d2inches

Linches

zinches

½ 20 ⅜ 16 0.91 1.30 0.79¾ 25 ⅜ 16 0.91 1.26 0.75¾ 25 ½ 20 1.14 1.42 0.871 32 ½ 20 1.14 1.46 0.911 32 ¾ 25 1.34 1.54 0.91

1¼ 40 ½ 20 1.34 1.69 1.101¼ 40 ¾ 25 1.34 1.69 1.061¼ 40 1 32 1.69 1.77 1.061½ 50 ½ 20 1.69 2.01 1.421½ 50 ¾ 25 1.69 2.01 1.381½ 50 1 32 1.69 2.01 1.301½ 50 1¼ 40 2.05 2.09 1.302 63 ½ 20 1.34 2.20 1.652 63 ¾ 25 1.34 2.20 1.572 63 1 32 1.69 2.28 1.572 63 1¼ 40 2.05 2.36 1.572 63 1½ 50 2.56 2.48 1.57

2½ 75 1½ 50 2.56 2.64 1.732½ 75 2 63 3.15 2.80 1.733 90 2 63 3.15 3.07 2.013 90 2½ 75 3.90 3.19 2.01

3½ 110 2 63 3.35 3.43 2.363½ 110 2½ 75 3.94 3.54 2.363½ 110 3 90 4.72 3.66 2.40

SOCKET FUSION STUB

FLANGE ADAPTERS

dnom

dmm

d2inches

D1inches

Linches

zinches

hinches

1½ 50 2.91 2.40 1.06 0.16 0.312 63 4.02 2.99 1.42 0.51 0.67

2½ 75 4.80 3.54 1.50 0.31 0.753 90 5.43 4.25 1.77 0.47 0.83

3½ 110 6.22 5.16 1.97 0.51 0.834 125 6.38 5.75 2.09 0.51 0.98

2.6

| FI

TTIN

GS D

IMEN

SIO

NAL

DATA

35

CONCENTRIC REDUCERSPLAIN END

dnom

dinches

dmm

d1nom

d1inches

d1mm

sinches

s1inches

Linches

L1inches

zinches

4 4.92 125 3½ 4.33 110 0.55 0.48 3.94 3.35 8.866 6.30 160 3½ 4.33 110 0.57 0.39 4.33 3.66 10.046 6.30 160 4 4.92 125 0.57 0.45 4.45 3.74 10.248 7.87 200 6 6.30 160 0.72 0.57 5.59 4.61 11.9310 9.84 250 6 6.30 160 0.89 0.57 5.43 4.37 13.3510 9.84 250 8 7.87 200 0.89 0.72 5.51 5.12 13.3910 9.84 250 9 8.86 225 0.89 0.81 5.51 5.12 13.3912 12.40 315 10 9.84 250 1.13 0.89 6.30 5.71 15.75

SOCKET FUSION

COUPLINGS

dnom

dmm

d2nom

Lmm

zinches

⅜ 16 0.91 1.22 0.20½ 20 1.14 1.34 0.20¾ 25 1.34 1.46 0.201 32 1.69 1.61 0.20

1¼ 40 2.05 1.81 0.201½ 50 2.56 2.05 0.202 63 3.31 2.36 0.20

2½ 75 3.90 2.56 0.203 90 4.72 2.99 0.39

3½ 110 5.83 3.15 0.244 125 6.50 3.54 0.39


NAL DATA

36

SOCKET FUSION CAP

dnom

dmm

d2inches

Linches

⅜ 16 0.91 0.94½ 20 1.14 0.98¾ 25 1.34 1.101 32 1.69 1.26

1¼ 40 2.05 1.421½ 50 2.56 1.612 63 3.11 1.89

2½ 75 3.90 2.133 90 4.72 2.60

3½ 110 5.83 3.114 125 6.50 3.43

2.6

| FI

TTIN

GS D

IMEN

SIO

NAL

DATA

dnom

dmm

hmm

Linches

½ 20 1.97 2.76¾ 25 2.24 2.761 32 2.40 2.76

1¼ 40 2.76 3.311½ 50 3.23 3.462 63 3.94 3.86

2½ 75 4.49 4.133 90 5.16 4.72

3½ 110 6.06 5.914 125 6.69 7.806 160 8.07 7.768 200 9.65 7.95

10 250 12.40 8.6612 315 14.76 11.0214 355 16.93 12.2816 400 18.15 13.39

ELECTRO-FUSION

COUPLINGS

37

CAPS PLAIN END

dnom

dinches

dmm

sinches

Linches

L1inches

6 6.30 160 0.57 5.98 4.768 7.87 200 0.72 7.24 5.5110 9.84 250 0.89 9.06 5.9812 12.40 315 1.13 12.09 10.51

SOCKET FUSION 45°

LATERAL WYE

dnom

dmm

Linches

zinches

z1inches

z2inches

1 32 3.50 2.09 1.69 0.281¼ 40 4.76 3.19 2.60 0.591½ 50 5.20 3.39 2.68 0.592 63 6.69 5.20 3.54 0.79

STUB FLANGE ADAPTERSPLAIN END

dnom

dinches

dmm

sinches

hinches

d1inches

d4inches

zinches

Linches

6 6.30 160 0.57 0.98 8.35 6.89 6.89 4.338 7.87 200 0.72 1.26 10.55 9.13 8.07 5.0010 9.84 250 0.89 1.38 12.60 11.22 9.25 5.7512 12.40 315 1.13 1.42 1.38 14.96 10.24 7.28


NAL DATA

38

dnom

dmm

d1nom

d1 mm

hinches SW

3 90 ½ 20 1.14 383 90 ¾ 25 1.14 383 90 1¼ 40 1.50 63

3½ 110 ½ 20 1.14 383½ 110 ¾ 25 1.14 383½ 110 1¼ 40 1.50 633½ 110 1½ 50 1.54 704 125 ½ 20 1.14 384 125 ¾ 25 1.14 384 125 1¼ 40 1.50 634 125 1½ 50 1.54 704 125 2 63 1.77 856 160 ½ 20 1.14 386 160 ¾ 25 1.14 386 160 1¼ 40 1.50 636 160 1½ 50 1.54 706 160 2 63 1.77 858 200 ½ 20 1.14 388 200 ¾ 25 1.14 388 200 1¼ 40 1.50 638 200 1½ 50 1.54 708 200 2 63 1.77 85

10 250 ½ 20 1.14 3810 250 ¾ 25 1.14 3810 250 1¼ 40 1.50 6310 250 1½ 50 1.54 7010 250 2 63 1.77 8512 315 ½ 20 1.14 3812 315 ¾ 25 1.14 3812 315 1¼ 40 1.50 6312 315 1½ 50 1.54 7012 315 2 63 1.77 8514 355 ½ 20 1.14 3814 355 ¾ 25 1.14 3814 355 1¼ 40 1.50 6314 355 1½ 50 1.54 7014 355 2 63 1.77 8516 400 ½ 20 1.14 3816 400 ¾ 25 1.14 3816 400 1¼ 40 1.50 6316 400 1½ 50 1.54 7016 400 2 63 1.77 85

WELDING SADDLES

WITH SOCKET FUSION

OUTLETS

2.6

| FI

TTIN

GS D

IMEN

SIO

NAL

DATA

*Note: Smaller sizes are available for 1-1/4" (40mm) through 2-1/2" (75mm) mains. Reducing saddles molded with integral male and female threaded adapters with lead free brass inserts. are also available Saddles with 1 inch (32mm) sizes are under development.

39

dnom

dmm

Linches

z inches

SWmm

SW1mm

⅜ 16 4.37 3.27 36 30½ 20 4.57 3.39 44 37¾ 25 4.69 3.27 44 371 32 5.28 3.78 51 46

1¼ 40 5.98 4.33 63 521½ 50 6.42 4.53 70 592 63 7.36 5.16 85 74

2½ 75 8.66 6.30 115 903 90 11.42 8.82 135 109

LEAD FREE* BRASS UNIONS

LEAD FREE* BRASS

FEMALE ADAPTERS

NPT

dnom

dmm

Rp inches

d2inches

D1inches

Linches

zinches SW

⅜ 16 ½ 1.38 0.94 1.50 0.43 36½ 20 ½ 1.38 1.14 1.57 0.43 36½ 20 ¾ 1.69 1.34 1.65 0.43 44¾ 25 ½ 1.38 1.34 1.61 0.43 36¾ 25 ¾ 1.69 1.34 1.65 0.43 44 1 32 ¾ 1.69 1.69 1.73 0.43 441 32 1 1.97 1.69 1.89 0.47 51

1¼ 40 1 2.44 2.17 2.13 0.55 631¼ 40 1¼ 2.44 2.17 2.13 0.51 631½ 50 1¼ 2.72 2.52 2.24 0.47 701½ 50 1½ 2.72 2.52 2.24 0.55 702 63 2 3.31 3.11 2.68 0.75 85

2½ 75 2½ 4.41 3.90 3.23 0.87 1153 90 3 5.28 4.72 4.25 1.54 135

3½ 110 4 6.65 5.83 4.76 1.65 1704 125 5 8.11 6.61 4.92 1.61 208


NAL DATA

*The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.


40

LEAD FREE* BRASS MALE ADAPTERS

dnom

dmm

Rinches

d2inches

D1inches

Linches

zinches

SW mm

⅜ 16 ½ 1.38 0.94 2.09 1.57 36½ 20 ½ 1.38 1.14 2.17 1.57 36½ 20 ¾ 1.69 1.34 2.28 1.65 44¾ 25 ½ 1.38 1.34 2.20 1.57 36 ¾ 25 ¾ 1.69 1.34 2.28 1.65 441 32 ¾ 1.69 1.69 2.28 1.65 441 32 1 1.97 1.69 2.60 1.89 51

1¼ 40 1 2.44 2.17 2.80 2.01 621¼ 40 1¼ 2.44 2.05 2.91 2.09 631½ 50 1¼ 2.72 2.52 3.03 2.13 701½ 50 1½ 2.72 2.52 3.03 2.13 702 63 2 3.31 3.11 3.62 2.56 85

2½ 75 2½ 4.41 3.90 4.41 3.23 1153 90 3 5.28 4.72 5.63 4.37 135

3½ 110 4 6.65 5.83 6.34 4.88 1704 125 5 8.11 6.61 6.69 5.12 208


2.6

| FI

TTIN

GS D

IMEN

SIO

NAL

DATA

ALL PLASTIC UNIONS

dnom

dmm

DN mm G L

inchesI

inchesl1

inchesz

inchesD

inches½ 20 15 1 1.73 0.69 1.02 0.59 1.81¾ 25 20 1¼ 1.87 0.75 1.10 0.59 2.201 32 25 1½ 2.03 0.83 1.18 0.59 2.60

1¼ 40 32 2 2.28 0.93 1.34 0.67 3.111½ 50 40 2¼ 2.60 1.04 1.54 0.75 3.432 63 50 2¾ 3.09 1.20 1.85 0.91 4.21

41

dnom

dmm

Sizeinches

Hanger Rod*Bolt Size inches

½ 20 0.79-0.91 ⅜¾ 25 0.98-1.10 ⅜1 32 1.22-1.38 ⅜

1¼ 40 1.57-1.69 ⅜1½ 50 1.85-2.09 ⅜2 63 2.52-2.64 ⅜

2½ 75 2.95 ⅜3 90 3.54 ⅜

3½ 110 4.33 ⅜4 125 4.92 ½6 160 6.30 ½7 180 6.30 ½8 200 6.30 ½9 225 6.30 ½10 250 6.30 ½

PIPE BRACKET (For Non-Insulated

Pipe)

dnom

dmm

Sinches

⅜-¾ 16-25 0.021 32 0.02

1¼ 40 0.021½ 50 0.022 63 0.02

2½ 75 0.023 90 0.02

3½ 110 0.02

SEMI-TUBESUPPORT


NAL DATA

Semi tube length is 118.1 inches for all sizes.

*Hanger Rods are not included with pipe bracket.Note: Pipe brackets for insulated piping are available, contact manufacturer.

43

3.0 System Sizing and Engineering Considerations3.1 Flow Rate, Velocity, and Head Loss (Pressure Drop) Data

3.2 Support Spacing for Polystar Pipes

3.3 Anchoring Polystar Pipes

3.4 Thermal Expansion and Contraction

3.5 Expansion/Contraction Compensation Guidelines

SECT

ION

THRE

E

POLYSTARTM

PolystarPipe.com

44

3.1

| FL

OW

RAT

E, V

ELO

CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA FLOW RATE, VELOCITY, AND HEAD

LOSS (PRESSURE DROP) DATAPipe diameter is a critical factor in properly designing the polystar pipe system. Polystar pipe systems are recommended to maintain an average flow velocity of 8 fps to provide energy efficient pumping, control of noise generation, and to dampen the affects of water hammer on the piping system. Once pipe sizes have been determined for the system the following equations can be used to determine the system pressure drop, and to select pump motor horsepower. When determining frictional pressure loss across a system it is recommended that a 20% safety factor be used to account for aging of pipe, non-smooth welds, and manufacturing tolerances.

DARCY METHOD h

f = Friction loss from flow in the pipe/fittings, (ft)

L = Length of pipe and/or equivalent length of pipe fitting (ft)

D = Inside diameter of pipe, (ft) V = Average flow velocity within pipe, (ft/s) g = 32.174, Gravitational constant, (ft/s2) f = Friction factor є = 2.2966E-05 , Absolute roughness of

polypropylene pipe, (feet) μ = Absolute viscosity of liquid in pipe, (lb

Mass/ft-s)

ν= Kinematic viscosity of fluid of liquid in pipe, (ft2/s) Re = Reynolds number ρ = Density of liquid in pipe, (lb

Mass/ft3)

Q = Volumetric flow, (gpm) C = Valve manufacturer's flow coefficient

The Darcy-Weisbach equation can be used to determine the friction loss for Polystar piping systems. It can be used to determine the system's friction loss across pipe, fittings, and valves.

In order to calcuate the friction loss using the Darcy-Weisbach equation one must first calculate the Reynolds number, which can be calculated with one of the below equations.

The Reynolds number allows the friction factor to be determined. Depending on how large or small the Reynolds number will determine which equation should be used to calculate the friction factor.

For Reynolds Numbers <2000, the flow condition is considered to be a laminar flow condition. For a laminar flow condition use the following equation to calculate the friction factor.

For Reynolds Numbers >4000, the flow condition is considered to be a turbulent flow condition. For turbulent flow conditions use the Colebrook equation to calculate the friction factor.

A Moody Diagram can be used to determine the friction factor as well. It can be used to determine the friction factor in laminar flow conditions, transitional flow conditions, or turbulent flow conditions. To use the Moody Diagram first calculate the Reynolds number, and a relative roughness number. Use these numbers with the Moody Diagram to determine the friction factor. An equation for relative roughness is shown below.

FRICTION HEAD LOSS ACROSS PIPEMeasure the developed length of pipe, the length of pipe in the system containing the same pipe diameter and same average flow velocity. Insert this length along with the average flow velocity and pipe diameter into the Darcy-Weisbach equation to calculate the frictional head loss of the pipe.

ℎ𝑓𝑓 = 𝑓𝑓 ∙

𝐿𝐿𝐷𝐷∙𝑉𝑉2

2 ∙ 𝑔𝑔

Darcy-Weisbach Equation

Colebrook Equation

Reynolds Number

𝑅𝑅𝑅𝑅 =

𝜌𝜌 ∙ 𝐷𝐷 ∙ 𝑉𝑉𝜇𝜇

=𝑉𝑉 ∙ 𝐷𝐷𝑣𝑣

𝑓𝑓 =

64𝑅𝑅𝑅𝑅

1

�𝑓𝑓= −2 ∙ 𝑙𝑙𝑙𝑙𝑔𝑔10 �

є3.7𝐷𝐷

+2.51𝑅𝑅𝑅𝑅�𝑓𝑓

�

𝑅𝑅𝑅𝑅𝑙𝑙𝑅𝑅𝑅𝑅𝑅𝑅𝑣𝑣𝑅𝑅 𝑅𝑅𝑙𝑙𝑅𝑅𝑔𝑔ℎ𝑛𝑛𝑅𝑅𝑛𝑛𝑛𝑛 =

𝜖𝜖𝐷𝐷

45

3.1 | FLOW

RATE, VELOCITY, AND HEAD LO

SS (PRESSURE DROP) DATA

FRICTIONAL HEAD LOSS ACROSS A FITTING Select the fitting's equivalent pipe length from the fitting table and use this length in the Darcy-Weisbach Equation to determine the frictional head loss across the fitting.

If the pipe and fitting have identical sizes and flow, the equivalent lenght of the fitting and the developed length of the pipe can be summed together as a combined equivalent length which can be used to determine the frictional head loss across the combined length of pipe.

FRICTIONAL HEAD LOSS ACROSS A VALVE Valves are provided with a K-factor which have the following L/D, friction factor relationship. The K-factor may very depending on the valve position for most valves. Select the higher K value which applies to the system operation to be conservative. Use the pipe diameter, K-factor and 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 head loss across the valve.

Some valve manufacturers will provide a flow coefficient rather than a K-factor for the valve. The flow coefficient of a valve is defined 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 drop of 1 psi across the valve. To determine the pressure drop across the valve insert the density of the chemical flowing through the valve, the volumetric flow rate, and the manufacturer's flow coefficient. The pressure drop will be provided in psi, not in feet of water column.

HAZEN & WILLIAMS METHODThe Hazen & Williams equation can be used for water at 60°F or any other fluid having a kinematic viscosity of .00001216 ft2/s. As water temperature varies from 32°F to 212°F the friction can vary as much as 40%, therefore one should use caution in using this equation.

D = Inside diameter of pipe, (inches) Q = Volumetric pipe flow, (gpm) C = 150, Flow coefficient for polypropylene pipe H

f = Friction head, (ft of water/100 ft of pipe)



2 ∙ 𝑔𝑔



2 ∙ 𝑔𝑔

𝐿𝐿𝐷𝐷

= 𝐾𝐾𝑓𝑓



2 ∙ 𝑔𝑔

𝑄𝑄 = 7.9 ∙ 𝐶𝐶�∆𝑃𝑃

𝜌𝜌𝐶𝐶ℎ𝑅𝑅𝑒𝑒𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙

∆𝑃𝑃 =

𝜌𝜌𝐶𝐶ℎ𝑅𝑅𝑒𝑒𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙62.4

∙ �𝑄𝑄𝐶𝐶�

2



2 ∙ 𝑔𝑔

where L = LDeveloped Length where L = L Valve Equiv Length = (D∙K)/f

where L = L Fitting Equiv Length

L = L Developed Length + L Fitting Equiv Length

𝐻𝐻𝑓𝑓 = 0.00083 ∙ �

100𝐶𝐶�

1.85

∙𝑄𝑄1.85

𝐷𝐷4.8655

46

3.1

| FL

OW

RAT

E, V

ELO

CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA PUMP/MOTOR

HTotal

= Total head, (ft)h

f = Frictional head loss, (ft)

hElevation

= Elevation change, (ft)m = Mass flow rate, (lbMass/minute)

Hydraulic Horse Power

Pump Brake Horse Power

KW Input To Motor

CONVERTING FROM FEET OF HEAD TO PSIA column of water is 2.31 feet high is equal to 1 psi at 65°F.

𝐻𝐻𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙 = ℎ𝑓𝑓 + ℎ𝐸𝐸𝑙𝑙𝑅𝑅𝑣𝑣𝑅𝑅𝑅𝑅𝑅𝑅𝑙𝑙𝑛𝑛

𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝑃𝑃 =

𝑒𝑒 ∙ 𝐻𝐻𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙33,000

𝑃𝑃𝑅𝑅𝑒𝑒𝑃𝑃 𝐵𝐵𝐵𝐵𝑅𝑅𝐵𝐵𝑅𝑅 𝐻𝐻𝑃𝑃 =

𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝑃𝑃𝑃𝑃𝑅𝑅𝑒𝑒𝑃𝑃 𝐸𝐸𝑓𝑓𝑓𝑓𝑅𝑅𝑒𝑒𝑅𝑅𝑅𝑅𝑛𝑛𝑒𝑒𝐻𝐻

𝐾𝐾𝐾𝐾 𝑅𝑅𝑛𝑛𝑃𝑃𝑅𝑅𝑅𝑅 𝑅𝑅𝑙𝑙 𝑒𝑒𝑙𝑙𝑅𝑅𝑙𝑙𝐵𝐵 =

𝑃𝑃𝑅𝑅𝑒𝑒𝑃𝑃 𝐵𝐵𝐵𝐵𝑅𝑅𝐵𝐵 𝐻𝐻𝑃𝑃 ∙ 0.7457𝑀𝑀𝑙𝑙𝑅𝑅𝑙𝑙𝐵𝐵 𝐸𝐸𝑓𝑓𝑓𝑓𝑅𝑅𝑒𝑒𝑅𝑅𝑅𝑅𝑛𝑛𝑒𝑒𝐻𝐻

𝐿𝐿𝑅𝑅𝐿𝐿𝑅𝑅𝑅𝑅𝐻𝐻 𝐻𝐻𝑅𝑅𝑅𝑅𝐻𝐻 𝑅𝑅𝑛𝑛 𝑓𝑓𝑅𝑅𝑅𝑅𝑅𝑅 𝑙𝑙𝑓𝑓 𝑤𝑤𝑅𝑅𝑅𝑅𝑅𝑅𝐵𝐵 =

𝑃𝑃𝑛𝑛𝑅𝑅 ∙ 2.31𝑆𝑆𝑃𝑃𝑅𝑅𝑒𝑒𝑅𝑅𝑓𝑓𝑅𝑅𝑒𝑒 𝐺𝐺𝐵𝐵𝑅𝑅𝑣𝑣𝑅𝑅𝑅𝑅𝐻𝐻

𝑆𝑆𝑃𝑃𝑅𝑅𝑒𝑒𝑅𝑅𝑓𝑓𝑅𝑅𝑒𝑒 𝐺𝐺𝐵𝐵𝑅𝑅𝑣𝑣𝑅𝑅𝑅𝑅𝐻𝐻 =

𝜌𝜌𝐶𝐶ℎ𝑅𝑅𝑒𝑒𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙𝜌𝜌𝐾𝐾𝑅𝑅𝑅𝑅𝑅𝑅𝐵𝐵

= 𝜌𝜌𝐶𝐶ℎ𝑅𝑅𝑒𝑒𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙

62.4 𝑙𝑙𝑙𝑙𝑀𝑀𝑅𝑅𝑛𝑛𝑛𝑛 𝑓𝑓𝑅𝑅3�

1 𝑃𝑃𝑛𝑛𝑅𝑅 = 2.31 𝑙𝑙𝑅𝑅𝐿𝐿𝑅𝑅𝑅𝑅𝐻𝐻 ℎ𝑅𝑅𝑅𝑅𝐻𝐻 𝑅𝑅𝑛𝑛 𝑓𝑓𝑅𝑅𝑅𝑅𝑅𝑅 𝑙𝑙𝑓𝑓 𝑤𝑤𝑅𝑅𝑅𝑅𝑅𝑅𝐵𝐵 𝑒𝑒𝑙𝑙𝑙𝑙𝑅𝑅𝑒𝑒

47

3.1 | FLOW



HEADLOSS - CT RED PIPE

HEADLOSS - CT-WHITE PIPE

48

3.1

| FL

OW

RAT

E, V

ELO

CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA HEADLOSS - CT-BLUE PIPE

CT-RED PRESSURE LOSS v. FLOW(½" THRU 1")

49

3.1 | FLOW



CT-RED PRESSURE LOSS v. FLOW(1¼" THRU 2")

CT-RED PRESSURE LOSS v. FLOW(2" THRU 4")

50

3.1

| FL

OW

RAT

E, V

ELO

CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA CT-RED PRESSURE LOSS v. FLOW

(4" THRU 10")

CT-WHITE PRESSURE LOSS v. FLOW(½" THRU 1")

51

3.1 | FLOW



CT-WHITE PRESSURE LOSS v. FLOW(1¼" THRU 2")

CT-WHITE PRESSURE LOSS v. FLOW(2" THRU 4")

52

CT-WHITE PRESSURE LOSS v. FLOW(4" THRU 10")

3.1

| FL

OW

RAT

E, V

ELO

CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA

CT-BLUE PRESSURE LOSS v. FLOW(½" THRU 1")

53

3.1 | FLOW



CT-BLUE PRESSURE LOSS v. FLOW(1¼" THRU 2")

CT-BLUE PRESSURE LOSS v. FLOW(2" THRU 4")

54

3.1

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ATA CT-BLUE PRESSURE LOSS v. FLOW

(4" THRU 12")

55

VELOCITY AND HEADLOSS v. FLOW RATE FOR WATER

1/2"

Polystar CT-White (Fibercore™ Reinforced)

Polystar CT-Red (Fibercore™ Reinforced) Polystar CT-Blue

1/2 Inch PipeSDR 7.4, 0.78 inch OD,

0.57 inch ID


0.57 inch ID

1/2 Inch PipeSDR 9, 0.78 inch OD,

0.61 inch ID

Flow(gal per min)

Velocity(ft per sec)

Headloss(ft per 100 ft)





0.5 0.63 0.532 0.63 0.532 0.55 0.389

1 1.26 1.87 1.26 1.87 1.10 1.36

1.5 1.89 3.89 1.89 3.89 1.65 2.83

2 2.51 6.55 2.51 6.55 2.20 4.76

2.5 3.14 9.82 3.14 9.82 2.74 7.12

3 3.77 13.7 3.77 13.7 3.29 9.89

3.5 4.40 18.1 4.40 18.1 3.84 13.1

4 5.03 23.0 5.03 23.0 4.39 16.6

4.5 5.66 28.5 5.66 28.5 4.94 20.6

5 6.29 34.5 6.29 34.5 5.49 24.9

5.5 6.91 41.0 6.91 41.0 6.04 29.6

6 7.54 47.9 7.54 47.9 6.59 34.6

6.5 8.17 55.4 8.17 55.4 7.14 40.0

7 8.80 63.4 8.80 63.4 7.68 45.7

7.5 9.43 71.8 9.43 71.8 8.23 51.7

8 10.1 80.7 10.1 80.7 8.8 58.1

9 11.3 99.9 11.3 99.9 9.9 71.9

10 12.6 121 12.6 121 11.0 87.0

11 13.8 144 13.8 144 12.1 103

12 15.1 168 15.1 168 13.2 121

13 16.3 195 16.3 195 14.3 140

14 17.6 222 17.6 222 15.4 160

3.1 | FLOW



56


3/4"




0.71 inch ID


0.71 inch ID

3/4 Inch PipeSDR 9, 0.98 inch OD,

0.76 inch ID

Flow(gal per min)







1 0.81 0.654 0.81 0.654 0.700 0.457

2 1.62 2.27 1.62 2.27 1.40 1.58

3 2.43 4.69 2.43 4.69 2.10 3.26

4 3.24 7.85 3.24 7.85 2.80 5.46

5 4.05 11.7 4.05 11.7 3.50 8.14

6 4.86 16.2 4.86 16.2 4.20 11.3

7 5.67 21.4 5.67 21.4 4.90 14.9

8 6.48 27.2 6.48 27.2 5.60 19

9 7.29 33.6 7.29 33.6 6.30 23.3

10 8.10 40.6 8.10 40.6 7.00 28.1

11 8.91 48.1 8.91 48.1 7.70 33.4

12 9.72 56.2 9.72 56.2 8.40 39.0

13 10.5 64.9 10.5 64.9 9.10 45.0

14 11.3 74.1 11.3 74.1 9.80 51.4

15 12.2 83.9 12.2 83.9 10.5 58.1

16 13.0 94.2 13.0 94.2 11.2 65.2

17 13.8 105 13.8 105 11.9 72.7

18 14.6 116 14.6 116 12.6 80.6

19 15.4 128 15.4 128 13.3 88.7

20 16.2 141 16.2 141 14.0 97.3

21 17.0 153 17.0 153 14.7 106

22 17.8 167 17.8 167 15.4 115

3.1

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57


1"



1 Inch PipeSDR 9, 1.26 inch OD,

0.98 inch ID


0.98 inch ID


1.03 inch ID

Flow(gal per min)







3 1.28 0.939 1.28 0.939 1.16 0.728

5 2.13 2.39 2.13 2.39 1.93 1.85

7 2.98 4.43 2.98 4.43 2.70 3.42

9 3.83 7.02 3.83 7.02 3.47 5.40

11 4.68 10.1 4.68 10.1 4.24 7.79

13 5.53 13.8 5.53 13.8 5.01 10.6

15 6.38 17.9 6.38 17.9 5.78 13.7

17 7.23 22.5 7.23 22.5 6.55 17.3

19 8.08 27.6 8.08 27.6 7.32 21.1

21 8.93 33.1 8.93 33.1 8.09 25.4

23 9.78 39.1 9.78 39.1 8.86 30.0

25 10.6 45.6 10.6 45.6 9.63 34.9

27 11.5 52.5 11.5 52.5 10.4 40.1

29 12.3 59.8 12.3 59.8 11.2 45.7

31 13.2 67.6 13.2 67.6 11.9 51.7

33 14.0 75.8 14.0 75.8 12.7 57.9

35 14.9 84.4 14.9 84.4 13.5 64.5

37 15.7 93.5 15.7 93.5 14.2 71.3

39 16.6 103 16.6 103 15.0 78.5

41 17.4 113 17.4 113 15.8 86.0

43 18.3 123 18.3 123 16.6 93.9

45 19.1 134 19.1 134 17.3 102

3.1 | FLOW



58


1¼"



1¼ Inch PipeSDR 11, 1.57 inch OD,

1.28 inch ID


1.22 inch ID


1.28 inch ID

Flow(gal per min)







5 1.25 0.655 1.37 0.822 1.25 0.655

8 1.99 1.53 2.20 1.93 1.99 1.53

10 2.49 2.29 2.74 2.89 2.49 2.29

12 2.99 3.19 3.29 4.03 2.99 3.19

14 3.49 4.21 3.84 5.33 3.49 4.21

16 3.99 5.36 4.39 6.80 3.99 5.36

18 4.49 6.64 4.94 8.42 4.49 6.64

20 4.99 8.03 5.49 10.2 4.99 8.03

22 5.48 9.54 6.04 12.1 5.48 9.54

24 5.98 11.2 6.59 14.2 5.98 11.2

26 6.48 12.9 7.14 16.4 6.48 12.9

28 6.98 14.8 7.68 18.8 6.98 14.8

30 7.48 16.7 8.23 21.3 7.48 16.7

32 7.98 18.8 8.78 23.9 7.98 18.8

34 8.48 21.0 9.33 26.7 8.48 21.0

36 8.98 23.2 9.88 29.6 8.98 23.2

38 9.47 25.6 10.4 32.7 9.47 25.6

42 10.5 30.7 11.5 39.2 10.5 30.7

46 11.5 36.2 12.6 46.3 11.5 36.2

50 12.5 42.1 13.7 53.8 12.5 42.1

54 13.5 48.3 14.8 61.9 13.5 48.3

58 14.5 55.0 15.9 70.5 14.5 55.0

3.1

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59


1½"



1½ Inch PipeSDR 11, 1.97 inch OD,

1.61 inch ID


1.51 inch ID


1.61 inch ID

Flow(gal per min)







8 1.26 0.519 1.43 0.694 1.26 0.519

10 1.58 0.775 1.79 1.04 1.58 0.775

15 2.36 1.61 2.69 2.15 2.36 1.61

20 3.15 2.70 3.58 3.61 3.15 2.70

25 3.94 4.03 4.5 5.40 3.94 4.03

30 4.7 5.59 5.4 7.50 4.7 5.59

35 5.5 7.38 6.3 9.91 5.5 7.38

40 6.3 9.38 7.2 12.6 6.3 9.38

45 7.1 11.6 8.1 15.6 7.1 11.6

50 7.9 14.0 9.0 18.8 7.9 14.0

55 8.7 16.6 9.9 22.4 8.7 16.6

60 9.5 19.4 10.7 26.2 9.5 19.4

65 10.2 22.5 11.6 30.2 10.2 22.5

70 11.0 25.7 12.5 34.5 11.0 25.7

75 11.8 29.0 13.4 39.1 11.8 29.0

80 12.6 32.6 14.3 43.9 12.6 32.6

85 13.4 36.4 15.2 49.0 13.4 36.4

90 14.2 40.3 16.1 54.3 14.2 40.3

95 15.0 44.4 17.0 59.9 15.0 44.4

100 15.8 48.7 17.9 65.7 15.8 48.7

105 16.5 53.2 18.8 71.7 16.5 53.2

110 17.3 57.8 19.7 78.0 17.3 57.8

3.1 | FLOW



60


2"




2.02 inch ID


1.92 inch ID


2.02 inch ID

Flow(gal per min)







10 1.00 0.238 1.11 0.303 1.00 0.238

20 2.00 0.851 2.22 1.08 2.00 0.851

30 3.00 1.79 3.32 2.29 3.00 1.79

40 4.00 3.04 4.43 3.89 4.00 3.04

50 5.01 4.58 5.54 5.86 5.01 4.58

60 6.01 6.40 6.65 8.20 6.01 6.40

70 7.01 8.49 7.76 10.9 7.01 8.49

80 8.01 10.8 8.86 13.9 8.01 10.8

90 9.01 13.5 9.97 17.3 9.01 13.5

100 10.0 16.3 11.1 21.0 10.0 16.3

110 11.0 19.5 12.2 25.0 11.0 19.5

120 12.0 22.8 13.3 29.4 12.0 22.8

130 13.0 26.5 14.4 34.0 13.0 26.5

140 14.0 30.3 15.5 39.0 14.0 30.3

150 15.0 34.4 16.6 44.3 15.0 34.4

160 16.0 38.7 17.7 49.9 16.0 38.7

170 17.0 43.3 18.8 55.8 17.0 43.3

180 18.0 48.1 19.9 62.0 18.0 48.1

190 19.0 53.1 21.1 68.4 19.0 53.1

200 20.0 58.4 22.2 75.2 20.0 58.4

210 21.0 63.8 23.3 82.3 21.0 63.8

220 22.0 69.5 24.4 89.6 22.0 69.5

3.1

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61


2½"




2.43 inch ID


2.29 inch ID


2.43 inch ID

Flow(gal per min)







20 1.38 0.350 1.56 0.467 1.38 0.350

30 2.08 0.734 2.34 0.980 2.08 0.734

40 2.77 1.24 3.12 1.66 2.77 1.24

50 3.46 1.87 3.89 2.49 3.46 1.87

60 4.15 2.60 4.67 3.48 4.15 2.60

70 4.84 3.45 5.45 4.61 4.84 3.45

80 5.53 4.40 6.23 5.89 5.53 4.40

90 6.23 5.46 7.01 7.31 6.23 5.46

100 6.92 6.61 7.79 8.86 6.92 6.61

110 7.61 7.87 8.57 10.5 7.61 7.87

120 8.30 9.22 9.35 12.4 8.30 9.22

130 8.99 10.7 10.1 14.3 8.99 10.7

140 9.68 12.2 10.9 16.4 9.68 12.2

150 10.4 13.9 11.7 18.6 10.4 13.9

160 11.1 15.6 12.5 20.9 11.1 15.6

170 11.8 17.4 13.2 23.4 11.8 17.4

180 12.5 19.3 14.0 26.0 12.5 19.3

190 13.1 21.3 14.8 28.7 13.1 21.3

200 13.8 23.4 15.6 31.5 13.8 23.4

210 14.5 25.6 16.4 34.4 14.5 25.6

225 15.6 29.1 17.5 39.1 15.6 29.1

240 16.6 32.7 18.7 43.9 16.6 32.7

3.1 | FLOW



62


3"




2.90 inch ID


2.75 inch ID


2.90 inch ID

Flow(gal per min)







20 0.971 0.152 1.08 0.197 0.971 0.152

40 1.94 0.534 2.16 0.693 1.94 0.534

60 2.91 1.12 3.24 1.45 2.91 1.12

80 3.89 1.88 4.32 2.44 3.89 1.88

100 4.86 2.82 5.40 3.66 4.86 2.82

120 5.83 3.93 6.48 5.10 5.83 3.93

140 6.80 5.20 7.56 6.74 6.80 5.20

160 7.77 6.63 8.64 8.60 7.77 6.63

180 8.74 8.21 9.72 10.6 8.74 8.21

200 9.71 9.94 10.8 12.9 9.71 9.94

220 10.7 11.8 11.9 15.3 10.7 11.8

240 11.7 13.8 13.0 18.0 11.7 13.8

260 12.6 16.0 14.0 20.8 12.6 16.0

280 13.6 18.3 15.1 23.8 13.6 18.3

300 14.6 20.8 16.2 26.9 14.6 20.8

320 15.5 23.4 17.3 30.3 15.5 23.4

340 16.5 26.1 18.4 33.8 16.5 26.1

360 17.5 28.9 19.4 37.5 17.5 28.9

380 18.5 31.9 20.5 41.4 18.5 31.9

400 19.4 35.0 21.6 45.4 19.4 35.0

420 20.4 38.3 22.7 49.6 20.4 38.3

440 21.4 41.6 23.8 54.0 21.4 41.6

3.1

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63


3½"




3.54 inch ID


3.36 inch ID


3.54 inch ID

Flow(gal per min)







30 0.978 0.121 1.09 0.156 0.98 0.121

50 1.63 0.305 1.81 0.393 1.63 0.305

70 2.28 0.560 2.53 0.722 2.28 0.560

90 2.93 0.882 3.26 1.14 2.93 0.882

110 3.59 1.27 3.98 1.63 3.59 1.27

130 4.24 1.71 4.70 2.21 4.24 1.71

150 4.89 2.22 5.43 2.86 4.89 2.22

170 5.54 2.78 6.15 3.59 5.54 2.78

190 6.19 3.40 6.87 4.39 6.19 3.40

210 6.85 4.07 7.60 5.25 6.85 4.07

230 7.50 4.80 8.32 6.19 7.50 4.80

250 8.15 5.58 9.05 7.20 8.15 5.58

270 8.80 6.41 9.77 8.27 8.80 6.41

290 9.45 7.29 10.5 9.42 9.45 7.29

310 10.1 8.22 11.2 10.6 10.1 8.22

330 10.8 9.20 11.9 11.9 10.8 9.20

350 11.4 10.2 12.7 13.2 11.4 10.2

370 12.1 11.3 13.4 14.6 12.1 11.3

390 12.7 12.4 14.1 16.1 12.7 12.4

410 13.4 13.6 14.8 17.6 13.4 13.6

440 14.3 15.5 15.9 20.0 14.3 15.5

470 15.3 17.4 17.0 22.5 15.3 17.4

3.1 | FLOW



64


4"




4.02 inch ID


3.82 inch ID


4.02 inch ID

Flow(gal per min)







50 1.26 0.168 1.40 0.215 1.26 0.168

75 1.90 0.348 2.10 0.445 1.90 0.348

100 2.53 0.582 2.80 0.746 2.53 0.582

125 3.16 0.868 3.50 1.11 3.16 0.868

150 3.79 1.20 4.20 1.55 3.79 1.20

175 4.42 1.59 4.90 2.04 4.42 1.59

200 5.06 2.02 5.60 2.59 5.06 2.02

225 5.69 2.49 6.30 3.20 5.69 2.49

250 6.32 3.01 7.00 3.87 6.32 3.01

275 6.95 3.57 7.70 4.59 6.95 3.57

300 7.58 4.17 8.40 5.37 7.58 4.17

325 8.21 4.81 9.10 6.20 8.21 4.81

350 8.85 5.49 9.80 7.08 8.85 5.49

375 9.48 6.22 10.5 8.02 9.48 6.22

400 10.1 6.98 11.2 9.00 10.1 6.98

425 10.7 7.78 11.9 10.0 10.7 7.78

450 11.4 8.62 12.6 11.1 11.4 8.62

475 12.0 9.49 13.3 12.3 12.0 9.49

500 12.6 10.4 14.0 13.4 12.6 10.4

525 13.3 11.4 14.7 14.7 13.3 11.4

565 14.3 13.0 15.8 16.7 14.3 13.0

615 15.5 15.1 17.2 19.5 15.5 15.1

665 16.8 17.4 18.6 22.4 16.8 17.4

715 18.1 19.8 20.0 25.5 18.1 19.8

765 19.3 22.3 21.4 28.8 19.3 22.3

815 20.6 25.0 22.8 32.3 20.6 25.0

865 21.9 27.8 24.2 36.0 21.9 27.8

915 23.1 30.7 25.6 39.8 23.1 30.7

965 24.4 33.8 27.0 43.8 24.4 33.8

3.1

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65


6"




5.55 inch ID


5.15 inch ID


5.15 inch ID

Flow(gal per min)







100 1.33 0.120 1.54 0.178 1.54 0.178

150 1.99 0.250 2.31 0.366 2.31 0.366

200 2.65 0.421 3.08 0.610 3.08 0.610

250 3.32 0.631 3.85 0.906 3.85 0.906

300 3.98 0.878 4.62 1.25 4.62 1.25

350 4.64 1.16 5.39 1.64 5.39 1.64

400 5.30 1.48 6.16 2.08 6.16 2.08

450 5.97 1.83 6.93 2.57 6.93 2.57

500 6.63 2.22 7.70 3.10 7.70 3.10

550 7.29 2.64 8.47 3.67 8.47 3.67

600 7.96 3.09 9.24 4.28 9.24 4.28

650 8.62 3.57 10.0 4.93 10.0 4.93

700 9.28 4.09 10.8 5.62 10.8 5.62

750 9.95 4.63 11.6 6.35 11.6 6.35

800 10.6 5.21 12.3 7.12 12.3 7.12

850 11.3 5.81 13.1 7.93 13.1 7.93

900 11.9 6.45 13.9 8.78 13.9 8.78

950 12.6 7.11 14.6 9.66 14.6 9.66

1000 13.3 7.81 15.4 10.6 15.4 10.6

1050 13.9 8.53 16.2 11.5 16.2 11.5

1100 14.6 9.28 16.9 12.5 16.9 12.5

1200 15.9 10.9 18.5 14.6 18.5 14.6

1300 17.2 12.6 20.0 16.8 20.0 16.8

1400 18.6 14.4 21.6 19.2 21.6 19.2

1500 19.9 16.3 23.1 21.7 23.1 21.7

1600 21.2 18.3 24.6 24.3 24.6 24.3

1700 22.5 20.4 26.2 27.1 26.2 27.1

1800 23.9 22.7 27.7 30.0 27.7 30.0

1900 25.2 25.0 29.3 33.0 29.3 33.0

3.1 | FLOW



66


8"




6.94 inch ID


6.44 inch ID


6.44 inch ID

Flow(gal per min)







150 1.27 0.090 1.48 0.124 1.48 0.124

220 1.87 0.175 2.17 0.243 2.17 0.243

290 2.46 0.283 2.86 0.394 2.86 0.394

360 3.05 0.412 3.55 0.576 3.55 0.576

430 3.65 0.562 4.24 0.786 4.24 0.786

500 4.24 0.731 4.92 1.02 4.92 1.02

570 4.83 0.919 5.61 1.29 5.61 1.29

640 5.43 1.12 6.30 1.58 6.30 1.58

710 6.02 1.35 6.99 1.89 6.99 1.89

780 6.62 1.59 7.68 2.23 7.68 2.23

850 7.21 1.84 8.37 2.59 8.37 2.59

920 7.80 2.11 9.06 2.98 9.06 2.98

990 8.40 2.40 9.75 3.39 9.75 3.39

1060 8.99 2.71 10.4 3.82 10.4 3.82

1130 9.58 3.03 11.1 4.27 11.1 4.27

1200 10.2 3.36 11.8 4.74 11.8 4.74

1270 10.8 3.71 12.5 5.24 12.5 5.24

1340 11.4 4.07 13.2 5.76 13.2 5.76

1410 12.0 4.45 13.9 6.29 13.9 6.29

1480 12.6 4.84 14.6 6.85 14.6 6.85

1550 13.1 5.25 15.3 7.43 15.3 7.43

1620 13.7 5.67 16.0 8.03 16.0 8.03

1690 14.3 6.10 16.6 8.64 16.6 8.64

1840 15.6 7.07 18.1 10.0 18.1 10.0

1990 16.9 8.11 19.6 11.5 19.6 11.5

2140 18.1 9.20 21.1 13.1 21.1 13.1

2290 19.4 10.4 22.6 14.7 22.6 14.7

3.1

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67


10"




8.68 inch ID


8.06 inch ID


8.06 inch ID

Flow(gal per min)







300 1.63 0.100 1.89 0.148 1.89 0.148

400 2.17 0.169 2.52 0.244 2.52 0.244

500 2.71 0.255 3.14 0.360 3.14 0.360

600 3.25 0.357 3.77 0.494 3.77 0.494

700 3.80 0.474 4.40 0.646 4.40 0.646

800 4.34 0.607 5.03 0.815 5.03 0.815

950 5.15 0.832 5.97 1.10 5.97 1.10

1100 5.96 1.09 6.92 1.42 6.92 1.42

1250 6.78 1.38 7.86 1.77 7.86 1.77

1400 7.59 1.70 8.80 2.16 8.80 2.16

1550 8.40 2.05 9.75 2.57 9.75 2.57

1700 9.22 2.43 10.7 3.02 10.7 3.02

1850 10.0 2.84 11.6 3.50 11.6 3.50

2000 10.8 3.28 12.6 4.01 12.6 4.01

2150 11.7 3.75 13.5 4.55 13.5 4.55

2300 12.5 4.24 14.5 5.12 14.5 5.12

2450 13.3 4.77 15.4 5.71 15.4 5.71

2600 14.1 5.32 16.3 6.33 16.3 6.33

2750 14.9 5.90 17.3 6.98 17.3 6.98

2900 15.7 6.51 18.2 7.66 18.2 7.66

3050 16.5 7.14 19.2 8.36 19.2 8.36

3200 17.3 7.80 20.1 9.09 20.1 9.09

3350 18.2 8.49 21.1 9.84 21.1 9.84

3500 19.0 9.20 22.0 10.6 22.0 10.6

3650 19.8 9.94 23.0 11.4 23.0 11.4

3900 21.1 11.2 24.5 12.8 24.5 12.8

4150 22.5 12.6 26.1 14.3 26.1 14.3

3.1 | FLOW



68


12"



12 Inch Pipe 12 Inch Pipe 12 Inch Pipe

SDR 11, 12.40 inch OD, 10.15 inch ID

Flow(gal per min)







400 1.59 0.081

600 2.38 0.168

750 2.97 0.252

900 3.57 0.350

1050 4.16 0.462

1250 4.96 0.633

1450 5.75 0.827

1650 6.54 1.04

1850 7.34 1.28

2050 8.13 1.55

2250 8.92 1.83

2450 9.71 2.13

2650 10.51 2.46

2850 11.30 2.80

3050 12.09 3.17

3250 12.89 3.55

3450 13.68 3.96

3750 14.87 4.60

4050 16.06 5.28

4350 17.25 6.01

4650 18.44 6.78

4950 19.63 7.59

5250 20.82 8.44

5550 22.01 9.34

5850 23.19 10.3

6150 24.38 11.2

6550 25.97 12.6

3.1

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69

EQUIVALENT LENGTHS OF FITTINGS (ft.)

Socket TeeThrough

main

Tee Throughbranch

Tee Conjunction

of flow

Tee Counter currentflow separation

Tee Counter currentflow conjunction

ReducerBy 1 dimension

⅜"16 mm .04 ⅜"

16 mm .04 ⅜"16 mm 2.1 ⅜"

16 mm 1.4 ⅜"16 mm 3.1 ⅜"

16 mm 5.2 ⅜"16 mm

½"20 mm .05 ½"

20 mm .05 ½"20 mm 2.6 ½"

20 mm 1.7 ½"20 mm 3.9 ½"

20 mm 6.5 ½"20 mm 0.9

¾"25 mm .07 ¾"

25 mm .07 ¾"25 mm 3.3 ¾"

25 mm 2.2 ¾"25 mm 4.9 ¾"

25 mm 8.2 ¾"25 mm 1.1

1"32 mm .09 1"

32 mm .09 1"32 mm 4.2 1"

32 mm 2.8 1"32 mm 6.3 1"

32 mm 10.4 1"32 mm 1.4

1¼"40 mm 1.1 1¼"

40 mm 1.1 1¼"40 mm 5.2 1¼"

40 mm 3.5 1¼"40 mm 7.9 1¼"

40 mm 13.1 1¼"40 mm 1.7

1½"50 mm 1.4 1½"

50 mm 1.4 1½"50 mm 6.6 1½"

50 mm 4.4 1½"50 mm 9.9 1½"

50 mm 16.4 1½"50 mm 2.2

2"63 mm 1.7 2"

63 mm 1.7 2"63 mm 8.3 2"

63 mm 5.5 2"63 mm 12.4 2"

63 mm 20.7 2"63 mm 2.8

2½"75 mm 2.1 2½"

75 mm 2.1 2½"75 mm 9.8 2½"

75 mm 6.6 2½"75 mm 14.8 2½"

75 mm 24.6 2½"75 mm 3.3

3"90 mm 2.5 3"

90 mm 2.5 3"90 mm 11.8 3"

90 mm 7.9 3"90 mm 17.7 3"

90 mm 29.5 3"90 mm 3.9

3½"110 mm 3.0 3½"

110 mm 3.0 3½"110 mm 14.4 3½"

110 mm 9.6 3½"110 mm 21.7 3½"

110 mm 36.1 3½"110 mm 4.8

4"125 mm 4.2 4"

125 mm 4.2 4"125 mm 20.1 4"

125 mm 13.4 4"125 mm 30.2 4"

125 mm 50.3 4"125 mm 6.7

6"200 mm 5.4 6"

200 mm 25.8 6"200 mm 17.2 6"

200 mm 38.7 6"200 mm 64.4 6"

200 mm 8.6

8"200mm 6.7 8"

200mm 32.2 8"200mm 21.5 8"

200mm 48.3 8"200mm 80.5 8"

200mm 10.7

10"250 mm 8.4 10"

250 mm 40.3 10"250 mm 26.8 10"

250 mm 60.4 10"250 mm 100.7 10"

250 mm 13.4

12"315 mm 10.6 12"

315 mm 50.7 12"315 mm 33.8 12"

315 mm 76.1 12"315 mm 126.9 12"

315 mm 16.9

14"355 mm 11.9 14"

355 mm 57.2 14"355 mm 38.1 14"

355 mm 85.8 14"355 mm 143.0 14"

355 mm 19.1

3.1 | FLOW



70


ReducerBy 2

dimensions

ReducerBy 3

dimensions

ReducerBy 4

dimensions

ReducerBy 5

dimensions

ReducerBy 6

dimensions

Cross Separation of

flow

CrossConjunction of

flow

⅜"16 mm

⅜"16 mm

⅜"16 mm

⅜"16 mm

⅜"16 mm

⅜"16 mm 3.7 ⅜"

16 mm 6.4

½"20 mm

½"20 mm

½"20 mm

½"20 mm

½"20 mm

½"20 mm 4.5 ½"

20 mm 8.0

¾"25 mm 1.4 ¾"

25 mm¾"

25 mm¾"

25 mm¾"

25 mm¾"

25 mm 5.7 ¾"25 mm 10.1

1"32 mm 1.7 1"

32 mm 2.1 1"32 mm

1"32 mm

1"32 mm

1"32 mm 7.3 1"

32 mm 12.9

1¼"40 mm 2.2 1¼"

40 mm 2.6 1¼"40 mm 3.1 1¼"

40 mm1¼"

40 mm1¼"

40 mm 9.2 1¼"40 mm 16.1

1½"50 mm 2.7 1½"

50 mm 3.3 1½"50 mm 3.8 1½"

50 mm 4.4 1½"50 mm

2"63 mm 3.4 2"

63 mm 4.1 2"63 mm 4.8 2"

63 mm 5.5 2"63 mm 6.2

2½"75 mm 4.1 2½"

75 mm 4.9 2½"75 mm 5.7 2½"

75 mm 6.6 2½"75 mm 7.4

3"90 mm 4.9 3"

90 mm 5.9 3"90 mm 6.9 3"

90 mm 7.9 3"90 mm 8.9

3½"110 mm 6.0 3½"

110 mm 7.2 3½"110 mm 8.4 3½"

110 mm 9.6 3½"110 mm 10.8

4"125 mm 8.4 4"

125 mm 10.1 4"125 mm 11.7 4"

125 mm 13.4 4"125 mm 15.1

6" 160 mm 10.7 6"

200 mm 12.9 6" 160 mm 15.0 6"

160 mm 17.2 6" 160 mm 19.3

8" 200mm 13.4 8"

200mm 16.1 8" 200mm 18.8 8"

200mm 21.5 8" 200mm 24.2

10" 250 mm 16.8 10"

250 mm 20.1 10" 250 mm 23.5 10"

250 mm 26.8 10" 250 mm 30.2

12" 315 mm 21.1 12"

315 mm 25.4 12" 315 mm 29.6 12"

315 mm 33.8 12" 315 mm 38.1

14" 355 mm 23.8 14"

355 mm 28.6 14" 355 mm 33.4 14"

355 mm 33.4 14" 355 mm 42.9

3.1

| FL

OW

RAT

E, V

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CITY

, AND

HEA

D LO

SS (P

RESS

URE

DRO

P) D

ATA

71


Elbow 90° Elbow 90°Street

Elbow 45° Elbow 45°Street

Adapter Female thread

Adapter Male thread

ElbowFemale thread

⅜"16 mm 1.3 ⅜"

16 mm 1.3 ⅜"16 mm 0.7 ⅜"

16 mm 0.7 ⅜"16 mm 0.9 ⅜"

16 mm 1.2 ⅜"16 mm 1.5

½"20 mm 1.6 ½"

20 mm 1.6 ½"20 mm 0.9 ½"

20 mm 0.9 ½"20 mm 1.1 ½"

20 mm 1.5 ½"20 mm 1.9

¾"25 mm 2.0 ¾"

25 mm 2.0 ¾"25 mm 1.1 ¾"

25 mm 1.1 ¾"25 mm 1.4 ¾"

25 mm 1.9 ¾"25 mm 2.4

1"32 mm 2.6 1"

32 mm 2.6 1"32 mm 1.4 1"

32 mm 1.4 1"32 mm 1.7 1"

32 mm 2.4 1"32 mm 3.0

1¼"40 mm 3.3 1¼"

40 mm 3.3 1¼"40 mm 1.7 1¼"

40 mm 1.7 1¼"40 mm 2.2 1¼"

40 mm 3.1

1½"50 mm 4.1 1½"

50 mm 2.2 1½"50 mm 2.7 1½"

50 mm 3.8

2"63 mm 5.2 2"

63 mm 2.8 2"63 mm 3.4 2"

63 mm 4.8

2½"75 mm 6.2 2½"

75 mm 3.3 2½"75 mm 4.1 2½"

75 mm 5.7

3"90 mm 7.4 3"

90 mm 3.9 3"90 mm 6.9

3½"110 mm 9.0 3½"

110 mm 4.8 3½"110 mm 8.4

4"125 mm 12.6 4"

125 mm 6.7

6" 160 mm 17.2 6"

200 mm 8.6

8" 200mm 21.5 8"

200mm 10.7

10" 250 mm 26.9 10"

250 mm 13.4

12" 315 mm 33.8 12"

315 mm 16.9

14" 355 mm 38.1 14"

355 mm 19.1

3.1 | FLOW



72


ElbowMale thread

TeeFemale thread

TeeMale thread

SaddleReducer

Through main

Saddle Reducer

Through branch

Saddle Reducer

Combination of flow

⅜"16 mm 1.7 ⅜"

16 mm 2.8 ⅜"16 mm

⅜"16 mm 0.4 ⅜"

16 mm 0.9 ⅜"16 mm 1.7

½"20 mm 2.2 ½"

20 mm 3.5 ½"20 mm 3.9 ½"

20 mm 0.5 ½"20 mm 1.1 ½"

20 mm 2.2

¾"25 mm 2.7 ¾"

25 mm 4.4 ¾"25 mm 0.7 ¾"

25 mm 1.4 ¾"25 mm 2.7

1"32 mm 3.5 1"

32 mm 5.6 1"32 mm 0.9 1"

32 mm 1.7 1"32 mm 3.5

1¼"40 mm 1.1 1¼"

40 mm 2.2 1¼"40 mm 4.4

1½"50 mm 1.4 1½"

50 mm 2.7 1½"50 mm 5.5

2"63 mm 1.7 2"

63 mm 3.4 2"63 mm 6.9

2½"75 mm 2.1 2½"

75 mm 4.1 2½"75 mm 8.2

3"90 mm 2.5 3"

90 mm 4.9 3"90 mm 9.8

3½"110 mm 3.0 3½"

110 mm 6.0 3½"110 mm 12.0

4"125 mm 4.2 4"

125 mm 8.4 4"125 mm 16.8

6" 160 mm 5.4 6"

160 mm 10.7 6" 160 mm 21.5

8"200 mm 6.7 8"

200 mm 13.4 8"200 mm 26.8

10"250 mm 8.4 10"

250 mm 16.8 10"250 mm 33.6

12" 315 mm 10.6 12"

315 mm 21.1 12" 315 mm 42.3

14" 355 mm 11.9 14"

355 mm 23.8 14" 355 mm 47.7

3.1

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SS (P

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73

3.2 | SUPPORT SPACING FO

R POLYSTAR PIPES

Support Spans for Polystar CT-Red Pipe

PipeSize

ODInch

Spans Length in (inches) @ Temperatures (°F)

68 86 104 122 140 158 176

1/2 inch 0.79 39 33 33 33 30 27 24

3/4 inch 0.98 39 39 36 33 33 30 30

1 inch 1.26 45 45 42 39 39 36 33

1 1/4 inch 1.57 51 48 48 45 42 42 39

1 1/2 inc 1.97 57 57 54 51 51 48 45

2 inch 2.48 63 60 57 57 54 51 51

2 1/2 inch 2.95 69 69 66 63 63 60 57

3 inch 3.54 75 72 69 69 66 63 57

3 1/2 inch 4.33 78 75 75 69 69 66 63

4 inch 4.92 84 81 81 75 72 69 63

6 inch 6.30 84 81 81 75 72 69 66

8 inch 7.87 96 90 90 84 81 78 75

10 inch 9.84 108 102 99 96 90 87 81

12 inch 12.40 Consult Factory

Support Spans for Polystar CT-White Pipes

PipeSize

ODInch


68 86 104 122 140 158 176

1/2 inch 0.79 30 30 30 30 27 24 21

3/4 inch 0.98 36 33 33 30 30 27 24

1 inch 1.26 42 39 39 36 33 33 30

1 1/4 inch 1.57 45 45 42 39 39 36 33

1 1/2 inc 1.97 54 51 51 48 45 45 42

2 inch 2.48 57 57 54 51 51 48 48

2 1/2 inch 2.95 63 63 60 57 57 54 51

3 inch 3.54 69 66 63 63 60 57 51

3 1/2 inch 4.33 72 69 69 63 63 60 57

4 inch 4.92 81 75 75 69 66 63 57

6 inch 6.30 81 75 72 69 66 63 57

8 inch 7.87 90 84 81 75 75 69 66

10 inch 9.84 96 93 90 87 81 78 72

>10 inch Consult Factory

74

3.2

| SU

PPO

RT S

PACI

NG F

OR

POLY

STAR

PIP

ES Support Spans for Polystar CT-Blue Pipes

PipeSize

ODInch


68 86 104 122 140

1/2 inch 0.79 21 21 18 15 15

3/4 inch 0.98 30 27 24 21 21

1 inch 1.26 33 33 27 27 24

1 1/4 inch 1.57 39 36 33 33 27

1 1/2 inc 1.97 45 45 39 39 33

2 inch 2.48 51 51 45 42 39

2 1/2 inch 2.95 57 57 51 48 45

3 inch 3.54 63 60 57 57 51

3 1/2 inch 4.33 69 66 63 60 54

4 inch 4.92 75 72 69 63 60

6 inch 6.30 78 75 72 69 63

8 inch 7.87 96 93 87 84 81

>8 inch Consult Factory

EXAMPLES OF COMMERCIALLY AVAILABLE ALTERNATIVE SUPPORTS AND CLAMPS FOR POLYSTAR PIPES (Other than Polystar Pipe Brackets)

Adjustable Steel Clevis

Steel PipeClamp

Adjustable Steel Band Hanger

Steel Double BoltPipe Clamp

Offset J-Hook

Pipe StanchionSaddle

Vee BottomClevis Hanger

Pipe Saddle Support

Pipe AlignmentGuide Hanger

Adjustable RollerHanger

* Consult support span requirements of local building code for minimum requirements.

75

3.3 | ANCHORING PO

LYSTAR PIPESANCHORING POLYSTAR PIPES

76

THERMAL EXPANSION AND CONTRACTIONThermal expansion and contraction can be calculated using the equations below.α

CT-Blue = 1.00E-03 Coeffient of linear expansion, (in/ft-F)

αCT-White

= 2.33E-04 Coeffient of linear expansion, (in/ft-F)

αCT-Red

= 2.33E-04 Coeffient of linear expansion, (in/ft-F)

∆T = Temperature change, (F) L

Pipe Length = Length of pipe, (ft)

∆L = Change in length do to thermal expansion, (in.)

3.4

| THE

RMAL

EXP

ANSI

ON A

ND C

ONTR

ACTI

ON

EXPANSION OF CT-BLUE PIPE

EXPANSION OF CT-WHITE/CT-RED PIPE

∆𝐿𝐿 =∝ 𝐿𝐿𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 𝐿𝐿𝑅𝑅𝑛𝑛𝑔𝑔𝑅𝑅 ℎ∆𝑇𝑇

0.00

5.00

10.00

15.00

20.00

25.00

0 20 40 60 80 100 120

Line

ar Ex

pans

ion

∆L (i

nche

s)

Temperature Diff ∆T (F)

Expansion Of CT-Blue Pipe

200 ft

150 ft

100 ft

80 ft

60 ft

40 ft

20 ft

10 ft

77

3.5 | EXPANSION/CONTRACTION COMPENSATION GUIDELINES

PipeDiameter

inch

ODmm

Linear Expansion, ∆L, (inches)1 2 3 4 5 6 7 8 9 10 11 12

½ 20 13 19 23 27 30 33 35 38 40 42 44 46

¾ 25 15 21 26 30 33 36 39 42 45 47 49 52

1 32 17 24 29 34 38 41 45 48 51 53 56 58

1 ¼ 40 19 27 33 38 42 46 50 53 56 60 62 65

1 ½ 50 21 30 36 42 47 52 56 60 63 67 70 73

2 63 24 33 41 47 53 58 63 67 71 75 78 82

2 ½ 75 26 36 45 52 58 63 68 73 77 82 85 89

3 90 28 40 49 56 63 69 75 80 85 89 94 98

3 ½ 110 31 44 54 62 70 76 83 88 94 99 104 108

4 125 33 47 58 67 74 82 88 94 100 105 110 115

6 160 38 53 65 75 84 92 100 106 113 119 125 130

8 200 42 60 73 84 94 103 111 119 126 133 140 146

10 250 47 67 82 94 105 115 125 133 141 149 156 163

12 315 53 75 91 106 118 129 140 149 158 167 175 183

14 355 56 79 97 112 125 137 148 159 168 177 186 194

16 400 60 84 103 119 133 146 157 168 179 188 197 206

18 450 63 89 109 126 141 155 167 179 189 200 209 219

20 500 67 94 115 133 149 163 176 188 200 210 221 231

Ls, Length Of Bending Shank, (inches)

EXPANSION/CONTRACTION COMPENSATION GUIDELINESThermal deformation from linear expansion can be absorbed by changing the direction of the pipe through adding 90 degree elbows to absorb pipe expansion, or by installing expansion loops.

Absorbing Linear Expansion With 90° Elbows

C 2.9762842 Material constant

∆L = Linear Expansion, a function of pipe length and temperature change, (inches)

ODPipe

= Pipe OD, (mm)

LS = Required length of the bending shank, (ft)

Absorbing Linear Expansion With Expansion Loops

BS = Minimum Safety Distance, (inches)

∆L = Linear Expansion, a function of pipe length and temperature change, (inches)

Bmin = Width of bending shank, (inches) 8 Minimum Bmin (inches)

𝐵𝐵𝑒𝑒𝑅𝑅𝑛𝑛 = 2 ∙ ∆𝐿𝐿 + 𝐵𝐵𝑆𝑆

𝐿𝐿𝑆𝑆 = 𝐶𝐶 ∙ �𝑂𝑂𝐷𝐷𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 ∙ ∆𝐿𝐿

79

4.0 Thermodynamic Considerations4.1 Heat Gain/Loss vs. Temperature for Polystar Piping

4.2 Insulation Thickness vs. Heat Loss

4.3 Freeze Protection for Polystar Piping

SECT

ION

FOUR

POLYSTARTM

PolystarPipe.com

80

4.1

| H

EAT

GAIN

/LO

SS V

. TEM

PERA

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FO

R PO

LYST

AR P

IPIN

G HEAT GAIN/LOSS V. TEMPERATURE FOR POLYSTAR PIPINGBare Polystar pipe material is considered to have excellent insulation characteristics with its low thermal conductivity value. Competing metal pipe such as copper, steel, and stainless steel are all considered poor insulators. Actually the metal pipe material is considered a conductor 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 advantages which Polystar pipe provides. With a 50°F delta temperature difference across the pipe, the heat loss/gain of the metal pipe is huge compared to that which is lost or gained by Polystar pipe.

There are two terms used to describe the heat loss within a pipe, these are K-Factor and R-Value. The K-Factor is also known as thermal conductivity. The thermal conductivity of a material is based 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 difference 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 0.021 BTU/hr-ft-°F @ 75°F. The K-Factor of steel is 31 BTU/hr-ft-°F @ 75°F. The K-Factor of copper is 227 BTU/hr-ft-°F @ 75°F. These are all quite high when compared to Polystar pipe, which has K-Factor of 0.139 BTU/hr-ft-°F @ 68°F.

The National Commercial & Industrial Insulation Standards Manual defines R-Value as “A measure of the ability to retard 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 and K-Factor is shown in the first equation below. For cylindrical pipe geometry equivalent thickness, use the equation shown in the middle box belowto determine 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 would equal the heat flux at the outer surface of a cylindrical geometry. The relationship between R-Value and K-Factor for pipe insulation is in the equation shown on the bottom below. The Table on page 80 displays the R-Values for Polystar Pipe at 68°F.

R-Value Equations

r2 = Outer Radius, r

1 = Inner Radius

𝐸𝐸𝐿𝐿𝑅𝑅𝑅𝑅𝑣𝑣𝑅𝑅𝑙𝑙𝑅𝑅𝑛𝑛𝑅𝑅 𝑇𝑇ℎ𝑅𝑅𝑒𝑒𝐵𝐵𝑛𝑛𝑅𝑅𝑛𝑛𝑛𝑛 = 𝐵𝐵2𝑥𝑥 ln �

𝐵𝐵2

𝐵𝐵1�

𝑅𝑅 − 𝑉𝑉𝑅𝑅𝑙𝑙𝑅𝑅𝑅𝑅 =

𝑇𝑇ℎ𝑅𝑅𝑒𝑒𝐵𝐵𝑛𝑛𝑅𝑅𝑛𝑛𝑛𝑛 (𝑅𝑅𝑛𝑛𝑒𝑒ℎ𝑅𝑅𝑛𝑛)𝐵𝐵 − 𝑓𝑓𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙𝐵𝐵 (𝐵𝐵𝑇𝑇𝐵𝐵 𝑅𝑅𝑛𝑛𝑒𝑒ℎ/(ℎ𝐵𝐵 𝑓𝑓𝑅𝑅2 𝐹𝐹)

𝑅𝑅 − 𝑉𝑉𝑅𝑅𝑙𝑙𝑅𝑅𝑅𝑅 =

𝐸𝐸𝐿𝐿𝑅𝑅𝑅𝑅𝑣𝑣𝑅𝑅𝑙𝑙𝑅𝑅𝑛𝑛𝑅𝑅 𝑇𝑇ℎ𝑅𝑅𝑒𝑒𝐵𝐵𝑛𝑛𝑅𝑅𝑛𝑛𝑛𝑛 (𝑅𝑅𝑛𝑛𝑒𝑒ℎ𝑅𝑅𝑛𝑛)𝐵𝐵 − 𝑓𝑓𝑅𝑅𝑒𝑒𝑅𝑅𝑙𝑙𝐵𝐵 (𝐵𝐵𝑇𝑇𝐵𝐵 𝑅𝑅𝑛𝑛𝑒𝑒ℎ/(ℎ𝐵𝐵 𝑓𝑓𝑅𝑅2 𝐹𝐹)

A B

A. Less insulation than steel, in many applications, results in installed cost savings.

B. The same amount of insulation applied to Polystar as steel pipe results in energy savings.

81

4.1 | HEAT GAIN/LO

SS V. TEMPERATURE FO

R POLYSTAR PIPING

Heat Loss, (BTU/Hr-Ft), 50 ∆F Delta, Pipe With No Insulation

Heat Loss (BTU/Hr-Ft), 50 ∆F Delta, Pipe With No Insulation

82

R-Value (US)

Polystar SDR 7.4

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 14.4 18

R-Value ((hr ft2 F) /BTU)

0.08 0.10

Polystar SDR 9

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 15.4 19.4 24.8 31 38.4 48.8 58.2 69.8 85.4 97


0.06 0.07 0.10 0.12 0.16 0.19 0.22 0.27 0.33 0.37

Polystar SDR 11

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 26.2 32.6 40.8 51.4 61.8 73.6 90 102.2 130.8 163.6 204.6


0.08 0.10 0.12 0.15 0.17 0.21 0.26 0.30 0.38 0.48 0.59

Polystar SDR 17

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 141 176.2 220.4 257.8


0.24 0.30 0.37 0.75

4.1

| HE

AT G

AIN/

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V. T

EMPE

RATU

RE F

OR

POLY

STAR

PIP

ING

83

Below are three charts which display the heat gain/loss (BTU/hr-ft) through the pipe wall versus delta temperature (°F). These charts analyze the heat gain/loss through the

pipe. The outdoor heat transfer coefficient is assumed to be 2.0 BTU/hr-ft2-°F. The inside heat transfer coefficients is not included in the calculation.

CT-Red Heat Loss/Gain v. Temperature

CT-White Heat Loss/Gain v. Temperature

4.1 | HEAT GAIN/LOSS V. TEM

PERATURE FOR PO

LYSTAR PIPING

84

CT-Blue Heat Loss/Gain v. Temperature4.

1 |

HEAT

GAI

N/LO

SS V

. TEM

PERA

TURE

FO

R PO

LYST

AR P

IPIN

G

Polystar has excellent heat transfer characteristics that can reduce the insulation required to maintain a required fluid temperature or to prevent sweating in cold temperature applications. However, it is important to always verify the actual amount of insulation required based on the specific insulation being used. Contact the Orion technical department for assistance in determining the actual insulation required for any Polystar application.

85

INSULATION THICKNESS V. HEAT LOSSThere is a definite thermal efficiency advantage associated with using Polystar pipe to that of using of metal pipe. The charts below display this as they compare the heat loss and heat gain through the Polystar pipe, and compare the Polystar pipe’s heat loss and heat gain to those associated with the metal pipe.

See the six charts below. The pipe insulation thickness is indicated in the chart heading of each chart. Calculations are based on closed cell foam insulation with a thermal conductivity of 0.25 (BTU-in/hr-ft2-F). Three different insulation thicknesses were evaluated. These insulation thicknesses include ½”, 1”, and 1½”. A temperature difference of 50°F is used in the calculations. This temperature differential was chosen to represent a heat-loss condition with hot water at 120°F and a room temperature at 70°F, or heat-gain condition of 50°F water pipe, which is located outdoors in a 100°F ambient temperature condition. Radiation and inner pipe heat film resistance is not included in the calculation. Below is a calculation which be can be used to estimate heat losses for other conditions.

Thermal Conductivities k

Polystar Pipe = 0.1387048

Thermal conductivity of Polystar pipe, (BTU/hr-ft-F)

k copper

= 227

Thermal conductivity of copper pipe, (BTU/hr-ft-F)

k steel

= 31

Thermal conductivity of steel, (BTU/hr-ft-F)

k Ins

= 0.0208333

Thermal conductivity of closed cell foam insulation, (BTU/hr-ft-F), 1/4" up to 1" of insulation

k Ins

= 0.02375

Thermal conductivity of closed cell foam insulation, (BTU/hr-ft-F), 1 1/2" up to 2" of insulation

Temperature Delta∆T = 50

Temperature differential beteen 120 F water and 70 F room temperature, (F)

Temperature differential beteen 50 F water and 100 F ambient temperature, (F)

Heat Transfer Coefficienth

O = 1.6 BTU/hr-ft2-F

Air heat transfer coefficient = 2 (BTU/hr-ft2-°F) at Avg temp = 100°F, Pipe Wall Temp = 80°F, Windspeed = 5 mph

Air heat transfer coefficient = 4.51 (BTU/hr-ft2-°F) at Avg temp = 100°F, Pipe Wall Temp = 80°F, Windspeed = 20 mph

This heat transfer coefficient is dependent on the average temperature, pipe wall temperature, pipe outer diameter, and wind speed. It typically has a value ranging from 0.5 to 4 (BTU/hr-ft2-°F). It is calculated by using the Zukauskas Equation. First calculate the Nusselt number for the condition. The Nusselt number is then used to calculate the outdoor heat transfer coefficient.

Calculated/Determined Values R

Pipe =Thermal resistance of pipe wall,

(hr ft F/BTU)

RIns

= Thermal resistance of pipe insulation, (hr ft F/BTU)

RO = Thermal resistance of outer air, (hr F/BTU)

RTotal

= Total thermal resistance of pipe and pipe insulation, (hr ft F/BTU)

qPipe

= Heatloss through a non-insulated pipe/ pipe length, (BTU/hr-ft)

qTotal

= Total heatloss through an insulated pipe/ pipe length, (BTU/hr-ft)

𝑅𝑅𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅=

ln �𝐵𝐵𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 ,𝑙𝑙𝐵𝐵𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 , 𝑅𝑅

�

2𝜋𝜋𝐵𝐵𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅

𝑅𝑅𝐼𝐼𝑛𝑛𝑛𝑛=

ln �𝐵𝐵𝐼𝐼𝑛𝑛𝑛𝑛 ,𝑙𝑙𝐵𝐵𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 , 𝑙𝑙

�

2𝜋𝜋𝐵𝐵𝐼𝐼𝑛𝑛𝑛𝑛

𝑅𝑅𝑂𝑂 =

12𝜋𝜋𝐵𝐵𝑂𝑂ℎ𝑂𝑂𝐿𝐿

𝑅𝑅𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙 = 𝑅𝑅𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 + 𝑅𝑅𝐼𝐼𝑛𝑛𝑛𝑛 + 𝑅𝑅𝑂𝑂

𝐿𝐿𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅= ∆𝑇𝑇

𝑅𝑅𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅

𝐿𝐿𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙 = ∆𝑇𝑇

𝑅𝑅𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙

4.2 | INSULATION THICKNESS V. HEAT LO

SS

86

Heat Loss (BTU/Hr-Ft), 50 ∆F Delta,0.5 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F


4.2

| IN

SULA

TIO

N TH

ICKN

ESS

V. H

EAT

LOSS

87

Heat Gain (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,1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F


SS

88

Heat Gain (BTU/Hr-Ft), 50 ∆F Delta,1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F

Heat Loss (BTU/Hr-Ft), 50 ∆F Delta,1 Inch Of Insulation, K=0.25 BTU-In/Hr-Ft2-F

4.2

| IN

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N TH

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V. H

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LOSS

89




SS

90


4.2

| IN

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TIO

N TH

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ESS

V. H

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LOSS

91

FREEZE PROTECTION FOR POLYSTAR PIPINGAll non-heat traced pipe placed in freezing conditions will freeze in time no matter how much or what type of insulation is used. All piping which could be exposed to freezing conditions should be heat traced or buried below frost depth elevations.

The calculation below can be used to determine the amount of time for water in a stagnant pipe to freeze in freezing conditions. It should be noted that in order to avoid pipe damage, pipe should not be exposed to the freezing condition for longer than ∆t

Liquid, the time calculated to

lower the liquid in the pipe to 32°F. Water requires 144 BTU/lb of heat to be released to the environment before it turns to ice. This heat loss is called the latent heat of fusion. The calculated time for the release of the latent

heat of fusion is ∆tFusion

. The overall time for the water in the pipe to freeze completely, ∆t

Total, is estimated by adding

∆tLiquid

and ∆tFusion

.

Pipe damage occurs due to the excessive water pressure build up, caused by the expansion of ice crystals, therefore it is important to avoid allowing pipe to be exposed to freezing conditions past time ∆t

Liquid.

The tables shown on page 93 can be referenced to determine the amount of time a pipe can be exposed in freezing conditions. These tables are based on stagnant flow within the pipe, 0°F ambient temperature, an initial 68°F water temperature, no pipe insulation, a pipe thermal conductivity of 1.665 (BTU inch/(hr-°F-ft2), an outside air velocity of 5 mph, and the outer pipe heat transfer coefficient determined using the Zukauskas Equation.

Design Parameters For Water

ρw = 62.4 Density of water, (lb/ft3)

CpWater

= 1 Specific heat of water, (BTU/lb F)

hFS

= 144 Latent heat of fusion of water, (BTU/lb)

Temperatures

TInitial

= 68 Initial temperature of water in pipe (F)

TOutside Air

= 0 Ambient temperature, wall temperature (F)

TFreezing

= 32 Final temperature water in pipe (F) T

Average = 34 (F)

Pipe Dimensions

Thickness Ins = 0 Pipe insulation thickness, (inches)

L = 100 Length of pipe, (ft)

Thermal Conductivities

kPipe = 1.664728 ((BTU in)/(hr ft2 F))

kIns

= ((BTU in)/(hr ft2 F))

4.3 | FREEZE PROTECTIO

N FOR PO

LYSTAR PIPING

D1

D3

D2

LIQUID

PIPE WALL

INSULATIONN

92

Properties Of Outdoor Air (Based on TAverage) Cp

Air = 0.2399 Specific heat of air, (BTU/lb °F)

@ Avg Temp

μAir

= 0.0421 Dynamic viscosity of air, (lb/hr ft) @ Avg Temp

kAir

= 0.0141 Thermal conductivity of air, ((BTU)/(hr ft F)) @ Avg Temp

Properties Of Outdoor Air (Based on T Wall) Cp

Air = 0.2397 Specific heat of air, (BTU/lb F)

@ Wall Temp

μAir

= 0.0394 Dynamic viscosity of air, (lb/hr ft) @ Wall Temp

kAir

= 0.0132 Thermal conductivity of air, ((BTU)/(hr ft F)) @ Wall Temp

υAir

= 0.530 Kinematic viscosity of air, (ft2/hr) @ Avg Temp

Wind Speed = 5 mph

VAir

= 26,400 Air velocity based on wind speed, (ft/hr)

Calculated/Determined Values C = Parameters for Zukauskas Equation

Dout

= Outer diameter used in outdoor heat coefficient, (ft)

hO = Outdoor heat transfer coefficient,

((BTU)/(hr ft2 F)

Nu= Nullset Number

Re = Reynolds Number

Pr = Prandtl Number

RPipe

= Thermal resistance of pipe wall, (hr F/BTU)

RIns

= Thermal resistance of pipe insulation, (hr F/BTU)

RO = Thermal resistance of outer film, (h F/BTU)

RT = Combined thermal resistance of pipe wall,

insulation, and exterior air film (hr F/BTU)

M = Mass of liquid water in the pipe, (lb)

m = Parameters for Zukauskas Equation

n = Parameters for Zukauskas Equation

∆tLiquid

= time to lower the liquid in the pipe to 32 F, (hr)

∆tFusion

= time to the heat of fusion to be released from the water, (hr)

∆tTotal

= time to freeze water in the pipe, (hr)

VAir

= Air velocity based on wind speed, (ft/hr)

q = Heat loss to cool the liquid to a freezing temperature, (BTU/hr)

qPipe Loss

= Heat loss from the pipe under ambient conditions, (BTU/hr)

M = Mass of water in the pipe, (lb)

Calculating Outside Heat Transfer Coefficient

Zukauskas Equation

All fluid properties are dependent on the average temperature, except for P

rs.

Prs is evaluated at the cylinder wall.

𝑁𝑁𝑅𝑅 =

ℎ𝑂𝑂𝐷𝐷𝑂𝑂𝐵𝐵𝐴𝐴𝑅𝑅𝐵𝐵

= 𝐶𝐶(𝑅𝑅𝑅𝑅)𝑒𝑒𝑃𝑃𝐵𝐵𝑛𝑛 �𝑃𝑃𝐵𝐵𝑃𝑃𝐵𝐵𝑛𝑛

�.25

Re C m

1-40 0.75 0.4

40-1000 0.51 0.5

1,000-200,000 0.26 0.6

200,000-1,000,000 0.08 0.7

Pr n

Less than 10 0.36

Greater than 10 0.37

𝑃𝑃𝐵𝐵 =

𝐶𝐶𝑃𝑃𝜇𝜇𝐵𝐵𝐴𝐴𝑅𝑅𝐵𝐵

𝑅𝑅𝑅𝑅 =

𝑉𝑉𝐴𝐴𝑅𝑅𝐵𝐵𝐷𝐷𝑂𝑂𝑅𝑅𝑅𝑅𝑅𝑅𝐵𝐵𝜐𝜐𝐴𝐴𝑅𝑅𝐵𝐵

𝑁𝑁𝑅𝑅 =

ℎ𝑂𝑂𝐷𝐷𝑂𝑂𝐵𝐵𝐴𝐴𝑅𝑅𝐵𝐵

= 𝐶𝐶(𝑅𝑅𝑅𝑅)𝑒𝑒𝑃𝑃𝐵𝐵𝑛𝑛 �𝑃𝑃𝐵𝐵𝑃𝑃𝐵𝐵𝑛𝑛

�.25

Parameters for Zukauskas Equation

4.3

| F

REEZ

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R PO

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AR P

IPIN

G

93

Thermal Resistance From Pipe Insulation

Thermal Resistance From Outdoor Heat Transfer Coefficient

Combined Thermal Resistance

Heat Loss From The Pipe Under Ambient Conditions

Time To Cool A Liquid To Freezing Temperature

Time For The Heat Of Fusion To Be Release From The Water

Total Time To Freeze Pipe

𝑅𝑅𝐼𝐼𝑛𝑛𝑛𝑛=

ln �𝐵𝐵3𝐵𝐵2�

2𝜋𝜋𝐿𝐿𝐵𝐵𝐼𝐼𝑛𝑛𝑛𝑛x 12

𝑅𝑅𝑂𝑂 =

12𝜋𝜋𝐵𝐵𝑂𝑂ℎ𝑂𝑂𝐿𝐿

𝑅𝑅𝑇𝑇 = 𝑅𝑅𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 + 𝑅𝑅𝐼𝐼𝑛𝑛𝑛𝑛 + 𝑅𝑅𝑂𝑂

𝐿𝐿𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 𝐿𝐿𝑙𝑙𝑛𝑛𝑛𝑛 =

(𝑇𝑇𝐼𝐼𝑛𝑛𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑙𝑙 − 𝑇𝑇𝑂𝑂𝑅𝑅𝑅𝑅𝑛𝑛𝑅𝑅𝐻𝐻𝑅𝑅 𝐴𝐴𝑅𝑅𝐵𝐵 )𝑅𝑅𝑇𝑇

∆𝑅𝑅𝐿𝐿𝑅𝑅𝐿𝐿𝑅𝑅𝑅𝑅𝐻𝐻 =

𝑀𝑀𝐶𝐶𝑃𝑃�𝑇𝑇𝐼𝐼𝑛𝑛𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑙𝑙 − 𝑇𝑇𝐹𝐹𝐵𝐵𝑅𝑅𝑅𝑅𝐹𝐹𝑅𝑅𝑛𝑛𝑔𝑔 �𝐿𝐿𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 𝐿𝐿𝑙𝑙𝑛𝑛𝑛𝑛

∆𝑅𝑅𝐹𝐹𝑅𝑅𝑛𝑛𝑅𝑅𝑙𝑙𝑛𝑛 =

ℎ𝐹𝐹𝑆𝑆𝑀𝑀𝐿𝐿𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅 𝐿𝐿𝑙𝑙𝑛𝑛𝑛𝑛

∆𝑅𝑅𝑇𝑇𝑙𝑙𝑅𝑅𝑅𝑅𝑙𝑙 = ∆𝑅𝑅𝐿𝐿𝑅𝑅𝐿𝐿𝑅𝑅𝑅𝑅𝐻𝐻 + ∆𝑅𝑅𝐹𝐹𝑅𝑅𝑛𝑛𝑅𝑅𝑙𝑙𝑛𝑛

Thermal Resistance From Pipe Wall

𝑅𝑅𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅=

ln �𝐵𝐵2𝐵𝐵1�

2𝜋𝜋𝐿𝐿𝐵𝐵𝑃𝑃𝑅𝑅𝑃𝑃𝑅𝑅x 12


N FOR PO

LYSTAR PIPING

Positioning of Self Regulating Heating Cables for 1 Cable Positioning of Self Regulating Heating Cables for 2 Cables

Attachment of Tapes to Secure Self Regulating Heating Cables

Apply Tape AcrossHeating Cable

94

4.3

| F

REEZ

E PR

OTE

CTIO

N FO

R PO

LYST

AR P

IPIN

G TIME TO FREEZE CHARTSPolystar piping systems may be installed in applications and conditions where freezing may occur. Generally, when water freezes in Polystar piping, it will not cause problems for the piping materials. This is largely due to the ductile nature of the thermoplastic piping which allows it to be very forgiving and to stretch with volumetric expansion of water due to freezing occurs. However, regardless of whether pipe becomes damaged, freezing will result in a blockage in the system, which is a problem if water must be conveyed through the system during these freezing periods.

The accompanying tables provide data as to how long it takes for water which is stagnant to freeze in various Polystar pipes. While this data may allow the user to understand if freezing may occur in their specific application, we recommend that if there is any question as to the possibility of freezing that freeze protection methods be applied to the Polystar piping system. Freeze protection methods include the use of anti-freeze (glycerin or glycol; polypropylene is not affected by these freeze protection solvents) or the use of self-regulating heating cables. Another measure that can be used is to insure that there is always minimum constant flow even during a power outage, which will assist in the prevention against freezing.

Regardless of the method chosen, all products must be used in accordance with the freeze protection system manufacturer’s recommendations, the product listings, and in compliance with all applicable local codes. When using any type of external heat source applied to the piping, such self-regulating heating cables, the product must be suitable for use with plastic piping. The self-regulating heat cables used should have their set temperature at low levels to insure against overheating. Consult Orion’s technical department for specific recommendations for use of self-regulating heat tracing cables as the means for freeze protection when this method is to be used.

Installation by the Spiraling Method

Installation on Flanges

Installation on Elbows

Installation at Supports

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 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 14.4 18

∆tLiquid , (hr) 0.066 0.0944

∆tFusion , (hr) 0.2639 0.3777

∆tTotal , (hr) 0.3298 0.4721

TIME TO FREEZE SDR 9 PIPE

Polystar SDR 9

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 15.4 19.4 24.8 31 38.4 48.8 58.2 69.8 85.4 97

∆tLiquid , (hr) 0.0703 0.1007 0.149 0.2134 0.3059 0.4495 0.6015 0.8174 1.1497 1.4315

∆tFusion , (hr) 0.2814 0.4026 0.5959 0.8538 1.2234 1.7982 2.4059 3.2696 4.5989 5.7261

∆tTotal , (hr) 0.3517 0.5033 0.7449 1.0672 1.5293 2.2477 3.0074 4.087 5.7487 7.1576

TIME TO FREEZE SDR 11 PIPE

Polystar SDR 11

inch ½ ¾ 1 1¼ 1 ½ 2 2 ½ 3 3 ½ 4 6 8 10 12

OD, Pipe (mm) 20 25 32 40 50 63 75 90 110 125 160 200 250 315

ID, Pipe (mm) 26.2 32.6 40.8 51.4 61.8 73.6 90 102.2 130.8 163.6 204.6 257.8

∆tLiquid , (hr) 0.1542 0.2189 0.3129 0.4548 0.6047 0.8168 1.1408 1.4144 2.1504 3.1539 4.6457 6.973

∆tFusion , (hr) 0.6168 0.8757 1.2518 1.8191 2.419 3.2673 4.5631 5.6575 8.6018 12.616 18.583 27.892

∆tTotal , (hr) 0.771 1.0946 1.5647 2.2739 3.0237 4.0841 5.7039 7.0719 10.752 15.769 23.229 34.865

Freezing times indicated in tables 4.3.1, 4.3.2, and 4.3.3 are based on a stagnant flow condition with 0°F ambient temperature, an initial 68F water temperature within the pipe, no pipe insulation around the pipe, a pipe thermal conductivity of 1.665 (BTU inch/(hr-°F-ft2), an outside air velocity of 5 mph, and the outer pipe heat transfer coefficient based on the Zukauskas Equation.

Preventing Surface Condensation On Polystar Piping

Condensation forms on the exterior pipe wall once the pipe surface wall reaches the dew point temperature. For assistance in determining whether insulation is required to prevent condensation, contact the Orion Engineering Department for additional information.


N FOR PO

LYSTAR PIPING

97

POLYSTARTM

PolystarPipe.com

5.0 Installation Requirements and Procedures5.1 Transportation, Delivery & Storage

5.2 Socket Fusion Procedure Using Hand-Held Polywelders

5.3 Socket Fusion Procedure Using Model 7125 Bench Socket Fusion Tools

5.4 Butt Fusion Procedure using Manual Track Butt Fusion Tools

5.5 Electrofusion Procedure using Beat-TR Electrofusion Processors

5.6 Saddle Fusion Procedure using Hand-Held Polywelders

5.7 Repair Procedures Using Hand Held Polywelders

SECT

ION

FIVE

98

WRONG CORRECT

PREVENT IMPACTS(especially against pipe ends)

PREVENT EXCESSIVE LOADS

PREVENT WRONG LYING PIPES

TRANSPORTATION, DELIVERY & STORAGE5.

1 | T

RANS

PORT

ATIO

N, D

ELIV

ERY

& ST

ORA

GE

Transport and storage

Polystar pipes may be stored outside at any temperature if protected from UV light. It is preferable to store pipes inside whenever possible. The pipes are shipped with a black protective outer poly bag. However, sometimes the protective bags may become ripped or torn during shipping and therefore sections of the pipe may become exposed. When storing outside, the pipes should be inspected to insure that they are thoroughly covered and protected fom the effects of UV light. Maximum outdoor storage time is 30 days if removed from factory-supplied UV-protected bags or for portions of pipe that are exposed due to rips and tears in the bags.

Outdoor installation

UV radiation has an effect on polymeric plastic products. Protect pipes against weathering and UV radiation to prevent damage. In applications where the installed pipe will be exposed to UV-radiation (such as rooftop or other outdoor applications), it is recommended that standard Polystar Piping (e.g. CT-White or CT-Blue) be provided with UV protection. The piping can be protected by a

number of methods, including priming with Rust-Oleum® Plastic Primer Spray or by priming and painting painting using Rust-Oleum Plastic Primer and Specialty Plastic Spray. Alternatively, the piping can be protected by use of protective tapes or can be covered with insulation or insulation jacketing.

At temperatures below 32°F (0°C), the piping has less ductility and it is more susceptible to damage by impact (especially against pipe ends), excessive loads, crushing or bending. Handle pipes with care at low temperatures.

A solid, flat, and level base for the pipe must be provided avoid a deformation of the pipes while in transport and storage. If the pipes are not stored properly, or are stacked to excessive heights, it can lead to excessive ovalization or bowing of the pipes.

99

SOCKET FUSION PROCEDURE USING HAND-HELD POLYWELDERSPreparations

Cut pipes square into sections. Thoroughly clean both joint faces, the pipe end and fitting socket, with alcohol and lint-free cloth or absorbent paper. Mark bushing depth on the pipe. Bring the heating element of a suitable polywelder to 500°F (260°C). Check the temperature settings before starting the welding process. Temperature tolerance for the polywelder is ± 18°F (10°C). The temperature of the heating element of a suitable polywelder must be checked periodically by the installer a suitable measuring device.

Do not start heating the joint parts before the heating temperature reaches 500°F. The mandrel and bushing must be clean and have to be purified before each following welding process. Before using a suitable polywelder read the User Manual carefully.

OverviewPolystar piping and fittings in sizes 4 inch (125mm) and under are primarily joined by socket fusion welding. In the socket welding procedure, the pipes and fittings are connected using heat fusion by overlapping the parts lengthwise. The heating of the pipe ends and fitting sockets is made using a heating element of a suitable polywelder with fitted bushings. After the correct welding temperature has been reached, the joining can proceed. The pipe and fitting socket diameters, as well as the respective heating bushings, are matched to build up the necessary pressure during the joining process.

The heating element of a suitable polywelder is electrically heated.

Push the pipe and fitting quickly and axially up to the stop of the mandrel and the marked insertion depth respectively and keep them fast without twisting. The heating of the joint faces is done according to the table on the next page.

At the end of the heating period pull the pipe and the fitting from the heating element of the suitable polywelder and join them immediately axially aligned and without torsion. Mind the correct insertion depth (see table, Page 98). The pipe must be pushed in up to the marked insertion depth of the bush bottom. Fix the two joint parts again for the duration of the heating period.

Do not expose the welded joint to mechanical stress before the expiration of the cooling period (see table, ).

PP-RCT pipes and fittings are to be used only as part of the entire system. CT-Blue, CT-White and CT-Red are to be used only with steel gray PP-RCT fittings.

1. Measure and cut pipe with suitable pipe cutters to the correct length. Pipe must be cut with a 90°square cut.

5.2 | SOCKET FUSIO

N PROCEDURE USING HAND-HELD PO

LYWELDERS

WARNING!

Do not use Polystar products to convey potable water except for those listed to NSF-PW! Consult the factory for assistance to determine which Polystar Prod-ucts carry this rating.

CAUTION!

Do not expose the welded joint to mechanical stress before the cooling period is over!

100

SOCKET FUSION INSERTION DEPTH0

inchesd

mmBush Depth =

Insertion Depth

½” 20 0.51"

¾” 25 0.63"

1” 32 0.71”

1¼” 40 0.81"

1½” 50 0.93”

2” 63 1.08"

2½” 75 1.18”

3” 90 1.30"

3½” 110 1.46”

4” 125 1.57”

3. Push the pipe end and the fitting socket to the heating element of a suitable Polywelder in axial direction. Heat pipe and fitting socket simultaneously.

4. The pipe and the fitting are to be removed from the suitable polywelder.

5. Insert the pipe in the axial direction. During joining do not turn the pipe end around its axis in the socket.2. Mark the bush depth on the welding distance to the

end of the pipe.

5.2

| SO

CKET

FUS

ION

PRO

CEDU

RE U

SING

HAN

D-HE

LD P

OLY

WEL

DERS WARNING!

Before using a suitable polywelder read the Owner's manual carefully.

CAUTION!

Before using a suitable pipe cutter read the owner's manual carefully.

101

Figures a, b and c schematically show the 3 stages of the welding process:

a = Welding preparation

b = Heating Phase

c = Welded joint

Standard values for socket fusion welding at room temperature of around 68°F (20°C). If room temperature is below +41°F (5°C), the heating phase should be increased by up to 100%. Directly after the cooling time the fused joints can be immediately pressure tested.

Definitions for Table Above:

Heating Phase: Amount of time in which the mandrel and bushing is required to heat the pipe and socket.

Changeover: Amount of time in which the pipe has to be pushed into the socket following the heat soak.

Fixed Cooling Time: The time in which the pipe/fitting must remain in the bench top fusion machine before it can be removed.

Total Cooling Time: The time in which the joint needs to cool before pressure testing is allowed.

5.2 | SOCKET FUSIO

N PROCEDURE USING HAND-HELD PO

LYWELDERS

a

b

c

HEATING ELEMENT

MANDREL

COUPLING PP-RCT PIPE

BUSHING

SOCKET FUSION PARAMETERS1 2 3 4 5

PIPEOUTSIDE

DIAMETERIN MM

HEATINGPHASE

SEC.

CHANGE OVER

SEC.

16 (⅜")20 (½")25 (¾")

557

46

10

20

2

32 (1")40 (1¼")50 (1½")

81218

6 4

63 (2")75 (2½")

2430

8 6

90 (3")110 (3½")125 (4")

405060

10 8

TOTALCOOLING

MIN.

FIXEDCOOLING

TIMESEC.

30

405060

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SOCKET FUSION PROCEDURE USING MODEL 7125 BENCH SOCKET FUSION TOOLSWelding:

Switch on the suitable socket welding machine polywelder for bench and 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 welding should take place within 5 minutes after the welding temperature has been reached. Split apart the machine slides and close down the heating element. Slowly move the machine slides by turning the hand wheel. Align the heating element so that the pipe and the fitting fit properly into the welding tools. Move the slides with steady forward motion up to the point until the stop has been reached. The heating timer of the joint surfaces starts only after the stop has been reached. After completion of the heating time the slides will be split and the heating unit must be brought into a rest position as fast as possible

Move the machine slides with the hand wheel with a steady forward motion up to the stroke end so that the precise jointing depth between the pipe and the fitting is reached. The welding jointing may be removed from the clamping jaws only after cooling down. Unscrew the clamping jaw with the handle lock and take off the welded unit.

Set the heating element in the holder. Mount the suitable welding tools (bushings and mandrels) and install the clamping jaws. Plug in the heating iron and verify iron temperature before welding. Allow heating iron, mandrel and bushing to cool before changing to a new size.

1. Pipes are measured and cut with suitable pipe cutters to the required length. Cutting should be perpendicular to the pipe axis (90°).

2. Place and adust the fitting in the clamping jaw and adjust the stop to hold the fitting.

3. Lay the pipe axially to the fitting and position it so that it is situated frontally to the fitting.

5.3

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Before using a suitable polywelder benchtop socket welding machine read the Owner's manual carefully.

103

7. After the warming time bond the pipe and the fitting.

5. Move the machine slides with the handle lock, warm up the pipe and the fitting in the welding tools.

6. Move the machine slides with the handle lock and remove the heating element.

8. Move the machine slides up to the stroke end.

4. Move the machine slides with the handle lock to set the heating element into the center between pipe and fitting.

5.3 | SOCKET FUSIO

N PROCEDURE USING M

ODEL 7125 BENCH SO

CKET FUSION TO

OLS

CAUTION!

Watch your fingers and hands!

Safety gloves required!

Eye protection required!

Machine is HOT!

104

BUTT FUSION PROCEDURE USING MANUAL TRACK BUTT FUSION TOOLS Welding Procedure

During butt welding with heating elements the areas to be joined are fitted with pressure at the location of the heating element (adjusting with merging pressure) until the specified bead height is reached. Continue heating up to the welding temperature with reduced pressure (14.5 ± 1.5 psi) then, after removing the heating element, join the pieces with merging pressure (Adaption).

2. Cut the pipes with a suitable pipe saw to the required length.

3. The spigots of the fittings and the pipe ends have to be planed by a suitable electrical planing tool. Ensure that the spigots of the fittings and the pipe ends are always planed before every welding.

4. During butt welding with heating elements the areas to be joined are heated up to the welding temperature by means of the heating element and compressed after the heating element has been removed. Heating temperature 410°F (210°C) ± 18°F (10°C).

5. After a double bead has been formed, the welding is uniform which indicates a successful weld.

1. Before using a suitable butt welding machine read its Owner's manual thoroughly.

5.4

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CAUTION!




Machine is HOT!

Consult Orion for proper pressure gauge settings and time requirements for the six phases of the Butt Fusion process. These parameters vary from one machine manufacturer to another. Some original equipment manufacturers' data may be inaccurate, consult with Orion.

NOTICE

105

ELECTROFUSION PROCEDURE USING BEAT-TR ELECTROFUSION PROCESSORSPreparing The Welding Surfaces

Cut the PP-RCT pipe ends rectangularly to the pipe axis with a suitable pipe cutter. Remove any chips on the outer surface oxide layer with a suitable scraper and purify with a non-fuzzing (lint-free), absorbent cloth and cleaning agent. The preferred cleaning agent is 99% Isopropyl Alcohol.

1. Cut the pipe perpendicularly with a suitable pipe cutter.

2. Remove the outside oxide layer using a suitable scraper.

3. For dimensions bigger than 3" (O.D.) we recommend using a peeling tool similar to the one shown above for removing the outside oxide layer.

4. Clean the joint surfaces with a purifying agent (e.g. 99% isopropyl alcohol).

5.5 | ELECTROFUSIO

N PRO

CEDURE USIN

G BEAT-TR ELECTRO

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WARNING!

Before using a suitable pipe cutter read the Owner's manual carefully.

WARNING!

Before using a suitable scraper or peeling tool read the Owner's manual carefully.

106

Mounting Of The Electrofusion Welding Sockets

Mark the socket depth on the pipe. After having finished all preparatory work, take the electrofusion socket out of its packaging; do not touch the inner surfaces of the socket. Then push the socket slowly onto the pipe to the marked position.

Connecting The Fusion Processor Leads

Position the electrofusion couplings in a way offering the easiest connection of the cord plugs to the contact bushes. Having checked that the required generator voltage is available, switch on the Beat-TR device and connect the cord plugs on to the contact bushings. Set the diameter of the pipes to be connected by using the bar code reader and scanning the bar code on the coupling (or by manually entering the correct information using the manual mode). Then start the welding process by pressing the enter button on the machine. The Beat-TR electrofusion processor automatically controls the required welding time controls the voltage necessary for the fusion, and displays a weld number when completed.

6 Push in the electrofusion couplings up to the marked position on the pipe.

7 . Align the pipes and the electrofusion socket by using a suitable aligning tool.

5. Mark up the bushing depth.

8. Plug in the cable pins in the contact bushings of a suitable electrofusion processor.

5.5

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WARNING!Before using a suitable aligning tool read the owner's manual carefully.

CAUTION!




107

Cooling Time

Observe the required cooling time if a cooling time is indicated on the bar code. All dimensions of electrofusion couplings contain a bar code showing welding time, working voltage and in some instances a cooling time

Repair Work With The Electrofusion Couplings

Remove the defective 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 and prepare the ends of the old pipe and new pipe piece as described before. Unpack two electrofusion couplings and push them completely over the two ends of the new pipe piece. Now fit in the new pipe piece and move the sockets to the marks on the old pipe.

9. The welding data can be seen on the barcode label of the socket. The data can be read by a barcode reader which should be part of a suitable electrofusion machine.

10. Start the welding device from the switch.

5.5 | ELECTROFUSIO

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WARNING!Before using a suitable electrofu-sion machine read the Owner's manual carefully.

108

SADDLE FUSION PROCEDURE USING HAND-HELD POLYWELDERS Additional Extension Of Existing Pipe Systems:

Direct connection of existing consumer pipe to a utility line. Alternative to T-pieces.

Welding Preparations:

Heat up the heating unit to 500°F (260°C). Check the preset temperature prior to the welding process. Temperature Tolerance ± 18°F (10°C). The welding elements must be clean and should be cleaned prior to every welding process.

After a cooling time of about 10 minutes the fused joint can be operated under pressure.

The appropriate branch connections will be assembled through socket fusion welding or by using female or male adapters with the welding saddle.

1. Drilling through the pipe wall. This task shall be carried out with an electric drill technically suitable for this task, thereby utilizing a suitable borer.

2. Push in the heat nozzle of a suitable welding saddle tool in the drill as well as the connecting piece of the welding saddle in the heating socket of a suitable polywelder. The heating time for all dimensions is about 30 seconds. After a cooling time of about 10 minutes the fused joint can be operated under pressure. The appropriate branch connections will be assembled through socket fusion welding or by using female or male adapters with the welding saddle.

3. Push the connecting piece of the welding saddle quickly into the heated bore hole. Push the fitting for about 15 seconds onto the pipe.

5.6

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WARNING!Before using a suitable polywelder read the owner's manual carefully.

WARNING!Before using an electric drill technically suitable for this task read the manual of the respective electric drill carefully.

WARNING!Before using a suitable welding saddle tool for polywelder read the owner's manual carefully.

109

REPAIR PROCEDURES USING HAND-HELD POLYWELDERS Application Area:

Repairing pipes damaged by drills.

Preparations:

Empty and uncover the damaged pipe. Select a suitable polywelder and a suitable welding tool, clean it before every welding process. Install the welding tools according to the instructions in the manual of the resp. welding tools. Pre-heat the heating unit to 500°F (260°C) ± 18°F (10°C).. Check the temperature before the welding process.

Selection of welding elements:

Suitable repairing-set: d=7 mm (0.28")For Welding of holes up to 0.24"

Suitable repairing-set: d=11 mm (0.43")For Welding of holes up to 0.39"

Mark the degree of the insertion depth (wall thickness) on the repairing plug. Fix distance tool according to the wall thickness of the pipe and tighten the screw.

Prevent damage to the pipe ends.

At temperatures lower than 32° F, pipes are less flexible and more prone to breakage. Prevent impacts (especially against pipe ends), excessive loads, crushing or bending. Handle pipes with care at low temperatures.

UV radiation can have an impact on polymeric plastic products. Protect pipes against weathering and UV radiation to prevent damages. Use plastic bags or cardboard boxes, that are included in the delivery.

1. Pre-heat the borehole and the welding plugs with the repairing-set for 15 seconds.

2. Remove the welding device and insert the repairing plug precisely without twisting it.

3. After a cooling time of approx. 5 minutes, remove the protruding end of the repairing plug.

5.6 | SADD

LE FUSION

PROCED

URE USING

HAND

-HELD PO

LYWELD

ERSWARNING!

Before using a suitable weld-ing tool for polywelder read the Owner's manual carefully.

WARNING!Before using a suitable polywelder or a suitable repairing-set for a polywelder read the Owner's manual carefully.

110

5.6

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ERS WELDING SADDLES W/ SOCKET WELDING OUTLETS*

(D) Nominal Saddle Range (Based On OD Of Pipe Main)**

(d) Nominal Socket Welding Outlet Size & Required Drill Bit Size**

Pipe Main11/4" - 2"(40 mm - 63 mm)

Pipe Main21/2" - 4"(75 mm - 125 mm)

Pipe Main31/2" - 4"(110 mm - 125 mm)

Pipe Main4"

(63 mm)

Pipe Main6" - 10"

(160 mm - 250 mm)

Pipe Main12" - 24"(315 mm - 630 mm)

½" (20 mm)*** X X X X

¾" (25 mm) X X X X

11/4" (40 mm) X X X

1½" (50 mm) X X X

2" (60 mm) X X X

* To perform a saddle fusion, the proper saddle, drill bit, and saddle fusion bushing must be used. For example, to install a saddle with ½" socket outlet connection into a 4" pipe. Drill a hole using a ¾" Polystar drill bit (part number 289038). Then use the bushing stamped with (B-R 2½"- 4") x ½" (part number 289032) to heat soak the saddle area of the pipe and the saddle itself (part number 282628).

dd

D


(d) Nominal Socket Welding Outlet Size of the Branch

Pipe Main11/4" - 2"(40 mm - 63 mm)

Pipe Main21/2" - 4"(75 mm - 125 mm)

Pipe Main31/2" - 4"(110 mm - 125 mm)

Pipe Main4"

(63 mm)

Pipe Main6" - 10"

(160 mm - 250 mm)

Pipe Main12" - 24"(315 mm - 630 mm)

½" (20 mm)*** 282605 282628 282644 282614

¾" (25 mm) 282606 282629 282464 282616

11/4" (40 mm) 282680 282643 282613

1½" (50 mm) 282676 282642 282612

2" (60 mm) 282679 282645 282658

WELDING SADDLES W/ SOCKET

WELDING OUTLET PART NUMBERS

** Welding saddles are available in the marked nominal saddle ranges / nominal socket welding outlet sizes.

***For saddles with the ½" socket outlet use a ¾" Polystar drill bit, otherwise match the drill bit with the socket outlet size.

111

5.6 | SADD

LE FUSION

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ERS



Pipe Main11/4" - 2"(40 mm - 63 mm)

Pipe Main21/2" - 4"(75 mm - 125 mm)

Pipe Main31/2" - 4"(110 mm - 125 mm)

Pipe Main4"

(63 mm)

Pipe Main6" - 10"

(160 mm - 250 mm)

Pipe Main12" - 24"(315 mm - 630 mm)

½" (20 mm)*** 289029

289032 289036 282658

¾" (25 mm)

11/4" (40 mm) 282667 289056 282669

1½" (50 mm) 289054 289060 282672

2" (60 mm) 289062 289063 282675



Pipe Main11/4" - 2"(40 mm - 63 mm)

Pipe Main21/2" - 4"(75 mm - 125 mm)

Pipe Main31/2" - 4"(110 mm - 125 mm)

Pipe Main4"

(63 mm)

Pipe Main6" - 10"

(160 mm - 250 mm)

Pipe Main12" - 24"(315 mm - 630 mm)

½" (20 mm)*** 289038 289038

¾" (25 mm)

11/4" (40 mm) 289072 289072

1½" (50 mm) 289073 289073

2" (60 mm) 289074

***For saddles with the ½" socket outlet use a ¾" Polystar drill bit, otherwise match the drill bit with the socket outlet size.

SADDLES BUSHING PART

NUMBERS

DRILL BIT PART NUMBERS

113

POLYSTARTM

PolystarPipe.com

6.0 Additional Considerations6.1 Testing Recommendations

6.2 Flushing and Grounding Recommendations

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RECOMMENDATIONSA pressure test should be performed following the complete installation of the piping system. This test should be performed in accordance within these recommendations and within requirements of the local building, and/or local plumbing codes. Water, air, or a mix of the two may be used to perform the pressure test. Pressure testing should be performed while the system is fully accessible to allow the contractor to access leaking joints. Polystar piping may be pressure tested as soon as the last joint made in the piping system has had the chance to cool to room temperature. We recommend that a preliminary low pressure air test, a static test and a cyclic test be performed during testing. The pressure gauge used to conduct the pressure tests should be calibrated to ±0.5 psi.

Hydrostatic Test

If a hydrostatic pressure test is to be performed as the static and cyclic tests, the system should be tested to 1.5 times the design pressure of the system, or 150 psi, whichever is higher. Testing to a pressure of less than 150 psi may not reveal all improperly welded joints. Further, for hot water pipes, testing to 1.5 times design pressure may not adequately be representative of the concurrent effects of pressure and temperature. For these reasons a minimum test pressure of 150 psi should be used, however the maximum test pressure should be limited so as not to exceed the ultimate rating of any element in the piping system. If any elements installed in the piping system have a rated pressure lower than 150 psi (e.g. valves made by Orion or by others, gauges, other appurtenances by others, etc.) we recommend that these elements be isolated from the rest of the system, so that all Polystar elements can be tested to a minimum of 150 psi.

Pneumatic Test

As an alternative to a hydrostatic test, the installing contractor may elect to conduct a pneumatic test using compressed air or inert gas. The installing contractor may elect to do a pneumatic air test, but in doing so will be doing this test at their own risk. Contractors should recognize that a compressed air test presents some inherent dangers. In such, cases, the contractor should take all necessary and reasonable precautions to limit the risk that is inherent in testing any piping material with compressed air. PP-RCT

materials are ductile at normal temperatures and will not fail in the compressed air system in the same manner as non-ductile thermoplastics such as PVC as CPVC (i.e. by shattering into sharp fragments). Nonetheless, testing with compressed air presents dangers due to the sudden and violent release of stored energy. This type of failure can occur from a failed weld or an over-pressurization of a piping component. When energy is released from the piping system in this manner under-supported and non-restrained pipe sections can whip out of position and bend pipe hanger supports or damage other equipment, piping components can be launched through the air, and excessive noise can be generated. These are the risks which the contractor must use caution against when testing any compressed air system for the first time, no matter what type of piping material is used.

While we prefer a hydrostatic test or a combined hydrostatic-pneumatic test be performed as to the pneumatic test, we also recommend Polystar pipe for a compressed air system. It is completely compatible with air within a compressed air system. Oil filled air compressors will mist oil into the piping system. This oil breaks down the chemical joint and cause stress fractures in the PVC/CPVC material. Polystar is uninfluenced by the presence of this oily mist, making it a safe piping material for compressed air systems.

For an alternative pneumatic test, the system should be tested to 1.1 times the design pressure of the system, or 150 psi, whichever is higher. If the installing contractor elects to conduct the pneumatic test at their own risk, the contractor should take certain precautions, including but not limited to: (a) providing redundant pressure regulators at the source of the air, testing and calibrating pressure regulators to insure that they are in safe working condition and set to the maximum test pressure (two or more regulators should be used 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 completed and that the piping system is thoroughly and adequately supported and anchored in accordance with the recommendations of this manual and the authority having local jurisdiction, (c) removing all persons from the areas of the piping to be tested that are not required to be present in order to conduct or witness the tests, and (d) providing all appropriate safety equipment and clothing/gear to protect workers who are associated with the test,

115

6.1 | TESTING

RECOM

MEN

DATIO

NS

(e) prior to conducting the high pressure test, completion of a low pressure test, i.e. first testing to ≤ 5 psi (0.3 bar); see below for description of a low air pressure air test, (f) the low air pressure test should be conducted 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, and (g) upon completion of the pressure test, the pressure should be immediately released in a controlled and safe manner. The foregoing recommendations are provided strictly for guidance. The decision to test with air, and the obligation to insure that such a test if performed is done in a safe manner, is strictly the responsibility of the contractor and Orion does not assume or accept any liability with respect to the performance of air testing by the contractor. In extremely cold temperatures (e.g. when the temperature is below 20°F) testing with air should be avoided entirely as the ductility of the materials will be substantially lessened, thereby increasing the chance of brittle failure.

Combined Hydrostatic-Pneumatic Test

A combined hydrostatic-pneumatic test can be conducted, whereby the piping system is filled completely and thoroughly with water, and compressed air is used as the means to pressurize the water. Thus an air compressor is used in lieu of a pump. This is considered to be the same as a hydrostatic test, and as such, the pressure requirements would be the same as those described on page 110 in the hydrostatic test procedure. However, when conducting this type of test, care should be taken to insure that all of the compressed air equipment which is used to generate the pneumatic pressure (e.g. generators, air compressor, tanks, valves, hoses, etc.) is handled in a safe manner, with all the necessary safety precautions taken.

Preliminary Low Pressure Air Test

Prior to conducting the static pressure test, a preliminary low pressure air test (≤ 5 psi // 0.3 bar) is recommended regardless of whether a hydrostatic pressure test, pneumatic pressure test, or a combined hydrostatic-pneumatic pressure test is performed. This test will help to prevent against unnecessary loss of water in the event there are joints in system which are not fully fused/tightened, and it is a test which is required by the pneumatic test procedure as a safety precaution. When conducting the test, the contractor should take all reasonable precautions. In particular, the contractor

should be sure to provide redundant pressure regulators at the source, verify that the regulators have been tested and calibrated, and insure they have been set to the maximum test pressure of ≤ 5 psi // 0.3 bar (two or more regulators should be used in case of the failure of the primary regulator). Once the system is filled and pressurized to a maximum pressure of ≤ 5 psi // 0.3 bar, all joints should be soaped and visually inspected for leaks. PP-RCT materials are not susceptible to stress cracking from ordinary dishwashing soaps as is the case with CPVC, and in some cases PVC, and as such the use of dishwashing soaps as a means to identify small leaks by the appearance of bubbles is a useful visual inspection means.

Once a preliminary low air pressure leak test has been completed, the contractor may commence with the static pressure test. If a hydrostatic test or combined hydrostatic-pneumatic test is to be conducted, care must be taken to insure that all entrained air is released from all localized high points in the system. The system should be designed so as to allow air to be released from any and all high points in the system. Air that is entrapped will become pressurized and will present dangers in the local area where it is entrained. The sudden opening or closing of a valve or the starting of a pump during the test can lead to a shock wave, which can instantaneously over-pressurize a pocket of trapped air and cause a pipe to burst. As such, care must be taken to insure that all entrained/entrapped air must be released from the system at all localized high points before a hydrostatic test or a combine hydrostatic-pneumatic test is conducted.

Primary Static Leak Test

When performing the primary static leak test, the material properties of Polystar PP-RCT will cause the pipe to expand. Pipe expansion is caused by the molecules stretching under the strain from the internal pressure within the pipe (this is true regardless of whether or not there is a temperature change). Pipe expansion will lead to a reduction in the internal pressure reading 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 lead to linear expansion and in turn a drop in test pressure. A temperature change of 20°F corresponds to a pressure difference of 7.5 to 15

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NS psi (≈ 0.5 to 1 bar) pressure. If possible, allow for the

temperature between the pipes and the test medium to reach equilibrium before reading the pressure gauge.

If necessary, the tester may re-pressurize the system until the system pressure stabilizes at the established test pressure, which is 1.5 times the design pressure or 150 psi (which-ever is greater) in the case where the hydrostatic test or combined pneumatic-hydrostatic test is performed, or 1.1 times the design pressure or 150 psi (which-ever is greater) in the case where the pneumatic test is performed. No matter which test is chosen do not to exceed the lowest pressure rated element in the piping system. Once the system is stable, the test should then be carried out for 60 minutes. The system must not lose more than 7.5 psi (0.5 bar) pressure in that time, this would indicate the system has a leak. If any leakage appears, stop the test and repair the leaks before proceeding.

Cyclic Test

Following a successful completion of the static test, a cyclic test should also be conducted. 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 does not lose more than 3 psi (0.2 bar) pressure in that time. The cyclic test can then be conducted by first bringing the pressure down to 0 psi (0 bar). Then, re-pressurize the system to the established test pressure (which-ever is greater 1.5 times the design pressure or 150 psi for hydrostatic testing or combined hydrostatic-pneumatic testing, or which- ever is greater, 1.1 times the design pressure or 150 psi, for pneumatic testing). No matter which test is chosen do not to exceed the lowest pressure rated element in the piping system. After holding the elevated pressure for 2 minutes with no pressure deviation, bring the system pressure down to 10% of the full test pressure. After holding this pressure with no pressure deviation for 2 more minutes, bring the system back to 0 and repeat this process 3 more times, with a final interval of 5 minutes. This cycling of pressure will ensure that all the fused connections are properly installed.

A record of the pressure test must be prepared and signed by the owner’s representative and installing contractor stating place, contractor information, and date. A system can be tested in phases provided that

every heat-fused connection is eventually tested and that the tests are properly documented upon completion. A test record template may be obtained by contacting Orion customer service.

The testing recommended here by Orion does not supersede or replace regulations or requirements of the local code authority having jurisdiction as well as all national and local regulations (e.g. OSHA requirements). A copy of the completed and signed test record should be sent by mail or fax to Orion at the contact information provided on the back cover of this document. An electronic version of the test record may alternatively be e-mailed to the company to: [email protected]

WARNING!Testing with compressed air pres-ents inherent dangers due to the stored energy which if suddenly released can lead to serious injury. Although PP-RCT materials are ductile materials at temperatures above 20°F (-7°C), and do not present the same danger of brittle failure as amorphous materials such as PVC and CPVC, serious injury can result from parts that can become airborne if dislodged and due to whipping and move-ment of materials that are not tied down properly. The decision to test Polystar materials with compressed air may be done so at the sole decision of the installing contractor. Orion does not accept any liability for the decision to test by air by the installing contractor.

CAUTION!

When testing Polystar products, it is important to make sure that all proper safety equipment, calibrated measuring instruments, clothing, and gear should be provided in order to assist in protecting per-sonnel involved in testing.

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6.2 | FLUSHING

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FLUSHING REQUIREMENTAll water systems, regardless of the material of construction, should be flushed thoroughly after their installation. Piping must be flushed clean of dirt, debris and impurities in order to insure the cleanliness of the inner surface of the pipe which will in turn help to provide protection of the water quality. It also must be done in order to avoid corrosion damage to downstream metallic piping components and equipment, to avoid malfunctions of pumps, heaters and other equipment.

These requirements can be met by flushing the system with water, or by flushing the system with a mixture of air and water. The flushing method and the flushing medium to be used may be determined by local codes, engineering specifications, or by the mechanical equipment used. In lieu of other requirements, potable water would be the typical medium used for flushing Polystar piping systems.

GROUNDINGThe majority of building codes in North America require that grounding be provided for conductive components inside the structure. It is important to note that Polystar pipes do not act as a conductor, but rather are dielectric and as such Polystar cannot be used to provide grounding. Therefore, if grounding is required, an alternative ground system or grounding method must be installed. In these situations, please contact the Orion factory for our specific recommendations for grounding based on the requirements of the specific application. While we will provide recommendations for providing grounding, the grounding system should be approved and inspected by a qualified electrician.

118

GLOSSARY

Bench Top Socket Fusion Tool

A mechanical device designed to act as a clamping system, as well as assist an installer with moving the pipe and fitting during the fusion process. It is also designed to assist with the control of the concentricity of the socket fusion weld, and to provide depth of insertion control. It is designed to enable a heating iron to be mounted and controlled so as to allow the concentricity and depth of insertion to be controlled.

Butt Fusion

Also referred to as heat element butt heat fusion, it references a connection where the face of one pipe (or the face/end of plain end fittings) is heat fused directly to the face of another pipe. This process is available for use on sizes above 4 inches for all Polystar piping systems.

Extrusion

The process by which Polystar PP-RCT pipes are manufactured. The PP-RCT material is supplied from a hopper, melted and then forced by means of a screw through a die-head and sizing sleeve in a single layer (CT-Blue™), two layers (CT-Lavender™) or three layers (CT-Red™, CT-White™) and cooled in long tanks, forming the Polystar pipes.

Fibercore Technology

A proprietary technology exclusive to Polystar systems whereby a PP-RCT and fiberglass matrix/blend is co-extruded as a middle layer in a triple extrusion process. The Fibercore technology results in a middle layer in which the inside and outside diameter of the ring is very uniformly controlled, thereby assuring consistent physical properties at any point along the length of the extrduded pipe. The Fibercore middle layer is not secured to the adjoining layers by adhesive, but rather the material bonds directly to the adjoining PP-RCT layers, and thus forming a homogeneous bond.

Fusion Outlet (Reducing Saddle Fitting)

A special fitting designed to fuse directly onto the side of a pipe to form a reducing branch into the side of a larger pipe, without having to purchase and install a molded tee. Since the outlets are joined by heat fusion, the resulting construction is a fully pressure rated connection.

Heat Fusion

Also referred to as heat welding or heat bonding, it describes the process of heating two similar thermoplastic materials forcing them together under pressure, and allowing the materials to cool and recrystallize into a homogenous part and thereby creating a strong bond between the once separate materials. This process usually results in a strength in the bonded (fused) area which is greater than the corresponding separate pieces due to the increased mass in the immediate area of the bond.

Injection Molding

The process through which Polystar fittings are manufactured. Molten PP-RCT material is injected into molds under pressure, followed immediately by cooling, creating strong fittings with no mechanical weaknesses.

Linear Thermal Expansion and Contraction

The growth/shrinkage in a pipe that occurs when the material changes temperature. It should be noted that linear expansion can also occur due to initial pressurization of PP-RCT materials.

Polypropylene Random Copolymer (PP-R)

A type of copolymer polypropylene material where the orientation of the monomers is attached in a random manner throughout the chain in each molecule. The resulting physical properties of the polymer typically exhibit very high impact strength, elongation and general forgiveness compared to other forms of polypropylene.

Polystar™

The tradename for a family of piping systems manufactured from a highly crystalline form of copolymer polypropylene (PP-RCT). The piping systems are manufactured in accordance with ASTM F2389 and CSA B137.11. It is offered in several different classes of piping, some which are coextruded with a Fibercore™ middle layer .

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Polystar CT-Blue™

A polypropylene pressure piping system designed for (cold) potable and food-grade applications, as well as non-potable water applications and process piping. It is identified by its steel-grey color with externally extruded blue stripes. It is extruded as a monolithic material (without a Fibercore™ middle reinforcement layer). The pipe and fittings are joined using heat fusion.

Polystar CT-Lavender™

A special formulation of Polystar piping systems with an extruded outer layer pigmented in purple color. This pipe is manufactured for use in rainwater and reclaimed water. This system is distinguished by the light purple color of the pipe, as required by the governing standards for this class of water piping.

Polystar CT-Red™

A polypropylene pressure piping system designed for hot potable and food-grade applications. It is identified by its steel-grey color with externally extruded red stripes. It is extruded with Fibercore™ middle reinforcement technology which assists to restrain the piping from linear expansion and contraction. The pipe and fittings are joined using heat fusion.

Polystar CT-White™

A polypropylene pressure piping system designed for heating and cooling as well as process piping applications. It is identified by its steel-grey color with externally extruded white stripes. It is extruded with Fibercore™ middle reinforcement technology which assists to restrain the piping from linear expansion and contraction. The pipe and fittings are joined using heat fusion.

PP-RCT Material

The basic material used in all of Polystar polypropylene piping systems. This resin is manufactured to result in highly crystalline formations of beta-crystalline arrangements of the random copolymer molecules. This results in a material which exhibits higher strength, especially at elevated temperatures, as well as an extremely smooth bore in an extruded pipe.

Socket Fusion

Also referred to as heat element socket fusion, this describes a heat-fusion connection using welding heads and special fittings. The inside of the fitting is fused to the outside of the pipe by means of matching heating mandrels and bushings, forming a quick and simple leak-proof connection. This process is available for application with Polystar on sizes from nominal 4 inches (125 mm) and smaller.

Transition, Flange

A flange connection using a polypropylene stub flange, a loose glass filled polypropylene encapsulated steel backing ring, and a gasket that can be attached to a same size flange of any other piping material with matching hole pattern and flange size. In Polystar materials, the flanges are standardly available as ANSI/ASME B16.5 150 psi hole patterns and dimensions.

Transition, Threaded Adapter

A special fitting machined from brass which is insert injection molded into the polypropylene. The insert is threaded for use with any other type of threaded connection. In Polystar, the threaded transitions are available in lead-free brass only (less than 0.25% by weight lead content) and are available in NPT threads.

Welding Heads

Teflon-coated aluminum madrels/bushings designed to match specific sizes of pipe and fittings. The welding heads are engineered for direct insertion over the pipe and and into the socket hubs of fittings and couplings. The parts are designed for full insertion to the specified depth of the sockets in each given size.

Welding Iron

A heating tool made with an aluminum heating surface that is controlled by an engineered heating element and electronic thermostatic temperature controls. The surface of the device is designed to heat welding heads to the proper welding temperature (in the case of socket fusion) and should never be in direct contact with the material being welded.

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Accessories 40, 41

Anchoring 75

Applications 9

Chemical Resistance 21-25

Couplings 40, 41

Dimensional Data 26-41

Equivalent Lengths 69-72

Fibercore Technology 8

Fittings 28-40

Flanges 34, 37

Flow Rates 44-48

Freeze Protection 91-96

Friction Loss 44-45, 55-68

Fusion

– Butt Fusion 104

– Electrofusion 105-107

– Reducing Saddle Fusion 108

– Repair Fusion 109

– Socket Fusion 98-103, 108-109

– Welding Saddles 110-111

Hanger Spacing 73-74

– hangers 74-75

Head Loss 47-48, 55-68

Heat Loss 80-84

Hoop Stress 16

Impact 14

Insulation 85-90

Linear expansion 76-77

Material Properties 14

Models, Summary of 10-11

Mounting devices 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-Lavender 119

Polystar CT-Red 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, 846 88-89, 93, 94, 99, 119

Pressure Loss 48-54

Presure Rating 15

Pump Information 46

Quality Control 8

Specifications

- Facility Water and Process Water Applications 18

- Hydronic Heating 18

- Short Form Specifications 17

Support Spacing 73-75

Support Types 74-75

Sweating 96

Testing

– Material testing 14

– Pressure testing 114-117

Threaded connections 38-40

Tools

– Socket Fusion 98-103, 108-109

– Butt Fusion 104

– Electrofusion 105-107

Transitions

– Flanges 34, 37

– Threaded 38-40

UV protection 98

Valves 11

Velocity 55-68

Warranty 4-5

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For additional information visit our website at PolystarPipe.com

C-OR-Polystar 1340 © 2013 Baenninger, Inc.

USA: Tel: (913) 342-1653 • Fax: (800) 777-1653 • www.polystarpipe.comCanada: (905) 332-4090 • Fax: (905) 332-7068 • www.polystarpipe.ca

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