Thermoplastic IndustrialPiping Systems PresentationPrepared and Presented byTIPS Product Line Committee of the PPFA

All text, charts, and photos prepared and edited by Chasis Consulting, Inc. Disclaimer The material in this presentation/handbook has been prepared for the general information of the reader/user. The information presented is believed to be technically correct, however, the author, PPFA, PPEF, and their directors, officers, staff, and agents do not warrant the presentation/handbook or any of its contents suitable for any specific application. The presented material is published as an information guideline only. It shall be the responsibility of the reader/user to incorporate prudent and generally accepted engineering practices and meet the requirements of all involved regulatory agencies and their codes and standards.

PPFA Educational MaterialsPPFA offers a wide range of educational materials, developed to help you become more proficient in the design, installation, and use of the ultimate piping system thermoplastics!Now available:Facilitated, on-site seminars (full-day, half-day, 90-minute)CD-based seminars (full-day, half-day, 90-minute)WorkbooksOnline tutorialsFor more information on these products, visit us at http://www.ppfahome.org/tips

What is the PPFA?The Plastic Pipe and Fittings Association (PPFA) is composed of more than 50 companies involved in the manufacturing of products for plastic piping systems. PPFA has been a major force in educating the American market for over two decades in thermoplastic residential, commercial and industrial piping products and installations. For further information, log on to www.ppfahome.org.

What is TIPS?TIPS is the acronym for Thermoplastic Industrial Piping Systems; it also is the name of a product line committee (plc) of the PPFA. TIPS/plc is made up of several prestigious manufacturers in the industry whose goals are to educate and promote to the market place the many benefits of thermoplastic industrial piping systems. For further information log on to www.ppfahome.org/tips.

What does TIPS exclude?For purposes of this presentation, TIPS is all piping excluding the following applications and product groups:IrrigationAbove-ground Fire Sprinkler SystemsResidential Swimming PoolsGas Distribution and TransmissionMunicipal, Commercial, and Residential Potable Water, Sewer, Drain and Vent Plastic-lined Metal PipingFlexible Tubing Composite PipingThermosets (Glass Reinforced Resins)

Presentation ObjectivesThis presentation is to provide knowledge, proficiency and a comfort level in designing, specifying, and installing TIPS. For maximum educational benefit, the joint use of the one-day PowerPoint CD and workbook is recommended.

Definitions and History

Plastic A material that contains organic, polymeric substances of large molecular weight, is solid in its finished state, and at some stage in its manufacture or processing into a finished article, can be shaped by flow

Thermoplastic A plastic that can be repeatedly softened by heating and hardened by cooling through a temperature range characteristic of the plastic, and that in the softened state, can be shaped by flow into an article by molding or extrusion

Thermoset A plastic that, when cured by application of heat or by chemical means, changes into a substantially infusible and product

MonomerA relatively simple compound that can react to form a polymerCopolymerA polymer formed by the polymerization of two chemically different monomers PolymerA substance consisting of molecules characterized by the repetition of one or more types of monomeric units

Resin Broadly stated, the term designates any polymer or copolymer that is the basic material for a plastic

Additives Chemical ingredients incorporated in the resin or added during the manufacturing process to give desired product performance characteristics. These can include the following: Heat Stabilizers - Protect against thermal degradationAntioxidants - Protect against oxidationUltraviolet Stabilizers - Protect against ultraviolet degradation Lubricants - Improve manufacturing processingPigments - Add a distinctive color & aid in UV protection Fillers - Reduce cost and may also increase stiffnessProperty Modifiers - Enhance a particular material propertyProcessing Aids - Assist material mixing/fusion during processing

Compound A mixture of a thermoplastic resin with other additives or ingredients

Extrusion All thermoplastic pipe is extruded. Extrusion is a process whereby heated plastic forced through a shaping orifice becomes one continuously formed piece.

Injection Molding Most voluminous thermoplastic non-pipe products are injection molded. Injection molding is the process of forming a material by forcing it, under pressure, from a heated cylinder through a sprue (runner) into the cavity of a closed mold.

Injection Molding Reciprocating Hydraulic Injection UnitScrew RotationTransmission ReciprocatingScrewInjection NozzleMoldSprue BushingPress Clamp Unit

Injection Molding HopperLoading SystemMaterialPlasticized In BarrelScrewMovement

Injection Molding Moving PlatenStationary Platen

Injection Molding Mold Halves

Injection Molding Molded Part

Injection Molding Ejector Pins

Injection Molding

Injection Molding ScrewMovement

History of Thermoplastic Piping Materials

Estimated Year Plastic DiscoveredPlastic Material*Estimated Year of Piping Usage1868Cellulose Nitrate (Celluloid)First semi-synthetic plastic1909Phenol Formaldehyde (Bakelite)First all synthetic plastic1927Polyvinyl Chloride (PVC)19401933Polyethylene (PE)19481938Cellulose Acetate Butyrate (CAB)19401938Polytetrafluoroethylene (PTFE)19601943Chlorinated Polyvinyl Chloride (CPVC)19601948Acrylonitrile Butadiene Styrene (ABS)19521955Ethylene Chlorotrifluoroethylene (ECTFE)19661956Fluorinated Ethylenepropylene (FEP)19651957Polypropylene (PP)19581960Cross-Linked Polyethylene (PEX)**19651962Polybutylene (PB)19711963Polyvinylidene Fluoride (PVDF)19641968Perfluoroalkoxy (PFA)1972* Items in bold print are plastic materials included in this presentation. **A thermoset material

Plastic Piping Materials Thermoplastics accounted for over 95% of an estimated 11 billion pounds of plastic that went into all pipe, conduit and fittings in 2002. The estimated TIPS Market ($) share by pipe/valves/fitting materials for Year 2002 is shown in the pie chart.

Material Characteristics

Plastic Material Designations ASTM is the standards development organization that classifies plastic piping materials by common physical characteristics categories. Over the past decade, there has been a movement to refine the classifications in a more meaningful way; however, the old designations are still in use.

Plastic Material DesignationsOld ASTM Designations: Material DesignationFirst Digit = TypeSecond Digit = GradeThird / Fourth Digit = Hydrostatic design stress divided by 100 Example: PVC 1120

Plastic Material DesignationsNew ASTM Designation Called Cell ClassificationFirst Digit = MaterialSecond Digit = Impact StrengthThird Digit = Tensile StrengthFourth Digit = Modulus of ElasticityFifth Digit = Heat Deflection TemperatureExample: PVC 12454 (Similar to PVC 1120)

Plastic Material DesignationsThis seminar will include the following materials:*

CPVCASTM D1784-03Cell Classification 23447/24448HDPEASTM D3350-02aCell Classification 345464CPPASTM D4101Type IPVCASTM D1784-03Cell Classification 12454PVDFASTM D3222Type I Grade 2* Thermoplastic compounds can be reformulated to accentuate certain properties. Check with product manufacturers for latest compound usage.ABS material is not included in the Engineering and Physical Characteristics sections, because most ABS applications in the USA are for residential drain waste and vent, rather than industrial uses.

Physical Characteristics** The physical values listed may differ slightly due to variations of manufacturers resins and compounds.

Specific Gravity The ratio of the density of a material to the density of water at standard temperature (ASTM D-792 Test Method). The lower the number, the lighter the weight. Note: Water= 1.0

PP0.91PE0.92PVC1.38CPVC1.55PVDF1.76

Tensile Strength The pulling force necessary to break a specimen, divided by the cross- section area at the point of failure. (ASTM D-638 Test Method) (psi @ 73F)

PVDF8000CPVC7500PVC7300PP4600PE3500

Modulus of Elasticity The ratio of the stress to the elongation per inch due to this stress, in a material that deforms elastically. (ASTM D-638 Test Method) (psi @ 73F x 105)

PVC4.2CPVC3.6PVDF2.1PP2.0PE1.2

Flexural Strength The strength of a plastic material in bending as expressed by the tensile stress of the outermost fibers of a bent test sample at the instant of failure. (ASTM D-790 Test Method) (psi)

PVC14500CPVC13400PVDF9700PP7000PE3000

Izod Impact Strength The resistance of a notched test specimen has to a sharp blow from a pendulum hammer. (ASTM Test D-256) (ft-lb/in) The lower the number, the lower the impact strength.

PE7.0PVDF3.8CPVC2.0PVC1.1PP0.8

Coefficient of Thermal Expansion The fractional change in a length of a specimen due to a unit change in temperature. (ASTM D-6960 Test Method) (in./in./F x 10-5) The lower the number, the lower the expansion rate.

PVC3.0CPVC3.8PP5.0PVDF7.3PE7.8

Thermal Conductivity The time rate of transferring heat by conduction through a material of a given thickness and area for a given temperature difference. (ASTM C-177 Test Method)(Btu in./hr/ft2/F) The lower the number, the less conductive.

CPVC0.95PVDF1.18PVC1.20PP1.20PE2.60

Heat Resistance The general maximum allowable temperature of a piping system in which 20-psi working pressure or less may be used (F)

PVC140PE160PP180CPVC210PVDF285

Abrasion Resistance Using the Taber Abrasion Test, the weight loss of a material is measured after being exposed to an abrasive wheel for 1000 cycles. (mg) The lower the number, the more abrasion resistant. Note:Stainless Steel is 50.

PE5PVDF5-10PP15-20PVC12-20CPVC20

Flash Ignition Temperature The lowest temperature of a substance at which sufficient combustible gas is evolved to be ignited by a small external flame. (F) Note: Wood products ignite at 500F and lower.

CPVC900PVDF790PVC730PE660PPN/A

Flammability Rating An Underwriter Laboratories test to measure a materials resistance to burning, dripping, glow emission and burn-through. The 94V-0 designation is the most resistant to burning; 94HB is the least resistant to burning.

PVDF94V-0CPVC94V-0PVC94V-0PP*94HBPE94V-2* Fire retardant grades can increase value to 94V-2.

Limiting Oxygen Index The percentage of oxygen needed in an atmosphere to support combustion (ASTM D2863 Test Method). The higher the number, the greater the resistance to burning. (%)

CPVC60PVDF44-75PVC43PP18PE17

Flame Spread /Smoke Development Indices These material characteristics are determined by testing the surface flame spread of and smoke developed by plastic piping as compared to fixed index elements of mineral fiber cement board and red oak flooring. (ASTM E-84, NFPA 255, UL 723 and UBC 8-1) (42-1 Test Method). Note: Major building and mechanical codes require that combustible piping installed within an air plenum must have a maximum flame spread index of 25 and a maximum smoke development index of 50.*CPVC, PP and PVC are available in specially formulated product compounds that have improved flame spread and/or smoke development characteristics.

Flame Spread Index*PVDF0PVC15-20CPVC15PPN/APEN/A

Smoke Development Index*PVDF5-50PVC>300CPVC>350PP>400PE>400

TIPS are...Environmentally soundEasy and safe to installReliableLong-lastingCost-effective

The PPFA has prepared this tutorial of Thermoplastic Industrial Piping Systems (TIPS). The presented material has been carefully collated and includes the most technically correct information available; however, the information is a guideline only. For specific applications, consult with a knowledgeable product manufacturer or distributor and use the services of an experienced professional engineer. The tutorial is presented in seven parts including the Introduction, Features & Benefits, Engineering Design Considerations, Joining/Installation/Testing/Repairing Methods, Product Availability, Selecting the Proper Plastic Piping Materials & Applications.The educational materials are the most inclusive and comprehensive available in the TIPS industry.The PPFA is a three-decade-old organization whose mission is to educate, promote and defend the use of plastic piping products in North America. Association members include piping product, plastic processing equipment, resin, compound, and additive manufacturers as well as industry consultants.The TIPS product line committee is relatively new and is comprised of companies with a combined experience of over 300 years of manufacturing and processing expertise in thermoplastic industrial piping systems.The majority of thermoplastic piping has and is being used for underground applications. Many of these underground piping applications have been excluded from the presentation as well as other plastics that are non-rigid, not thermoplastic or are thermoplastics combined with other non-plastic materials. To benefit most from this tutorial be open to and inquisitive of new piping ideas and concepts.The word plastic is a derivative of the Latin word plasticus or the Greek word plastikos; both mean the sameto mold or shape.The two major plastic sub-divisions are thermoplastic and thermoset. Thermoplastic piping includes but is not limited to vinyls (PVC/CPVC), polyolefins (PE/PP), Fluoropolymers (PVDF) and ABS.Thermoset piping includes, but is not limited to: PEX, phenolics, reinforced epoxies, polyesters and vinyl esters. Whether the plastic piping material is a polymer, co-polymer or tri-polymer, the building block of most plastics is the monomer. Organic chemists using pressure, heat, and additives form monomers into chains of carbon-hydrogen rich formulations producing the desired resultant plastic. Most thermoplastic piping resins are made from feedstocks of oil or gas. The feedstocks produce carbon and hydrogen compounds that are combined with other elements such as chlorine, fluorine, nitrogen or oxygen to form a particular plastic resin.Each plastic compound manufacturer is like a chef preparing a generic entre. The entre is recognizable and is made predominantly from a common base but by adding seasoning (or additives), each has a slightly different taste (or performance characteristics).Fortunately, each group of plastic piping compounds must adhere to stringent standards as listed by the American Society of Testing & Materials (ASTM) so that the compounds, although slightly different, must share many similar physical characteristics.The plastic extrusion process is similar in principle to using a cornucopia shaped paper or bag filler with decorative icing. When the exterior of the bag is squeezed, the icing (or heated plastic) is forced though a nozzle (or die) into the desired shape and diameter. Thermoplastic piping is extruded in diameters from -inch to 48-inches and larger mostly in lengths of 10 & 20 feet; however, the automatic pipe cutter, downstream of the extruder, is adjustable to any shippable length requirement.Injection molding is similar to a gelatin mold, except, unlike gelatin making, the plastic material is poured in the mold cavity under pressure and high temperature. Most thermoplastic fittings and valves are injection molded in sizes from -inch to 12-inches and larger. Extruded pipe and rod are used to fabricate non-injection molded fittings. Rotational molding and vacuum forming are forms of plastic processing used mostly in large thin walled products such as tanks and large filter or heat exchange housings.The diagram represents a typical injection molding process.The hopper loads the plastic compound in the heated barrel which houses a specially designed rotating screw. The screw is designed for the particular thermoplastic being extruded.The heated plastic material is transported into the mold situated between the stationary and moving platens.As the desired time is reached for the plastic material to flow into and cool in the mold, the movable platen retracts.The molded part is now solid and cool enough to be automatically released.The spring-loaded ejector pins push out the finished product from the mold.The male and female sections of the mold are forced together as the moveable platen returns to begin the injection process cycle again.The process begins anew.John Hyatt is credited with discovering the first plastic, cellulose nitrate, in his search for a replacement for ivory used in the manufacturing of billiard balls. From this auspicious start, thermoplastic piping has become the preferred piping material in many markets such as under-ground sprinkler systems, acid-waste drainage, residential drain, waste and vent, ultra-high purity water, gas distribution, water mains, sewer pipe, and swimming pools. Vinyls, due to their physical characteristics and competitive pricing, have an estimated 70% of the TIPS market in dollars. Polyolefins are the fasted growing segment of the TIPS market with an estimated 20% of the market in dollars.The American Society for Testing & Materials (ASTM) is a national standards organization who lists standards for most of TIPS products and is frequently used as a third party to insure these standards are met and maintained by inspecting products and plant manufacturing sites. Almost all thermoplastic piping, fittings and valves, unlike other non-plastic fluid handling products, are clearly marked to designate the type of material used in manufacturing. These external designations assure the engineer, installer and user of product compatibility and adherence to published standards.The new material designations are more detailed and descriptive when compared to the older material designations. Manufacturers of thermoplastic piping compounds have slightly different formulations resulting in slightly different physical properties. The following values shown are estimated and could range plus or minus 5% or more.Thermoplastics have the lowest specific gravities of any piping materials. Polyolefins have a S.G. less than water which may allow these piping materials to be uniquely installed in underground water applications.Tensile strength or breaking load and tensile modulus of elasticity of a material are instrumental in determining the long-term pressure capabilities of thermoplastic piping.The modulus of elasticity affects the stiffness of pipe and is normally represented by stress-strain curves at any given elongation point on the curve.The flexural strength and flexural modulus of a material determines the pipes stiffness which affects support spacing and resistance to earth loads in buried piping.The resistance or mechanical energy absorbed by a plastic on impact determines the outer toughness of the piping products.Due to a larger coefficient of thermal expansion than other materials, thermoplastics expand and contract at a greater rate than other piping products.Almost all thermoplastics, when compared to other piping materials, have much lower thermal conductivity resulting in reduced or no need for piping insulation and significantly reduces the possibility of developing condensate (sweating) on the pipe exterior.The tensile strength and pressure ratings of thermoplastic piping decrease with an increase in temperature. These pressure-temperature relationships are calculated and listed in engineering tables.Most thermoplastic piping materials have an ability to resist abrasion and erosion much greater than other non-plastic piping.Plastic ignition temperatures are less than most other piping materials; however, in no case can plastic piping materials flash or self-ignite until temperatures approach 650F or higher.Vinyls and fluorocarbons excel at resisting burning. Polyolefins are less resistant. The limiting oxygen index (LOI) is another method of determining which materials burn easier than other materials. For example, cotton requires a LOI of 16 while CPVC and PVDF have an LOI of 45 to 75.Flame spread and smoke development indices determine which piping materials could be used in plenum spaces.