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Transcript of ©2003, 2004, 2005 - Plastics Pipe and Fittings Association Thermoplastic Industrial Piping Systems...
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Thermoplastic IndustrialPiping Systems Presentation
Prepared and Presented byTIPS Product Line Committee of the PPFA
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
All text, charts, and photos prepared and edited by Chasis Consulting, Inc.
DisclaimerThe 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.
3 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
PPFA Educational Materials• PPFA 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)– Workbooks– Online tutorials
• For more information on these products, visit us at http://www.ppfahome.org/tips
4 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
5 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
6 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
What does TIPS exclude?• For purposes of this presentation, TIPS is all piping
excluding the following applications and product groups:
– Irrigation– Above-ground Fire Sprinkler Systems– Residential Swimming Pools– Gas Distribution and Transmission– Municipal, Commercial, and Residential Potable Water, Sewer,
Drain and Vent – Plastic-lined Metal Piping– Flexible Tubing – Composite Piping– Thermosets (Glass Reinforced Resins)
7 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Presentation Objectives• This 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.
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Definitions and History
9 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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
10 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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
Water analogy: Thermoplastics, similar to water, can be heated and cooled repeatedly without any change in the material’s basic properties. (i.e., recyclable)
11 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Thermoset • A plastic that, when cured by application of heat or
by chemical means, changes into a substantially infusible and product
Egg analogy: Thermosets, similar to eggs, can be processed only once with changes occurring in the material’s basic properties.
12 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Monomer• A relatively simple compound that can react to form
a polymer
Copolymer• A polymer formed by the polymerization of two
chemically different monomers
Polymer• A substance consisting of molecules characterized
by the repetition of one or more types of monomeric units
13 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Resin • Broadly stated, the term designates any polymer or
copolymer that is the basic material for a plastic
Plastic resin
14 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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 degradation– Antioxidants - Protect against oxidation– Ultraviolet Stabilizers - Protect against ultraviolet degradation – Lubricants - Improve manufacturing processing– Pigments - Add a distinctive color & aid in UV protection – Fillers - Reduce cost and may also increase stiffness– Property Modifiers - Enhance a particular material property– Processing Aids - Assist material mixing/fusion during processing
15 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Compound • A mixture of a thermoplastic resin with other
additives or ingredients
Plastic pellet andpowder compound
16 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Extrusion Extrusion Diagram• All thermoplastic pipe is extruded. Extrusion is a
process whereby heated plastic forced through a shaping orifice becomes one continuously formed piece.
Extruder
17 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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 Diagram
Injection MoldingMachine
18 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Reciprocating Hydraulic Injection Unit
Screw RotationTransmission
ReciprocatingScrew
Injection Nozzle
MoldSprue Bushing
Press Clamp Unit
19 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
“Hopper”Loading System
MaterialPlasticized In Barrel
ScrewMovement
20 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Moving PlatenStationary Platen
ScrewMovement
21 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Platen Movement
Mold Halves
22 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Molded Part
23 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Ejector Pins
24 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Platen Movement
25 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
ScrewMovement
26 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Estimated Year Plastic Discovered Plastic Material* Estimated Year of Piping Usage
1868 Cellulose Nitrate (Celluloid) First semi-synthetic plastic
1909 Phenol Formaldehyde (Bakelite) First all synthetic plastic
1927 Polyvinyl Chloride (PVC) 1940
1933 Polyethylene (PE) 1948
1938 Cellulose Acetate Butyrate (CAB) 1940
1938 Polytetrafluoroethylene (PTFE) 1960
1943 Chlorinated Polyvinyl Chloride (CPVC) 1960
1948 Acrylonitrile Butadiene Styrene (ABS) 1952
1955 Ethylene Chlorotrifluoroethylene (ECTFE) 1966
1956 Fluorinated Ethylenepropylene (FEP) 1965
1957 Polypropylene (PP) 1958
1960 Cross-Linked Polyethylene (PEX)** 1965
1962 Polybutylene (PB) 1971
1963 Polyvinylidene Fluoride (PVDF) 1964
1968 Perfluoroalkoxy (PFA) 1972
* Items in bold print are plastic materials included in this presentation. **A thermoset material
History of Thermoplastic Piping Materials
27 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Material Characteristics
29 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
30 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations• Old ASTM Designations: Material Designation
– First Digit = Type– Second Digit = Grade– Third / Fourth Digit = Hydrostatic design stress divided by 100
• Example: PVC 1120
31 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations• New ASTM Designation Called Cell Classification
– First Digit = Material– Second Digit = Impact Strength– Third Digit = Tensile Strength– Fourth Digit = Modulus of Elasticity– Fifth Digit = Heat Deflection Temperature
• Example: PVC 12454 (Similar to PVC 1120)
32 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations• This seminar will include the following materials:*
CPVC ASTM D1784-03 Cell Classification 23447/24448
HDPE ASTM D3350-02a Cell Classification 345464C
PP ASTM D4101 Type I
PVC ASTM D1784-03 Cell Classification 12454
PVDF ASTM D3222 Type 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.
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Physical Characteristics*
* The physical values listed may differ slightly due to variations of manufacturer’s resins and compounds.
34 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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
PP 0.91
PE 0.92
PVC 1.38
CPVC 1.55
PVDF 1.76
PE Piping Lighter than Water
35 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Tensile Plastic Specimen Test
Tensile Testing
Machine
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 @ 73°F)
PVDF 8000
CPVC 7500
PVC 7300
PP 4600
PE 3500
36 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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 @ 73°F x 105)
PVC 4.2
CPVC 3.6
PVDF 2.1
PP 2.0
PE 1.2
37 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flexural Testing
Machine
Flexural Strength • The strength of a plastic material in bending as
expressed by the tensile stress ofthe outermost fibers of a bent testsample at the instant of failure.(ASTM D-790 Test Method) (psi)
PVC 14500
CPVC 13400
PVDF 9700
PP 7000
PE 3000
Flexural Plastic Specimen Test
38 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
PE 7.0
PVDF 3.8
CPVC 2.0
PVC 1.1
PP 0.8 Izod Testing Machine
Izod Testing Machine
39 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
PVC 3.0
CPVC 3.8
PP 5.0
PVDF 7.3
PE 7.8
40 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
CPVC 0.95
PVDF 1.18
PVC 1.20
PP 1.20
PE 2.60
Thermal Conductivity via Modulated DSC
41 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Heat Resistance • The general maximum allowable temperature of a
piping system in which 20-psi working pressure or less may be used (°F)
PVC 140
PE 160
PP 180
CPVC 210
PVDF 285
Heat Deflection Testing Machine
42 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
PE 5
PVDF 5-10
PP 15-20
PVC 12-20
CPVC 20
Taber Machine
43 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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 igniteat 500°F and lower.
CPVC 900
PVDF 790
PVC 730
PE 660
PP N/A
Instrument to Test Flash Points of Materials
44 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flammability Rating • An Underwriter Laboratories test to measure a
material’s 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.
PVDF 94V-0
CPVC 94V-0
PVC 94V-0
PP* 94HB
PE 94V-2
* Fire retardant grades can increase value to 94V-2.
Flammability Testing by Underwriter Laboratories
45 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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. (%)
CPVC 60
PVDF 44-75
PVC 43
PP 18
PE 17
46 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
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.
Flame Spread Index*
PVDF 0
PVC 15-20
CPVC 15
PP N/A
PE N/A
Smoke Development Index*
PVDF 5-50
PVC >300
CPVC >350
PP >400
PE >400
*CPVC, PP and PVC are available in specially formulated product compounds that have improved flame spread and/or smoke development characteristics.
47 - Introduction ©2003, 2004, 2005 - Plastics Pipe and Fittings Association
TIPS are...
• Environmentally sound• Easy and safe to install• Reliable• Long-lasting• Cost-effective