Engineer Manual - Engineer and Design Liquid Process Piping - Review

CECW-ET 10 January 2003
Errata Sheet
No. 1
Engineering and Design
Liquid Process Piping
EM 1110-1-4008
5 May 1999
Reference to MSS SP -119 on page A-6, paragraph A-1 is in error. The title of the
document is incorrect. Page A-6, paragraph A-1: The title for MSS SP -119 should be as
follows: Belled End Socket Welding Fittings, Stainless Steel and Copper -Nickel.
CEMP-RA Department of the Army EM 1110-1-4008
U.S. Army Corps of Engineers
Engineer Manual Washington, DC 20314-1000 5 May 1999
1110-1-4008
Engineer and Design
LIQUID PROCESS PIPING
Distribution Restriction Statement

Approved for public release; distribution is
unlimited.
EM 1110-1-4008
5 May 1999
US Army Corps
of Engineers
ENGINEERING AND DESIGN
ENGINEER MANUAL
AVAILABILITY
Electronic copies of this and other U.S. Army Corp of Engineers publications are available on the Internet at
http://www.usace.army.mil/inet/usace-docs/. This site is the only repository for all official USACE engineer regulations,
circulars, manuals, and other documents originating from HQUSACE. Publications are provided in portable document
format (PDF).
DEPARTMENT OF THE ARMY EM 1110-l-4008
CEMP-RA Washington, DC 20314-1000
Manual
No. 1110-l-4008 5 May 1999

1. The purpose of this manual is to provide information for the design of liquid process
piping.
2. Applicability. This manual applies to all HQUSACE elements and all USACE Commands
having responsibility for the design of unit processes for treatment of liquids.
3. Distribution Restriction. Approved for public release; distribution is unlimited.
4. References. References are provided in Appendix A.
5. Scope. This manual is to be used in the selection of piping systems and materials for chemical
and physical unit processes. Process piping systems include pipe and appurtenances used to
transport fluids. Separate guidance has been provided for plumbing, potable water, sewage, storm
drainage, fuel and lubricant systems.
6. Discussion. This manual includes criteria for the design of component parts and assemblies of
liquid process piping systems. Compliance with these criteria requires that fundamental design
principles are followed. Modification or additions to existing systems solely for the purpose of
meeting criteria in this manual are not authorized.
FOR THE COMMANDER:
4 Appendices
(See Table of Contents) Major General, U. S. Army
Chief of Staff
DEPARTMENT OF THE ARMY EM 1110-1-4008
CEMP-RA Washington, DC 20314-1000
Manual
No. 1110-1-4008 5 May 1999

TABLE OF CONTENTS
SUBJECT PARAGRAPH PAGE SUBJECT PARAGRAPH PAGE
Chapter 1
Introduction
Purpose . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 Design Pressure . . . . . . . . . . . . . . . . . 4-3 4-9
Applicability . . . . . . . . . . . . . . . . . . . 1-2 1-1 Piping Supports for Metallic
References . . . . . . . . . . . . . . . . . . . . . 1-3 1-1 Piping Systems . . . . . . . . . . . . . . . . . 4-4 4-9
Distribution . . . . . . . . . . . . . . . . . . . . 1-4 1-1 Joining . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-12
Scope . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-1 Thermal Expansion . . . . . . . . . . . . . . 4-6 4-12
Metrics . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-1 Ductile Iron . . . . . . . . . . . . . . . . . . . . 4-7 4-17
Brand Names . . . . . . . . . . . . . . . . . . . 1-7 1-1 Carbon Steel . . . . . . . . . . . . . . . . . . . 4-8 4-17
Accompanying Guidance Stainless Steel . . . . . . . . . . . . . . . . . . 4-9 4-18
Specification . . . . . . . . . . . . . . . . . . 1-8 1-1 Nickel and Nickel Alloys . . . . . . . . . 4-10 4-19
Manual Organization . . . . . . . . . . . . . 1-9 1-3 Aluminum . . . . . . . . . . . . . . . . . . . . 4-11 4-20
Copper . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-21
Chapter 2
Design Strategy Chapter 5
Design Analyses . . . . . . . . . . . . . . . . 2-1 2-1 Plastic Piping Systems
Specifications . . . . . . . . . . . . . . . . . . . 2-2 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1
Drawings . . . . . . . . . . . . . . . . . . . . . . 2-3 2-1 Polyvinyl Chloride (PVC) . . . . . . . . . 5-2 5-9
Bases of Design . . . . . . . . . . . . . . . . . 2-4 2-2 Polytetrafluoroethylene (PTFE) . . . . . 5-3 5-9
Loading Conditions . . . . . . . . . . . . . . 2-5 2-7 Acrylonitrile-Butadiene-Styrene
Piping Layout . . . . . . . . . . . . . . . . . . . 2-6 2-10 (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-9
Chlorinated Polyvinyl Chloride
Chapter 3 (CPVC) . . . . . . . . . . . . . . . . . . . . . . 5-5 5-10
General Piping Design Polyethylene (PE) . . . . . . . . . . . . . . . 5-6 5-10
Materials of Construction . . . . . . . . . 3-1 3-1 Polypropylene (PP) . . . . . . . . . . . . . . 5-7 5-10
Design Pressure . . . . . . . . . . . . . . . . . 3-2 3-2 Polyvinylidene Fluoride (PVDF) . . . . 5-8 5-10
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-7
Stress Analysis . . . . . . . . . . . . . . . . . . 3-4 3-17 Chapter 6
Flange, Gaskets and Bolting Rubber and Elastomer Piping Systems
Materials . . . . . . . . . . . . . . . . . . . . . 3-5 3-19 General . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1
Pipe Identification . . . . . . . . . . . . . . . 3-6 3-23 Design Factors . . . . . . . . . . . . . . . . . . 6-2 6-1
Piping Supports . . . . . . . . . . . . . . . . . 3-7 3-23 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6-4
Testing and Flushing . . . . . . . . . . . . . 3-8 3-29 Piping Support and Burial . . . . . . . . . 6-4 6-5
Fluoroelastomer . . . . . . . . . . . . . . . . . 6-5 6-5
Chapter 4 Isobutylene Isoprene . . . . . . . . . . . . . 6-6 6-5
Metallic Piping Systems Acrylonitrile Butadiene . . . . . . . . . . . 6-7 6-5
General . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 Polychloroprene . . . . . . . . . . . . . . . . . 6-8 6-5
Corrosion . . . . . . . . . . . . . . . . . . . . . . 4-2 4-1 Natural Rubber . . . . . . . . . . . . . . . . . 6-9 6-5
i
EM 1110-1-4008
5 May 99
TABLE OF CONTENTS - CONTINUED
SUBJECT PARAGRAPH PAGE SUBJECT PARAGRAPH PAGE
Chapter 7 Chapter 12
Thermoset Piping Systems Corrosion Protection
General . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 Corrosion Protection . . . . . . . . . . . . 12-1 12-1
Reinforced Epoxies . . . . . . . . . . . . . . 7-2 7-5 Cathodic Protection . . . . . . . . . . . . . 12-2 12-1
Reinforced Polyesters . . . . . . . . . . . . 7-3 7-5 Isolation Joints . . . . . . . . . . . . . . . . . 12-3 12-2
Reinforced Vinyl Esters . . . . . . . . . . . 7-4 7-6 Protective Coatings . . . . . . . . . . . . . 12-4 12-4
Reinforced Furans . . . . . . . . . . . . . . . 7-5 7-6
Appendix A
Chapter 8 References
Double Containment Piping Systems
General . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 Appendix B
Piping System Sizing . . . . . . . . . . . . . 8-2 8-6 Fluid/Material Matrix
Double Containment Piping
System Testing . . . . . . . . . . . . . . . . . 8-3 8-7 Appendix C
Leak Detection Systems . . . . . . . . . . . 8-4 8-8 Design Example
Chapter 9 Appendix D
Lined Piping Systems Index
General . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1
Plastic Lined Piping Systems . . . . . . . 9-2 9-3
Other Lined Piping Systems . . . . . . . 9-3 9-8
Chapter 10
Valves
General . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1
Valve Types . . . . . . . . . . . . . . . . . . . 10-2 10-9
Valve Sizing and Selection . . . . . . . 10-3 10-13
Valve Schedule . . . . . . . . . . . . . . . . 10-4 10-20
Chapter 11
Ancillary Equipment
Flexible Couplings . . . . . . . . . . . . . . 11-1 11-1
Air and Vacuum Relief . . . . . . . . . . 11-2 11-1
Drains . . . . . . . . . . . . . . . . . . . . . . . . 11-3 11-5
Sample Ports . . . . . . . . . . . . . . . . . . 11-4 11-5
Pressure Relief Devices . . . . . . . . . . 11-5 11-5
Backflow Prevention . . . . . . . . . . . . 11-6 11-7
Static Mixers . . . . . . . . . . . . . . . . . . 11-7 11-8
Expansion Joints . . . . . . . . . . . . . . . 11-8 11-9
Piping Insulation . . . . . . . . . . . . . . . 11-9 11-10
Heat Tracing . . . . . . . . . . . . . . . . . 11-10 11-12
ii
EM 1110-1-4008
5 May 99
LIST OF TABLES
TABLE PAGE TABLE PAGE
1-1 Standard Pipe Dimensions . . . . . . . . . . . . 1-2 5-9 Values of EN Modulus of Soil Reaction
2-1 System Description . . . . . . . . . . . . . . . . . . 2-1 for Various Soils . . . . . . . . . . . . . . . . . . . 5-8
2-2 PFDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 5-10 Polyethylene Designations . . . . . . . . . . . 5-11
2-3 P&IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 6-1 Common Materials Used in Rubber/
2-4 Standards and Codes . . . . . . . . . . . . . . . . . 2-5 Elastomer Piping Systems . . . . . . . . . . . 6-1
2-5 Valve Location Design . . . . . . . . . . . . . . 2-15 6-2 Rubber and Elastomer Hose
2-6 Pump Connections Design . . . . . . . . . . . 2-15 Standards . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
3-1 Pipe Material Roughness 6-3 General Chemical Compatibility
Coefficients . . . . . . . . . . . . . . . . . . . . . . 3-10 Characteristics of Common
3-2 Estimated Pressure Drop for Elastomers . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Thermoplastic Lined Fittings 6-4 RMA Oil and Gasoline Resistance
and Valves . . . . . . . . . . . . . . . . . . . . . . 3-12 Classifications . . . . . . . . . . . . . . . . . . . . . 6-3
3-3 Minor Loss Coefficients (K) . . . . . . . . . . 3-13 6-5 Typical Hose Couplings . . . . . . . . . . . . . . 6-4
3-4 Gasket Compression . . . . . . . . . . . . . . . . 3-21 7-1 Thermoset Piping Systems
3-5 Gasket Factors and Seating Stress . . . . . 3-23 Standards (As of Nov. 1997) . . . . . . . . . 7-2
3-6 Color Codes for Marking Pipe . . . . . . . . 3-25 7-2 Recommended Temperature Limits
3-7 Beam Coefficient (m) . . . . . . . . . . . . . . . 3-26 for Reinforced Thermosetting
3-8 Support Type Selection for Horizontal Resin Pipe . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Attachments: Temperature Criteria . . . 3-28 7-3 Support Spacing for Reinforced
4-1 Galvanic Series . . . . . . . . . . . . . . . . . . . . . 4-2 Epoxy Pipe . . . . . . . . . . . . . . . . . . . . . . . 7-3
4-2 Environments Which Cause 7-4 Loop Leg Sizing Chart for Fibercast
Intergranular Corrosion in Sensitized RB-2530 Pipe . . . . . . . . . . . . . . . . . . . . . 7-5
Austenitic Stainless Steels . . . . . . . . . . . 4-6 8-1 Double Containment Piping Material
4-3 Alloy/Susceptible Environment Combinations . . . . . . . . . . . . . . . . . . . . . 8-3
Combinations for Stress-Corrosion 8-2 Common Orifice Coefficients . . . . . . . . . . 8-7
Cracking (Partial Listing) . . . . . . . . . . . . 4-7 9-1 Thermoplastic Liner Temperature
4-4 Support Spacing for Steel Pipe . . . . . . . 4-10 Limits (Continuous Duty) . . . . . . . . . . . . 9-1
4-5 Support Spacing for Nickel Pipe . . . . . . 4-11 9-2 ANSI Class 125 and Class 150
4-6 Support Spacing for Aluminum Systems (Lightly Oiled Bolting) . . . . . . . 9-4
Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 9-3 ANSI Class 300 Systems (Lightly
4-7 Support Spacing for Copper Oiled Bolting) . . . . . . . . . . . . . . . . . . . . . 9-4
Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 9-4 ANSI Class 125 and Class 150
4-8 Applicable Codes for Metallic Fittings . 4-14 Systems (Teflon-Coated Bolting) . . . . . . 9-5
5-1 Abbreviations for Thermoplastic 9-5 ANSI Class 300 Systems (Teflon-
Materials . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Coated Bolting) . . . . . . . . . . . . . . . . . . . . 9-5
5-2 Thermoplastic Joining Methods . . . . . . . . 5-3 9-6 Plastic Liner Material Properties . . . . . . . 9-6
5-3 Thermoplastic Joining Standards . . . . . . . 5-3 9-7 Liquid-Applied Coating Thickness . . . . . 9-6
5-4 Support Spacing for Schedule 80 9-8 Typical PVDF Liner Thickness
PVC Pipe . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Required to Prevent Permeation . . . . . . . 9-7
5-5 Support Spacing for Schedule 80 10-1 Recommended Flow
PVDF Pipe . . . . . . . . . . . . . . . . . . . . . . . 5-6 Characteristics . . . . . . . . . . . . . . . . . . . 10-3
5-6 Support Spacing for Schedule 80 10-2 Standard Control Valve Body
CPVC Pipe . . . . . . . . . . . . . . . . . . . . . . . 5-7 Materials . . . . . . . . . . . . . . . . . . . . . . . . 10-4
5-7 Bedding Factor (K x) . . . . . . . . . . . . . . . . . 5-7 10-3 Wear and Galling Resistance Chart
5-8 Deflection Lag Factor (d e) . . . . . . . . . . . . 5-8 of Material Combinations . . . . . . . . . . . 10-5
iii
EM 1110-1-4008
5 May 99
LIST OF TABLES - CONTINUED
TABLE PAGE TABLE PAGE
10-4 Elastomer General Properties . . . . . . . . . 10-6 C-3 Minor Losses for 80-INF-1500:
10-5 Valve Seat Leakage Classifications . . . . 10-7 Run A-J . . . . . . . . . . . . . . . . . . . . . . . . . C-8
10-6 Class VI Seat Allowable Leakage . . . . . 10-7 C-4 Minor Losses for 80-INF-1500:
10-7 Valve Packing . . . . . . . . . . . . . . . . . . . . . 10-8 Run C-J . . . . . . . . . . . . . . . . . . . . . . . . . C-8
10-8 Common Globe Valve Seating . . . . . . . 10-12 C-5 Minor Losses for 80-INF-1500:
10-9 Example Values of Valve Run F-G . . . . . . . . . . . . . . . . . . . . . . . . C-9
Capacity Factors . . . . . . . . . . . . . . . . . 10-17 C-6 Flow Coefficient - Cv - Characterized
10-10 Valve Schedule . . . . . . . . . . . . . . . . . . . 10-21 Seat Control Valves . . . . . . . . . . . . . . C-11
10-11 Valve Operator Schedule . . . . . . . . . . . 10-22 C-7 Line 80-INF-1500 Moments . . . . . . . . C-17
11-1 Summary of Pressure Device Limits . . . 11-6 C-8 Line 80-INF-1500 Displacement
11-2 Typical Reduced Pressure Backflow Stresses . . . . . . . . . . . . . . . . . . . . . . . . C-19
Prevention Assembly . . . . . . . . . . . . . . 11-8 C-9 Line 80-INF-1500 Supports . . . . . . . . . C-20
11-3 Material Temperature Ranges . . . . . . . 11-11 C-10 Line 80-IAS-1600 Supports . . . . . . . . . C-21
11-4 Typical Manufacturers' Data List . . . . . 11-11 C-11 Minor Losses for 80-IAS-1620 . . . . . . C-22
B-1 Fluid/Material Index . . . . . . . . . . . . . . . . B-2 C-12 Line 80-IAS-1620 Displacement
C-1 Pollutant Concentrations . . . . . . . . . . . . . C-1 Stresses . . . . . . . . . . . . . . . . . . . . . . . . C-26
C-2 Process Conditions, Design C-13 Line 80-IAS-1620 Supports . . . . . . . . . C-27
Example Process Flow Diagram, C-14 Minor Losses for 40-SLG-1660 . . . . . . C-29
Continued . . . . . . . . . . . . . . . . . . . . . . . C-3 C-15 Minor Losses for 25-PYS-101 . . . . . . . C-34
C-16 Minor Losses for 40-FES-111 . . . . . . . C-40
LIST OF FIGURES
FIGURE PAGE FIGURE PAGE
2-1 Process Flow Diagram (PFD) . . . . . . . . . 2-3 10-1 Valve Flow Characteristics . . . . . . . . . . . 10-2
2-2 Piping and Instrumentation 10-2 Control Valve Pressure Drop Curve . . 10-14
Diagram (P&ID) . . . . . . . . . . . . . . . . . . . 2-4 10-3 Control Valve Sizing . . . . . . . . . . . . . . 10-15
2-3 Flexibility Arrangements . . . . . . . . . . . . 2-12 10-4 Valve Factor Diagram . . . . . . . . . . . . . 10-18
2-4 Remediation Process 10-5 Critical Pressure Ratios . . . . . . . . . . . . 10-19
Piping Plan . . . . . . . . . . . . . . . . . . . . . . . 2-13 11-1 Flexible Coupling . . . . . . . . . . . . . . . . . . 11-2
2-5 Isometric View . . . . . . . . . . . . . . . . . . . . 2-14 11-2 Pressure and Vacuum Breaker . . . . . . . . 11-4
3-1 Moody Diagram . . . . . . . . . . . . . . . . . . . 3-11 12-1 Cathodic Protection Methods . . . . . . . . . 12-3
3-2 Pipe Supports for Ambient C-1 Design Example Process
Applications . . . . . . . . . . . . . . . . . . . . . 3-29 Flow Diagram . . . . . . . . . . . . . . . . . . . . C-2
4-1 Concentration-Cell Corrosion of C-2 Design Example Piping and
Underground Pipeline . . . . . . . . . . . . . . . 4-5 Instrumentation Diagram . . . . . . . . . . . C-4
8-1 Primary Piping Thermal C-3 Piping Layout Plan . . . . . . . . . . . . . . . . . C-5
Expansion . . . . . . . . . . . . . . . . . . . . . . . . 8-4 C-4 Piping Layout Plan with Support
8-2 Double Containment Piping Locations . . . . . . . . . . . . . . . . . . . . . . . C-37
Expansion Loop Configuration . . . . . . . . 8-5
iv
EM 1110-1-4008
5 May 99
Chapter 1 1004/10 (Air Force) contain additional guidance

Introduction pertaining to cathodic protection of underground
pipelines.
1-1. Purpose
1-6. Metrics
This United States Army Corps of Engineers (USACE)
Engineer Manual (EM) 1110-1-4008 provides Both the International System of Units (SI) (the
information for the design of liquid process piping Modernized Metric System) and the Inch-Pound (IP)
systems. ("English") system of measurement are used in this
manual. Pipe and appurtenances are provided in standard
dimensions, either in International Organization for
1-2. Applicability
Standardization (ISO) sizes which are SI based, or in
Liquid process piping systems include all pipe and American National Standards Institute (ANSI) sizes
appurtenances which are used to convey liquids to, from which are IP based. Table 1-1 compares the standard
and between pumping, storage and treatment units and sizes of the measurement systems. Standard sizes under
which are not integral to any unit (i.e., piping that is the two systems are close, but not equivalent. A similar
furnished as a part of the unit). Plumbing is covered by table is included in the Tri-Service CADD Details
TM 5-810-5, potable water piping is covered by TI 814- Library.
03, sewage piping is covered by TI 814-10, storm
drainage, and fuel and lubricant supply piping are a. SI Design Requirement
excluded.
In accordance with ER 1110-1-4, where feasible, all
project designs for new facilities after 1 January 1994
1-3. References
must be developed using the SI system of measurement.
Required and related references are listed in Appendix A. The USACE metric conversion has been closely
coordinated with that of the construction industry. Where
the industry has committed to a "hard" metric product,
1-4. Distribution
USACE must specify and use that product in its designs.
Where the industry is as yet undecided, IP products
This manual is approved for public release; distribution
should be used with a "soft" conversion when design
is unlimited.
efficiency or architectural treatments are not
compromised. The limited availability of some metric
1-5. Scope
products may require additional investigation, may result
in more complex procurement, and may alter scheduling
This manual includes criteria for the design of component
during construction.
parts and assemblies of liquid process piping systems.
Compliance with these criteria requires only that
1-7. Brand Names
fundamental design principles be followed. Materials
and practices not prohibited by this manual or its basic
The citation in this manual of brand names of
references should also be considered. Where special
commercially available products does not constitute
conditions and problems are not specifically addressed in
official endorsement or approval of the use of such
this manual, acceptable industry standards should be
products.
followed. Modifications or additions to existing systems
solely for the purpose of meeting criteria in this manual
1-8. Accompanying Guidance Specification
are not authorized.
This manual is intended to be used in conjunction with
a. Cathodic Protection
CEGS 15200, Liquid Process Piping.
All underground ferrous piping will be cathodically
protected. TM 5-811-7 (Army) and MIL-HDBK-
1-1
EM 1110-1-4008
5 May 99
Table 1-1
Standard Pipe Dimensions
ANSI ISO
Nominal Pipe Size Actual Do
Nominal Pipe Size Actual Do
(in) (in) (mm) (in) (mm) (in)
c 0.405 6 (0.236) 10 (0.394)

¼ 0.540 8 (0.315) 12 (0.472)
d 0.675 10 (0.394) 16 (0.630)
½ 0.840 15 (0.591) 20 (0.787)
¾ 1.050 20 (0.787) 25 (0.984)
1 1.315 25 (0.984) 32 (1.260)
1¼ 1.660 32 (1.260) 40 (1.575)
1½ 1.900 40 (1.575) 50 (1.969)
2 2.375 50 (1.969) 63 (2.480)
2½ 2.875 65 (2.559) 75 (2.953)
3 3.500 80 (3.150) 90 (3.543)
4 4.500 100 (3.937) 110 (4.331)
5 5.563 125 (4.921) 140 (5.512)
6 6.625 150 (5.906) 160 (6.299)
8 8.625 200 (7.874) 225 (8.858)
10 10.75 250 (9.843) 280 (11.024)
12 12.75 300 (11.81) 315 (12.402)
14 14.00 350 (13.78) 356 (14.00)
16 16.00 400 (15.75) 407 (16.00)
18 18.00 450 (17.72) 457 (18.00)
20 20.00 500 (19.69) 508 (20.00)
-- -- 550 (21.65) 559 (22.00)
24 24.00 600 (23.62) 610 (24.02)
-- -- 650 (25.59) 660 (25.98)
28 28.00 700 (27.56) 711 (27.99)
30 30.00 750 (29.53) 762 (30.00)
32 32.00 800 (31.50) 813 (32.00)
-- -- 850 (33.46) 864 (34.02)
36 36.00 900 (35.43) 914 (35.98)
40 40.00 1000 (39.37) 1016 (40.00)
-- -- 1050 (41.34) 1067 (42.00)
44 44.00 1100 (43.31) 1118 (44.00)
48 48.00 1200 (47.24) 1219 (48.00)
52 52.00 1300 (51.18) 1321 (52.00)
56 56.00 1400 (55.12) 1422 (56.00)
60 60.00 1500 (59.06) 1524 (60.00)
Note: Do = Outer Diameter
1-2
EM 1110-1-4008
5 May 99
1-9. Manual Organization
Chapter 2 of this manual provides basic principles and

guidance for design. Chapter 3 presents engineering
calculations and requirements for all piping systems,
regardless of construction material. Subsequent chapters
address engineering requirements for specific materials
of construction, valves, ancillary equipment, and
corrosion protection.
a. Fluid/Material Matrix
Appendix B contains a matrix that compares pipeline

material suitability for different process applications.
Design for specific process applications should consider
temperature, pressure and carrier fluid. The use of
Appendix B is addressed in Chapter 3.
1-3
EM 1110-1-4008
5 May 99
Chapter 2
Table 2-1
Design Strategy System Description
2-1. Design Analyses 1. Function

The design analyses includes the design of the process 2. Bases of Design
piping systems. The design criteria includes applicable
codes and standards, environmental requirements, and Environmental
other parameters which may constrain the work. Safety
Performance Requirements
a. Calculations Codes and Standards
Engineering calculations included in the design analyses 3. Description

document the piping system design. Combined with the
piping design criteria, calculations define the process General Overview
flow rates, system pressure and temperature, pipe wall System Operation
thickness, and stress and pipe support requirements. Major Components
Design calculations are clear, concise, and complete.
The design computations should document assumptions
made, design data, and sources of the data. All references
(for example, manuals, handbooks, and catalog cuts), 2-3. Drawings
alternate designs investigated, and planned operating
procedures are included. Computer-aided design Contract drawings include layout piping drawings,
programs can be used but are not a substitute for the fabrication or detail drawings, equipment schedules, and
designer's understanding of the design process. pipe support drawings. Isometric drawings may also be
included and are recommended as a check for
b. System Descriptions interferences and to assist in pipe stress analyses. A
detailed pipe support drawing containing fabrication
System descriptions provide the functions and major details is required. Piping supports can be designed by
features of each major system and may require inputs the engineer or the engineer may specify the load, type of
from mechanical, electrical and process control support, direction and degree of restraint.
disciplines. The system description contains system
design bases, operating modes and control concepts, and a. Drawings Requirements
both system and component performance ratings. System
descriptions provide enough information to develop The requirements and procedures for the preparation and
process flow diagrams (PFDs), piping and approval of drawings shall meet ER 1110-345-700,
instrumentation diagrams (P&IDs), and to obtain any Design Analysis, Drawings and Specifications. This
permits or approvals necessary to proceed. Table 2-1 regulation addresses the stages of design and
lists the typical contents of a system description. construction, other than shop drawings.
2-2. Specifications b. Process Flow Diagram (PFD) Content
Piping specifications define material, fabrication, PFDs are the schematic illustrations of system
installation and service performance requirements. The descriptions. PFDs show the relationships between the
work conforms to ER 1110-345-700, Design Analysis, major system components. PFDs also tabulate process
Drawings and Specifications. In addition, the project design values for different operating modes, typically
design must adhere to general quality policy and normal, maximum and minimum. PFDs do not show
principles as described in ER 1110-1-12, Quality piping ratings or designations, minor piping systems, for
Management. example, sample lines or valve bypass lines;
2-1
EM 1110-1-4008
5 May 99
instrumentation or other minor equipment, isolation

valves, vents, drains or safety devices unless operable in Table 2-3
a described mode. Table 2-2 lists the typical items P&IDs
contained on a PFD, and Figure 2-1 depicts a small and
simplified PFD. 1. Mechanical Equipment, Names and Numbers
2. All Valves and Identification

Table 2-2
PFDs 3. Instrumentation and Designations
1. Major Equipment Symbols, Names, 4. All Process Piping, Sizes and Identification
Identification Number
5. Miscellaneous Appurtenances including
2. Process Piping Vents, Drains, Special Fittings, Sampling
Lines, Reducers and Increasers
3. Control Valves and Other Valves that Affect
Operations 6. Direction of Flow
4. System Interconnections 7. Class Change
5. System Ratings and Operational Variables 8. Interconnections
maximum, average, minimum flow 9. Control Inputs/Outputs and Interlocks

maximum, average, minimum pressure
maximum, average, minimum temperature
6. Fluid Composition 2-4. Bases of Design
The bases of design are the physical and material

parameters; loading and service conditions; and
c. Piping and Instrumentation Diagram (P&ID) environmental factors that are considered in the detailed
Content design of a liquid process piping system to ensure a
reasonable life cycle. The bases of design must be
P&IDs schematically illustrate the functional relationship developed in order to perform design calculations and
of piping, instrumentation and system equipment prepare drawings.
components. P&IDs show all of the piping, including the
intended physical sequence of branches, reducers, and a. Predesign Surveys
valves, etc.; equipment; instrumentation and control
interlocks. The P&IDs are used to operate the process Predesign surveys are recommended for the design of
systems. Table 2-3 lists the typical items contained on a liquid process piping for new treatment processes and are
P&ID, and Figure 2-2 depicts a small and simplified a necessity for renovation or expansion of existing
P&ID. processes. A site visit provides an overview of the
project. Design requirements are obtained from the
d. Piping Sketches customer, an overall sense of the project is acquired, and
an understanding of the aesthetics that may be involved is
Major piping sketches may be included in a preliminary developed. For an existing facility, a predesign survey
design submittal. Sketches of the major piping systems can be used to evaluate piping material compatibility,
may be overlaid on preliminary equipment locations and confirm as-built drawings, establish connections, and
structural plans to indicate new pipe runs and provide develop requirements for aesthetics.
data input for a cost estimate.
2-2
Figure 2-1. Process Flow Diagram (PFD)
2-3
5 May 99
EM 1110-1-4008
(Source: SAIC, 1998.)

2-4
5 May 99
EM 1110-1-4008
Figure 2-2. Piping and Instrumentation Diagram (P&ID)

EM 1110-1-4008
5 May 99
Soil conditions play a major role in the selection of piping These combinations are referred to as the service
systems. Soils which contain organic or carbonaceous conditions of the piping. Service conditions are used to
matter such as coke, coal or cinders, or soils set design stress limits and may be defined or specified by
contaminated with acid wastes, are highly corrosive. code, or are determined based on the system description,
These conditions impact ferrous metals more than site survey, and other design bases.
nonferrous metals. For normally acceptable metals, soil
variations may be significant. Buried pipes corrode faster c. Design Codes and Standards
at the junction line of dissimilar soils. In fact, electric
potentials up to one (1) volt may be generated by placing Standards, codes and specifications referenced
a metal pipe where it crosses dissimilar soils. throughout this document are issued by the organizations
listed in Table 2-4. Codes and standards are reviewed
Paragraph 12-2d addresses requirements for predesign based on project descriptions to determine and verify
surveys and soils sampling that may be necessary to applicability. This manual generally follows the
design cathodic protection systems. American Society of Mechanical Engineers (ASME)
Code for Pressure Piping, B31. ASME B31 includes the
b. Service Conditions minimum design requirements for various pressure
piping applications. While this manual is not
The piping system is designed to accommodate all comprehensive in including code requirements, it
combinations of loading situations (pressure changes, includes standards and recommendations for design of
temperature changes, thermal expansion/contraction and pressure piping.
other forces or moments) that may occur simultaneously.
Table 2-4
Standards and Codes
ANSI American National Standards Institute

11 West 42nd Street, New York, NY 10036
API American Petroleum Institute
1220 L Street NW, Washington, DC 20005
ASME The American Society of Mechanical Engineers
345 47th Street, New York, NY 10017
ASQC American Society for Quality Control
P. O. Box 3005, Milwaukee, WI 53201
ASTM American Society for Testing and Materials
100 Barr Harbor Drive, West Conshohocken, PA 19428
ISO International Organization for Standardization
1 Rue de Varembe, Geneva, Switzerland
MSS Manufacturer’s Standardization Society for the Valves and Fittings Industry
127 Park Street NE, Vienna, VA 22180
NIST National Institute of Standards and Technology Department of Commerce
Washington, D.C.
2-5
EM 1110-1-4008
5 May 99
Piping codes supply required design criteria. These manual, TM 5-811-7 (Army) and MIL-HDBK-1004/10
criteria are rules and regulations to follow when (Air Force), contain additional guidance pertaining to
designing a piping system. The following list is a sample cathodic protection of underground pipelines.
of some of the parameters which are addressed by design
criteria found in piping codes: Design concerns for the effects of physically damaging
events fall into two broad categories: operational
- allowable stresses and stress limits; phenomena (for example, fires, spills, power outages,
- allowable dead loads and load limits; impacts/collisions, and breakdown or failure of associated
- allowable live loads and load limits; equipment) and natural phenomena (for example, seismic
- materials; occurrences, lightning strikes, wind, and floods). Risk is
- minimum wall thickness; a combination of probability and consequence. There are
- maximum deflection; infinite possibilities and all scenarios will not be covered
- seismic loads; and by direct reference to codes. Design experience must be
- thermal expansion. combined with a thorough evaluation of the likelihood of
all abnormal events.
Codes do not include components such as fittings, valves,
and meters. Design of these piping system components Working fluids carry abrasives that may wear internal
should follow industry standards. Standards supply surfaces. The accumulating damage may be impossible
required design criteria and rules for individual to observe until after system failure has occurred. The
components or classes of components, such as valves, most effective defense against this damage is to design
meters, and fittings. The purpose of standards is to protection into the system. Depending upon the process,
specify rules for each manufacturer of these components. monitoring pipe wall thicknesses may be necessary as an
This permits component interchangeability in a piping additive or alternate method to prevent failure due to
system. Standards apply to both dimensions and erosion.
performance of system components and are prescribed
when specifying construction of a piping system. It may not be practical in many cases to provide
corrosion-resistant materials due to structural needs or
d. Environmental Factors other overriding physical constraints. In these cases, the
most effective solution may be to design thicker
The potential for damage due to corrosion must be components to allow for the effects of corrosion
addressed in the design of process piping. Physical occurring, over time. However, an understanding of a
damage may also occur due to credible operational and system’s environmental factors is required. For example,
natural phenomena, such as fires, earthquakes, high although it is generally true that thicker components will
winds, snow or ice loading, and subsidence. Two last longer in a corrosive situation, in a situation where
instances of temperature changes must be considered as severe pitting corrosion (see Paragraph 4-2 for
a minimum. First, there are diurnal and seasonal definitions and description of various types of corrosion)
changes. Second, thermal expansion where elevated is occurring thicker components may not last much longer
liquid temperatures are used must be accommodated. than those with standard thicknesses. In this case other
Compensation for the resulting expansions and design solutions are provided.
contractions are made in both the piping system and
support systems. Internal wear and erosion also pose The most common installation constraint is the need to
unseen hazards that can result in system failures. avoid interconnection of dissimilar metals. For example,
piping is often totally destroyed by connecting brass
Chapter 4 discusses why corrosion occurs in metallic valves to carbon steel pipe. Short, easily replaced spools
piping, the problems that can result from corrosion, and may be considered for installation on both sides of such
how appropriate material choices can be made to components in order to protect the piping.
minimize corrosion impacts. All underground ferrous
piping must be cathodically protected. Chapter 12 of this
2-6
EM 1110-1-4008
5 May 99
e. Safety Provisions (1) For transient pressure conditions which exceed

the design pressure by 10 percent or less and act for
Safety provisions as required by EM 385-1-1, The Safety less than 10 percent of the total operating time,
and Health Requirements Manual, USACE guide neglect the transient and do not increase the design
specifications, trade standards, codes, and other manuals pressure.
are referenced here. Requirements of the Occupational (2) For transients whose magnitude or duration is
Safety and Health Administration (OSHA) are minimum greater than 10 percent of the design pressure or
design constraints in USACE projects. operating time, increase the design pressure to
encompass the range of the transient.
2-5. Loading Conditions
The determination of design pressure and analysis of
As described in Paragraph 2-4, the stresses on a piping pressure transients are addressed in Paragraph 3-2.
system define the service conditions of the piping system
and are a function of the loads on that system. The Dead weight is the dead load of a piping system or the
sources of these loads are internal pressure, piping weight of the pipe and system components. Dead weight
system dead weight, differential expansion due to generally does not include the weight of the system fluid.
temperature changes, wind loads, and snow or ice loads. The weight of the fluid is normally considered an
Loads on a piping system are classified as sustained or occasional load by code.
occasional loads.
For buried piping, dead weight is not a factor. However,
a. Sustained Loads a sustained load that is analyzed is the load from the earth
above the buried piping. Because of the different
Sustained loads are those loads that do not vary potential for deformation, the effects of an earth load on
considerably over time and are constantly acting on the flexible piping and rigid piping are analyzed differently.
system. Examples of sustained loads are the pressures, Paragraph 5-1 f addresses earth loads on buried flexible
both internal and external, acting on the system and the piping. The earth load on rigid piping may be calculated
weight of the system. The weight of the system includes using the following formula.1
both that of the piping material and the operating fluid.
TH
FE '
The sustained maximum system operating pressure is the a
basis for the design pressure. The design temperature is
the liquid temperature at the design pressure. The
minimum wall thickness of the pipe and the piping where:
components pressure rating is determined by the design FE = earth load, kPa (psi)
temperature and pressure. Although the design pressure T= soil weight, kg/m3 (lb/ft3); typically 1,922 kg/m3
is not to be exceeded during normal, steady-state (120 lb/ft3)
operations, short-term system pressure excursions in H = height of cover, m (ft)
excess of the design pressures occur. These excursions a = conversion factor, 102 kg/m2/kPa (144
are acceptable if the pressure increase and the time lb/ft2/psi).
durations are within code defined limits.
b. Occasional Loads
Piping codes provide design guidance and limits for
design pressure excursions. If a code does not have an Occasional loads are those loads that act on the system on
over-pressure allowance, transient conditions are an intermittent basis. Examples of occasional loads are
accounted for within the system design pressure. A those placed on the system from the hydrostatic leak test,
reasonable approach to over-pressure conditions for seismic loads, and other dynamic loads. Dynamic loads
applications without a specific design code is: are those from forces acting on the system, such as forces
1
AWWA C150, pp. 4-5.
2-7
EM 1110-1-4008
5 May 99
caused by water hammer (defined on page 3-5) and the cases, local climate and topography dictate a larger load.
energy released by a pressure relief device. Another type This is determined from ANSI A58.1, local codes or by
of occasional load is caused by the expansion of the research and analysis of other data. Snow loads can be
piping system material. An example of an expansion load ignored for locations where the maximum snow is
is the thermal expansion of pipe against a restraint due to insignificant. Ice buildup may result from the
a change in temperature. environment, or from operating conditions.
Wind load is a transient, live load (or dynamic load) The snow loads determined using ANSI A58.1 methods
applied to piping systems exposed to the effects of the assume horizontal or sloping flat surfaces rather than
wind. Obviously the effects of wind loading can be rounded pipe. Assuming that snow laying on a pipe will
neglected for indoor installation. Wind load can cause take the approximate shape of an equilateral triangle with
other loads, such as vibratory loads, due to reaction from the base equal to the pipe diameter, the snow load is
a deflection caused by the wind. The design wind speed calculated with the following formula.
is determined from ASCE 7 and/or TI 809-01, Load
Assumptions for Buildings, although a minimum of 161
WS ' ½ n D o S L
km/h (100 miles per hour) will be used. By manipulating
Bernoulli’s equation, the following equation may be
obtained to calculate the horizontal wind load on a
projected pipe length. where:
WS = design snow load acting on the piping, N/m

FW ' CW1 VW2 CD Do (lb/ft)
Do = pipe (and insulation) outside diameter, mm (in)
SL = snow load, Pa (lb/ft2)
where: n = conversion factor, 10-3 m/mm (0.083 ft/in).
FW = design wind load per projected pipe length,
N/m (lb/ft) Ice loading information does not exist in data bases like
VW = design wind speed, m/s (miles/hr) snow loading. Unless local or regional data suggests
CD = drag coefficient, dimension less otherwise, a reasonable assumption of 50 to 75 mm (2 to
Do = pipe (and insulation) outside diameter, mm (in) 3 in) maximum ice accumulatio is used to calculate an ice
CW1 = constant, 2.543 x 10-6 (N/m)/[mm(m/s)] (2.13 loading:
x 10-4 (lb/ft)/[in(mile/hr)]).
WI ' B n3 SI tI (Do % tI)
The drag coefficient is obtained from ASCE 7 and is a
function of the Reynolds Number, Re, of the wind flow
across the projected pipe.
where:
WI = design ice load, N/m (lbs/ft)
Re ' CW2 VW Do
SI = specific weight of ice, 8820 N/m3 (56.1 lbs/ft3)
tI = thickness of ice, mm (in)
Do = pipe (and insulation) outside diameter, mm (in)
where: n3 = conversion factor, 10-6 m2 /mm2 (6.9 x 10 -3
2 2
Re = Reynolds Number ft /in ).
VW = design wind speed, m/s (miles/hr)
Do = pipe (and insulation) outside diameter, mm (in) Seismic loads induced by earthquake activity are live
CW2 = constant, 6.87 s/mm-m (780 hr/in-mile). (dynamic) loads. These loads are transient in nature.
Appropriate codes are consulted for specifying piping
Snow and ice loads are live loads acting on a piping systems that may be influenced by seismic loads. Seismic
system. For most heavy snow climates, a minimum snow zones for most geographical locations can be found in
load of 1.2 kPa (25 psf) is used in the design. In some TM 5-809-10, American Water Works Association
2-8
EM 1110-1-4008
5 May 99
(AWWA) D110, AWWA D103, or CEGS 13080, - always include a neoprene washer or grommet with
Seismic Protection for Mechanical Electrical Equipment. ceiling hangers; and
ASME B31.3 (Chemical Plant and Petroleum Refinery - inspect hanger rods during installation to ensure that
Piping) requires that the piping is designed for they are not touching the side of the isolator housings.
earthquake induced horizontal forces using the methods
of ASCE 7 or the Uniform Building Code. Flexible pipe connections should have a length of 6 to 10
times the pipe diameter and be a bellows-type or wire-
Hydraulic loads are by their nature transient loads caused reinforced elastomeric piping. Tie-rods are not used to
by an active influence on a piping system. Examples of bolt the two end flanges together2.
dynamic loads inherent to piping systems are pressure
surges such as those caused by pump starts and stops, Loads applied to a piping system can be caused by forces
valve actuation, water hammer, and by the energy resulting from thermal expansion and contraction. A load
discharged by a pressure relief valve. Examples of is applied to a piping system at restraints or anchors that
hydraulic loads causing pressure transients and the effect prevent movement of the piping system. Within the pipe
upon the design are provided in Paragraph 3-2b. material, rapid changes in temperature can also cause
loads on the piping system resulting in stresses in the
Vibration in a piping system is caused by the impact of pipe walls. Finally, loads can be introduced in the system
fluctuating force or pressure acting on the system. by combining materials with different coefficients of
Mechanical equipment such as pumps can cause expansion.
vibrations. Typically the low to moderate level of
periodic excitation caused by pumps do not result in Movements exterior to a piping system can cause loads to
damaging vibration. The potential for damage occurs be transmitted to the system. These loads can be
when the pressure pulses or periodic forces equate with transferred through anchors and supports. An example is
the natural resonant frequencies of the piping system. the settlement of the supporting structure. The settling
TM 5-805-4, Noise and Vibration Control, provides movement transfers transient, live loads to the piping
design recommendations for vibration control, system.
particularly vibration isolation for motor-pump
assemblies. In addition, TM 5-805-4 recommends the Live loads can result from the effects of vehicular traffic
following vibration isolation for piping systems: and are referred to as wheel loads. Because above
ground piping is isolated from vehicle traffic, these live
For connections to rotating or vibrating equipment, use loads are only addressed during the design of buried
resilient pipe supports and: piping. In general, wheel loads are insignificant when
compared to sustained loads on pressure piping except
- the first three supports nearest the vibrating equipment when buried at “shallow” depths.3 The term shallow is
should have a static deflection equal to ½ of that required defined based upon both site specific conditions and the
for the equipment; the remaining pipe supports should piping material. “However, as a rule, live loads diminish
have a static deflection of 5 to 12.5 mm (0.2 to 0.49 in); rapidly for laying depths greater than about four feet for
- provide a minimum 25 mm (1 in) clearance for a wall highways and ten feet for railroads.”4 Wheel loads are
penetration, support the pipe on both sides of the calculated using information in AASHTO H20 and
penetration to prevent the pipe from resting on the wall, guidance for specific materials such as AWWA C150
and seal the penetration with a suitable compound (fire- (ductile-iron and metallic), AWWA C900 (PVC) and
stop system, if required); AWWA C950 (FRP). For example, wheel loads for rigid
- use neoprene isolators in series with steel spring metallic piping over an effective length of 0.91 m (3 ft)
isolators; can be calculated using the following formula.5
2
TM 5-805-4, pp. 8-10 - 8-11.
3
EM 1110-2-503, p. 7-15.
4
Ibid., p. 7-15.
5
AWWA C150, pp. 4-5.
2-9
EM 1110-1-4008
5 May 99
Pipe flexibility is required to help control stress in liquid

C R P F
FW ' piping systems. Stress analysis may be performed using
b Do specialized software. The bases of the analyses are
developed in Chapter 3. Considerations that must be
accounted for in routing piping systems in order to
where: minimize stress include: avoiding the use of a straight
FW = wheel load, kPa (psi) pipe run between two equipment connections or fixed
C = surface load factor, see AWWA C150, Table anchor points (see Figure 2-3); locating fixed anchors
10.6M/10.6 near the center of pipe runs so thermal expansion can
R = reduction factor for a AASHTO H20 truck on an occur in two directions; and providing enough flexibility
unpaved or flexible paved road, see AWWA C150, in branch connections for header shifts and expansions.
Table 10.4M/10.4
P = wheel weight, kg (lb); typically 7,257 kg The load and minimum spacing requirements and support
(16,000 lb) hardware are addressed throughout this manual. The
F = impact factor; typically 1.5 layout design must also deal with piping support. Piping
b = conversion factor, 0.031 kg/m/kPa (12 lb/ft/psi) on racks are normally designed to bottom of pipe (BOP)
Do = pipe outside diameter, mm (in). elevations rather than centerline.
2-6. Piping Layout In addition, the piping layout should utilize the
surrounding structure for support where possible.
The bases of design establish the factors that must be Horizontal and parallel pipe runs at different elevations
included in liquid process piping design. The preparation are spaced for branch connections and also for
of the piping layout requires a practical understanding of independent pipe supports.
complete piping systems, including material selections,
joining methods, equipment connections, and service Interferences with other piping systems; structural work;
applications. The standards and codes previously electrical conduit and cable tray runs; heating, ventilation
introduced establish criteria for design and construction and air conditioning equipment; and other process
but do not address the physical routing of piping. equipment not associated with the liquid process of
concern must be avoided. Insulation thickness must be
a. Computer Aided Drafting and Design accounted for in pipe clearances. To avoid interferences,
composite drawings of the facility are typically used.
Computer based design tools, such as computer aided This is greatly aided by the use of CADD software.
draft and design (CADD) software, can provide powerful Figure 2-4 presents a simple piping layout and Figure 2-5
and effective means to develop piping layouts. Much of is a CADD generated 3-dimensional drawing of the
the commercially available software can improve layout. However, as mentioned previously in this chapter
productivity and may also assist in quality assurance, communications between engineering disciplines must be
particularly with interference analyses. Some CADD maintained as facilities and systems are typically designed
software has the ability to generate either 3-dimensional concurrently though designs may be in different stages of
drawings or 2-dimensional drawings, bills of material, completion.
and databases.
Lay lengths and other restrictions of in-line piping
b. Piping Layout Design equipment and other system equipment constraints must
be considered. For example, valve location
System P&IDs; specifications; and equipment locations considerations are listed in Table 2-5. Valves and other
or layout drawings that are sufficiently developed to show equipment such as flow instrumentation and safety relief
equipment locations and dimensions, nozzle locations and devices have specific location requirements such as
pressure ratings are needed to develop the piping layout. minimum diameters of straight run up- and downstream,
A completely dimensioned pipe routing from one point of vertical positioning and acceptable velocity ranges that
connection to another with all appurtenances and require pipe diameter changes. Manufacturers should be
branches as shown on the P&ID is prepared. consulted for specific requirements.
2-10
EM 1110-1-4008
5 May 99
Piping connections to pumps affect both pump operating

efficiency and pump life expectancy. To reduce the
effects, the design follows the pump manufacturer's
installation requirements and the Hydraulic Institute
Standards, 14th Edition. Table 2-6 provides additional
guidelines. The project process engineer should be
consulted when unique piping arrangements are required.
Miscellaneous routing considerations are: providing

piping insulation for personnel protection, access for
future component maintenance, heat tracing access,
hydrostatic test fill and drain ports, and air vents for
testing and startup operations. System operability,
maintenance, safety, and accessibility are all
considerations that are addressed in the design.
2-11
EM 1110-1-4008
5 May 99
Figure 2-3. Flexibility Arrangements

2-12
EM 1110-1-4008
5 May 99
Figure 2-4. Remediation Process Piping Plan

2-13
EM 1110-1-4008
5 May 99
Figure 2-5. Isometric View

2-14
EM 1110-1-4008
5 May 99
Table 2-5
Valve Location Design
1. Control valves - install with a minimum of 3 diameters of straight run both upstream and downstream, and
install vertically upright.
2. Butterfly and check valves - install with a minimum of 5 diameters of straight run upstream.
3. Non-control valves - install with stems in the horizontal to vertical positions and avoid head, knee, and tripping
hazards.
4. Chemical service valves - locate below eye level.
5. All valves - provide a minimum of 100 mm (3.94 in.) hand clearance around all hand wheels, allow space for
valve parts removal or maintenance, and avoid creating water hammer conditions.
Note: These guidelines are generally accepted practices. However, designs should conform to manufacturer’s
recommendations and commercial standards; for example, ASME and ISA standards.
Source: SAIC, 1998.
Table 2-6
Pump Connections Design
Supports Piping is independently supported from the pump. A

pipe anchor is provided between a flexible coupling and
the pump.
Suction Connections The pump suction is continuously flooded, has 3

diameters of straight run, uses long radius elbows, and
can accommodate a temporary in-line strainer.
Fittings An eccentric reducer, flat side up, is provided when a

pipe reduction is required at the pipe suction.
Flanges mating to flat faced pump flanges are also flat
faced and use full-faced gaskets and common (normal
strength) steel bolting.
Note: These guidelines are generally accepted practices. However, designs should conform to manufacturer’s
recommendations and Hydraulic Institute Standards.
Source: SAIC, 1998.
2-15
EM 1110-1-4008
5 May 99
Chapter 3 c. Toughness
General Piping Design
The toughness of a material is dependent upon both
strength and ductility. Toughness is the capability of a
3-1. Materials of Construction
material to resist brittle fracture (the sudden fracture of
Most failures of liquid process systems occur at or within materials when a load is rapidly applied, typically with
interconnect points - - the piping, flanges, valves, fittings, little ductility in the area of the fracture). Two common
etc. It is, therefore, vital to select interconnecting ASTM test methods used to measure toughness are the
equipment and materials that are compatible with each Charpy Impact and Drop-Weight tests. The Charpy
other and the expected environment. Materials selection brittle transition temperature and the Drop-Weight
is an optimization process, and the material selected for NDTT are important design parameters for materials that
an application must be chosen for the sum of its have poor toughness and may have lower operating
properties. That is, the selected material may not rank temperatures. A material is subject to brittle,
first in each evaluation category; it should, however, be catastrophic failure if used below the transition
the best overall choice. Considerations include cost and temperature.
availability. Key evaluation factors are strength, ductility,
toughness, and corrosion resistance. d. Corrosion Resistance
a. Strength Appendix B provides a matrix that correlates process

fluids, piping materials and maximum allowable process
The strength of a material is defined using the following temperatures to assist in determining material suitability
properties: modulus of elasticity, yield strength, and for applications.
ultimate tensile strength. All of these properties are
determined using ASTM standard test methods. e. Selection Process
The modulus of elasticity is the ratio of normal stress to Piping material is selected by optimizing the basis of
the corresponding strain for either tensile or compressive design. First, eliminate from consideration those piping
stresses. Where the ratio is linear through a range of materials that:
stress, the material is elastic; that is, the material will
return to its original, unstressed shape once the applied - are not allowed by code or standard;
load is removed. If the material is loaded beyond the - are not chemically compatible with the fluid;
elastic range, it will begin to deform in a plastic manner. -have system rated pressure or temperatures that do not
The stress at that deformation point is the yield strength. meet the full range of process operating conditions; and
As the load is increased beyond the yield strength, its - are not compatible with environmental conditions such
cross-sectional area will decrease until the point at which as external corrosion potential, heat tracing requirements,
the material cannot handle any further load increase. The ultraviolet degradation, impact potential and specific joint
ultimate tensile strength is that load divided by the requirements.
original cross-sectional area.
The remaining materials are evaluated for advantages and
b. Ductility disadvantages such as capital, fabrication and installation
costs; support system complexity; compatibility to handle
Ductility is commonly measured by either the elongation thermal cycling; and cathodic protection requirements.
in a given length or by the reduction in cross-sectional The highest ranked material of construction is then
area when subjected to an applied load. The hardness of selected. The design proceeds with pipe sizing, pressure-
a material is a measure of its ability to resist deformation. integrity calculations and stress analyses. If the selected
Hardness is often measured by either of two standard piping material does not meet those requirements, then
scales, Brinell and Rockwell hardness.
3-1
EM 1110-1-4008
5 May 99
the second ranked material is used and the pipe sizing, pressure has been addressed from a process requirement
pressure-integrity calculations and stress analyses are viewpoint to ensure proper operation of the system as a
repeated. whole. At this point in the detail design of the piping
system, it is necessary to ensure that the structural
Example Problem 1: integrity of the pipe and piping system components is
Assume a recovered material process line that handles maintained during both normal and upset pressure and
nearly 100% ethyl benzene at 1.20 MPa (174 psig) and temperature conditions. In order to select the design
25EC (77EF) is required to be installed above ground. pressure and temperature, it is necessary to have a full
The piping material is selected as follows: understanding and description of all operating processes
and control system functions. The pressure rating of a
Solution: piping system is determined by identifying the maximum
Step 1. Above ground handling of a flammable liquid by steady state pressure, and determining and allowing for
thermoplastic piping is not allowed by ASME B31.31. pressure transients.
Step 2. Review of the Fluid/Material Corrosion Matrix a. Maximum Steady State Pressure
(Appendix B) for ethyl benzene at 25EC (77EF) indicates
that aluminum, Hastelloy C, Monel, TP316 stainless The determination of maximum steady state design
steel, reinforced furan resin thermoset and FEP lined pipe pressure and temperature is based on an evaluation of
are acceptable for use. FKM is not available in piping. specific operating conditions. The evaluation of
conditions must consider all modes of operation. This is
Step 3. Reinforced furan resin piping is available to a typically accomplished utilizing design references, codes
system pressure rating of 689 kPa (100 psig)2; therefore, and standards. An approach using the code requirements
this material is eliminated from consideration. The of ASME B31.3 for maximum pressure and temperature
remainder of the materials have available system pressure loads is used herein for demonstration.
ratings and material allowable stresses greater than the
design pressure. Piping components shall be designed for an internal
pressure representing the most severe condition of
Step 4. FEP lined piping is not readily available coincident pressure and temperature expected in normal
commercially. Since other material options exist, FEP operation.3 This condition is by definition the one which
lined piping is eliminated from consideration. results in the greatest required pipe thickness and the
highest flange rating. In addition to hydraulic conditions
Step 5. The site specific environmental conditions are based on operating pressures, potential back pressures,
now evaluated to determine whether any of the remaining surges in pressures or temperature fluctuations, control
materials (aluminum, Hastelloy C, Monel or TP316 system performance variations and process upsets must
stainless steel) should be eliminated prior to ranking. be considered. The system must also be evaluated and
The material is then selected based on site specific designed for the maximum external differential pressure
considerations and cost. conditions.
3-2. Design Pressure Piping components shall be designed for the temperature
representing the most severe conditions described as
After the piping system’s functions, service conditions, follows:
materials of construction and design codes and standards
have been established (as described in Chapter 2) the - for fluid temperatures below 65EC (150EF), the metal
next step is to finalize the system operational pressures design temperature of the pipe and components shall be
and temperatures. Up to this point, the system operating taken as the fluid temperature.
1
ASME B31.3, p. 95.
2
Schweitzer, Corrosion-Resistant Piping Systems, p. 140.
3
ASME B31.3, p. 11.
3-2
EM 1110-1-4008
5 May 99
- for fluid temperatures above 65EC (150EF), the metal (d) The total number of pressure-temperature
design temperature of uninsulated pipe and components variations above the design conditions shall not exceed
shall be taken as 95% of the fluid temperature, except 1000 during the life of the piping system.
flanges, lap joint flanges and bolting shall be 90%, 85%
and 80% of the fluid temperature, respectively. (e) In no case shall the increased pressure exceed the
- for insulated pipe, the metal design temperature of the test pressure used under para. 345 [of ASME B31.3] for
pipe shall be taken as the fluid temperature unless the piping system.
calculations, testing or experience based on actual field
measurements can support the use of other temperatures. (f) Occasional variations above design conditions shall
- for insulated and heat traced pipe, the effect of the heat remain within one of the following limits for pressure
tracing shall be included in the determination of the metal design.
design temperature.4
(1) Subject to the owner's approval, it is permissible to
In addition to the impact of elevated temperatures on the exceed the pressure rating or the allowable stress for
internal pressure, the impact of cooling of gases or vapors pressure design at the temperature of the increased
resulting in vacuum conditions in the piping system must condition by not more than:
be evaluated.
(a) 33% for no more than 10 hour at any one time and
b. Pressure Transients no more than 100 hour per year; or
As discussed in Paragraph 2-5, short-term system
(b) 20% for no more than 50 hour at any one time and
pressure excursions are addressed either through code
no more than 500 hour per year.
defined limits or other reasonable approaches based on
experience. The ASME B31.3 qualification of
The effects of such variations shall be determined by the
acceptable pressure excursions states:
designer to be safe over the service life of the piping
system by methods acceptable to the owner. (See
“302.2.4 Allowances for Pressure and Temperature
Appendix V [of ASME B31.3])
Variations. Occasional variations of pressure or
temperature, or both, above operating levels are
(2) When the variation is self-limiting (e.g., due to a
characteristic of certain services. The most severe
pressure relieving event), and lasts no more than 50
conditions of coincident pressure and temperature
hour at any one time and not more than 500 hour/year,
during the variation shall be used to determine the
it is permissible to exceed the pressure rating or the
design conditions unless all of the following criteria are
allowable stress for pressure design at the temperature
met.
of the increased condition by not more than 20%.
(a) The piping system shall have no pressure containing
(g) The combined effects of the sustained and cyclic
components of cast iron or other nonductile metal.
variations on the serviceability of all components in the
system shall have been evaluated.
(b) Nominal pressure stresses shall not exceed the yield
strength at temperature (see para. 302.3 of this Code
(h) Temperature variations below the minimum
[ASME B31.3] and Sy data in [ASME] BPV Code,
temperature shown in Appendix A [of ASME B31.3] are
Section II, Part D, Table Y-1).
not permitted unless the requirements of para. 323.2.2
[of ASME B31.3] are met for the lowest temperature
(c) Combined longitudinal stress shall not exceed the
during the variation.
limits established in paragraph 302.3.6 [of ASME
B31.3].
4
ASME B31.3, pp. 11-12.
3-3
EM 1110-1-4008
5 May 99
(i) The application of pressures exceeding pressure- the effects of compression to 17.2 MPa (2,500 psig)
temperature ratings of valves may under certain using steam tables:
conditions cause loss of seat tightness or difficulty of
operation. The differential pressure on the valve
<&<f ' &0.000013 m 3/kg (&0.00021 ft 3/lbm)
closure element should not exceed the maximum
differential pressure rating established by the valve
manufacturer. Such applications are the owner's <f at 177EC (350EF) ' 0.001123 m 3/kg
responsibility.”5
(0.01799 ft 3/lbm), saturated
The following example illustrates a typical procedure for
the determination of design pressures. < at 17.2 MPa (2,500 psig)
' 0.001123 m 3/kg % (&0.000013 m 3/kg)

Example Problem 2:
Two motor-driven boiler feed pumps installed on the ' 0.001110 m 3/kg (0.01778 ft 3/lbm),
ground floor of a power house supply 0.05 m3/s (793 compressed
gpm) of water at 177EC (350EF) to a boiler drum which
is 60 m (197 ft) above grade. Each pump discharge pipe
is 100 mm (4 in), and the common discharge header to
the boiler drum is a 150 mm (6 in) pipe. Each pump where:
discharge pipe has a manual valve that can isolate it from < = specific volume of water, m3/kg (ft3/lbm)
the main header. A relief valve is installed upstream of <f = specific volume of feed water, m3/kg (ft3/lbm)
each pump discharge valve to serve as a minimum flow
bypass if the discharge valve is closed while the pump is The static head above the pumps due to the elevation of
operating. The back pressure at the boiler drum is 17.4 the boiler drum is:
MPa (2,520 psig). The set pressure of the relief valve is
1 m
19.2 MPa (2,780 psig), and the shutoff head of each Pst ' (60 m) 9.81
3
pump is 2,350 m (7,710 ft). The piping material is m s2
0.001110
ASTM A 106, Grade C, with an allowable working stress kg
of 121 MPa (17,500 psi), over the temperature range of
-6.7 to 343EC (-20 to 650EF). The corrosion allowance ' 530 kPa (76.9 psig)
is 2 mm (0.08 in) and the design code is ASME B31.1
(Power Piping).
where:
The design pressures for the common discharge header Pst = static head, kPa (psig)
and the pump discharge pipes upstream of the isolation
valve must be determined. Also the maximum allowable Step 2. The total discharge pressure at the pump exit is:
pressure is to be calculated assuming the relief valve on
a pump does not operate when its discharge valve is P ' Pb % Pst
closed.
' 17.4 MPa % 0.530 MPa
' 17.9 MPa (2,600 psig)
Solution:
Step 1. Determination of design pressure for the 150 mm
(6 in) header is as follows. The specific volume of where:
177EC (350EF) saturated water is 0.001123 m3/kg P = total discharge pressure, MPa (psig)
(0.01799 ft3/lbm). The specific volume is corrected for Pb = back pressure, MPa (psig)
Pst = static head, MPa (psig)
5
ASME B31.3, pp. 13-14.
3-4
EM 1110-1-4008
5 May 99
The design pressure for the 150 mm (6 in) header should

be set slightly above the maximum operating pressure.
Therefore the design pressure for the 150 mm (6 in) S ) ' 1.20 (S) ' 1.20 (121 MPa)
' 145 MPa (21,000 psi)
header is 18.3 MPa (2,650 psig).
Step 3. Determination of design pressure for the 100 mm

(4 in) pipe is as follows. The set pressure of the relief where:
valve is 19.2 MPa (2,780 psig). The design pressure of S' = higher allowable stress, MPa (psi)
the 100 mm (4 in) pipe upstream of the pump discharge S = code allowable stress, MPa (psi)
valve should be set at the relief pressure of the relief
valve. Although not shown in this example, the design Step 6. The maximum pressure rating of the 100 mm (4
pressure should also take into account any over-pressure in) pipe is calculated using the following equation8:
allowance in the relief valve sizing determination.
Therefore, for this example, the design pressure for the 2 S E (tm & A)
Pmax '
100 mm (4 in) pipe upstream of the pump isolation Do & 2 y (tm & A)
valves is 19.2 MPa (2,780 psig).
Step 4. The maximum allowable pressure in the 100 mm where:

(4 in) pipe is compared to that which would be observed Pmax = maximum allowable pressure, MPa (psig)
during relief valve failure. The probability that a valve S = code allowable stress, MPa (psi)
will fail to open is low. It is recognized that variations in E = joint efficiency
pressure and temperature inevitably occur. tm = pipe wall thickness, mm (in)
A = corrosion allowance, mm (in)
Do = outside diameter of pipe, mm (in)
"102.2.4 Ratings: Allowance for Variation From y = temperature-based coefficient, see ASME B31.1,
Normal Operation. The maximum internal pressure and for cast iron, non-ferrous metals, and for ferric
temperature allowed shall include considerations for steels, austenitic steels and Ni alloys less than
occasional loads and transients of pressure and 482EC (900EF), y = - 0.4.
temperature."6
The calculated stress resulting from such a variation in Step 7. For this example, the value of S is set to equal to
pressure and/or temperature may exceed the maximum S' and E = 1.00 for seamless pipe. The pipe wall
allowable stress from ASME B31.1 Appendix A by 15% thickness is determined in accordance to pressure
if the event duration occurs less than 10% of any 24- hour integrity, see Paragraph 3-3b, and is assumed equal to
operating period, or 20% if the event duration occurs less 87½% of the nominal wall thickness of schedule XXS
than 1% of any 24-hour operating period.7 The pipe. Therefore:
occasional load criteria of ASME B31.1, paragraph
102.2.4, is applied, and it is assumed that the relief valve tm ' 17.1 mm (0.875)
failure-to-open event occurs less than 1% of the time. ' 15.0 mm (0.590 in)
Therefore, the allowable stress is 20% higher than the
basic code allowable stress of 121 MPa (17,500 psi).
where
Step 5. The higher allowable stress is denoted as S': tm = pipe wall thickness, mm (in)
6
ASME B31.1, p. 13.
7
Ibid., p. 13.
8
Ibid., p. 17.
3-5
EM 1110-1-4008
5 May 99
and The velocity of the pressure wave is affected by the fluid

properties and by the elasticity of the pipe. The pressure
wave velocity in water is approximately 1,480 m/s (4,800
2(145 MPa)(1.0)(15.0 mm & 2 mm)
Pmax ' ft/s). For a rigid pipe, the pressure wave velocity is
114.3 mm & 2(0.4)(15.0 mm & 2 mm) calculated by:
' 36.3 MPa (5,265 psig)
1/2
Es
Vw '
where: n1 D
Pmax = maximum allowable pressure, MPa (psig)
Step 8. Therefore, the maximum allowable pressure in where:

the 100 mm (4 in) pipe section during a relief valve Vw = pressure wave velocity, m/s (ft/s)
failure is 36.3 MPa (5,265 psig). Es = fluid's bulk modulus of elasticity, MPa (psi)
D = fluid density, kg/m3 (slugs/ft3)
Another common transient pressure condition is caused n1 = conversion factor, 10-6 MPa/Pa for SI units (1
by suddenly reducing the liquid flow in a pipe. When a ft2/144 in2 for IP units)
valve is abruptly closed, dynamic energy is converted to
elastic energy and a positive pressure wave is created Because of the potential expansion of an elastic pipe, the
upstream of the valve. This pressure wave travels at or pressure wave for an elastic pipe is calculated by:
near the speed of sound and has the potential to cause
pipe failure. This phenomenon is called water hammer. 1/2
Es
Vw '
The maximum pressure rise is calculated by: E s Di
n1 D 1 %
Ep t
Pi ' D ) V Vw n1
where:
where: Vw = pressure wave velocity, m/s (ft/s)
Pi = maximum pressure increase, MPa (psi) Es = fluid's bulk modulus of elasticity, MPa (psi)
D = fluid density, kg/m3 (slugs/ft3) D = fluid density, kg/m3 (slugs/ft3)
) V = sudden change in liquid velocity, m/s (ft/s) Ep = bulk modulus of elasticity for piping material,
Vw = pressure wave velocity, m/s (ft/s) MPa (psi)
n1 = conversion factor, 10-6 MPa/Pa for SI units (1 Di = inner pipe diameter, mm (in)
ft2/144 in2 for IP units) t = pipe wall thickness, mm (in)
n1 = conversion factor, 10-6 MPa/Pa for SI units (1
The maximum time of valve closure that is considered ft2/144 in2 for IP units)
sudden (critical) is calculated by:
If the valve is slowly closed (i.e., the time of closure is
2 L
tc ' greater than the critical time), a series of small pressure
Vw waves is transmitted up the pipe and returning negative
pressure waves will be superimposed on the small
pressure waves and full pressure will not occur. The
where: pressure developed by gradual closure of a value is:
tc = critical time, s
L = length of pipe, m (ft)
2 D L V n1
Vw = pressure wave velocity, m/s (ft/s) PNi '
tv
3-6
EM 1110-1-4008
5 May 99
where: 1/2
PNI = pressure increase, MPa (psi) 2,180 MPa
Vw '
tv = valve closure time (10&6 MPa/Pa) (998.2 kg/m 3)
D = fluid density, kg/m3 (slugs/ft3)
L = length of pipe, m (ft) ' 1,478 m/s (4,848 ft/s)
V = liquid velocity, m/s (ft/s)
ft2/144 in2 for IP units) Step 2. Critical time for valve closure;
CECER has a computer program, WHAMO, designed to

2 L 2 (150 m)
simulate water hammer and mass oscillation in pumping tc ' '
facilities. The program determines time varying flow and Vw 1,478 m/s
head in a piping network which may includevalves,
' 0.2 s
pumps, turbines, surge tanks and junctions arranged in a
reasonable configuration. Transients are generated in the
program due to any variation in the operation of pumps,
valves, and turbines, or in changes in head. where:
tc = critical time, s
Example Problem 3: L = Length of pipe, m (ft)
Water at 20EC (68EF) flows from a tank at a velocity of Vw = pressure wave velocity, m/s (ft/s)
3 m/s (9.8 ft/s) and an initial pressure of 275 kPa (40 psi)
in a 50 mm (2 in) PVC pipe rated for 16 kgf/cm2 (SDR Step 3. Maximum pressure rise (valve closure time <
26); i.e., wall thickness is 4.7 mm (0.091 in for SDR 26). critical time, tc);
A valve 150 m (492 ft) downstream is closed. Determine
the critical time of closure for the valve and the internal
Pi ' D ) V Vw n1
system pressure if the valve is closed suddenly versus
gradually (10 times slower).
Solution: where:
Step 1. Velocity of the pressure wave assuming rigid Pi = maximum pressure increase, MPa (psi)
pipe; D = fluid density, kg/m3 (slugs/ft3)
) V = sudden change in liquid velocity, m/s (ft/s)
Vw = pressure wave velocity, m/s (ft/s)
1/2
Es ft2/144 in2 for IP units)
Vw '
n1 D
kg m m MPa
Pi ' 998.2 3 1,478 10&6
where: m3 s s Pa
Vw = pressure wave velocity, m/s (ft/s)
Es = fluid's bulk modulus of elasticity; for water at ' 4.43 MPa (642 psi)
20EC (68EF) = 2,180 MPa (319,000 psi)
ft2/144 in2 for IP units) Therefore, maximum system pressure is
D= fluid density, for water at 20EC (68EF) = 998.2
kg/m3 (1.937 slugs/ft3) Pmax ' 4.43 MPa % 275 kPa (10&3 MPa/kPa)
' 4.71 MPa (682 psig)
3-7
EM 1110-1-4008
5 May 99
Step 4. Pressure increase with gradual valve closure Before the determination of the minimum inside diameter
(valve closure time = critical time, tc, x 10 = 2s) can be made, service conditions must be reviewed to
determine operational requirements such as
2 D L V n1
PNi ' recommended fluid velocity for the application and liquid
tv characteristics such as viscosity, temperature, suspended
solids concentration, solids density and settling velocity,
abrasiveness and corrosivity. This information is then
where: used to determine the minimum inside diameter of the
PNI = pressure increase, MPa (psi) pipe for the network.
tv = valve closure time
D = fluid density, kg/m3 (slugs/ft3) For normal liquid service applications, the acceptable
L = length of pipe, m (ft) velocity in pipes is 2.1 ± 0.9 m/s (7 ± 3 ft/s) with a
V = liquid velocity, m/s (ft/s) maximum velocity limited to 2.1 m/s (7 ft/s) at piping
n1 = conversion factor, 10-6 MPa/Pa for SI units (1 discharge points including pump suction lines and drains.
ft2/144 in2 for IP units) As stated, this velocity range is considered reasonable for
normal applications. However, other limiting criteria
such as potential for erosion or pressure transient
kg m conditions may overrule. In addition, other applications
2 998.2 (150m) 3
m 3 s kPa may allow greater velocities based on general industry
PNi ' 10&3
2 s Pa practices; e.g., boiler feed water and petroleum liquids.
' 449 kPa (65 psi) Pressure drops throughout the piping network are
designed to provide an optimum balance between the
installed cost of the piping system and operating costs of
Therefore, the maximum system pressure is 449 kPa + the system pumps. Primary factors that will impact these
275 kPa = 724 kPa (105 psig). costs and system operating performance are internal pipe
diameter (and the resulting fluid velocity), materials of
For a more complex review of water hammer effects in construction and pipe routing.
pipes, refer to the references found in Appendix A,
Paragraph A-4. Pressure drop, or head loss, is caused by friction between
the pipe wall and the fluid, and by minor losses such as
3-3. Sizing flow obstructions, changes in direction, changes in flow
area, etc. Fluid head loss is added to elevation changes to
The sizing for any piping system consists of two basic determine pump requirements.
components fluid flow design and pressure integrity
design. Fluid flow design determines the minimum A common method for calculating pressure drop is the
acceptable diameter of the piping necessary to transfer Darcy-Weisbach equation:
the fluid efficiently. Pressure integrity design determines
the minimum pipe wall thickness necessary to safely
f L V2
handle the expected internal and external pressure and hL ' % EK ; loss coefficient method
loads. Di 2 g
a. Fluid Flow Sizing

or
The primary elements in determining the minimum
(L % Le) V 2
acceptable diameter of any pipe network are system hL ' f ; equivalent length method
design flow rates and pressure drops. The design flow Di 2 g
rates are based on system demands that are normally
established in the process design phase of a project.
3-8
EM 1110-1-4008
5 May 99
where: and entrance losses. The coefficients can be determined

hL = head loss, m (ft) from Table 3-3.
f = friction factor
L = length of pipe, m (ft) Another method for calculating pressure drop is the
Di = inside pipe diameter, m (ft) Hazen-Williams formula:
Le = equivalent length of pipe for minor losses, m
(ft)
K = loss coefficients for minor losses 1.85
V
V = fluid velocity, m/s (ft/sec) hL ' (L % Le)
g = gravitational acceleration, 9.81 m/sec2 (32.2 a C (Di /4)0.63
ft/sec2)
The friction factor, f, is a function of the relative where:

roughness of the piping material and the Reynolds hL = head loss, m (ft)
number, Re. L = length of pipe, m (ft)
Di V
Re ' (ft)
< V = fluid velocity, m/s (ft/s)
a = empirical constant, 0.85 for SI units (1.318 for
IP units)
where: C = Hazen-Williams coefficient
Re = Reynolds number Di = inside pipe diameter, m (ft)
Di = inside pipe diameter, m (ft)
V = fluid velocity, m/s (ft/s) The Hazen-Williams formula is empirically derived and
< = kinematic viscosity, m2/s (ft2/s) is limited to use with fluids that have a kinematic
viscosity of approximately 1.12 x 10-6 m2/s (1.22 x 10-5
If the flow is laminar (Re < 2,100), then f is determined ft2/s), which corresponds to water at 15.6EC (60EF), and
by: for turbulent flow. Deviations from these conditions can
64 lead to significant error. The Hazen-Williams coefficient,
f ' C, is independent of the Reynolds number. Table 3-1
Re
provides values of C for various pipe materials.
The Chezy-Manning equation is occasionally applied to

where: full pipe flow. The use of this equation requires turbulent
f = friction factor flow and an accurate estimate of the Manning factor, n,
Re = Reynolds number which varies by material and increases with increasing
pipe size. Table 3-1 provides values of n for various pipe
If the flow is transitional or turbulent (Re > 2,100), then materials. The Chezy-Manning equation is:
f is determined from the Moody Diagram, see Figure 3-1.
The appropriate roughness curve on the diagram is V2 n2
hL ' (L % Le)
determined by the ratio ,/Di where , is the specific a (Di /4)4/3
surface roughness for the piping material (see Table 3-1)
and Di is the inside pipe diameter.
where:
The method of equivalent lengths accounts for minor hL = head loss, m (ft)
losses by converting each valve and fitting to the length V = fluid velocity, m/s (ft/s)
of straight pipe whose friction loss equals the minor loss. n = Manning factor
The equivalent lengths vary by materials, manufacturer a = empirical constant, 1.0 for SI units (2.22 for IP
and size (see Table 3-2). The other method uses loss units)
coefficients. This method must be used to calculate exit
3-9
EM 1110-1-4008
5 May 99
Table 3-1
Pipe Material Roughness Coefficients
Pipe Material Specific Roughness Hazen-Williams Manning Factor, n

Factor, ,, mm (in) Coefficient, C
Steel, welded and seamless 0.061 (0.0002) 140
Ductile Iron 0.061 (0.0002) 130
Ductile Iron, asphalt coated 0.12 (0.0004) 130 0.013
Copper and Brass 0.61 (0.002) 140 0.010
Glass 0.0015 (0.000005) 140
Thermoplastics 0.0015 (0.000005) 140
Drawn Tubing 0.0015 (0.000005)
Sources:
Hydraulic Institute, Engineering Data Book.
Various vendor data compiled by SAIC, 1998.
3-10
Figure 3-1. Moody Diagram
(Source: L.F. Moody, “Friction Factors for Pipe Flow,” Transactions
3-11
5 May 99
EM 1110-1-4008
of the ASME, Vol. 66, Nov. 1944, pp. 671-678, Reprinted by permission of ASME.)
EM 1110-1-4008
5 May 99
Table 3-2
Estimated Pressure Drop for Thermoplastic Lined Fittings and Valves
Standard tee
Vertical Horizontal
Size Standard Through Through Plug Diaphragm Check Check
mm (in) 90E elbow run branch Valve Valve Valve Valve
25 (1) 0.55 (1.8) 0.37 (1.2) 1.4 (4.5) 0.61 (2.0) 2.1 (7) 1.8 (6.0) 4.9 (16)
40 (1½) 1.1 (3.5) 0.70 (2.3) 2.3 (7.5) 1.3 (4.2) 3.0 (10) 1.8 (6.0) 7.0 (23)
50 (2) 1.4 (4.5) 0.91(3.0) 3.0 (10) 1.7 (5.5) 4.9 (16) 3.0 (10) 14 (45)
65 (2½) 1.7 (5.5) 1.2 (4.0) 3.7 (12) N.A. 6.7 (22) 3.4 (11) 15 (50)
80 (3) 2.1 (7.0) 1.2 (4.1) 4.6 (15) N.A. 10 (33) 3.7 (12) 18 (58)
100 (4) 3.0 (10) 1.8 (6.0) 6.1 (20) N.A. 21 (68) 6.1 (20) 20 (65)
150 (6) 4.6 (15) 3.0 (10) 9.8 (32) N.A. 26 (85) 9.4 (31) 46 (150)
200 (8) 5.8 (19) 4.3 (14) 13 (42) N.A. 46 (150) 23 (77) 61 (200)
250 (10) 7.6 (25) 5.8 (19) 16 (53) N.A. N.A. N.A. N.A.
300 (12) 9.1 (30) 7.0 (23) 20 (64) N.A. N.A. N.A. N.A.
Notes:
Data is for water expressed as equal length of straight pipe in m (ft)
N.A. = Part is not available from source.
Source:
“Plastic Lined Piping Products Engineering Manual”, p. 48.
3-12
EM 1110-1-4008
5 May 99
Table 3-3
Minor Loss Coefficients (K)
Minor loss Description K
Pipe Entrance sharp edged 0.5

inward projected pipe 1.0
rounded 0.05
Pipe Exit all 1.0
Contractions sudden 0.5 [1 - ($2)2]

gradual, N < 22E 0.8 (sin N) (1 - $2)
gradual, N > 22E 0.5 (sin N)0.5 (1 - $2)
Enlargements sudden [1 - ($2)2]2

gradual, N < 22E 2.6 (sin N) (1 - $2)2
gradual, N > 22E (1 - $2)2
Bends 90E standard elbow 0.9

45E standard elbow 0.5
Tee standard, flow through run 0.6

standard, flow through branch 1.8
Valves globe, fully open 10

angle, fully open 4.4
gate, fully open 0.2
gate, ½ open 5.6
ball, fully open 4.5
butterfly, fully open 0.6
swing check, fully open 2.5
Notes:
N = angle of convergence/divergence
$ = ratio of small to large diameter
Sources:
Hydraulic Institute, "Pipe Friction Manual, 3rd Ed.
Valve data from Crane Company, "Flow of Fluids," Technical Paper 410; reprinted by permission of the Crane
Valve Group.
3-13
EM 1110-1-4008
5 May 99
Di = inside pipe diameter, m (ft) Step 2. From Table 1-1, select 150 mm (6 in) as the
L = length of pipe, m (ft) actual pipe size and calculate actual velocity in the pipe.
(ft) Q Q
V ' '
A B
It is common practice in design to use higher values of , D2
4 i
and n and lower values of C than are tabulated for new
pipe in order to allow for capacity loss with time.
0.05 m 3/s
'
Example Problem 4: B
(0.150 m)2
An equalization tank containing water with dissolved 4
metals is to be connected to a process tank via above
grade piping. A pump is required because the process ' 2.83 m/s (9.29 ft/s)
tank liquid elevation is 30 m (98.4 ft) above the
equalization tank level.
The piping layout indicates that the piping system Step 3. At 25EC, < = 8.94 x 10 -7 m2/s. So the Darcy-
requires: Weisbach equation is used to calculate the pressure drop
through the piping.
- 2 isolation valves (gate);
f L V2
- 1 swing check valve; hL ' % GK
- 5 standard 90E elbows; and Di 2 g
- 65 m (213.5 ft) of piping.
The process conditions are:

Step 4. Determine the friction factor, f, from the Moody
- T = 25EC (77 EF); and Diagram (Figure 3-1) and the following values.
- Q = 0.05 m3/s (1.77 ft3/s).
Di V (0.150 m)(2.83 m/s)
The required piping material is PVC. The design Re ' '
< 8.94 x 10&7 m 2/s
program now requires the pipe to be sized and the
pressure drop in the line to be determined in order to
' 4.75 x 105 & turbulent flow
select the pump.
Solution: , ' 1.5 x 10&6 m from Table 3&1

Step 1. Select pipe size by dividing the volumetric flow
rate by the desired velocity (normal service, V = 2.1 m/s). 1.5 x 10&6 m
,/Di ' ' 0.00001;
0.150 m
Di 2 Q
A ' B '
4 V
0.5 therefore, f = 0.022 from Figure 3-1.

4 0.05 m 3/s mm
Di ' 1000
B 2.1 m/s m Step 5. Determine the sum of the minor loss coefficients
from Table 3-3:
' 174 mm (6.85 in)
3-14
EM 1110-1-4008
5 May 99
minor loss K system operating conditions have been established, the

entry 0.5 minimum wall thickness is determined based on the
2 gate valves 0.2x2 pressure integrity requirements.
check valve 2.5
5 elbows 0.35x5 The design process for consideration of pressure integrity
exit 1.0 uses allowable stresses, thickness allowances based on
sum 6.15 system requirements and manufacturing wall thickness
tolerances to determine minimum wall thickness.
Step 6. Calculate the head loss.
Allowable stress values for metallic pipe materials are
generally contained in applicable design codes. The
f L V2
hL ' % GK codes must be utilized to determine the allowable stress
Di 2 g based on the requirements of the application and the
material to be specified.
(0.022)(65 m) (2.83 m/s)2
' % 5.15 For piping materials that are not specifically listed in an
0.150 m 2 (9.81 m/s 2) applicable code, the allowable stress determination is
based on applicable code references and good
' 6.4 m (21 ft) engineering design. For example, design references that
address this type of allowable stress determination are
contained in ASME B31.3 Sec. 302.3.2. These
Step 7. The required pump head is equal to the sum of requirements address the use of cast iron, malleable iron,
the elevation change and the piping pressure drop. and other materials not specifically listed by the ASME
B31.3.
Phead ' 30 m % 6.4 m ' 36.4 m
After the allowable stress has been established for the
application, the minimum pipe wall thickness required
for pressure integrity is determined. For straight metallic
The prediction of pressures and pressure drops in a pipe pipe, this determination can be made using the
network are usually solved by methods of successive requirements of ASME B31.3 Sec. 304 or other
approximation. This is routinely performed by computer applicable codes. The determination of the minimum
applications now. In pipe networks, two conditions must pipe wall thickness using the ASME B31.3 procedure is
be satisfied: continuity must be satisfied (the flow described below (see code for additional information).
entering a junction equals the flow out of the junction); The procedure and following example described for the
and there can be no discontinuity in pressure (the determination of minimum wall thickness using codes
pressure drop between two junctions are the same other than ASME B31.3 are similar and typically follow
regardless of the route). the same overall approach.
The most common procedure in analyzing pipe networks

tm ' t % A
is the Hardy Cross method. This procedure requires the
flow in each pipe to be assumed so that condition 1 is
satisfied. Head losses in each closed loop are calculated
and then corrections to the flows are applied successively where:
until condition 2 is satisfied within an acceptable margin. tm = total minimum wall thickness required for
pressure integrity, mm (in)
b. Pressure Integrity t = pressure design thickness, mm (in)
A = sum of mechanical allowances plus corrosion
The previous design steps have concentrated on the allowance plus erosion allowance, mm (in)
evaluation of the pressure and temperature design bases
and the design flow rate of the piping system. Once the
3-15
EM 1110-1-4008
5 May 99
Allowances include thickness due to joining methods,

Di % 2A
corrosion/erosion, and unusual external loads. Some y '
methods of joining pipe sections result in the reduction of Do % Di % 2A
wall thickness. Joining methods that will require this
allowance include threading, grooving, and swagging.
Anticipated thinning of the material due to effects of
corrosion or mechanical wear over the design service life where:
of the pipe may occur for some applications. Finally, Di = inside diameter of the pipe, mm (in)
site-specific conditions may require additional strength to Do = outside diameter of the pipe, mm (in)
account for external operating loads (thickness allowance A = sum of mechanical allowances plus corrosion
for mechanical strength due to external loads). The stress allowance plus erosion allowance, mm (in)
associated with these loads should be considered in
conjunction with the stress associated with the pressure Example Problem 5:
integrity of the pipe. The greatest wall thickness In order to better illustrate the process for the
requirement, based on either pressure integrity or determination of the minimum wall thickness, the
external loading, will govern the final wall thickness example in Paragraph 3-2b will be used to determine the
specified. Paragraph 3-4 details stress analyses. wall thickness of the two pipes. For the 150 mm (6 in)
header, the values of the variables are:
Using information on liquid characteristics, the amount of
corrosion and erosion allowance necessary for various P = 18.3 MPa (2650 psig)
materials of construction can be determined to ensure Do = 160 mm (6.299 in)
reasonable service life. Additional information S = 121 MPa (17,500 psi)
concerning the determination of acceptable corrosion Assume t <12.75 in/6, so y = 0.4 from ASME B31.3
resistance and material allowances for various categories A = 2 mm (0.08 in)
of fluids is contained in Paragraph 3-1a. E = 1.0
The overall formula used by ASME B31.3 for pressure Solution:

design minimum thickness determination (t) is: Step 1. Determine the minimum wall thickness.
P Do
t ' tm ' t % A
2 (S E % P y)
P Do
t '
where: 2 (S E % P y)
P = design pressure, MPa (psi)
Do = outside diameter of the pipe, mm (in)
S = allowable stress, see Table A-1 from ASME
B31.3, MPa (psi) Therefore,
E = weld joint efficiency or quality factor, see Table
A-1A or Table A-1B from ASME B31.3 P Do
tm ' % A
y = dimensionless constant which varies with 2 (S E % P y)
temperature, determined as follows:
For t < Do/6, see table 304.1.1 from ASME B31.3 (18.3 MPa)(160 mm)
for values of y '
2[(121 MPa)(1.0) % (18.3 MPa)(0.4)]
For t $ Do/6 or P/SE > 0.385, then a special
consideration of failure theory, fatigue and thermal % 2 mm
stress may be required or ASME B31.3 also allows
the use of the following equation to calculate y:
' 13.4 mm (0.528 in)
3-16
EM 1110-1-4008
5 May 99
Step 2. The commercial wall thickness tolerance for Step 5. Select a commercially available pipe by referring
seamless rolled pipe is +0, -12½%; therefore, to to a commercial standard. Using ANSI
determine the nominal wall thickness, the minimum wall B36.10M/B36.10, XXS pipe with a nominal wall
thickness is divided by the smallest possible thickness thickness of 17.1 mm (0.674 in) is selected.
allowed by the manufacturing tolerances.
Step 6. Check whether the wall thickness for the selected
100 mm (4 in) schedule XXS pipe is adequate to
13.4 mm
tNOM ' ' 15.3 mm (0.603 in) withstand a relief valve failure. The shutoff head of the
1.0 & 0.125 pump was given as 2,350 m (7,710 ft), and the specific
volume of pressurized water at 177EC (350EF) was
previously determined to be 0.001110 m3/kg (0.01778
Step 3. Select a commercially available pipe by referring ft3/lbm). The pressure equivalent to the shutoff head may
to a commercial specification. For U.S. work ANSI be calculated based upon this specific volume.
B36.10M/B36.10 is used commercially; the nearest
commercial 150 mm (6 in) pipe whose wall thickness 1 m
exceeds 15.3 mm (0.603 in) is Schedule 160 with a P ' (2,350 m) 9.81
3
m s2
nominal wall thickness of 18.3 mm (0.719 in). 0.001110
Therefore, 150 mm (6 in) Schedule 160 pipe meeting the kg
requirements of ASTM A 106 Grade C is chosen for this
application. This calculation does not consider the effects ' 20.8 MPa (3,020 psig)
of bending. If bending loads are present, the required
wall thickness may increase.
Step 7. Since the previously determined maximum
Step 4. For the 100 mm (4 in) header, the outside allowable pressure 36.3 MPa (5,265 psig) rating of the
diameter of 100 mm (4 in) pipe = 110 mm (4.331 in). XXS pipe exceeds the 20.8 MPa (3,020 psig) shutoff
Therefore: head of the pump, the piping is adequate for the intended
. service.
P Do The design procedures presented in the forgoing problem

tm ' % A are valid for steel or other code-approved wrought
2 (S E % P y) materials. They would not be valid for cast iron or
ductile iron piping and fittings. For piping design
procedures which are suitable for use with cast iron or
ductile iron pipe, see ASME B31.1, paragraph
104.1.2(b).
(19.2 MPa)(110 mm)
' 3-4. Stress Analysis
2[(121 MPa)(1.0) % (19.2 MPa)(0.4)]
% 2 mm After piping materials, design pressure and sizes have
been selected, a stress analysis is performed that relates
' 10.2 mm (0.402 in) the selected piping system to the piping layout (Paragraph
2-6) and piping supports (Paragraph 3-7). The analysis
ensures that the piping system meets intended service and
10.2 mm loading condition requirements while optimizing the
tNOM ' ' 11.7 mm (0.459 in)
1.0 & 0.125 layout and support design. The analysis may result in
successive reiterations until a balance is struck between
stresses and layout efficiency, and stresses and support
The required nominal wall thickness is 11.7 mm (0.459 locations and types. The stress analysis can be a
in). simplified analysis or a computerized analysis depending
upon system complexity and the design code.
3-17
EM 1110-1-4008
5 May 99
a. Code Requirements The longitudinal stress due to weight is dependent upon

support locations and pipe spans. A simplified method to
Many ASME and ANSI codes contain the reference data, calculate the pipe stress is:
formulae, and acceptability limits required for the stress
analysis of different pressure piping systems and services.
W L2
ASME B31.3 requires the analysis of three stress limits: SL ' 0.1
stresses due to sustained loads, stresses due to n Z
displacement strains, and stresses due to occasional
loads. Although not addressed by code, another effect
resulting from stresses that is examined is fatigue. where:
SL = longitudinal stress, MPa (psi)
b. Stresses due to Sustained Loads W = distributed weight of pipe material, contents
and insulation, N/m (lbs/ft)
The stress analysis for sustained loads includes internal L = pipe span, m (ft)
pressure stresses, external pressure stresses and n = conversion factor, 10-3m/mm (1 ft/12 in)
longitudinal stresses. ASME B31.3 considers stresses Z = pipe section modulus, mm3 (in3)
due to internal and external pressures to be safe if the
wall thickness meets the pressure integrity requirements 4 4
(Paragraph 3-3b). The sum of the longitudinal stresses in B Do & Di
Z '
the piping system that result from pressure, weight and 32 Do
any other sustained loads do not exceed the basic
allowable stress at the maximum metal temperature.
where:
Do = outer pipe diameter, mm (in)
ESL # Sh
Di = inner pipe diameter, mm (in)
c. Stresses due to Displacement Strains

where:
SL = longitudinal stress, MPa (psi) Constraint of piping displacements resulting from thermal
Sh = basic allowable stress at maximum material expansion, seismic activities or piping support and
temperature, MPa (psi), from code (ASME B31.3 terminal movements cause local stress conditions. These
Appendix A). localized conditions can cause failure of piping or
supports from fatigue or over-stress, leakage at joints or
The internal pressure in piping normally produces distortions. To ensure that piping systems have sufficient
stresses in the pipe wall because the pressure forces are flexibility to prevent these failures, ASME B31.3
offset by pipe wall tension. The exception is due to requires that the displacement stress range does not
pressure transients such as water hammer which add load exceed the allowable displacement stress range.
to pipe supports. The longitudinal stress from pressure
is calculated by:
SE # SA
P Do
SL '
4 t where:
SE = displacement stress range, MPa (psi)
SA = allowable displacement stress range, MPa (psi)
where:
SA ' f [1.25 (Sc % Sh) & SL]
P = internal design pressure, MPa (psi)
Do = outside pipe diameter, mm (in)
t = pipe wall thickness, mm (in)
3-18
EM 1110-1-4008
5 May 99
where:
SA = allowable displacement stress range, MPa (psi) 4 4
B Do & Di
f = stress reduction factor Z '
Sc = basic allowable stress of minimum material 32 Do
temperature, MPa (psi), from code (ASME B31.3
Appendix A)
Sh = basic allowable stress at maximum material where:
temperature, MPa (psi), from code (ASME B31.3 Do = outer pipe diameter, mm (in)
Appendix A) Di = inner pipe diameter, mm (in)
Mt
St '
f ' 6.0 (N)&0.2 # 1.0 2 Z n
where: where:
f = stress reduction factor St = torsional stress, MPa (psi)
N = equivalent number of full displacement cycles Mt = torsional moment, N-m (lb-ft)
during the expected service life, < 2 x 106. Z = section modulus, mm3 (in3)
n = conversion factor, 10-3m/mm (1 ft/12 in)
2 2
SE ' (Sb % 4St ) 0.5 A formal flexibility analysis is not required when: (1) the
new piping system replaces in kind, or without significant
change, a system with a successful service record; (2) the
new piping system can be readily judged adequate by
comparison to previously analyzed systems; and (3) the
where: new piping system is of uniform size, has 2 or less fixed
SE = displacement stress range, MPa (psi) points, has no intermediate restraints, and meets the
Sb = resultant bending stress, MPa (psi) following empirical condition.9
St = torsional stress, MPa (psi)
Do Y
2 2 0.5 # K1
[(ii Mi ) % (io Mo) ] (L & Ls)2
Sb '
n Z
where:
where: Do = outside pipe diameter, mm (in)
Sb = resultant bending stress, MPa (psi) Y = resultant of total displacement strains, mm (in)
ii = in plane stress intensity factor (see Table in code, L = length of piping between anchors, m (ft)
ASME B31.3 Appendix D) Ls = straight line distance between anchors, m (ft)
Mi = in plane bending moment, N-m (lb-ft) K1 = constant, 208.3 for SI units (0.03 for IP units)
io = out plane stress intensity factor (see table in
code, ASME B31.3 Appendix D) d. Stresses due to Occasional Loads
Mo = out plane bending moment, N-m (lb-ft)
n = conversion factor, 10-3m/mm (1 ft/12 in) The sum of the longitudinal stresses due to both sustained
Z = Section modulus, mm3 (in3) and occasional loads does not exceed 1.33 times the basic
allowable stress at maximum material temperature.
9
ASME B31.3, p. 38.
3-19
EM 1110-1-4008
5 May 99
per fatigue curve.

E SNL # 1.33 Sh
The assumption is made that fatigue damage will occur
when the cumulative usage factor equals 1.0.
where:
SNL = longitudinal stress from sustained and 3-5. Flange, Gaskets and Bolting Materials
occasional loads, MPa (psi)
Sh = basic allowable stress at maximum material ANSI, in association with other technical organizations
temperature, MPa (psi), from code (ASME B31.3 such as the ASME, has developed a number of
Appendix A) predetermined pressure-temperature ratings and
standards for piping components. Pipe flanges and
The longitudinal stress resulting from sustained loads is flanged fittings are typically specified and designed to
as discussed in Paragraph 3-4b. The occasional loads ASME B16.5 for most liquid process piping materials.
that are analyzed include seismic, wind, snow and ice, The primary exception to this is ductile iron piping,
and dynamic loads. ASME B31.3 states that seismic and which is normally specified and designed to AWWA
wind loads do not have to be considered as acting standards. The use of other ASME pressure-integrity
simultaneously. standards generally conforms to the procedures described
below.
e. Fatigue
a. Flanges
Fatigue resistance is the ability to resist crack initiation
and expansion under repeated cyclic loading. A Seven pressure classes -- 150, 300, 400, 600, 900, 1,500
material’s fatigue resistance at an applied load is and 2500 -- are provided for flanges in ASME B16.5.
dependent upon many variables including strength, The ratings are presented in a matrix format for 33
ductility, surface finish, product form, residual stress, and material groups, with pressure ratings and maximum
grain orientation. working temperatures. To determine the required
pressure class for a flange:
Piping systems are normally subject to low cycle fatigue,
where applied loading cycles rarely exceed 105. Failure Step 1. Determine the maximum operating pressure and
from low cycle fatigue is prevented in design by ensuring temperature.
that the predicted number of load cycles for system life is Step 2. Refer to the pressure rating table for the piping
less than the number allowed on a fatigue curve, or S-N material group, and start at the class 150 column at the
curve, which correlates applied stress with cycles to temperature rating that is the next highest above the
failure for a material. Because piping systems are maximum operating temperature.
generally subject to varying operating conditions that Step 3. Proceed through the table columns on the
may subject the piping to stresses that have significantly selected temperature row until a pressure rating is
different magnitudes, the following method can be used reached that exceeds the maximum operating pressure.
to combine the varying fatigue effects. Step 4. The column label at which the maximum
operating pressure is exceeded at a temperature equal to
or above the maximum operating temperature is the
ni
U ' G required pressure class for the flange.
Ni
Example Problem 6:
U < 1.0 A nickel pipe, alloy 200, is required to operate at a
maximum pressure of 2.75 MPa (399 psi) and 50EC
(122EF).
where:
U = cumulative usage factor Solution:
ni = number of cycles operating at stress level i Nickel alloy 200 forged fitting materials are
Ni = number of cycles to failure at stress level i as manufactured in accordance with ASTM B 160 grade
3-20
EM 1110-1-4008
5 May 99
N02200 which is an ASME B16.5 material group 3.2. metallic gaskets, installation procedures are critical. The
Entering Table 2-3.2 in ASME B16.5 at 200 degrees F, manufacturer’s installation procedures should be
the next temperature rating above 50 EC (122 EF), a class followed exactly.
400 flange is found to have a 3.31 MPa (480 psi) rating
and is therefore suitable for the operating conditions. The compression used depends upon the bolt loading
before internal pressure is applied. Typically, gasket
Care should be taken when mating flanges conforming to compressions for steel raised-face flanges range from 28
AWWA C110 with flanges that are specified using to 43 times the working pressure in classes 150 to 400,
ASME B16.1 or B16.5 standards. For example, C110 and 11 to 28 times in classes 600 to 2,500 with an
flanges rated for 1.72 MPa (250 psi) have facing and assumed bolt stress of 414 MPa (60,000 psi). Initial
drilling identical to B16.1 class 125 and B16.5 class 150 compressions typically used for other gasket materials are
flanges; however, C110 flanges rated for 1.72 MPa (250 listed in Table 3-4.
psi) will not mate with B16.1 class 250 flanges.10
b. Gaskets
Table 3-4
Gaskets and seals are carefully selected to insure a leak- Gasket Compression
free system. A wide variety of gasket materials are
available including different metallic and elastomeric Gasket Material Initial Compression,
products. Two primary parameters are considered, MPa (psi)
sealing force and compatibility. The force that is required
at this interface is supplied by gasket manufacturers. Soft Rubber 27.6 to 41.4
Leakage will occur unless the gasket fills into and seals (4,000 to 6,000)
off all imperfections.
Laminated 82.7 to 124
The metallic or elastomeric material used is compatible Asbestos (12,000 to 18,000)
with all corrosive liquid or material to be contacted and
is resistant to temperature degradation. Composition 207
(30,000)
Gaskets may be composed of either metallic or
Metal Gaskets 207 to 414
nonmetallic materials. Metallic gaskets are commonly
(30,000 to 60,000)
designed to ASME B16.20 and nonmetallic gaskets to
ASME B16.21. Actual dimensions of the gaskets should Note: These guidelines are generally accepted
be selected based on the type of gasket and its density, practices. Designs conform to
flexibility, resistance to the fluid, temperature limitation, manufacturer’s recommendations.
and necessity for compression on its inner diameter, outer Source: SAIC, 1998
diameter or both. Gasket widths are commonly classified
as group I (slip-on flange with raised face), group II
(large tongue), or group III (small tongue width).
Typically, a more narrow gasket face is used to obtain In addition to initial compression, a residual compression
higher unit compression, thereby allowing reduced bolt value, after internal pressure is applied, is required to
loads and flange moments. maintain the seal. A minimum residual gasket
compression of 4 to 6 times the working pressure is
Consult manufacturers if gaskets are to be specified standard practice. See Paragraph 3-5c, following, for
thinner than 3.2 mm (1/8 in) or if gasket material is determination of bolting loads and torque.
specified to be something other than rubber.11 For non-
10
AWWA C110, p. ix-x.
11
Ibid., p. 44.
3-21
EM 1110-1-4008
5 May 99
c. Bolting Materials
Wm1
Am1 '
Carbon steel bolts, generally ASTM A 307 grade B Sb
material, should be used where cast iron flanges are
installed with flat ring gaskets that extend only to the
bolts. Higher strength bolts may be used where cast iron where:
flanges are installed with full-face gaskets and where Am1 = total cross-sectional area at root of thread,
ductile iron flanges are installed (using ring or full-face mm2 (in2)
gaskets).12 For other flange materials, acceptable bolting Wm1 = minimum bolt load for operating conditions,
materials are tabulated in ASME B16.5. Threading for N (lb)
bolts and nuts commonly conform to ASME B1.1, Sb = allowable bolt stress at design temperature,
Unified Screw Threads. MPa (psi), see code (e.g. ASME Section VIII, UCS-
23)
The code requirements for bolting are contained in
Sections III and VIII of the ASME Boiler and Pressure Gasket seating is obtained with an initial load during joint
Vessel Code. To determine the bolt loads in the design assembly at atmosphere temperature and pressure. The
of a flanged connection that uses ring-type gaskets, two required bolt load is:
analyses are made and the most severe condition is
applied. The two analyses are for operating conditions Wm2 ' 3.14 b G y
and gasket seating.
Under normal operating conditions, the flanged where:

connection (i.e., the bolts) resists the hydrostatic end Wm2 = minimum bolt load for gasket seating, N (lbs)
force of the design pressure and maintains sufficient b = effective gasket seating width, mm (in), see code
compression on the gasket to assure a leak-free (e.g., ASME Section VIII, Appendix 2, Table 2-5.2)
connection. The required bolt load is calculated by13: G = gasket diameter, mm (in)
= mean diameter of gasket contact face when
seating width, b, # 6.35 mm (0.25 in)
Wm1 ' 0.785 G 2 P % (2 b)(3.14 G m P) = outside diameter of gasket contact face less 2b
when seating width, b > 6.35 mm (0.25 in)
y = gasket unit seating load, MPa (psi), see Table 3-
where: 5
Wm1 = minimum bolt load for operating conditions,
N (lb) The required bolt area is then:
G = gasket diameter, mm (in)
= mean diameter of gasket contact face when Wm2
Am2 '
seating width, b, # 6.35 mm (0.25 in), or Sa
= outside diameter of gasket contact face less 2 b
when seating width, b, > 6.35 mm (0.25 in)
P = design pressure, MPa (psi) where:
b = effective gasket seating width, mm (in), see code Am2 = total cross-sectional area at root thread, mm2
(e.g., ASME Section VIII, Appendix 2, Table 2-5.2) (in2)
m = gasket factor, see Table 3-5 Wm2 = minimum bolt load for gasket seating, N (lbs)
Sa = allowable bolt stress at ambient temperature,
The required bolt area is then: MPa (psi), see code (e.g. ASME Section VIII, UCS-
23)
12
AWWA C110, p. 44.
13
ASME Section VIII, pp. 327-333.
3-22
EM 1110-1-4008
5 May 99
Table 3-5
Gasket Factors and Seating Stress
Gasket Material Gasket Factor, Minimum Design Seating Stress,

m y, MPa (psi)
Self-energizing types (o-rings, metallic, elastomer) 0 0 (0)
Elastomers without fabric

below 75A Shore Durometer 0.50 0 (0)
75A or higher Shore Durometer 1.00 1.38 (200)
Elastomers with cotton fabric insertion 1.25 2.76 (400)
Elastomers with asbestos fabric insertion (with or

without wire reinforcement
3-ply 2.25 15.2 (2,200)
2-ply 2.50 20.0 (2,900)
1-ply 2.75 25.5 (3,700)
Spiral-wound metal, asbestos filled

carbon 2.50 68.9 (10,000)
stainless steel, Monel and nickel-based alloys 3.00 68.9 (10,000)
Corrugated metal, jacketed asbestos filled or asbestos

inserted
soft aluminum 2.50 20.0 (2,900)
soft copper or brass 2.75 25.5 (3,700)
iron or soft steel 3.00 31.0 (4,500)
Monel or 4% to 6% chrome 3.25 37.9 (5,500)
stainless steels and nickel-based alloys 3.50 44.8 (6,500)
Corrugated metal
soft aluminum 2.75 25.5 (3,700)
soft copper or brass 3.00 31.0 (4,500)
iron or soft steel 3.25 37.9 (5,500)
Monel or 4% to 6% chrome 3.50 44.8 (6,500)
stainless steels and nickel-based alloys 3.75 52.4 (7,600)
Ring joint
iron or soft steel 5.50 124 (18,000)
Monel or 4% to 6% chrome 6.00 150 (21,800)
stainless steels and nickel-based alloys 6.50 179 (26,000)
Notes:
This table provides a partial list of commonly used gasket materials and contact facings with recommended design
values m and y. These values have generally proven satisfactory in actual service. However, these values are
recommended and not mandatory; consult gasket supplier for other values.
Source:
ASME Section VIII of the Boiler and Pressure Vessel Code, Appendix 2, Table 2-5.1, Reprinted by permission of
ASME.
3-23
EM 1110-1-4008
5 May 99
The largest bolt load and bolt cross-sectional area by the using agency. ANSI A13.1 has three main
controls the design. The bolting is selected to match the classifications: materials inherently hazardous, materials
required bolt cross-sectional area by: of inherently low hazard, and fire-quenching materials.
All materials inherently hazardous (flammable or
2
explosive, chemically active or toxic, extreme
0.9743
As ' 0.7854 D & temperatures or pressures, or radioactive) shall have
N yellow coloring or bands, and black legend lettering. All
materials of inherently low hazard (liquid or liquid
admixtures) shall have green coloring or bands, and white
where: legend lettering. Fire-quenching materials shall be red
As = bolt stressed area, mm2 (in2) with white legend lettering.
D = nominal bolt diameter, mm (in)
N = threads per unit length, 1/mm (1/in) 3-7. Piping Supports
The tightening torque is then calculated using the Careful design of piping support systems of above grade
controlling bolt load14: piping systems is necessary to prevent failures. The
design, selection and installation of supports follow the
T m ' Wm K D n Manufacturers Standardization Society of the Valve and
Fitting Industry, Inc. (MSS) standards SP-58, SP-69, and
SP-89, respectively. The objective of the design of
where: support systems for liquid process piping systems is to
Tm = tightening torque, N-m (in-lb) prevent sagging and damage to pipe and fittings. The
Wm = required bolt load, N (lb) design of the support systems includes selection of
K = torque friction coefficient support type and proper location and spacing of supports.
= 0.20 for dry Support type selection and spacing can be affected by
= 0.15 for lubricated seismic zone( see Paragraph 2-5b).
D = nominal bolt diameter, mm (in)
n = conversion factor, 10-3 m/mm for SI units (1.0 a. Support Locations
for IP units)
The locations of piping supports are dependent upon four
3-6. Pipe Identification factors: pipe size, piping configuration, locations of
valves and fittings, and the structure available for
Pipes in exposed areas and in accessible pipe spaces shall support. Individual piping materials have independent
be provided with color band and titles adjacent to all considerations for span and placement of supports.
valves at not more than 12 m (40 ft) spacing on straight
pipe runs, adjacent to directional changes, and on both Pipe size relates to the maximum allowable span between
sides where pipes pass through wall or floors. Piping pipe supports. Span is a function of the weight that the
identification is specified based on CEGS 09900 which supports must carry. As pipe size increases, the weight
provides additional details and should be a part of the of the pipe also increases. The amount of fluid which the
contract documents. Table 3-6 is a summary of the pipe can carry increases as well, thereby increasing the
requirements weight per unit length of pipe.
a. Additional Materials The configuration of the piping system affects the

location of pipe supports. Where practical, a support
Piping systems that carry materials not listed in Table 3-6 should be located adjacent to directional changes of
are addressed in liquid process piping designs in piping. Otherwise, common practice is to design the
accordance with ANSI A13.1 unless otherwise stipulated length of piping between supports equal to, or less than,
14
3-24
EM 1110-1-4008
5 May 99
Table 3-6
Color Codes for Marking Pipe
LETTERS AND
MATERIAL BAND ARROW LEGEND
Cold Water (potable) Green White POTABLE WATER
Fire Protection Water Red White FIRE PR. WATER
Hot Water (domestic) Green White H. W.
Hot Water recirculating (domestic) Green White H. W. R.
High Temp. Water Supply Yellow Black H. T. W. S
High Temp. Water Return Yellow Black H.T.W.R.
Boiler Feed Water Yellow Black B. F.
Low Temp. Water Supply (heating) Yellow Black L.T.W.S.
Low Temp. Water Return (heating) Yellow Black L.T.W.R.
Condenser Water Supply Green White COND. W.S.
Condenser Water Return Green White COND. W.R.
Chilled Water Supply Green White C.H.W.S.
Chilled Water Return Green White C.H.W.R.
Treated Water Yellow Black TR. WATER
Chemical Feed Yellow Black CH. FEED
Compressed Air Yellow Black COMP. AIR
Natural Gas Blue White NAT. GAS
Freon Blue White FREON
Fuel Oil Yellow Black FUEL OIL
Steam Yellow Black STM.
Condensate Yellow Black COND.
Source: USACE, Guide Specification 09900, Painting, General, Table 1.
3-25
EM 1110-1-4008
5 May 99
75% of the maximum span length where changes in where:

direction occur between supports. Refer to the l = span, m (ft)
appropriate piping material chapters for maximum span n = conversion factor, 10-3 m/mm (1 ft/12 in)
lengths. m = beam coefficient, see Table 3-7
CN = beam coefficient = 5/48 for simple, one-span
As discussed in Chapter 10, valves require independent beam (varies with beam type)
support, as well as meters and other miscellaneous Z = section modulus, mm3 (in3)
fittings. These items contribute concentrated loads to the S = allowable design stress, MPa (psi)
piping system. Independent supports are provided at W = weight per length, N/mm (lb/in)
each side of the concentrated load.
4 4
B Do & Di
Location, as well as selection, of pipe supports is Z '
dependent upon the available structure to which the 32 Do
support may be attached. The mounting point shall be
able to accommodate the load from the support. Supports
are not located where they will interfere with other design where:
considerations. Some piping materials require that they Z = section modulus, mm3 (in3)
are not supported in areas that will expose the piping Do = outer pipe diameter, mm (in)
material to excessive ambient temperatures. Also, piping Di = inner pipe diameter, mm (in)
is not rigidly anchored to surfaces that transmit
vibrations. In this case, pipe supports isolate the piping
system from vibration that could compromise the Table 3-7
structural integrity of the system. Beam Coefficient (m)
b. Support Spans m Beam Characteristic
Spacing is a function of the size of the pipe, the fluid

conveyed by piping system, the temperature of the fluid 76.8 simple, single span
and the ambient temperature of the surrounding area.
Determination of maximum allowable spacing, or span 185.2 continuous, 2-span
between supports, is based on the maximum amount that
144.9 continuous, 3-span
the pipeline may deflect due to load. Typically, a
deflection of 2.5 mm (0.1 in) is allowed, provided that the
153.8 continuous, 4 or more span
maximum pipe stress is limited to 10.3 MPa (1,500 psi)
or allowable design stress divided by a safety factor of
Note: These values assume a beam with free ends
415, whichever is less. Some piping system
and uniform loads. For piping systems with
manufacturers and support system manufacturers have
a fixed support, cantilever beam coefficients
information for their products that present recommended
may be more appropriate.
spans in tables or charts. These data are typically
Source: Manual of Steel Construction, pp. 2-124
empirical and are based upon field experience. A method
to 2-127.
to calculate support spacing is as follows:
Z S 0.5 The term W, weight per length, is the uniformly

l ' n m CN distributed total weight of the piping system and includes
W
the weight of the pipe, the contained fluid, insulation and
15
3-26
EM 1110-1-4008
5 May 99
jacket, if appropriate. Due to the many types of where:

insulation, the weight must be calculated after the type of I = moment of inertia, mm4 (in4)
insulation is selected; see Chapter 11 for insulation Do = outer pipe diameter, mm (in)
design. The following formula can be used to determine Di = inner pipe diameter, mm (in)
the weight of insulation on piping:
Improper spacing of supports can allow fluids to collect
in the sag of the pipe. Supports should be spaced and
Wi ' B K * Ti (Do % Ti ) mounted so that piping will drain properly. The elevation
of the down-slope pipe support should be lower than the
elevation of the lowest point of the sag in the pipe. This
where: is determined by calculating the amount of sag and
Wi = weight of insulation per length, N/mm (lbs/in) geometrically determining the difference in height
* = insulation specific weight, N/m3 (lbs/ft3) required.
K = conversion factor, 10-9 m3 /mm3 (5.79 x 10 -4
3 3
ft /in )
(l/n)2 y
Ti = insulation thickness, mm (in) h '
Do = outer pipe diameter, mm (in) 0.25 (l/n)2 & y 2
Proper spacing of supports is essential to the structural

integrity of the piping system. An improperly spaced where:
support system will allow excessive deflection in the line. h = difference in elevation of span ends, mm, (in)
This can cause structural failure of the piping system, l = span, m (ft)
typically at joints and fittings. Excessive stress can also n = conversion factor, 10-3 m/mm (1 ft/12 in)
allow for corrosion of the pipe material by inducing stress y = deflection, mm (in)
on the pipe and, thereby, weakening its resistance to
corrosive fluids. c. Support Types
The amount of sag, or deflection in a span, is calculated The type of support selected is equally important to the
from the following equation: design of the piping system. The stresses and movements
transmitted to the pipe factor in this selection. Pipe
supports should not damage the pipe material or impart
W (l/n)4 other stresses on the pipe system. The basic type of
y '
m E I support is dictated by the expected movement at each
support location.
where: The initial support design must address the load impact
y = deflection, mm (in) on each support. Typically, a moment-stress calculation
W = weight per length, N/mm (lb/in) is used for 2-dimensional piping, and a simple beam
l = span, m (ft) analysis is used for a straight pipe-run.
n = conversion factor, 10-3 m/mm (1 ft/12 in)
m = beam coefficient, see Table 3-7. If a pipe needs to have freedom of axial movement due to
E = modulus of elasticity of pipe material, MPa (psi) thermal expansion and contraction or other axial
I = moment of inertia, mm4 (in4) movement, a roller type support is selected. If minor
axial and transverse (and minimal vertical) movements
B are expected, a hanger allowing the pipe to ‘swing’ is
I ' (Do4 & Di4) selected. If vertical movement is required, supports with
64
springs or hydraulic dampers are required. Other
structural requirements and conditions that have the
potential to affect piping systems and piping support
systems are analyzed. Pipes that connect to heavy tanks
3-27
EM 1110-1-4008
5 May 99
or pass under footings are protected from differential Some piping systems utilize protective saddles between
settlement by flexible couplings. Similarly, piping the pipe and the support member. This is done to
attached to vibrating or rotating equipment are also minimize the stress on the pipe from point loads. In
attached with flexible couplings. addition, pipe insulation requires protection from
supports. Saddles support piping without damaging
d. Selection of Support Types insulation.
The selection of support types is dependent upon four The method by which the supports attach to buildings or
criteria: the temperature rating of the system, the other structures is addressed by the design. Typical pipe
mechanism by which the pipe attaches to the support, supports are in the form of hangers, supporting the pipe
protective saddles that may be included with the support, from above. These hangers may be attached to a ceiling,
and the attachment of the support to the building or other beam, or other structural member. Pipelines may be
structures. Support types are most commonly classified supported from below as well, with pipe stanchions or
in accordance with MSS SP-58. Figure 3-2 displays pipe racks. Pipe supports may be rigidly attached to a
some of the support types applicable to liquid process structure, or allow for a pivoting axial motion, depending
piping systems. The selection of the appropriate support on the requirements of the system.
type is made according to MSS SP-69. Table 3-8
provides guidance for process system temperatures.
Table 3-8
Support Type Selection for Horizontal Attachments: Temperature Criteria
Process Temperature, EC (EF) Typical MSS SP-58 Types Application
A-1. Hot Systems 2, 3, 24, clamps

49 to 232EC 1, 5, 7, 9, 10, hangers
(120 to 450EF) 35 through 38, 59, sliding
41, 43 through 46, rollers
39, 40 insulation protection
B. Ambient Systems 3, 4, 24, 26, clamps

16 to 48EC 1, 5, 7, 9, 10, hangers
39, 40 insulation protection
C-1. Cold Systems 3, 4, 26, clamps

1 to 15EC 1, 5, 7, 9, 10, hangers
40 insulation protection
Source:
MSS SP-69, pp. 1, 3-4.
3-28
Figure 3-2. Pipe Supports for Ambient Applications
3-29
5 May 99
EM 1110-1-4008
(Source: MSS SP-69, Pipe Hangers and Supports - Selection and Application, pp. 5-6)
EM 1110-1-4008
5 May 99
Some piping systems require adjustable pipe supports. preparing the test plans and procedures include:
One reason for this requirement is the cold spring action.
Cold spring is the action whereby a gap is left in the final (1) Determination of the test fluid.
joint of a piping run to allow for thermal expansion of the (2) Comparison of the probable test fluid
pipeline. This action results in the offset of all points temperature relative to the brittle fracture toughness
along the piping system, including the attachments to of the piping materials (heating the test fluid may be
pipe supports, and requires that supports be adjustable to a solution).
accommodate this offset. From a maintenance (3) Depending upon the test fluid, placement of
consideration, cold springing should be avoided if temporary supports where permanent supports were
possible through proper thermal expansion and stress not designed to take the additional weight of the test
analyses. fluid.
(4) Depending upon the test fluid, location of a
Vertical adjustment is also usually necessary for pipe relief valve to prevent excessive over-pressure from
supports. Settlement, particularly in new construction, test fluid thermal expansion. No part of the system
may result in an improper deflection of the elevation of a will exceed 90% of its yield strength.
pipe support. To maintain the proper slope in the (5) Isolation of restraints on expansion joints.
pipeline, thereby avoiding excessive sag between (6) Isolation of vessels, pumps and other equipment
supports and accumulation of the product being carried which may be over stressed at test pressure.
by the pipe, the possibility of vertical adjustment is (7) Location of the test pump and the need for
accommodated in the design of pipe supports. additional pressure gauges.
(8) Accessibility to joints for inspection (some
e. Coatings codes require that the weld joints be left exposed
until after the test). All joints in the pipe system
Installation of piping systems in corrosive environments must be exposed for inspection.
may warrant the specification of a protective coating on (9) Prior to beginning a leak test, the pipe line
pipe supports. The coating may be metallic or non- should be inspected for defects and errors and
metallic; MSS SP-58 is used to specify coatings. Support omissions.
manufacturers can provide specific recommendations for
coatings in specific environments, particularly for Testing of piping systems is limited by pressure. The
nonmetallic coatings. In addition, compatibility between pressure used to test a system shall not produce stresses
the support materials and piping system materials is at the test temperature that exceed the yield strength of
reviewed to avoid galvanic action. Electrical isolation the pipe material. In addition, if thermal expansion of the
pads or different support materials are sometimes test fluid in the system could occur during testing,
required. precautions are taken to avoid extensive stress.
3-8. Testing and Flushing Testing of piping systems is also limited by temperature.
The ductile-brittle transition temperature should be noted
This section addresses the requirements for pressure and and temperatures outside the design range avoided. Heat
leak testing of piping systems. In addition to these types treatment of piping systems is performed prior to leak
of tests, welding procedures, welders and qualifications testing. The piping system is returned to its ambient
of welding operators must conform with the welding and temperature prior to leak testing.
nondestructive testing procedures for pressure piping
specified in CEGS 05093, Welding Pressure Piping. In general, piping systems should be re-tested after
repairs or additions are made to the system. If a leak is
a. Test Procedure detected during testing and then repaired, the system
should be re-tested. If a system passes a leak test, and a
A written test procedure is specified and utilized to component is added to the system, the system should be
perform a leak test. The procedure should prescribe re-tested to ensure that no leaks are associated with the
standards for reporting results and implementing new component.
corrective actions, if necessary. Review items for
3-30
EM 1110-1-4008
5 May 99
The documented test records required for each leak test For cases in which the test temperature is less than the
are specified. The records are required to be design temperature, the minimum test pressure is16:
standardized, completed by qualified, trained test
personnel and retained for a period of at least 5 years.
1.5 P ST
PT '
Test records include: S
- date of the test;

- personnel performing the test and test location; and
- identification of the piping system tested;
- test method, fluid/gas, pressure, and temperature; and ST
# 6.5
- certified results. S
Flushing of a piping system prior to leak testing should be

performed if there is evidence or suspicion of where:
contaminants, such as dirt or grit, in the pipeline. These PT = test pressure, MPa (psi)
contaminants could damage valves, meters, nozzles, jets, P = design pressure, MPa (psi)
ports, or other fittings. The flushing medium shall not ST = stress at test temperature, MPa (psi)
react adversely or otherwise contaminate the pipeline, S = stress at design temperature, MPa (psi)
testing fluid, or service fluid. Flushing should be of
sufficient time to thoroughly clean contaminants from For a typical liquid process piping system with
every part of the pipeline. temperatures approximately ambient and low pressure,
the ST/S ratio equals 1.0. If the test pressure would
b. Preparation produce an ST in excess of the material yield strength,
then the test pressure may be reduced to limit ST below
Requirements for preparation of a leak test are also the yield strength.
specified. All joints in the piping system are exposed for
the leak test in order to allow the inspector to observe the The time period required by ASME B31.3 for a
joints during the test to detect leaks. Specified leak test hydrostatic leak test is at least ten (10) minutes, but
requirements provide for temporary supports. Temporary normally one (1) hour is used.
supports may be necessary if the test fluid weighs more
than the design fluid. d. Pneumatic Leak Test
c. Hydrostatic Leak Test Pneumatic leak tests are not recommended for liquid
process piping systems and are only used when the liquid
The fluid used for a typical hydrostatic leak test is water. residue left from a hydrostatic test has a hazard potential.
If water is not used, the fluid shall be non-toxic and be The test fluid for a pneumatic leak test is a gas. The gas
non-flammable. The test pressure is greater than or equal shall be non-flammable and non-toxic. The hazard of
to 1.5 times the design pressure. released energy stored in a compressed gas shall be
considered when specifying a pneumatic leak test. Safety
PT $ 1.5 P must be considered when recommending a gas for use in
this test.
where: The test temperature is a crucial consideration for the

PT = test pressure, MPa (psi) pneumatic leak test. Test temperature shall be considered
P = design pressure, MPa (psi)
16
ASME B31.3, p. 83.
3-31
EM 1110-1-4008
5 May 99
when selecting the pipe material. Brittle failure is a f. Sensitive Leak Test
consideration in extremely low temperatures for some
materials. The energy stored in a compressed gas, A sensitive leak test is required for all Category M fluids
combined with the possibility of brittle failure, is an (optional for Category D fluids) using the Gas and
essential safety consideration of the pneumatic leak test. Bubble Test Method of the ASME Boiler and Pressure
Vessel Code, Section V, Article 10, or equivalent. The
A pressure relief device shall be specified when test pressure for the sensitive leak test is 25% of the
recommending the pneumatic leak test. The pressure design pressure or 105 kPa (15 psig), whichever is lower.
relief device allows for the release of pressure in the
piping system that exceeds a set maximum pressure. The Category M fluid service is one in which the potential for
set pressure for the pressure relief device shall be 110% personnel exposure is judged to be possible, and in which
of the test pressure, or 345 kPa (50 psi) above test a single exposure to a small quantity of the fluid (caused
pressure, whichever is lower. by leakage) can produce serious and irreversible
personnel health damage upon either contact or
The test pressure for a pneumatic leak test is 110% of the breathing.18
design pressure. The pressure shall gradually increase to
50% of the test pressure or 170 kPa (25 psig), whichever g. Non-Metallic Piping Systems
is lower, at which time the piping system is checked.
Any leaks found are then fixed before retesting. The test Testing requirements, methods, and recommendations for
shall then proceed up to the test pressure before plastic, rubber and elastomer, and thermoset piping
examining for leakage. systems are the same as those for metallic piping systems,
with the following exceptions. The hydrostatic leak test
e. Initial Service Leak Test method is recommended and a pneumatic leak test is only
performed with the permission of the using agency. The
An initial service leak test is permitted by ASME B31.3 test pressure shall not be less than 1.5 times the system
with the concurrence of the using agency. This test is a design pressure. However, the test pressure is less than
preliminary check for leakage at joints and connections. the lowest rated pressure of any component in the system.
If this test is performed, and all observed leaks are
repaired, it is permissible to omit joint and connection
PT $ 1.5 P
examination during the hydrostatic (or pneumatic) leak
tests. The initial service leak test is limited to piping and
systems subject to Category D fluid service only.
PT < Pmin
A Category D fluid is defined as non-flammable, non-
toxic, and not damaging to human tissues. For this
system the operating pressure is less than 1.035 MPa where:
(150 psi), and the operating temperature range is between PT = test pressure, MPa (psi)
-29EC (-20EF) to 186EC (366EF)17. P = system design pressure, MPa (psi)
Pmin = lowest component rating, MPa (psi)
Typically, the service fluid is used for the initial service
leak test. This is possible for a Category D fluid. During h. Double Containment and Lined Piping Systems
the test, the pressure in the piping system should be
gradually increased to operating pressure. The piping Testing requirements, methods, and recommendations for
system is then inspected for leaks. double containment and lined piping systems are identical
to those pertaining to the outer (secondary) pipe material.
17
ASME B31.3, p. 5.
18
Ibid., p. 5.
3-32
EM 1110-1-4008
5 May 99
Chapter 4 of metal occurs at the anode where the corrosion current

Metallic Piping Systems enters the electrolyte and flows to the cathode. The
general reaction which occurs at the anode is the
dissolution of metal as ions:
4-1. General
The metallic materials that are commonly used in liquid M ÷ M %n % n e &

process piping systems can be categorized as ferrous
(ductile iron, carbon steel, stainless steel and alloys with
iron as the principal component) and non-ferrous alloys
of nickel, aluminum, copper and lead. Metallic piping where:
systems other than those addressed in this chapter are M = metal involved
available (e.g. zirconium, 416 SS). Such materials may n = valence of the corroding metal species
be used if cost and technical criteria are met. Applicable e- = represents the loss of electrons from the anode.
design principles from this manual are applied to use
these materials. Examination of this basic reaction reveals that a loss of
electrons, or oxidation, occurs at the anode. Electrons
lost at the anode flow through the metallic circuit to the
4-2. Corrosion
cathode and permit a cathodic reaction (or reactions) to
When metallic components are used, corrosion of some occur.
type(s) will occur. USACE policy requires that all
underground ferrous piping be cathodically protected. Practically all corrosion problems and failures
Chapter 12, TM 5-811-7 and MIL-HDBK-1004/10 encountered in service can be associated with one or
contain guidance pertaining to cathodic protection of more of the following basic forms of corrosion. These
underground pipelines. Conditions which promote are: general corrosion, galvanic corrosion, concentration
corrosion are: cell (crevice) corrosion, pitting attack, intergranular
corrosion, stress-corrosion cracking (environmentally-
- contact between dissimilar metals which may become induced-delayed failure), dealloying (dezincification and
immersed in a conductive medium; graphitic corrosion), and erosion corrosion.
- exposure of piping to corrosive soils or water;
- high temperatures; Corrosion control and avoidance is a highly specialized
- low-velocity, stagnant-type flow conditions; field. All pre-design surveys, Cathodic Protection (CP)
- abrasive effects that may cause the surfaces of metals to designs, and acceptance surveys must be performed by a
be eroded; "corrosion expert." A "corrosion expert" is a person who,
- application of tensile stresses within a corrosive by reason of thorough knowledge of the physical sciences
environment; and the principles of engineering and mathematics
- highly acidic solutions combined with holes near metal- acquired by a professional education and related practical
to-metal surfaces or near sealing surfaces; and experience, is qualified to engage in the practice of
- any metals close to sources of atomic hydrogen. corrosion control of buried or submerged metallic piping
and tank systems. Such a person must be accredited or
a. Theory of Corrosion certified by the National Association of Corrosion
Engineers (NACE) as a NACE Accredited Corrosion
Corrosion occurs by an electrochemical process. The Specialist or a NACE certified CP Specialist or be a
phenomenon is similar to that which takes place when a registered professional engineer who has certification or
carbon-zinc "dry" cell generates a direct current. licensing that includes education and experience in
Basically, an anode (negative electrode), a cathode corrosion control of buried or submerged metallic piping
(positive electrode), electrolyte (corrosive environment), and tank systems. USACE Construction Engineering
and a metallic circuit connecting the anode and the Research Laboratories (CECER) provides corrosion
cathode are required for corrosion to occur. Dissolution expertise on request.
4-1
EM 1110-1-4008
5 May 99
For information on metallic piping system material be expected to fail in these aggressive environments. As
compatibility with various chemicals, see appendix B. the resistivity of the soil decreases, the magnitude of the
Material compatibility considers the type and corrosion damage increases.
concentration of chemical in the liquid, liquid
temperature and total stress of the piping system. The c. Galvanic Corrosion
selection of construction materials is made by an engineer
experienced in corrosion. See Appendix A, paragraph A- Galvanic corrosion can occur when two
4 - Other Sources of Information, for additional sources electrochemically-dissimilar metals or alloys (see Table
of corrosion data. 4-1) are metallically connected and exposed to a
corrosive environment. The less noble material (anode)
b. General Corrosion suffers accelerated attack and the more noble material
(cathode) is protected by the galvanic current.
General corrosion is sometimes referred to as uniform
attack. When this form of corrosion occurs, anodic
dissolution is uniformly distributed over the entire Table 4-1
metallic surface. The corrosion rate is nearly constant at Galvanic Series (Partial Listing)
all locations. Microscopic anodes and cathodes, which
are continuously changing their electrochemical behavior Wasting End (anodic or least noble)
from anode to cathode and cathode to anode, are believed Magnesium alloys
to provide the corrosion cells for uniform attack. Zinc
Galvanized steel
Readily obtained from weight-loss and electrochemical Aluminum
tests, the general corrosion rates for many metals and Aluminum alloys
alloys in a wide variety of environments are known. Carbon steel
When a metal or alloy is exposed to an environment Cast iron
where the corrosion rate is known, equipment-life Stainless steel (active state)
expectancy can be estimated (providing general corrosion Lead
is the only form of corrosion which will occur). It is Nickel (active state)
common practice to select materials having general Brass
corrosion rates which are acceptable for the application Copper
involved. Bronze
Nickel alloys
Time-to-failure should not be the only corrosion criteria Nickel (passive state)
used for materials selection. Quite often, even trace Stainless steel (passive state)
amounts of metal which are introduced into the Titanium
environment by very low corrosion rates are, or should Graphite
be, unacceptable. For example, relatively non-corrosive Platinum
domestic waters can dissolve sufficient amounts of
certain metals, such as lead and copper, from the piping Protected End (cathodic or most noble)
to create a health hazard. Corrosion-produced trace Sources:
elements which are considered toxic and frequently found Schweitzer, Corrosion-Resistant Piping
in the domestic waters of buildings include cadmium and Systems, p. 264 (courtesy of Marcel Dekker,
antimony (from solder) and lead (an impurity in hot-dip, Inc.).
galvanized coatings). SAIC, 1998.
One of the environments where general corrosion can One common galvanic corrosion problem clearly
occur is soil. Steel is especially susceptible to general illustrates the "area and distance effects". For example,
corrosion when exposed to soils having resistivities less consider a building where a copper water service line and
than about 10,000 ohm-cm. Even galvanized-steel can
4-2
EM 1110-1-4008
5 May 99
a coated carbon steel natural gas service line are laid in is generally characterized in a appearance by severe
the same ditch. Assuming soil in the area has low pitting attack. Cases are known where galvanic corrosion
resistivity, it is easily recognized that a cathode (copper has perforated 7.6 mm (0.3 in) thick, aluminum-alloy
tube), an anode (steel pipe), and an electrolyte (soil) pipe in two (2) years.
exist. In order to have a galvanic cell, only a metallic
path for electron flow is needed; this is provided when the A number of methods and practices are available which
two dissimilar materials are metallically connected will either prevent or minimize galvanic corrosion. These
through the hot-water heater. Because the cathodic area include: the use of materials which are electrochemically
is large (bare copper tube) and the anodic area is small similar (that is, close together in the galvanic series);
(steel exposed at locations where "holidays", or defects, avoiding unfavorable (large) cathode-to-anode area
exist in the coating), corrosion produced leaks in the ratios; breaking the metallic circuit by the proper use of
natural gas line can occur in relatively short times. insulators (for example, isolating flanges and insulating
(Generally, natural gas leaks occur first in soil near the unions); the use of inhibitors (preferably cathodic
foundations of buildings where fertilizing and watering inhibitors, or a sufficient amount of anodic inhibitor to
have lowered the resistivity of the native soil.) The fact insure that the anodic reaction will be completely stifled);
that the two service lines were laid only inches apart and keeping the dissimilar metals or alloys physically distant
in the same ditch is also a factor in this corrosion from each other; avoiding the use of threaded joints
problem. Had the lines been located in separate ditches, between dissimilar metals; cathodic protection; applying
the distance between them may have been sufficient to protective coatings to both dissimilar metals; and
prevent the flow of galvanic current. possibly increasing the resistivity of the environment.
Severe galvanic corrosion is a problem in many potable- d. Concentration Cell Corrosion

water systems. Providing the water is sufficiently
aggressive, connecting steel or galvanized steel (the zinc Electrochemical attack of a metal or alloy because of
coating is generally destroyed by threading) to copper or differences in the environment is called concentration cell
copper-base alloys will cause galvanic attack of the steel. corrosion. This form of corrosion is sometimes referred
Similarly, connecting aluminum and its alloys to copper- to as "crevice corrosion", "gasket corrosion", and "deposit
base materials exposed to corrosive potable waters corrosion" because it commonly occurs in localized areas
generally accelerates attack of the aluminum. However, where small volumes of stagnant solution exist. Normal
there are many waters where dissimilar metals and alloys mechanical construction can create crevices at sharp
can be directly connected without accelerated attack of corners, spot welds, lap joints, fasteners, flanged fittings,
the less noble material. In general, waters of high pH and couplings, threaded joints, and tube-sheet supports.
low carbon dioxide, or those capable of producing a thin Deposits which promote concentration cell corrosion can
continuous layer of calcareous scale on the metal surface, come from a number of sources; other sites for crevice
do not promote galvanic attack. attack can be established when electrolyte-absorbing
materials are used for gaskets and the sealing of threaded
Galvanic corrosion is also an important cause of rapid joints.
deterioration to underground aluminum-alloy structures.
For example, in aircraft refueling areas, it is common There are at least five types of concentration cells. Of
practice to use aluminum-alloy pipe between the filter- these, the "oxygen" and "metal ion" cell are most
meter pit and the hydrant outlets. Steel pipe is usually commonly considered in the technical literature. The
used between the filter meter pit and the fuel storage area. "hydrogen ion", "neutral salt", and "inhibitor" cells must
For safety, convenience, and aesthetic reasons, all of the be considered in any discussion of concentration cell
pipe is underground. When the two dissimilar pipe corrosion.
materials (see Table 4-1) are metallically connected (for
example, flanged at a filter meter pit) and exposed to a It is known that areas on a surface in contact with
highly conductive, chloride containing soil, galvanic electrolyte having a high oxygen content will generally be
corrosion can be expected to occur. In these cathodic relative to those areas where less oxygen is
environments, galvanic corrosion of the aluminum alloy present. Oxygen can function as a cathodic depolarizer;
4-3
EM 1110-1-4008
5 May 99
in neutral and alkaline environments, regions of high e. Pitting Corrosion

oxygen would be preferred cathodic sites where the
reduction of oxygen can occur. This is the commonly Pitting corrosion is a randomly occurring, highly
referred to as an "oxygen concentration cell," see Figure localized form of attack on a metal surface. In general, it
4-1. is characterized by the observation that the depth of
penetration is much greater than the diameter of the area
A mechanism is proposed wherein the dissolution of affected. Pitting is similar to concentration cell-corrosion
metal (anodic process) and reduction of oxygen (cathodic in many respects. The two should be distinguished,
process) initially occur uniformly over the entire surface, however, because crevices, deposits, or threaded joints
including the interior of the crevice. In time, the oxygen are not requisites for pit initiation. Further, concentration
within the crevice is consumed and the localized (oxygen cell corrosion can occur in environments where the metal
reduction) cathodic process stops in this area. The or alloy is immune to pitting attack.
overall rate of oxygen reduction, however, remains
essentially unaltered because the area within the crevice Pitting attack appears to occur in two distinct stages.
is quite small compared to the area outside of the crevice. First, there is an incubation period during which the pits
The rate of corrosion within and outside the crevice are initiated; second, there is a propagation period during
remains equal. which the pits develop and penetrate into the metal. It is
generally agreed that a sufficient concentration of an
Concentration cell corrosion can occur at threaded joints aggressive anion (generally chloride, but also bromide,
of pipe used to convey aggressive, liquids. When the iodide, and perchlorate) and an oxidizing agent (dissolved
joints are improperly sealed, rapid crevice attack occurs oxygen, Fe+++, H2O2, Cu++ , and certain others) must be
in the threaded area where stagnant, low-oxygen-content present in the electrolyte. A stagnant volume of liquid
fluids exist. Since the wall thickness of the pipe is must exist in the pit or pitting will not occur. In addition,
reduced by threading, failures due to concentration cell for a given metal/electrolyte system, the redox potential
corrosion can be a frequent and common occurrence at must be more noble than a certain critical value. It is also
threaded joints. Threaded joints sealed with liquid- agreed that the corrosion processes within the pit produce
absorbing materials (for example, string or hemp) can fail conditions of low pH and high chloride ion content; these
in times as short as nine months. Similarly, transport keep the localized anodic areas electrochemically active.
deposits of solids can be a major cause of concentration
cell corrosion. Many grades of stainless steel are particularly susceptible
to pitting corrosion when exposed to saline environments.
Some of the methods to reduce concentration cell Alloying elements in a stainless steel, however, greatly
corrosion damage include: using butt welds instead of affect its resistance to pitting attack; the tendency to pit
riveted, spot-welded, and bolted joints; caulking, welding decreases as the content in nickel, chromium and
and soldering existing lap joints; avoiding the use of fluid molybdenum increases. In sea water, austenitic stainless
absorbing materials for gaskets and threaded-joint steels containing 18% chromium and a 2-3%
sealants; providing a more uniform environment, for molybdenum addition (e.g., Type 316 stainless steel)
example, placing homogeneous sand around underground exhibit much better pitting-corrosion resistance than
steel structures; removing suspended solids from similar alloys which contain no molybdenum (e.g., Type
solution; periodic cleaning to remove deposits from the 302 stainless steel). For certain grades of ferritic
surface; improving the design, for example, providing stainless steel, relatively low chloride content waters can
adequate slope on the inside bottoms of underground cause severe pitting corrosion. For example, Type 430,
storage tanks so accumulated liquid will flow to the ferritic grade, stainless steel (16% Cr) tubes failed by
sump; cathodic protection; and protective coatings, pitting corrosion and pinhole leaks when they were used
especially on the interior surfaces of storage tanks and to convey cooling water containing only a small amount
carbon steel piping. of chlorides.
4-4
EM 1110-1-4008
5 May 99
Figure 4-1. Concentration-Cell Corrosion of Underground Pipeline

(Source: USACE CECER, 1998.)
4-5
EM 1110-1-4008
5 May 99
In many cases, methods which minimize concentration

cell corrosion can be used to successfully mitigate pitting Table 4-2
attack. Widely-used practices and procedures for Environments Which Cause Intergranular
reducing damage by pitting corrosion include: keeping Corrosion in Sensitized
the fluid uniformly aerated; keeping the fluid at a low and Austenitic Stainless Steels
uniform temperature; improving the homogeneity of the
metal's surface by polishing, heat treating, or passivation; Acetic Acid Phosphoric Acid
using inhibitors; implementing cathodic protection; Ammonium Nitrate Phthalic Acid
reducing the concentration of aggressive ions in the
electrolyte; selecting materials which have good pitting Beet Juice Salt Spray
corrosion resistance; and using anodic protection by Chromic Acid Sea Water
controlling the metal or alloy's potential in the passive Copper Sulfate Sodium Bisulfate
range at a value more negative than the critical potential Crude Oil Sulfite Cooking Liquor
for pitting.
Fatty Acids Sulfite Digestor Acid
f. Intergranular Corrosion Lactic Acid Sulfamic Acid
Maleic Acid Sulfur Dioxide (wet)
Intergranular corrosion is the localized attack which Nitric Acid Sulfuric Acid
occurs at or in narrow zones immediately adjacent to the
grain boundaries of an alloy. Severe intergranular attack Oxalic Acid Sulfurous Acid
usually occurs without appreciable corrosion of the Source: USACE CECER, 1998.
grains; eventually, the alloy disintegrates or loses a
significant amount of its load-bearing capability. The use of extra-low carbon grades of stainless steel, for
Although a number of alloy systems are susceptible to example, Type 304L, essentially eliminates the
intergranular attack, most of the problems encountered in intergranular corrosion problem. These alloys are
service involve austenitic stainless steels and the 2xxx immune to sensitization because of their low carbon
and 7xxx series aluminum alloys. Welding, stress-relief content. It is well known that sensitization can occur only
annealing, improper heat treating, or overheating in if the carbon content of the alloy exceeds about 0.02 to
service generally establish the microscopic, 0.03%. The control of carbon to a maximum of 0.03%,
compositional inhomogeneities which make a material by blowing oxygen through the melt and using low-
susceptible to intergranular corrosion. carbon ferrochrome, has permitted steel manufacturers to
produce alloys which can be welded, stress-relief
Several grades of austenitic stainless steels (for example, annealed, and used in corrosive environments without
Type 304, which contains about 0.08% carbon) are major concern for intergranular attack.
susceptible to intergranular corrosion after they have
been heated into the temperature range of about 425EC to g. Stress-Corrosion Cracking
790EC (800EF to 1450EF). Provided the time in this
temperature range is sufficiently long, but not extended, Stress-corrosion cracking (environmentally-induced-
the stainless steel becomes sensitized. Intergranular delayed failure) describes the deleterious phenomena
corrosion will occur if the alloy is subsequently exposed which can occur when many alloys are subjected to static,
to certain environments. surface tensile stresses and exposed to certain corrosive
environments. Cracks are initiated and propagated by the
Some of the environments which reportedly cause combined effect of a surface tensile stress and the
intergranular corrosion in sensitized, austenitic stainless environment. When stress-corrosion cracking occurs, the
steels are listed in Table 4-2. Examination of this table tensile stress involved is often much less than the yield
reveals that intergranular corrosion can occur in many strength of the material; the environment is generally one
environments where austenitic stainless steels normally in which the material exhibits good resistance to general
exhibit excellent corrosion resistance. corrosion. For example, various steels have good general
4-6
EM 1110-1-4008
5 May 99
corrosion resistance to anhydrous liquid ammonia. Steel h. Dealloying

tanks are widely and successfully used for the storage and
transport of this liquified gas. Stress-corrosion cracking Dealloying, sometimes referred to as parting or selective
failures have occurred in some large-diameter liquid leaching, is a corrosion process wherein one element is
ammonia tanks, however, probably because the high preferentially removed from an alloy. The process is
residual tensile stresses introduced during fabrication unique in that corrosion occurs without appreciable
were not removed by stress-relief annealing. Several of change in the size or shape of the component being
the alloy/susceptible environment combinations where attacked. The affected areas become brittle, weak, and
stress-corrosion cracking can occur are given in Table 4- porous but the overall dimensions of the component do
3. not change appreciably.
Table 4-3
Alloy/Susceptible Environment Combinations for Stress-Corrosion Cracking
(Partial Listing)
Alloy System Environment Type of Cracking
Mild Steel OH- Intergranular

NO3- Intergranular
Alpha Brass NH4+ Transgranular at high pH; intergranular in

(70 Cu- 30 Zn) neutral solutions
Austenitic Stainless Steel Cl- Transgranular
2XXX - Series Al Alloys Cl- Adjacent to grain boundaries
7XXX - Series Al Alloys Cl- Intergranular
Cu-P Alloys NH4+ Intergranular
Titanium Alloys* Cl- Transgranular or intergranular
Mg-A1 Alloys Cl- Intergranular; sometimes transgranular
Beta Brass Cl- Transgranular

NH4+ Intergranular
Martensitic Low-Alloy Cl- Along prior-austenite grain boundaries
18 Ni Maraging Steel Cl- Along prior-austenite grain boundaries
Note: *Includes Ti-8Al-1Mo-1V, Ti-6Al-4V and Ti-5Al-2.5Sn alloys.

Source: USACE CECER, 1998.
4-7
EM 1110-1-4008
5 May 99
The two most important examples of dealloying are the Many metallic materials are susceptible to erosion
preferential removal of zinc from copper-zinc alloys corrosion at sufficiently high flow rates or excessive
(dezincification) and the preferential removal of iron from turbulence. Some of the equipment and components
gray-cast iron (graphitic corrosion). Other cases of where erosion-corrosion damage frequently occurs
dealloying include the preferential removal of aluminum, include: piping systems (particularly at elbows, tees, and
nickel, and tin from copper-base alloys and cobalt from bends), pump impellers, valves, propellers, orifices of
a Co-W-Cr alloy. measuring devices, nozzles, heat-exchanger tubes, and
turbine blades. Erosion corrosion is characterized in
Dezincification commonly occurs when yellow brass appearance by the presence of waves, valleys, deep
(67Cu-33Zn) is exposed to waters having a high chloride grooves, and gullies on the metal surface. An absence of
content, low temporary hardness, and pH above residual corrosion products and a clean metal appearance
approximately 8. Other alloys which are susceptible to in the area of attack also suggest that the destructive
dezincification in many waters include Muntz metal process is erosion corrosion. For copper, the effected area
(60Cu-40Zn) and non-inhibited aluminum brass (76Cu- is usually bright and shiny, resembling that of a new
22Zn-2.Al). Generally, higher zinc content brasses are penny.
more susceptible to dezincification than alloys containing
smaller amounts of the solute element. Some of the other material/environmental combinations
where erosion corrosion can occur include: red brass
Dezincification problems are generally solved by (85Cu-15Zn) in potable hot waters; hard lead
changing alloys. This includes the use of low-zinc- (92Pb-8Sb) in heated, dilute sulfuric acid solutions;
content alloys such as red brass (85Cu-15Zn) and carbon steel in heated, acidified distilled waters;
specially-alloyed materials such as arsenical Admiralty austenitic stainless steels in heated sulfuric acid-ferrous
Metal (70Cu-29Zn-lSn-0.05As) and arsenical aluminum sulfate slurries; and cupro-nickel alloys in heated sea
brass (76Cu-22Zn-2Al-0.05As). For severe applications, water. It is important to appreciate that none of these
it may be necessary to use cupro-nickel alloys, for environments would appreciably corrode the respective
example, 90Cu-l0Ni, which contain a small amount of materials under static or low-flow conditions. For
iron. In some process streams, dezincification can be example, hard lead corrodes at a negligible rate in
eliminated by changing the fluid chemistry, but this stagnant 10% sulfuric acid at 90EC (194EF). When the
should be done with caution and not without expert same sulfuric acid solution is circulated at 11.8 m/s (39
advice. ft/s), the erosion-corrosion penetration rate of hard lead
is about 1000 microns/y (40 mils/y).
i. Erosion Corrosion
A number of techniques are available for minimizing
Most metals and alloys depend upon a protective surface- erosion corrosion. Velocities in a system must be
film for corrosion resistance. When the protective film or considered before materials are selected and used.
corrosion products have poor adherence, an acceleration Materials which are susceptible to erosion corrosion
or increase in the rate of localized corrosion can occur should not be used when the environment is going to be
because of relative movement between the liquid and the circulated at high velocities. For this reason, copper
metal. Generally, movement of the liquid is quite rapid tubing is not recommended for conveying aggressive,
and mechanical wear effects or abrasion (due to potable hot waters at temperatures above 60E C (140E
suspended solids and entrained gases in the environment) F); 90-10 cupro-nickel should be used when high-
can be involved. Repetitive formation (a corrosion temperature, potable waters must be circulated at high
process) and destruction (a mechanical erosion process) flow rates. Similarly, use of Monel can generally
of the surface films is referred to as erosion corrosion. eliminate the "wire drawing" which occurs in brass valve
The term includes impingement attack, a special form of seats.
erosion corrosion is cavitation.
4-8
EM 1110-1-4008
5 May 99
Cavitation corrosion is a special form of erosion (3) Unlisted components, components not listed in
corrosion. The process is basically the result of gas ASME B31.3 but conforming to other published
bubbles forming at low pressure and collapsing under standards, may be utilized if the requirements of the
high pressure at or near the liquid-metal interface. published standard are comparable to ASME B31.3
Bubble collapse, which produces very high localized requirements and if the pressure design satisfies the
pressures (shock waves), destroys the metal's protective ASME B31.3 pressure design of components.
film. Repetitive formation and destruction of the film on
a localized basis results in severe damage. Cavitation b. Pressure Transients
corrosion damaged surfaces are characterized by their
deeply pitted and "spongy" appearance. Most design codes for metal pipe provide allowances for
short duration transient conditions which do not increase
j. Microbially Induced Corrosion the design pressure and temperature. When following
ASME B31.3 or similar codes, the limitations of using
Microbiological activity can induce corrosion as a result these allowances without increasing the design conditions
of byproducts such as carbon dioxide, hydrogen sulfide, are typically specified within the code. Before finalizing
ammonia and acids. In some instances microorganisms the system design pressure and temperature, allowances
may also consume metal. Biological activity can be for transient conditions within the applicable design code
reduced through the use of biocides and/or occasional pH are reviewed and the anticipated conditions that would be
variations. covered by the allowances in the code are fully evaluated.
4-3. Design Pressure 4-4. Piping Supports for Metallic Piping Systems
In addition to the requirements of Paragraph 3-2, a key Specific metallic piping materials have particular
consideration when specifying metal pipe and requirements for the design of piping supports. Care
components is compliance with established pressure and should be taken to minimize stress in the pipe that may
temperature rating of applicable codes and standards. induce corrosion. Concentrated loads, such as valves,
meters, and other fittings, should be independently
a. Maximum Steady Pressure supported. As a rule of thumb, spans for insulated lines
should be reduced by approximately 30% from those for
When using ASME B31.3 as the governing code, the uninsulated pipes.
following pressure and temperature rating issues must be
addressed for the metal pipe to be specified: Tables 4-4 through 4-7 present support spacing examples
for various metals. Calculations should be performed for
(1) For listed components having established rating, each application since material strength varies by temper
utilization of materials falling within the acceptable and manufacturing method. Table 4-4 summarizes
service ratings are listed in the codes and standards support spacing for carbon and stainless steel pipe.
contained in Table 326.1 of ASME B31.3.
(2) For listed components not having established Support of nickel pipe should follow similar principles of
ratings, utilization of components of the same other metallic piping systems. Table 4-5 summarizes
materials with the same allowable stress as material support spacing for nickel 200 and nickel 201. Nickel
specified in the codes and standards contained in 200 is pure wrought nickel. Nickel 201 is a low-carbon
Table 326.1, if the service ratings are based on alloy of nickel 200, for higher temperature applications.
straight seamless pipe and the pipe components to
be utilized are not manufactured from straight When designing aluminum pipe system supports, either
seamless pipe. Because of this deviation from the aluminum or padded pipe supports should be specified.
listed rating, the pipe components should be rated Aluminum will corrode when exposed to other metals.
using not more than 87.5% of the nominal wall Contact with metals such as copper, brass, nickel, and
thickness of the listed pipe less allowances applied carbon steel should be avoided. The support spacing for
to the pipe. aluminum alloy 6063 pipe is summarized in Table 4-6.
4-9
EM 1110-1-4008
5 May 99
Table 4-4
Support Spacing for Steel Pipe
Nominal Maximum Support Spacing, m (ft)

Pipe Size,
mm (in) SS, Sch 5S SS, Sch 10S CS, Sch 40 SS Sch 40S CS Sch 80
15 (0.5) 2.9 (9.4) 2.9 (9.6) 2.1 (7.0)* 2.9 (9.6) 2.5 (8.3)
*
20 (0.75) 3.2 (10.3) 3.2 (10.6) 2.1 (7.0) 3.3 (10.7) 2.9 (9.4)
*
25 (1) 3.4 (11.2) 3.6 (11.9) 2.1 (7.0) 3.6 (12.0) 3.2 (10.5)
*
40 (1.5) 3.8 (12.6) 4.2 (13.8) 2.7 (9.0) 4.3 (14.2) 3.9 (12.7)
*
50 (2) 4.1 (13.4) 4.5 (14.9) 3.0 (10.0) 4.8 (15.6) 4.3 (14.1)
80 (3) 4.8 (15.7) 5.2 (17.1) 3.7 (12.0)* 5.8 (18.9) 5.2 (17.1)
100 (4) 5.0 (16.5) 5.6 (18.3) 4.3 (14.0)* 6.4 (21.0) 5.8 (19.2)
*
150 (6) 5.9 (19.4) 6.3 (20.6) 5.2 (17.0) 7.5 (24.6) 7.0 (23.0)
*
200 (8) 6.2 (20.2) 6.8 (22.4) 5.8 (19.0) 8.3 (27.4) 7.9 (25.8)
*
250 (10) 7.1 (23.3) 7.4 (24.1) 6.1 (22.0) 9.1 (30.0) 8.7 (28.7)
*
300 (12) 7.4 (24.3) 7.8 (25.6) 7.0 (23.0) 9.8 (32.2) 9.5 (31.1)
Notes:
CS - electric resistance welded carbon steel ASTM A 53, grade A.
SS - seamless stainless steel ASTM A 312, TP316L.
Span lengths are based on a piping system that is a simple single span pipe run, is not insulated, has a full
flow condition that is essentially water and is subject to a maximum operating condition of 93 EC (200 EF).
*
Maximum horizontal spacing based on MSS SP-69 (std. wt. steel pipe, water service)
Source: Calculations by SAIC, 1998
4-10
EM 1110-1-4008
5 May 99
Table 4-5
Support Spacing for Nickel Pipe
Maximum Support Spacing, m (ft)

Nominal
Pipe Size, Ni 200, Ni 201, Ni 200, Ni 201, Ni 200, Ni 201,
mm (in) Sch 5 Sch 5 Sch 10 Sch 10 Sch 40 Sch 40
15 (0.5) 2.4 (7.8) 2.1 (6.9) 2.4 (7.9) 2.1 (6.9) 2.4 (7.9) 2.1 (6.9)
20 (0.75) 2.6 (8.6) 2.3 (7.5) 2.7 (8.8) 2.3 (7.7) 2.7 (8.8) 2.4 (7.8)
25 (1) 2.9 (9.4) 2.5 (8.2) 3.0 (9.8) 2.6 (8.6) 3.0 (9.9) 2.6 (8.7)
40 (1.5) 3.2 (10.6) 2.8 (9.3) 3.5 (11.5) 3.1 (10.1) 3.6 (11.8) 3.1 (10.3)
50 (2) 3.4 (11.3) 3.0 (9.9) 3.8 (12.5) 3.3 (10.9) 4.0 (13.0) 3.5 (11.4)
80 (3) 4.0 (13.2) 3.5 (11.6) 4.4 (14.4) 3.8 (12.6) 4.8 (15.7) 4.2 (13.8)
100 (4) 4.3 (14.0) 3.7 (12.3) 4.7 (15.4) 4.1 (13.6) 5.3 (17.5) 4.7 (15.3)
150 (6) 4.5 (14.7) 4.0 (13.2) 4.8 (15.6) 4.3 (14.0) 5.6 (18.4) 5.0 (16.4)
200 (8) 4.7 (15.4) 4.2 (13.8) 5.2 (17.0) 4.6 (15.2) 6.3 (20.5) 5.6 (18.4)
250 (10) 5.4 (17.8) 4.8 (15.9) 5.6 (18.3) 5.0 (16.4) 6.9 (22.5) 6.1 (20.1)
300 (12) 5.7 (18.5) 5.1 (16.6) 5.9 (19.4) 5.3 (17.4) 7.4 (24.2) 6.6 (21.6)
Notes:
Ni 200 = seamless nickel ASTM B 161, alloy N02200, annealed.
Ni 201 = seamless nickel ASTM B 161, alloy N02201, annealed.
Span lengths are based on a piping system that is a simple single span pipe run, is not insulated, has a full flow
condition that is essentially water and is subject to a maximum operating condition of 93 EC (200 EF).
Source: Calculations by SAIC, 1998.
4-11
EM 1110-1-4008
5 May 99
Table 4-6
Support Spacing for Aluminum Pipe

Nominal Pipe
Size, mm (in) Al 6063, Sch 5 Al 6063, Sch 10 Al 6063, Sch 40 Al 6063, Sch 80
15 (0.5) 2.3 (7.6) 2.4 (8.0) 2.5 (8.3) 2.6 (8.5)
20 (0.75) 2.5 (8.1) 2.6 (8.6) 2.8 (9.1) 2.9 (9.4)
25 (1) 2.6 (8.5) 3.0 (9.7) 3.1 (10.1) 3.2 (10.5)
40 (1.5) 2.7 (9.0) 3.2 (10.6) 3.6 (11.4) 3.7 (12.2)
50 (2) 2.8 (9.3) 3.4 (11.1) 3.7 (12.3) 4.0 (13.3)
80 (3) 3.2 (10.7) 3.7 (12.2) 4.5 (14.7) 4.8 (15.9)
100 (4) 3.3 (10.9) 3.9 (12.6) 4.9 (16.0) 5.3 (17.5)
150 (6) 3.8 (12.6) 4.2 (13.8) 5.5 (18.1) 6.3 (20.5)
200 (8) 3.9 (12.9) 4.5 (14.7) 6.0 (19.8) 6.9 (22.7)
250 (10) 4.5 (14.8) 4.8 (15.6) 6.5 (21.4) 7.6 (25.0)
300 (12) 4.7 (15.4) 5.0 (16.4) 6.9 (22.7) 8.2 (27.1)
Notes:
Al 6063 = seamless aluminum ASTM B 241 A96063, type T6 with welded joints.
Design of copper pipe support follows principles similar API standards. Table 4-8 presents applicable sections of
to those for other metallic piping systems. Galvanic relevant codes and standards for the metallic fittings. In
action between pipe supports and copper piping must be selecting a joining method for liquid process piping
considered when specifying support materials. Table 4-7 systems, the advantages and disadvantages of each
summarizes support spacing for copper pipe. method must be evaluated.
4-5. Joining 4-6. Thermal Expansion
Common methods for the joining of metallic pipe for Thermal expansion can impact the design of the piping
liquid process systems include utilization of welded, system in the following critical areas: excessive stress
flanged, threaded and mechanical joints including flared, related to thermal loads on the liquid being contained by
flareless, compression, caulked, brazed and soldered the piping system, reduction of allowable stress due to
joints. The application requirements and material elevated material temperature and stresses caused by
specifications for these fittings are typically found in elongation of the metal pipe; excessive thrust loads or
accompanying sections of the codes and standards used bending moments at connected equipment due to thermal
for the specification of the metallic pipe. The most expansion of the metal pipe; and leaking at pipe joints
common sources for application requirements and due to thermal expansion of the metal pipe.
material specifications can be found in ASME, MSS and
4-12
EM 1110-1-4008
5 May 99
Table 4-7
Support Spacing for Copper Pipe

Nominal Pipe
Size, mm (in) Cu Light Wall Cu Regular Wall Cu X-Strong Wall
15 (0.5) 1.5 (5.0)* 1.5 (5.0)* 1.5 (5.0)*

20 (0.75) 1.5 (5.0)* 1.5 (5.0)* 1.5 (5.0)*
25 (1) 1.8 (6.0)* 1.8 (6.0)* 1.8 (6.0)*
40 (1.5) 2.2 (7.3) 2.4 (8.0)* 2.4 (8.0)*
50 (2) 2.4 (7.8) 2.4 (8.0)* 2.4 (8.0)*
80 (3) 2.8 (9.2) 3.0 (10.0)* 3.0 (10.0)*
100 (4) 3.2 (10.4) 3.7 (12.0)* 3.7 (12.0)*
150 (6) 3.8 (12.6) 4.2 (13.9) 4.3 (14.0)*
200 (8) 4.5 (14.6) 4.8 (15.8) 4.9 (16.0)*
250 (10) 4.9 (16.1) 5.3 (17.4) 5.5 (18.0)*
300 (12) 5.4 (17.6) 5.9 (19.4) --
Notes:
Cu = seamless copper ASTM B 42, allow C 12200, drawn with brazed fittings.
*
Maximum horizontal spacing based on MSS SP-69 (copper tube, water service).
4-13
EM 1110-1-4008
Change 1
16 Sep 02
Table 4-8
Applicable Codes for Metallic Fittings
Reference
Standard Key Aspects of Standard
API 605 Large Diameter Carbon Steel Flanges

ASME B16.1 Cast Iron Pipe Flanges and Flanged Fittings, Classes 25, 125, 250, and 800
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.9 Factory Mad e, Wrought Steel Butt-Welding Fittings
ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded
ASME B16.24 Bronze Pipe Flanges and Flanged Fittings, Classes 150 and 300
ASME B16.25 Butt-Welding Ends
ASME B16.31 Non-Ferrous Pipe Flanges
Chemical Plant and Petroleum Refinery Piping - Chapter II Design Parts 3
ASME B31.3 and 4, Chapter III, Chapter IV, and Chapter V
ASME B16.42 Ductile Iron Pipe Flanges and Flanged Fitting s, Classes 150 and 300
ASME B16.47 Large Diameter Steel Flanges
MSS SP-43 Wrought Stainless Steel Butt-welding Fittings
MSS SP-44 Steel Pipeline Flanges
MSS SP-51 Class 150 LW Corrosion Resistant Cost Flanges and Flanged Fittings
Brazing Joints for Wrought and Cast Copper Alloy Solder Joint Pressure
MSS SP-73 Fittings
MSS SP-104 Wrought Copper Solder Joint Pressure Fittings
MSS SP-106 Cast Copper Alloy Flan ges and Flanged Fittings, Class 125, 150 and 300
Corrosion Resistant Pipe Fittings Threaded and Socket Welding, Class 150
MSS SP-114 and 1000
MSS SP-119 Belled End Socket Welding Fittings, Stainless Steel and Copper Nickel
Source: Compiled by SAIC, 1998.
When designing a piping system subject to thermal sessment is to first identify th e operating conditions
expansion due to anticipated operating temperatures that will expose the piping to the most severe thermal
and in which the piping is restrained at supports, an- loading conditions.
chors, equipment nozzles and penetrations, thermal
stresses and loads m ay be large and must be analyzed Once these conditions have been established, a free
and accounted for within the design. The syste m or unrestrained thermal analysis of the piping is per-
PFDs and P&IDs are analyzed to determine the ther- formed. This analysis is performed by assuming no
mal conditions or modes to which the piping system intermediate pipe supports, only terminal connections
will be subjected to during operation. Based on this to anchors, equipment nozzles, and equipment pene-
analysis, the design and material specification re - trations. If, based on this analysis, th e stress resulting
quirements are followe d as an applicable standard. from thermal expansion is less than 68.9 MPa (10
ksi), the pipe section analyze d has sufficient flexibil-
The need for detailed thermal stress analysis is as- ity to accommodate t he thermal expansion and ri gid
sessed for piping system s. An approach for this as - supports can be utilized. The termin al loadings on
4-14
EM 1110-1-4008
Change 1
16 Sep 02
equipment determined from this analysis can then be E = modulus of elasticity at the working tem-
used to assess the equipment capabilities fo r with- perature, kPa (psi)
standing the loading from the piping system. It SA = maximum allowable stress at the working
should also be noted that this analysis at e quipment temperature, kPa (psi)
and anchor terminations should consider the move- ∆ = change in length due to te mperature
ment and stress impacts of the “cold” condition. change, mm (in.)
C1 = constant, 0.3333
If the initial free th ermal analysis in dicates that the ASHRAE states that for the comm only used A53
resulting stresses will require the piping system to be Grade B seamless or electric resistanc e welded
designed to accommodate thermal expansion, the (ERW) pipe, an allowable stress SA of 155 MPa
design should conform to applicable codes and stan- (22,500 psi) can be used without overstressing the
dards. pipe. However, this may result in very high end re-
actions and anchor forces, especially with large -
A basic approach to assess the need for additional diameter pipe. Designing to a stress range SA= 103
thermal stress analysis for piping system s includes MPa (15,000 psi) and assuming E = 1.92 × 105 MPa
identifying operating conditions that will expose the (27.9 × 106 psi), the above equation reduces to:
piping to the most severe thermal loading conditions.
Once these conditions have been established, a ther- L = 74.7(∆D)0.5 (Metric Units)
mal analysis o f the piping can be performed to estab-
lish location, sizing, and arrangement of expansion L = 6.225(∆D)0.5 (English Units)
loops, or expansion joints (generally, bellows or slip
types). This provides reasonably low en d reactions without
requiring too much extra pipe. In addition, this
If the application requires the use of a bellow or pis- equation may be used with A53 butt-welded pipe and
ton joint, the manufacturer of the joint should be con- B88 drawn copper tubing.
sulted to determine design and installation require-
ments. An alternative is an expansion loop. Expan- When welded fittin gs are used in expansion loops
sion loops can be used in vertical or horizontal rather than pipe bends, another important considera-
planes. If an expansion loop is to be required, the tion is the effects o f bending on the fittings used to
following formula can be used. This formula is install the expansion loop. The loop should be in-
based on guided-cantilever-beam theory in which stalled in consultation with the fittin g manufacturer to
both ends are fixed and limited pipe rotation is as- ensure that specified fittin gs are capable of with-
sumed. The loop is also geometrically similar (as standing the anticipated loading conditions, constant
depicted in Figure 2-3d) with the middle parallel leg and cyclic, at the design temperatures of the system.
equal to ½ of each of the tangential legs. Terminal loadings on equipment determined from
this analysis can then be used to assess the equipment
L = X + 2Y=(∆DE/C1SA)0.5 (Metric Units)1 capabilities for with standing the loading from the
piping system . It should also be noted that this ter-
or mination analysis at equipment and anchor termina-
tions should consider the movement and stress im-
L = X + 2Y=(3∆DE/(144 in.2/ft2)SA)0.5 pacts of the “cold” condition.
(English Units)2
Example Problem 7:
where: A 145-m-long (475-ft-long) steel, 200-mm (8-in.) di-
ameter liquid process pipe operates at 90°C (194°F)
L = loop length to accommodate the rmal and 1.55 MPa (225 psig). The expansion caused by
expansion, mm (ft) the process stream must be absorbed using U-bends
X = parallel leg of loop, mm (ft) without damage to the pipe.
Y = 2X = tangential leg of loop, mm (ft)
D = actual outside pipe diameter, mm (in.)
1
1988 ASHRAE Handbook, EQUIPMENT
2
2000 ASHRAE Handbook, Heating, Ventilating,
and Air-Conditioning, SYSTEMS AND
EQUIPMENT
4-15
EM 1110-1-4008
Change 1
16 Sep 02
Solution: Ductile iron is a hard, nonmalleab le ferrous metal

Step 1. Establish a temperature differential ( ∆T). that must be molded into the various component
Assume an installation temperature of 4.4°C (40°F). shapes. It is used for those piping applications re-
This would be a conservative, yet reas onable, as- quiring strength, shock resistance, and machinability.
sumption. Therefore, the temperature differe ntial It has good resistance to general corrosion, but reacts
would be 90°C – 4.4°C, or 85.6°C (194°F – 40°F, or readily with h ydrogen sulfide.
154°F).
a. Ductile Iron Specifications
Step 2. Determine the thermal expansion (∆).
Due to the long use of ductile iron in water service,
∆ = αL0(∆T) ductile iron piping is most commonly specified pur-
suant to AWWA standards. As noted in Paragraph 3-
where: 5, care must be taken when joining AWWA piping
systems to ASME piping syste ms.
∆ = thermal expansion of pipe run, mm (in.)
α = coefficient of thermal expansion, 11.7 × 4-8. Carbon Steel
10–6 mm/(mm °C), (6.5 × 10–6 in./[in. °F]) 3
L0 = original length of pipe run, mm (in.) Carbon steel is a hot-rolled, all-purpose material. It
∆T = temperature differen tial is the most common and economical metal used in
industry. It will read ily rust (corrode) in ambient
atmospheres, and therefore casting applications
∆= 11.7 × 10–6 mm/(mm °C) × 145,000 mm ×
should be considered. It will also become embrittled
85.6°C
with prolonged contact with alkaline or strong caustic
(6.5 × 10–6 in./(in. °F) × 5700 in × 154°F)
fluids and contact with acid accelerates corrosion. It
∆= 145.2 mm
may react directly with hy drogen sulfide gas. The
(5.71 in.)
material/flu id matrix in Appendix B should be con-
sulted for each application.
Step 3. Determine dimensions of expansion loop.
The expansion loop is centered between anchored
a. Carbon Steel Pipe Specifications
supports as schematically shown in Figure 2- 3d.
A wide variety of mechanical properties is available
L = X + 2Y= 74.7(∆D)0.5 6.225(∆D)0.5 by varying the carbon content and heat treatments.
The most commonly specified carbon steel piping is
and manufactured to meet ASTM A 53. The type and
grade of the pipe must be specified: type F (furnace-
Y = 2X butt-welded), grade A; type E (electric-resistance
welded), grade A or B; or type S (seamless), grade A
So or B. Type F should not be used if flanging is re-
quired, and grade A is preferred if cold-bending is to
L = 5X= 74.7(145.2 mm × 220 mm)0.5 occur. Options that can be specified pursuant to
6.225 (5.71 in. × 8.625 in.)0.5 ASTM A 53 include hot-dip galvanizing, threaded
L = 5X= 13,351 mm (43.7 ft) ends and dimensions, schedule 40, 80, 160 and others
X = 2670 mm (8.74 ft) that may be available depending on pipe diameter.
Y = 2(2670 mm) = 5340 mm (17.5 ft)
Many other options exist. For example, ASTM A
The length of the parallel leg of the expansion loop is 587 specifies an electric-res istance welded carbon
2670 mm (8.74 ft), and the length of each of the two steel pipe intended for use in the chemical industry.
tangential legs of the expansion loop is 5340 mm The material is low-carbon and can also be specified
(17.5 ft). for galvanizing; either of t hese factors will reduce
corrosion effects. The pipe is available in two nomi-
4-7. Ductile Iron nal wall thicknesses from 15 mm (½ in.) to 250 mm
(10 in.) in diameter. Another carbon steel pipe stan-
3 dard is ASTM A 106 which specifies seamless car-
Design of Ma chine Elements, 5th Edition, Spotts,
bon steel pipe for high temperature service, but
M.F., Tables 2-1, 2-1A, Prentice Hall, 1978.
4-16
EM 1110-1-4008
Change 1
16 Sep 02
graphitization at prolonged high temperature may silicon may also be included as part of the alloy fo r
still occur. Additional manufacturing standards for various steel types. Chromium is the primary addi-
specialized carbon steel pi ping include, but are not tive that makes steel “stainless”; stainless steels are
limited to: ASTM A 135, schedule 10 electric-resis- actually a very broad range of highly corrosion-
tance welded carbon steel pipe; ASTM A 333, seam - resistant alloys that have a variety of trace elements.
less or welded carbon steel (and low-alloy steel) pipe
for low temperature service; and ASTM A 691, 405 a. Stainless Steel Types
mm (16 in.) and larger diameter electric-fusion
welded carbon steel (and low-alloy steel) pipe for The most common types of stainless steel used for
high pressure service at high temperatures. ASTM liquid process applications are 304 and 316. One
standards are reviewed for unusual process condi- caution: stainless steel is not totally co rrosion resis-
tions or requirements to select the material most tant. Chemicals such as sodium bisulfide, ferric chlo-
compatible to the application. ride, ozone and hydrochloric acid can attack stainless
steel successfully. Ch eck the material/flu id matrix in
b. Carbon Steel Fittings Appendix B for compatibility with the application.
The most commonly used se ries for corrosion resis-
Fittings for carbon steel piping can be threaded, tance are discussed below.
welded or flanged; all are commonly used. Fittin g
materials can be cast malleable iron, forged carbon Types 304 and 304L are austenitic stainless steels
steel and low-carbon or other specialized steel. In that provide outstanding resistance to bases such as
non-corrosive applications with threaded fittin gs, lime and sodium hydroxide. They are highly resis-
malleable iron conforming to ASTM A 47 is typi- tant to many acids, including hot or cold nitric.
cally used. Howe ver, as the process dictates, forged Types 316 and 316L are stainless steel types that ex-
carbon steel threaded fittings pursuant to ASTM A hibit better resistance to sulfides and chlorides than
105 are applicable for ambient to high temperature 304 and 304L, and will provide adequate resistance
service, and low-carbon steel threaded fittings pursu- to corrosion from sulfuric acid. Otherwise, 316 and
ant to ASTM A 858 are applicable for ambient to low 316L provide the same outstanding resistance to ac-
temperature or corrosive service. Welded fittin gs can ids and bases as 304 and 304L. The “L” designation
be butt-welded or socket welded with ASTM A 105 indicates alloys developed to minimize post-welding
or ASTM A 858 conforming materials. Malleable intergranular corrosion, and these alloys are strongly
iron is not welded. Other ASTM materials may also recommended whenever welding is involved. In
be appropriate; select a material and fitting that are general, the “L” stainless steels provide more resis-
compatible to the application. tance to sulfuric acid/nitric acid mixed solutions than
non-low carbon steels.
Due to the relative inexpense of carbon steel flanges,
carbon steel piping is usually flanged at connections Austenitic stainless steel piping is commonly speci-
to equipment and appurtenances such as valves or fied to c onform to ASTM A 312, ASTM A 813 or
other items that may have to be removed or replaced. ASTM A 814. All three of these standards address
Common flange material is ASTM A 105 forge d car- austenitic stainless steel pipe intended for general
bon steel for ambient to high temperature and ASTM corrosive and/or high temperature service. ASTM A
A 727 forged carbon steel for tem peratures between 312 specifies seamless and straight-seam welded
–30ΕC (–20ΕF) and 345ΕC (650ΕF). pipe; ASTM A 813 covers straight-seam single- or
double-welded pipe that is of fit-up and alignment
In addition to fittings described above, carbon steel quality; an d ASTM A 814 addresses flanged and
piping may be joined by mechanical couplings. The cold-bending quality (co ld worked) straight-seam
pipe sections must, however, be specified with single- or double-welded pipe.
grooved ends. Most of the manufacturers that pro-
duce mechanical couplings for ductile iron piping Austenitic stainless steel fitt ings may be threaded,
also produce them for carbon steel piping. welded or flang ed. The materials should match the
associated pipe. For example, WP316L fittin gs or
4-9. Stainless Steel F316L fl anges should be used with type 316L pipe.
Welding fittin gs are typically specified under ASTM
Stainless steel is the produc t of steel alloyed with A 403. Class WP welding fittings are standard use as
chromium and, to a lesser e xtent, nickel. Other ele- they conform to ASME B16.9 and ASME B16.11.
ments such as molybdenum, copper, manganese and Class CR welding fittin gs are light weight and con-
4-17
EM 1110-1-4008
Change 1
16 Sep 02
form to MSS SP-43. Threaded and flanged fittin gs Nickel alloy 200 and 201 pipe can be specified
are commonly specified under ASTM A 182. seamless or welded. Cold-worked seam less pipe is
readily av ailable in nominal pipe sizes 6 mm (1/8 in.)
Ferritic and martensitic stainless steels are used less to 200 mm (8 in.), dimensioned as schedule 5, 10, 40,
commonly than austenitic. Unlike austenitic steels, or 80, pursuant to ASTM B 161 and ASTM B 829.
ferritic stain less steels do not contain nickel and do Welded pipe, intended for corrosive service, is manu-
not resist reducing chemicals such as hydrochloric factured in accordance with ASTM B 725 and B 775,
acids. Ferritic stain less steels have excellent resis- and is readily available in nomin al pipe sizes 6 mm
tance to chlori de attack and orga nic acids. 4 A com- (1/8 in.) to 750 mm (30 in.), dimensioned as schedule
monly used ferritic stain less steel is typ e 430. Mart- 5S, 10S, and 40S. The material condition must be
ensitic stainless steels, however, may contain nickel specified for both seam less and welded pipe as an-
because their chromium content is limited . Typi- nealed or stress relieved. The latter conditioning
cally, martensitic steels exhibit less corrosion resis- provides more tensile strength. For example, the
tance than austenitic steels. tensile strength for a seamless alloy 200 pipe is 380
MPa (55,000 psi) annealed and 450 MPa (65,000 psi)
Ferritic and martensitic stainless steel p iping should stress relieved.
conform to ASTM A 731, which addresses both
seamless and welded pipe intended for general corro- Hastelloy, a nickel-molybdenum-chromium alloy,
sive and high-temperature service. Welding fittin gs offers excellent resistance to wet chlorine, hypochlo-
are typically s pecified under ASTM A 815 as Class rite bleach, fe rric chloride and nitric acid. Hastelloy,
WP or CR similar to austenitic stainless steel fittin gs. and related allo ys, can be seamless or welded.
Threaded and flanged fittin gs are specified in accor- Seamless pipe is manufactured pursuant to ASTM B
dance with ASTM A 182. 622 and ASTM B 829, and is readily available in
nominal pipe sizes 8 mm (1/4 in.) to 80 mm (3 in.),
b. Stainless Steel Pipe Construction dimensioned to schedule 10, 40, or 80. Welded pipe
is readily av ailable in nominal pipe sizes 6 mm (1/8
Standard nominal pipe sizes are 15 through 300 mm in.) to 200 mm (8 in.), dimensioned to 5S, 10S, 40S,
(½ through 12 in.) commonly available in schedules and 80S, pursuant to ASTM B 619 and ASTM B 775.
5S, 10S, 40S and 80S. Schedule 5S and 10S piping The material class is specifie d as class 1 or 2. Class 1
can not be threaded due to wall thickness constraints. pipe is welded and solution annealed, and class 2 is
welded, cold-worked and then solution annealed.
4-10. Nickel and Nickel Alloys Class 1 pipe may have sunken welds up to 15% of the
wall thickness, while class 2 pipe does not have
Nickel is used for its strong resistance to certain cor- sunken welds.
rosive chemicals.
Monel, a nickel-copper alloy, combines high strength
a. Common Alloys with high ductility (usually a trad eoff in metals se-
lection), as well as excellent general corrosion resis-
Refer to the corrosion compatibility tables for spe- tance. It is s pecified particularly whe re seawater or
cific applications of these alloys. Alth ough other industrial chemicals may be accom panied by high
nickel alloys are used for specialty ap plications, these temperatures. It must not be exposed, when hot, to
are the more commonly prescribed. sulfur or molten metals.
Alloy 200 is commercially pure wrought nickel, and Monel can also be provided either seamless or
201 is a low-carbon version of 200 that is used for welded. Seamless, cold-worked pipe is available in
applications above 315ΕC (600ΕF). Corrosion resis- nominal pipe sizes 6 mm (1/8 in.) to 200 mm (8 in.),
tances are the same for both alloys. T hey are resis- dimensioned to schedule 5, 10, 40, or 80, pursuant to
tant to caustic soda and most alkalis (key exception: ASTM B 165 and ASTM B 829. Welded Monel,
ammonium hydroxide). They are not subject to stress intended for general corrosive service, is manufac-
corrosion in chloride salts. They are excellent for dry tured in accordance with ASTM B 725 and ASTM B
handling of chlorine and hydrogen chloride at ele- 775, and is readily available in nominal pipe sizes 6
vated temperatures. mm (1/8 in.) to 750 mm (30 in.), dimensioned as
schedules 5S, 10S, and 40S. The pipe material con-
4 ditioning, either annealed or stress relieved, should be
Schweitzer, Corrosion-Resistant Piping Systems, p.
specified.
234.
4-18
EM 1110-1-4008
Change 1
16 Sep 02
Inconel, a nickel-chromium-iron alloy, is n oted for Aluminum piping resists corrosion well by forming a
having high temperature strength, while maintaining protective aluminum oxide film. Refer to the
excellent corrosion resistance. Similar t o all the fluid/material matrix in Appendix B for com patibility
nickel and nickel alloy piping systems, Inconel pipe applications. It is very resistant to sulfur compounds
can be provided either seamless or welded. Seamless and most organics, including halogenated organic
Inconel pipe is available in nominal pipe sizes 8 mm compounds. Aluminum should not, however, di-
(1/4 in.) to 150 mm (6 in.), dimensioned to schedule rectly contact conc rete because alkalis in the conc rete
5, 10, 40 or 80. It is manufactured pursuant to will attack the aluminum. One note of cau tion is that
ASTM B 167 and ASTM B 829. The material resistance of aluminum to some combinations of
conditioning should be specified; hot-worked, hot- compounds is poor, even though aluminum may be
worked annealed or cold-worked annealed. The strongly resistant to each compound in the mixture.
conditioning determines tensile strength; for An example would be strong resistance to either car-
example, the tensile strength of a 150 mm (6 in.) bon tetrachloride or methyl alcohol separately, but
seamless Inconel pipe is 515 MPa (75,000 psi) for poor resistance to a mixture of the two. Also, alumi-
hot-worked and hot-worked annealed tempering and num has poor resistance to contaminants such as
is 550 MPa (80,000 psi) for cold-worked annealed halide ions (like chloride) and reducible metals (like
tempering. Welded Inconel pipe, intended for copper) contained in comm ercial chemical grades of
general corrosive and heat resisting applications, is some chemicals. Aluminum piping is not compatible
produced in accordance with ASTM B 517 and with most inorganic acids, bases and salts outside a
ASTM B 775. Manufacturers will have to be pH range of approximately 4 to 9. In addition, nearly
contacted to confirm available sizes and schedules. all dry acid s, alcohols and phenols near their boiling
points can cause excessive aluminum corrosion.6
b. Nickel and Nickel Alloy Fittings
b. Aluminum Pipe Construction
Welding and threaded fittin gs for nickel and nickel
alloy piping systems are manufactured in confor- All alloys are available in nominal pipe sizes from 15
mance with ASTM B 366. Threaded fittings meet mm (½ in.) to 300 mm (12 in.), in schedules 5, 10, 40
ASME B 16.11. Welding fittings can be class WP, and 80. The preferred method for joining aluminum
which conforms to ASME B 16.9, ASME B 16.11 pipe to handle corrosives is welding; however,
and ASME B 16.28, or class CR which are light welding reduces tensile strength. Only schedule 40
weight and conform to MSS SP-43. Flanges are and 80 pipe can be threaded. Threading is not rec-
commonly specified to ASTM B 564 (and ASTM B ommended for aluminum piping systems that handle
160 for nickel alloys 200 and 201), annealed temper corrosives. Flanges are no t normally used to join
only. Fitting dimensions and ratings are specified pipe sections and should be limited to connecting
pursuant to ASME standards. aluminum pipe to equipment such as pumps and
process vessels.
4-11. Aluminum
Aluminum piping materials are most commonly
Aluminum is highly ductile. Alth ough it has rela- specified using ASTM B 241. This standard covers
tively low strength, its high strength-to-weight ratio seamless pipe intended for pressure applications and
results in the extensive use of aluminum alloys where includes many aluminum alloys and tempering op-
that feature is required. tions. The temper required to obtain the proper ten-
sile strength must be specified. For example, temper
a. Aluminum Pipe Use T6 is the strongest tensile strength for alloy 6063—
206.8 MPa (30,000 psi). As an option, pipe lengths
Alloys 1060, 3003, 5052, 6061, and 6063 are the specified by ASTM B 241 may also have threade d
most common compositions of its aluminum pipe. ends.
Alloy 6063 is most widely used due to cost, good
corrosion resistance, and mechanical properties. Al- Aluminum piping materials may also be specified to
loys 3003 and 5052 are best used for extremely lo w meet ASTM B 345 which covers seamless pipe for
temperatures. Alloy 5052 has the best corrosion re- internal pressure applications. The number of alloys
sistance for slightly alk aline solutions.5 and tempers available under this standard is less than
ASTM B 241. However, additional options for pipe
5
Schweitzer, Corrosion-Resistant Piping Systems, p.
6
253. Ibid., p. 254.
4-19
EM 1110-1-4008
Change 1
16 Sep 02
length ends exist, including threaded, beveled, a. Copper Pipe Construction

grooved, or specialty end configurations such as the
V-groove or modified Vee. If used with end configu- Seamless copper pipe is specified pursuant to ASME
rations for mechanical coupling, the burden of mating B 42. Various alloys and te mpers may be selected.
the end configuration with the mechanical coupling The copper alloys vary based upon the oxyg en and
used should be placed on the coupling supplier in the phosphorus contents, and temper is selected based on
specifications. required tensile streng th. Nominal pipe sizes range
from 6 mm (1/8 in.) to 300 mm (12 in.), in three wall
Welding fitting s are addressed in ASTM B 361, and thicknesses: light, regular, and extra strong.
threaded or flanged fittings materials are fo rged in
accordance with ASTM B 247. Dim ensions and con- Other options for copper based piping exist. For ex-
figurations for the fittin gs should reference the ap- ample, ASTM B 608 provides copper alloys that
propriate ASME standard(s). contain nickel for brackish or sea water applications
with nominal pipe sizes from 100 mm (4 in.) to 1,200
mm (48 in.). In addition, aluminum-bronze, copper-
4-12. Copper nickel and red brass piping materials are also avail-
able.
Copper is very ductile and malleable metal and does
not corrode easily in normal wet/dry environments. b. Copper and Copper Alloy Fittings
Being a noble metal, it does not normally displace
hydrogen from a solution containing hydrogen ions. Flanges and fittings for copper piping systems are
However, copper corrodes rapidly when exposed to component casted. The material is typically pro-
oxidizing agents such as chlorine, ozone, hydroge n duced in accordance with ASTM B 61 for high-grade
sulfide, nitric acid and chromic acid. It is very sus- metal (used in limited steam applications) and for
ceptible to galvanic action, and this demands that valve-bronze alloys, or with ASTM B 62 for a lesser
padded pipe hangers are used and that attention is grade alloy. Configuration and pressure ratings must
paid to contact with dissimilar metals. be specified pursuant to ASME standards.
4-20
EM 1110-1-4008
5 May 99
Chapter 5 a. Corrosion
Plastic Piping Systems
Unlike metallic piping, thermoplastic materials do not
display corrosion rates2. That is, the corrosion of
5-1. General
thermoplastic materials is dependent totally on the
Thermoplastic piping systems, commonly referred to as material’s chemical resistance rather than an oxide layer,
plastic piping systems, are composed of various additives so the material is either completely resistant to a chemical
to a base resin or composition. Thermoplastics are or it deteriorates. This deterioration may be either rapid
characterized by their ability to be softened and reshaped or slow. Plastic piping system corrosion is indicated by
repeatedly by the application of heat. Table 5-1 lists the material softening, discoloration, charring, embrittlement,
chemical names and abbreviations for a number of stress cracking (also referred to as crazing), blistering,
thermoplastic piping materials. Because of the slightly swelling, dissolving, and other effects. Corrosion of
different formulations, properties of plastic piping plastics occurs by the following mechanisms:
materials (for example, polyvinyl chloride - PVC) may
vary from manufacturer to manufacturer1. Therefore, - absorption;
designs and specifications need to address specific - solvation;
material requirements on a type or grade basis, which - chemical reactions such as oxidation (affects chemical
may have to be investigated and confirmed with bonds), hydrolysis (affects ester linkages), radiation,
manufacturers. dehydration, alkylation, reduction, and halogenation
(chlorination);
Table 5-1
Abbreviations for Thermoplastic Materials
Abbreviation Chemical Name
ABS Acrylonitrile-Butadiene-Styrene
CPVC Chlorinated Poly(Vinyl Chloride)
ECTFE Ethylene-Chlorotrifluoroethylene
ETFE Ethylene-Tetrafluoroethylene
FEP Perfluoro(Ethylene-Propylene) Copolymer
PE Polyethylene
PFA Perfluoro(Alkoxyalkane) Copolymer
PP Polypropylene
PTFE Polytetrafluoroethylene
PVC Poly(Vinyl Chloride)
PVDC Poly(Vinylidene Chloride)
PVDF Poly(Vinylidene Fluoride)
Sources: ASTM D 1600.
ASME B31.3 (Used by permission of ASME).
1
2
Ibid., p. 18.
5-1
EM 1110-1-4008
5 May 99
- thermal degradation which may result in either

PR ' 2(HDS)(t/Dm)
depolymerization or plasticization;
- environmental-stress cracking (ESC) which is
essentially the same as stress-corrosion cracking in
metals; where:
- UV degradation; and PR = pipe pressure rating, MPa (psi)
- combinations of the above mechanisms. t = minimum wall thickness, mm (in)
Dm = mean diameter, mm (in)
For plastic material compatibility with various chemicals, HDS = (HDB)(DF)
see Appendix B. If reinforcing is used as part of the
piping system, the reinforcement is also a material that is The minimum pipe wall thickness can also be determined
resistant to the fluid being transported. Material selection using the requirements of ASME B31.3 as described in
and compatibility review should consider the type and Paragraph 3-3b. This procedure is not directly applicable
concentration of chemicals in the liquid, liquid to thermoplastic pipe fittings, particularly in cyclic
temperature, duration of contact, total stress of the piping pressure operations due to material fatigue. Therefore, it
system, and the contact surface quality of the piping should not be assumed that thermoplastic fittings labeled
system. See Appendix A, paragraph A-4 - Other Sources with a pipe schedule designation will have the same
of Information, for additional sources of corrosion data. pressure rating as pipe of the same designation. A good
example of this is contained in ASTM D 2466 and D
b. Operating Pressures and Temperatures 2467 which specify pressure ratings for PVC schedule 40
and 80 fittings. These ratings are significantly lower than
The determination of maximum steady state design the rating for PVC pipe of the same designation. For
pressure and temperature is similar to that described for thermoplastic pipe fittings that do not have published
metallic piping systems. However, a key issue that must pressure ratings information similar to ASTM standards,
be addressed relative to plastic piping systems is the the fitting manufacturer shall be consulted for fitting
impact of both minimum and maximum temperature pressure rating recommendations.
limits of the materials of construction.
d. Joining
c. Sizing
Common methods for the joining of thermoplastic pipe
The sizing for plastic piping systems is performed for liquid process waste treatment and storage systems
consistent with the procedures of Paragraph 3-3. are contained in Table 5-2. In selecting a joining method
However, one of the basic principles of designing and for liquid process piping systems, the advantages and
specifying thermoplastic piping systems for liquid disadvantages of each method are evaluated and the
process piping pressure applications is that the short and manner by which the joining is accomplished for each
long term strength of thermoplastic pipe decreases as the liquid service is specified. Recommended procedures
temperature of the pipe material increases. and specification for these joining methods are found in
codes, standards and manufacturer procedures for joining
Thermoplastic pipe is pressure rated by using the thermoplastic pipe. Table 5-3 lists applicable references
International Standards Organization (ISO) rating for joining thermoplastic pipe.
equation using the Hydrostatic Design Basis (HDB) as
contained in ASTM standards and Design Factors (DFs). e. Thermal Expansion
The use of DFs is based on the specific material being
used and specific application requirements such as When designing a piping system where thermal
temperature and pressure surges. The following is the expansion of the piping is restrained at supports, anchors,
basic equation for internal hydraulic pressure rating of equipment nozzles and penetrations, large thermal
thermoplastic piping: stresses and loads must be analyzed and accounted for
within the design. The system PFDs and P&IDs are
analyzed to determine the thermal conditions or modes to
5-2
EM 1110-1-4008
5 May 99
Table 5-2
Thermoplastic Joining Methods
Joining Method ABS PVC CPVC PE PP PVDF
Solvent Cementing X X X
Heat Fusion X X X
*
Threading X X X X X X
Flanged Connectors** X X X X X X
***
Grooved Joints X X X X X X
****
Mechanical Compression X X X X X X
Elastomeric seal X X X X X X
Flaring X
Notes:
X = applicable method
*
Threading requires a minimum pipe wall thickness (Schedule 80).
**
Flanged adapters are fastened to pipe by heat fusion, solvent cementing, or threading.
***
Grooving requires a minimum pipe wall thickness (material dependent).
****
Internal stiffeners are required.
Table 5-3
Thermoplastic Joining Standards
Reference Key Aspects of Reference
ASTM D 2657 Recommended practice for heat fusion.

ASTM D 2855 Standard practice for solvent cementing PVC pipe and fittings.
ASTM D 3139 Elastomeric gasketed connections for pressure applications.
ASTM F 1290 Recommended practice for electrofusion.
which the piping system will be subjected during identifying operating conditions that will expose the
operation. Based on this analysis, the design and material piping to the most severe thermal loading conditions.
specification requirements from an applicable standard or Once these conditions have been established, a free or
design reference are followed in the design. unrestrained thermal analysis of the piping can be
performed to establish location, sizing, and arrangement
A basic approach to assess the need for additional of expansion loops, or expansion joints (generally,
thermal stress analysis for piping systems includes bellows or slip types).
5-3
EM 1110-1-4008
5 May 99
If the application requires the use of a bellow or piston E = tensile modulus of elasticity, MPa (psi)
joint, the manufacturer of the joint shall be consulted to Do = pipe outer diameter, mm (in)
determine design and installation requirements. e = elongation due to temperature rise, mm (in)
S = maximum allowable stress, MPa (psi)
When expansion loops are used, the effects of bending on
the fittings used to install the expansion loop are In determining the elongation due to temperature rise
considered. Installation of the loop should be performed information from the manufacturer on the material to be
in consultation with the fitting manufacturer to ensure that used should be consulted. For example, the coefficient of
specified fittings are capable of withstanding the expansion is 6.3 x 10-5 mm/mm/EC (3.4 x 10-5 in/in/EF)
anticipated loading conditions, constant and cyclic, at the for Type IV Grade I CPVC and 5.4 x 10-5 mm/mm/EC
design temperatures of the system. Terminal loadings on (2.9 x 10 -5 in/in/EF) for Type I Grade I PVC. Other
equipment determined from this analysis can then be used sources of information on thermal expansion coefficients
to assess the equipment capabilities for withstanding the are available from plastic pipe manufacturers.
loading from the piping system. It should also be noted
that this termination analysis at equipment and anchor PVC and CPVC pipe does not have the rigidity of metal
terminations should consider the movement and stress pipe and can flex during expansion, especially with
impacts of the "cold" condition. smaller diameters. If expansion joints are used, axial
guides should be installed to ensure straight entrance into
No rigid or restraining supports or connections should be the expansion joint, especially when maximum movement
made within the developed length of an expansion loop, of the joint is anticipated. Leakage at the seals can occur
offset, bend or brand. Concentrated loads such as valves if the pipe is cocked. Independent anchoring of the joint
should not be installed in the developed length. Piping is also recommended for positive movement of expansion
support guides should restrict lateral movement and joints.
should direct axial movement into the compensating
configurations. Calculated support guide spacing f. Piping Support and Burial
distances for offsets and bends should not exceed
recommended hanging support spacing for the maximum Support for thermoplastic pipe follows the same basic
temperature. If that occurs, distance between anchors principles as metallic piping. Spacing of supports is
will have to be decreased until the support guide spacing crucial for plastic pipe. Plastic pipe will deflect under
distance equals or is less than the recommended support load more than metallic pipe. Excessive deflection will
spacing. Use of the rule of thumb method or calculated lead to structural failure. Therefore, spacing for plastic
method is not recommended for threaded Schedule 80 pipe is closer than for metallic pipe. Valves, meters, and
connections. Properly cemented socket cement joints fittings should be supported independently in plastic pipe
should be utilized. systems, as in metallic systems.
Expansion loops, offsets and bends should be installed as In addition, plastic pipe systems are not located near
nearly as possible at the mid point between anchors. sources of excessive heat. The nature of thermoplastic
pipe is that it is capable of being repeatedly softened by
Values for expansion joints, offsets, bends and branches increasing temperature, and hardened by decreasing
can be obtained by calculating the developed length from temperature. If the pipe is exposed to higher than design
the following equation. value ambient temperatures, the integrity of the system
could be compromised.
1/2
3 E Do e Contact with supports should be such that the plastic pipe
L ' n1
S material is not damaged or excessively stressed. Point
contact or sharp surfaces are avoided as they may impose
excessive stress on the pipe or otherwise damage it.
where:
L = developed length, m (ft) Support hangers are designed to minimize stress
n1 = conversion factor, 10-3 m/mm (1/12 ft/in) concentrations in plastic pipe systems. Spacing of
5-4
EM 1110-1-4008
5 May 99
supports should be such that clusters of fittings or PS = pipe stiffness, MPa (psi)
concentrated loads are adequately supported. Valves, EN = soil modulus, MPa (psi), see Table 5-9
meters, and other miscellaneous fittings should be
supported exclusive of pipe sections. (H)(Do)(()
' ' ' (S)(Do)
144
Supports for plastic pipe and various valves, meters, and
fittings, should allow for axial movement caused by where:
thermal expansion and contraction. In addition, external ' = weight per length of overburden, N/m (lb/in)
stresses should not be transferred to the pipe system H = height of cover, m (ft)
through the support members. Supports should allow for Do = outer pipe diameter, mm (in)
axial movement, but not lateral movement. When a ( = density of soil N/m3 (lb/ft3)
pipeline changes direction, such as through a 90E elbow, S = soil overburden pressure, MPa (psi)
the plastic pipe should be rigidly anchored near the
elbow. (E)(Ia)
PS '
Plastic pipe systems should be isolated from sources of 0.149 (R)3
vibration, such as pumps and motors. Vibrations can
negatively influence the integrity of the piping system,
particularly at joints. where:
PS = pipe stiffness, MPa (psi)
Support spacing for several types of plastic pipe are E = modulus of elasticity of pipe, MPa (psi)
found in Tables 5-4 through 5-6. Spacing is dependent Ia = area moment of inertia per unit length of pipe,
upon the temperature of the fluid being carried by the mm4/mm (in4/in)
pipe. R = mean radii of pipe, MPa (psi)
The determining factor to consider in designing buried (Do & t)

thermoplastic piping is the maximum allowable R '
deflection in the pipe. The deflection is a function of the 2
bedding conditions and the load on the pipe. The where:
procedure for determining deflection is as follows3: R = mean radii of pipe, MPa (psi)
Do = outer pipe diameter, mm (in)
100 ) Y t = average wall thickness, mm (in)
% deflection '
Do t3
Ia '
12
where:
) Y = calculated deflection where:
Do = outer pipe diameter, mm (in) Ia = area moment of inertia per unit length of pipe,
mm4/mm (in4/in)
t = average wall thickness, mm (in)
(Kx)(de)(')
)Y '
[0.149(PS) % 0.061(EN)] Proper excavation, placement, and backfill of buried
plastic pipe is crucial to the structural integrity of the
where: system. It is also the riskiest operation, as a leak in the
) Y = calculated deflection system may not be detected before contamination has
Kx = bedding factor, see Table 5-7 occurred. A proper bed, or trench, for the pipe is the
de = deflection lag factor, see Table 5-8 initial step in the process. In cold weather areas,
' = weight per length of overburden, N/m (lb/in) underground pipelines should be placed no less than one
3
ASTM D 2412, Appendices.
5-5
EM 1110-1-4008
5 May 99
Table 5-4
Support Spacing for Schedule 80 PVC Pipe
Nominal Maximum Support Spacing, m (ft) at Various Temperatures

Pipe Size,
mm (in) 16EC (60EF) 27EC (80EF) 38EC (100EF) 49EC (120EF) 60EC (140EF)*
25 (1) 1.83 (6.0) 1.68 (5.5) 1.52 (5.0) 1.07 (3.5) 0.91 (3.0)
40 (1.5) 1.98 (6.5) 1.83 (6.0) 1.68 (5.5) 1.07 (3.5) 1.07 (3.5)
50 (2) 2.13 (7.0) 1.98 (6.5) 1.83 (6.0) 1.22 (4.0) 1.07 (3.5)
80 (3) 2.44 (8.0) 2.29 (7.5) 2.13 (7.0) 1.37 (4.5) 1.22 (4.0)
100 (4) 2.74 (9.0) 2.59 (8.5) 2.29 (7.5) 1.52 (5.0) 1.37 (4.5)
150 (6) 3.05 (10.0) 2.90 (9.5) 2.74 (9.0) 1.83 (6.0) 1.52 (5.0)
200 (8) 3.35 (11.0) 3.2 (10.5) 2.90 (9.5) 1.98 (6.5) 1.68 (5.5)
250 (10) 3.66 (12.0) 3.35 (11.0) 3.05 (10.0) 2.13 (7.0) 1.83 (6.0)
300 (12) 3.96 (13.0) 3.66 (12.0) 3.2 (10.5) 2.29 (7.5) 1.98 (6.5)
350 (14) 4.11 (13.5) 3.96 (13.0) 3.35 (11.0) 2.44 (8.0) 2.13 (7.0)
Note: The above spacing values are based on test data developed by the manufacturer for the specific product and
continuous spans. The piping is insulated and is full of liquid that has a specific gravity of 1.0.
* The use of continuous supports or a change of material (e.g., to CPVC) is recommended at 60EC (140EF).
Source: Harvel Plastics, Product Bulletin 112/401 (rev. 10/1/95), p. 63.
Table 5-5
Support Spacing for Schedule 80 PVDF Pipe
Maximum Support Spacing, m (ft) at Various Temperatures

Nominal Pipe
Size, mm (in) 20EC (68EF) 40EC (104EF) 60EC (140EF) 80EC (176EF)
25 (1) 1.07 (3.5) 0.91 (3.0) 0.91 (3.0) 0.76 (2.5)

40 (1.5) 1.22 (4.0) 0.91 (3.0) 0.91 (3.0) 0.91 (3.0)
50 (2) 1.37 (4.5) 1.22 (4.0) 0.91 (3.0) 0.91 (3.0)
80 (3) 1.68 (5.5) 1.22 (4.0) 1.22 (4.0) 1.07 (3.5)
100 (4) 1.83 (6.0) 1.52 (5.0) 1.22 (4.0) 1.22 (4.0)
150 (6) 2.13 (7.0) 1.83 (6.0) 1.52 (5.0) 1.37 (4.5)
Source: Asahi/America, Piping Systems Product Bulletin P-97/A, p. 24.
5-6
EM 1110-1-4008
5 May 99
Table 5-6
Support Spacing for Schedule 80 CPVC Pipe

Nominal
Pipe Size, 23EC 38EC 49EC 60EC 71EC 82EC
mm (in) (73EF) (100EF) (120EF) (140EF) (160EF) (180EF)
25 (1) 1.83 (6.0) 1.83 (6.0) 1.68 (5.5) 1.52 (5.0) 1.07 (3.5) 0.91 (3.0)
40 (1.5) 2.13 (7.0) 1.98 (6.5) 1.83 (6.0) 1.68 (5.5) 1.07 (3.5) 0.91 (3.0)
50 (2) 2.13 (7.0) 2.13 (7.0) 1.98 (6.5) 1.83 (6.0) 1.22 (4.0) 1.07 (3.5)
80 (3) 2.44 (8.0) 2.44 (8.0) 2.29 (7.5) 2.13 (7.0) 1.37 (4.5) 1.22 (4.0)
100 (4) 2 59 (8.5) 2 59 (8.5) 2 59 (8.5) 2.29 (7.5) 1.52 (5.0) 1.37 (4.5)
150 (6) 3.05 (10.0) 2.90 (9.5) 2.74 (9.0) 2.44 (8.0) 1.68 (5.5) 1.52 (5.0)
200 (8) 3.35 (11.0) 3.20 (10.5) 3.05 (10.0) 2.74 (9.0) 1.83 (6.0) 1.68 (5.5)
250 (10) 3.51 (11.5) 3.35 (11.0) 3.20 (10.5) 2.90 (9.5) 1.98 (6.5) 1.83 (6.0)
300 (12) 3.81 (12.5) 3.66 (12.0) 3.51 (11.5) 3.20 (10.5) 2.29 (7.5) 1.98 (6.5)
Source: Harvel Plastics, Product Bulletin 112/401 (rev. 10/1/95), p. 63.
Table 5-7
Bedding Factor, K x
Type of Installation Kx
Shaped bottom with tamped backfill material placed at the sides of the pipe, 95% Proctor density 0.083
or greater
Compacted coarse-grained bedding and backfill material placed at the side of the pipe, 70-100% 0.083
relative density
Shaped bottom, moderately compacted backfill material placed at the sides of the pipe, 85-95% 0.103
Proctor density
Coarse-grained bedding, lightly compacted backfill material placed at the sides of the pipe, 40-70% 0.103
relative density
Flat bottom, loose material placed at the sides of the pipe (not recommended); <35% Proctor 0.110
density, <40% relative density
Source: Reprinted from Schweitzer, Corrosion-Resistant Piping Systems, p. 49, by courtesy of Marcel Dekker, Inc.
5-7
EM 1110-1-4008
5 May 99
Table 5-8
Deflection Lag Factor, de
Installation Condition de
Burial depth <5 ft. with moderate to high degree of compaction (85% or greater Proctor, ASTM D 698 2.0
or 50% or greater relative density ASTM D-2049)
Burial depth <5 ft. with dumped or slight degree of compaction (Proctor > 85%, relative density > 40%) 1.5
Burial depth >5 ft. with moderate to high degree of compaction 1.5
Burial depth > 5 ft. with dumped or slight degree of compaction 1.25
Source: Reprinted from Schweitzer, Corrosion-Resistant Piping Systems, p. 49, by courtesy of Marcel Dekker, Inc.
Table 5-9
Values of EN Modulus of Soil Reaction for Various Soils
EN for Degree of Compaction of Bedding, MPa (lb/ft2)
Soil Type and Pipe Bedding Slight Moderate High

Material <85% Proctor 85-95% Proctor >90% Proctor
Dumped >40% rel. den. 40-70% rel. den. >70% rel. den.
Fine-grained soils (LL >50) No data available - consult a soil engineer or use EN = 0
with medium to high plasticity
CH, MH, CH-MH
Fine-grained soils (LL <50) 0.35 (50) 1.38 (200) 2.76 (400) 6.90 (1000)
with medium to no plasticity
CL, ML, ML-CL, with <25%
coarse-grained particles
Fine-grained soils (LL <50) 0.69 (100) 2.76 (400) 6.90 (1000) 13.8 (2000)
with no plasticity CL, ML,
ML-CL, with >25% coarse-
grained particles.
Coarse-grained soils with fines 0.69 (100) 2.76 (400) 6.90 (1000) 13.8 (2000)
GM, GC, SM, SC contains
>12% fines.
Coarse-grained soils with little 1.38 (200) 6.90 (1000) 13.8 (2000) 20.7 (3000)
or no fines GW, SW, GP, SP
contains <12% fines (or any
borderline soil beginning with
GM-GC or GC-SC)
Crushed rock 6.90 (1000) 20.7 (3000) 20.7 (3000) 20.7 (3000)
Notes: LL = liquid limit
Sources: AWWA C900, Table A.4., p.17.
Schweitzer, Corrosion-Resistant Piping Systems, p. 48, (by courtesy of Marcel Dekker, Inc.).
5-8
EM 1110-1-4008
5 May 99
foot below the frost line. The trench bottom should be pipes, elevated temperatures, or longer support span
relatively flat, and smooth, with no sharp rocks that could spacing. The system is selected based upon the
damage the pipe material. The pipe should be bedded application and design calculations.
with a uniformly graded material that will protect the pipe
during backfill. Typical installations use an American The ranking of PVC piping systems from highest to
Association of State Highway Transportation Officials lowest maximum operating pressure is as follows:
(AASHTO) #8 aggregate, or pea-gravel for six inches Schedule 80 pipe socket-welded; Schedule 40 pipe with
below and above the pipe. These materials can be Schedule 80 fittings, socket-welded; and Schedule 80
dumped in the trench at approximately 90-95% Proctor pipe threaded. Schedule 40 pipe provides equal pressure
without mechanical compaction. The remainder of the rating to threaded Schedule 80, making Schedule 80
trench should be backfilled with earth, or other material threaded uneconomical. In addition, the maximum
appropriate for surface construction, and compacted allowable working pressure of PVC valves is lower than
according to the design specifications. a Schedule 80 threaded piping system.
5-2. Polyvinyl Chloride (PVC) 5-3. Polytetrafluoroethylene (PTFE)
Polyvinyl chloride (PVC) is the most widely used Polytetrafluoroethylene (PTFE) is a very common
thermoplastic piping system. PVC is stronger and more thermoplastic material used in many other applications in
rigid than the other thermoplastic materials. When addition to piping systems. PTFE is chemically resistant
specifying PVC thermoplastic piping systems particular and has a relatively wide allowable temperature range of
attention must be paid to the high coefficient of -260EC (-436EF) to 260EC (500EF). Furthermore,
expansion-contraction for these materials in addition to PTFE has a high impact resistance and a low coefficient
effects of temperature extremes on pressure rating, of friction and is often considered “self-lubricating.” The
viscoelasticity, tensile creep, ductility, and brittleness. most common trade name for PTFE is Teflon, registered
trademark of E.I Dupont Company.
a. PVC Specifications
5-4. Acrylonitrile-Butadiene-Styrene (ABS)
PVC pipe is available in sizes ranging from 8 to 400 mm
(1/4 to 16 in), in Schedules 40 and 80. Piping shall Acrylonitrile-Butadiene-Styrene (ABS) is a thermoplastic
conform to ASTM D 2464 for Schedule 80 threaded material made with virgin ABS compounds meeting the
type; ASTM D 2466 for Schedule 40 socket type; or ASTM requirements of Cell Classification 4-2-2-2-2
ASTM D 2467 for Schedule 80 socket type. (pipe) and 3-2-2-2-2 (fittings). Pipe is available in both
solid wall and cellular core wall, which can be used
Maximum allowable pressure ratings decrease with interchangeably. Pipe and fittings are available in size 32
increasing diameter size. To maintain pressures ratings mm (1-1/4 in) through 300 mm (12 in) in diameter. The
at standard temperatures, PVC is also available in pipe can be installed above or below grade.
Standard Dimension Ratio (SDR). SDR changes the
dimensions of the piping in order to maintain the a. ABS Standards
maximum allowable pressure rating.
ASTM D 2282 specifies requirements for solid wall ABS
b. PVC Installation pipe. ASTM D 2661 specifies requirements for solid
wall pipe for drain, waste, and vents. ASTM F 628
For piping larger than 100 mm (4 in) in diameter, specifies requirements for drain, waste, and vent pipe and
threaded fittings should not be used. Instead socket fittings with a cellular core. Solid wall ABS fittings
welded or flanged fittings should be specified. If a conform to ASTM D 2661. The drainage pattern for
threaded PVC piping system is used, two choices are fittings is specified by ASTM D 3311.
available, either use all Schedule 80 piping and fittings,
or use Schedule 40 pipe and Schedule 80 threaded ABS compounds have many different formulations that
fittings. Schedule 40 pipe will not be threaded. Schedule vary by manufacturer. The properties of the different
80 pipe would be specified typically for larger diameter formulations also vary extensively. ABS shall be
5-9
EM 1110-1-4008
5 May 99
specified very carefully and thoroughly because the 40 socket type. However, note that Schedule 40 socket
acceptable use of one compound does not mean that all may be difficult to procure.
ABS piping systems are acceptable. Similarly, ABS
compositions that are designed for air or gas handling 5-6. Polyethylene (PE)
may not be acceptable for liquids handling.
Polyethylene (PE) piping material properties vary as a
b. ABS Limitations result of manufacturing processes. Table 5-10 lists the
common types of PE, although an ultra high molecular
Pigments are added to the ABS to make pipe and fittings weight type also exists. PE should be protected from
resistant to ultraviolet (UV) radiation degradation. Pipe ultraviolet radiation by the addition of carbon black as a
and fittings specified for buried installations may be stabilizer; other types of stabilizers do not protect
exposed to sunlight during construction, however, and adequately4. PE piping systems are available in sizes
prolonged exposure is not advised. ranging from 15 to 750 mm (½ to 30 in). Like PVC, PE
piping is available in SDR dimensions to maintain
ABS pipe and fittings are combustible materials; maximum allowable pressure ratings.
however, they may be installed in noncombustible
buildings. Most building codes have determined that 5-7. Polypropylene (PP)
ABS must be protected at penetrations of walls, floors,
ceilings, and fire resistance rated assemblies. The Polypropylene (PP) piping materials are similar to PE,
method of protecting the pipe penetration is using a containing no chlorine or fluorine. PP piping systems are
through-penetration protection assembly that has been available in Schedule 40, Schedule 80, and SDR
tested and rated in accordance with ASTM E 814. The dimensions. With a specific gravity of 0.91, PP piping
important rating is the "F" rating for the through systems are one of the lightest thermoplastic piping
penetration protection assembly. The "F" rating must be systems.
a minimum of the hourly rating of the fire resistance rated
assembly that the ABS plastic pipe penetrates. Local 5-8. Polyvinylidene Fluoride (PVDF)
code interpretations related to through penetrations are
verified with the jurisdiction having authority. Polyvinylidene fluoride (PVDF) pipe is available in a
diameter range of 15 to 150 mm (½ to 6 in); Schedules
5-5. Chlorinated Polyvinyl Chloride (CPVC) 40 and 80; and pressure ratings of 1.03 MPa (150 psig)
and 1.59 MPa (230 psig). Use of PVDF with liquids
Chlorinated polyvinyl chloride (CPVC) is more highly above 49EC (120EF) requires continuous support. Care
chlorinated than PVC. CPVC is commonly used for must be taken in using PVDF piping under suction.
chemical or corrosive services and hot water above 60EC PVDF does not degrade in sunlight; therefore, PVDF
(140EF) and up to 99EC (210EF). CPVC is does not require UV stabilizers or antioxidants. PVDF
commercially available in sizes of 8 to 300 mm (1/4 to 12 pipe is chemically resistant to most acids; bases and
in) for Schedule 40 and Schedule 80. Exposed CPVC organics; and can transport liquid or powdered halogens
piping should not be pneumatically tested, at any such as chlorine or bromine. PVDF should not be used
pressure, due to the possibility of personal injury from with strong alkalies, fuming acids, polar solvents, amines,
fragments in the event of pipe failure; see Paragraph 3-8d ketones or esters5. Trade names for PVDF pipe include
for further information. Kynar by Elf Atochem, Solef by Solvay, Hylar by
Ausimont USA, and Super Pro 230 by Asahi America.
ASTM specifications for CPVC include: ASTM F 437
for Schedule 80 threaded type; ASTM F 439 for Fusion welding is the preferred method for joining PVDF
Schedule 80 socket type; and ASTM F 438 for Schedule pipe. Threading can only be accomplished on Schedule
80 pipe.
4
Schweitzer, Corrosion-Resistant Piping System, p. 39.
5
Ibid., p. 43.
5-10
EM 1110-1-4008
5 May 99
Table 5-10
Polyethylene Designations
Type Standard Specific Gravity
Low Density (LDPE) ASTM D 3350, Type I 0.91 to 0.925
Medium Density (MDPE) ASTM D 3350, Type II 0.926 to 0.940
High Density (HDPE) ASTM D 3350, Type III 0.941 to 0.959

and ASTM D 1248 Type IV
Source: Compiled by SAIC, 1998
5-11
EM 1110-1-4008
5 May 99
Chapter 6 6-2. Design Factors

Rubber and Elastomer Piping Systems
In selecting and sizing a rubber or elastomeric pipin g
system, four factors must be considered: servic e
6-1. General
conditions, (pressure and temperature); operatin g
The diverse nature of the chemical and physica l conditions (indoor/outdoor use, vibration resistance ,
characteristics of rubber and elastomeric materials makes intermittent of continu ous service, etc.); end connections;
these material suited for many chemical handling an d and environment requirements (flame resistance, material
waste treatment applications. The most commo n conductivity, labeling requirements, etc.).
elastomeric piping systems are comprised of hoses .
These hoses are constructed of three components: th e a. Service Conditions
tube, the reinforcement, and the cover. The tube is most
commonly an elastomer and must be suitable for th e For applications requiring pressure or vacuum servic e
chemical, temperature, and pressure conditions that a reinforcement can improve the mechanical properties of
particular application involves. Table 6-1 lists severa l the hose. The maximum recommended operatin g
elastomers used in piping systems and the chemica l pressure in industrial applications utilizing Society o f
identifications of the polymers. Physical and chemica l Automotive Engineers (SAE) standards hos e
characteristics of elastomers used in hose manufacturing designations is approximately 25% of the rated bursting
are specified in ASTM D 2000. Hose reinforcement i s pressure of the specific hose. Table 6-2 lists commo n
designed to provide protection from internal forces , SAE hose standards.
external forces, or both. Reinforcement usually consists
of a laye r of textile, plastic, metal, or a combination o f In determining the maximum operating conditions ,
these materials. Hose covers are designed to provid e special consideration must be given to the operatin g
hoses with protection from negative impacts resultin g temperatures. Rubber and elastomer materials ar e
from the environment in which the hose is used. Covers temperature sensitive, and both the mechanical qualities
are also typically composed of textile, plastic, metal, or a and chemical resistance properties of the materials ar e
combination of these materials. effec ted by temperature. Appendix B provide s
information regarding the effects of temperature o n
chemical resistance, and Table 6-1 provides information
Table 6-1
Common Materials Used in Rubber/Elastomer Piping Systems
ASTM Minimum Service Maximum Service

D 1418 Common or Temperature - Temperature -
Elastomer Class Trade Name Continuous Operations Continuous Operations
Fluoroelastomer FKM FKM, Viton, -23EC (-10EF) 260EC (500EF)

Fluorel
Isobutylene Isoprene IIR Butyl -46EC (-50EF) 148EC (300EF)
Acrylonitrile NBR Buna-N, -51EC (-60EF) 148EC (300EF)
Butadiene Nitrile
Polychloroprene CR Neoprene -40EC (-40EF) 115EC (240EF)
Natural Rubber or NR or Gum Rubber; -51EC (-60EF) 82EC (180EF)
Styrene Butadiene SBR Buna-S
6-1
EM 1110-1-4008
5 May 99
Table 6-2
Rubber and Elastomer Hose Standards
SAE Designation Tube Reinforcement Cover
100R1A one-wire-braid synthetic-rubber

100RIT one-wire-braid thin, nonskive
100R2A two-wire-braid synthetic rubber
100R2B two spiral wire plus one wire-braid synthetic rubber
100R2AT two-wire-braid thin, nonskive
100R2BT two spiral wire plus one wire-braid thin, nonskive
100R3 two rayon-braided synthetic rubber
100R5 one textile braid plus one wire-braid textile braid
100R7 thermoplastic synthetic-fiber thermoplastic
100R8 thermoplastic synthetic-fiber thermoplastic
100R9 four-ply, light-spiral-wire synthetic-rubber
100R9T four-ply, light-spiral-wire thin, nonskive
on the temperature limitations of the mechanica l General compatibility information for common elastomer
properties of rubber and elastomeric materials. As th e is listed in Table 6-3. Information regarding th e
operating temperature increases, the use of jacketed o r compatibility of various elastomers with specifi c
reinforced hose should be considered to accommodat e chemicals can be found in Appendix B. In addition ,
lower pressure ratings of the elastomeric materials. standards for resistance to oil and gasoline exposure have
been developed by the Rubber Manufacturer' s
Like plastic piping systems, rubber and elastome r Association (RMA). These standards are related to th e
systems do not display corrosion rates, as corrosion i s effects of oil or gasoline exposure for 70 hours at 100 EC
totally dependent on the material's resistance t o (ASTM D 471) on the physical/mechanical properties of
environmental factors rather than on the formation of an the material. Table 6-4 summarizes the requirements of
oxide layer. The corrosion of rubbers and elastomers is the RMA oil and gasoline resistance classes.
indicated by material softening, discoloring, charring ,
embrittlement, stress cracking (also referred to a s b. Operating Conditions
crazing), blistering, swelling, and dissolving. Corrosion
of rubber and elastomers occurs through one or more of In most cases, the flexible nature of elastomers wil l
the following mechanisms: absorption, solvation , compensate for vibration and thermal expansion an d
chemical reactions, thermal degradation, an d contraction in extreme cases. However, designs should
environmental stress cracking. incorporate a sufficient length of hose to compensate for
the mechanical effects of vibration and temperature.
6-2
EM 1110-1-4008
5 May 99
Table 6-3
General Chemical Compatibility Characteristics of Common Elastomers
Material Good Resistance Poor Resistance
Fluoroelastomer Oxidizing acids and Aromatics; fuels containing >30%

oxidizers, fuels containing aromatics
<30% aromatics
Isobutylene Isoprene Dilute mineral acids, Hydrocarbons and oils, most solvents,
alkalies, some concentrated nitric and sulfuric acids
concentrated acids,
oxygenated solvents
Acrylonitrile Butadiene Oils, water, and solvents Strong oxidizing agents, polar solvents,
chlorinated hydrocarbons
Polychloroprene Aliphatic solvents, dilute Strong oxidizing acids, chlorinated and

mineral acids, salts, aromatic hydrocarbons
alkalies
Natural Rubber or Styrene Butadiene Non-oxidizing acids, Hydrocarbons, oils, and oxidizing agents
alkalies, and salts
Notes: See Appendix B for more chemical resistance information.

Table 6-4
RMA Oil and Gasoline Resistance Classifications
RMA Designation Maximum Volume Change Tensile Strength Retained
Class A (High oil resistance) +25% 80%
Class B (Medium-High oil resistance) +65% 50%
Class C (Medium oil resistance) +100% 40%
Source: RMA, "The 1996 Hose Handbook," IP-2, p. 52.
6-3
EM 1110-1-4008
5 May 99
c. End Connections hose is designated as conducting or nonconducting, th e

electrical properties are uncontrolled. Standards do not
Hose couplings are used to connect hoses to a proces s currently exist for the prevention and safe dissipation of
discharge or input point. Meth ods for joining elastomeric static charge from hoses. Methods used to contro l
hose include banding/clamping, flanged joints, an d electrical properties include designing contact between a
threaded and mechanical coupling systems. Thes e body reinforcing wire and a metal coupling to provid e
methods are typically divided into reusable and non - electrical continuity for the hose or using a conductiv e
reusable couplings. Table 6-5 lists common types o f hose cover. ASTM D 380 describes standard tes t
couplings for hoses. Selection of the proper couplin g methods for the conductivity of elastomeric hoses. For a
should take into account the operating conditions an d hose to be considered non-conductive, it should be tested
procedures that will be employed. using these methods.
d. Environmental Requirements 6-3. Sizing
Hose is also manufactured with conductive, non - The primary considerations in determining the minimum
conductive, and uncontrolled electrical properties . acceptable diameter of any elastomeric hose are desig n
Critical applications such as transferring aircraft hose or flow rate and pressure drop. The design flow rate i s
transferring liquids aro und high-voltage lines, require the based on system demands that a re normally established in
electrical properties of hose to be controlled. Unless the the process design phase of a proje ct and which should be
Table 6-5
Typical Hose Couplings
Class Description
Reusable with clamps 1. Short Shank Coupling

2. Long Shank Coupling
3. Interlocking Type
4. Compression Ring Type
Reusable without clamps 1. Screw Type

2. Push-on Type
Non-reusable couplings 1. Swaged-on

2. Crimped-on
3. Internally Expanded Full Flow Type
4. Built-in Fittings
Specialty couplings 1. Sand Blast Sleeves

2. Radiator and Heater Clamps
3. Gasoline Pump Hose Couplings
4. Coaxial Gasoline Pump Couplings
5. Welding Hose Couplings
6. Fire Hose Couplings
6-4
EM 1110-1-4008
5 May 99
fully defined by this stage of the system design. Pressure 6-6. Isobutylene Isoprene
drop through the elastomeric hose must be designed t o
provide an optimum balance between installed costs and Isobutylene isoprene (Butyl or II R) has excellent abrasion
operating costs. Primary factors that will impact thes e resistance and excellent flexing properties. Thes e
costs and system operating performance are interna l characteristics combine to give isobutylene isoprene very
diameter (and the resulting fluid velocity), materials o f good weathering and aging resistance. Isobutylen e
construction and length of hose. isoprene is impermeable to most gases, but provides poor
resistance to petroleum based fluids. Isobutylen e
6-4. Piping Support and Burial isoprene is also not flame resistant.
Support for rubber and elastomer piping systems should 6-7. Acrylonitrile Butadiene
follow similar principles as metallic and plastic pipe .
However, continuous pi ping support is recommended for Acrylonitrile butadiene (nitrile, Buna-N or NBR) offers
most applications due to the flexible nature of thes e excellent resistance to petroleum oils, aromati c
materials. Also due to its flexible nature, elastome r hydrocarbons and many acids. NBR also has goo d
piping is not used in buried service because the piping is elongation properties. However, NBR does not provide
unable to support the loads required for buried service. good resistance to weathering.
When routing el astomer hose, change in piping direction 6-8. Polychloroprene

can be achieved through bending the hose rather tha n
using fittings. When designing a rubber or elastome r Polychloroprene (neoprene or CR) is one of the oldes t
piping system, it is important to make sure that the bend synthetic rubbers. It is a good all-purpose elastomer that
radius used does not exceed the max imum bend radius for is resistant to ozone, ultraviolet radiation, and oxidation.
the hose used. If the maximum bend radius is exceeded, Neoprene is also heat and flame resistant. Thes e
the hose may collapse and constricted flow or materia l characteristics give neoprene excellent resistance to aging
failure could occur. As a rule of thumb, the bend radius and weathering. Neoprene also provides good chemical
should be six times the diameter of a hard wall hose o r resistance to many petroleum based products an d
twelve times the diameter of a soft wall hose. aliphatic hydrocarbons. However, neoprene is vulnerable
to chlorinated solvents, polar s olvents, and strong mineral
6-5. Fluoroelastomer acids.
Fluoroelastomer (FKM) is a class of materials whic h 6-9. Natural Rubber

includes several fluoropolymers used for hose products.
Trade names of these materials incl ude Viton and Fluorel. Natural rubber (styrene butadiene, gum rubber, Buna-S,
Fluoroelastomers provide excellent high temperatur e NR, or SBR) has high resilience, good tear resistance ,
resistance, with the maximum allowable operatin g and good tensile strength. I t also exhibits wear resistance
temperatures for fluoroelastomer varying from 232 t o and is flexible at low te mperatures. These characteristics
315EC (450 to 600EF), depending upon th e make natural rubber suitable for general service outdoor
manufacturer. Fluoroelastomers also provide very good use. However, natural rubber is not flame resistant and
chemical resistance to a wide variety of chemical classes. does not provide resistance to petroleum based fluids.
6-5
EM 1110-1-4008
5 May 99
Chapter 7 resistance. Other types of commercially available

Thermoset Piping Systems reinforcement include graphite fibers for use with
fluorinated chemicals such as hydrofluoric acid; aramid;
polyester; and polyethylene. The types of fiberglass used
7-1. General
are E-glass; S-glass for higher temperature and tensile
Thermoset piping systems are composed of plastic strength requirements; and C-glass for extremely
materials and are identified by being permanently set, corrosive applications.
cured or hardened into shape during the manufacturing
process. Thermoset piping system materials are a Most thermoset piping systems are manufactured using a
combination of resins and reinforcing. The four primary filament winding process for adding reinforcement. This
thermoset resins are epoxies, vinyl esters, polyesters, and process accurately orients and uniformly places tension
furans. Other resins are available. on the reinforcing fibers for use in pressure applications.
It also provides the best strength-to-weight ratio as
a. Thermoset Piping Characteristics compared to other production methods. The other main
method of manufacturing is centrifugal casting,
Advantages of thermoset piping systems are a high particularly using the more reactive resins.
strength-to-weight ratio; low installation costs; ease of
repair and maintenance; hydraulic smoothness with a Thermoset piping can be provided with a resin-rich layer
typical surface roughness of 0.005 mm (0.0002 in); (liner) to protect the reinforcing fibers. The use of liners
flexibility, since low axial modulus of elasticity allows is recommended for chemical and corrosive applications.
lightweight restraints and reduces the need for expansion Liners for filament wound pipe generally range in
loops; and low thermal and electrical conductivity. thickness from 0.25 to 1.25 mm (0.01 to 0.05 in), but can
Disadvantages of thermoset piping systems are low be custom fabricated as thick as 2.8 mm (0.110 in) and
temperature limits; vulnerability to impact failure; are often reinforced. Liner thickness for centrifugally cast
increased support requirements, a drawback of the low thermoset piping generally ranges from 1.25 to 2.0 mm
modulus of elasticity; lack of dimensional standards (0.05 to 0.08 in); these liners are not reinforced. If not
including joints since pipe, fittings, joints and adhesives reinforced, liners may become brittle when exposed to
are generally not interchangeable between manufacturers; low temperatures. Impacts or harsh abrasion may cause
and susceptibility to movement with pressure surges, failure under these conditions.
such as water hammer. Table 7-1 lists applicable
standards for thermoset piping systems. Fittings are manufactured using compression molding,
filament winding, spray-up, contact molding and mitered
b. Corrosion Resistance processes. Compression molding is typically used for
smaller diameter fittings, and filament winding is used
Like other plastic materials, thermoset piping systems for larger, 200 to 400 mm (8 to 16 in), fittings. The
provide both internal and external corrosion resistance. spray-up, contact molding and mitered processes are used
For compatibility of thermoset plastic material with for complex or custom fittings. The mitered process is
various chemicals, see Appendix B. Due to the different typically used for on-site modifications.
formulations of the resin groups, manufacturers are
contacted to confirm material compatibility. For d. Operating Pressures and Temperatures
applications that have limited data relating liquid services
and resins, ASTM C 581 provides a procedure to Loads; service conditions; materials; design codes and
evaluate the chemical resistance of thermosetting resins. standards; and system operational pressures and
temperatures are established as described in Chapters 2
c. Materials of Construction and 3 for plastic piping systems. Table 7-2 lists
recommended temperature limits for reinforced
Fiberglass is the most common reinforcing material used thermosetting resin pipe.
in thermoset piping systems because of its low cost, high
tensile strength, light weight and good corrosion
7-1
EM 1110-1-4008
5 May 99
Table 7-1
Thermoset Piping Systems Standards (As of Nov. 1997)
Standard Application
ASTM D 2310 Machine-made reinforced thermosetting pipe.

ASTM D 2996 Filament wound fiberglass reinforced thermoset pipe.
ASTM D 2997 Centrifugally cast reinforced thermoset pipe.
ASTM D 3517 Fiberglass reinforced thermoset pipe conveying water.
ASTM D 3754 Fiberglass reinforced thermoset pipe conveying industrial process
liquids and wastes.
ASTM D 4024 Reinforced thermoset flanges.
ASTM D 4161 Fiberglass reinforced thermoset pipe joints using elastomeric seals.
ASTM F 1173 Epoxy thermoset pipe conveying seawater and chemicals in a marine
environment.
AWWA C950 Fiberglass reinforced thermoset pipe conveying water.
API 15LR Low pressure fiberglass reinforced thermoset pipe.
Table 7-2
Recommended Temperature Limits for Reinforced
Thermosetting Resin Pipe
Materials Recommended Temperature Limits

Minimum Maximum
Resin Reinforcing
EF EC EF EC
Epoxy Glass Fiber -20 -29 300 149

Furan Carbon -20 -29 200 93
Furan Glass Fiber -20 -29 200 93
Phenolic Glass Fiber -20 -29 300 149
Polyester Glass Fiber -20 -29 200 93
Vinyl Ester Glass Fiber -20 -29 200 93
Source: ASME B31.3, p. 96, Reprinted by permission of ASME.
7-2
EM 1110-1-4008
5 May 99
e. Thermoset Piping Support sleeve at least the thickness of the pipe wall. This
provides protection for the pipe material on either side of
Support for thermoset piping systems follow similar the anchor.
principles as thermoplastic piping systems. Physical
properties of the materials are similar enough that the Reinforced polyester pipe requires a wide support surface
same general recommendations apply. Spacing of on the hanger. It also calls for a rubber or elastomeric
supports is crucial to the structural integrity of the piping cushion between the hanger and the pipe to isolate the
system. Valves, meters, and other miscellaneous fittings pipe from point loads. This cushion is approximately 3
are supported independently of pipe sections. Separate mm (1/8 in) thick. Table 7-3 summarizes the maximum
supports are provided on either side of flanged support spacing at various system pressures for
connections. Additionally, anchor points, such as where reinforced epoxy pipe.
the pipeline changes direction, are built-up with a rubber
Table 7-3
Support Spacing for Reinforced Epoxy Pipe

Nominal Pipe
Size, mm (in) 24EC 66EC 79EC 93EC 107EC 121EC
(75EF) (150EF) (175EF) (200EF) (225EF) (250EF)
25 (1) 3.20 (9.9) 2.99 (9.8) 2.96 (9.7) 2.87 (9.4) 2.83 (9.3) 2.65 (8.7)
40 (1.5) 3.54 (11.6) 3.47 (11.4) 3.44 (11.3) 3.35 (11.0) 3.29 (10.8) 3.08 (10.1)
50 (2) 3.99 (13.1) 3.93 (12.9) 3.90 (12.8) 3.78 (12.4) 3.72 (12.2) 3.47 (11.4)
80 (3) 4.57 (15.0) 4.51 (14.8) 4.45 (14.6) 4.33 (14.2) 4.27 (14.0) 3.96 (13.0)
100 (4) 5.09 (16.7) 5.03 (16.5) 4.97 (16.3) 4.82 (15.8) 4.75 (15.6) 4.42 (14.5)
150 (6) 5.76 (18.9) 5.67 (18.6) 5.61 (18.4) 5.46 (17.9) 5.36 (17.6) 5.00 (16.4)
200 (8) 6.10 (20.0) 6.10 (20.0) 6.04 (19.8) 5.88 (19.3) 5.79 (19.0) 5.39 (17.7)
250 (10) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 5.73 (18.8)
300 (12) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.00 (19.7)
350 (14) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0) 6.10 (20.0)
Note: The above spacing values are based on long-term elevated temperature test data developed by the manufacturer
for the specific product. The above spacing is based on a 3-span continuous beam with maximum rated pressure
and 12.7 mm (0.5 in) deflection. The piping is assumed to be centrifugally cast and is full of liquid that has a
specific gravity of 1.00.
Source: Fibercast, Centricast Plus RB-2530, p. 2.
7-3
EM 1110-1-4008
5 May 99
The same principles for pipe support for reinforced loads must be analyzed and accounted for within the
polyester apply to reinforced vinyl ester and reinforced design. The system PFDs and P&IDs are analyzed to
epoxy thermoset pipe. Span distances for supports vary determine the thermal conditions or modes to which the
from manufacturer to manufacturer. The design of piping piping system will be subjected during operation. Based
systems utilizing reinforced vinyl ester or reinforced on this analysis, the design and material specification
epoxy pipe reference the manufacturer’s requirements are determined from an applicable standard
recommendations for support spacing. or design reference.
Each section of thermoset piping has at least one support. The primary objective of the analysis is to identify
Additionally, valves, meters, flanges, expansion joints, operating conditions that will expose the piping to the
and other miscellaneous fittings are supported most severe thermal loading conditions. Once these
independently. Supports are not attached to flanges or conditions have been established, a free or unrestrained
expansion joints. Supports allow axial movement of the thermal analysis of the piping can be performed to
pipe. establish location, sizing, and arrangement of expansion
joints or loops. Due to the cost of thermoset piping, the
f. Thermoset Piping Burial use of loops is not normally cost-effective.
Reinforced polyester, vinyl ester, and epoxy pipe may be The following procedure can be used to design expansion
buried. The same basic principles which apply to joints in fiberglass piping systems. The expansion joint
burying plastic pipe also apply for thermoset pipe must be selected and installed to accommodate the
regarding frost line, trench excavation, pipe installation, maximum axial motion in both expansion and
and backfill. For operating pressures greater than 689 contraction. This typically requires that some amount of
kPa (100 psi), the internal pressure determines the preset compression be provided in the expansion joint to
required wall thickness. For operating pressures less accommodate for all operating conditions. In addition,
than 689 kPa (100 psi), the vertical pressure on the pipe suitable anchors must be provided to restrain the
from ground cover and wheel load dictates the required expansion joint; guides must be installed to assure that
wall thickness of the pipe. the pipe will move directly into the expansion joint in
accordance with manufacturer requirements; and pipe
g. Joining supports, which allow axial movement, prevent lateral
movement, and provide sufficient support to prevent
Common methods for the joining of thermoset pipe for buckling, must be included in the design.
liquid process waste treatment and storage systems
include the use of adhesive bonded joints, over wrapped Step 1: Determine Required Preset
joints, and mechanical joining systems. The application
requirements and material specification for these fittings
R(Ti & Tmin)
are found in various codes, standards, and manufacturer Length of Preset '
procedures and specifications, including: Tmax & Tmin
- ASME B31.3 Chapter VII;

- ASME B31.1 Power Piping Code; where:
- The Piping Handbook, 6th Edition; and R = rated movement of expansion joint, mm (in)
- Fibercast Company Piping Design Manual. Ti = installation temperature, EC (EF)
Tmin = minimum system temperature, EC (EF)
h. Thermal Expansion Tmax = maximum system temperature, EC (EF)
When designing a piping system in which thermal Step 2: Design expansion loops using the equation
expansion of the piping is restrained at supports, anchors, provided in Paragraph 4-6, or consult with the piping
equipment nozzles, and penetrations, thermal stresses and manufacturer; for example, see Table 7-4.
7-4
EM 1110-1-4008
5 May 99
Table 7-4
Loop Leg Sizing Chart for Fibercast RB-2530 Pipe
Thermal Expansion, mm (in), versus Minimum Leg Length, m (ft)

Do
mm (in) 25.4 mm 50.8 mm 76.2 mm 127 mm 178 mm 229 mm
(1 in) (2 in) (3 in) (5 in) (7 in) (9 in)
33.40 (1.315) 1.22 m (4 ft) 1.52 m (5 ft) 1.83 m (6 ft) 2.44 m (8 ft) 2.74 m (9 ft) 3.05 m (10 ft)
Notes: Do = outside diameter of standard Fibercast pipe. Do may be different for other manufacturers.
Thermal expansion characteristics and required loop lengths will vary between manufacturers.
Source: Fibercast, Piping Design Manual, FC-680, p. 6.
7-2. Reinforced Epoxies 7-3. Reinforced Polyesters
Although epoxies cure without the need for additional Reinforced polyester thermoset piping systems are the
heat, almost all pipe is manufactured with heat-cure. most widely used due to affordability and versatility. The
Reinforced epoxy piping systems are not manufactured to maximum continuous operating temperature for optimum
dimensional or pressure standards. Therefore, chemical resistance is 71EC (160EF). Like the epoxies,
considerable variation between manufacturers exist in reinforced polyester piping systems are not manufactured
regard to available size, maximum pressure rating and to dimensional or pressure standards. Variation of
maximum temperature rating. Performance available piping sizes, maximum pressure rating, and
requirements, including manufacturing, conforms to maximum temperature ratings exist between
ASTM standards in order to not sole-source the piping manufacturers. Performance requirements, including
system. manufacturing, conform to ASTM standards in order to
not sole-source the piping system.
1
7-5
EM 1110-1-4008
5 May 99
7-4. Reinforced Vinyl Esters 7-5. Reinforced Furans
The vinyl ester generally used for chemical process The advantage of furan resins is their resistance to
piping systems is bisphenol-A fumarate due to good solvents in combination with acids or bases2. Furans are
corrosion resistance1. Reinforced vinyl ester piping difficult to work with and should not be used for
systems vary by manufacturer for allowable pressures and oxidizing applications. Maximum operating
temperatures. Performance requirements, including temperatures for furan resins can be 189EC (300EF).
manufacturing, conforms to ASTM standards in order to Furan resin piping is commercially available in sizes
not sole-source the piping system. ranging from 15 to 300 mm (½ to 12 in) standard.
2
7-6
EM 1110-1-4008
5 May 99
Chapter 8 different primary (carrier) and secondary (containment)

Double Containment Piping Systems piping systems based on physical dimensions. However,
the commercial availability of components must be
carefully reviewed for the selected materials of
8-1. General
construction. Availability of piping sizes, both diameter
To date, the double containment piping system design has and wall thickness; joining methods; and pressure ratings
not been standardized. If possible, the use of double may preclude the combination of certain primary and
containment piping should be deferred until design and secondary piping system materials.
construction standards are published by a national
standards organization, such as ASTM. An alternative to In addition, some manufacturers offer “pre-engineered”
the factory designed secondary containment piping may double containment piping systems. Some of these
be the use of single wall piping inside a sealed, systems may have been conceptualized without detailed
watertight, 360-degree secondary containment barrier; engineering of system components. If specified for use,
refer to CEGS 11145, Aviation Fueling Systems. Due to the detailed engineering of the “pre-engineered” system
the nature of the liquids transported in double must be performed, including any required customizing,
containment piping systems, the primary standard for the details, and code review.
design of these systems is the ASME B31.3, Chemical
Plant and Petroleum Refinery Piping Code. c. Material Selection
a. Regulatory Basis For piping system material compatibility with various

chemicals, see Appendix B. Material compatibility
Secondary containment is a means by which to prevent should consider the type and concentration of chemicals
and detect releases to the environment. Therefore, when in the liquid, liquid temperature, and total stress of the
dealing with regulated substances in underground storage piping system. The selection of materials of construction
tank systems or when managing hazardous wastes, should be made by an engineer experienced in corrosion
regulations typically require secondary containment of or similar applications. See Appendix A, Paragraph A-4
piping systems for new construction. Double wall piping - Other Sources of Information, for additional sources of
systems are available to provide secondary containment. corrosion data.
The double containment piping system is composed of an
outer pipe that completely encloses an inner carrier pipe Corrosion of metallic and thermoplastic piping systems
in order to detect and contain any leaks that may occur was addressed in Paragraphs 4-2 and 5-1. However, it
and to allow detection of such leaks. must be remembered that cracking, such as stress-
corrosion cracking and environmental stress cracking, is
Under storage tank regulation 40 CFR 280, secondary a potentially significant failure mechanism in double
containment is required for tanks containing hazardous containment piping systems. Differential expansion of
substances (as defined by CERCLA 101-14) or inner and outer piping can cause reaction loads at
petroleum products. The requirement applies whenever interconnecting components. These loads can produce
10% or more of the volume of the tank is underground. tensile stresses that approach yield strengths and induce
Tank standards in hazardous waste regulations in 40 CFR stress cracking at the interconnection areas.
264 and 40 CFR 265 also require secondary containment
of piping systems. These requirements are not only Material combinations may be classified into three main
applicable to RCRA Part B permitted treatment storage categories:
and disposal facilities, but also apply to interim status
facilities and to generators accumulating waste in tanks (1) the primary and secondary piping materials are
with ancillary piping. identical except for size, for example, ASTM A 53
carbon steel and A 53 carbon steel, respectively;
b. Design Requirements (2) the primary and secondary piping are the same
type of materials but not identical, for example,
Many options seem to exist for the combination of 316L stainless steel and A 53 carbon steel; and
(3) different types of materials are used, for example,
8-1
EM 1110-1-4008
5 May 99
PVDF as primary and A 53 carbon steel as lengths and before and after complex fittings to relieve
secondary. Table 8-1 provides a further breakdown thermal stress and prevent fitting failure1. Plastic piping
and description of these three groups. systems relieve themselves through deformation and wall
relaxation, potentially leading to failure. Totally
d. Thermal Expansion restrained systems should undergo a stress analysis and a
flexibility analysis as part of the design.
As discussed in the previous chapters, when a piping
system is subjected to a temperature change, it expands The combined stress on the secondary piping system is
or contracts accordingly. Double containment piping the result of bending, as well as torsional, internal
systems have additional considerations, including hydrostatic, and thermal expansion induced axial stresses.
expansion-contraction forces occurring between two The following method, which assumes that internal
potentially different, interconnected piping systems. hydrostatic and thermal expansion induced axial stresses
Thermal stresses can be significant when flexibility is not approximate the total stress, can be used to determine
taken into account in the design. For a double whether a totally restrained design is suitable2:
containment piping system, the primary and secondary
piping systems must be analyzed both as individual Sc ' (Fat)2 % (Fp)2
systems and as parts of the whole. The basic correlations
between the systems are: (1) the primary piping system
has a greater temperature change; and (2) the secondary
piping system has a greater temperature change. where:
Sc = combined stress, MPa (psi)
Because of the insulating effect of the secondary piping Fat = thermal induced axial stress, MPa (psi)
system, the primary piping system usually only exhibits Fp = internal hydrostatic stress, MPa (psi)
a larger temperature induced change when the process
dictates, for example, when a hot liquid enters the piping Fat ' E " ) T
system. In both above grade and buried systems,
secondary piping system expansions are typically
compensated for with expansion loops, changes in where:
direction, or a totally restrained system. Expansion joints Fat = thermal induced axial stress, MPa (psi)
are not recommended for this use due to potential leaks, E = modulus of elasticity, MPa (psi)
replacement and maintenance, unless they can be located " = coefficient of thermal expansion, mm/mm/EC
in a tank or vault. (in/in/EF)
) T = differential between maximum operating and
To accommodate the dimensional changes of the primary installation temperature, EC (EF)
piping system in expansion loops and change of direction
elbows, secondary piping systems are often increased in P (Do & t)
size. Another alternative is to fully restrain the primary Fp '
2 t
piping system. Figure 8-1 demonstrates the result of
differential movement between the piping systems
without full restraint, and Figure 8-2 depicts an expansion
loop with an increase to the secondary piping diameter. where:
Fp = internal hydrostatic stress, MPa (psi)
Totally restrained systems are complex. Stresses are P = liquid pressure, MPa (psi)
induced at points of interconnection, at interstitial Do = outside pipe diameter, mm (in)
supports, and at other areas of contact. For rigid piping t = pipe wall thickness, mm (in)
systems, restraints are placed at the ends of straight pipe
1
2
Ibid., pp. 418-420.
8-2
EM 1110-1-4008
5 May 99
Table 8-1
Double Containment Piping Material Combinations
Catagory Primary Secondary Comments Common Materials
1 M M Used with elevated temperatures and/or pressures. CS, 304 SS, 304L SS, 316 SS,
Good structural strength and impact resistant. 316L SS, 410 SS, Ni 200, Ni 201,
May be required by fire or building codes. Cu/Ni alloys
Cathodic protection required if buried.
1 TS TS Common for above grade and buried use for organic, polyester resin, epoxy resin, vinyl
inorganic, and acid wastes/chemicals. ester resin, furan resin
Good chemical resistance and structural strength.
Conductive to field fabrication.
1 TP TP Easily joined and fabricated. PVC, CPVC, HDPE, PP, PVDF,
Resistant to soil corrosion and many chemicals. ECTFE, ETFE, PFA
May be restricted by fire/building codes.
Impact safety may require safeguards.
2 M M May be required by fire codes or mechanical properties. CS-SS, Cu/Ni alloy - CS, CS-Ni,
Galvanic actions must be controlled at crevices and CS-410 SS
interconnections.
Cathodic protection required if buried.
2 TS TS Not advisable to combine resin grades. polyester-epoxy, vinyl ester-epoxy,
Epoxy and polyester resins are most economical. vinyl ester-polyester
2 TP TP Common for above grade and buried acid/caustic use. Many - PVDF-PP, PVDF-HDPE,
Economical - many commercial systems are available. PP-HDPE
3 M TS Common and economical. epoxy-M (CS, SS, Ni, Cu),
Practical - interconnections have been developed. polyester-M (CS, SS, Ni, Cu)
Good for buried use, may eliminate cathodic protection
requirements.
3 M TP Common and economical. HDPE - M (CS, SS),
Good for buried use, may eliminate cathodic protection PVDF- M (CS, SS),
requirements. PP-M (CS, SS)
May be limited by fire or building codes.
3 M O Limited practical use except for concrete trench. concrete trench - M
Ability for leak detection is a concern.
3 TS M Common for above grade systems requiring thermoset many
chemical resistance and metallic mechanical properties.
Can meet category “M” service per ASME code.
3 TS TP Economical. epoxy-TP (HDPE, PVC, PP),
Good for buried applications. polyester-TP (HDPE, PVC, PP)
3 TS O Limited practical use except for concrete trench. concrete trench - TS
Ability for leak detection is a concern.
3 TP M Common for above grade systems requiring thermoset many
chemical resistance and metallic mechanical properties.
Can meet category “M” service per ASME code.
3 TP TS Limited in use - thermoplastic chemical resistance needed limited
with thermoset mechanical properties.
May not meet UL acceptance standards.
3 TP O Limited practical use except for concrete trench or pipe. concrete trench - TP,
Ability for leak detection is a concern. concrete pipe - PVC
3 O M Interconnections may be difficult. CS-glass, CS-clay
Good for protection of brittle materials.
Notes: The primary piping material is listed first on primary-secondary combinations.
Material designations are: M - metallic materials; TS - thermoset materials; TP - thermoplastic materials; and O - other nonmetallic
materials
8-3
EM 1110-1-4008
5 May 99
Figure 8-1.Primary Piping Thermal Expansion

(Source: SAIC, 1998)
8-4
EM 1110-1-4008
5 May 99
Figure 8-2. Double Containment Piping Expansion Loop Configuration

8-5
EM 1110-1-4008
5 May 99
If the value of the combined stress, Sc, is less than the where:
design stress rating of the secondary piping material, then lg = maximum span between guides, mm (in)
the totally restrained design can be used. f = allowable sag, mm (in)
E = modulus of elasticity, MPa (psi)
When double containment piping systems are buried, and I = moment of inertia, mm4 (in4)
the secondary piping system has a larger temperature Z = section modulus, mm3 (in3)
change than the primary system, the ground will generally Sc = combined stress, MPa (psi)
provide enough friction to prevent movement of the outer
pipe. However, if extreme temperature differentials are 8-2. Piping System Sizing
expected, it may be necessary to install vaults or trenches
to accommodate expansion joints and loops. The method for sizing of the carrier pipe is identical to
the methods required for single wall piping systems; see
For double containment systems located above grade, previous chapters.
with secondary piping systems that have a larger
temperature differential than primary systems, two a. Secondary Pipe
common solutions are used. First, expansion joints in the
outer piping can accommodate the movement. Second, Secondary piping systems have more factors that must be
the secondary piping can be insulated and heat traced to considered during sizing. These factors include
reduce the potential expansion-contraction changes. The secondary piping function (drain or holding), pressurized
latter would be particularly effective with processes that or non-pressurized requirements, fabrication
produce constant temperature liquids; therefore, the requirements, and type of leak detection system. The
primary piping is relatively constant. assumption has to be made that at some point the primary
piping system will leak and have to be repaired, thus
e. Piping Support requiring the capability to drain and vent the secondary
piping system. Most systems drain material collected by
Support design for double containment piping systems the secondary piping system into a collection vessel.
heeds the same guidelines as for the piping material used Pressurized systems, if used, are generally only used with
to construct the containment system. The support design continuous leak detection methods, due to the required
is also based on the outside (containment) pipe size. compartmentalization of the other leak detection systems.
Spans for single piping systems of the same material as
the outer pipe may be used. The same recommendations Friction loss due to liquid flow in pressurized secondary
may be applied for burial of double containment piping piping systems is determined using the standard
systems as for the outer containment pipe material. equations for flow in pipes with the exception that the
hydraulic diameter is used, and friction losses due to the
The following equation approximates the maximum primary piping system supports have to be estimated.
spacing of the secondary piping system guides, or The hydraulic diameter may be determined from:
interstitial supports. The maximum guide spacing should
be compared to the maximum hanger spacing (at Dh ' di & Do
maximum operating temperature) and the lesser distance
used. However, the flexibility of the system should still
be analyzed using piping stress calculations to where:
demonstrate that elastic parameters are satisfied3. Dh = hydraulic diameter, mm (in)
di = secondary pipe inside diameter, mm (in)
0.5
48 f E I Do = primary pipe outside diameter, mm (in)
lg '
4 Z Sc
3
8-6
EM 1110-1-4008
5 May 99
In addition, for double containment piping systems that

Aa
have multiple primary pipes inside of a single secondary t ' I dh, for h1 & h2
piping system, pressurized flow parameters can be Cd AD 2 g h
calculated using shell and tube heat exchanger
approximations ( for more information, refer to the
additional references listed in Paragraph A-4 of where:
Appendix A). t = time, s
Aa = annular area, m2 (ft2)
8-3. Double Containment Piping System Testing C d = Cc C v
Cc = coefficient of contraction, see Table 8-2
The design of double containment piping systems Cv = coefficient of velocity, see Table 8-2
includes the provision for pressure testing both the AD = area of drain opening, m2 (ft2)
primary and secondary systems. Testing is specified in g = gravitational acceleration, 9.81 m/s2 (32.2 ft/s2)
the same manner as other process piping systems. The h = fluid head, m (ft)
design of each piping system contains the necessary
devices required for safe and proper operation including Step 2. Flushing Flow through Drain.
pressure relief, air vents, and drains.
Aa
Pressurized secondary piping systems are equipped with t ' I dh, for h1 & h2
pressure relief devices, one per compartment, as [(Cd AD 2 g h) & Qfl]
appropriate. Care should be taken with the placement of
these devices to avoid spills to the environment or
hazards to operators. where:
Qfl = flushing liquid flow rate, m3/s (ft3/s)
Low points of the secondary piping system should be t = time, s
equipped with drains, and high points should be equipped Aa = annular area, m2 (ft2)
with vents. If compartmentalized, each compartment C d = Cc C v
must be equipped with at least one drain and one vent. Cc = coefficient of contraction, see Table 8-2
Drains and vents need to be sized to allow total drainage Cv = coefficient of velocity, see Table 8-2
of liquid from the annular space that may result from AD = area of drain opening, m2 (ft2)
leaks or flushing. The following equations can be used g = gravitational acceleration, 9.81 m/s2 (32.2 ft/s2)
for sizing4: h = fluid head, m (ft)
Step 1. Drainage Flow through Drain.
Table 8-2
Common Orifice Coefficients
Condition Cv Cc
Short tube with no separation of fluid flow from walls 0.82 1.00
Short tube with rounded entrance 0.98 0.99
Source: Reprinted from Schweitzer, Corrosion-Resistant Piping Systems, p. 414, by courtesy of Marcel
Dekker, Inc.
4
Schweitzer, Corrosion-Resistant Piping Systems, pp. 414-415.
8-7
EM 1110-1-4008
5 May 99
8-4. Leak Detection Systems - at the cable entry into and exit from each pipe run;
- after every two changes in direction;
Leak detection is one of the main principles of double - at tee branches and lateral connections;
containment piping systems. Any fluid leakage is to be - at splices or cable branch connections; and
contained by the secondary piping until the secondary - after every 30.5 m (100 feet) of straight run.
piping can be drained, flushed, and cleaned; and the
primary piping system failure can be repaired. Without Power surges or temporary outages will set off alarms.
leak detection, the potential exists to compromise the To avoid such occurrences, consideration should be given
secondary piping system and release a hazardous to UPS.
substance into the environment. Early in the design of a
double containment piping system, the objectives of leak Installation requirements for a cable system include the
detection are established in order to determine the best completing of testing and thorough cleaning and drying of
methods to achieve the objectives. Objectives include: the secondary piping system prior to installation to avoid
false alarms. In addition, a minimum annular clearance
- need to locate leaks; of 18 mm (3/4 in) for conductance cables and 38 to 50
- required response time; mm (1-1/2 to 2 inches) for impedance cables is required
- system reliability demands; and to allow installation. These values may vary between
- operation and maintenance requirements. manufacturers.
a. Cable Leak Detection Systems b. Probe Systems
Cable detection systems are a continuous monitoring Probes that measure the presence of liquids through
method. The purpose of this method is to measure the conductivity, pH, liquid level, moisture, specific ion
electrical properties (conductance or impedance) of a concentrations, pressure, and other methods are used as
cable; when properties change, a leak has occurred. sensing elements in leak detection systems. The double
These systems are relatively expensive compared to the containment piping systems are separated into
other methods of leak detection. Many of the compartments with each compartment containing a probe
commercially available systems can determine when a with probe systems. Leaks can only be located to the
leak has occurred, and can also define the location of the extent to which the compartment senses liquid in the
leak. Conductance cable systems can detect the secondary containment piping.
immediate presence of small leaks, and impedance
systems can detect multiple leaks. However, it must be c. Visual Systems
remembered that these types of systems are sophisticated
electronic systems and that there may be problems with Visual systems include the use of sumps and traps;
false alarms, power outages, and corroded cables5. installation of sight glasses into the secondary piping
Design requirements for these systems include: access, system; equipping the secondary piping system with clear
control panel uninterruptible power supply (UPS), and traps; and use of a clear secondary piping material. Some
installation requirements. manufacturers offer clear PVC. Visual systems are often
used in addition to other leak detection methods.
Access ports should be provided in the secondary piping
system for installation and maintenance purposes. The
ports should be spaced similar to any other electrical
wiring:
5
8-8
EM 1110-1-4008
5 May 99
Chapter 9 Lined piping systems are used primarily for handling

Lined Piping Systems corrosive fluids in applications where the operating
pressures and temperatures require the mechanical
strength of metallic pipe. Therefore, the determination of
9-1. General
maximum steady state design pressure is based on the
When properly utilized, a lined piping system is an same procedure and requirements as metallic pipe shell,
effective means by which to protect metallic piping from and the design temperature is based on similar
internal corrosion while maintaining system strength and procedures and requirements as thermoplastic pipe.
external impact resistance. Cathodic protection is still
required for buried applications to address external Table 9-1 lists recommended temperature limits of
corrosion. Manufacturing standard options for the outer thermoplastic used as liners. The temperature limits are
piping material are usually Schedule 40 or 80 carbon based on material tests and do not necessarily reflect
steel. Lined piping systems are not double containment evidence of successful use as piping component linings in
piping systems. specific fluid serviced at the temperatures listed. The
manufacturer is consulted for specific application
a. Design Parameters limitations.
Design factors that must be taken into account for the c. Liner Selection
engineering of lined piping systems include: pressure,
temperature and flow considerations; liner selection Liner selection for piping systems must consider the
factors of permeation, absorption, and stress cracking; materials being carried (chemical types and
and heat tracing, venting and other installation concentrations, abrasives, flow rates), the operating
requirements. conditions (flow, temperature, pressure), and external
situations (high temperature potential).
b. Operating Pressures and Temperatures
For the material compatibility of metallic lined piping
The requirements for addressing pressure and system with various chemicals, see Appendix B. As
temperature conditions for lined piping systems are discussed in Chapter 4, metallic material compatibility
summarized in the following paragraphs. should consider the type and concentration of chemicals
Table 9-1
Thermoplastic Liner Temperature Limits (Continuous Duty)
Recommended Temperature Limits

Minimum Maximum
Materials EF EC EF EC
ECTFE -325 -198 340 171

ETFE -325 -198 300 149
FEP -325 -198 400 204
PFA -325 -198 500 260
PP 0 -18 225 107
PTFE -325 -198 500 260
PVDC 0 -18 175 79
PFDF 0 -18 275 135
Note: Temperature compatibility should be confirmed with manufacturers before use is specified.
Source: ASME B31.3, p. 96, Reprinted by permission of ASME.
9-1
EM 1110-1-4008
5 May 99
in the liquid, liquid temperature and total stress of the d. Joining

piping system. The selection of materials of construction
should be made by an engineer experienced in corrosion Two available methods for joining lined pipe are flanged
or similar applications. See Appendix A, Paragraph A-4, joints and mechanical couplings (in conjunction with heat
for additional sources of corrosion data. fusion of the thermoplastic liners).
As discussed in Chapter 5, thermoplastic materials do not Thermoplastic spacers are used for making connections
display corrosion rates and are, therefore, either between lined steel pipe and other types of pipe and
completely resistant to a chemical or will rapidly equipment. The spacer provides a positive seal. The
deteriorate. Plastic lined piping system material failure bore of the spacer is the same as the internal diameter
occurs primarily by the following mechanisms: (Di) of the lined pipe. Often, a gasket is added between
absorption, permeation, environmental-stress cracking, the spacer and a dissimilar material to assist in providing
and combinations of the above mechanisms. a good seal and to protect the spacer.
Permeation of chemicals may not affect the liner but may When connecting lined pipe to an unlined flat face flange,
cause corrosion of the outer metallic piping. The main a 12.7 mm (½ in) thick plastic spacer of the same
design factors that affect the rate of permeation include material as the pipe liner is used. A gasket and a spacer
absorption, temperature, pressure, concentration, and will connect to an unlined raised face flange. Both a
liner density and thickness. As temperature, pressure, gasket and a spacer is recommended to connect to glass-
and concentration of the chemical in the liquid increase, lined equipment nozzles. Install a 12.7 mm (½ in) thick
the rate of permeation is likely to increase. On the other spacer between lined pipe or fittings and other plastic-
hand, as liner material density and thickness increase, lined components, particularly valves, if the diameters of
permeation rates tend to decrease1. the raised plastic faces are different.
For plastic material compatibility with various chemicals, For small angle direction changes, tapered face spacers
see Appendix B. See Appendix A, Paragraph A-4, for may be used3. It is not recommended to exceed a five
additional sources of corrosion data. For the material degree directional change using a tapered face spacer.
compatibility of elastomeric and rubber as well as other For directional changes greater than five degrees,
nonmetallic material lined piping systems with various precision-bent fabricated pipe sections are available from
chemicals, see appendix B. lined pipe manufacturers.
Liners should not be affected by erosion with liquid Gaskets are not necessary to attain a good seal between
velocities of less than or equal to 3.66 m/s (12 ft/s) when sections of thermoplastic lined pipe, if recommended
abrasives are not present. If slurries are to be handled, fabrication and installation practices are followed. Often,
lined piping is best used with a 50% or greater solids leaks result from using insufficient torque when trying to
content and liquid velocities in the range of 0.61 to 1.22 seal a joint. The addition of a gasket provides a softer
m/s (2 to 4 ft/s). Particle size also has an effect on material which seals under the lesser stress developed by
erosion. Significant erosion occurs at >100 mesh; some low torque. When gaskets or any dissimilar materials are
erosion occurs at >250 but <100 mesh; and little erosion used in the pipe joint, the lowest recommended torque for
occurs at <250 mesh. Recommended liners for slurry the materials in the joint is always used.
applications are PVDF and PTFE, and soft rubber; by
comparison, in a corrosive slurry application, PP erodes Gaskets are put in when previously used lined pipe is
2 times as fast and carbon steel erodes 6.5 times as fast2. reinstalled following maintenance. Gaskets are also used
between plastic spacers and non-plastic-lined pipe,
valves, or fittings.
1
Schweitzer, Corrosion-Resistant Piping Systems, pp.149-151.
2
Ibid., p. 153.
3
Crane/Resistoflex, “Plastic Lined Piping Products Engineering Manual,” p. 41.
9-2
EM 1110-1-4008
5 May 99
The recommended bolt torque values for thermoplastic f. Heat Tracing and Insulation
lined piping systems are shown on Tables 9-2 through 9-
5. Excessive torque causes damage to the plastic sealing Heat tracing, insulation, and cladding can be installed on
surfaces. When bolting together dissimilar materials, the lined piping systems when required. The key for the
lowest recommended torque of the components in the design is to not exceed the maximum allowable
joint is used. temperature of the lining. Manufacturers
recommendations on electrical heat tracing design should
Bolting torque is rechecked approximately 24 hours after be followed to avoid localized hot spots. Steam heat
the initial installation or after the first thermal cycle. This tracing should not be used with most plastic lined piping
is required to reseat the plastic and allow for relaxation of systems due to the high temperature potential. Venting is
the bolts. Bolting is performed only on the system in the required on many lined piping systems to allow for
ambient, cooled state, and never while the process is at permeating vapor release. If insulation or cladding is to
elevated temperature or excessive force could result upon be mounted on the piping system, vent extenders should
cooling. be specified to extend past the potential blockage.
e. Thermal Expansion g. Piping Support and Burial
Thermal expansion design for lined piping systems can Design of support systems for lined piping systems
be handled in a similar manner as metallic piping. follows the same guidelines as for the outer piping
Expansion joints have been used to compensate for material. Spans for systems consisting of the material
thermal expansion. However, expansion joints are used in the outer pipe may be used. Supports should
usually considered the weakest component in a piping permit the pipe to move freely with thermal expansion
system and are usually eliminated through good and contraction. The design requirements for buried
engineering practices. Due to the bonding between the lined piping systems are the same as those for the outer
liner and the metallic pipe casing, pre-manufactured piping material. That is, a buried plastic lined carbon
sections of pipe designed to allow for changes in steel pipe should be treated the same way as a carbon
movement of the piping system are available from steel pipe without a liner.
manufacturers.
9-2. Plastic Lined Piping Systems
On long straight pipe runs, lined pipe is treated similarly
to carbon steel piping. Changes in direction in pipe runs Thermoplastic lined piping systems are commonly used
are introduced wherever possible to allow thermal and widely available commercially under a variety of
expansion. trade names. Table 9-6 presents a summary of some of
the material properties for plastic liners, and Table 9-7
A common problem is the installation of lined piping lists some of the liner thicknesses used for the protection
between a pump and another piece of equipment. On of oil production equipment when applied as a liquid
new installations, equipment can be laid out such that coating. Standard liner thicknesses are 3.3 to 8.6 mm
there are no direct piping runs. Where a constricted (0.130 to 0.340 inches).
layout is required or a piping loop would not be practical,
the solution is to allow the pump to "float." The pump- a. Common Plastic Liners
motor base assemblies are mounted on a platform with
legs. These bases are available from several Most thermoplastics can be used as liner material.
manufacturers or can be constructed. These bases allow However, the more common and commercially available
movement in order to relieve the stresses in the piping plastic liners include polyvinylidene chloride,
system. perfluoroalkoxyl, polypropylene, polytetrafluoroethylene,
and polyvinylidene fluoride.
9-3
EM 1110-1-4008
5 May 99
Table 9-2
ANSI Class 125 and Class 150 Systems
(Lightly Oiled Bolting)
Bolt Torque, N-m (ft-lb)

Pipe Size, Number of Bolt
mm (in) Bolts Diameter
PVDC PP PVDF PTFE
mm (in)
25 (1) 4 14 (½) 41 (30) 37 (35) 75 (55) 34 (25)
40 (1½) 4 14 (½) 54 (40) 102 (75) 81 (60) 75 (55)
50 (2) 4 16 (5/8) 61 (45) 149 (110) 169 (125) 102 (75)
65 (2½) 4 16 (5/8) 75 (55) 169 (125) N.A. N.A.
80 (3) 4 16 (5/8) 95 (70) 169 (125) 169 (125) 149 (110)
100 (4) 8 16 (5/8) 68 (50) 190 (140) 169 (125) 129 (95)
150 (6) 8 20 (3/4) 129 (95) 305 (225) 305 (225) 169 (125)
200 (8) 8 20 (3/4) 217 (160) 305 (225) 305 (225) 258 (190)
250 (10) 12 24 (7/8) N.A. 468 (345) N.A. 271 (200)
Notes: These torques are only valid for lightly oiled ASTM A 193 bolts and nuts. Lightly oiled is considered WD-40
(WD-40 is a registered trademark of WD-40 Company, San Diego, CA) or equivalent.
Source: Crane/Resistoflex, “Plastic Lined Piping Products Engineering Manual,” p. 54.
TABLE 9-3
ANSI Class 300 Systems
(Lightly Oiled Bolting)
Bolt Bolt Torque, N-m (ft-lb)

Pipe Size Number of Diameter
mm (in) Bolts mm (in) PVDC PP PVDF PTFE
25 (1) 4 16 (5/8) 37 (35) 61 (45) 95 (70) 41 (30)

40 (1½) 4 16 (5/8) 81 (60) 149 (110) 230 (170) 108 (80)
50 (2) 8 16 (5/8) 34 (25) 75 (55) 115 (85) 54 (40)
80 (3) 8 20 (3/4) 54 (40) 136 (100) 210 (155) 88 (65)
100 (4) 8 20 (3/4) 81 (60) 230 (170) 305 (225) 149 (110)
150 (6) 12 20 (3/4) 88 (65) 224 (165) 305 (225) 115 (85)
200 (8) 12 24 (7/8) 169 (125) 441 (325) 495 (365) 203 (150)
Note: These torques are only valid for lightly oiled ASTM A 193, B7 bolts and ASTM A 194, 2H nuts. Lightly oiled
is considered WD-40 (WD-40 is a registered trademark of WD-40 Company, San Diego, CA) or equivalent.
9-4
EM 1110-1-4008
5 May 99
Table 9-4
ANSI Class 125 and Class 150 Systems
(Teflon - Coated Bolting)
Pipe Size, Number of Bolt Bolt Torque N-m (ft-lb)

mm (in) Bolts Diameter
mm (in) PVDC PP PVDF PTFE
25 (1) 4 14 (½) 27 (20) 34 (25) 54 (40) 20 (15)

40 (1½) 4 14 (½) 41 (30) 75 (55) 61 (45) 54 (40)
50 (2) 4 16 (5/8) 41 (30) 95 (70) 122 (90) 68 (50)
65 (2½) 4 16 (5/8) 37 (35) 122 (90) N.A. N.A.
80 (3) 4 16 (5/8) 68 (50) 122 (90) 122 (90) 95 (70)
100 (4) 8 16 (5/8) 37 (35) 122 (90) 122 (90) 81 (60)
150 (6) 8 20 (3/4) 41 (30) 102 (75) 102 (75) 68 (50)
200 (8) 8 20 (3/4) 75 (55) 102 (75) 102 (75) 102 (75)
250 (10) 12 24 (7/8) N.A. 339 (250) N.A. 203 (150)
300 (12) 12 24 (7/8) N.A. 339 (250) N.A. 271 (200)
Notes: These torques are valid only for Teflon-coated ASTM A 193, B7 bolts and ASTM A 194, 2H nuts.
TABLE 9-5
ANSI Class 300 Systems
(Teflon - Coated Bolting)
Bolt Torque N-m (ft-lb)

Pipe Size Number of Bolt
mm (in) Bolts Diameter PVDC PP PVDF PTFE
mm (in)
25 (1) 4 16 (5/8) 41 (30) 37 (35) 61 (45) 27 (20)
40 (1½) 4 20 (3/4) 34 (25) 61 (45) 95 (70) 41 (30)
50 (2) 8 16 (5/8) 27 (20) 61 (45) 95 (70) 41 (30)
80 (3) 8 20 (3/4) 34 (25) 61 (45) 81 (60) 34 (25)
100 (4) 8 20 (3/4) 41 (30) 95 (70) 102 (75) 61 (45)
150 (6) 12 20 (3/4) 41 (30) 95 (70) 102 (75) 37 (35)
200 (8) 12 24 (7/8) 129 (95) 312 (230) 346 (255) 163 (120)
Notes: These torques are valid only for Teflon-coated ASTM A 193, B7 bolts and ASTM A 194, 2H nuts.
9-5
EM 1110-1-4008
5 May 99
Table 9-6
Plastic Liner Material Properties
Liner Shell Specific Tensile Available Size Maximum

Material Material Gravity Strength, MPa Range, mm (in) Temperature,
(psi) EC (EF)
PVC -- 1.45 41.4 (6,000) -- 82 (180)
PVDC carbon steel 1.75 18.6 (2,700) 25 to 200 (1 to 8) 79 (175)
PE carbon steel, 0.94 8.27 (1,200) 50 to 200 (2 to 8) 66 (150)

aluminum
PP carbon steel 0.91 31.0 (4,500) 25 to 300 (1 to 12) 107 (225)
PTFE carbon steel, 2.17 17.2 (2,500) 25 to 300 (1 to 12) 232 (450)
TP304L stainless
steel
FEP carbon steel 2.15 23.4 (3,400) 25 to 750 (1 to 30) 204 (400)
PFA carbon steel 2.15 24.8 (3,600) 25 to 750 (1 to 30) 260 (500)
ETFE carbon steel 1.7 44.8 (6,500) as required* 150 (300)
PVDF carbon steel 1.78 31.0 (4,500) 25 to 200 (1 to 8) 135 (275)
ECTFE carbon steel, 1.68 48.3 (7,000) 25 to 200 (1 to 8) 150 (300)

stainless steel
Note: *Typically liquid applied; availability based upon shell piping availability.
Source: Compiled by SAIC, 1998; note that confirmation is required from the specific vendor for a selected product.
Table 9-7
Liquid-Applied Coating Thickness
Material Total Dry Film Thickness Range
Fluoropolymers (ETFE, ECTFE) 50 to 125 µm (2 to 5 mils)
PVDF 500 to 1,500 µm (20 to 60 mils)
Source: NACE, RP 0181-94, p. 3.
9-6
EM 1110-1-4008
5 May 99
Polytetrafluoroethylene (PTFE) is a fully fluorinated carbon tetrachloride, toluene, ferric chloride,

polymer. Although PTFE is chemically inert to most hydrochloric acid, and other liquids. PFA lacks the
materials, some chemicals will permeate through the physical strength of PTFE at higher temperatures and
liner. Therefore, venting of the joint area between the fails at 1/4 of the life of PTFE under flexibility tests7.
liner and outer casing is required4. PTFE materials are PFA resins are manufactured according to ASTM D
produced in accordance with ASTM D 1457 with 3307, and lined piping and fittings are manufactured to
material parameters specified by the designation of type conform to ASTM F 781.
(I through VIII) and class (specific to each type). The
manufacture of PTFE lined pipe and materials are in
accordance with ASTM F 423. Table 9-8
Typical PVDF Liner Thickness
Polyvinylidene fluoride (PVDF) is similar to PTFE but is Required to Prevent Permeation
not fully fluorinated. PVDF liners can be produced with
sufficient thickness to prevent permeation of gases Nominal Pipe Size, Liner Thickness,
(seeTable 9-8) so that liner venting is not required5. mm (in) mm (in)
PVDF resins are produced in accordance with ASTM D
3222 with material parameters specified by the
designation of either type 1 (class 1 or 2) or type 2. 25 (1) 3.81 (0.150)
PVDF lined pipe and fittings are manufactured to
conform to ASTM F 491. 40 (1 ½) 4.07 (0.160)
Polyvinylidene chloride (PVDC) is a proprietary product 50 (2) 4.37 (0.172)

of Dow Chemical (trade name Saran). PVDC is often
used in applications where purity protection is critical. 80 (3) 4.45 (0.175)
PFA resins are manufactured according to ASTM D 729,
and lined piping and fittings are manufactured to conform 100 (4) 5.26 (0.207)
to ASTM F 599.
150 (6) 5.54 (0.218)
Polypropylene (PP) lined pipe is typically inexpensive
compared to other lined plastic piping systems. In
addition, PP does not allow permeation; therefore, liner 200 (8) 5.54 (0.218)
venting is not required6. Physical parameters (e.g.,
density, tensile strength, flexural modulus) of PP Source: Reprinted from Schweitzer, Corrosion-
materials are specified by cell classification pursuant to Resistant Piping Systems, p. 182, by
ASTM D 4101. Additional material requirements may courtesy of Marcel Dekker, Inc.
be added using the ASTM D 4000 suffixes; for example,
W = weather resistant. The manufacture of PP lined pipe
b. Plastic Lined Piping Construction
and materials are in accordance with ASTM F 492.
As discussed in Paragraph 9-1d, plastic lined pipe piping
Perfluoroalkoxyl (PFA) is a fully fluorinated polymer that
is joined using flanges or mechanical couplings and
is not affected by chemicals commonly found in chemical
fittings that are normally flanged. Some manufacturers
processes. Depending upon process conditions PFA will
can provide pre-bent pipe sections to avoid the use of
absorb some liquids, however, including benzaldehyde,
flanged elbows. Use of pre-bent pipe sections requires
4
Schweitzer, Corrosion-Resistant Piping Systems, pp. 161-162.
5
Ibid., p. 165.
6
Ibid., p. 166.
7
Ibid., p. 164.
9-7
EM 1110-1-4008
5 May 99
that the design take into account the manufacturer’s MPa (150 psi) or 2.06 MPa (300 psi). Joining is
standard bend radius which is often larger than the bend typically accomplished through the use of flanges.
radius for conventional elbows.
Glass-lined piping systems are commercially available
9-3. Other Lined Piping Systems with carbon steel outer piping in sizes of 25 to 300 mm
(1 to 12 in), standard. Joining is accomplished using
The elastomer and rubber materials most commonly used class 150 split flanges, although class 300 split flanges
as liner materials include natural rubber, neoprene, butyl, are also available as options. A PTFE envelope gasket is
chlorobutyl, nitrile, and EPDM, which tend to be less recommended8. Stress is to be avoided; expansion joints
expensive than other liners. Design criteria that need to should be used to isolate vibration and other stresses from
be considered before selecting elastomeric and rubber the piping system. Sudden changes in process
lined piping systems include: corrosion resistance, temperatures should also be avoided.
abrasion resistance, maximum operating temperature, and
potential contamination of conveyed material. Nickel-lined piping systems are available in sizes from
40 to 600 mm (1½ to 24 in) with liner thickness of
Elastomeric and rubber linings vary in thickness from 3.2 0.0008 to 0.015 inches. Joining is accomplished either
to 6.4 mm (1/8 to 1/4 in). Lined pipe is available from by welding or flanging, with welding the preferred
40 to 250 mm (1½ to 10 in), standard, at ratings of 1.03 method9.
.
8
9
Ibid., p. 199.
9-8
EM 1110-1-4008
5 May 99
Chapter 10 The purpose of characterizing control valves is to allow

Valves for relatively uniform control stability over the expected
operating range of the piping system. A design goal is to
match a control valve flow characteristic to the specific
10-1. General
system. Figure 10-1 illustrates some typical flow
For liquid piping systems, valves are the controlling characteristic curves for control valves.
element. Valves are used to isolate equipment and piping
systems, regulate flow, prevent backflow, and regulate Table 10-1 provides guidelines for the selection of proper
and relieve pressure. The most suitable valve must be flow characteristics. There are exceptions to these
carefully selected for the piping system. The minimum guidelines, and a complete dynamic analysis is performed
design or selection parameters for the valve most suitable on the piping system to obtain a definite characteristic.
for an application are the following: size, material of Quick opening valves are primarily used for open/close
construction, pressure and temperature ratings, and end applications (or on/off service) but may also be
connections. In addition, if the valve is to be used for appropriate for applications requiring near linear flow.
control purposes, additional parameters must be defined. For processes that have highly varying pressure drop
These parameters include: method of operation, operating conditions, an equal percentage valve may be
maximum and minimum flow capacity requirement, appropriate.
pressure drop during normal flowing conditions, pressure
drop at shutoff, and maximum and minimum inlet b. Material of Construction
pressure at the valve. These parameters are met by
selecting body styles, material of construction, seats, The selection of valve body material and trim material is
packing, end connections, operators and supports. typically based on pressure, temperature, corrosive and
erosive properties of the liquid. Table 10-2 provides
a. Body Styles basic information on typical castable materials used for
control valve bodies. Certain service conditions require
The control valve body type selection requires a other alloys and metals to withstand corrosive and erosive
combination of valve body style, material, and trim properties of the liquid. The materials that can be used
considerations to allow for the best application for the for these situations are similar to the piping materials;
intended service. therefore, the material fluid matrix found in Appendix B
can be used as a guide to select materials for these special
Valve body styles have different flow characteristics as conditions. The use of non-standard materials is much
they open from 0 to 100%. The flow rate through each more expensive than the use of standard valve body
type or body style will vary according to different curves materials.
with constant pressure drops. This is referred to as the
valve flow characteristics. A quick opening flow c. Seats
characteristic produces a large flow rate change with
minimal valve travel until the valve plug nears a wide Valve seats are an integral part of a valve. The materials
open position. At that point, the flow rate change is for valve seats are specified under valve trim for each
minimal with valve travel. A linear flow characteristic is valve. As such, valve seats are manufacturer specific and
one that has a flow rate directly proportional to valve should not be interchanged. Seat material is selected for
travel. An equal percentage flow characteristic is one in compatibility with the fluid. Valve seats can be either
which a flow rate change is proportional to the flow rate metallic or non-metallic. The fluid/material matrix found
just prior to the change in valve position. Equal in Appendix B may be used to assist in material selection.
increments of valve travel result in equal percentage Table 10-3 provides a wear and galling resistance chart
changes to the existing flow rate. That is, with a valve for different metallic valve plug and seat combinations.
nearly closed (existing flow rate is small), a large valve Table 10-4 provides general information for elastomers
travel will result in a small flow rate change, and a large used in valve seats.
flow rate change will occur when the valve is almost
completely open, regardless of the amount of valve travel.
10-1
EM 1110-1-4008
5 May 99
Figure 10-1. Valve Flow Characteristics

(Source: Fisher, Control Valve Handbook, 2nd Ed., p. 60.)
10-2
EM 1110-1-4008
5 May 99
Table 10-1
Recommended Flow Characteristics
Control Recommended Flow
System Application Characteristic
Liquid Level Constant ªP. Linear
Liquid Level Decreasing ªP with increasing flow; ªPmin > 20% ªPmax. Linear
Liquid Level Decreasing ªP with increasing flow; ªPmin < 20% ªPmax. Equal Percentage
Liquid Level Increasing ªP with increasing flow; ªPmax < 200% ªPmin. Linear
Liquid Level Increasing ªP with increasing flow; ªPmax > 200% ªPmin. Quick Opening
Flow Measurement signal proportional to flow; valve in series with Linear

measurement device; wide range of flow required.
Flow Measurement signal proportional to flow; valve in series with Equal Percentage
measurement device; small range of flow required with large
ªP change for increasing flow.
Flow Measurement signal proportional to flow; valve in parallel Linear
(bypass) with measurement device; wide range of flow
required.
Flow Measurement signal proportional to flow; valve in parallel Equal Percentage
(bypass) with measurement device; small range of flow
required with large ªP change for increasing flow.
Flow Measurement signal proportional to flow squared; valve in Linear
series with measurement device; wide range of flow required.
Flow Measurement signal proportional to flow squared; valve in Equal Percentage
series with measurement device; small range of flow required
with large ªP change for increasing flow.
parallel (bypass) with measurement device; wide range of flow
required.
parallel (bypass) with measurement device; small range of flow
required with large ªP change for increasing flow.
Pressure All. Equal Percentage
Source: Control Valve Handbook, Fisher Controls Company, pp. 61-62.
10-3
EM 1110-1-4008
5 May 99
Table 10-2
Standard Control Valve Body Materials
Cast Material Standard Comments
Carbon Steel ASTM A 216 Moderate services such as non-corrosive liquids. Higher
Gr. WCB pressures and temperatures than cast iron. Check codes
for suitability at extended high temperatures.
Chrome-Moly Steel ASTM A 217, Used for mildly corrosive fluids such as sea water, oils.
Gr. C5 Resistant to erosion and creep at high temperatures. Can
be used to 595EC (1,100EF).
Type 304 Stainless Steel ASTM A 351, Used for oxidizing or very corrosive fluids (see
Gr. CF8 Appendix C).
Can be used above 540EC (1,000EF).
Type 316 Stainless Steel ASTM A 351, Used for oxidizing or very corrosive fluids, resistant to
Gr. CF8M corrosion pitting and creep (see Appendix C). Provides
greater strength than 304 S.S.
Monel ASTM A 494 Resistant to nonoxidizing acids.
Gr. M35-1 Used with seawater and other mildly corrosive fluids at
high temperatures.
Expensive.
Hastelloy-C ASTM A 494 Used particularly with chlorine and chloride compounds.
Gr. CW2N Expensive.
Iron ASTM A 126 Inexpensive and non-ductile.
Class B Used for water and non-corrosive liquids.
Bronze ASTM B 61 ASTM B 61 typically used for trim.
and B 62 ASTM B 62 typically used for valve body.
Can be used for water and dilute acid service (see
Appendix B).
Note: Gr. = grade; grade designation pursuant to the referenced standard.
10-4
Table 10-3
Wear and Galling Resistance Chart of Material Combinations
Type Type
304 316 Hastelloy Hastelloy Titanium Alloy 416 440 Alloy 6 Cr- Al-
SS SS Bronze Inconel Monel B C 75A Nickel 20 Hard Hard (Co-Cr) Plate Bronze
304 SS P P F P P P F P P P F F F F F
316 SS P P F P P P F P P P F F F F F
Bronze F F S S S S S S S S F F F F F
Inconel P P S P P P F P F F F F F F S
Monel P P S P P P F F F F F F S F S
Hastelloy B P P S P P P F F S F F F S S S
Hastelloy C F F S F F F F F F F F F S S S
Titanium 75A P P S P F F F P F F F F S F S
Nickel P P S F F S F F P P F F S F S
Alloy 20 P P S F F F F F P P F F S F S
Type 416 Hard F F F F F F F F F F F F S S S
Type 440 Hard F F F F F F F F F F S F S S S
17-4 PH F F F F F F F F F F F S S S S
Alloy 6 (Co-Cr) F F F F S S S S S S S S F S S
ENC* F F F F F F F F F F S S S S S
Cr Plate F F F F F S S F F F S S S P S
Al Bronze F F F S S S S S S S S S S S P
*
Electroless nickel coating
S - Satisfactory
F - Fair
P - Poor
Source: Control Valve Handbook, Fisher Controls Company, p. 49.
10-5
5 May 99
EM 1110-1-4008
10-6
Table 10-4
5 May 99
Elastomer General Properties

Natural Ethylene
2 2,3
Property Rubber Buna-S Nitrile Neoprene Butyl Thiokol Silicone Hypalon Viton Polyurethane 3 Propylene 4
EM 1110-1-4008
Tensile PureGum 3000 400 600 3500 3000 300 200-450 4000
--- --- ---
Strength, (207) (28) (41) (241) (207) (21) (14-31) (276)
psi (Bar)
Reinforced 4500 3000 4000 3500 3000 1500 1100 4400 2300 6500 2500
(310) (207) (276) (241) (207) (103) (76) (303) (159) (448) (172)
Tear Resistance Excellent Poor-Fair Fair Good Good Fair Poor-Fair Excellent Good Excellent Poor
Abrasion Resistance Excellent Good Good Excellent Fair Poor Poor Excellent Very Excellent Good
Good
Aging: Sunlight Poor Poor Poor Excellent Excellent Good Good, Excellent, Excellent Excellent Excellent
Oxidation Good Fair Fair Good Good Good Very Very Excellent Excellent Good
Good Good
Heat (Max. Temp.) 93EC 93EC 121EC 93EC 93EC 60EC 232EC 149EC 204EC 93EC 177EC
(200EF) (200EF) (250EF) (200EF) (200EF) (140EF) (450EF) (300EF) (400EF) (200EF) (350EF)
Static (Shelf) Good Good Good Very Good Fair Good Good --- --- Good
Good
Flex Cracking Excellent Good Good Excellent Excellent Fair Fair Excellent --- Excellent ---
Resistance
Compression Set Good Good Very Excellent Fair Poor Good Poor Poor Good Fair
Resistance Good
Low Temperature -54EC -46EC -40EC -40EC -40EC -40EC -73EC -29EC -34EC -40EC -45EC
Flexibility (Max.) (-65EF) (-50EF) (-40EF) (-40EF) (-40EF) (-40EF) (-100EF) (-20EF) (-30EF) (-40EF) (-50EF)
Permeability to Gases Fair Fair Fair Very Very Good Fair Very Good Good Good
Good Good Good
Resilience Very Fair Fair Very Very Poor Good Good Good Fair Very Good
Good Good Good
Elongation (Max.) 700% 500% 500% 500% 700% 400% 300% 300% 425% 625% 500%
1
Notes: Trademark of Thiokol Chemical Co.
2
Trademark of E.I. DuPont Co.
3
Do not use with ammonia.
4
Do not use with petroleum base fluids. Use with ester base nonflammable hydraulic oils and low pressure steam applications to 300 EF (140EC).
See Appendix B for more details regarding fluid compatibility with elastomers.
Source: Control Valve Handbook, Fisher Controls Company, p. 57.
EM 1110-1-4008
5 May 99
In addition, the amount of valve leakage is determined d. Packing

based on acceptability to process and design
requirements. Control valve seats are classified in Most control valves use packing boxes with the packing
accordance with ANSI/FCI 70-2-1991 for leakage. retained and adjusted by flange and stud bolts. Several
These classifications are summarized in Table 10-5 and packing materials are available for use, depending upon
Table 10-6. the application. Table 10-7 provides information on
some of the more typical packing arrangements.
Table 10-5 e. End Connections

Valve Seat Leakage Classifications
The common end connections for installing valves in pipe
Leakage Class
include screwed pipe threads, bolted gasketed flanges,
Designation Maximum Allowable Leakage
welded connections, and flangeless (or wafer) valve
I --- bodies.
II 0.5% of rated capacity Screwed end connections are typically used with small
III 0.1% of rated capacity valves. Threads are normally specified as tapered female
National Pipe Thread (NPT). This end connection is
IV 0.01% of rated capacity limited to valves 50 mm (2 in) and smaller and is not
V 5 x 10 -12 m3/s of water per mm of recommended for elevated temperature service. This
seat diameter per bar differential connection is also used in low maintenance or
(0.0005 ml/min per inch of seat non-critical applications.
diameter per psi differential)
Flanged end valves are easily removed from piping and,
VI Not to exceed amounts shown in with proper flange specifications, are suitable for use
Table 10-6 (based on seat through the range of most control valve working
diameter) pressures. Flanges are used on all valve sizes larger than
Source: ANSI/FCI 70-2-1991 50 mm (2 in). The most common types of flanged end
connections are flat faced, raised faced, and the ring joint.
Flat faced flanges are typically used in low pressure, cast
Table 10-6 iron or brass valves and have the advantage of
Class VI Seat Allowable Leakage minimizing flange stresses. Raised faced flanges can be
used for high pressure and temperature applications and
Nominal Port Allowable Leakage are normally standard on ANSI Class 250 cast iron and
Diameter Rate on all steel and alloy steel bodies. The ring-type joint
mm (in) (ml per minute) flange is typically used at extremely high pressures of up
to 103 MPa (15,000 psig) but is generally not used at
#25 (#1) 0.15 high temperatures. This type of flange is furnished only
38 (1½) 0.30 on steel and alloy valve bodies when specified.
51 (2) 0.45 Welding ends on valves have the advantage of being leak
64 (2½) 0.60 tight at all pressures and temperatures; however, welding
end valves are very difficult to remove for maintenance
76 (3) 0.90 and/or repairs. Welding ends are manufactured in two
102 (4) 1.70 styles: socket and butt.
152 (6) 4.00 Flangeless valve bodies are also called wafer-style valve
203 (8) 6.75 bodies. This body style is common to rotary shaft control
valves such as butterfly valves and ball valves.
Source: ANSI/FCI 70-2-1991
10-7
EM 1110-1-4008
5 May 99
TABLE 10-7
Packing
Type Application
PTFE Resistant to most chemicals.

Requires extremely smooth stem finish to seal properly.
Will leak if stem or packing is damaged.
Laminated/Filament Graphite Impervious to most liquids and radiation.
Can be used at high temperatures, up to 650EC (1,200EF).
Produces high stem friction.
Semi-Metallic Used for high pressures and temperatures, up to 480EC (900EF).
Fiberglass Good for general use.
Used with process temperatures up to 288EC (550EF).
Ferritic steel stems require additive to inhibit pitting.
Kevlar and Graphite Good for general use.
Used with process temperatures up to 288EC (550EF).
Corrosion inhibitor is included to avoid stem corrosion.
Flangeless bodies are clamped between two pipeline type or a pneumatic piston. While these pneumatic
flanges by long through-bolts. One of the advantages of operators are also available for rotary shaft valves,
a wafer-style body is that it has a very short face-to-face electrical operators tend to be more common on the
body length. rotary valves.
f. Operators Spring and diaphragm operators are pneumatically

operated using low pressure air supplied from a
Valve operators, also called actuators, are available in controller position or other source. Styles of these
manual, pneumatic, electric, and hydraulic styles. operators include direct acting, in which increasing air
pressure pushes down the diaphragm and extends the
Manual operators are used where automatic control is not actuator stem; reverse acting, in which increasing air
required. These valves may still result in good throttling pressure pushes up the diaphragm and retracts the
control, if control is necessary. Gate, globe and stop actuator stem; and direct acting for rotary valves.
check valves are often supplied with hand wheel Pneumatic operators are simple, dependable, and
operators. Ball and butterfly valves are supplied with economical. Molded diaphragms can be used to provide
hand levers. Manual operators can be supplied with linear performance and increase travel. The sizes of the
direct mount chain wheels or extensions to actuate valves operators are dictated by the output thrust required and
in hard-to-reach locations. Manually operated valves are available air pressure supply.
often used in a three-valve bypass loop around control
valves for manual control of the process during down Pneumatic piston operators are operated using high
time on the automatic system. Manual operators are pressure air. The air pressure can be up to 1.03 MPa
much less expensive than automatic operators. (150 psig), often eliminating the need for a pressure
regulator that is required on a diaphragm actuator. The
For sliding stem valves, that is, valves that are not rotary, best design for piston actuators is double acting. This
the most common operator type is a pneumatic operator. allows for the maximum force in both directions on the
A pneumatic operator can be a spring and diaphragm piston. Piston actuators can be supplied with accessories
10-8
EM 1110-1-4008
5 May 99
that will position the valve in the event of loss of air Electro-pneumatic transducers and electro-pneumatic
supply. These accessories include spring return, positioners are used in electronic control loops to position
pneumatic trip valves, and lock-up type systems. It is pneumatically operated control valves. The positioner or
common to include manual operators along with transducer receives a current input signal and then
pneumatic piston operators in a design. These manual supplies a proportional pneumatic output signal to the
operators can then act as travel stops to limit either full pneumatic actuator to position the valve.
opening or full closing of the valve.
g. Supports
Electric and electro-hydraulic operators are more
expensive than pneumatic actuators; however, they offer Specific pipe material design recommendations are
advantages when no existing air supply source is followed when designing supports for valves. In general,
available, where low ambient temperatures could affect one hanger or other support should be specified for each
pneumatic supply lines, or where very large stem forces side of a valve, that is, along the two pipe sections
or shaft forces are required. Electrical operators only immediately adjacent to the valve. The weight of the
require electrical power to the motors and electrical input valve is included in the calculation of the maximum span
signal from the controller in order to be positioned. of supports.
Electrical operators are usually self-contained and
operate within either a weather-proof or an 10-2. Valve Types
explosion-proof casing.
The main valve types have many variations and may have
An auxiliary positioner or booster is sometimes used on different names depending upon manufacturer. Careful
pneumatic operating systems when it is necessary to split selection and detailed specifications are required to insure
the controller output to more than one valve, to amplify that design and performance requirements are met.
the controller above the standard range in order to
provide increased actuator thrust, or to provide the best a. Check Valves
possible control with minimum overshoot and fastest
possible recovery following a disturbance or load change. Check valves are self-actuated. These valves are opened,
Determination of whether to use a positioner or a booster and sustained in the open position, by the force of the
depends on the speed of the system response. If the liquid velocity pressure. They are closed by the force of
system is relatively fast, such as is typical of pressure gravity or backflow. The seating load and tightness is
control and most flow control loops, the proper choice is dependent upon the amount of back pressure. Typical
a booster. If the system is relatively slow, as is typical of check valves include swing check, tilting disc check, lift
liquid level, blending, temperature and reactor control check, and stop check. Other check valve types are
loads, the proper choice is a positioner1. available, however.
Hydraulic snubbers dampen the instability of the valve Swing check valves are used to prevent flow reversal in
plug in severe applications and are used on pneumatic horizontal or vertical upward pipelines (vertical pipes or
piston and direct acting diaphragm actuators. pipes in any angle from horizontal to vertical with
upward flow only). Swing check valves have discs that
Limit switches can be used to operate signal lights, swing open and closed. The discs are typically designed
solenoid valves, electric relays, or alarms. The limit to close on their own weight, and may be in a state of
switches are typically provided with 1 to 6 individual constant movement if velocity pressure is not sufficient to
switches and are operated by the movement of the valve hold the valve in a wide open position. Premature wear
stem. It is common for each switch to be individually or noisy operation of the swing check valves can be
adjustable and used to indicate the full open or full closed avoided by selecting the correct size on the basis of flow
position on a valve.
1
Fisher Control Company, p. 35.
10-9
EM 1110-1-4008
5 May 99
conditions. The minimum velocity required to hold a

swing check valve in the open position is expressed by V ' j$2 <
the empirical formula2:
where:
V ' j v V = liquid flow, m/s (ft/s)
v = specific volume of the liquid, m3/N (ft3/lb)
j = 152.8 (40) for bolted cap
where: = 534.7 (140) for Y-pattern
V = liquid flow, m/s (ft/s) $ = ratio of port diameter to inside pipe diameter
v = specific volume of the liquid, m3/N (ft3/lb)
j = 133.7 (35) for Y-pattern Stop check valves are typically used in high pressure and
= 229.1 (60) for bolted cap hazardous applications. Stop check valves have a
= 381.9 (100) for U/L listed floating disc. Sizing of these valves is extremely
important because of the floating disc, and manufacturer's
Tilting disc check valves are pivoted circular discs recommended procedures should be used. Stop check
mounted in a cylindrical housing. These check valves valves typically have a manual operator and, in this
have the ability to close rapidly, thereby minimizing manner, can be forced closed to prevent any backflow of
slamming and vibrations. Tilting disc checks are used to materials. The minimum velocity required for a full disc
prevent reversals in horizontal or vertical-up lines similar lift in a stop check valve is estimated by the following
to swing check valves. The minimum velocity required empirical formula5:
for holding a tilting check valve wide open can be
determined by the empirical formula3: V ' j$2 <
V ' j v where:
V = liquid flow, m/s (ft/s)

where: v = specific volume of the liquid, m3/N (ft3/lb)
V = liquid flow, m/s (ft/s) j = 210.0 (55) globe, OS&Y blocked bonnet
v = specific volume of the liquid, m3/N (ft3/lb) = 286.4 (7S) angle, OS&Y blocked bonnet
j = 305.5 (80) for a 5E disc angle (typical for steel) = 229.1 (60) Y-pattern, OS&Y bolted bonnet
= 114.6 (30) for a 15E disc angle (typical for iron) = 534.7 (140) Y-pattern, threaded bonnet
$ = ratio of port diameter to inside pipe diameter
Lift check valves also operate automatically by line
pressure. They are installed with pressure under the disc. Use of these empirical methods may result in a check
A lift check valve typically has a disc that is free floating valve sized smaller than the piping which is used. If this
and is lifted by the flow. Liquid has an indirect line of is the case, reducers are used to decrease pipe size to the
flow, so the lift check is restricting the flow. Because of smaller valve. The pressure drop is no greater than that
this, lift check valves are similar to globe valves and are of the larger valve that is partially open, and valve life is
generally used as a companion to globe valves. Lift extended6.
check valves will only operate in horizontal lines. The
minimum velocity required to hold a lift check valve open
is calculated using the following empirical formula4:
2
Crane Valves, Engineering Data, p. 53.
3
Ibid., p. 53.
4
Ibid., p. 53.
5
Ibid., p. 54.
6
Crane Valves, Cast Steel Valves, p. 14.
10-10
EM 1110-1-4008
5 May 99
b. Ball Valves with matching tapered seats. Therefore, the refacing or

repairing of the seating surfaces is not a simple operation.
Ball valves with standard materials are low cost, Gate valves should not, therefore, be used frequently to
compact, lightweight, easy to install, and easy to operate. avoid increased maintenance costs. In addition, a slightly
They offer full flow with minimum turbulence and can open gate valve can cause turbulent flow with vibrating
balance or throttle fluids. Typically, ball valves move and chattering of the disc.
from closed to full open in a quarter of a turn of the shaft
and are, therefore, referred to as quarter turn ball valves. A gate valve usually requires multiple turns of its hand
Low torque requirements can permit ball valves to be wheel manual operator in order to be opened fully. The
used in quick manual or automatic operation, and these volume of flow through the valve is not in direct
valves have a long reliable service life. Ball valves can proportion to the number of turns of the hand wheel.
be full ball or other configurations such as V-port.
d. Globe and Angle Valves
Full ball valves employ a complete sphere as the flow
controlling member. They are of rotary shaft design and Liquid flow does not pass straight through globe valves.
include a flow passage. There are many varieties of the Therefore, it causes an increased resistance to flow and a
full ball valves, and they can be trunion mounted with a considerable pressure drop. Angle valves are similar to
single piece ball and shaft to reduce torque requirements globe valves; however, the inlet and outlet ports are at
and lost motion. 90E angles to one another, rather than at 180E angles.
Because of this difference, the angle valves have slightly
One of the most popular flow controlling members of the less resistance to flow than globe valves. However, both
throttling-type ball valves is a V-port ball valve. A valve types operate similarly in principle and, for the
V-port ball valve utilizes a partial sphere that has a V- purposes of this document, discussion of globe valves
shaped notch in it. This notch permits a wide range of will also pertain to angle valves.
service and produces an equal percentage flow
characteristic. The straight-forward flow design produces There are a number of common globe valve seating types.
very little pressure drop, and the valve is suited to the Table 10-8 presents some of the more common seating
control of erosive and viscous fluids or other services that types, along with advantages and disadvantages of each.
have entrained solids or fibers. The V-port ball remains
in contact with the seal, which produces a shearing effect The seating of the plug in a globe valve is parallel to the
as the ball closes, thus minimizing clogging. line of liquid flow. Because of this seating arrangement,
globe valves are very suitable for throttling flow with a
c. Gate Valves minimal seat erosion or threat of wire drawing.
The gate valve is one of the most common valves used in A globe valve opens in direct proportion to the number of
liquid piping. This valve, as a rule, is an isolation valve turns of its actuator. This feature allows globe valves to
used to turn on and shut off the flow, isolating either a closely regulate flow, even with manual operators. For
piece of equipment or a pipeline, as opposed to actually example, if it takes four turns to open a globe valve fully,
regulating flow. The gate valve has a gate-like disc then approximately one turn of a hand wheel will release
which operates at a right angle to the flow path. As such, about 25% of the flow, two turns will release 50%, and
it has a straight through port that results in minimum three turns will release 75%. In addition, the shorter
turbulence erosion and resistance to flow. However, travel saves time and work, as well as wear on valve
because the gate or the seating is perpendicular to the parts.
flow, gate valves are impractical for throttling service and
are not used for frequent operation applications. Maintenance is relatively easy with globe valves. The
seats and discs are plugs, and most globe valves can be
Repeated closure of a gate valve, or rather movement repaired without actually removing the valve from the
toward closure of a gate valve, results in high velocity pipe.
flow. This creates the threat of wire drawing and erosion
of seating services. Many gate valves have wedge discs
10-11
EM 1110-1-4008
5 May 99
Table 10-8
Common Globe Valve Seating
Type Comments
Plug Long taper with matching seat provides wide seating contact area.
Excellent for severe throttling applications.
Resistant to leakage resulting from abrasion.
With proper material selection, very effective for resisting erosion.
Conventional Disc Narrow contact with seat.
Good for normal service, but not for severe throttling applications.
Subject to erosion and wire drawing.
Good seating contact if uniform deposits (such as from coking actions) occur.
Non-uniform deposits make tight closure difficult.
Composition Disc “Soft” discs provided in different material combinations depending upon liquid
service.
Good for moderate pressure applications except for close throttling, which will
rapidly erode the disc.
Needle Sharp pointed disc with matching seat provides fine control of liquid flow in
small-diameter piping.
Stem threads are fine, so considerable stem movement is required to open or
close.
e. Butterfly Valves f. Pinch Valves
Butterfly valves provide a high capacity with low Pinch valves, as the name suggests, pinch an elastomeric
pressure loss and are durable, efficient, and reliable. The sleeve shut in order to throttle the flow through the
chief advantage of the butterfly valve is its seating pipeline. Because of the streamlined flow path, the pinch
surface. The reason for this advantage is that the disc valve has very good fluid capacity. Pinch valves typically
impinges against a resilient liner and provides bubble have a fairly linear characteristic. However, some
tightness with very low operating torque. Butterfly manufacturers offer field reversible cam-characterizable
valves exhibit an approximately equal percentage of flow positioners. These positioners will vary the rate of stem
characteristic and can be used for throttling service or for change as a function of position in order to match the
on/off control. flow characteristics desired. In some instances, the cams
are set up to provide an equal percentage flow
Typical butterfly bodies include a wafer design, a lug characteristic through a pinch valve.
wafer design (a wafer with the addition of lugs around the
bodies), and a flanged design. In all designs, butterfly The pinch valve sleeve is available in various elastomer
valves are typically made with standard raised face piping materials in order to adjust for chemical resistance. In
flanges. Butterfly valves are available standard in sizes addition, because the throttling takes place in the
up to 72 inches for many different applications. The elastomer sleeve, and elastomers typically have very good
operators can be either pneumatic or electric. abrasion resistance; pinch valves are often used for
slurries or liquids that contain high amounts of solids.
10-12
EM 1110-1-4008
5 May 99
g. Plug Valves the required flow. Control valves that are sized too large
or are arbitrarily sized to match the connecting pipe, will
Plug valves are another type of isolation valve designed result in increased capital costs, decreased valve life (due
for uses similar to those of gate valves, where quick to the throttling and erosion effects when operating near
shutoff is required. They are not generally designed for to the closed position), and decreased performance (by
flow regulation. Plug valves are sometimes also called limiting rangeability). Control valves are optimally
cock valves. They are typically a quarter turn open and selected by identifying the flow characteristic required,
close. Plug valves have the capability of having multiple then calculating an expected flow coefficient and the
outlet ports. This is advantageous in that it can simplify maximum allowable pressure drop. These factors are
piping. Plug valves are available with inlet and outlet then compared to manufacturers' data for specific valve
ports with four-way multi-port valves which can be used types and sizes.
in place of two, three or four straight valves.
To select a control valve, the process application must be
h. Self-Contained Automatic Valves understood. Minimum information considered includes
desired flow characteristics; type, temperature, viscosity,
Self-contained automatic valves are used for pressure- and specific gravity of the liquid; minimum and
reducing stations. The valve body itself is normally a maximum flow capacity; minimum and maximum valve
globe-type valve. It is normally diaphragm actuated and inlet pressure; and minimum and maximum valve outlet
hydraulically operated. The valves are capable of pressure.
maintaining constant downstream pressure regardless of
the fluctuations in flow or upstream pressure by internal For example, Figure 10-2 depicts a piping system curve,
hydraulic controllers. with and without the control valve, and an overlying
pump curve. Typically, a valve differential pressure (ªP)
10-3. Valve Sizing and Selection of approximately 33% of the total piping system friction
drop at maximum flow is desired (as shown on Figure
Valve sizing and type selection is a critical component of 10-2). For systems that require low turndown, or face
a piping design. Valve type is shown on P&IDs, and abrasion or other problems, the valve ªP may be as low
valve size is commonly provided on valve schedules. as 15%7.
The sizing and selection procedures are different for non-
control and control valves.
Once a desired ªP is determined, the valve flow
a. Non-Control Valves coefficient (Cv) and allowable pressure drop (ªPallow) are
calculated for a fully open valve in accordance with the
Non-control valves used for isolation are the same size as flow chart depicted on Figure 10-3. The valve recovery
the connecting pipe. This sizing reduces pressure loss. factor (Rm) and cavitation index (Kc) are determined from
Check valves may be smaller than the connecting pipe, manufacturers' data for a specific type and size of valve.
provided that the valves are properly sized to ensure full
open operation without flow restriction. Materials of The sizing formulas for incompressible flow without
construction, wetted or otherwise, and end connections mixed-phase fluids, dense slurries, dry solids or non-
are in compliance with applicable codes and standards Newtonian liquids are as follows8:
and address the fluid application for corrosivity (see Q s.g.
Paragraph 10-1). Cv '
N1 ªP
b. Control Valves
where:
Control valves are sized and selected to optimize Cv = valve flow coefficient
application. Valves that are sized too small will not pass Q = flow, m3/hour (gpm)
7
Gardellin, p. 4.
8
ISA-S75.01, pp. 15-18, 33-35.
10-13
EM 1110-1-4008
5 May 99
Figure 10-2. Control Valve Pressure Drop Curve

10-14
EM 1110-1-4008
5 May 99
Figure 10-3. Control Valve Sizing

10-15
EM 1110-1-4008
5 May 99
N1 = Conversion factor, 0.085 when Q is in m3/hour 1/2

and ªP is in kPa (1.00 when Q is in gpm and ªP is in Pv
rc ' 0.96 & 0.28
psi) Pc
s.g. = specific gravity of liquid
ªP = differential pressure across valve, kPa (psi)
where:
rc = critical pressure ratio
1/4
N4 Fd Q Rm2 Cv2 Pv = liquid vapor pressure, kPa (psi)
Rev ' % 1 Pc = absolute thermodynamic critical pressure, kPa
1/2 1/2
< Rm C v N2 d 4 (psi)
where: ) Pc ' Kc (Pi & Pv)

Rev = valve Reynolds number
N4 = conversion factor, 76,000 when Q is in m3/hour
and d is in mm (17,300 when Q is in gpm and d is in
inches) where:
Fd = valve style modifier, see Table 10-9 ªPc = valve ªP at which cavitation damage occurs,
Q = volumetric flow rate, m3/hour (gpm) kPa (psi)
< = kinematic viscosity, mm2/sec (centistoke) Kc = cavitation index, from manufacturers' data
Rm = valve recovery factor, from manufacturers' data Pi = value inlet pressure, kPa (psi)
(see Table 10-9) Pv = liquid vapor pressure, kPa (psi)
Cv = valve flow coefficient
N2 = conversion factor, 0.00214 when d is in mm Example Problem 8:
(890 when d is in inches) Figure 10-2 represents the process to be controlled and
d = valve inlet diameter, mm (in) control valve is for flow control purposes with an orifice
plate flow measurement device. The liquid is water with
trace hydrocarbons. The pipe size is 100 mm and the
Cv
Cvc ' operating conditions are: T = 15.6EC; Pi = 517 kPa,
FR 172.4 kPa, and 1030 kPa for normal, minimum, and
maximum operating conditions, respectively.
where: Solution:
Cvc = valve flow coefficient corrected for viscosity Step 1. From Figure 10-2, ªP at max. flow = 496 kPa
FR = valve Reynolds number factor (see Figure 10-4) and Q = 17 m3/hour normal
10 m3/hour minimum
21.5 m3/hour maximum
ªPallow ' Rm2 (Pi & rc Pv)
Step 2. The flow measurement device is proportional to
flow squared so that an equal percentage for
where: characteristic is desired. Assume a butterfly valve will be
ªPallow = maximum valve ªP to avoid choked flow, used so Fd = 0.7, and Rm = 0.7 (from Table 10-9)
kPa (psi)
Rm = valve recovery factor, from manufacturers' data Step 3. From common fluid mechanics reference
(see Table 10-9) materials: s.g. = 1.0; Pv = 1.85 kPa; Pc = 22.09 MPa; < =
Pi = valve inlet pressure, kPa (psi) 1.13 mm2/sec.
rc = critical pressure ratio, calculation as follows or
see Figure 10-5 Step 4. Therefore, the valve calculations are:
Pv = liquid vapor pressure, kPa (psia)
10-16
EM 1110-1-4008
5 May 99
TABLE 10-9
Example Values of Valve Capacity Factors
Valve Type Trim Type Flow Direction* Rm Fd** Cv/d2***
Globe Ported plug Either 0.9 1.0 6,129 (9.5)

- Single port
Contoured plug Open 0.9 1.0 7,098 (11)
Close 0.8 1.0 7,098 (11)
Characterized cage Open 0.9 1.0 9,032 (14)
Close 0.85 1.0 10,322 (16)
Wing guided Either 0.9 1.0 7,098 (11)
- Double port Ported plug Either 0.9 0.7 8,065 (12.5)
Contoured plug Either 0.85 0.7 8,387 (13)
Wing guided Either 0.9 0.7 9,032 (14)
- Rotary Eccentric Spherical plug Open 0.85 1.0 7,742 (12)
Close 0.68 1.0 8,710 (13.5)
Angle Contoured plug Open 0.9 1.0 10,968 (17)
Close 0.8 1.0 12,903 (20)
Characterized cage Open 0.85 1.0 7,742 (12)
Close 0.8 1.0 7,742 (12)
Venturi Close 0.5 1.0 14,194 (22)
Ball Segmented Open 0.6 1.0 16,129 (25)
Standard port (diameter – 0.8d) Either 0.55 1.0 14,194 (22)
Butterfly 60-Degree aligned Either 0.68 0.7 11,290 (17.5)
Fluted vane Either 0.7 0.7 16,129 (25)
90-Degree offset seat Either 0.60 0.7 18,710 (29)
*
Flow direction tends to open or close the valve: i.e., push the closure member away from or towards the seat.
**
In general, an Fd value of 1.0 can be used for valves with a single flow passage. An Fd value of 0.7 can be used
for valves with two flow passages, such as double-ported globe valves and butterfly valves.
***
In this table, d may be taken as the nominal valve size, mm (in).
NOTE: The values are typical only for the types of valves shown at their rated travel for full-size trim. Significant
variations in value may occur because of any of the following reasons: reduced travel, trim type, reduced
port size, and valve manufacturer.
Source: ISA -S75.01, p. 31; Copyrighted material reprinted by permission of the Instrument Society of America, all
rights reserved.
10-17
EM 1110-1-4008
5 May 99
Figure 10-4. Valve Factor Diagram

(Source: ISA-S75.01-1985 (R 1995), p. 34.)
10-18
EM 1110-1-4008
5 May 99
Figure 10-5. Critical Pressure Ratio

(Source: Fisher, Control Valve Handbook, 2nd Ed., p. 67)
10-19
EM 1110-1-4008
5 May 99
Cv '
Q s.g. ) Pallow ' Rm2 (Pi & rc Pv)
N1 )P
' (0.75)2[1030 kPa & (0.96)(1.85 kPa)]
21.5 m 3/hour 1.0 ) Pallow ' 578 kPa at max. flow (full open)
Cv ' '11.4
0.085 496 kPa
ªPallow š ªP at maximum flow, therefore, the valve is

1/4 acceptable.
N4 Fd Q Rm2 Cv2
Rev ' % 1
< Rm1/2CV1/2 N2 d
4 10-4. Valve Schedule
Many manufacturers have PC-based sizing programs that

1/4 will size and select their optimum valve for a specific
(76,000)(0.7)(21.5) (0.7)2(11.4)2
Rev' %1 application. In addition, computerized piping system
(1.13)(0.7)1/2(11.4)1/2 (0.00214)(100)4 design programs may also have valve sizing and selection
routines that will select the optimum valve in their
Rev ' 3.57 x 105 databases. Although these sizing programs can provide
useful data, the optimum valve for a particular application
may be found elsewhere. For design purposes, contract
FR = 1.0 from Figure 10-4 (a viscosity correction is not drawings include a valve schedule to aid in the bidding
required due to the high Reynolds number).Therefore, Cvc and proper supply of valves.
= 11.4.
a. Valve Schedule
Step 5. From manufacturer's data, a 25 mm, 60E V-port
ball valve at full open in a 50 mm pipe has a Cv of 11.2 Table 10-10 presents a valve schedule that is included in
and a Rm of 0.75. Therefore, neck the connecting piping the contract drawings for liquid process piping design.
down to 50 mm, and select a 25 mm V-port ball valve
(has an equal percentage flow characteristic). b. Valve Operators Schedule
Step 6. The allowable pressure drop of the system is Table 10-11 is a valve operator schedule that is
compared to the actual valve differential pressure to sometimes included in the contract drawings. This
confirm that the valve will operate satisfactorily. schedule is used when additional information, beyond that
shown on a valve schedule, is required.
1/2
Pv
rc ' 0.96 & 0.28
Pc
1/2
1.85kPa
' 0.96 & 0.28
22,090kPa
rc ' 0.96
10-20
Table 10-10
Valve Schedule
Valve Size Flange Screwed Design Body Trim Bolting

Tag/Ref Description Range Rating Ends Rating Materials Materials Materials Operation Service Remarks
V120 Ball Valve, Full Port 50 mm & -- Taper 1.39 MPa 316 SS 316 SS Ball & Stem -- Lever IWW, SLG,
Positive Shut-off Smaller ANSI B2.1 Glass Filled TFE WPS
Seats, TFE Seals
V121 Ball Valve, Full Port 80 mm ANSI B16.5 -- 689 kPa 316 SS 316 SS Ball & Stem CS Lever SW, ALT, Instrument Isolation
Positive Shut-off Class 150 Glass Filled TFE ASTM A 307 RO, AL, Valves Only
Seats, TFE Seals Gr B SWW, RL
V122 Ball Valve, Full Port 40 mm & ANSI B16.5 -- 1.03 MPa 316 SS 316 SS Ball & Stem CS Lever WCR
Positive Shut-off Smaller Class 300 Glass Filled TFE ASTM A 307
Seats, TFE Seals Gr B
V123 Solid Wedge Gate Valve 50 mm & ANSI B16.5 -- 1.03 MPa CS 13% Cr Steel Seats & CS Handwheel SLP
O.S. & Y., Rising Stem Larger Class 300 ASTM A 216 SS Stem ASTM A 307
GR WCB Gr B
V124 Double Disc Gate Valve 50 mm & ANSI B16.5 -- 689 kPa CS UT Trim CS Handwheel SL
O.S. & Y., Rising Stem Larger Class 150 ASTM A 216 316 SS Stem ASTM A 307
GR WCB Gr B
V150 Swing Check Valve 50 mm to ANSI B16.5 -- 689 kPa CS 13% Cr Steel Seats & CS -- XLT, ALT, All Drain Points to be
300 mm Class 150 ASTM A 216 Disc ASTM A 307 RL, AL, Threaded & Plugged
GR WCB Gr B SLO, PLO
V151 Swing Check Valve 50 mm & -- Taper 1.39 MPa Bronze Bronze -- -- PW All Drain Points to be
Smaller ANSI B2.1 Threaded & Plugged
V152 Y-Pattern Check Valve 50 mm & -- Socket 17.2 MPa CS 13% Cr Steel Seats & -- -- FWH
Smaller Weld ASTM A 105 302 SS Spring
V153 Lined Wafer Check Valve 250 mm Fit -- 689 kPa PFA Coated PFA Coated Steel -- -- DWH
Between CS
Class 150
V154 Wafer Style Check Valve 100 mm Fit -- 689 kPa 410 SS 302 SS -- -- AP All Drain Points to be
to Between ASTM A 276 Threaded & Plugged
250 mm Class 150
PCV-452 Globe Valve, Bolted 100 mm ANSI B16.5 -- 689 kPa CS SS CS Pneumatic RCY
Bonnet, Class 150 ASTM A 216 ASTM A 307 Diaphragm
O.S. & Y., Rising Stem GR WCB Gr B R.A.
FCV-501 Butterfly Valve 100 mm Fit -- 689 kPa PFA Lined PFA Lined D.I. & SS -- Electric AG, AV
Between D.I. Stem
Class 150
FCV-625 Butterfly Valve 300 mm Fit -- 689 kPa PFTE Lined PTFE Lined CS & -- Electric, DWH
Between CS SS Stem Enclosed
Class 150 Gear
Source: Example Schedule by SAIC, 1998.
10-21
5 May 99
EM 1110-1-4008
10-22
5 May 99
EM 1110-1-4008
Table 10-11
Valve Operator Schedule
Operator Maximum Electrical Materials of Failure Enclosure Associated

Tag/Ref Description Type Air Pressure Supply Action Construction Mode Rating Accessories Valve Remarks
V120 Ball Valve, Full Port Pneumatic, 103 kPa -- R.A Manufacturer’s F.O. Weather Positioner, PCV-452
Positive Shut-off Diaphragm Standard with Epoxy Proof Filter/Regulator,
Coating Handwheel
V121 Ball Valve, Full Port Pneumatic, 1.03 MPa -- D.A. Manufacturer’s F.C. Weather Positioner, PCV-1013
Positive Shut-off Piston Standard with Epoxy Proof Filter,
Coating Handwheel
V122 Ball Valve, Full Port Pneumatic, 1.03 MPa -- D.A. Aluminum F.L. NEMA 4 I/P, Filter FCV-485
Positive Shut-off Rotary
V123 Solid Wedge Gate Valve Electric, -- 120 V, D.A. Manufacturer’s F.L. NEMA 4 FCV-501
O.S. & Y., Rising Stem Rotary 20 A, Standard with Epoxy
1 ph Coating
V124 Double Disc Gate Valve Electric, -- 120 V, D.A. Manufacturer’s F.C. NEMA 4X Enclosed Gear, FCV-625
O.S. & Y., Rising Stem Rotary 20 A, Standard
1 ph
Source: Example Schedule by SAIC, 1998.

EM 1110-1-4008
5 May 99
Chapter 11 d. Couplings for Non-metallic Piping

Ancillary Equipment
Flexible couplings for non-metallic piping are very
similar to metallic piping couplings. There are three
11-1. Flexible Couplings
main configuration alternatives for these couplings. The
Flexible couplings are used to join pipe sections, to first is the same configuration as the metallic piping, in
insulate sections from one other, to absorb concentrated which there is a middle ring that is sealed by gaskets and
pipe movement, and to join plain end pipe to flanged held in place with end pieces that are bolted together.
valves and other equipment. The basic purpose of The second method is very similar, except that the end
flexible couplings is to provide flexible but leak-tight pieces are lock rings, similar to compression fittings,
connections that will last for the life of the piping. threaded to hold the middle ring in place. In both
Flexible couplings are generally available in sizes from instances, the wetted-parts materials are selected in order
15 mm (½ in) to 1.8 m (6 feet) and larger. to meet the application. The last type of typical flexible
coupling for non-metallic piping is a bellows expansion
a. Metallic Flexible Couplings joint (see Paragraph 11-8c). The bellows expansion
joints can accommodate directional changes of
The basic configuration of a flexible coupling is a compression/extension and lateral offset and angular
metallic middle ring that slips over the joint between two rotation of the connected piping; however, these joints are
pipe sections with a gasket and a follower at each end. not capable of absorbing torsional movement. If a
This configuration compresses the gasket and seals the bellows expansion joint is used as a flexible connector, a
middle ring (see Figure 11-1). The middle ring can be minimum of two corrugations should be provided. The
provided standard in a number of different materials, such potential movement of the bellows is calculated to obtain
as plastic or rubber lined, stainless steel, aluminum, the proper number of corrugations.
Monel, carbon steel, and ductile iron (see Appendix B for
the proper material and contact the manufacturers to 11-2. Air and Vacuum Relief
determine availability). The gaskets are likewise
available in different materials (typically, elastomers and During startup, shutdown and in normal operations, it is
rubber materials). common for liquid process piping system to produce
situations where air needs to be exhausted or allowed to
b. Transition Couplings re-enter. The devices used include air-release valves,
air-vacuum valves, vacuum breakers, and combination
Similar to flexible couplings in construction, transition air-release and air-vacuum valves. The type of valve
couplings connect pipe with a small difference in outside required varies for the specific applications.
diameter: the middle ring in transition couplings is pre-
deflected to adjust for the differences in diameter. As a. Air-release Valves
with the flexible couplings, the transitional coupling's
middle ring and gaskets are available in different For liquid process piping in which air tends to collect
materials, depending upon the application. within the lines (as occurs under pressure systems as air
dissolves and then reappears as the pressure decreases),
c. Flanged Couplings air-release valves are necessary. A very common
operating problem occurs when air collects in the high
Flanged couplings are typically provided with a places of the piping systems, producing air pockets.
compression end connection on one end and a flange on These air pockets can reduce the effective area of the pipe
the other. The flanges can be provided in different ANSI through which the liquid can flow, causing a problem
or AWWA standards, as required for the application. known as air binding. Air binding results in pressure
The manufacturer should be consulted for pressure loss, thus increasing pumping costs.
ratings.
11-1
EM 1110-1-4008
5 May 99
Figure 11-1. Flexible Coupling

(Source: Dresser Industries, Inc., “Style 38 Dresser Couplings for Steel
Pipe Sizes, Sizes and Specifications,” Form 877-C Rev. 1095)
11-2
EM 1110-1-4008
5 May 99
It is typical for air-release valves to be installed to Qexhaust = Qmax

eliminate these problems. Air-release valves should be
installed at pumping stations where air can enter the
system, as well as at all high points in the pipeline system where:
where air can collect. Air-release valves automatically Qexhaust = volumetric flow rate of exhaust air, m3/s
vent any air that accumulates in the piping system while (ft3/s)
the system is in operation and under pressure. However, Qmax = maximum liquid filling rate, m3/s (ft3/s)
the potential for accumulating hazardous gases must be
taken into account, and the vents located in a manner
such that it does not cause a hazardous atmosphere for the Qintake = Qgravity
operators. Air-release valves do not provide vacuum
protection nor vent large quantities of air as required on
pipeline filling; air-vacuum valves are designed for these where:
purposes. Qintake = volumetric flow rate of intake air, m3/s (ft3/s)
Qgravity = gravity flow rate of liquid during draining,
The sizing of air-release valves is based upon engineering m3/s (ft3/s)
judgement and experience. The parameters which affect
valve size are the potential for air entrainment, pipe c. Vacuum Breakers
diameter, volumetric flow rate, system pressure, fluid
viscosity, surface condition of the pipe wall, and the Two primary types of vacuum breakers are available --
degree of pipe slope adjacent to the piping high point. atmospheric and pressure. Atmospheric vacuum
Manufacturers’ data can assist in the selection. breakers operate in the event of total pressure loss.
Pressure vacuum breakers provide protection against
b. Air-Vacuum Valves back siphonage and pressure surges. The configuration
of pressure vacuum breakers vary by manufacturer. The
For piping systems that are used intermittently and are configuration used to prevent back siphonage of
therefore periodically filled and drained, air-vacuum hazardous liquids often involves a check valve as well as
valves are used to prevent damage to the piping system. an air intake.
The damage could result from over-pressurization and
velocity surges during filling, or collapse during draining. Figure 11-2 depicts a combination pressure vacuum
breaker and its typical installation requirements. The
Air-vacuum valves are installed at piping high points. pressure vacuum breaker is a spring-loaded check valve
These valves are float operated, have large discharge and that opens during forward flow and is closed by the
inlet ports that are equal in size, and automatically allow spring when the flow stops. When the pressure drops to
large volumes of air to be rapidly exhausted from or a low value, a second valve will open and allow air to
admitted into a pipeline. As with air-release valves, the enter the breaker.
potential for releasing hazardous gases must be addressed
in the design and the vents located to permit a hazard The configuration used for applications that may involve
condition for personnel. Air-vacuum valves will not vent pressure surges have associated air-release valves. The
gases when the piping system is in normal operation and latter arrangement allows the large volumes of air,
under pressure. Air-release valves are designed for that admitted by the vacuum breaker, to be slowly exhausted
purpose. by the air-release valve under operating conditions and
act as a pressure surge reservoir.
The sizing of air-vacuum valves is performed
independently for each location and requires the review d. Combination Air-release and Air-Vacuum Valves
of both functions; i.e., air exhaust and air intake. The
largest valve required for either function is selected. The The operating functions of both an air-release valve and
flow capacity required is compared to manufacturers' data an air-vacuum valve are accommodated in a single
relating acceptable pressure drop to valve size. The flow combination air-release and air-vacuum valve. Using this
capacity requirements are determined as follows: type of valve in lieu of air-release and air-vacuum valves
11-3
EM 1110-1-4008
5 May 99
Figure 11-2. Pressure and Vacuum Breaker

(Source: FEBCO, Service Information Model 765 Pressure
Vacuum Breaker Assembly, vendor bulletin Oct 89)
11-4
EM 1110-1-4008
5 May 99
typically provides the piping system with maximum a. Port Locations

protection. However, each individual location should be
carefully reviewed. Sample piping should be as short as possible, protected
from physical damage, and easily accessed by operators.
e. Air and Vacuum Relief Application Sample connections are made on feed, intermediate and
product streams for process control. Process engineers
Suggested application of air and vacuum relief devices are consulted in order to determine the number and
into the piping design is as follows: location of sample ports.
- Locate air-vacuum valves at all system high points b. Design Requirements

where the piping system will be likely used intermittently.
For non-hazardous service with continuous operations, It is recommended that the minimum size connection to
manual valves or other methods may be more cost either the process equipment or the piping be 15 mm (¾
effective. in). If the sample line is longer than a meter
- Locate combination air-release and air-vacuum valves (approximately 3 feet), two valves are installed in the
at all system high points where the potential for air sample line. The first valve is located as close to the
accumulation exists. actual sample point as possible. The second valve is a
- Locate air-release valves at intervals of 500 to 850 m final block valve and should be located near the end of
(1,640 to 2,790 ft) on long horizontal pipe runs lacking the sample piping. The valves should be quick opening,
a clearly defined high point. Air-release valves are either gate or ball type, and all materials of construction
installed with an isolation valve, typically a full port ball should meet the application.
valve, between the air-release valve and the piping
system for maintenance purposes. 11-5. Pressure Relief Devices
- Locate vacuum breakers on closed vessels.
The ASME B31 Pressure Piping Code provides the
11-3. Drains standards and requirements for pressure relief devices
and systems including piping downstream of pressure
All low points in liquid process piping systems should be relief devices. Table 11-1 provides a summary of the
provided with drain or blow-off valves. These valves relief pressure limits, but these limits shall not be used
allow flushing of sediments from, or draining of, the without consulting the proper ASME B31 section. Note
entire lines. The most common valves used for draining that high pressure piping is not included.
purposes are gate valves. If rapid draining is not
important, globe valves may also be used, provided that a. Pressure Relief Valves
sediment accumulation is not a concern. Pipelines 50
mm (2 in) and smaller should use 15 mm (½ in) valves, Pressure relief valves are automatic pressure relieving
as a minimum size. Pipelines that are 65 mm (2½ in) or devices that protect piping systems and process
greater should have a minimum valve size of 20 mm (¾ equipment. The valves protect systems by releasing
in). excess pressure. During normal operation, the valve disc
is held against the valve seat by a spring. The spring is
11-4. Sample Ports adjustable to the pressure at which the disc lifts. The
valve disc lift is proportional to the system pressure so
Materials of construction for sample ports and sample that, as the system pressure increases, the force exerted
valves match the piping system and the required by the liquid on the disc forces the disc up and relieves
application. Coordination with CEGS 01450, Chemical the pressure. The valve will reseat when the pressure is
Data Quality Control, is necessary to ensure proper reduced below the set spring pressure. Pressure relief
sampling. valve materials and process pressure range must be
accounted for to specify the correct pressure relief device.
11-5
EM 1110-1-4008
5 May 99
Table 11-1
Summary of Pressure Device Limits
Service Relief Set Limit Code Reference
Metallic Piping - Category D Service* # 120% design pressure ASME B31.3 - 322.6
Nonmetallic Piping - Category D Service = design pressure ASME B31.3 - A322.6
Metallic Piping - Category M Service** # 110% design pressure ASME B31.3 - M322.6
Nonmetallic Piping - Category M Service = design pressure ASME B31.3 - MA322.6
Notes: *Category D Service is a fluid service in which the fluid handled is non-flammable, nontoxic and not
damaging to human tissues; the design pressure does not exceed 1.035 MPa (psig); and the design
temperature is from -29EC (-20EF) to 186EC (366EF). (ASME B31.3, p. 5. )
**Category M Service is a fluid service in which the potential for personnel exposure is judged to be
significant and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can
produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative
measures are taken. (ASME B31.3, p. 5.)
Source: ASME B31.3, Reprinted by permission of ASME.
b. Rupture Discs discharge systems where it is necessary to protect the

discharge side of the pressure relief valve from corrosion.
A rupture disc is another form of a pressure relief device. Gate valves (but not safety valves) may also be placed in
Rupture discs are designed to rupture automatically at a front of rupture discs, allowing for shutoff or maintenance
predetermined pressure and will not reclose. These discs of the discs. Discs usually require periodic replacement
can relieve very large volumes of liquid in a rapid as operating experience and conditions dictate.
manner. Materials of construction include metals,
graphite or plastic materials held between special flanges Rupture disc sizing is based on the premise that, if
and of such a thickness, diameter and shape, and material, adequate flow is allowed from the disc, pressure will be
that it will rupture at a pre-determined pressure. There relieved. Rupture discs are not intended to be explosion
are also metal rupture discs coated with plastics. In relief devices. The following sizing equation is derived
addition, for highly corrosive service, precious metals from Bernoulli's equation and the conservation of
such as silver, gold, and platinum are also used. momentum, and can be used for liquid service. The
equation assumes that the disc vents immediately to
Pressure relief valves and rupture discs may be used in atmosphere (no relief piping) and that nozzle friction
series. In such cases, rupture discs are designed to losses are negligible. Use of this equation complies with
rupture at a pressure approximately 5 to 10% above the ASME B31 requirements, but its use should be reviewed
pressure at which a relief valve is designed to activate. In with respect to local pressure vessel codes1.
this manner, the rupture disc acts as a backup device. It
can be used upstream of a safety relief device to protect Q s.g.
A ' n
the valve components from corrosion or malfunction due K Pr
to process materials. Rupture discs are occasionally
placed downstream of relief valves in manifolded relief
1
Fike Metal Products, Rupture Discs & Explosion Protection, p. 9.
11-6
EM 1110-1-4008
5 May 99
where: 11-6. Backflow Prevention

A = required rupture disc area, mm2 (in2)
n = conversion coefficient, 2.280 x 104 for SI units Backflow prevention is often handled by three main
and 0.0263 for IP units. methods, one of which is check valves which were
Q = flow, m3/s (gpm) discussed in Chapter 10. Another method is the use of
K = flow coefficient (K = 0.62 per ASME B31) pressure and vacuum breakers, which were discussed in
s.g. = specific gravity Paragraph 11-2. The third method is use of a reduced
Pr = relieving pressure, MPa (psi) pressure backflow prevention assembly.
Example Problem 9: a. Reduced Pressure Backflow Prevention

Assume that a toxic liquid with a specific gravity of 1.04
is flowing at a rate of 0.050 m3/s (800 gpm) through Reduced pressure backflow prevention assemblies are
stainless steel piping that has a maximum working mandatory for the mechanical protection of potable water
pressure rating of 2.207 MPa (300 psi). A rupture disc against the hazards of cross-connection contamination.
will be used as the primary relief device. Whenever the potential exists for hazardous materials to
come in contact with potable waters, reduced pressure
Solution: backflow prevention assemblies are required per AWWA
Step 1. In accordance with ASME B31.3, a primary standards.
pressure relief device should not exceed 10% over
maximum allowable working pressure. The reduced pressure backflow prevention assembly
typically has two Y-type check valves in series, in
Pr ' (2.17 MPa)(110%) ' 2.39 MPa (330 psig) between which is located an internal relief valve. In a
flow condition, the check valves are open with a liquid
pressure that is typically about 35 kPa (5.0 psi) lower
Step 2. than the inlet pressure. If flow or reversal of flow occurs,
the relief valve, which activates on a differential pressure
0.05 m 3/s 1.04
A ' (2.280 x 104) measurement, will open and discharge in order to
0.62 2.39 MPa maintain the zone between the check valves at least 14
kPa (2 psi) lower than the supply pressure. When normal
' 1,213 mm 2 (1.88 in 2) flow resumes, the relief valve closes as the differential
pressure resumes. The relief valve discharge is
BDi2 4 A 0.5 potentially hazardous material. The design of a facility
A ' Y Di ' takes that potential discharge into account.
4 B
Reduced pressure backflow prevention assemblies are
Di ' 39.3 mm (1.55 in), minimum used in different configurations. In one standard
configuration, the inlet and outlet are in line. Another
Therefore, from Table 1-1 (page 1-2), the bore diameter common configuration is an angle pattern in which the
of the pressure relief disc is 40 mm (1 ½ in). inlet to the assembly is vertical up and the outlet is
vertical down.
c. Safety Considerations
b. Installation
The use of pressure relief devices requires careful
material selection and determination of activation Reduced pressure backflow prevention assemblies are
pressure. In addition, the design includes means to installed, or designed to be installed, with a minimum of
collect the released liquid once it leaves the pipeline to clearance of 305 mm (12 in) between the discharge port
protect the operators and the environment. of the relief valve and the floor grade. The assemblies
11-7
EM 1110-1-4008
5 May 99
need to be installed in a location where testing and evaluated in the design of a static mixer system: the
maintenance can be performed. Situations that could materials of construction, the size of the pipe, the head
result in excessive pressure are eliminated. These loss requirements for the mixer, the number of mixing
situations include thermal water expansion and/or water elements, and the quality of mixing to be achieved.
hammer. Local plumbing codes are reviewed for specific
installation requirements. Some codes prohibit vertical b. Materials of Construction
installation. Materials of construction are typically
limited. Reduced pressure backflow prevention Common materials used for static mixers include
assemblies are normally used for potable water stainless steel, carbon steel, polyvinyl chloride (PVC),
applications. Typical characteristics and materials of reinforced fiberglass, polytetrafluoroethylene (PTFE) and
construction for the assemblies are presented in Table polyvinylidene fluoride (PVDF). The materials available
11-2. are dependent upon the manufacturer, and some
manufacturers offer additional material options for
11-7. Static Mixers specific applications.
Static mixers provide a means of in-line rapid mixing for In choosing the appropriate materials, the requirements
chemical addition or the combination of two liquid of both the static mixer's housing and the mixing elements
streams. As opposed to conventional rapid mixers, such are accommodated. By combining materials, one can
as turbines and hydraulic jumps, static mixers have no produce a static mixer which provides both chemical
moving parts. This characteristic makes the static mixer resistance and structural strength to the static mixer
a low maintenance alternative for rapid mixing. housing and mixing elements. See Appendix B for
material compatibility with fluids.
a. Design Requirements
Static mixers are commonly built from standard diameter
Static mixers are generally customized to meet the piping. Available pipe diameters vary by manufacturer;
requirements of each application. Five parameters are however, common pipe diameters start at 20 mm (¾ in).
Table 11-2
Typical Reduced Pressure Backflow Prevention Assembly
Characteristic/Parts Rating/Material
Assembly Body Bronze, ASTM B 584-78

Relief Valve Body Bronze, ASTM B 584-78
Seat Disc Nitrile, ASTM D 2000 or Silicone
Diaphragm Nitrile, fabric reinforced
Springs SS, 300 series options
End Connections Threaded, ASME B1.20.1
Maximum Working Pressure 1.2 MPa (175 psi)
Fluid Temperature Range 0EC to 60EC (32EF to 140EF)
Source: CMB Industries, FEBCO Backflow Prevention, Reduce Pressure Assembly for High Hazard Service,
Model 825Y, vendor bulletin.
11-8
EM 1110-1-4008
5 May 99
c. Pressure Loss and manufacturers can best determine the number of

mixing elements required to achieve the desired
The end connections available for static mixers include homogeneity.
ends prepared for welding, threaded NPT ends, and
flanged ends of various classes. Both the pipe diameter Additional considerations for the design of a static mixer
and end connections are typically designed to match the include the number and location of injection ports and the
process piping system used. However, the diameter of method of chemical injection. The location, connection
mixer housing can be sized based on the pressure drop type and size of injection ports can be customized to
available, or desired, if the application requires. match each application. Several types of injection quills
are available, as options and specifications vary from
Whereas mechanical mixers require energy to drive the manufacturer to manufacturer. It is advisable to contact
mixing motor, static mixers obtain their required energy static mixer manufacturers to determine what selections
the velocity of the fluids being mixed. Thus, every static may suit the desired application and the reasons for
mixer will have a resulting pressure drop. The pressure recommendation of those options. The contract drawings
drop through the static mixer is dependent upon the flow and specifications are then coordinated to reflect
rate through the static mixer, the specific gravity and acceptable alternatives.
viscosity of the fluids being mixed, the diameter of the
mixer housing, and the friction loss attributable to the 11-8. Expansion Joints
mixing elements. Each manufacturer has sizing
equations and/or flow coefficients that are specific for Expansion joints are used to absorb pipeline expansion
their product. Although the sizing calculations are typically resulting from thermal extensions. The use of
reviewed to ensure that correct parameter values are expansion joints is often required where expansion loops
used, the specifications place performance requirements are undesirable or impractical. However, expansion
on the mixer manufacturer. joints are not used for direct buried service. Expansion
joints are available slip-type, ball, and bellows
d. Configuration configurations.
The number of mixing elements effects the quality of a. Slip-Type Expansion Joints
mixing achieved, the length of the mixer, and the head
loss requirements of the mixer. Factors which affect the Slip-type expansion joints have a sleeve that telescopes
number of mixing elements required include the flow into the body. Leakage is controlled by packing located
regime, the difference in viscosities of the fluids being between the sleeve and the body. Because packing is
mixed, the volumetric ratio of the fluids being mixed, the used, a leak-free seal is not assured. Properly specified,
method of injection, and the miscibility of the fluids. these expansion joints do not leak; however, because
Different manufacturers produce mixing elements in packing is used, these expansion joints should not be
different configurations. The different element used where zero leakage is required. Occasional
configurations produce varying mixing results, and maintenance is required to repair, replace, and replenish
estimates on the number of elements required are best the packing. Slip-type joints are particularly suited for
obtained by contacting the static mixer manufacturer. axial movements of large magnitude. They cannot,
however, tolerate lateral offset or angular rotation due to
The quality of mixing achieved by a static mixer is often potential binding. Therefore, pipe alignment guides are
discussed in terms of homogeneity. Homogeneity refers necessary with slip-type expansion joints.
to how closely the combined fluid resembles a
homogeneous mixture after passing through a static b. Ball Expansion Joints
mixer. Homogeneity is often expressed as a percentage
standard deviation from the mean, and is determined by Ball expansion joints consist of a socket and a ball, with
sampling for the desired mixing parameter seals placed in between the two parts. Ball expansion
(concentration, temperature, conductivity) and joints can handle angular and axial rotation; however,
determining the mean and standard deviation of the they cannot tolerate axial movements.
samples. Required homogeneity is application specific,
11-9
EM 1110-1-4008
5 May 99
c. Bellows Expansion Joints Step 3. Calculate the maximum movements (contraction

and expansion) to be absorbed by the expansion joint (see
Bellows expansion joints can be metallic or rubber in previous chapters for thermal expansion).
material of construction. They do not have packing.
These joints typically have bellows, or corrugations, that Step 4. Determine the expansion joint performance
expand or contract as required to absorb piping requirements and the required bellows configuration:
expansion. End connections can be welded and/or - calculate the required cycle life, for example, assume
flanged. Bellows expansion joints can adjust to lateral a process is anticipated to undergo 2 on-off cycles per
offset and angular rotation as well as to axial movements. week and a 10 year process life is desired
However, they are not capable of handling torsional
movement. In order to provide this flexibility, metal
bellows are typically much thinner than the associated 2 process cycles 52 weeks
(10 years)
piping and are subject to over-pressure failure. Metal week year
fatigue due to the cyclic life of the bellows is another ' 1,040 cycles required
factor that must be included in the design.
For example, a typical method to select and size a

bellows expansion joint is as follows: (note that a manufacturer's standard warranty is 2,000
cycles for axial movement with cycle life is increased to
Step 1. Determine the basic type required by the piping 7,000 if the expansion joint sized for movement = 75%
system: expansion joint rating2);
- standard without reinforced corrugations (non- - select the number of corrugations from
equalizing); manufacturers' data (function of corrugation size, wall
- standard with reinforced corrugations (equalizing thickness, amount of movement, and design cycle life, see
rings); Table 11-4);
- hinged (single plane angular movement only); - determine whether an internal sleeve is required.
- gimbal (multiple plane angular movement only); Sleeves are recommended when
- tied (lateral movement only); D # 150 mm (6 in) and V > 0.02 m/s per mm
- balanced (axial and lateral movement only); diameter (1.66 ft/s per inch diameter),
- or other. and when
D > 150mm (6 in) and V > 3 m/s (10 ft/s);
Step 2. Determine the body requirements of the where:
expansion joint: D = nominal pipe size, mm (in)
- maximum system pressure and temperature; V = fluid velocity, m/s (ft/s).3
- internal diameter equal to the inner diameter of the
pipe (Di); 11-9. Piping Insulation
- end connections (flanged, welded end, combinations,
or other); Liquid process piping often has to be insulated when
- material of construction for bellows and sleeves, if potential heat loss from piping cannot be tolerated in the
required (select material based on application, see process, freezing potential exists, or protection of
Appendix B and Table 11-3, Material Temperature personnel from hot piping is required. CEGS 15080,
Ranges); Thermal Insulation for Mechanical Systems, is used for
- external body cover, if required (damage protection, engineering information and construction requirements.
insulation application).
2
ADSCO Manufacturing LLC, Expansion Joints Cat. 1196.
3
Ibid.
11-10
EM 1110-1-4008
5 May 99
Table 11-3
Material Temperature Ranges
Material Acceptable Temperature Range
304 Stainless Steel -185EC to 815EC (-300EF to 1,500EF)

Aluminum -198EC to 204EC (-325EF to 400EF)
Nickel 200 -156EC to 315EC (-250EF to 600EF)
Inconel 600 -156EC to 649EC (-250EF to 1,200EF)
Inconel 625 -156EC to 649EC (-250EF to 1,200EF)
Monel 400 -156EC to 815EC (-250EF to 1,500EF)
Incoloy 800 -156EC to 815EC (-250EF to 1,500EF)
Incoloy 825 -156EC to 538EC (-250EF to 1,000EF)
Source: ADSCO Manufacturing LLC, Expansion Joints Cat 1196
Table 11-4
Typical Manufacturers' Data List
Size, in Number of Convolutions Total Axial Movement, in
1 7/16
2 7/8
3 1-5/16
4 1-3/4
5 2-3/16
4
6 2-5/8
7 3-1/16
8 3-1/2
9 3-15/16
10 4-3/8
Source: ADSCO Manufacturing LLC, Expansion Joints Cat. 1196
11-11
EM 1110-1-4008
5 May 99
In addition, the specification provides guidance on

insulation thickness based on pipe size, insulation
thermal conductivity or material, and range of
temperature service. CEGS 15080 is coordinated with
the liquid process piping specification section and
contract drawings.
11-10. Heat Tracing
For the purposes of liquid process piping, heat tracing is

the continuous or intermittent application of heat to the
piping system, including pipe and associated equipment,
to replace heat loss. As with insulation, heat tracing is
used when potential heat loss from the piping cannot be
tolerated by the process or when freezing potential exists.
Heat tracing may be accomplished through the use of
fluids such as steam, organic/synthetic liquids, and glycol
mixtures, or through electrical systems such as self-
regulating parallel resistance cable (most common), zone
parallel resistance cable, continuous-wattage cables and
other methods.
a. Heat Tracing System Selection
The selection criteria for determining the most suitable

heat tracing methods include: cost, availability of utilities
such as steam or electricity, amount of heat to be
provided, area hazardous classification as defined by the
National Electric Code (NFPA 70), temperature control
requirements and consequence of failure. Economics
generally favor electrical heat tracing systems when the
piping is less than 300 mm (12 in) in diameter and the
temperature to be maintained is 120EC (248EF) or lower.
Computer programs are available to assist in selecting the
type of system that is most appropriate. In addition, many
heat tracing vendors have software available to design a
heat tracing system using their products. Typical inputs
are piping size and geometry; ambient, process and
desired maintenance temperature; control requirements;
labor costs and utility rates. Outputs are typically worst
case heat loss; a bill of materials for the heat tracing
system; and capital, installation and operating costs.
11-12
EM 1110-1-4008
5 May 99
Chapter 12 12-2 Cathodic Protection

Corrosion Protection
Cathodic protection and protective coatings shall both be
provided for the following buried/submerged ferrous
12-1. Corrosion Protection
metallic structures, regardless of soil or water resistivity:
Among other factors, the integrity and life of a piping - natural gas propane piping;
system is dependent upon corrosion control. As - liquid fuel piping;
discussed in previous chapters of this manual, internal - oxygen piping;
corrosion of piping systems is controlled by the selection - underground storage tanks;
of appropriate materials of construction, wall thickness, - fire protection piping;
linings and by the addition of treatment chemicals. - ductile iron pressurized piping under floor (slab on
External corrosion can also be addressed through grade) in soil;
materials of construction. However, other methods may - underground heat distribution and chilled water
be required when metallic piping systems are applied. piping in ferrous metallic conduit in soils with resistivity
of 30,000 ohm-cm or less; and
a. Buried Installations - other structures with hazardous products as
identified by the user of the facility.
In buried installations, leaks due to corrosion in metallic
piping systems can cause environmental damage. a. Cathodic Protection Requirements
Furthermore, certain types of processes pose safety
problems if cathodic protection is not properly installed The results of an economic analysis and the
and maintained. The design and installation of the piping recommendation by a "corrosion expert" shall govern the
system without consideration of cathodic protection is not application of cathodic protection and protective coatings
acceptable. for buried piping systems, regardless of soil resistivity.
In addition, cathodic protection for metallic piping
b. Above Grade Installations supported above ground may be warranted. TM 5-811-7,
Electrical Design, Cathodic Protection, provides criteria
The external surfaces of metallic piping installed above for the design of cathodic protection for aboveground,
grade will also exhibit electrochemical corrosion. The buried, and submerged metallic structures including
corrosion rate in air is controlled by the development of piping. Cathodic protection is mandatory for
surface-insoluble films. This development is, in turn, underground gas distribution lines, 946 m3 (250,000 gal)
affected by the presence of moisture, particulates, sulfur or greater water storage tanks and underground piping
compounds, nitrogen-based compounds, and salt. This systems located within 3 m (10 ft) of steel reinforced
corrosion is typically uniform, although pitting and concrete.1
crevice corrosion are also common. Besides selecting a
material of construction that is appropriate for the For ductile iron piping systems, the results of an analysis
ambient environment, the primary method of corrosion by a "corrosion expert," as defined in Paragraph 12-2b,
control in above grade piping system is the application of shall govern the application of cathodic protection and/or
protective coatings. However, a stray current survey bonded and unbonded coatings. Unbonded coatings are
must be performed to ensure that electrical currents have defined in AWWA C105.
not been created through the piping support system.
1
TM 5-811-7, p. 2-2.
12-1
EM 1110-1-4008
5 May 99
b. Cathodic Protection Designer two methods is that the galvanic system relies on the
difference in potential between the anode and the pipe,
All pre-design surveys, cathodic protection designs, and and the impressed current system uses an external power
acceptance surveys must be performed by a "corrosion source to drive the electrical cell.
expert." A corrosion expert is defined as a person who,
by reason of thorough knowledge of the physical sciences d. Cathodic Protection Design
and the principles of engineering and mathematics
acquired by a professional education and related practical The design of a cathodic protection system must conform
experience, is qualified to engage in the practice of to the guidance contained in TM 5-811-7 (Army), and
corrosion control of buried or submerged metallic piping MIL-HDBK-1004/10 (Air Force). Field surveys and
and tank systems. Such a person must be accredited or other information gathering procedures are available in
certified by the National Association of Corrosion TM 5-811-7. The following steps and information is
Engineers (NACE) as a NACE Accredited Corrosion required to ensure a cathodic protection system will
Specialist, or a NACE Certified Cathodic Protection perform as designed:
Specialist licensing that includes education and
experience in corrosion control of buried or submerged Step 1. Collect data:
metallic piping and tank systems. The "corrosion expert" - corrosion history of similar piping in the area;
designing the system must have a minimum of five years - drawings;
experience in the design of cathodic protection systems, - tests to include current requirement, potential survey,
and the design experience must be type specific. For and soil resistivity survey;
instance, a cathodic protection engineer who only has - life of structures to be protected;
experience designing water tank systems should not - coatings; and
design the cathodic protection system for an underground - short circuits.
gas line.
Step 2. Calculate the surface area to be protected and
The design of the cathodic protection system shall be determine the current requirement.
completed prior to construction contract advertisement
except for design-construct projects and pre-approved Step 3. Select the anode type and calculate the number of
underground distribution systems. The liquid process anodes required.
piping specification section shall be coordinated with
CEGS 13110, Cathodic Protection System (Sacrificial Step 4. Calculate circuit resistance, required voltage, and
Anode); CEGS 13111, Cathodic Protection System (Steel current.
Water Tanks); and CEGS 13112, Cathodic Protection
System (Impressed Current) as required. Step 5. Prepare life cycle cost analyses.
c. Cathodic Protection Methods Step 6. Prepare plans and specifications.
As previously discussed, galvanic corrosion is an 12-3. Isolation Joints

electrochemical process in which a current leaves the
pipe at the anode site, passes through an electrolyte, and When piping components, such as pipe segments,
re-enters the pipe at the cathode site. Cathodic protection fittings, valves or other equipment, of dissimilar materials
reduces corrosion by minimizing the difference in are connected, an electrical insulator must be used
potential between the anode and cathode. The two main between the components to eliminate electrical current
types of cathodic protection systems, galvanic (or flow. Complete prevention of metal-to-metal contact
sacrificial) and impressed current, are depicted in Figure must be achieved. Specification is made for dielectric
12-1. A galvanic system makes use of the different unions between threaded dissimilar metallic components;
corrosive potentials that are exhibited by different isolation flanged joints between non-threaded dissimilar
materials, whereas an external current is applied in an metallic components; flexible (sleeve-type) couplings for
impressed current system. The difference between the
12-2
EM 1110-1-4008
5 May 99
Figure 12-1. Cathodic Protection Methods

(Source: U.S. Air Force)
12-3
EM 1110-1-4008
5 May 99
plain end pipe sections, see Chapter 11 for further deformation (for example, thermal expansion/contraction)
information concerning these couplings; and under and environmentally induced stress (for example, wind
special aboveground situations that have USACE induced shear). Obviously, the coating must be applied
approval split-sleeve couplings. For the flanged isolation without holidays and remain undamaged, without cracks
joints complete isolation is required; additional non- or pinholes.
metallic bolt isolation washers, and full length bolt
isolation sleeves are required. Dielectric isolation shall
conform to NACE RP-0286. Copper water service lines
will be dielectrically isolated from ferrous pipe.
a. Installation
Proper installation of isolation joints is critical.

Installation procedures should follow the manufacturer's
recommendations exactly.
b. Isolation from Concrete
A ferrous metallic pipe passing through concrete shall not

be in contact with the concrete. The ferrous metal pipe
shall be separated by a non-metallic sleeve with
waterproof dielectric insulation between the pipe and the
sleeve. Ferrous metal piping passing through a concrete
thrust block or concrete anchor block shall be insulated
from the concrete or cathodically protected.
c. Surge Protection
The need for surge and fault current protection at

isolating devices (dielectrically insulated flanges) should
be considered. If an insulated flange is installed in an
area classified by National Fire Protection Association
(NFPA) criteria, such as a flammable liquid pipe joint
inside the classified area, a sealed, weatherproof surge
arrester must be installed across each isolating device.
The arrester should be the gapless, self-healing, solid
state type, such as metal oxide varistor. Cable
connections from arresters to isolating devices should be
short, direct, and a size suitable for short-term, high
current loading.
12-4. Protective Coatings
Since corrosion of metallic piping is electrochemical, if

a protective coating that is continuous, impervious and
insulating is applied to the piping exterior, the electrical
circuit cannot be completed, and corrosion will not occur.
The bases of selection for an exterior pipe coating are
chemical inertness, adhesiveness, electrical resistance,
imperviousness, and flexibility to adjust to both pipe
12-4
EM 1110-1-4008
5 May 99
Appendix A TI 814-10
References Wastewater Collection
CEGS 02150
A-1. U.S. Army Corps of Engineers (CEGS, EM,
Piping: Off-Gas
TM, etc.)
TM 5-805-4 CEGS 05093

Noise and Vibration Control Welding Pressure Piping
TM 5-809-10 CEGS 09900

Seismic Design for Buildings Painting, General
TM 5-810-5 CEGS 11145

Plumbing Aviation Fueling Systems
TM 5-811-7 CEGS 13080

Electrical Design, Cathodic Protection Seismic Protection for Mechanical, Electrical
Equipment
TM 5-813-9
Water Supply: Pumping Stations CEGS 13110
Cathodic Protection system (Sacrificial Anode)
MIL-HDBK-1004/10 (Air Force)
Electrical Engineering, Cathodic Protection CEGS 13111
Cathodic Protection system (Steel Water Tanks)
ER 1110-1-4
Metric Measurements in USACE Publication Media CEGS 13112
Cathodic Protection system (Impressed Current)
ER 1110-1-12
Quality Management CEGS 15080
Thermal Insulation for Mechanical Systems
ER 1110-345-700
Design Analysis, Drawings and Specifications CEGS 15200
EM 385-1-1
Safety and Health Requirements Manual A-2. Industrial and Commercial References
(NFPA, ASTM, ANSI, ASME, etc.)
EM 1110-2-503
Design of Small Water Systems a. American Association of State Highway and
Transportation Officials
TI 809-01
Load Assumptions for Buildings AASHTO H20
Highway Design Standards
TI 814-01
Water Supply b. American National Standards Institute
TI 814-03 ANSI A13.1

Water Distribution Scheme for the Identification of Piping Systems
A-1
EM 1110-1-4008
5 May 99
ANSI A58.1 ASME B16.21

Minimum Design Loads for Buildings and Other Nonmetallic Gaskets for Pipe Flanges
Structures
ASME B16.24
ANSI B36.10M/B36.10 Cast Copper Alloy Pipe Flanges and Flanged Fittings
Welded and Seamless Wrought Steel Pipe
ASME B16.25
c. American Petroleum Institute Buttwelding Ends
API Spec 5L ASME B16.28

Line Pipe Wrought steel Buttwelding Short Radius Elbows and
Returns
API Spec 15LR
Low Pressure Fiberglass Line Pipe ASME B16.31
Non-Ferrous Pipe Flanges
API 605
Large Diameter Carbon Steel Flanges ASME B16.42
Ductile Iron Pipe Flanges and Flanged Fittings
d. American Society of Civil Engineers
ASME B16.47
ASCE 7 Large Diameter Steel Flanges
Minimum Design Loads for Buildings and Other
Structures ASME B31.1
Power Piping
e. American Society of Mechanical Engineers
ASME B31.3
ASME Boiler and Pressure Vessel Code Chemical Plant and Petroleum Refinery Piping
Sections IV, V, VIII
f. American Society for Testing and Materials
ASME B1.1
Unified Screw Threads ASTM A 47M/A 47
Malleable Iron Castings
ASME B1.20.1
Pipe Threads, General Purpose ASTM A 53
Pipe, Steel, Black and Hot-Dipped, Zinc Coated
ASME B16.1 Welded and Seamless
Cast Iron Pipe Flanges and Flanged Fittings
ASTM A 105M/A 105
ASME B16.5 Carbon Steel Forgings
Pipe Flanges and Flanged Fittings
ASTM A 106
ASME B16.9 Seamless Carbon Steel Pipe
Factory-Made Wrought Steel Buttwelding Fittings
ASTM A 126
ASME B16.11 Gray Iron Castings for Valves, Flanges, and Pipe
Forged Fittings, Socket-Welding and Threaded Fittings
ASME B16.20 ASTM A 135

Metallic Gaskets for Pipe Flanges Electric-Resistance-Welded Steel Pipe
A-2
EM 1110-1-4008
5 May 99
ASTM A 182M/A 182 ASTM A 731M/A 731

Forged or Rolled Alloy-Steel Pipe Flanges, Forged Seamless, Welded Ferritic, and Martensitic Stainless
Fittings, and Valves and Parts Steel Pipe

Alloy-Steel and Stainless Steel Bolting Materials Single- or Double-Welded Austenitic Stainless Steel
Pipe
ASTM A 194M/A 194
Carbon and Alloy Steel Nuts for Bolts for ASTM A 814M/A 814
High-Pressure and High-Temperature Service. Cold-Worked Welded Austenitic Stainless Steel Pipe

Steel Castings, Carbon, for High Temperature Service Wrought Ferritic, Ferritic/Austenitic, and Martensitic
Stainless Steel Piping Fittings
ASTM A 217M/A 217
Steel Castings, Martensitic Stainless Steel and Alloys, ASTM A 858M/A 858
for High Temperature Service Heat-Treated Carbon Steel Fittings
ASTM A 307 ASTM B 42

Carbon Steel Bolts and Studs, 60,000 PSI Tensile Seamless Copper Pipe, Standard Sizes
Strength
ASTM B 61
ASTM A 312M/A 312 Steam or Valve Bronze Castings
Seamless and Welded Austenitic Stainless Steel Pipes
ASTM B 62
ASTM A 333M/A 333 Composition Bronze or Ounce Metal Castings
Seamless and Welded Steel pipe for Low-Temperature
Service ASTM B 160
Nickel Rod and Bar
ASTM A 351M/A 351
Castings, Austenitic, Austenitic-Ferric ASTM B 161
Nickel Seamless Pipe and Tube
ASTM A 403M/A 403
Wrought Austenitic Stainless Steel Piping Fittings ASTM B 165
Nickel-Copper Alloy (N04400) Seamless Pipe and
ASTM A 494 Tube
Castings, Nickel and Nickel Alloy.
ASTM B 241M/B 241
ASTM A 587 Aluminum and Aluminum-Alloy Seamless Pipe and
Electric-Resistance-Welded Low-Carbon Steel Pipe Seamless Extruded Tube
ASTM A 691 ASTM B 247M/B 247

Carbon and Alloy Steel Pipe, EFW for High-Pressure Aluminum and Aluminum-Alloy Die Forgings, Hand
Service at High Temperatures Forgings, and Rolled Ring Forgings
ASTM A 727M/a 727 ASTM B 345M/B 345

Carbon Steel Forgings for Piping Components Aluminum and Aluminum-Alloy Seamless Pipe and
Seamless Extruded Tube for Gas and Oil Transmission
and Distribution Piping Systems
A-3
EM 1110-1-4008
5 May 99
ASTM B 361 ASTM D 1457

Factory-Made Wrought Aluminum and Aluminum- Polytetrafluoroethylene (PTFE) Molding and Extrusion
Alloy Welding Fittings Materials

Factory-Made Wrought Nickel and Nickel Alloy Terminology for Abbreviated Terms relating to Plastics
Fittings
ASTM D 2000
ASTM B 517 Standard Classification for Rubber Products in
Welded Nickel-Chromium-Iron Alloy (N06600), Automotive Applications
N06025, N06045 Pipe
ASTM D 2282
ASTM B 564 Acrylonitrile-Butadiene-Styrene (ABS) Plastic Pipe
Nickel Alloy Forgings (SDR-PR)

Copper Alloy Sand Castings for General Applications Standard Classification for Machine-Made "Fiberglass"
(Glass-Fiber-Reinforced Thermosetting-Resin) Pipe
ASTM B 608
Welded Copper-Alloy Pipe ASTM D 2464
Threaded Poly(Vinyl Chloride) (PVC) Plastic Pipe
ASTM B 619 Fittings, Schedule 80
Welded Nickel and Nickel-Cobalt Alloy Pipe
ASTM D 2466
ASTM B 622 Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings,
Seamless Nickel and Nickel-Cobalt Alloy Pipe and Schedule 40
Tube
ASTM D 2467
ASTM B 725 Socket-Type Poly(Vinyl Chloride) (PVC) Plastic Pipe
Welded Nickel (N02200/N02201) and Nickel-Copper Fittings, Schedule 80
Alloy (N04400)Pipe
ASTM D 2657
ASTM B 775 Heat-Joining Polyolefin Pipe and Fittings
General Requirements for Nickel and Nickel Alloy
Welded Pipe ASTM D 2661
Acrylonitrile-Butadiene-Styrene (ABS) Schedule 40
ASTM B 829 Plastic Drain, Waste and Vent Pipe
General Requirements for Nickel and Nickel Alloys
Seamless Pipe and Tube ASTM D 2855
Making Solvent-Cemented Joints with Poly(Vinyl
ASTM D 380 Chloride) (PVC) Pipe and Fittings
Test Methods for Rubber Hose
ASTM D 2996
ASTM D 471 Filament-Wound "Fiberglass" (Glass-Fiber-Reinforced
Test Method for Rubber Property-Effect of Liquids Thermosetting Resin) Pipe
ASTM D 729 ASTM D 2997

Vinylidene Chloride Molding Compounds Centrifugally Cast "Fiberglass" (Glass-Fiber-
Reinforced Thermosetting Resin) Pipe
A-4
EM 1110-1-4008
5 May 99
ASTM D 3139 ASTM F 438

Joints for Plastic Pressure Pipes using Flexible Socket-Type Chlorinated Poly(Vinyl Chloride)
Elastomeric Seals (CPVC) Plastic Pipe Fittings, Schedule 40

Unmodified Poly (Vinylidene Fluoride) (PVDF) Socket-Type Chlorinated Poly(Vinyl Chloride)
Molding, Extrusion and Coating Materials (CPVC) Plastic Pipe Fittings, Schedule 80

PFA-Fluorocarbon Molding and Extrusion Materials Poly (Vinylidene Fluoride) (PVDF) Plastic-Lined
Ferrous Metal Pipe and Fittings
ASTM D 3311
Drain, Waste, and Vent (DWV) Plastic Fittings ASTM F 492
Patterns Propylene and Polypropylene (PP) Plastic Lined
ASTM D 3517
"Fiberglass" (Glass-Fiber-Reinforced Thermosetting ASTM F 599
Resin) Pressure Pipe Poly (Vinylidene Chloride) (PVDC) Plastic-Lined
ASTM D 3754
"Fiberglass" (Glass-Fiber-Reinforced Thermosetting ASTM F 628
Resin) Sewer and Industrial Pressure Pipe Acrylonitrile-Butadiene-Styrene (ABS) Schedule 40
Plastic Drain, Waste and Vent Pipe with a Cellular
ASTM D 4000 Core
Classification System for Specifying Plastic Materials
ASTM F 781
ASTM D 4024 Perfluoro (Alkoxyalkane) Copolymer (PFA) Plastic-
Machine Made "Fiberglass" (Glass-Fiber-Reinforced Lined Ferrous Metal Pipe and Fittings
Thermosetting Resin) Flanges
ASTM F 1173
ASTM D 4101 Epoxy Resin Fiberglass Pipe and Fittings for Marine
Propylene Plastic Injection and Extrusion Materials Applications

"Fiberglass" (Glass-Fiber-Reinforced Thermosetting Electrofusion Joining Polyolefin Pipe and Fittings
Resin) Pipe Joints Using Flexible Elastomeric Seals
g. American Water Works Association
ASTM E 814
Fire Tests of Through-Penetration Fire Stops AWWA C105
Polyethylene Encasement for Ductile-Iron Pipe
ASTM F 423 Systems
Polytetrafluoroethylene (PTFE) Plastic-Lined Ferrous
Metal Pipe, Fittings, and Flanges AWWA C110
Ductile-Iron and Gray-Iron Fittings
ASTM F 437
Threaded Chlorinated Poly(Vinyl Chloride) (CPVC) AWWA C150
Plastic Pipe Fittings, Schedule 80 Thickness Design of Ductile-Iron Pipe
AWWA C900
Polyvinyl Chloride (PVC) Pressure Pipe
A-5
EM 1110-1-4008
Change 1
16 Sep 02
AWWA C950 MSS SP-114

Fiberglass Pressure Pipe Corrosion Resistant Pipe Fittings Threaded and
Socket Welding
AWWA D103
Factory-Coated Bolted Steel Tanks for Water Storage MSS SP-119
Balled End Socket Welding Fittings, Stainless Steel
AWWA D110 and Copper-Nickel
Wire-Wound, Circular Prestressed Concrete Water
Tanks k. National Association of Corrosion Engi-
neers
h. Fluid Controls Institute
NACE RP-0286
FCI 70-2 Electrical Isolation of Cathodically Protected Pipe-
Control Valve Seat Leakage lines
i. Instrument Society of America l. National Fire Protection Association
ISA-S75.01 NFPA 70
Flow Equations for Sizing Control Valves National Electric Code
j. Manufacturers Standardiz ation Society of A-3. Other Sources (Journals, Textbooks, Vendor
the Valve and Fittings Industry (MSS) Information, etc.)
MSS SP-43 ADSCO Manufacturing LLC, Expansion Joints

Wrought Stainless Steel Buttwelding Fittings Catalog 1196, Buffalo, New York, 1996.
MSS SP-44 American Institute of Steel Construction, Inc., Man-

Steel Pipeline Flanges ual of Steel Construction, 8th Edition, Chicago, Illi-
nois, 1980.
MSS SP-51
Class 150LW Corrosion Resistant Cast Flanges and Asahi/ America, Inc., Piping Systems Product Bulle-
Flanged Fittings tin P-97/A, Malden, Massachusetts, 1997.
MSS SP-58 ASHRAE Handbook 2000, Heating, Ventilating and

Pipe Hangers and Supports - Materials, Design and Air Conditionong, Atlanta, Georgia, 2000.
Manufacturer
CMB Industries, FEBCO Backflow Prevention Ser-
MSS SP-69 vice Information Model 765 Pressure Vacuum
Pipe Hangers and Supports - Selection and Applica- Breaker Assembly Catalog, Fresno, Califo rnia, 1989.
tion
Crane Company, Cast Steel Valves, Cra ne Valve
MSS SP-73 Catalog, Joliet, Illin ois, 1995.
Brazing Joints for Wrought and Cast Copper Alloy
Solder Joint Pressure Fittings Crane Company, Flow of Fluids, Technical Paper
410, Joliet, Illin ois, 1995.
MSS SP-89
Pipe Hangers and Supports - Fabrication and Instal- Crane/Resistoflex Corporation, “Plastic-Lined Piping
lation Practices Products Engineering Manual,” Marion, North Caro-
lina, 1998.
MSS SP-104
Wrought Copper Solder Joint Pressure Fittings Dresser Industries, Inc., Style 38 Dresse r Couplings
for Steel Pipe Sizes, Sizes and Specifications , Form
MSS SP-106 877-0C, Bradford, Pennsylvania, 1995.
Cast Copper Alloy Flan ges and Flanged Fittings
A-6
EM 1110-1-4008
Change 1
16 Sep 02
Fibercast Company, Piping Design Manual, FC-680, A-4. Other Sources of Information (Not Refer-
Sand Springs, Oklahoma, 1995. enced)
Fisher Controls Company, Control Valve Handbook, a. Metallic Pipin g Corrosion

2nd Edition, Fisher Controls International, Inc., Mar-
shalltown, Iowa, 1977. Corrosion Data Survey, Metals Sectio n, 6th Edition,
National Association of Corrosion Engineers, Hous-
ton, Texas, 1985.
Gardellin, David J., MOYNO® RKL Con trol Valve
Sizing Handbook, Bulletin 250A, Robbins & Myers, Phillip A. Schweitzer, Corrosion and Corrosion Pro-
Inc., Lumberton, New Jersey, 1982. tection Handbook, Marcel Dekker, Inc., New York,
1983.
Harvel Plastics, Product Bulletin 112/401, Easton,
Pennsylvania, 1995. b. Nonmetallic Piping Corrosion
Hydraulic Institute Standards, 14th Edition, Hydrau- Chemical Resistance Tables, Modern Plastics Ency-
lic Institute, Cleveland, Ohio. clopedia, McGraw-Hill, New York, 1 989.
Hydraulic Institute Engineering Data Book, Hydrau- Compass Corrosion Guide, La Mesa, California,
lic Institute, Cleveland, Ohio. 1983.
Corrosion Data Survey, Nonmetals Section, 5th Edi-

Rubber Manufacturers Asso ciation, The 1996 Hose
tion, National Association of Corrosion Engineers,
Handbook, IP-2, Washington, D.C., 1996.
Houston, Texas, 1985.
Schweitzer, Philip, A., P.E., Corrosion-Resistant Handbook of PVC Pipe, 3rd Edition, Uni-Bell Plastic
Piping System s, Marcel Dekker, Inc., New York, Pipe Association, Dallas, Texas, 1979.
1994.
c. Water Hammer
Schweitzer, Phillip, A., P.E., Corrosion Resistance
Tables, Metals, Nonmetals, Coatings, Mortars, Plas- Ernest F. Braler and Horace W. King, Handbook of
tics, Elastomers and Linings, and Fabrics, 4th Edi- Hydraulics, 6th Ed.
tion, Marcel Dekker Inc., New York, 1995.
Tyler & Hick s, Editor in Chief, Standard Handbook
Spotts, M.F., Design of Machine Elements, 5th Edi- of Engineering Calculations, 3rd Ed.
tion, Prentice Hall, 1978.
d. Expansion Loops
Worcester Controls, A BTR Company, Series CPT
Characterized Seat Control Valve Catalog, PB-V-3, Piping Design and Engineering, 5th Ed., ITT Grinnell
Marlborough, Massachusetts, 1998. Industrial Piping, Providence, Rhode Island, 1976.
A-7
EM 1110-1-4008
5 May 99
Appendix B b. Temperature Correlation

Fluid/Material Matrix
The matrix temperatures are provided in both the metric
If a potentially corrosive fluid, or a piping material, is not and IP units (degrees C and degrees F, respectively).
found in the fluid/material matrix, then the reference Materials with unsatisfactory chemical resistance or
materials listed in Appendix A should be directly corrosion rates at temperatures above ambient
reviewed. If the references cannot satisfactorily resolve temperatures are indicated with a "U". Matrix entries for
the issue, then a special study may be required to materials with insufficient information are left blank.
determine material compatibility and acceptable use. If
doubt of material suitability remains after the study due to B-2. Material Abbreviations
exceptional conditions, a report should be submitted to
HQUSACE (CEMP-EG). ABS - Acrylonitrile-butadiene-styrene
CPVC - Chlorinated polyvinyl chloride
Resins
B-1. Use of the Fluid/Material Matrix
Furan - Furfural alcohol
The following matrix is arranged alphabetically according Polyester - Bisphenol A-fumarate
to the list of fluids typically found or used at hazardous HDPE - High density polyethylene
and toxic waste remediation sites. Unless otherwise PP - Polypropylene
noted, the liquids are considered pure. All percentages PTFE - Teflon1
shown are expressed in percent by weight. PVC Type 2 - Polyvinyl chloride Type 2
PVDF - Polyvinylidene fluoride
a. Corrosion Resistivity Butyl - Butyl rubber GR-1 (IIR)
EPDM - Ethylene-propylene-diene
The matrix provides the temperature above ambient EPT - Ethylene-propylene terpolymer
conditions of 15EC (60EF) at which corrosion or FEP - Perfluorethylenepropylene
chemical resistivity of a material is acceptable for use FKM - Fluoroelastomer
with an identified fluid. For metals, an acceptable Neoprene2 - Polychloroprene
corrosion rate is less than 1.27 mm (50 mils) penetration Nitrile - Butadiene-acrylonitrile
per year. For non-metals and other materials, N-Rubber - Natural rubber
acceptability is considered based on the material’s PFA - Perfluoroalkoxyalkane copolymer
resistance to solvation or chemical reaction. Although PVDC - Polyvinylidene chloride
materials may be corrosion resistant below the listed SBR Styrene - Butadiene-styrene-elastomer
temperatures, other physical or mechanical properties of
that material may preclude its acceptability for a specific B-3. Matrix
use. A thorough evaluation considering all physical and
mechanical properties of a material for its intended use is Data contained within this matrix was obtained primarily
required. from Schweitzer, Corrosion Resistance Tables, 4th
Edition, see Appendix A for the complete reference
information.
1
Teflon is a registered trademark of E.I. DuPont.
2
Neoprene is a registered trademark of E.I. DuPont.
B-1
EM-1110-1-4008 Table B-1. Fluid/Material Matrix
5 May 99
Aluminum Chloride, Aq.

Acetic Acid Glacial
Acetic Acid 10%
Acetic Acid 20%
Acetic Acid 50%
Acetic Acid 80%

FLUID/MATERIAL
Acetone
METALS
Aluminum 65 (150) 87 (190) 76 (170) 76 (170) 98 (210) 260 (500) U
Bronze 93 (200) U U U U 204 (400) U
Carbon Steel U U U U U 149 (300) U
Copper 38 (100) U U U U 60 (140) 26 (80)
Ductile Iron, Pearlitic
Hastelloy C 149 (300) 149 (300) 149 (300) 149 (300) 293 (560) 93 (200) 98 (210)
Inconel 26 (80) 32 (90) 54 (130) 32 (90) 104 (220) 87 (180) U
Monel 26 (80) 98 (210) 93 (200) 93 (200) 143 (290) 87 (180) U
Nickel 32 (90) 32 (90) 60 (140) 49 (120) U 87 (180) 149 (300)
304 SS 93 (200) 104 (220) 104 (220) 110 (230) 98 (210) 87 (180) U
316 SS 216 (420) 204 (400) 204 (400) 110 (230) 204 (400) 204 (400) U
NON-METALS
ABS 38 (100) 54 (130) 53 (130) U U U 60 (140)
CPVC 32 (90) 82 (180) U U U U 93 (200)
Resins - Epoxy 82 (190) 43 (110) 43 (110) 43 (110) 43 (110)
- Furan 127 (260) 121 (230) 93 (200) 93 (200) 132 (270) 93 (200) 127 (260)
- Polyester 104 (220) 93 (200) 71 (160) 71 (160) U U 93 (200)
- Vinyl Ester 93 (200) 93 (200) 82 (180) 65 (150) 65 (150) U 127 (260)
HDPE 60 (140) 60 (140) 60 (140) 26 (80) 38 (100) 49 (120) 60 (140)
PP 104 (220) 104 (220) 93 (200) 93 (200) 85 (190) 104 (220) 93 (200)
PTFE 243 (470) 243 (470) 243 (470 ) 243 (470 ) 243 (470) 243 (470) 243 (470)
PVC Type 2 38 (100) 60 (140) 32 (90) U U U 60 (140)
PVDF 149 (300) 149 (300) 149 (300) 87 (190) 87 (190) U 149 (300)
OTHER MATERIALS
Butyl 65 (150) 65 (150) 43 (110) 43 (110) 32 (90) 71 (160) 65 (150)
EPDM 149 (300) 60 (140) 60 (140) 60 (140) 149 (300) 149 (300) 149 9300)
EPT U U U U U U 82 (180)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 82 (180) 93 (200) 82 (180) 82 (180) U U 204 (400)
Borosilicate Glass 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 121 (250) 121 (250)
Neoprene 71 (160) 71 (160) 71 (160) 71 (160) U U 93 (200)
Nitrile 93 (200) 93 (200) 93 (160) 98 (210) 38 (100) U 93 (200)
N-Rubber 65 (150) 26 (80) U U U U 60 (140)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 121 (250) 93 (200) 93 (200)
PVDC 60 (140) 49 (120) 54 (130) 54 (130) 60 (140) 32 (90) 65 (150)
SBR Styrene U U U U U 93 (200)
Notes: U = unsatisfactory
XX (XX) = degrees C (degrees F)
B-2
Table B-1. Fluid/Material Matrix EM-1110-1-4008
5 May 99
Ammonia Hydroxide (Sat.)

Ammonia Hydroxide 10%
Ammonia Hydroxide 25%

Aluminum Sulfate (Sat.)
Ammonia (Anhydrous)
Ammonium Nitrate
FLUID/MATERIAL
Benzene
METALS
Aluminum U 82 (180) 176 (350) 176 (350) 176 (350) 176 (350) 98 (210)
Bronze 98 (210) 26 (80) U U U U 204 (400)
Carbon Steel U 204 (400) 98 (210) 98 (210) 98 (210) U 60 (140)
Copper 26 (80) 26 (80) U U U U 38 (100)
Ductile Iron, Pearlitic 26 (80) 85 (185)
Hastelloy C 98 (210) 298 (570) 98 (210) 398 (570) 398 (570) 32 (90) 98 (210)
Inconel U 298 (570) 32 (90) 26 (80) 32 (90) 32 (90) 98 (210)
Monel 98 (210) 298 (570) U U U U 98 (210)
Nickel 98 (210) 32 (90) U U 149 (300) 32 (90) 98 (210)
304 SS 98 (210) 249 (480) 98 (210) 110 (230) 98 (210) 98 (210) 110 (230)
316 SS 98 (210) 298 (570) 98 (210) 110 (230) 98 (210) 149 (300) 204 (400)
NON-METALS
ABS 60 (140) U 26 (80) 32 (90) 26 (80) 60 (140) U
CPVC 93 (200) 82 (180) 93 (200) 82 (180) 82 (180) 93 (200) U
Resins - Epoxy 149 (300) U 87 (190) 60 (140) 71 (160) 121 (250) 82 (180)
- Furan 127 (260) 127 (260) 82 (180) 127 (260) 93 (200) 127 (260) 127 (260)
- Polyester 93 (200) 104 (220) 60 (140) 38 (100) 104 (220) U
- Vinyl Ester 121 (250) 104 (220) 66 (150) 66 (150) 121 (250) U
HDPE 60 (140) 60 (140) 60 (140) 60 (140) 60 (10) 60 (140) U
PP 104 (220) 104 (220) 104 (220) 93 (200) 93 (200) 93 (200) 60 (140)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 32 (90) 60 (140) 60 (140) 60 (140) 60 (140) U
PVDF 149 (300) 138 (280) 138 (280) 138 (280) 138 (280) 138 (280) 65 (150)
OTHER MATERIALS
Butyl 87 (190) U 87 (190) 87 (190) 87 (190) 82 (180) U
EPDM 149 (300) 149 (300) 98 (210) 38 (100) 149 (300) 149 (300) U
EPT 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 82 (180) U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 198 (380) U 87 (190) 87 (190) 87 (190) U 204 (400)
Borosilicate Glass 121 (250) 122 (250) 122 (250) 122 (250) 93 (200) 121 (250)
Neoprene 93 (200) 93 (200) 90 (200) 93 (200) 98 (210) 93 (200) U
Nitrile 93 (200) 87 (190) 93 (200) 93 (200) 98 (210) 82 (180) U
N-Rubber 65 (150) U 26 (80) U 32 (90) 76 (170) U
PFA 104 (220) 93 (200) 138 (280) 138 (280) 138 (280) 93 (200) 93 (200)
PVDC 82 (180) U U U 49 (120) 26 (80)
SBR Styrene 93 (200) U
B-3
5 May 99
Calcium Hydroxide (Sat.)

Calcium Hydroxide 10%

Calcium Chloride Dilute
Bleach 12.5% Active Cl
Calcium Chloride (Sat.)

FLUID/MATERIAL
METALS
Aluminum U 15 (60) 38 (100) 26 (80) 26 (80) 26 (80) U
Bronze 98 (210)
Carbon Steel U 15 (60) 60 (140) 26 (80) U U 26 (80)
Copper 15 (60) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
Ductile Iron, Pearlitic 98 (210)
Hastelloy C 93 (200) 176 (350) 76 (170) 76 (170) 76 (170)
Inconel 15 (60) 26 (80) 98 (210) 98 (210) 98 (210) 32 (90)
Monel 98 (210) 176 (350) 98 (210) 98 (210) 98 (210) 93 (200)
Nickel 15 (60) 26 (80) 98 (210) 98 (210) 98 (210) 93 (200)
304 SS 65 (150) 26 (80) 98 (210) 98 (210) 98 (210) 93 (200)
316 SS U 60 (140) 98 (210) 98 (210) 98 (210) 98 (210)
NON-METALS
ABS U 60 (140) 60 (140) 60 (140) 60 (140)
CPVC 93 (200) 82 (180) 82 (180) 76 (170) 76 (170) 76 (170) 98 (210)
Resins - Epoxy 93 (200) 87 (190) 98 (210) 93 (200) 93 (200) 82 (180)
- Furan 127 (260) 127 (260) 104 (220) 104 (220) 104 (220) 127 (260)
- Polyester 104 (220) 104 (220) 82 (180) 71 (160) 71 (160) 71 (160)
- Vinyl Ester 82 (180) 82 (180) 82 (180) 98 (210) 98 (210)
HDPE 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PP 60 (140) 104 (220) 104 (220) 93 (200) 93 (200) 93 (200) 104 (220)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 138 (280) 138 (280) 132 (270) 132 (270) 149 (300) 138 (280)
OTHER MATERIALS
Butyl 65 (150) 87 (190) 87 (190) 87 (190) 87 (190) 87 (190) 87 (190)
EPDM 149 (300) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210) 149 (300)
EPT U 82 (180) 82 (180) 82 (180) 82 (180) 82 (180) 98 (210)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 204 (400) 143 (290) 149 (300) 149 (300) 149 (300) 149 (300) 204 (400)
Borosilicate Glass 122 (250) 121 (250) U U U U
Neoprene 32 (90) 93 (200) 93 (200) 104 (220) 104 (220) 104 (220) 104 (220)
Nitrile U 93 (200) 82 (180) 82 (180) 76 (170) 82 (180) 82 (180)
N-Rubber 32 (90) 65 (150) 65 (150) 93 (200) 93 (200) 93 (200) 93 (200)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 82 (180) 138 (280) 71 (160) 71 (160) 71 (160) 71 (160)
SBR Styrene 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
B-4
5 May 99
Calcium Hypochlorite (Sat.)

Calcium Hypochlorite 30%
Chlorophenol, 5% Aq.
Chlorine Water (Sat.)
FLUID/MATERIAL
Chlorobenzene
Copper Sulfate
Chloroform
METALS
Aluminum U U 26 (80) 65 (150) 76 (170) U
Bronze U U U 204 (400) 204 (400) U
Carbon Steel U U U 98 (210) U 15 (60) U
Copper U U U 32 (90) 26 (80) U
Hastelloy C 98 (210) 176 (350) 98 (210) 98 (210)
Inconel U 32 (90) 98 (210) 98 (210) 32 (90)
Monel U U U 204 (400) 98 (210) 32 (90)
Nickel U U 49 (120) 98 (210) 32 (90)
304 SS U U U 98 (210) 98 (210) 176 (350) 98 (210)
316 SS 26 (80) U 138 (280) 98 (210) 176 (350) 204 (400)
NON-METALS
ABS 60 (140) 60 (140) U U 60 (140)
CPVC 82 (180) 93 (204) 98 (210) U U U 98 (210)
Resins - Epoxy U 87 (190) 43 (110) 98 (210)
- Furan U 127 (260) 127 (260) 116 (240) 104 (220) 127 (260)
- Polyester 98 (210) 104 (220) U U 104 (220)
- Vinyl Ester 82 (180) 82 (180) 43 (110) U 116 (240)
HDPE 60 (140) 60 (140) U 26 (80) 60 (140)
PP 65 (170) 98 (210) 60 (140) U U 93 (200)
PTFE 93 (200) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) U U U 60 (140)
PVDF 93 (200) 138 (280) 104 (220) 104 (220) 121 (250) 65 (150) 138 (280)
OTHER MATERIALS
Butyl U 65 (150) U U U 87 (190)
EPDM 154 (310) 149 (300) 15 (60) U U 149 (300)
EPT U 26 (80) U U 82 (180)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 204 (400) 204 (400) 87 (190) 204 (400) 204 (400) 204 (400)
Borosilicate Glass 121 (250) 93 (200) 121 (250) 121 (250) 121 (200)
Neoprene 26 (80) 15 (60) U U U 93 (200)
Nitrile U U U U U 93 (200)
N-Rubber U 32 (90) 65 (150) U U 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 49 (120) 82 (180) 26 (80) U 82 (180)
SBR Styrene U U 93 (200)
B-5
5 May 99
Detergent Solution
Dichlorobenzene
FLUID/MATERIAL
Esters, General
Ethyl Alcohol
Diesel Fuels
Crude Oil
Cumene
METALS
Aluminum 38 (100) 15 (60) 32 (90) 98 (210)
Bronze 38 (100) 32 (90) 204 (400) 204 (400)
Carbon Steel 38 (100) 15 (60) 87 (190) 116 (240)
Copper 26 (80) 15 (60) 38 (100)
Hastelloy C 32 (90) 71 (160) 176 (350) 93 (200) 98 (210)
Inconel 26 (80)
Monel 149 (300) 98 (210)
Nickel 93 (200)
304 SS 98 (210) 82 (180) 26 (80) 32 (90) 93 (200)
316 SS 98 (210) 82 (180) 43 (110) 32 (90) 93 (200) 204 (400)
NON-METALS
ABS 32 (90) U 49 (120)
CPVC 98 (210) 71 (160) U 38 (100) 82 (180) U
Resins - Epoxy 149 (300) 60 (140) 121 (250) 87 (190) 122 (250) 66 (150) 71 (160)
- Furan 121 (250) 127 (260 ) 122 (250) 127 (260) 122 (250)
- Polyester 104 (220) 60 (140) 32 (90) 93 (200) 32 (90)
- Vinyl Ester 121 (250) 60 (140) 49 (120) 43 (110) 104 (220) 38 (100) 66 (150)
HDPE 49 (120) 60 (140) U 49 (120) 60 (140) 26 (80)
PP 65 (150) 65 (150) 65 (150) 38 (100) 82 (180)
PTFE 243 (470) 149 (300) 243 (470) 243 (470) 243 (470) 243 (470) 244 (470)
PVC Type 2 60 (140) 60 (140) U 60 (140) U
PVDF 138 (280) 49 (120) 138 (280) 138 (280) 76 (170)
OTHER MATERIALS
Butyl U 88 (190)
EPDM U U 143 (290) U U 144 (290)
EPT U 98 (210) U U 82 (180)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 149 (300) 209 (140) 204 (400) 82 (180) 204 (400) 176 (350)
Borosilicate Glass 93 (200) 93 (200) 93 (200)
Neoprene U U 71 (160) U 26 (80) 93 (200)
Nitrile 82 (180) U 87 (190) U 93 (200) 82 (180)
N-Rubber U U U 66 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 65 (150) U 49 (120) 66 (150) 26 (80)
SBR Styrene U 93 (200) 93 (200) 93 (200)
B-6
5 May 99
Ferric Chloride, 50% Aq.
Formaldehyde Dilute
Ferric Nitrate (Sat.)
FLUID/MATERIAL
Ethylene Glycol
Ethers, General
Ethyl Benzene
Ferric Sulfate
METALS
Aluminum 32 (90) 66 (150) 38 (100) U U
Bronze 93 (200) U 171 (340) U U U 66 (150)
Carbon Steel 93 (200) U 38 (100) U U U
Copper 26 (80) 38 (100) U U 26 (80)
Hastelloy C 93 (200) 116 (240) 299 (570) 98 (210) 66 (150) 66 (150) 98 (210)
Inconel 32 (90) 98 (210) 26 (80) U U 98 (210)
Monel 32 (90) 82 (180) 98 (210) U U 26 (80) 98 (210)
Nickel 26 (80) 98 (210) U U U 98 (210)
304 SS 93 (200) 20 (70) 98 (210) U 26 (80) 298 (570)
316 SS 92 (200) 66 (150) 171 (340) U 60 (140) 93 (200) 110 (230)
NON-METALS
ABS U 60 (140) 60 (140) 38 (100)
CPVC U 98 (210) 82 (180) 82 (180) 82 (180) 60 (140)
Resins - Epoxy 32 (90) U 149 (300) 122 (250) 93 (200) 93 (200) 44 (110)
- Furan 32 (90) 98 (210) 127 (260) 116 (240) 122 (250) 127 (260) 71 (160)
- Polyester U 104 (220) 104 (220) 93 (200) 104 (220) 26 (80)
- Vinyl Ester 82 (180) U 98 (210) 98 (210) 93 (200) 93 (200) 66 (150)
HDPE U 20 (70) 60 (140) 60 (140) 60 (140)
PP U U 110 (230) 98 (210) 93 (200) 93 (200) 93 (200)
PTFE 244 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 149 (300)
PVC Type 2 U U 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 49 (120) 60 (140) 138 (280) 138 (280) 138 (280) 138 (280) 49 (120)
OTHER MATERIALS
Butyl U 88 (190) 71 (160) 88 (190)
EPDM U 149 (300) 149 (300) 144 (290) 138 (280) 60 (140)
EPT U U 82 (180) 82 (180) 82 (180) 82 (180) 82 (180)
FEP 204 (400) 49 (120) 204 (400) 204 (400) 204 (400) 204 (400)
FKM U 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 110 (230)
Borosilicate Glass 66 (170) 122 (250) 138 (280) 93 (200)
Neoprene U U 71 (160) 71 (160) 93 (200) 60 (140)
Nitrile 49 (120) U 93 (200) 82 (180) 82 (180) 93 (200) U
N-Rubber U U 66 (150) 66 (150) 66 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 82 (180) 60 (140) 49 (120) 66 (150) 60 (140)
SBR Styrene 93 (200) 93 (200) 93 (200)
B-7
5 May 99
Formic Acid Anhydrous

Formic Acid 10-85%
Gasoline, Refined
Gasoline, Leaded
Formic Acid 5%
FLUID/MATERIAL
Gasohol
Fuel Oil
METALS
Aluminum U 98 (210) 98 (210) 60 (140) 66 (150) 38 (100) 98 (210)
Bronze 98 (210) 98 (210) 176 (350) 66 (150) 38 (100) 93 (200)
Carbon Steel U U 93 (200) 66 (150) 38 (100) 93 (200)
Copper 66 (150) 98 (210) 98 (210) 26 (80) 66 (150) 38 (100) 32 (90)
Hastelloy C 98(210) 98 (210) 98 (210) 93 (200) 66 (150) 38 (100) 93 (200)
Inconel 66 (150) 98 (210) 98 (210) 60 (140) 26 (80)
Monel 66 (150) 98 (210) 98 (210) 82 (180) 66 (150) 38 (100) 38 (100)
Nickel 66 (150) 98 (210) 98 (210) 82 (180) 38 (100) 38 (100)
304 SS 66 (150) 104 (220) 54 (130) 122 (250) 32 (90) 132 (270)
316 SS 66 (150) 204 (400) 98 (210) 71 (160) 66 (150) 32 (90) 98 (210)
NON-METALS
ABS U U U U U
CPVC 26 (80) 60 (140) 76 (170) U 66 (150)
Resins - Epoxy 38 (100) 20 (70) 32 (90) 122 (250) 122 (250) 66 (150)
- Furan 104 (220) 127 (260) U 122 (250) 122 (250) 127 (260)
- Polyester 66 (150) 66 (150) 38 (100) 26 (80) 32 (90) 26 (80)
- Vinyl Ester 82 (180) 38 (100) U 93 (200) 44 (110) 82 (180)
HDPE 60 (140) 60 (140) 71 (160) 93 (200) U U
PP 66 (150) 98 (210) 82 (180) 76 (170) U U U
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 93 (200) 243 (470) 243 (470)
PVC Type 2 32 (90) 60 (140) 60 (140) U
PVDF 122 (250) 122 (250) 60 (140) 138 (280) 138 (280) 138 (280)
OTHER MATERIALS
Butyl 66 (150) 66 (150) 66 (150) U
EPDM 98 (210) 149 (300) 32 (90) U U U
EPT 93 (200) 82 (180) 98 (210) U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 82 (180) 88 (190) 66 (150) 199 (390) 32 (100) 88 (190) 82 (180)
Neoprene 93 (200) 71 (160) 38 (100) 93 (200) 32 (90) 32 (90)
Nitrile U U U 104 (220) 26 (80) 88 (190) 93 (200)
N-Rubber U U U U U
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 66 (150) 66 (150) 66 (150) 49 (120) 71 (160) 32 (90)
SBR Styrene U U
B-8
5 May 99
Hydrochloric Acid, Dilute
Hydrochloric Acid 20%

Gasoline, Unleaded
FLUID/MATERIAL
Heptane
Glycols
Hexane
METALS
Aluminum 98 (210) 26 (80) 38 (100) 26 (80) U U U
Bronze 176 (350) 38 (100) 176 (350) 176 (350) U U U
Carbon Steel 176 (350) 26 (80) 176 (350) 176 (350) U U U
Copper 32 (90) 26 (80) U U U
Hastelloy C 160 (320) 93 (200) 122 (250) 82 (180) 66 (150) 66 (150)
Inconel 26 (80) 38 (100) 93 (200) 32 (90) 26 (80) U
Monel 38 (100) 38 (100) 93 (200) 38 (100) 32 (90) 26 (80) U
Nickel 38 (100) 98 (210) 26 (80) 32 (90) 26 (80) U
304 SS 26 (80) 38 (100) 122 (250) 122 (250) U U U
316 SS 26 (80) 26 (80) 176 (350) 122 (250) U U U
NON-METALS
ABS U 60 (140) 54 (130) U 32 (90) 32 (90) 60 (140)
CPVC U 82 (180) 82 (180) 66 (150) 82 (180) 82 (180) 66 (150)
Resins - Epoxy 122 (250) 149 (300) 66 (150) 82 (180) 88 (190) 93 (200) 32 (90)
- Furan 138 (280) 98 (210) 66 (150) 127 (260) 127 (260) 122 (250)
- Polyester 32 (90) 104 (220) 93 (200) 32 (90) 88 (190) 88 (190) 54 (130)
- Vinyl Ester 38 (100) 98 (210) 98 (210) 71 (160) 110 (230) 104 (220) 82 (180)
HDPE 60 (140) 60 (140) 44 (110) 26 (80) 71 (160) 60 (140) 60 (140)
PP U 66 (150) 26 (80) 44 (110) 104 (220) 104 (220) 104 (220)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 20 (70) 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 138 (280) 138 (280) 138 (280) 138 (280) 138 (280) 138 (280)
OTHER MATERIALS
Butyl 66 (150) U 49 (120) U U
EPDM U 149 (300) U U 149 (300) 38 (100) 32 (90)
EPT U 98 (210) U U 98 (210) U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 82 (180) 204 (400) 176 (350) 210 (410) 176 (350) 176 (350) 176 (350)
Neoprene 93 (200) 71 (160) 93 (200) 93 (200) 66 (150) 82 (180) 82 (180)
Nitrile 93 (200) 104 (220) 82 (180) 104 (220) 66 (150) 54 (130) U
N-Rubber U 49 (120) U U 60 (140) 66 (150) 82 (180)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 122 (250) 122 (250) 122 (250)
PVDC 66 (150) 66 (150) 66 (150) 82 (180) 82 (180) 82 (180)
SBR Styrene U U U U
B-9
5 May 99
Hydrofluoric Acid, Dilute

Hydrofluoric Acid 30%

FLUID/MATERIAL
METALS
Aluminum U U U U U U U
Bronze U U 66 (150) 60 (140) 26 (80) U U
Carbon Steel U U U U U U U
Copper U U 66 (150) 60 (140) 26 (80) U U
Hastelloy C 60 (150) 26 (80) 98 (210) 98 (210) 93 (200) 110 (230) 93 (200)
Inconel U U 26 (80) U U U U
Monel U U 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
Nickel U U 44 (110) 76 (170) 60 (140) 71 (160) 38 (100)
304 SS U U U U U U U
316 SS U U U U U U U
NON-METALS
ABS 60 (140) 54 (130) U U U U U
CPVC 76 (170) 82 (180) 26 (80) U 76 (170) U 32 (90)
Resins - Epoxy 60 (140) 104 (220) U U U U U
- Furan 122 (250) 32 (90) 127 (260) U U U
- Polyester U 32 (90) 38 (100) 32 (90) U
- Vinyl Ester 82 (180) 60 (140) 71 (160) U U U U
HDPE 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) U
PP 93 (200) 44 (110) 93 (200) 82 (180) 93 (200) 93 (200) 93 (200)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 32 (90) 54 (130) 66 (150) 20 (70)
PVDF 138 (280) 138 (280) 138 (280) 127 (260) 116 (240) 104 (220) 98 (210)
OTHER MATERIALS
Butyl U 54 (130) 176 (350) 176 (350) 66 (150) 66 (150) 66 (150)
EPDM 60 (140) 15 (60) 15 (60) 15 (60) U U
EPT 32 (90) U 98 (210) 60 (140) U U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 176 (350) 138 (280) 98 (210) 98 (210) 176 (350) 176 (350) 176 (350)
Borosilicate Glass 122 (250) 122 (250) U U U U U
Neoprene 32 (90) U 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
Nitrile U 93 (200) U U U U U
N-Rubber 82 (180) 82 (90) 38 (100) 38 (100) 32 (90) 38 (100) U
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 82 (180) 82 (180) 82 (180) 71 (160) 76 (170) 66 (150)
SBR Styrene U U U U U U U
B-10
5 May 99
Hydrogen Sulfide, Aq. Soln.

Hydrogen Peroxide, Dilute
Hydrogen Peroxide 30%

FLUID/MATERIAL
Jet Fuel JP-4

METALS
Aluminum U 176 (350) 176 (350) 15 (60) 176 (350) 76 (170)
Bronze 72 (160) U U U 32 (90) 204 (400)
Carbon Steel 66 (150) U U U U 76 (170)
Copper U U U U U
Hastelloy C 98 (210) 93 (200) 38 (100) 38 (100) 93 (200) 149 (300) 38 (100)
Inconel 49 (120) 66 (150) 60 (140) 26 (80) 32 (90) 93 (200) 32 (90)
Monel 98 (210) 49 (120) 15 (60) 32 (90) 32 (90) 98 (210) 32 (90)
Nickel 49 (120) 76 (170) 32 (90) 93 (200) 26 (80)
304 SS U 98 (210) 98 (210) 93 (200) 93 (200) U 38 (100)
316 SS 26 (80) 216 (420) 204 (400) 204 (400) 204 (400) 93 (200) 204 (400)
NON-METALS
ABS U 26 (80) U U U 60 (140)
CPVC U U 82 (180) 82 (180) 82 (180) 82 (180) 93 (200)
Resins - Epoxy U 66 (150) 60 (140) U U 149 (300) 66 (150)
- Furan 138 (280) U U 26 (80) 127 (260) 60 (140)
- Polyester 66 (150) 32 (90) U U 26 (80)
- Vinyl Ester U 60 (140) 76 (170) 44 (110) 66 (150) 71 (160) 82 (180)
HDPE 49 (120) 60 (140) 60 (140) 26 (80) 60 (140)
PP 93 (200) 38 (100) 38 (100) 66 (150) 44 (110) 82 (180) 20 (70)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 244 (470) 243 (470) 243 (470)
PVC Type 2 U 38 (100) U 60 (140) 60 (140)
PVDF 93 (200) 122 (250) 122 (250) 122 (250) 49 (120) 104 (220) 122 (250)
OTHER MATERIALS
Butyl U U U U U U
EPDM U 38 (100) 38 (100) 38 (100) 38 (100) 60 (140) U
EPT U 26 (80) U U U 82 (180) U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 20 (70) 176 (350) 176 (350) 176 (350) 122 (250) U 204 (400)
Borosilicate Glass U 122 (250) 122 (250) 122 (250) 122 (250) 44 (110) 82 (180)
Neoprene U U U U U U
Nitrile U 32 (90) 32 (90) U U U 93 (200)
N-Rubber U 26 (80) U U U U
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC U 49 (120) 49 (120) 54 (130) 49(120) 71 (160) 26 (80)
SBR Styrene U 93 (200) U
B-11
5 May 99
Ketones, General
FLUID/MATERIAL
Methyl Alcohol
Lubricating Oil
Jet Fuel JP-5
Machine Oil
Lime Slurry
Kerosene
METALS
Aluminum 38 (100) 76 (170) 38 (100) 66 (150) 66 (150)
Bronze 204 (400) 176 (350) 38 (100) 66 (150) 188 (370)
Carbon Steel 38 (100) 176 (350) 93 (200) 66 (150) 66 (150) 98 (210) 98 (210)
Copper 32 (90) 32 (90) 98 (210)
Hastelloy C 38 (100) 98 (210) 38 (100) 49 (120) 98 (210) 122 (250)
Inconel 26 (80) 32 (90) 98 (210)
Monel 38 (100) 76 (170) 38 (100) 66 (150) 38 (100) 98 (210)
Nickel 26 (80) 98 (210) 38 (100) 98 (210)
304 SS 38 (100) 204 (400) 122 (250) 66 (150) 98 (210) 122 (250)
316 SS 204 (400) 204 (400) 132 (270) 66 (150) 66 (150) 98 (210) 176 (350)
NON-METALS
ABS 32 (90) U 38 (100) U
CPVC 60 (140) 82 (180) U 82 (180) 82 (180) 66 (150)
Resins - Epoxy 66 (150) 122 (250) U 93 (200) 110 (230) 32 (90)
- Furan 66 (150) 122 (250) 38 (100) 122 (250)
- Polyester 32 (90) 66 (150) 98 (210) 66 (150)
- Vinyl Ester 49 (120) 132 (270) U 82 (180) 93 (200) 38 (100)
HDPE 26 (80) 26 (80) U 60 (140)
PP 20 (70) 32 (90) 44 (110) 20 (70) 44 (110) 88 (190)
PTFE 243 (470) 243 (470) 243 (470) 82 (180) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) U 60 (140) 60 (140) 60 (140)
PVDF 122 (250) 127 (260) 44 (110) 138 (280) 93 (200) 138 (280)
OTHER MATERIALS
Butyl U U U U 88 (190)
EPDM U U U 38 (100) U U 149 (300)
EPT U U U 204 (400) 60 (140)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 60 (140) 204 (400)
FKM 204 (400) 204 (400) U 204 (400) 93 (200) U
Neoprene U 93 (200) U 82 (180) 93 (200) 93 (200) 104 (220)
Nitrile 93 (200) 110 (230) U 104 (220) 104 (220)
N-Rubber U U U 71 (160)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 32 (90) 49 (120) 32 (90) 49 (120) 71 (160)
SBR Styrene U U U 93 (200)
B-12
5 May 99
Methyl Ethyl Ketone (MEK)
Methyl Isobutyl Ketone
Methylene Chloride
FLUID/MATERIAL
Mixed Acids
Mineral Oil
Motor Oil
Naphtha
METALS
Aluminum 60 (140) 66 (150) 98 (210) 76 (170) U 82 (180)
Bronze 176 (350) 176 (350) 204 (400) U 38 (100) 204 (400)
Carbon Steel 93 (200) 66 (150) 38 (100) 38 (100) U 122 (250) 32 (90)
Copper 32 (90) 32 (90) 32 (90) 32 (90) 66 (150) 32 (90)
Hastelloy C 98 (210) 93 (200) 98 (210) 93 (200)
Inconel 98 (210) 93 (200) 98 (210) 38 (100) 32 (90) 32 (90) 66 (150)
Monel 93 (200) 93 (200) 98 (210) 38 (100) U 32 (90) 49 (120)
Nickel 93 (200) 98 (210) 38 (100) U 49 (120)
304 SS 66 (150) 93 (200) 98 (210) 32 (90) 66 (150) 122 (250) 122 (250)
316 SS 176 (350) 176 (350) 204 (400) 176 (350) 66 (150) 122 (250) 98 (210)
NON-METALS
ABS U U U 38 (100) 32 (90) 60 (140)
CPVC U U U 82 (180) 93 (200) 82 (180) 60 (140)
Resins - Epoxy 32 (90) 60 (140) 20 (70) 110 (230) 26 (80) 104 (220)
- Furan 76 (170) 122 (250) 138 (280) U 127 (260)
- Polyester U U U 98 (210) 66 (150)
- Vinyl Ester U U U 122 (250) 122 (250) 98 (210)
HDPE U U 26 (80) 26 (80)
PP 66 (150) 26 (60) 20 (70) 44 (110) U U 44 (110)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 U U U 60 (140) 20 (70) 60 (140) 60 (140)
PVDF U 44 (110) 49 (120) 122 (250) 122 (250) 138 (280)
OTHER MATERIALS
Butyl 38 (100) 26 (80) U U U
EPDM 149 (300) 15 (60) U U U U
EPT U U U U U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM U U 20 (70) 210(410) 38 (100) 88 (190) 204 (400)
Neoprene U U U 93 (200) U U
Nitrile U U U 82 (180) U 88 (190) 60 (140)
N-Rubber U U U U U
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC U 26 (80) U 49 (120) 66 (150)
SBR Styrene U U U U
B-13
5 May 99
Nitric Acid 10%
Nitric Acid 20%
Nitric Acid 30%
Nitric Acid 40%
Nitric Acid 50%

FLUID/MATERIAL
Nitric Acid 5%
Naphthalene
METALS
Aluminum 98 (210) U U U U U U
Bronze 38 (100) U U U U U U
Carbon Steel 82 (180) U U U U U U
Copper 38 (100) U U U U U U
Hastelloy C 93 (200) 98 (210) 98 (210) 88 (190) 88 (190) 82 (180) 110 (230)
Inconel 98 (210) 32 (90) 32 (90) 26 (80) 26 (80) 26 (80) 26 (80)
Monel 98 (210) U U U U U U
Nickel 98 (210) U U U U U U
304 SS 204 (400) 98 (210) 160 (320) 149 (300) 98 (210) 98 (210) 93 (200)
316 SS 204 (400) 98 (210) 98 (210) 144 (290) 149 (300) 104 (220) 93 (200)
NON-METALS
ABS U 60 (140) 60 (140) 54 (130) U U U
CPVC U 82 (180) 82 (180) 71 (160) 93 (200) 82 (180) 82 (180)
Resins - Epoxy 93 (200) 71 (160) 60 (140) 38 (100) U U U
- Furan 127 (260) 93 (200) 26 (80) U U U U
- Polyester 82 (180) 71 (160) 66 (150) 38 (100) 26 (80) 98 (210) 26 (80)
- Vinyl Ester 98 (210) 82 (180) 66 (150) 66 (150) 38 (100) 98 (210) U
HDPE 26 (80) 60 (140) 60 (140) 60 (140) 60 (140) U U
PP 98 (210) 60 (140) 93 (200) 60 (140) 66 (150) 66 (150) 66 (150)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 U 38 (100) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 93 (200) 93 (200) 82 (180) 82 (180) 82 (180) 82 (180)
OTHER MATERIALS
Butyl 71 (160) 71 (160) 71 (160) 49 (120) 38 (100) U
EPDM U 15 (160) 15 (160) 15 (160) 15 (60) U U
EPT U U U U U U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
Neoprene U U U U U U U
Nitrile U U U U U U U
N-Rubber U U U U U U U
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 32 (90) 54 (130) 66 (150) 66 (150) 49 (120) 49 (120)
SBR Styrene U U U U U U
B-14
5 May 99
Nitric Acid 100% (Anhydrous)
Oxalic Acid (Sat.)

Oxalic Acid 10%
Oxalic Acid 50%

Nitric Acid 70%
FLUID/MATERIAL
Oxalic Acid 5%
Oil and Fats
METALS
Aluminum U 32 (90) 66 (150) 88 (190) 44 (110) 88 (190) 54 (130)
Bronze U U 66 (150) 98 (210) 98 (210) 98 (210) 98 (210)
Carbon Steel U U 66 (150) U U U U
Copper U U 98 (210) 98 (210) 98 (210) 98 (210)
Hastelloy C 93 (200) 26 (80) 122 (250) 98 (210) 98 (210) 98 (210) 98 (210)
Inconel U U 98 (210) 98 (210) 98 (210) 26 (80)
Monel U U 98 (210) 98 (210) 66 (150) 32 (90)
Nickel U U 15 (60) 32 (90) 38 (100) 49 (120) 98 (210)
304 SS 98 (210) 26 (80) 66 (150) U U U U
316 SS 204 (400) 44 (110) 122 (250) 176 (350) 176 (350) 176 (350) U
NON-METALS
ABS U U 60 (140) 60 (140) 38 (100) 38 (100) 38 (100)
CPVC 82 (180) U 98 (210) 60 (140) 88 (190) 98 (210) 93 (200)
Resins - Epoxy U U 132 (270) 132 (270) 132 (270) 132 (270)
- Furan U U 122 (250) 88 (190) 93 (200)
- Polyester 104 (220) 104 (220) 104 (220) 104 (220) 104 (220)
- Vinyl Ester U U 98 (210) 98 (210) 93 (200) 98 (210) 98 (210)
HDPE U U U 60 (140) 60 (140) 60 (140) 60 (140)
PP U U 82 (180) 71 (160) 66 (150) 66 (150) 60 (140)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) U 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 49 (120) 66 (150) 144 (290) 71 (160) 66 (150) 93 (200) 60 (140)
OTHER MATERIALS
Butyl 32 (90) U 76 (170) 88 (190) 66 (150) 66 (150)
EPDM U U 154 (310) 149 (300) 149 (300) 144 (290)
EPT U U U 60 (140) 60 (140) 60 (140) 98 (210)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 88 (190) 88 (190) 82 (180) 204 (400) 204 (400) 204 (400) 204 (400)
Neoprene U U 26 (80) 93 (200) 93 (200) 38 (100) U
Nitrile U U 93 (200) U U U 20 (70)
N-Rubber U U 66 (150) 66 (150) 66 (150) 66 (150)
PFA 122 (250) 26 (80) 93 (200)
PVDC U U 66 (150) 82 (180) 76 (170) 76 (170) 49 (120)
SBR Styrene U U
B-15
5 May 99
Phosphoric Acid 25-50%

Petroleum Oils, Refined
Phosphoric Acid 10%

Petroleum Oils, Sour
Phosphoric Acid 5%
FLUID/MATERIAL
Phenol 10%
Phenol
METALS
Aluminum 32 (90) U 98 (210) 66 (150) U 38 (100) U
Bronze 26 (80) U U 38 (100) U U 65 (150)
Carbon Steel 98 (210) 93 (200) U U
Copper 32 (90) U U 49 (120) 32 (90) U U
Hastelloy C 299 (570) 176 (350) 32 (90) 98 (210) 98 (210)
Inconel 299 (570) 49 (120) 26 (80) 93 (200) 98 (210)
Monel 32 (90) U 299 (570) 104 (220) 26 (80) 26 (80) 26 (80)
Nickel 299 (570) 93 (200) 26 (80) 26 (80)
304 SS 26 (80) 26 (80) 299 (570) 93 (200) 93 (200) 88 (190) 98 (210)
316 SS 26 (80) 26 (80) 299 (570) 93 (200) 98 (210) 144 (290) 93 (200)
NON-METALS
ABS U U 60 (140) 38 (100)
CPVC 82 (180) 82 (180) 60 (140) 32 (90) 98 (210) 82 (180) 82 (180)
Resins - Epoxy U U 38 (100) 71 (160) 60 (140)
- Furan 98 (210) U 122 (250) 121 (250)
- Polyester U U 104 (220) 104 (220)
- Vinyl Ester 93 (200) 93 (200) U 38 (100) 98 (210) 93 (200) 93 (200)
HDPE 26 (80) 26 (80) 38 (100) 38 (100) 60 (140) 60 (140) 60 (140)
PP 66 (150) 32 (90) 82 (180) 93 (200) 82 (180) 122 (250) 98 (210)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 U U 60 (140) 60 (140)
PVDF 127 (260) 122 (250) 93 (200) 98 (210) 132 (270) 138 (280) 121 (250)
OTHER MATERIALS
Butyl 66 (150) 66 (150) 66 (150) 66 (150) 87 (190)
EPDM U 15 (60) 26 (80) 149 (300) 149 (300) 60 (140)
EPT U U 26 (80) 26 (80) 82 (180) 82 (180) 82 (180)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 88 (190) 88 (190) 98 (210) 216 (420) 204 (400) 204 (400) 87 (190)
Neoprene 38 (100) U U 93 (200) 93 (200) 82 (180)
Nitrile 82 (180) 82 (180) U U U U U
N-Rubber U U 26 (80) 66 (150) 66 (150) 65 (150)
PFA 93 (200) 93 (200) 93 (200)
PVDC U 26 (80) 76 (170) 82 (180) 49 (120)
SBR Styrene U U U U 93 (200) 93 (200)
B-16
5 May 99
Potassium Hydroxide 27%

Phosphoric Acid 50-85%
Potassium Nitrate 1-5%
Potassium Nitrate 80%

FLUID/MATERIAL
METALS
Aluminum U U U U U 176 (350) 176 (350)
Bronze U 32 (90) 15 (60) 32 (90) 26 (80) 98 (210)
Carbon Steel U 98 (210) 93 (200) 32 (90) 26 (80) 54 (130)
Copper U 38 (100) 32 (90) 98 (210) 26 (80) 32 (93)
Hastelloy C 98 (210) 98 (210) 127 (260) 127 (260) 65 (150) 98 (210) 98 (210)
Inconel 87 (190) 98 (210) 98 (210) 98 (210) 26 (80) 98 (210) 98 (210)
Monel 204 (400) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
Nickel U 98 (210) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
304 SS 49 (120) 149 (300) 98 (210) 98 (210) U 121 (250) 121 (250)
316 SS 204 (400) 176 (330) 176 (350) 171 (340) 176 (350) 176 (350) 176 (350)
NON-METALS
ABS 54 (130) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
CPVC 82 (180) 82 (180) 82 (180) 82 (180) 127 (260) 82 (180) 82 (180)
Resins - Epoxy 43 (110) 93 (200) 82 (180) 98 (210) 65 (150) 127 (260) 149 (300)
- Furan 127 (260) 121 (250) 121 (250) 121 (250) 132 (270) 132 (270)
- Polyester 104 (220) 65 (150) 32 (90) 76 (170) 104 (220) 104 (220)
- Vinyl Ester 98 (210) 65 (150) 65 (150) U U 104 (220) 98 (210)
HDPE 38 (100) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PP 98 (210) 98 (210) 65 (150) 82 (180) 65 (150) 56 (150) 56 (150)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 121 (250) 98 (210) 104 (220) 98 (210) 98 (210) 138 (280) 138 (280)
OTHER MATERIALS
Butyl 65 (150) 82 (180) 82 (108) 82 (180) 82 (180) 82 (180)
EPDM 60 (140) 149 (300) 149 (300) 149 (300) 149 (300) 149 (300) 149 (300)
EPT 82 (180) 98 (210) 98 (210) 98 (210) 98 (210) 82 (180) 82 (180)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 149 (300) 160 (320) 26 (80) U U 204 (400) 204 (400)
Borosilicate Glass 149 (300) U U U U 121 (250) 121 (250)
Neoprene 60 (140) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
Nitrile U 26 (80) 15 (60) 65 (150) 65 (150) 104 (220) 104 (220)
N-Rubber 43 (110) 38 (100) 38 (100) 38 (100) 38 (100) 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 54 (130) 38 (100) 38 (100) 38 (100) 38 (100) 65 (150) 65 (150)
SBR Styrene U U U U 93 (200) 93 (200)
B-17
5 May 99
Potassium Permanganate 10%
Potassium Permanganate 20%
Potassium Sulfate 10%
Soap Solution 5%
Propylene Glycol
FLUID/MATERIAL
Soap Solutions
Silicone Oil
METALS
Aluminum 98 (210) 98 (210) 98 (210) 76 (170) 38 (100) 149 (300)
Bronze 93 (200) 26 (80) 26 (80) 98 (210) 176 (350) 176 (350) 176 (350)
Carbon Steel 26 (80) 26 (80) 98 (210) 98 (210) 38 (100) 65 (150) 76 (170)
Copper 26 (80) 26 (80) 65 (150) 32 (90) 38 (100) 26 (80)
Hastelloy C 98 (210) 98 (210) 98 (210) 32 (90) 38 (100) 32 (90)
Inconel 98 (210) 98 (210) 98 (210) 32 (90) 32 (90) 32 (90)
Monel 98 (210) 98 (210) 98 (210) 32 (90) 43 (110) 38 (100)
Nickel 98 (210) 98 (210) 98 (210) 32 (90) 65 (150) 60 (140)
304 SS 98 (210) 98 (210) 98 (210) 32 (90) 38 (100) 65 (150) 32 (90)
316 SS 175 (350) 176 (350) 176 (350) 98 (210) 38 (100) 65 (150) 32 (90)
NON-METALS
ABS U 32 (90) 60 (140) 32 (90)
CPVC 87 (190) 60 (140) 82 (180) U 87 (190) 83 (180) 82 (180)
Resins - Epoxy 65 (150) 65 (150) 121 (250) 98 (210) 26 (80) 32 (90)
- Furan 127 (260) 71 (160) 121 (250) 121 (250)
- Polyester 98 (210) 104 (220) 104 (220) 93 (200) 32 (90) 26 (80)
- Vinyl Ester 104 (220) 98 (210) 98 (210) 98 (210) 60 (140) 60 (140)
HDPE 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PP 65 (150) 60 (140) 104 (220) 60 (140) 60 (140) 60 (140) 82 (180)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 32 (90) 60 (140) U 32 (90) 26 (80)
PVDF 138 (280) 138 (280) 138 (280) 127 (260) 121 (250) 26 (80) 38 (100)
OTHER MATERIALS
Butyl 54 (130) 54 (130) 82 (180) U 65 (150)
EPDM 98 (210) 60 (140) 149 (300) 149 (300) 149 (300) 154 (310)
EPT 98 (210) 87 (190) 98 (210) 149 (300) 93 (200) 98 (210) 98 (210)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 71 (160) 71 (160) 204 (400) 149 (300) 204 (400) 204 (400) 204 (400)
Neoprene 38 (100) 38 (100) 93 (200) 32 (90) 15 (60) 93 (200) 93 (200)
Nitrile 49 (120) U 104 (220) 82 (180) 104 (220) 104 (220) 110 (230)
N-Rubber U U 65 (150) U 65 (150) 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 98 (210)
PVDC 54 (130) 54 (130) 76 (170) 76 (170) 82 (180)
SBR Styrene 93 (200) 93 (200)
B-18
5 May 99
Sodium Bicarbonate 20%
Sodium Hydroxide 10%

Sodium Aluminate
Sodium Carbonate
Sodium Bisulfate
Sodium Chloride
FLUID/MATERIAL
METALS
Aluminum 32 (90) 65 (150) U U U U U
Bronze U 32 (90) 38 (100) 38 (100) 98 (210) 87 (190) 98 (210)
Carbon Steel 65 (150) 38 (100) 49 (120) 49 (120) 71 (160) 98 (210) 98 (210)
Copper 26 (80) 38 (120) 38 (120) 98 (210) 98 (210) 98 (210)
Ductile Iron, Pearlitic 30 (86) 82 (180) 50 (122)
Hastelloy C 65 (150) 98 (210) 98 (210) 98 (210) 98 (210) 109 (230) 98 (210)
Inconel 98 (210) 98 (210) 98 (210) 98 (210) 149 (300) 98 (210)
Monel 65 (150) 98 (210) 98 (210) 98 (210) 98 (210) 176 (350) 176 (350)
Nickel 98 (210) 98 (210) 98 (210) 98 (210) 98 (210) 209 (410)
304 SS 26 (80) 121 (250) 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
316 SS 60 (140) 176 (350) 176 (350) 176 (350) 176 (350) 176 (350) 149 (300)
NON-METALS
ABS 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
CPVC 98 (210) 98 (210) 98 (210) 98 (210) 87 (190) 82 (180)
Resins - Epoxy 121 (250) 149 (300) 149 (300) 98 (210) 87 (190) 93 (200)
- Furan 127 (260) 127 (260) 127 (260) 127 (260) U U
- Polyester 65 (150) 71 (160) 71 (160) 71 (160) 104 (220) 54 (130) 65 (150)
- Vinyl Ester 65 (150) 93 (200) 82 (180) 82 (180) 82 (180) 76 (190) 65 (150)
HDPE 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 76 (170)
PP 104 (220) 104 (220) 104 (220) 104 (220) 104 (220) 98 (210)
PTFE 149 (300) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 138 (280) 138 (280) 138 (280) 98 (210) 98 (210)
OTHER MATERIALS
Butyl 82 (180) 82 (180) 82 (180) 82 (180) 82 (180) 82 (180)
EPDM 93 (200) 149 (300) 149 (300) 149 (300) 149 (300) 149 (300) 149 (300)
EPT 82 (180) 82 (180) 82 (180) 82 (180) 98 (210) 98 (210)
FEP 38 (100) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 93 (200) 204 (400) 87 (190) 87 (190) 204 (400) 15 (60) 15 (60)
Borosilicate Glass 121 (250) 121 (250) 121 (250) 121 (250) U U
Neoprene 65 (150) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
Nitrile 82 (180) 104 (220) 93 (200) 93 (200) 109 (230) 71 (160) 71 (160)
N-Rubber 65 (150) 82 (180) 82 (180) 54 (130) 65 (150) 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 121 (250) 121 (250)
PVDC 82 (180) 82 (180) 82 (180) 82 (180) 32 (90) 32 (90)
SBR Styrene 93 (200) U
B-19
5 May 99
Sodium Hydroxide Soln. (Conc.)
Sodium Hypochlorite (Conc.)

Sodium Hypochlorite 20%
Sodium Hyposulfite 5%
FLUID/MATERIAL
METALS
Aluminum U U U U 26 (80) U
Bronze 38 (100) 60 (140) 32 (90) 26 (80) 26 (80) U
Carbon Steel 98 (210) 38 (100) 98 (210) 143 (290) U U
Copper 32 (90) 60 (140) 65 (150) 26 (80) 26 (80) U 32 (90)
Ductile Iron, Pearlitic 127 (260) 127 (260)
Hastelloy C 98 (210) 98 (210) 104 (220) 49 (120) U 54 (130) 32 (90)
Inconel 149 (300) 149 (300) 98 (210) 26 (80) U U 26 (80)
Monel 98 (210) 149 (300) 143 (290) 176 (350) 26 (80) U 26 (80)
Nickel 149 (300) 149 (300) 98 (210) 93 (200) U U 26 (80)
304 SS 98 (210) 98 (210) 109 (230) 32 (90) U 26 (80) U
316 SS 98 (210) 176 (350) 109 (230) 176 (350) U 26 (80) U
NON-METALS
ABS 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
CPVC 82 (180) 82 (180) 82 (180) 87 (190) 87 (190) 82 (180)
Resins - Epoxy 93 (200) 93 (200) 121 (250) 26 (80)
- Furan U U 127 (260) U U U
- Polyester 65 (150) 104 (220) U 60 (140) 82 (180)
- Vinyl Ester 65 (150) 104 (220) U 82 (180) 38 (100) 98 (210)
HDPE 76 (170) 76 (170) 60 (140) 60 (140) 60 (140) 60 (140)
PP 98 (210) 104 (220) 104 (220) 60 (140) 49 (120) 43 (110)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 98 (210) 104 (220) 71 (160) 65 (150) 138 (280) 138 (280) 127 (260)
OTHER MATERIALS
Butyl 82 (180) 87 (190) 82 (180) 54 (130) 32 (90)
EPDM 154 (310) 149 (300) 149 (300) 149 (300) 71 (160) 60 (140) 60 (140)
EPT 98 (210) 93 (200) 87 (190) 26 (80) U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 15 (60) 15 (60) 15 (60) 15 (60) 193 (380) 204 (400) 82 (180)
Borosilicate Glass U U U U 121 (250) 65 (140) 121 (250)
Neoprene 93 (200) 93 (200) 93 (200) 93 (200) U U
Nitrile 71 (160) 65 (150) 71 (160) 65 (150) U U
N-Rubber 65 (150) 65 (150) 65 (140) 65 (140) 32 (90) 32 (90)
PFA 121 (250) 121 (250) 26 (80) 93 (200)
PVDC 60 (140) 65 (150) 54 (80) U 54 (130) 49 (120)
SBR Styrene U U U U
B-20
5 May 99
Sodium Phosphate Alkaline
Sodium Phosphate Neutral

Sodium Phosphate Acid
Solfonated Detergents
Sodium Sulfite 10%
FLUID/MATERIAL
Sodium Nitrate
Sour Crude Oil

METALS
Aluminum 176 (350) U U U 98 (210)
Bronze 38 (100) 98 (210) 32 (90) 98 (210) U
Carbon Steel 65 (150) 65 (150) 26 (80)
Copper 43 (110) 26 (80) 32 (90) 32 (90) 26 (80)
Hastelloy C 32 (90) 98 (210) 98 (210) 98 (210) 98 (210) 65 (150) 65 (150)
Inconel 93 (200) 98 (210) 98 (210) 98 (210) 98 (210)
Monel 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
Nickel 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
304 SS 98 (210) 98 (210) 98 (210) 98 (210) 98 (210)
316 SS 176 (350) 98 (210) 98 (210) 98 (210) 98 (210)
NON-METALS
ABS 60 (140) 60 (140) 60 (140)
CPVC 82 (180) 76 (170) 82 (180) 82 (180) 82 (180) 87 (190) 76 (170)
Resins - Epoxy 149 (300) U U U 121 (250) 87 (190) 121 (250)
- Furan 71 (160) 121 (250) U 121 (250) 121 (250)
- Polyester 104 (220) 98 (210) 93 (200) 104 (220) 93 (200)
- Vinyl Ester 98 (210) 109 (320) 98 (210) 98 (210) 98 (210) 127 (260) 98 (210)
HDPE 60 (140) 32 (90) 26 (80) 26 (80) 60 (140) 26 (80)
PP 98 (210) 93 (200) 98 (210) 93 (200) 60 (140) 65 (150) 49 (120)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 138 (280) 138 (280) 138 (280) 138 (280) 138 (280)
OTHER MATERIALS
Butyl 82 (180) 93 (200) 82 (180) 93 (200) 87 (190)
EPDM 138 (280) 98 (210) 98 (210) 98 (210) 60 (140) U
EPT 82 (180) 98 (210) 98 (210) 98 (210) 98 (210) U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 15 (60) 87 (190) 82 (180) 87 (190) 87 (190) U
Borosilicate Glass 121 (250) 98 (210) 93 (200) 98 (210) U 98 (210)
Neoprene 93 (200) 60 (140) 93 (200) 60 (140) 87 (190)
Nitrile 65 (150) 82 (180) 93 (200) 82 (180) 87 (190) 60 (140)
N-Rubber 65 (150) 71 (160) 71 (160) 71 (160) 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 65 (150) 65 (150) 65 (150) 65 (150) 65 (150) 65 (150)
SBR Styrene
B-21
5 May 99
Sulfuric Acid 10%
Sulfuric Acid 30%
Sulfuric Acid 50%
Sulfuric Acid 60%
Sulfuric Acid 70%
Sulfuric Acid 80%
Sulfuric Acid 90%

FLUID/MATERIAL
METALS
Aluminum U U U U U U U
Bronze U U U U U U U
Carbon Steel U U U U U U U
Copper U U U U U U U
Hastelloy C 98 (210) 87 (190) 109 (230) 127 (260) 93 (200) 116 (240) 87 (190)
Inconel U U U U U U U
Monel 26 (80) 26 (80) 49 (120) 54 (130) 26 (80) 26 (80) U
Nickel 26 (80) 26 (80) 32 (90) 32 (90) U U U
304 SS U U U U U 32 (90) 26 (80)
316 SS U U U U U 43 (110) 26 (80)
NON-METALS
ABS 60 (140) 32 (90) 54 (130) U U U U
CPVC 82 (180) 82 (180) 82 (180) 87 (190) 93 (200) 116 (240) U
Resins - Epoxy 60 (140) 49 (1230) 43 (110) 43 (110) 43 (110) U U
- Furan 121 (250) 121 (250) 127 (260) 121 (250) 127 (260) U U
- Polyester 104 (220) 104 (220) 104 (220) 71 (160) 71 (160) U U
- Vinyl Ester 93 (200) 82 (180) 98 (210) 87 (190) 82 (180) U U
HDPE 60 (140) 60 (140) 60 (140) 26 (80) 26 (80) U U
PP 93 (200) 93 (200) 93 (200) 98 (210) 82 (180) 76 (170) 82 (180)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) U U
PVDF 121 (240) 104 (220) 104 (220) 116 (240) 104 (220) 93 (200) 98 (210)
OTHER MATERIALS
Butyl 82 (180) 82 (180) 65 (150) 38 (100) 38 (100) U
EPDM 60 (140) 60 (140) 60 (140) 60 (140) 15 (60) U
EPT 93 (200) 60 (140) 98 (210) 98 (210) 38 (100) 26 (80)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 176 (350) 176 (350) 176 (350) 176 (350) 176 (350) 176 (350)
Neoprene 93 (200) 93 (200) 93 (200) 93 (200) U U
Nitrile 60 (140) 60 (140) 93 (200) U 15 (60) U
N-Rubber 65 (150) 65 (150) 38 (100) U U U
PFA 121 (250) 121 (250) 121 (250) 121 (250) 121 (250) 121 (250) 121 (250)
PVDC 49 (120) 26 (80) U U U U U
B-22
5 May 99
Sulfuric Acid, Fuming

Sulfuric Acid 100%
Sulfuric Acid 103%

Sulfuric Acid 95%
Sulfuric Acid 98%
Tetrachloroethane
FLUID/MATERIAL
Sulfurous Acid
METALS
Aluminum U U U 32 (90) 187 (370) 15 (60)
Bronze U U U U U
Carbon Steel 32 (90) 38 (100) 43 (110) U 26 (80)
Copper U U U 38 (100) 15 (60)
Hastelloy C 143 (290) 98 (210) 87 (190) 32 (90) 187 (370) 71 (160)
Inconel U U U U U 32 (90)
Monel U U U U U U
Nickel U U U U U
304 SS 32 (90) 26 (80) 26 (80) U 32 (90) U 26 (80)
316 SS 98 (210) 98 (210) 98 (210) 32 (90) 98 (210) 65 (150) 15 (60)
NON-METALS
ABS U U U U U 60 (140)
CPVC U U U U 15 (60) 82 (180) U
Resins - Epoxy U U U U U 116 (240) 32 (90)
- Furan U U U U 71 (160) 71 (160)
- Polyester U U 43 (110)
- Vinyl Ester U U U U U 49 (120) 49 (120)
HDPE U U U U U 60 (140) U
PP 15 (60) 49 (120) U U U 82 (180) 15 (60)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470) 243 (470)
PVC Type 2 U U U U U 60 (140) U
PVDF 98 (210) 60 (140) U U U 121 (250) 121 (250)
OTHER MATERIALS
Butyl U U U U 65 (150)
EPDM U U U U U U U
EPT U U U U 82 (180) U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 216 (420) 204 (400)
FKM 176 (350) 198 (390) 87 (190) 93 (200) 204 (400) 93 (200)
Neoprene U U U U U U U
Nitrile U U U U 15 (60) U
N-Rubber U U U U U U
PFA 121 (250) 93 (200) 26 (80) 98 (210)
PVDC U U U U U 26 (80)
B-23
5 May 99
Transformer Oil DTE/30
1,1,1 Trichloroethane
Tetrachloroethylene
Thread Cutting Oil
Trichloroethylene
FLUID/MATERIAL
Transformer Oil
Toluene
METALS
Aluminum 98 (210) 98 (210) 26 (80) 65 (150) 149 (300)
Bronze 32 (90) 176 (350) 32 (90) 65 (150) 26 (80)
Carbon Steel 82 (180) 176 (350) 26 (80) 65 (150) 26 (80) 26 (80)
Copper 32 (90) 98 (210) 26 (80)
Hastelloy C 98 (210) 32 (90) 65 (150) 98 (210)
Inconel 98 (210) 98 (210)
Monel 98 (210) 32 (90) 65 (150) 187 (370)
Nickel 98 (210) 32 (90) 98 (210)
304 SS 65 (150) 98 (210) 32 (90) 32 (90) 98 (210)
316 SS 65 (150) 176 (350) 32 (90) 65 (150) 187 (370)
NON-METALS
ABS U U U U
CPVC U 38 (100) U 82 (180) 82 (180) U U
Resins - Epoxy U 65 (150) 109 (230) 60 (140)
- Furan 121 (250) 127 (260) 26 (80) 82 (180)
- Polyester 43 (110) U 104 (220) U
- Vinyl Ester 49 (120) 49 (120) 149 (300) U U
HDPE U U 60 (140) 60 (140) U U
PP U 49 (120) 15 (60) 43 (110) 65 (150) U 15 (60)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 149 (300) 243 (470) 243 (470)
PVC Type 2 U U U U
PVDF 121 (250) 93 (200) 98 (210) 49 (120) 127 (260)
OTHER MATERIALS
Butyl U U U
EPDM U U U U U U U
EPT U U U U U U
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 204 (400) 204 (400) 204 (400) 26 (80) 204 (400)
Neoprene U 54 (130) U U U
Nitrile U 15 (60) 65 (150) 104 (220) 60 (140) U U
N-Rubber U U U
PFA 93 (200) 98 (210) 93 (200) 93 (200)
PVDC 49 (120) 28 (80) 32 (90) 26 (80)
SBR Styrene U U U
B-24
5 May 99
Water, Demineralized
Water, Acid Mine
FLUID/MATERIAL
Water, Distilled
Water, Potable
Water, Salt
Turpentine
Water, Sea
METALS
Aluminum 87 (190) U 82 (180) U 98 (210) U 38 (100)
Bronze 176 (350) U 93 (200) 98 (210) 121 (250) 121 (250)
Carbon Steel 26 (80) U U U 26 (80) 32 (90)
Copper 26 (80) U 32 (90) 98 (210) 26 (80) 26 (80)
Hastelloy C 38 (100) 32 (90) 93 (200) 298 (570) 98 (210) 149 (300) 298 (570)
Inconel 26 (80) 32 (90) 60 (140) 15 (60) 26 (80) 26 (80)
Monel 43 (110) U 98 (210) 121 (250) 121 (250)
Nickel 26 (80) U 93 (200) 26 (80) 26 (80) 32 (90)
304 SS 93 (200) 49 (120) 227 (440) 121 (250) 98 (210) 26 (80) 26 (80)
316 SS 176 (340) 49 (120) 227 (440) 121 (250) 98 (210) 121 (250) 121 (250)
NON-METALS
ABS U 60 (140) 60 (140) 60 (140) 26 (80) 60 (140) 32 (90)
CPVC 60 (140) 82 (180) 82 (180) 82 (180) 98 (210) 82 (180) 82 (180)
Resins - Epoxy 65 (150) 149 (300) 121 (250) 98 (210) 98 (210) 149 (300)
- Furan 121 (250) 93 (200) 121 (250)
- Polyester 26 (80) 71 (160) 93 (200) 98 (210) 82 (180) 104 (220)
- Vinyl Ester 65 (150) 98 (210) 98 (210) 98 (210) 98 (210) 82 (180) 82 (180)
HDPE U 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PP 26 (80) 104 (220) 104 (220) 104 (220) 82 (180) 104 (220) 104 (220)
PTFE 243 (470) 243 (470) 243 (470) 243 (470) 204 (400) 243 (470) 243 (470)
PVC Type 2 U 60 (140) 60 (140) 60 (140) 60 (140) 60 (140) 60 (140)
PVDF 138 (280) 104 (220) 138 (280) 138 (280) 138 (280) 138 (280) 138 (280)
OTHER MATERIALS
Butyl U 60 (140) 87 (190)
EPDM U 93 (200) 121 (250) 149 (300) 121 (250) 121 (250) 121 (250)
EPT U 98 (210) 98 (210) 98 (210) 93 (200) 93 (200)
FEP 204 (400) 204 (400) 204 (400) 204 (400) 204 (400) 204 (400)
FKM 209 (410) 87 (290) 87 (190) 87 (190) 149 (300) 87 (190) 87 (190)
Neoprene U 98 (210) 98 (210) 93 (200) 82 (180) 98 (210) 98 (210)
Nitrile 104 (220) 98 (210) 98 (210) 98 (210) 82 (180) 98 (210) 98 (210)
N-Rubber U 65 (150) 65 (150) 65 (150)
PFA 93 (200) 93 (200) 93 (200) 93 (200) 93 (200) 93 (200)
PVDC 49 (120) 82 (180) 76 (170) 76 (170) 76 (170) 82 (180) 76 (170)
SBR Styrene U 93 (200) 98 (210) 93 (200) 93 (200) 93 (200)
B-25
5 May 99
FLUID/MATERIAL
Water, Sewage
Zinc Chloride
Xylene
METALS
Aluminum 93 (200) U
Bronze 32 (90) 121 (250) U
Carbon Steel 32 (90) 93 (200) U
Copper 32 (90) 93 (200) U
Ductile Iron, Pearlitic U
Hastelloy C 149 (300) 121 (250)
Inconel 93 (200) 26 (80)
Monel 39 (200) 93 (200)
Nickel 93 (200) 93 (200)
304 SS 32 (90) 93 (200) U
316 SS 32 (90) 93 (200) 93 (200)
NON-METALS
ABS 26 (80) U 60 (140)
CPVC 82 (180) U 82 (180)
Resins - Epoxy 60 (140) 121 (250)
- Furan 127 (260) 127 (260)
- Polyester 32 (90) 121 (250)
- Vinyl Ester 60 (140) 82 (180)
HDPE 60 (140) U 60 (140)
PP 104 (220) 15 (60) 93 (200)
PTFE 243 (470) 243 (470) 243 (470)
PVC Type 2 60 (140) U 60 (140)
PVDF 121 (250) 98 (210) 127 (260)
OTHER MATERIALS
Butyl U 87 (190)
EPDM 98 (210) U 149 (300)
EPT 60 (140) U 82 (160)
FEP 204 (400) 227 (440) 204 (400)
FKM 87 (190) 204 (400) 204 (400)
Borosilicate Glass 121 (250) 98 (210)
Neoprene 71 (160) U 71 (160)
Nitrile 87 (190) U 104 (220)
N-Rubber U 65 (150)
PFA 93 (200) 93 (200) 93 (200)
PVDC 76 (170) U 76 (170)
SBR Styrene U
B-26
EM 1110-1-4008
5 May 99
Appendix C metal cleaning using organic solvents and painting

Design Example operations. The retrofit is to include the renovation and
splitting of an existing, covered, concrete wetwell
The following paragraphs present an example design that (P1560). Half of the wetwell will now act as an influent
utilizes the material and information contained in wetwell (P1560) to a new treatment train and the other
Chapters 1 through 12, and Appendix B. The half will act as the clearwell (P1510) for the effluent from
calculations and assumptions are specific to the example the new treatment system. The new treatment system will
conditions presented, and may not necessarily represent include a low-profile air stripper to reduce solvent
conditions at an actual, specific site. concentrations followed by a ferrous-based precipitation
reactor and associated flocculation tank and clarifier.
Figure C-1 is the flow diagram of the proposed
C-1. Design Example
pretreatment system renovation, and Figure C-2 is the
A facility requires an upgrade and retrofit to their existing piping and instrumentation diagram. Figure C-3 is the
wastewater pretreatment system. The pretreatment general equipment arrangement with the anticipated
system is required to reduce the dissolved metal content piping layout.
of two process waste waters before introduction into a
biologically based central treatment plant. Due to The influent to the pretreatment system averages 3.79 x
process changes over the years and reduced effluent 10-3 m3/s with a maximum future flow of 5.36 x 10-3 m3/s
limits, the existing pretreatment facility no longer and a process temperatures of 16EC-minimum, 23.9EC-
removes enough metals to consistently meet effluent normal, and 46EC-maximum. The average pH is 5.4 due
requirements. to the presence of chromic and sulfuric acids, although
occasional upsets have produced pH as low as 3.6. The
The waste waters are produced from a plating process pollutant concentrations are summarized in Table C-1.
(Process A) and from the finishing stages of a metal
fabrication facility (Process B). The latter could include
Table C-1
Pollutant Concentrations
Parameter Maximum (mg/l) Average (mg/l)

Total Cyanide 0.368 0.078
Chromium 80.2 24.9
Nickel 74.9 15.3
Copper 6.29 0.71
Zinc 10.3 0.88
Lead 12.8 1.57
Silver 0.84 0.21
Cadmium 3.24 0.77
Xylene 210 53.2
Toluene 180 45.1
111-Trichloroethylene 500 48.3
Ethyl Ether 54.3 15.2
C-1
C-2
5 May 99
EM 1110-1-4008
Figure C-1. Design Example Process Flow Diagram

(Process Conditions Table continued on next page)
Table C-2
Process Conditions, Design Example Process
Flow Diagram, Continued
Normal Maximum Minimum
Point Line Flow Temp. Pressure Flow Temp. Pressure Flow Temp. Pressure
Designation (m3/s x 10-3) (EC) (kPa) (m3/s x 10-3) (EC) (kPa) (m3/s x 10-3) (EC) (kPa)
a XXX-INF-1500 3.79 23.9 tbd 5.36 46.0 tbd 3.79 16.0 tbd
b XXX-IAS-1600 3.79 23.9 tbd 5.36 46.0 tbd 3.79 16.0 tbd
c XXX-IAS-1620 3.79 23.9 tbd 5.36 46.0 tbd 3.79 16.0 tbd
d XXX-PRI-1630 3.79 23.9 gravity flow 5.36 46.0 gravity flow 3.79 16.0 gravity flow
e XXX-EFF-1640 3.79 23.9 gravity flow 5.36 46.0 gravity flow 3.79 16.0 gravity flow
f XXX-SLG-1650 2.30 23.9 250 2.75 46.0 250 2.30 16.0 250
g XXX-SLG-1651 0.36 23.9 250 2.75 46.0 250 0.36 16.0 250
h XXX-SLG-1660 1.94 23.9 250 2.75 46.0 250 1.94 16.0 250
I XXX-PYS-101 0.438 23.9 tbd 0.438 46.0 79.5 0.438 16.0 tbd
j XXX-PYS-102 0.00105 23.9 tbd 0.00131 46.0 79.5 0.00105 16.0 tbd
k XXX-FES-111 0.842 23.9 tbd 0.842 46.0 79.5 0.842 16.0 tbd
l XXX-FES-112 0.0105 23.9 tbd 0.0131 46.0 79.5 0.0105 16.0 tbd
Notes:
XXX - line size to be determined in calculations
tbd - to be determined
C-3
5 May 99
EM 1110-1-4008
C-4
5 May 99
EM 1110-1-4008
Figure C-2. Design Example Piping and Instrumentation Diagram

EM 1110-1-4008
5 May 99
Figure C-3. Piping Layout Plan
C-5
EM 1110-1-4008
5 May 99
C-2. Solution MATERIAL OF CONSTRUCTION
a. Line XXX-INF-1500 Referring to the fluid/material matrix in Appendix B, the

Influent from Wetwell P1560 to Air Stripper potential for mixed acids eliminates aluminum, bronze,
P1600 copper, carbon steel and stainless steel alloys; and the
solvent content in the wastewater eliminates ABS, PVC,
CPVC, HDPE and FRP. Similarly, examining the
potential use of lined piping, the solvents eliminate
rubber, PP and PVDC, However, PTFE and PVDF liners
are acceptable.
The design specifications shall be developed to allow a

liner of either PVDF , minimum thickness of 4.45 mm
(confirm with pipe sizing), or PTFE (to be provided with
weep vents) and a carbon steel shell of ASTM A 106,
Grade A. The shell is to be joined with chamfered
threaded flanges. The PVDF liner is selected for the
example calculations.
PIPE SIZING/PRESSURE DROP
Step 1. Select pipe size by dividing the volumetric

flowrate by the desired velocity (normal service, V = 2.1
m/s with the mid-range preferred for most applications).
Di2 Q
A ' B '
4 V
Sketch C-1 0.5

4 (5.36 x 10&3) m 3/s mm
Di ' 1000
B 2.1 m/s m
Flow is either through A-D or C-D, but not both
simultaneously ' 57 mm
Maximum Flowrate, Q = 5.36 x 10-3 m3/s
Elevation Change (H-I) = 2.44 m (= 23.9 kPa head) Step 2. From Table 1-1, the next largest nominal
diameter is 65 mm. The commercial availability of 65
Total run = 7.84 m for A-J mm lined pipe is checked (65 mm is not a commonly
= 7.33 m for C-J used pipe size). This size is not available except through
special order. The size choices are 50 mm or 80 mm.
Fittings (identical for either A-J or C-J)
1 swing check valve 50 mm pipe: From Table 9-8, a PVDF thickness of
1 gate valve (isolation) 4.37 mm is required to prevent
1 flow control valve permeation.
1 reducer
1 expansion
C-6
EM 1110-1-4008
5 May 99
Therefore, the 80 mm PVDF lined pipe is specified and

Di ' 50 mm & (4.37 mm)(2) ' 41.3 mm
Di = 71.1 mm, oD = 90 mm and the structural wall
Q Q thickness = 5 mm. The line designation is amended to:
V ' ' 80-INF-1500.
A B 2
D
4 i In addition, a pipe reduction is required to accommodate
5.36 x 10&3 m 3/s a magnetic flowmeter. From an instrument vendor
' ' 4.0 m/s nomograph over the process flow range, the magmeter
B
(0.0413 m)2 should have a 40 mm bore with minimum straight,
4 unobstructed runs of 3 x Di upstream and 2 xi D
downstream. From lined piping catalogs, lined piping
typically has a minimum section length. For 40 mm pipe,
The actual velocity, 4.0 m/s, > the one vendor has fixed flange spools available with a
acceptable range, 2.1 ± 0.9 m/s. minimum length of 819 mm. Use a 80 mm by 40 mm
Therefore, the 50 mm pipe size is concentric reducer/expansion at one end of each straight
rejected. pipe run; see Sketch C-2.
80 mm pipe: From Table 9-8, a PVDF thickness of The actual velocity through the reduced section is
4.45 mm is required to prevent required for pressure drop calculations. From Table 9-8,
permeation. a PVDF thickness of 4.07 mm is required to prevent
permeation.
Di ' 80 mm & (4.45 mm)(2) ' 71.1 mm Di ' 40 mm & (4.07 mm)(2) ' 31.9 mm
Q Q Q Q
V ' ' V ' '
A B 2 A B 2
D D
4 i 4 i
5.36 x 10&3 m 3/s 5.36 x 10&3 m 3/s

' ' 1.35 m/s ' ' 6.71 m/s
B B
(0.0711 m)2 (0.0319 m)2
4 4
The actual velocity, 1.35 m/s, is The 40 mm spools have a length of

within the acceptable range, 2.1 ± 0.9 819 mm which equals 25.7 x Di.
m/s. Therefore, the minimum unobstructed
run requirement for the meter is
satisfied.
Sketch C-2
C-7
EM 1110-1-4008
5 May 99
Notes:
Table C-3
A= identical 80 mm by 40 mm concentric reducers, $ =
Minor Losses for 80-INF-1500: Run A-J
0.5, N = 7.56E
B = identical 40 mm spools with flanged ends, 819 mm Minor Loss K
length
C = wafer style mag-meter, lay length is 70 mm. 1 gate valve (open) 0.2
Step 3. At 23.9EC, < = 8.94 x 10 -7 m2/s and the Darcy- 1 swing check valve 2.5
Weisbach equation is used to calculate the pressure drop
4 x 90E elbows 4(0.9)
through the piping.
1 tee-flow through 0.6
Ref. p. 3-8.
1 concentric reducer 0.08
f L V2 1 exit 1.0
hL ' % GK
Di 2 g
80 mm GK= 7.98
f L V2
% % GK f L V2
Di 2 g
40 mm
hL80 ' % GK
Di 2 g
(0.028)(7.84 &1.7 m) (1.35 m/s)2

80 mm pipe: ' % 7.98
0.0711 m 2 (9.81 m/s 2)
Ref. p. 3-8.
' 0.97 m
Di V (0.0711 m)(1.35 m/s)

Re ' ' From Sketch C-1, for run C-J the sum
< 8.94 x 10&7 m 2/s of the minor loss coefficients from
Table 3-3:
Table C-4
, ' 0.0015 mm from Table 3&1 Minor Losses for 80-INF-1500: Run C-J
Minor Loss K
0.0015 mm
,/Di ' ' 0.00002
71.1 mm 1 swing check valve 2.5
3 x 90E elbows 3(0.9)

Therefore, f = 0.028 from the Moody 1 tee-branch flow 1.6
Diagram (Figure 3-1).
1 concentric reducer 0.08
From Sketch C-1, for run A-J the sum
of the minor loss coefficients from 1 exit 1.0
Table 3-3:
GK= 8.08
C-8
EM 1110-1-4008
5 May 99
f L V2 f L V2
hL80 ' % GK hL40 ' % GK
Di 2 g Di 2 g
(0.028)(7.33 &1.7 m) (1.35 m/s)2 (0.026)(1.7 m) (6.71 m/s)2

' % 8.08 ' % (&0.19)
0.0711 m 2 (9.81 m/s 2) 0.0319 m 2 (9.81 m/s 2)
' 0.96 m ' 2.74 m
Therefore, use run A-J as worst case The total pressure drop through line 80-INF-1500: hL =
for the 80 mm pipe section; hL = 0.97 0.97 m. + 2.74 m = 3.71 m or 35.4 kPa. This does not
m. include the pressure drop resulting from the control
valve, FCV-1570.
40 mm pipe section:
Step 4. Size the control valve, FCV-1570, such that the
Ref. p. 3-8. pressure drop through FCV-1570 = 33% of the piping
system loss = 0.33 (36.4 kPa) = 12.0 kPa. The flow
Di V (0.0319 m)(6.71 m/s) measurement device is proportional to flow squared so
Re ' ' that an equal percentage for characteristic is desired.
< 8.94 x 10&7 m 2/s Assume a ball valve with V-port will be used so let Fd =
1.0, and Rm = 0.9 (from Table 10-9). From reference
' 2.4 x 105 & turbulent flow materials, s.g. = 1.0.
Ref. p. 10-13.
, ' 0.0015 mm from Table 3&1
0.0015 mm Q s.g.
,/Di ' ' 0.00005 Cv '
31.9 mm N1 )P
Therefore, f = 0.026 from the Moody (5.36 x 10&3 m 3/s)(3600 s/hr) 1.0
'
Diagram (Figure 3-1). 0.085 12.0 kPa
From Sketch C-1, for run FG the sum ' 65.5

of the minor loss coefficients from
Table 3-3: 1/4
N4 Fd Q Rm2 Cv2
Rev ' % 1 '
< Rm C V
1/2 1/2
N2 d 4
Table C-5
Minor Losses for 80-INF-1500: Run F-G
(76,000)(1.0)[(5.36 x 10&3)(3600)]
x
MinorLoss K (.894)(0.9)1/2(65.5)1/2
1 enlargement -0.19 (pressure gain)

1/4
(0.9)2(65.5)2
GK= -0.19 %1 ' 2.2 x 105
(0.00214)(80)4
C-9
EM 1110-1-4008
5 May 99
FR = 1.0 from Figure 10-4 (a viscosity correction is not 2

required due to the high Reynolds number). ) Pallow ' Rm (Pi & rc Pv)
Ref. p. 10-13. ' (0.86)2 [84.7 kPa & (0.96)(13.17 kPa)]
) Pallow ' 60.4 kPa > ) Pv ,

Cvc ' (Cv)(FR) ' (65.5)(1.0) ' 65.5
so the valve is acceptable.
From manufacturer's data (see Table C-6), a 80 mm, 60E

V-port ball valve at 80% travel in a 80 mm pipe has a Cv PRESSURE INTEGRITY
of 67.2 and a Rm of 0.86.
The design pressure is equal to the required pump head
Ref. p. 10-13. = 89.6 kPa. No potential pressure transients exist
because the valve fails in the last position. An external
corrosion allowance of 2 mm is to be designed. Pressure
s.g. integrity is acceptable if the minimum wall thicknesses
) Pactual '
2 for both the 80 mm and 40 mm pipe sections meet ASME
N1 Cv
31.3 code. For ASTM A 106, Grade A pipe, ASME
Q
B31.3 tables provide S = 110 MPa, E = 1.0, and y = 0.4.
1.0 Ref. p. 3-15.

' ' 11.4 kPa
2
(0.085)(67.2)
(5.36 x 10&3)(3600) P Do
tm ' t % A ' % A
2 (S E % P y)
Step 5. The required pump head is equal to the sum of
the elevation change, the piping pressure drop and the
valve pressure loss. 80 mm pipe:
Phead ' 23.9 kPa % 36.4 kPa % 11.4 kPa (0.0896 MPa)(90 mm)
tm '
2[(110 MPa)(1.0) % (0.0896 MPa)(0.4)]
' 71.7 kPa x 1.25 safety factor
% 2 mm ' 2.04 mm
' 89.6 kPa
The commercial wall thickness

Step 6. The control valve ) P is checked. The valve inlet tolerance for seamless rolled pipe is
pressure, Pi, is equal to the required pump head less the +0, -12½%.
piping losses from the pump to the valve (C-FCV on
Sketch 1; approximately 4.9 kPa).
2.04 mm
tNOM ' ' 2.3 mm
1.0 & 0.125
Pi ' 89.6 kPa & 4.9 kPa ' 84.7 kPa

Nominal 80 mm pipe has a thickness
of 5 mm; therefore, the 80 mm pipe
Ref. p. 10-17. section satisfies pressure intergrity.
C-10
EM 1110-1-4008
5 May 99
Table C-6
Flow Coefficient - Cv - Characterized Seat Control Valves
Percent of Rated Travel (Degree of Rotation)

Valve Line
Size Size 10 20 30 40 50 60 70 80 90 100
mm (in) mm (in) (9) (18) (27) (36) (45) (54) (63) (72) (81) (90)
12.7 (0.5), 6.35 15 (½) 0.02 0.03 0.07 0.12 0.16 0.20 0.24 0.28 0.32 0.36
(0.25), 0.79 (0.0313) 20 (3/4) 0.02 0.03 0.07 0.10 0.14 0.18 0.21 0.25 0.29 0.32
Wide Slot 25 (1) 0.02 0.03 0.06 0.10 0.13 0.16 0.18 0.21 0.27 0.30
12.7 (0.5), 6.35 15 (½) 0.02 0.07 0.20 0.33 0.46 0.60 0.73 0.86 0.99 1.10
(0.25), 1.59 (0.0625) 20 (3/4) 0.02 0.06 0.18 0.29 0.41 0.53 0.65 0.77 0.88 0.98
Wide Slot 25 (1) 0.02 0.06 0.17 0.27 0.38 0.50 0.61 0.71 0.82 0.91
12.7 (0.5), 15 (½) 0.02 0.10 0.20 0.34 0.55 0.83 1.11 1.59 2.08 2.50
6.35 (0.25) 20 (3/4) 0.02 0.09 0.18 0.30 0.49 0.74 0.99 1.41 1.85 2.22
30EV 25 (1) 0.02 0.08 0.17 0.28 0.46 0.69 0.92 1.32 1.73 2.07
12.7 (0.5), 15 (½) 0.02 0.12 0.33 0.90 0.84 1.35 1.95 3.10 4.37 5.92
6.35 (0.25) 20 (3/4) 0.02 0.10 0.29 0.44 0.75 1.20 1.74 2.76 3.90 5.27
60EV 25 (1) 0.02 0.10 0.27 0.41 0.70 1.12 1.62 2.57 3.63 4.91
25 (1) 25 (1) 0.02 0.21 0.56 0.96 1.58 2.39 3.43 4.62 6.15 7.26
30EV 40 (1.5) 0.02 0.16 0.44 0.75 1.23 1.86 2.68 3.60 4.80 5.66
50 (2) 0.02 0.15 0.40 0.69 1.14 1.72 2.47 3.33 4.43 5.23
25 (1) 25 (1) 0.02 0.30 0.78 1.24 2.27 3.59 5.28 8.29 11.6 15.5
60EV 40 (1.5) 0.02 0.23 0.61 0.97 1.77 2.80 4.12 6.47 9.05 12.1
50 (2) 0.02 0.22 0.56 0.89 1.63 2.58 3.80 5.97 8.35 11.2
50 (2) 50 (2) 0.02 0.55 1.72 3.41 5.65 8.26 12.1 16.6 22.2 26.5
30EV 80 (3) 0.02 0.45 1.41 2.80 4.63 6.77 9.92 13.6 18.2 21.7
100 (4) 0.02 0.41 1.27 2.52 4.18 6.11 8.95 12.3 16.4 19.6
50 (2) 50 (2) 0.02 0.70 2.64 4.90 9.32 15.5 22.2 32.1 47.2 61.6
60EV 80 (3) 0.02 0.57 2.16 4.02 7.64 12.7 18.2 26.3 38.7 50.5
100 (4) 0.02 0.52 1.95 3.63 6.90 11.5 16.4 23.8 34.9 45.6
80 (3) 80 (3) 0.02 0.75 2.68 6.00 10.2 16.9 24.5 33.9 44.8 54.2
30EV 100 (4) 0.02 0.54 1.93 4.32 7.34 12.2 17.6 24.4 32.3 39.0
150 (6) 0.02 0.41 1.47 3.30 5.61 9.30 13.5 18.6 24.6 29.8
80 (3) 80 (3) 0.02 0.95 4.25 10.1 18.6 29.4 46.3 67.2 94.4 124.6
60EV 100 (4) 0.02 0.68 3.06 7.27 13.4 21.2 33.3 48.4 68.0 89.7
150 (6) 0.02 0.52 2.34 5.56 10.2 16.2 25.5 37.0 51.9 68.5
100 (4) 100 (4) 0.02 0.80 3.59 8.50 16.1 26.8 40.2 56.6 72.5 89.8
30EV 150 (6) 0.02 0.52 2.33 5.53 10.5 17.4 26.1 36.8 47.1 58.4
200 (8) 0.02 0.44 1.97 4.68 8.86 14.7 22.1 31.1 39.9 49.4
100 (4) 0.02 0.90 5.69 15.4 28.8 48.6 73.4 107.0 150.7 200.0
100 (4) 150 (6) 0.02 0.59 3.70 10.0 18.7 31.6 47.7 69.6 98.0 130.0
60EV 200 (8) 0.02 0.50 3.13 8.47 15.8 26.7 40.4 58.9 82.9 110.0
RM 0.96 0.95 0.94 0.93 0.92 0.90 0.88 0.86 0.82 0.75
Note: Cv is defined as the flow of liquid in gallons per minute through a valve with a pressure drop of 1 psi across the valve.
Source: Table condensed from Worchester Controls “Series CPT Characterized Seat Control Valve”, PB-V-3, Supplement 1.
C-11
EM 1110-1-4008
5 May 99
40 mm pipe: 40 mm pipe:
(0.0896 MPa)(50 mm) B

tm ' W40 ' 67.1 N/m % 31.9 mm2 (9781 N/m 3) x
2[(110 MPa)(1.0) % (0.0896 MPa)(0.4)] 4
% 2 mm ' 2.02 mm (10&6m 2/mm 2) ' 74.9 N/m; uniformly distributed
The commercial wall thickness Step 3. Wind - From TI 809-01, the basic wind speed is
tolerance for seamless rolled pipe is 40.2 m/s. The plant is located in an area with exposure
+0, -12½%. C (open terrain with scattered obstructions having heights
less than 10 m) so a gust factor of 33% is added to the
basic wind speed to determine the design wind speed,
2.02 mm
tNOM ' ' 2.3 mm Vdw.
1.0 & 0.125
Vdw ' (40.2 m/s) (1.33) ' 53.5 m/s

Nominal 40 mm pipe has a thickness (or 192.6 km/hr, > minimum of 161 km/hr)
of 5 mm; therefore, the 40 mm pipe
section satisfies pressure intergrity.
80 mm pipe:
LOADS
Ref. p. 2-7.
Step 1. Pressure - See the pressure integrity calculations
Re80 ' CW2 VW Do
for the design pressure.
' 6.87 (53.5 m/s) (90 mm) ' 3.3 x 104
Step 2. Weight - The 80-INF-1500 dead weight is
strictly the piping. 80-INF-1500 will not be insulated
because it will be under continuous use. Because the
piping section will be continuously full, the weight of the Using the Re value in the ASCE 7
fluid will be determined as part of the dead weight. drag coefficient chart and assuming an
infinite circular cylinder (i.e., L:D >
5:1), CD = 1.21.
B 2
W ' WP % WL ' AP *P % D *
4 i L Ref. p. 2-7.
FW80 ' CW1 VW2 CD Do '

From a lined piping manufacturer, (AP)(*P) = 133 N/m
for 80 mm lined piping and 67.1 N/m for 40 mm lined (2.543x10 &6)(53.5 m/s)2(1.21)[90 mm%2(0)]
piping.
' 0.79 N/m
80 mm pipe:
B 40 mm pipe:
W80 ' 133 N/m % 71.1 mm2 (9781 N/m 3) x
4
Ref. p. 2-7.
(10&6m 2/mm 2) ' 172 N/m; uniformly distributed
C-12
EM 1110-1-4008
5 May 99
Step 5. Ice - No data is readily available; therefore,

Re40 ' CW2 VW Do
assume a maximum buildup of 12.5 mm.
' 6.87 (53.5 m/s) (50 mm) ' 1.8 x 104
80 mm pipe:
Ref. p. 2-8.
Using the Re value in the ASCE 7
drag coefficient chart and assuming an
infinite circular cylinder (i.e., L:D > WI80' B n3 SI tI (Do % tI) ' B (10&6m 2/mm 2) x
5:1), CD = 1.21.
(8820 N/m 3)(12.5 mm)(90 % 12.5 mm)
Ref. p. 2-7. ' 35.5 N/m
FW40 ' CW1 VW2 CD Do

40 mm pipe:
' (2.543x10 &6)(53.5 m/s)2(1.21)[50 mm % 2(0)]
Ref. p. 2-8.
' 0.44 N/m
WI40' B n3 SI tI (Do % tI) ' B (10&6m 2/mm 2) x

The design wind loads are uniformly distributed
horizontally (i.e., perpendicular to the weight load). (8820 N/m 3)(12.5 mm)(50 % 12.5 mm)
' 21.6 N/m
Step 4. Snow - From TI 809-01, the basic snow load is
239 kPa.
The design ice loads are uniformly distributed and
80 mm pipe: additive to the weight.
Ref. p. 2-8. Step 6. Seismic - From TM 5-809-10, the facility is

located in a seismic zone 0; therefore, the seismic loading
Ws80 ' ½ n Do SL
is not applicable.
' ½ (10&3 m/mm) [90 mm % 2(0)] (239 kPa)
Step 7. Thermal - Thermal loads will be examined under
' 10.8 N/m the stress analysis. The coefficient of thermal expansion
= 1.11 x 10-5 mm/mm-EC over the range 16 to 46 EC.
40 mm pipe: STRESS ANALYSIS
Ref. p. 2-8. Step 1. Internal Stresses - 80-INF-1500 meets the

pressure integrity requirements; therefore, the limits of
Ws40 ' ½ n Do SL
stress due to internal pressure are satisfied.
' ½ (10&3 m/mm) [50 mm % 2(0)] (239 kPa)
Step 2. External Stresses - For sustained loads, the sum
' 5.98 N/m of the longitudinal stresses must be less than the
allowable stress at the highest operating temperature:
The design snow loads are uniformly distributed and Ref. p. 3-17.
additive to the weight.
E S L # Sh;
C-13
EM 1110-1-4008
5 May 99
and for occasional loads, the sum of the longitudinal The span length is less than the MSS
stresses due to both sustained and occasional loads must SP-69 guidance for schedule 40
be less than 1.33 Sh: carbon steel filled with water (3.7 m),
so length is acceptable.
E SNL # 1.33 Sh;
40 mm pipe:
Ref. p. 3-25.
To determine the longitudinal stress due to uniformly
distributed loads, the support spans and spacing must first 4 4
B Do & Di
be determined. Note that because the liner does not add Z40 '
structural strength, the liner thickness is not included as 32 Do
part of Di for the purposes of calculating support spans.
B (50 mm)4 & (40 mm)4
'
80 mm pipe: 32 (50 mm)
' 7.25 x 103 mm 3

Ref. p. 3-25.
4 4
B Do & Di
Z80 ' It is assumed that snow and ice will
32 Do not occur concurrently and since the
ice loading is greater than the snow
B (90 mm)4 & (80 mm)4
' loading, the sustained loads are equal
32 (90 mm) to the weight of the piping system and
the ice.
' 2.69 x 104 mm 3
WN40 ' 74.9 N/m % 21.6 N/m

It is assumed that snow and ice will
' 96.5 N/m (10&3 m/mm) ' 9.65 x 10&2 N/mm
not occur concurrently and since the
loading, the sustained loads are equal
to the weight of the piping system and Ref. p. 3-25.
the ice.
0.5
Z S
l40 ' n m CN ' (10&3 m/mm) x
WN80 ' 172 N/m % 35.5 N/m W
0.5
' 208 N/m (10&3 m/mm) ' 0.208 N/mm 5 (7.25 x 103 mm 3)(10.3 MPa)
(76.8)
48 (9.65 x 10&2 N/mm)
Ref. p. 3-25. ' 2.49 m
0.5
Z S
l80 ' n m CN ' (10&3 m/mm) x
W The span length is less than the MSS
SP-69 guidance for schedule 40
0.5
5 (2.69 x 104 mm 3) (10.3 MPa) carbon steel filled with water (2.7 m),
(76.8) so length is acceptable.
48 (0.208 N/mm)
' 3.26 m Therefore, the check for longitudinal stresses from
sustained loads is as follows.
C-14
EM 1110-1-4008
5 May 99
80 mm pipe: 40 mm pipe:
Ref. p. 3-17. Ref. p. 3-17.

P Do W L2 W L2
G SL80' % 0.1 G SNL40 ' G SL40 % 0.1 ' 2.9 MPa %
4 t n Z n Z
'
(0.0896 MPa)(90 mm)
% (21.6 N/m)(1.7 m)2
0.1 ' 3.8 MPa
4 (5 mm) (10&3m/mm)(7.25 x 103mm 3)
(172 N/m)(3.26 m)2
0.1 ' 6.6 MPa 1.33 Sh ' 1.33 (110 MPa) ' 146 MPa
(10&3m/mm)(2.69 x 104mm 3)
For both pipes, G SNL # 1.33Sh ; therefore, the pipes are

40 mm pipe: acceptable for the anticipated occasional loads.
Ref. p. 3-17. Step 3. To ensure that piping systems have sufficient

flexibility to prevent these failures, ASME B31.3
requires that the displacement stress range does not
P Do W L2
G SL40' % 0.1 exceed the allowable displacement stress range. Due to
4 t n Z the length of the 40 mm pipe section, flexibility is not a
factor. Therefore, only the flexibility of the 80 mm pipe
(0.0896 MPa)(50 mm)
' % section will be checked. From ASME B31.3, Table
4 (5 mm) 302.3.5 and with the assumption that the total process
(74.9 N/m)(1.7 m)2 cycles over the process life will be less than 7000, f =
0.1 ' 2.9 MPa 1.0. From ASME B31.1, Table A-1, Sc = Sh = 110 MPa.
(10&3m/mm)(7.25 x 103mm 3)
Ref. p. 3-18.
From ASME B31.3, Table A-1, Sh = 110 MPa. For both

pipes, G SL # Sh ; therefore, the pipes are acceptable for SE # SA; and SA' f [1.25 (Sc % Sh) & SL]
sustained loads.
SA' 1.0[(1.25)(110 MPa%110 MPa)&7 MPa]
Assuming that snow and ice will not occur
simultaneously and ignoring the wind load (small and ' 268 MPa; therefore, SE # 268 MPa
horizontal to the snow/ice load), the ice load will be the
worst case and the check for occasional loads is as
follows.
The center of gravity is located to review the stability of
80 mm pipe: the system with respect to the fittings and equipment
loads.
Ref. p. 3-17.
W L2
G SNL80 ' G SL80 % 0.1 ' 6.6 MPa %
n Z
(35.5 N/m)(3.26 m)2

0.1 ' 8.0 MPa
&3
(10 m/mm)(2.69 x 104mm 3)
C-15
EM 1110-1-4008
5 May 99
Sketch C-3
C-16
EM 1110-1-4008
5 May 99
Referencing Sketch C-3: E - 116 N

x = support location (S1501 supports a check valve, F - 116 N
S1502 supports a check valve and a gate valve, and FG - 206 N
S1503 supports the control valve). G - 116 N
! = component load H - 420 N
u = center of gravity J - 39 N.
The loads and their locations are as follows: Table C-7 contains the results of the moment
A - 39 N calculations. The center of gravity of the piping section
S1501 - 293 N is behind S1503; therefore, 2 more supports are needed
BD - 293 N for stability. Locate S1504 and S1505 at points F and G
C - 39 N respectively. S1505 supports the vertical run and keeps
S1502 - 586 N the load off of the equipment flange.
S1503 - 458 N
Table C-7
Line 80-INF-1500 Moments
moment about axis y-y moment about axis z-z
N m N-m N m N-m
39 -0.75 -29.3 39 0.6 23.4
293 -0.15 -44.0 103 0.3 30.9
129 -0.375 -48.4 39 5.18 202
39 -1.2 -46.8 293 5.18 1520
586 -0.6 -352 129 5.18 668
206 -0.6 -124 293 4.8 1410
39 2.14 83.5 39 4.43 173
103 2.14 220 586 4.43 2600
420 2.14 899 206 4.43 913
116 1.91 222 891 2.59 2710
206 1.07 220 458 2.13 976
116 0.23 26.7
367 1.07 393
2660 1420 3080 10600
C-17
EM 1110-1-4008
5 May 99
n = 10-9 m3/mm3
E = 2.03 x 105 MPa (reference ASME B31.3, Table C-
1,420 N&m
' 0.53 m from y&y; 6)
2,660 N
B
10,600 N&m I ' [(Do)4 &(Di)4]
' 3.44 m from z&z. 64
3,080 N
B
' [(90 mm)4 &(80 mm)4]
64
The thermal expansion deflections are determined based
on: 1) the manufacturer of the air stripper, P1600, has ' 1.21 x 106 mm 4
indicated that a 1.6 mm upward movement of the flange
mating at point J will occur when operating conditions
are established; 2) the flanges at points A and C mate 2) for sections HI and IJ:
with pumps and are not subject to movements; 3) support
S1505, located at point G supports piping section H-I-J
3 E I y
and will prevent vertical deflection at point H; and 4) M '
given that the piping system will be installed at 21EC, the L2
thermal expansion of the piping will be:
) L ' (1.11 x 10&5 mm/mm&EC) x where:
(1,000 mm/m)(46EC & 21EC) ' 0.278 mm/m. LHI = length of HI
LIJ = length of IJ
Sketch C-4 depicts the approximate deflections that will The displacement stress is now calculated from the
occur. These deflections are: deflections.
C AB will deflect out at point B,(0.75 m) (0.278 mm/m) Ref. p. 3-18.

= 0.21 mm
C CD will deflect out at point D,(1.2 m) (0.278 mm/m) = SE ' (Sb2 % 4St2) 0.5
0.33 mm
C BE will deflect out at point E,(5.18 m) (0.278 mm/m)
= 1.4 mm Ref. p. 3-18.
C EH will deflect out at each end,[(0.5)(2.14 m)] (0.278 0.5
mm/m) = 0.30 mm (ii Mi)2 % (io Mo)2
Sb ' ; and
C HI will deflect up at point I,(2.44 m) (0.278 mm/m) = Z n
0.68 mm
C IJ will deflect out at point I,(0.6 m) (0.278 mm/m) = Mt
St '
0.17 mm 2 Z n
From beam calculations,

where:
1) for sections BE and EH: Mo = 0
ii = io = 1.0
3 E I y Z = 2.69 x 104 mm3 (see page C-17 for calculation)
M ' (n) n = 10-3 m/mm
a (l % a)
Table C-8 summarizes the results of the calculations for

where: each piping segment.
aBE = the length from S1503 to point E
aEH = the length from S1504 to point E
C-18
EM 1110-1-4008
5 May 99
Sketch C-4
Table C-8
Line 80-INF-1500 Displacement Stresses
Segment Mi Sb Mt St SE
(N-m) (MPa) (N-m) (MPa) (MPa)
BE 20.0 0.74 0 0 0.74
EH 2395 89.0 42.0 0.78 89.0
HI 21.0 0.78 0 0 0.78
IJ 1883 70.0 272 5.1 70.7
C-19
EM 1110-1-4008
5 May 99
In all of the piping segments, SE < SA (268 MPa); b. Line XXX-IAS-1600

therefore, line 80-INF-1500 satisfies required flexibility Air Stripper P1600 Effluent to Duplex Pumps
constraints. P1605/1610
SUPPORTS
The support spacing and spans were calculated as part of

the stress analyses. The types of supports are selected
based upon process temperature (see Table 3-8) and
application ( see Figure 3-2 and MSS SP-69).
Table C-9
Line 80-INF-1500 Supports
Support Type (MSS SP-58)
S1501 36
S1502 36 Sketch C-5
S1503 36
Flow is either through A-B or A-C, but not both
S1504 36 simultaneously
S1505 37 Maximum Flowrate, Q = 5.36 x 10-3 m3/s
MATERIAL OF CONSTRUCTION
FLANGE CONNECTIONS
Line XXX-IAS-1600 handles essentially the same fluid
From Table 9-2, the flange connections for the as 80-INF-1500 except that most of the volatile organic
thermoplastic lined 80-INF-1500 shall have the following solvents have been stripped out. Therefore, for
bolting requirements: constructability purposes, make the materials of
construction identical to 80-INF-1500:
80 mm flanges: 4 x 16 mm bolts per flange
ASTM A 193 bolts and nuts, lightly The piping shall be ASTM A 106, Grade A, carbon steel
oiled lined with PVDF that has a minimum thickness of 4.45
169 N-m bolt torque for PVDF lined mm. Because the line is on the influent side of the
piping. pumps, the piping shall be full vacuum rated pursuant to
ASTM F 423. Joints and fittings shall be chamfered
40 mm flanges: 4 x 14 mm bolts per flange threaded flanges.
ASTM A 193 bolts and nuts, lightly
oiled The sizing is identical to 80-INF-1500 because the
81 N-m bolt torque for PVDF lined maximum flowrate is identical. Therefore, the line
piping. designation is amended to 80-IAS-1600.
The pressure integrity, loads, stress analysis and

flexibility are similar to 80-INF-1500; therefore, line 80-
IAS-1600 is acceptable.
C-20
EM 1110-1-4008
5 May 99
SUPPORTS Fittings (identical for either A-H or C-H)

1 swing check valve
Locate supports as shown (spans are less than the 2 gate valves (isolation)
maximum spans calculated for 80-INF-1500); support
type as follows. MATERIAL OF CONSTRUCTION
Line XXX-IAS-1620 handles essentially the same fluid

Table C-10
as 80-IAS-1600. Therefore, for constructability
Line 80-IAS-1600 Supports
purposes, make the materials of construction identical to
Support Type (MSS SP-58) 80-INF-1500 and 80-IAS-1600:
S1041 36 The piping shall be ASTM A 106, Grade A, carbon steel

lined with PVDF that has a minimum thickness of 4.45
S1042 36 mm. Because the line is on the influent side of the
pumps, the piping shall be full vacuum rated pursuant to
ASTM F 423. Joints and fittings shall be chamfered
FLANGE CONNECTIONS threaded flanges.
From Table 9-2, the flange connections for the SIZING/PRESSURE DROP
thermoplastic lined 80-IAS-1600 shall have the following
bolting requirements: The sizing is identical to 80-INF-1500 and 80-IAS-1600
because the maximum flowrate is identical: lined Di =
80 mm flanges: 4 x 16 mm bolts per flange 71.1 mm, V = 1.35 m/s, and Do = 90 mm (5 mm wall
ASTM A 193 bolts and nuts, lightly thickness). Therefore, the line designation is amended to
oiled 80-IAS-1620.
169 N-m bolt torque for PVDF lined
piping. At 23.9EC, < = 8.94 x 10 -7 m2/s and the Darcy-Weisbach
equation is used to calculate the pressure drop through
the piping. The worst case pressure drop will be run A-H
c. Line XXX-IAS-1620 due to the additional pipe length.
Duplex Pumps P1605/1610 Discharge to
Reactor P1620 Ref. p. 3-8.
f L V2
Referencing Sketch C-6: hL ' % GK
Di 2 g
Flow is either through A-D or C-D, but not both
simultaneously
Ref. p. 3-8.
Maximum Flowrate, Q = 5.36 x 10-3 m3/s
Di V (0.0711 m)(1.35 m/s)
Elevation Change = -0.61 m (= -5.98 kPa) Re ' '
< 8.94 x 10&7 m 2/s
Total run ' 1.1 x 105 & turbulent flow
= 8.55 m for A-H
= 7.19 m for C-H
, ' 0.0015 mm from Table 3&1
Back-pressure from liquid level in Reactor
P1620 = 3.65 m (35.8 kPa). 0.0015 mm
,/Di ' ' 0.00002
71.1 mm
C-21
EM 1110-1-4008
5 May 99
Sketch C-6
Therefore, f = 0.028 from the Moody Diagram (Figure 3-

1). From Sketch C-6, for run A-H the sum of the minor f L V2
hL ' % GK
loss coefficients from Table 3-3: Di 2 g
(0.028)(8.55 m) (1.35 m/s)2

Table C-11 ' % 8.1
Minor Losses for 80-IAS-1620: Run A-H
0.0711 m 2 (9.81 m/s 2)
Minor Loss K ' 1.1 m (10.8 kPa)
2 gate valves (open) 2(0.2)

The required pump head is equal to the sum of the
1 swing check valve 2.5 elevation change, the piping pressure drop and the back
pressure from the reactor P1620.
4 x 90E elbows 4(0.9)
1 tee-flow through 0.6 Phead ' &5.98 kPa % 10.8 kPa % 35.8 kPa
1 exit 1.0 ' 40.6 kPa x 1.25 safety factor ' 50.8 kPa
GK= 8.1
C-22
EM 1110-1-4008
5 May 99
PRESSURE INTEGRITY Step 6. Seismic - From TM 5-809-10, the facility is

The design pressure is equal to the required pump head is not applicable.
= 50.8 kPa. No potential pressure transients exist. The
design external corrosion allowance is 2 mm. Pressure Step 7. Thermal - Thermal loads will be examined under
integrity is acceptable if the minimum wall thickness the stress analysis. The coefficient of thermal expansion
meets ASME 31.3 code. According to ASME B31.3, for = 1.11 x 10-5 mm/mm-EC over the range 16 to 46 EC.
ASTM A 106, Grade A pipe, S = 110 MPa, E = 1.0, and
y = 0.4. STRESS ANALYSIS
Ref. p. 3-15. Step 1. Internal Stresses - Line 80-IAS-1620 meets the

P Do stress due to internal pressure are satisfied.
tm ' t % A ' % A
2 (S E % P y) Step 2. External Stresses - For sustained loads, the sum
of the longitudinal stresses must be less than the
(0.0508 MPa)(90 mm) allowable stress at the highest operating temperature:
tm '
2[(110 MPa)(1.0) % (0.0508 MPa)(0.4)]
Ref. p. 3-17.
% 2 mm' 2.02 mm
E S L # Sh;
tolerance for seamless rolled pipe is
+0, -12½%. and for occasional loads, the sum of the longitudinal
stresses due to both sustained and occasional loads must
2.02 mm be less than 1.33 Sh:
tNOM ' ' 2.3 mm
1.0 & 0.125
E SNL # 1.33 Sh;
Nominal 80 mm pipe has a thickness of 5 mm; therefore,
the 80 mm piping satisfies pressure integrity.
LOADS distributed loads, the support spans and spacing must first
be determined: maximum support span length, L, = 3.26
Step 1. Pressure - See the pressure integrity calculations m (see 80-INF-1500 stress analysis). Therefore, the
for the design pressure. check for longitudinal stresses from sustained loads is as
follows.
Step 2. Weight - Load per unit length will be identical to
80-INF-1500; W = 172 N/m (including liquid content). Ref. p. 3-25.
Step 3. Wind - Load per unit length will be identical to 4 4

B Do & Di
80-INF-1500; Fw = 0.79 N/m (horizontal). Z80 '
32 Do
Step 4. Snow - Load per unit length will be identical to
B (90 mm)4 & (80 mm)4
80-INF-1500; Ws = 10.8 N/m. '
32 (90 mm)
Step 5. Ice - Load per unit length will be identical to 80-
' 2.69 x 104 mm 3
INF-1500; WI = 35.5 N/m.
C-23
EM 1110-1-4008
5 May 99
Ref. p. 3-17. Referencing Sketch C-7:

x = support location
P Do ! = component load
W L2 (0.0508MPa)(90mm)
G SL' % 0.1 '
4 t n Z 4 (5mm) The loads and their locations are as follows:
(172 N/m)(3.26 m) 2 B - 807 N
% 0.1 ' 7.02 MPa D - 807 N
(10&3m/mm)(2.69 x 104mm 3) E - 116 N
F - 116 N
G - 116 N
From ASME B31.3, Table A-1, Sh = 110 MPa. For 80- S1052 - 293 N
IAS-1620, G SL # Sh; therefore, the pipe is acceptable for H - 39 N.
sustained loads.
Based upon the symmetry of the piping segment, the
Assuming that snow and ice will not occur system is stable with the supports located where shown.
simultaneously and ignoring the wind load (small and Support S1046 supports the two vertical runs AB and
horizontal to the snow/ice load), the ice load will be the CD, and the check valves and gate valve at the pump
worst case and the check for occasional loads is as outlets, and S1052 supports the vertical run FG and
follows. keeps that load off of the equipment flange. Supports
S1047 and S1051 are needed for stability and to keep the
Ref. p. 3-17. maximum span length within the constraint.
W L2
G SNL ' G S L % 0.1 ' 7.02 MPa % The thermal expansion deflections are determined based
n Z on: 1) the assumption that no substantial movement of the
flange mating at point H will occur when operating
(35.5 N/m)(3.26 m)2
0.1 ' 8.42 MPa conditions are established; 2) the flanges at points A and
(10&3m/mm)(2.69 x 104mm 3) C mate with pumps and are not subject to movements; 3)
support S1052, will prevent vertical deflection at point
G; and 4) given that the piping system will be installed at
For 80-IAS-1620, G SNL # 1.33Sh; therefore, the pipe is 21EC, the thermal expansion of the piping will be:
acceptable for the anticipated occasional loads.
) L ' (1.11 x 10&5 mm/mm&EC)
Step 3. To ensure that piping systems have sufficient
x (1,000 mm/m)(46EC & 21EC) ' 0.278 mm/m.
flexibility to prevent failures resulting from displacement
strains, ASME B31.3 requires that the displacement
stress range does not exceed the allowable displacement Sketch C-8 depicts the approximate deflections that will
stress range. From ASME B31.3, Table 302.3.5 and occur. These deflections are:
with the assumption that the total process cycles over the
process life will be less than 7000, f = 1.0. From ASME C AB will deflect up at point B, (0.61 m) (0.278 mm/m)
B31.1, Table A-1, Sc = Sh = 110 MPa. = 0.17 mm
C CD will deflect up at point D, (0.61 m) (0.278 mm/m)
Ref. p. 3-18. = 0.17 mm
C BE will deflect out at each end, [(0.5)(2.38 m) (0.278
mm/m) = 0.33 mm
SE # SA; and SA ' f [1.25 (Sc % Sh) & SL]
C EF will deflect out at each end, [(0.5)(3.74 m)] (0.278
SA' 1.0[(1.25)(110 MPa%110 MPa)&7 MPa] mm/m) = 0.52 mm
C FG will deflect up at point F, (1.21 m) (0.278 mm/m)
' 268 MPa; therefore, SE # 268 MPa = 0.34 mm
C GH will deflect out at point G, (0.61 m) (0.278 mm/m)
= 0.17 mm
C-24
EM 1110-1-4008
5 May 99
Sketch C-7
Sketch C-8
C-25
EM 1110-1-4008
5 May 99
From beam calculations, LCD = length of CD

LFG = length of FG
1) for sections BE (Mo caused) and EF (M
o and i M
caused): The displacement stress is now calculated from the
deflections.
3 E I y
M ' (n) Ref. p. 3-18:
a (l % a)
SE ' (Sb2 % 4St2) 0.5

where:
aBE = 0.37 m 0.5
aEH = 1.7 m (ii Mi)2 % (io Mo)2 Mt
Sb ' and St '
n = 10-9 m3/mm3 Z n 2 Z n
E = 2.03 x 105 MPa (reference ASME B31.3, Table C-
6)
I = 1.21 x 106 mm4 (see 80-INF-1500 calculations)
where:
2) for sections AB, CD and FG: ii = io = 1.0
Z = 2.69 x 104 mm3 (see page C-16 for calculation)
3 E I y n = 10-3 m/mm
M '
L2
Table C-12 summarizes the results of the calculations for
each piping segment.
where:
LAB = length of AB In all of the piping segments, SE < SA (268 MPa);
therefore, line 80-IAS-1620 satisfies required flexibility
constraints.
Table C-12
Line 80-IAS-1620 Displacement Stresses
Segment Mi Mo Sb Mt St SE
(N-m) (N-m) (MPa) (N-m) (MPa) (MPa)
AB 654 0 24.3 135 2.51 24.8
CD 277 0 10.3 736 13.7 29.3
BE 67.6 31 2.76 35.8 0.67 3.07
EF 176 181 9.39 0 0 9.39
FG 262 85.6 10.2 0 0 10.2
GH 0 0 0 523 9.72 19.4
C-26
EM 1110-1-4008
5 May 99
SUPPORTS
f. Line 80-SLG-1650
The support spacing and spans were calculated as part of Sludge Discharge from Clarifier P1640 to
the stress analyses. The types of supports are selected Sludge Pumps
based upon process temperature (see Table 3-8) and
application ( see Figure 3-2 and MSS SP-69). The line is supplied by the process system manufacturer.
Provide performance requirements for the piping in the
equipment specifications.
Table C-13
Line 80-IAS-1620 Supports
g. Line 25-SLG-1651
Support Type (MSS SP-58) Sludge Recycle from Sludge Pumps to Reactor
P1620
S1046 38
The line is supplied by the process system manufacturer.
S1047 38 Provide performance requirements for the piping in the
S1051 38 equipment specifications.
S1052 37
h. Line XXX-SLG-1660
Waste Sludge Discharge from Sludge Pumps to
FLANGE CONNECTIONS Sludge Pit P1450
From Table 9-2, the flange connections for the Referencing Sketch C-9:
thermoplastic lined 80-IAS-1620 shall have the following
bolting requirements: Maximum Flowrate, Q = 2.75 x 10-3 m3/s
80 mm flanges: 4 x 16 mm bolts per flange Total run = 22.0 m

ASTM A 193 bolts and nuts, lightly = 20.3 m below grade
oiled
169 N-m bolt torque for PVDF lined Buried depth = 0.9 m, t.o.p.
piping.
Fittings below grade:
3 x 90E elbows
d. Line 100-PRI-1630 2 x 45E bends
Process Flow from Reactor P1620 to Floc Tank 1 x swing check valve
P1630
Sludge Pump Head = 250 kPa.
The line is gravity flow. Design in accordance with TI
814-10 Wastewater Collection; Gravity Sewers and MATERIAL OF CONSTRUCTION
Appurtenances.
To match other materials at the facility, the piping shall
be zinc coated ASTM A 53, Type E, Grade A, carbon
steel. Joints shall be buttwelded with chill rings. Below
e. Line 100-EFF-1640
grade fittings shall be forged ASTM A 105M steel of the
Clarifier P1640 Effluent to Clearwell P1510
same thickness of the piping and shall conform to ASME
B 16.9, buttweld type. The exception to this shall be the
The line is gravity flow. Design in accordance with TI
connection to the swing check valve; this end connection
814-10 Wastewater Collection; Gravity Sewers and
shall be a welding neck flange and located in a valve box.
Appurtenances.
C-27
EM 1110-1-4008
5 May 99
Sketch C-9
The flange connections to the existing sludge line should

0.5
be field inspected to ensure a compatible connection. 4 (2.75 x 10&3) m 3/s mm
The above ground connection to the waste sludge pump, Di ' 1000
B 2.1 m/s m
isolation ball valve and clean-out shall also be flanged.
All flanges shall be constructed of ASTM A 105M
material. ' 40.8 mm

Step 2. From Table 1-1, the size choices are 40 mm or
Step 1. Select pipe size by dividing the volumetric 50 mm. Select 40 mm as the actual pipe size and
flowrate by the desired velocity (normal service, V = 2.1 calculate actual velocity in the pipe.
m/s).
Q Q 2.75x10 &3m 3/s
2 V ' ' ' ' 2.19 m/s
Di Q A B B
A ' B ' D 2
(0.040 m) 2
4 V 4 i 4
C-28
EM 1110-1-4008
5 May 99
The actual velocity, 2.19 m/s, is within the normal

f L V2
acceptable range, 2.1 ± 0.9 m/s. Therefore, a 40 mm hL ' % GK
pipe is acceptable, the line designation is amended to 40- Di 2 g
SLG-1660, and Di = 40 mm, Do = 50 mm, and V = 2.19
m/s. (0.024)(22.0 m) (2.19 m/s)2
' % 12.5
0.040 m 2 (9.81 m/s 2)
At 23.9EC, < = 8.94 x 10 -7 m2/s and the Darcy-Weisbach
equation is used to calculate the pressure drop through ' 6.28 m (61.7 kPa)
the piping.
Ref. p. 3-8. The maximum waste sludge pump head is 250 kPa which
is adequate to overcome the piping pressure drop.
f L V2
hL ' % GK
Di 2 g PRESSURE INTEGRITY
The design pressure is equal to the maximum pump head

Ref. p. 3-8. = 250 kPa. No potential pressure transients exist. An
external corrosion allowance of 2 mm and an internal
Di V (0.040 m)(2.19 m/s) erosion allowance of 2 mm are to be designed. Pressure
Re ' ' integrity is acceptable if the minimum wall thickness
< 8.94 x 10&7 m 2/s meets ASME 31.3 code. For ASTM A 53, Grade A pipe,
ASME B31.3 tables provide S = 110 MPa, E = 1.0, and
y = 0.4.
, ' 0.061 mm from Table 3&1
Ref. p. 3-15.
0.061 mm
,/Di ' ' 0.0015
40 mm
P Do
tm ' t % A ' % A
2 (S E % P y)
1). From Sketch C-9, the sum of the minor loss (0.250 MPa)(50 mm)
coefficients from Table 3-3: tm '
2[(110 MPa)(1.0) % (0.250 MPa)(0.4)]
Table C-14 % 4 mm ' 4.06 mm

Minor Losses for 40-SLG-1660
Minor Loss K
1 ball valve (open) 4.5 tolerance for seamless rolled pipe is
+0, -12½%.
1 tee-branch flow 1.8
4.06 mm
3 x 90E elbows 3(0.9) tNOM ' ' 4.64 mm
1.0 & 0.125
2 x 45E bends 2(0.5)
1 swing check valve 2.5 Nominal 40 mm pipe has a thickness of 5 mm; therefore,
the 40 mm piping satisfies pressure integrity.
1 exit 1.0
GK= 12.5
C-29
EM 1110-1-4008
5 May 99
LOADS For occasional loads, the sum of the longitudinal stresses

due to both sustained and occasional loads must be less
Based on the previous calculations for this site, the above than 1.33 Sh:
ground piping segment will be acceptable for the loads
applied. The below grade piping will be subject to
internal and external pressure loads. E SNL # 1.33 Sh
Step 1. Internal Pressure - See the pressure integrity

calculations for the design pressure. With below grade placement, the piping is continuously
supported and sustained loads are a result of longitudinal
Step 2. External Pressure/Loads - The external pressure and earth pressure. Therefore, the check for
pressure/loads will result from the earth load and perhaps longitudinal stresses from sustained loads is as follows.
a wheel load, a sustained load and an occasional load
respectively. Ref. p. 3-17.
Earth Load: P Do (275 kPa)(50 mm)

G SL ' % FE '
4 t 4 (5 mm)
Ref. p. 2-7.
% 17.0 kPa ' 705 kPa
TH (1,922 kg/m 3)(0.9 m)
FE' ' ' 17.0 kPa
a kg/m 2
102 From ASME B31.3, Table A-1, Sh = 110 MPa. For 40-
kPa
SLG-1660, G SL # Sh; therefore, the pipe is acceptable for
sustained loads.
Wheel Load:
The only additional occasional load is a wheel load.
Ref. pp. 2-9 - 2-10. Therefore, the check for occasional loads is as follows.
C R P F (0.098 /m)(7,257 kg)(1.5) Ref. p. 3-17.

FW ' '
b Do kg/m
0.031 (50 mm) G SNL ' G S L % FW ' 705 kPa % 688 kPa
kPa
' 688 kPa ' 1.39 MPa
STRESS ANALYSIS For 40-SLG-1660, G SNL # 1.33Sh; therefore, the pipe is

acceptable for the anticipated occasional loads.
Step 1. Internal Stresses - Line 40-SLG-1660 meets the
pressure integrity requirements; therefore, the limits of FLANGE CONNECTIONS
The flange connections will be carbon steel welding neck
Step 2. External Stresses - For sustained loads, the sum flanges, raised face, and 1.03 MPa rated (class 150)
of the longitudinal stresses must be less than the pursuant to ASME B16.5.
allowable stress at the highest operating temperature:
Operating bolt load:
Ref. p. 3-17. Ref. pp. 3-21 - 3-22.

Wm1 ' 0.785 G 2 P % (2 b)(3.14 G m P)
E S L # Sh
C-30
EM 1110-1-4008
5 May 99
from ASME B16.5, Table E1, for a As > m1A ; therefore, the selected
flange on a 40 mm pipe, G = 48.7 mm bolting is acceptable.
and b = 12.2 mm;
from Table 3-5, m = 0.5 for an CATHODIC PROTECTION
elastomeric gasket; (See TM 5-811-7 Electrical Design, Cathodic Protection
for Guidance)
Wm1 ' (0.785)(48.7 mm)2(0.250 MPa)
40-SLG-1660 is a zinc coated steel pipe installed below
% (2)(12.2 mm)(3.14)(48.7 mm)(0.5)(0.250 MPa)
grade; therefore, cathodic protection is required. Due to
' 932 N the small size of the structure, galvanic protection is
selected. Existing data and the design bases are reviewed
Wm1 to obtain the following design data:
Am1 ' average soil resistivity (p) = 4,500 S-cm,
Sb
90 % coating (zinc) efficiency is anticipated,
20 year life is desired,
21.5 ma/m2 is required, and
from ASME B31.3, Table A-2, for packaged type magnesium anodes are to be
alloy steel ASTM A 193, B7M, Sb = specified.
137 MPa.
Step 1. The total area of the underground piping is
932 N calculated.
Am1 ' ' 6.80 mm 2
137 MPa
A ' B Do L ' B (0.050 m)(20.3 m)
Initial load during assembly: ' 3.19 m 2
Ref. p. 3-21.
and the total piping area to be protected is determined.
Wm2 ' 3.14 b G y
AT ' A (0.10) ' (3.19 m 2) (0.10) ' 0.319 m 2
from Table 3-5, y = 0; therefore, Wm2
= 0.
Step 2. The maximum protective current, I, is:
Thus the design is controlled by the operating condition
and the bolting is selected to match the required bolt
cross-sectional area: I ' (21.5 ma/m 2) AT
Ref. p. 3-23. ' (21.5 ma/m 2)(0.319 m 2)' 68.6 ma

2
0.9743
As ' 0.7854 D &
N Step 3. The weight of the anode based on a 20 year life
is calculated (see TM 5-811-7, eqn. C-1).
Y S I
select 14 mm bolts with a coarse W '
thread (pitch = 1/N = 2) E
2 (20 years)(4.0 kg/A&yr)(0.0069 A)
As ' 0.7854 (14) &
0.9743
' 114 mm 2 ' ' 1.10 kg
1/2 0.50
C-31
EM 1110-1-4008
5 May 99
Step 4. A standard, package anode will be used so this T = thrust generated, N

type of anode is reviewed to determine how many anodes Do = outer diameter of pipe, mm
are required to satisfy the current. The weight of a P = design pressure, MPa
standard packaged magnesium anode is 1.4 kg (see TM Ê = angle of bend, degree
5-811-7, Table C-4). The current output to ground is
calculated for the anode (see TM 5-811-7, eqn. C-2). For the 90Ebends:
2
C f y 50 mm 90
i ' T90 ' 2 B (0.250 MPa) sin
P 2 2
' 694 N
where:
C = 120,000 for a well coated structure (see TM 5-
811-7) For the 45Ebends:
f = 0.53 (see TM 5-811-7, Table C-4)
y = 1.0 (see TM 5-811-7, Table C-5) 50 mm 2
45
P = average soil resistivity = 4,500 S-cm T45 ' 2 B (0.250 MPa) sin
2 2
C f y (120,000) (0.53) (1.0) ' 376 N
i ' ' ' 14.1 ma
P 4,500 S&cm
The area of the thrust block is calculated by (see TI 814-

Step 5. The number of anodes required is determined 03 equation C-2):
(see TM 5-811-7, eqn. C-3).
T
I 6.85 ma ATB ' f
' ' 0.49 a s
i 14.1 ma
The 1.4 kg anode satisfies the current output where:

requirements. Smaller packages anodes are not readily ATB = area of thrust block (mm2)
available. T = thrust generated, N
a = safe soil bearing value, MPa; assume 20.5 MPa
THRUST BLOCKS fs = safety factor, typically 1.5
(see TI 814-03, Water Distribution, for guidance)
For the 90Ebends:
Thrust blocks are required at the 90E and 45E bends.
Concrete thrust blocks will be used so the area of the 694 N
A90TB ' 1.5 ' 51 mm 2
thrust block will be determined. Because the pipes are 20.5 MPa
already cathodically protected, additional protection or
insulation between the concrete and the pipe is not
required. The thrust at each bend is calculated first (see For the 45Ebends:
TI 814-03, eqn. C-1).
376 N
A90TB ' 1.5 ' 28 mm 2
2 20.5 MPa
Do Ê
T ' 2 B P sin
2 2
where:
C-32
EM 1110-1-4008
5 May 99
i. Line XXX-PYS-101 mm diameter, schedule 80 PVC with electrical heat

Chemical Feed from Bulk Polymer to Polymer tracing and insulation to maintain 20EC (maximum
Day Tank temperature differential will be 45EC).
Referencing Sketch C-10: PIPE SIZING/PRESSURE DROP
Polymer demand = 0.3785 m3/day; Step 1. Using the same size nominal pipe size of the
therefore, assuming a 15 minute fill existing pipe results in an actual Di of 24.3 mm.
the maximum flow rate, Therefore, the liquid velocity is:
Q = 2.628 x 10-2 m3/min = 4.38 x 10-4
m3/s Q Q 4.38 x 10&4m 3/s
V ' ' '
A B 2 B
Existing run = 50.0 m Di (0.0243 m)2
4 4
New run = 25.0 m
' 0.94 m/s
Maximum elevation change = 3.0 m
Existing polymer pump head = 8.1 m (79.5 The actual velocity, 0.94 m/s, is somewhat
kPa) slower than the acceptable range, 2.1 ± 0.9 m/s,
but the pressure drop will be checked using this
Fittings: velocity due to the limited pump head. The line
6 x 90E elbows designation is amended to 25-PYS-101.
1 branch Tee
3 isolation ball valves Step 2. At 23.9EC, < = 8.94 x 10 -7 m2/s and the Darcy-
Weisbach equation is used to calculate the pressure drop
MATERIAL OF CONSTRUCTION through the piping.
The existing polymer line is 25 mm diameter, schedule Ref. p. 3-8.

80 PVC. The polymer makeup is proprietary but is
f L V2
approximately 99% water. From a site inspection there hL ' % GK
is no evidence of existing pipe erosion or breakdown. Di 2 g
Therefore, the extension or new pipe run will also use 25
Sketch C-10
C-33
EM 1110-1-4008
5 May 99
Ref. p. 3-8. 7.15 m and the actual pump head available is 8.1 m. The
pipe should not be sized smaller (even though the flow is
below the desired range) unless the pump is to be
Di V (0.0243 m)(0.94 m/s) replaced.
Re ' '
< 8.94 x 10&7 m 2/s
PRESSURE INTEGRITY
4
= 79.5 kPa. A pressure transients exists due to potential
, ' 0.0015 mm from Table 3&1
water hammer conditions from the solenoid valve at the
tank inlet. Therefore, the transient will be minimized by
0.0015 mm having the valve be a “slow-opening” valve.
,/Di ' ' 0.00006
24.3 mm
Ref. p. 3-6.
Therefore, f = 0.024 from the Moody Diagram (Figure 3- 0.5

1). From Sketch C-10, the sum of the minor loss Es
Vw '
coefficients from Table 3-3: n1 D
0.5
2,180 MPa
' ' 1,478 m/s
&6
Table C-15 (10 MPa/Pa)(998.2 kg/m 3)
Minor Losses for 25-PYS-101
Minor Loss K
and
3 x ball valves (open) 3(4.5)
2 L 2 (75 m)
1 tee-flow through 0.6 tc ' ' ' 0.10 s
Vw 1,478 m/s
6 x 90E elbows 6(0.5)
1 exit 1.0
A gradual valve closure, tv, = 20 xc t = 2 s is to be
GK= 18.1 provided. Therefore, the pressure rise is determined.
Ref. p. 3-6.
f L V2
hL ' % GK 2 D L V n1
Di 2 g PiN ' '
tv
(0.024)(75.0 m) (0.94 m/s)2
' % 18.1 2 (998.2 kg/m 3)(75 m)(0.94 m/s)(10&3kPa/Pa)
0.0243 m 2 (9.81 m/s 2)
2 s
' 4.15 m
' 70.4 kPa
The total pump head required is the sum of the piping

losses, hL , and the temporary elevation of 3 m over the Because the pressure transient is significant (>10% of the
walkway. Therefore, the total pump head required is operating pressure), it must be included as part of the
design pressure.
C-34
EM 1110-1-4008
5 May 99
P ' 79.5 kPa % 70.4 kPa ' 150 kPa

W ' (4.12 x 10&4m 2)(13,517 N/m 3)
% B (314 N/m 3)(9.525 mm) x

From ASME B31.3, the minimum wall thickness, tm, for
(32 mm % 9.525 mm)(10&6m 2/mm 2)
thermoplastic pipe is:
B
% (24.3 mm)2(9,795 N/m 3)(10&6m 2/mm 2)
P Do 4
tm '
(2 S % P) ' 10.5 N/m; uniformly distributed
S = hydrostatic design stress = 13.8 Step 3. Wind - From TI 809-01, the basic wind speed is
MPa (reference ASME B31.3, Table 40.2 m/s. The plant is located in an area with exposure
B-1) C (open terrain with scattered obstructions having heights
less than 10 m) so a gust factor of 33% is added to the
basic wind speed to determine the design wind speed,
(0.150 MPa)(24.3 mm) Vdw.
t m' ' 0.131 mm
[2 (13.8 MPa)%(0.150 MPa)]
Vdw ' (40.2 m/s) (1.33) ' 53.5 m/s
(or 192.6 km/hr, > minimum of 161 km/hr)

Nominal 25 mm, schedule 80 pipe
has a thickness of 4.5 mm; therefore,
the 25 mm pipe section satisfies Ref. p. 2-7.
pressure integrity.
Re ' CW2 VW Do
LOADS ' (6.87)(53.5 m/s)[32 mm % 2 (9.525 mm)]
Step 1. Pressure - See the pressure integrity calculations ' 1.9 x 104
Step 2. Weight - The 25-PYS-101 dead weight is the Using the Re value in the ASCE 7
piping and the insulation. Because the piping section will drag coefficient chart and assuming an
be continuously full, the weight of the fluid will be infinite circular cylinder (i.e., L:D >
determined as part of the dead weight. 5:1), CD = 1.21.
The insulation for the piping was selected pursuant to Ref. p. 2-7.
CEGS 15250 to be flexible cellular (elastomeric) foam,
9.525 mm thick and with a specific weight of FW ' CW1 VW2 CD Do
approximately 314 N/m3.
' (2.543 x 10&6)(53.5 m/s)2(1.21) x
W ' WP %Wi % WL [32 mm % 2 (9.525 mm)] ' 0.45 N/m
B
' AP *PVC % B *I Ti (Do % Ti ) % D2 *
4 i L
The design wind loads are uniformly distributed
horizontally (i.e., perpendicular to the weight load).
C-35
EM 1110-1-4008
5 May 99
Step 4. Snow - From TI 809-01, the basic snow load is From ASME B31.3, Table A-1, Sh = 13.8 MPa.
239 kPa.
Ref. p. 2-8. 1.33Sh ' 1.33 (13.8 MPa) ' 18.4 MPa
Ws ' ½ n Do SL
' ½ (10&3 m/mm)[32 mm % 2 (9.525 mm)] x distributed loads such as weight, the support spans and
(239 kPa) ' 6.1 N/m spacing must first be determined. Referring to Figure C-
3, Piping Layout Plan, all three chemical feed lines will
be run parallel and will be supported on a pipe rack. As
The design snow loads are uniformly distributed and the smallest diameter pipe of the three chemical feed
additive to the weight. lines, 25-PYS-101 will control the support spacing.
From manufacturer’s data (see Table 5-4), the maximum
Step 5. Ice - No data is readily available; therefore, support spacing, L, for 25 mm PVC pipe is 1.7 m; see
assume a maximum buildup of 12.5 mm. Figure C-4, Piping Layout Plan with Support Locations.
Ref. p. 2-8. Ref. p. 3-17.

WI ' B n3 SI tI (Do % tI) W L2
G SL ' 0.1
n Z
' B (10&6 m 2/mm 2)(8,820 N/m 3)(12.5 mm) x
[32 mm%2 (9.525 mm)%12.5 mm] ' 22.0 N/m
Ref. p. 3-25.
The design ice loads are uniformly distributed and 4 4

B Do & Di
additive to the weight. Z '
32 Do
Step 6. Seismic - From TM 5-809-10, the facility is
B (32 mm)4 & (24.3 mm)4
located in a seismic zone 0; therefore, the seismic loading ' ' 2,147 mm 3
is not applicable. 32 (32 mm)
Step 7. Thermal - Thermal loads will be examined under

the stress analysis. The coefficient of thermal expansion It is assumed that snow and ice will
= (54 x 10-6 mm/mm-EC) (45EC) = 2.43 x 10-3 mm/mm. not occur concurrently and since the
STRESS ANALYSIS loading, the sustained loads are equal
to the weight of the piping system and
Step 1. Internal Stresses - 25-PYS-101 meets the the ice.
stress due to internal pressure are satisfied. Ref. p. 3-17.
[(10.5 N/m) % (22.0 N/m)](1.7 m)2
Step 2. External Stresses - In accordance with ASME G SL ' (0.1)
B31.3, for thermoplastic piping the sum of the external (10&3 m/mm)(2,147 mm 3)
stresses resulting from loads must be less than 1.33 Sh:
' 4.4 MPa
Ref. p. 3-17.
E SL # 1.33 Sh For 25-PYS-101, G SL # 1.33Sh; therefore, the system is

acceptable for the design stress loading.
C-36
EM 1110-1-4008
5 May 99
Figure C-4. Piping Layout Plan with Support Locations
C-37
EM 1110-1-4008
5 May 99
Step 3. Stresses are imposed upon the piping system due

to thermal expansion and contraction. To ensure that 1 m
LABCD ' x
thermoplastic piping systems have sufficient flexibility to 1,000 mm
prevent these failures, a minimum offset is required 0.5
mm
between a bend and a restrained anchor. For 25-PYS- 3(2,895MPa)(32mm)[(2.43x10 &3 )(3,000mm)]
mm
101, there are a series of Z-shaped arrangements: A-B-C-
13.8MPa
D, C-D-E-F, and E-F-G-H; see Sketch C-10.
' 0.38 m, minimum.
Since ½ (B-C) = ½ (3 m) > LABCD, the

flexibility of the piping segment is
acceptable. The restraints (anchors)
should be located at a minimum 1/4 L
= 1/4 (0.38 m) = 0.10 m from the
bends. That is, a pipe guide should be
located at support no. S1006 and
another within the existing pipe trench
- field check rack location.
For pipe section C-D-E-F with a length of approximately

10.7 m:
1 m
LCDEF ' x
1,000 mm
Sketch C-11
0.5
mm
3(2,895MPa)(32mm)[(2.43x10 &3 )(10,700mm)]
mm
13.8MPa
Referencing Sketch C-11, for Z-shapes:
' 0.72 m, minimum.
0.5
1 m 3 E Do Q
L '
1,000 mm S Since ½ (D-E) = ½ (10.7 m) > LCDEF,
the flexibility of the piping segment is
acceptable. The anchors should be
where: located at a minimum 1/4 L = 1/4
L = offset pipe length, m (0.72 m) = 0.36 m from the bends.
E = modulus of elasticity = 2,895 MPa That is, a pipe guide should be located
S = allowable stress = 13.8 MPa at support no. S1026 and a vertical
Do = outer pipe diameter = 32 mm guide 0.36 m from bottom of pipe
Q = thermal expansion coefficient = 2.43 x 10-3 mm/mm (BOP) on support no. S1038.
For pipe section A-B-C-D with a length of approximately For pipe section E-F-G-H with a length of approximately
3 m: 1.5 m:
C-38
EM 1110-1-4008
5 May 99
Ensure that the process engineer, or the engineer that is

1 m specifying the day tanks, designs the polymer day tank
LEFGH ' x
1,000 mm with the proper discharge port - 15 mm taper threaded
0.5 nozzle, female.
mm
3(2,895MPa)(32mm)[(2.43x10 &3 )(1,500mm)]
mm
13.8MPa
k. Line XXX-FES-111
' 0.27 m, minimum. Chemical Feed from Bulk Ferrous Sulfate to
Ferrous Sulfate Day Tank
Since ½ (F-G) = ½ (3 m) > LEFGH, the flexibility of the Referencing Sketch C-12:
piping segment is acceptable. The anchors should be
located at a minimum 1/4 L = 1/4 (0.27 m) = 0.07 m Ferrous sulfate demand = 0.757 m3/day;
from the bends. That is, relocate the vertical pipe guide therefore, assuming a 15 minute fill the
established on S1038 at 0.36 m BOP down to ½ the maximum flow rate, Q = 5.05 x 10-2 m3/min =
vertical run, ½ (2 m) = 1 m BOP. Also locate the support 8.42 x 10-4 m3/s
for the solenoid valve at 0.07 m from the bend at G.
Existing run = 30.0 m
New run = 50.0 m
j. Line 15-PYS-102
Chemical Feed from Polymer Day Tank to Maximum elevation change = -0.5 m (the
Polymer Controlled Volume Pump elevation difference between E and A is 0.5 m
down)
The controlled volume pump has a 15 mm female taper
threaded connection. The piping from the pump to the Existing ferrous sulfate pump head = 3.05 m
process injection point is supplied by the process unit (29.9 kPa)
manufacturer and is 15 mm SAE 100R7 hose. Therefore,
15-PYS-102 is selected to be identical to the process Fittings:
hose: 15 mm SAE 100R7 hose ( thermoplastic tube, 8 x 90E elbows
synthetic-fiber reinforcement, thermoplastic cover) with 1 x Tee, branch flow
15 mm male taper threaded end connections, built-in 1 x Tee, flow-through
fittings. Minimum hose length is 3 m. 4 x isolation ball valves
Sketch C-12
C-39
EM 1110-1-4008
5 May 99
MATERIAL OF CONSTRUCTION
Di V (0.040 m)(0.67 m/s)
The existing ferrous sulfate line is 40 mm diameter, Re ' '
< 1.05 x 10&6 m 2/s
schedule 80 PVC. The ferrous sulfate is 20% solution
with a specific gravity, s.g. = 1.18. Ferrous sulfate is
compatible with PVC and from a site inspection there is
no evidence of existing pipe erosion or breakdown.
Therefore, the extension or new pipe run will also use 40 , ' 0.0015 mm from Table 3&1
mm diameter, schedule 80 PVC with electrical heat
tracing and insulation to maintain 20EC (maximum 0.0015 mm
temperature differential will be 45EC).
,/Di ' ' 0.00004
40 mm

Step 1. Using the same size nominal pipe size of the 1). From Sketch C-12, the sum of the minor loss
existing pipe results in an actual Di of 40 mm. Therefore, coefficients from Table 3-3:
the liquid velocity is:
Table C-16
Q Q Minor Losses for 40-FES-111
V ' '
A B 2
D
4 i Minor Loss K
8.42 x 10&4 m 3/s 4 x ball valves (open) 4(4.5)

' ' 0.67 m/s
B
(0.040 m)2 1 tee-branch flow 1.8
4
1 tee-flow through 0.6
8 x 90E elbows 8(0.5)

The actual velocity, 0.67 m/s, is
somewhat slower than the acceptable 1 exit 1.0
range, 2.1 ± 0.9 m/s, but the pressure
drop will be checked using this GK= 25.4
velocity due to the limited pump head.
The line designation is amended to
40-FES-111. f L V2
hL ' % GK
Di 2 g
Step 2. At 23.9EC, < = 1.05 x 10 -6 m2/s and the Darcy-
Weisbach equation is used to calculate the pressure drop (0.024)(80.0 m) (0.67 m/s)2
' % 25.4
through the piping. 0.040 m 2 (9.81 m/s 2)
Ref. p. 3-8. ' 1.68 m
f L V2
hL ' % GK
Di 2 g The total pump head required is the sum of the piping
losses, hL , and the elevation gain of - 0.5 m. Therefore,
the total pump head required is 1.98 m + (-0.5 m) = 1.48
Ref. p. 3-8. m and the actual pump head available is 3.05 m. The
pipe should not be sized smaller (even though the flow is
below the desired range) unless the pump is to be
replaced.
C-40
EM 1110-1-4008
5 May 99
PRESSURE INTEGRITY From ASME B31.3, the minimum wall thickness, tm, for
thermoplastic pipe is:
= 29.9 kPa. A pressure transients exists due to potential P Do
water hammer conditions from the solenoid valve at the tm '
tank inlet. Therefore, the transient will be minimized by (2 S % P)
having the valve be a “slow-opening” valve.
Ref. p. 3-6. S = hydrostatic design stress = 13.8

MPa (reference ASME B31.3, Table
0.5
Es B-1)
Vw'
n1 D
0.5 (0.093 MPa)(40 mm)
2,180 MPa tm '
' ' 1,360 m/s [2 (13.8 MPa) % (0.093 MPa)]
&6
(10 MPa/Pa)(1,178 kg/m 3)
' 0.134 mm
and
Nominal 40 mm, schedule 80 pipe
has a thickness of 5.1 mm; therefore,
2 L 2 (80 m)
tc ' ' ' 0.12 s the 40 mm pipe section satisfies
Vw 1,360 m/s pressure integrity.
LOADS
A gradual valve closure, tv, of 2 s is to be provided.
Therefore, the pressure rise is determined. Step 1. Pressure - See the pressure integrity calculations
Ref. p. 3-6.
Step 2. Weight - The 40-FES-111 dead weight is the
2 D L V n1 piping and the insulation. Because the piping section will
PiN ' ' be continuously full, the weight of the fluid will be
tv
determined as part of the dead weight.
2 (1,178 kg/m 3)(80 m)(0.67 m/s)(10&3kPa/Pa)
The insulation for the piping was selected pursuant to GS
2 s 15250 to be flexible cellular (elastomeric) foam, 9.525
' 63.1 kPa mm thick and with a specific weight of approximately
314 N/m3.
Because the pressure transient is significant (>10% of the

W ' WP %Wi % WL
operating pressure), it must be included as part of the
design pressure. B
' AP *PVC % B *I Ti (Do % Ti ) % D2 *
4 i L
P ' 29.9 kPa % 63.1 kPa ' 93 kPa
C-41
EM 1110-1-4008
5 May 99
Step 4. Snow - From TI 809-01, the basic snow load is

&4 2 3 239 kPa.
W ' (6.89 x 10 m ) (13,517 N/m )
% B (314 N/m 3)(9.525 mm) x Ref. p. 2-8.
(50 mm % 9.525 mm)(10&6m 2/mm 2)

Ws ' ½ n Do SL '
B
% (40 mm)2(11,560 N/m 3)(10&6 m 2/mm 2) ½ (10&3m/mm)[50 mm%2(9.525 mm)](239 kPa)
4
' 24.4 N/m; uniformly distributed ' 8.25 N/m
Step 3. Wind - From TI 809-01, the basic wind speed is The design snow loads are uniformly distributed and
40.2 m/s. The plant is located in an area with exposure additive to the weight.
C (open terrain with scattered obstructions having heights
less than 10 m) so a gust factor of 33% is added to the Step 5. Ice - No data is readily available; therefore,
basic wind speed to determine the design wind speed, assume a maximum buildup of 12.5 mm.
Vdw.
Ref. p. 2-8.
Vdw ' (40.2 m/s) (1.33) ' 53.5 m/s
WI ' B n3 SI tI (Do % tI)
(or 192.6 km/hr, > minimum of 161 km/hr)
' B (10&6m 2/mm 2)(8,820 N/m 3)(12.5 mm) x
Ref. p. 2-7. [50 mm%2(9.525 mm)%12.5 mm] ' 28.2 N/m
Re ' CW2 VW Do
The design ice loads are uniformly distributed and
' (6.87)(53.5 m/s)[50 mm % 2 (9.525 mm)] additive to the weight.
' 2.54 x 104 Step 6. Seismic - From TM 5-809-10, the facility is

is not applicable.
Using the Re value in the ASCE 7
drag coefficient chart and assuming an Step 7. Thermal - Thermal loads will be examined under
infinite circular cylinder (i.e., L:D > the stress analysis. The coefficient of thermal expansion
5:1), CD = 1.21. = (54 x 10-6 mm/mm-EC) (45EC) = 2.43 x 10-3 mm/mm.
Ref. p. 2-7. STRESS ANALYSIS
Step 1. Internal Stresses - 40-FES-111 meets the

FW ' CW1 VW2 CD Do pressure integrity requirements; therefore, the limits of
' (2.543 x 10&6)(53.5 m/s)2(1.21) x
Step 2. External Stresses - In accordance with ASME
[50 mm % 2 (9.525 mm)] ' 0.61 N/m B31.3, for thermoplastic piping the sum of the external
stresses resulting from loads must be less than 1.33 Sh:
The design wind loads are uniformly distributed Ref. p. 3-17.

horizontally (i.e., perpendicular to the weight load).
C-42
EM 1110-1-4008
5 May 99
[27.4 N/m % 28.2 N/m](1.7 m)2

E SL # 1.33 Sh G SL' (0.1)
(10&3 m/mm)(7,245 mm 3)
' 2.26 MPa
From ASME B31.3, Table A-1, Sh = 13.8 MPa.
For 40-FES-111, G SL # 1.33Sh; therefore, the system is

1.33Sh ' 1.33 (13.8 MPa) ' 18.4 MPa acceptable for the design stress loading.
Step 3. Stresses are imposed upon the piping system due

To determine the longitudinal stress due to uniformly to thermal expansion and contraction. To ensure that
distributed loads such as weight, the support spans and thermoplastic piping systems have sufficient flexibility to
spacing must first be determined. Referring to Figure C- prevent these failures, a minimum offset is required
3, Piping Layout Plan, all three chemical feed lines will between a bend and a restrained anchor. For 40-FES-
be run parallel and will be supported on a pipe rack. As 111, there are a series of Z-shaped arrangements: A-B-C-
the smallest diameter pipe of the three chemical feed D, C-D-E-F, E-F-G-H, and G-H-I-J; see Sketch C-12.
lines, 40-FES-111 will control the support spacing.
From manufacturer’s data (see Table 5-4), the maximum
support spacing, L, for 40 mm PVC pipe is 1.7 m; see
Figure C-4, Piping Layout Plan with Support Locations.
Ref. p. 3-17.
W L2
G SL ' 0.1
n Z
Ref. p. 3-25.
4 4
B Do & Di
Z '
32 Do
Sketch C-13
B (50 mm)4 & (40 mm)4
' ' 7,245 mm 3
32 (50 mm)
Referencing Sketch C-13, for Z-shapes:
0.5
It is assumed that snow and ice will 1 m 3 E Do Q
not occur concurrently and since the L '
1,000 mm S
loading, the sustained loads are equal
to the weight of the piping system and where:
the ice. L = offset pipe length, m
E = modulus of elasticity = 2,895 MPa
Ref. p. 3-17. S = allowable stress = 13.8 MPa
Do = outer pipe diameter = 32 mm
Q = thermal expansion coefficient = 2.43 x 10-3 mm/mm
C-43
EM 1110-1-4008
5 May 99
1 m
LEFGH ' x
For pipe section A-B-C-D with a length of approximately 1,000 mm
3 m: 0.5
mm
3(2,895MPa)(50mm)[(2.43x10 &3 )(7,500mm)]
mm
1 m 13.8MPa
LABCD ' x
1,000 mm ' 0.75 m, minimum.
0.5
mm
3(2,895MPa)(50mm)[(2.43x10 &3 )(3,500mm)]
mm
Since ½ (F-G) = ½ (7.5 m) > LEFGH,
13.8MPa
the flexibility of the piping segment is
' 0.52 m, minimum. acceptable. The anchors should be
located at a minimum 1/4 L = 1/4
(0.75 m) = 0.19 m from the bends.
Since ½ (B-C) = ½ (3.5 m) > LABCD, That is, a pipe guide should be located
the flexibility of the piping segment is at support no. 1016 and a vertical
acceptable. The restraints (anchors) pipe guide established at 0.2 m from
should be located at a minimum 1/4 L BOP on support no. S1036.
= 1/4 (0.52 m) = 0.13 m from the
bends. For pipe section G-H-I-J with a length of approximately
1.5 m:
For pipe section C-D-E-F with a length of approximately
3 m: 1 m
LGHIJ ' x
1,000 mm
1 m
LCDEF ' x mm 0.5
1,000 mm 3(2,895MPa)(50mm)[(2.43x10 &3 )(1,500mm)]
mm
0.5
mm 13.8MPa
3(2,895MPa)(50mm)[(2.43x10 &3 )(3,000mm)]
mm
' 0.24 m, minimum.
13.8MPa
' 0.34 m, minimum.
Since ½ (H-I) = ½ (1.5 m) > LGHIJ, the
flexibility of the piping segment is
Since ½ (D-E) = ½ (3 m) > LCDEF, the acceptable. The anchors should be
flexibility of the piping segment is located at a minimum 1/4 L = 1/4
acceptable. The anchors should be (0.24 m) = 0.06 m from the bends.
located at a minimum 1/4 L = 1/4 That is, relocate the vertical pipe
(0.34 m) = 0.08 m from the bends. guide established on S1036 at 0.20 m
That is, a pipe guide should be located BOP down to ½ the vertical run, ½ (2
at support no. S1006 and another m) = 1 m BOP. Also locate the
within the existing pipe trench. support for the solenoid valve at 0.06
m from the bend at I.
For pipe section E-F-G-H with a length of approximately
7.5 m:
C-44
EM 1110-1-4008
5 May 99
l. Line 20-FES-112
Chemical Feed from Ferrous Sulfate Day Tank
to Ferrous Sulfate Controlled Volume Pump
The controlled volume pump has a 20 mm female taper

threaded connection. The piping from the pump to the
process injection point is supplied by the process unit
manufacturer and is 20 mm SAE 100R7 hose. Therefore,
20-FES-112 is selected to be identical to the process
hose: 20 mm SAE 100R7 hose (thermoplastic tube,
synthetic-fiber reinforcement, thermoplastic cover) with
20 mm male taper threaded end connections, built-in
fittings. Minimum hose length is 2 m.
Ensure that the process engineer, or the engineer that is

specifying the day tanks, designs the ferrous sulfate day
tank with the proper discharge port - 20 mm taper
threaded nozzle, female.
C-45
EM 1110-1-4008
5 May 99
Appendix D American Water Works Association, 2:8-9; 3:19; 4:17;

Index 11:1, 7
Numerals before and after colons designate chapters and Anchors

pages respectively (for example, 4:6 designates page 4- for fiberglass pipe, 7:4
6). Italicized numerals indicate that the subject is
illustrated in a figure. ANSI
see American National Standards Institute
Abrasion, 7:1; 9:1-2
control, 2:6; 4:8-9 API
see American Petroleum Institute
Abrasiveness, 3:8
ASCE 7, 2:8
ABS
see Acrylonitrile butadiene styrene pipe ASME Boiler and Pressure Vessel Code
Absorption, 9:1-2 ASME B31, Code for Pressure Piping, 11: 5-6
B31.1, Power Piping, 3:4-5
Acrylonitrile butadiene styrene pipe, 5:1, 3, 9-10 B31.3, Chemical plant and petroleum refinery piping,
2:8-9; 3:2-3, 15, 17-19; 5:2; 11:6-7
AASHTO, 2:9; 5:5
ASME Standards for
Air relief valves, 11:1, 3, 4, 5 cast iron pipe flanges and flanged fittings, 4:14
factory-made wrought steel butt welding fittings, 4:14
Air vents, 2:11; 8:7 pipe flanges and flanged fittings, 4:14
welded and seamless wrought steel pipe, 4:14
Allowable stress, 2:6; 3:5, 15-17; 4:14, 16
ASTM
Allowable pressure, maximum, 2:7; 3:2, 4-6; 4:9 see American Society for Testing and Materials
Allowance, corrosion-erosion, 3:4-5, 15-16 Atmospheric vacuum breaker, 11:1, 3
Aluminum, 3:2; 4:10, 12, 20-21 Austenitic stainless steel, 4:18

alloys, 4:20-21
AWWA
see American Water Works Association
Ambient temperature, 3:17, 28
Backflow prevention, 10:1; 11:7-8
American National Standards Institute, 2:5; 3:17, 19;
11:1
Ball Valve, 10:8, 11
V-port, 10:11
American Petroleum Institute, 2:5; 4:10
Bedding factors, 5:5, 7, 8
American Society of Mechanical Engineers, 2:5; 3:17,19;
4:14
Bending, 3:16
American Society for Quality Control, 2:5
Bill of materials, 3:21
American Society for Testing and Materials, 2:5; 3:1; 5:2
Bleed-off of air, 11:1, 3-5
D-1
EM 1110-1-4008
5 May 99
Bolting, 3:19-21, 23; 9:2-3 Coatings, protective,

Torque, 3:23; 9:4-5 for piping, 12:4
for supports, 3:30
Bolting Materials, 3:21
Codes, 2:5-6
Brass pipe, 4:21 organizations, 2:5
Brazed joints, 4:10 Coefficient of expansion, 2:9
Brinell Hardness, 3:1 Component standards, 2:6
Brittle transition temperature, 3:1, 29 Compression molding, 7:1
Butterfly valve, 2:15; 10:8, 12, 16-17, 21-22 Computer-aided drafting design (CADD), 2:10
Cable leak detection systems, 8:8 Computer programs

CADD, 2:10
CADD heat tracing, 11:12
see Computer-aided drafting design pipeline design and analyses, 2:1, 10
pipe networks, 3:4
Calculations, 2:1 stress analysis, 3:17
valve selection, 10:20
Carbon steel pipe, 4:17-18; 8:3; 9:1-3
specifications, 4:17 Concentration cell, 4:1
Category D fluid service, 3:31; 11:6 Construction Engineering Research Laboratories,

USACE (CERL), 4:1-2
Category M fluid service, 11:6
sensitive leak test, 3:31 Copper and copper alloy pipe, 4:21
support spacing for, 4:10,13
Cathodic protection, 1:1; 4:1, 3-4, 6; 9:1; 12:1-2, 3, 4
design, 12:2 Corrosion, 2:6; 4:1-9
impressed current system, 12:3 allowance, 3:4-5, 15-16
galvanic protection, 12:3 coatings, 4:1; 12:4
isolation joints, 4:3; 12:2,4 concentrated cell, 4:1, 3-4, 5
dealloying, 4:1, 8
Caulked joints, 4:10 erosion corrosion, 4:1, 8-9
external, 7:1; 9:1; 12:1
Cavitation, 4:8-9 galvanic, 4:1-3
general, 4:1-2
Charpy impact test, 3:1 intergranular, 4:1, 6
internal, 4:4, 6, 8-9; 7:1; 9:1; 12:1
Check valve, 2:15; 10:9-10, 21 microbially induced, 4:9
pitting, 4:1, 4, 6
Chemical resistance; 7:5 protection, 4:1, 4, 6; 12:1-4
stress-corrosion cracking, 4:1, 7; 5:1; 8:1; 9:1-2
Chlorinated polyvinyl chloride pipe (CPVC), 5:1, 3, theory of, 4:1
4, 10
support spacing for, 5:7 Corrosion expert, qualifications, 4:1; 12:1-2
D-2
EM 1110-1-4008
5 May 99
Corrosion resistance, 3:1, 26; 4:2, 17-18; 5:1-2; 6:2; 7:1; Dimensional standards, 7:1
B:1
Dissimilar materials, interconnection of, 2:6; 4:2-3; 9:2
Cost, 3:1, 8; 7:1; 10:13
preliminary for system design, 2:2 Dissolved gases, 3:3
Couplings, 2:15; 9:2; 11:1 Double check valve backflow preventer, 11:7-8
Dresser, 11:2
Double containment piping, 8:1-8, 9:1
CPVC regulatory basis for, 8:1
see Chlorinated polyvinyl chloride pipe standards, 8:1
Cracks, 4:7; 8:1 Drain, 2:11; 8:6-7; 11:5
Critical closure time, 3:6-7 Drain valve, 11:5
Critical pressure ratio, 10:17, 19 Drawing generation, 2:1-2, 3-4, 10, 12-13
Damage, physical, 2:6 Dresser couplings, 11:2
Darcy-Weisbach Drop-weight impact test, 3:1

equation, 3:8-9
friction factor, 3:8-9, 11, 14 Ductile iron pipe, 4:17
loss coefficients, 3:8-9, 13
Ductility, 3:1
Dead weight, 2:7
Dynamic loads, 2:7
Deflection, 2:6; 3:25-26; 5:5
lag factor, 5:8 Elasticity, 3:1, 6; 8:6
Deformation, 3:1; 8:2; 12:4 Elastomeric piping, 6:1-5

connections, 6:4
Design corrosion resistance, 6:2-3
bases, 2:2, 5, 10 liners, 9:7
conditions, 2:5 standards, 6:2
criteria, 2:1,6 temperature limits, 6:1
factors, 9:1-2
flow rate, 3:7-14 Elastomeric seals, 7:2
pressure, 2:5,7
external, 2:7 Elastomeric seats, 10:1, 6
internal, 2:7
pressure integrity, 3:5, 7, 14-17 Electrical isolation, 12:2, 4
specifications, 2:1
system descriptions, 2:1 Elongation, 3:1; 4:14
temperature, 2:5, 7
Environmental factors, 2:6
Diaphragm valve, 10:8, 21-22
Environmental stress cracking, 5:2; 8:1; 9:1
Differential pressure, 10:13, 14-15, 17, 20
Equivalent length of piping, 3:8-9, 12
D-3
EM 1110-1-4008
5 May 99
Erosion, 2:6; 3:15; 10:13 Flanged joints, 2:15; 3:2, 19-20; 4:14; 9:2
Erosion corrosion, 4:1, 8-9 Flexible connections, 2:15, 12; 3:26; 11:1
Excess pressure, due to water hammer, 3:5-7 Flexibility, 2:12, 15; 4:15; 7:1; 8:2, 6
Excursions, pressure/temperature, 2:7; 3:3, 5-7 Flow, 3:7-14; 9:1

characteristic for valves, 10:1, 2, 3
Expansion, 2:8; 11:9 coefficient, 3:9; 10:13, 15, 16, 17, 20
fluid, 11:7 drainage, 8:7
thermal, 2:8, 10; 4:14; 7:4-5; 8:2, 4, 6; 9:3 flushing, 8:7
rate, 3:7; 10:1
Expansion-contraction, 2:10; 7:4; 8:2, 6 resistance coefficient, 3:9
velocity, 3:8
Expansion joints, 4:15; 5:3; 7:4; 8:2, 6; 9:3; 11:11
ball, 11:9-10 Flushing, system, 3:30-31; 8:7
bellows, 4:15; 5:3; 11:1, 9-10
corrugated, 11:1, 10 Friction factor-turbulent flow, 3:8, 9, 10
slip, 4:15; 5:3; 11:9
Friction loss, 3:8
Expansion Loop, 2:12; 4:15-17; 5:3-4; 7:1, 4-5; 8:2, 5,
6 FRP
see Fiberglass reinforced plastic
Fatigue, 3:15, 18-19
Galvanic action, dissimilar joints, 4:2-3
Fiberglass, 7:1; 10:8
Galvanic protection for supports, 3:29
Filament winding, 7:1-2
Galvanic series, 4:2
Fittings, 2:6; 4:14
cast bronze/brass, 4:21 Galvanizing, 4:17
flanged, 4:17-20
threaded, 4:17-20 Gaskets, 3:19-22; 9:2
malleable iron, 4:17
nickel alloy, 4:20 Gate valve, 10:11, 21
steel, 4:17-19
thermoplastic, 5:2, 9-10 Glass, glass-lined pipe, 9:7
welding, 4:15, 17-20
butt welding, 4:14, 18 Glass pipe, 8:3
socket welding, 4:14, 18
Globe valve, 10:10-11, 16, 21-22
Flammable fluids, 3:2
Hangers, 2:9, 3:26
Flange, 3:2, 19-20; 7:2; 10:7
facings, 3:20 Hardness, 3:1
materials, 3:19
ratings, 3:2 Hardy Cross method, 3:14
selection and limitations, 3:19-20
thermoset, 7:2 Hastalloy, 3:2; 4:19
D-4
EM 1110-1-4008
5 May 99
Hazardous applications, 10:10 Insulation thickness, 3:25
Hazardous substance, 8:1, 8 Intergranular attack, 4:6
Hazardous wastes, 9:1 Internal piping, 1:1
Hazen-Williams formula, 3:19 International Organization for Standardization, 2:5; 5:2

coefficient, 3:9-10
limitations, 3:14 ISO
see International Organization for Standardization
HDPE, 5:11
Isolation
Head loss, 3:8 joints, 12:2,4
of supports for reinforced polyester pipe, 7:3
Heat-tracing, 2:10; 8:6; 9:1, 3; 11:12 valves, 10:1, 11, 13
design consideration, 2:10; 8:6
Isometric drawings, 2:1, 14
Hydraulic conditions, backpressure, 3:2
Joining, thickness allowance, 3:15
Hydraulic diameter, 8:6-7
Joints, piping, 4:10, 14
Hydraulic loads, 2:9 brazed, 4:10
caulked, 4:10
Hydraulic snubber, 10:9 compression, 4:10
compression couplings, 11:1
Hydrostatic testing, 2:11; 3:30 coupled, 11:1
test pressure, 3:30 DIP, 4:14
flanged, 2:15; 3:2, 19-20; 4:14; 7:2; 9:1; 10:7
Ice load, 2:8 flared, 4:10
gasketed, 3:19-22
Identification of piping, 3:23-24 grooved, 3:15, 4:20
inspection, 3:29
Impact mechanical, 4:18, 20; 9:2
failure, 7:1 metallic, applicable codes, 4:14
strength, 3:1 screwed, 10:7
test, 3:1 soldered, 4:10, 14
swagging, 3:15
Inconel, 4:19-20 thermoplastic, 5:2-3
thermoset, 7:1-2
Installation threaded, 3:15; 4:10, 14, 20; 5:9
above ground, 5:5; 6:5; 8:6; 9:3; 12:1 welded, 3:29; 4:10, 14; 10:7
below ground, 5:5, 9; 6:5; 7:4; 8:6; 9:3; 12:1
leak detection systems, 8:8 Laminar flow, 3:8, 10
reduced pressure backflow prevention assemblies,
11: 7-8 LDPE, 5:11
supports, 3:25; 9:3
Leak detection, 8:1, 8
Insulation
electrical isolation, 3:29; 12:2, 4 Leak-testing, 3:29-31
thermal, 2:10; 3:25-27; 8:6; 9:3; 11:10 methods, 3:29-31
D-5
EM 1110-1-4008
5 May 99
planning, 3:29 Mechanical joints, 4:18, 20

records, 3:29-30
sensitive leak test, 3:31 Minor loss coefficients, 3:8, 12
Leakage Modulus of elasticity, 3:1; 7:1

expansion joints, 11:9
valve seats, 10:7 Modulus of soil reaction, 5:9
Length equivalents, 3:8, 11 Monel, 3:2; 4:19
Lift check valve, 10:9-10 Moody diagram, 3:8, 10

Reynolds number, 3:8, 10
Liner, pipe, 7:1; 9:1-2
liquid applied, 9:6 MSS
material properties, 9:6 see Manufacturer Standardization Society of
the Valve and Fitting Industry
Lined piping, 9:1-7
elastomeric/rubber, 9:7 National Fire Protection Association, 11:12
glass, 9:8
nickel, 9:8 National Institute of Standards and Technology (NIST),
PFA, 9:3, 7 2:5
PP, 9:2-7
PTFE, 9:2-7 NFPA
PVDC, 9:3-7 see National Fire Protection Association
PVDF, 9:2-7
Nickel and nickel alloys, 4:10-11, 19-20
Live load, 2:7-10 liner, 9:7
Loading conditions, 2:6-10 NIST

dead load, 2:7 see National Institute of Standards and Technology
live load, 2:7-10
occasional load, 2:7-10 Nominal pipe size, 1:2
sustained load, 2:7; 3:19
Nominal thickness, 1:2
Malleable iron, 4:17
NPS
Manning factors, 3:9-10, 14 see Nominal pipe size
Manufacturer Standardization Society of the Valve and Operators, valve

Fitting Industry (MSS), 2:5; 3:28, 29; 4:14 electric, 10:8-9
hydraulic, 10:8-9
Martensitic stainless steel pipe, 4:18-19 manual, 10:8
pneumatic, 10:8-9, 21
Material combinations schedule, 10:20, 22
double containment piping, 8:1-3
valve seat, 10:4-5 Over pressure protection, 3:4-5
Material selection guidelines, B:1 Piping and instrumentation diagrams (P&ID), 2:1-2, 4,
9; 4:14-15; 5:2; 10:13
MDPE, 5:11
D-6
EM 1110-1-4008
5 May 99
Permeability, 9:1-2 reinforced vinyl ester, 7:1-2, 4-5

sizing, 3:1, 7-14; 5:2; 8:6-7
Personnel protection, 8:7 sizing criteria, 3:8
standard sizes, 1:1-2; 3:16
PFD see Process flow diagram tolerances, 3:15-16
toughness, 3:1
Pinch valve, 10:12 wall thickness, 2:6-7; 3:5, 14-17; 7:4
Pipe Piping
acrylonitrile butadiene styrene, 5:1, 3, 9-10 accessibility, 2:11
aluminum, 3:2; 4:10, 12, 20-21 codes and standards, 2:5-6
brass, 4:21 double containment piping, 8:1-8; 9:1
carbon steel, 4:17-18; 8:3; 9:1-3 feedwater, 3:3-7
chlorinated polyvinyl chloride, 5:1, 3, 4, 7, 10 flexibility, 2:10, 12
copper, 4:10, 13, 21 heat tracing, 8:6; 9:1, 3; 11:12
ductile iron, 4:17 instrumentation diagram (P&ID), and, 2:1-2, 4, 10;
ductility, 3:1 4:14-15; 5:2; 10:13
fiberglass, 7:1 insulation, thermal, 2:10; 3:25-27; 8:6; 9:3; 11:10
glass, 8:3 interferences, 2:10
glass-lined, 9:7 layout considerations, 2:2, 10, 13-14, 15; 3:17
joints, 3:15; 4:10, 14; 5:2-3; 7:1, 4 material selection, 3:1-2
identification, 3:23-24 metallic, 4:1-21; 8:3
liners, 7:1; 9:1-7 network, 3:8, 14
material selection, 3:1-2 physical sketches, 2:2
nickel, 4:10-11, 19-20 pump, 2:10, 15; 3:3-5
polyethylene, 5:1, 5, 10-11 rack, 2:9; 3:27
polypropylene, 5:1, 3, 10-11 relief valve, 3:4-5, 16-17, 29; 11:5-6
polyvinyl chloride, 5:1, 3- 4, 6, 9 specifications, 2:1
pressure, 2:7; 3:2-7 supports, 2:1, 9-10, 15; 3:17, 23-29; 7:3-4; 8:6
red brass, 4:21 drawings, 2:1
steel system, 1:1
carbon, 4:9-10, 17-18; 8:3; 9:1-3 thermoplastic pipe and fittings, 5:1-11; 8:3
stainless, 3:2; 4:9-10, 18-19 thermoset piping and fittings, 7:1-7; 8:3
strength, 3:1 vents and drains, 3:29
stress, 2:1 wall thickness, 2:6-7; 3:5, 14-17; 7:4
allowable, 2:6; 3:5, 15-17; 4:14, 16
code limits, 2:6 P&IDs
combined longitudinal, 3:17, 19; 4:16; 8:2, 6 see Piping and instrumentation diagrams
external pressure, 3:15
internal pressure, 3:15-17 Piping components, 2:1-2, 6; 3:2-3,19
supports, 2:1, 9-10, 15; 3:17, 23-28, 29, 20; 7:3-4; 8:6
drawings, 2:1 Piping fatigue, 3:15, 18-19
types, 3:29
thermal expansion, 2:7-8, 10; 4:14; 7:4-5; 8:2, 4, 6; Piping system design, 2:1-15
9:3 sizing criteria, 3:8
thermoplastic, 5:1-11
thermoset Plant layout, 2:2, 10, 12-14, 15; 3:17
reinforced epoxy, 7:1-5
reinforced furan, 3:2; 7:1-2, 4-5 Plasticization, 5:1
reinforced polyester, 7:1-5
D-7
EM 1110-1-4008
5 May 99
Plug valve, 10:12 Pressure-temperature rating, 3:3, 19
Pneumatic testing, 3:30-31 Pressure variation, transients, 2:7; 3:3-7; 4:9

design pressure, 3:31
Pressure wave, 3:5-7
Polyester fiberglass pipe, 7:3-5
Probe leak detection system, 8:8
Polyethylene (PE), 5:1, 5, 10-11
Process control, 2:1-2, 4
Polypropylene (PP), 5:1, 3, 10-11
liner, 9:2, 6 Process flow diagrams (PFD), 2:1-2, 3; 4:14-15; 5:2; 7:4
Polytetrafluoroethylene (PTFE), 5:1, 9 Protective coatings

liner, 9:2-3, 6-7 for piping, 4:1; 12:4
valve packing, 10:8 for supports, 3:29
Polyvinyl chloride (PVC), 5:1, 3-4, 6, 9 PTFE

supports spacing for, 5:6 see Polytetrafluoroethylene
Polyvinylidene fluoride (PVDF), 5:1, 10-11 Pump

supports spacing for, 5:6 installation piping, 2:10, 15
liner, 9:2-3, 6-7 system curves, 10:13-14
Positioner, for valve, 10:9, 21-22 PVC

see Polyvinyl chloride
PP
see Polypropylene PVDF
see Polyvinylidene fluoride
Predesign survey, 2:2,5; 12:2
Qualification
Pressure, 3:2-7; 9:1 of welders, 3:29
class, 3:19-20 of welding procedures, 3:29
design, 3:2-4
drop, 3:7-8; 10:1, 13, 14-15; 11:8 Quality, 2:1
head, 3:8
integrity, 3:1, 14-17, 19 Rack piping, 2:10; 3:27
internal, 2:7; 3:2-3, 7, 17; 7:4
maximum steady state, 3:2 Reduced pressure backflow preventer, 11:7-8
rating, 3:5, 20; 5:2; 7:5; 10:1
surges, 7:1 Reduction of area, 3:1
tests, 3:29-31
transients, 2:7; 3:3-8; 4:9 Reinforcement, 7:1
wave, 3:5-7
Relief valves, 3:4-5, 16-17, 29; 11:5-6
Pressure, maximum allowable, 2:7; 3:2, 4; 4:9
Resins, 7:1
Pressure relief devices, 11:5-7
for double containment piping, 8:7 Restrained design, 8:2,6
for pneumatic testing, 3:30
D-8
EM 1110-1-4008
5 May 99
Reynolds number, 3:8, 10, 13; 10:13, 17, 18 rupture discs, 11:6-7
thermoplastic pipe, 5:2
RMA valves, 10: 13, 14-15, 16-17, 18-19, 20
see Rubber Manufacturers Association
Slurry, 9:2; 10:12
Rockwell hardness, 3:1
Snow load, 2:8
Rotary shaft valve, 10:8-9, 21-22
Society of Automotive Engineers, 6:1-2
Roughness, 3:8-9; 7:1
Soil conditions, 2:5; 12:2
Route selection, 2:10-11 modulus of soil reaction, 5:8
Rubber Manufacturers Association, 6:2 Specifications, 2:1
Rupture disk, 11:6-7 Stainless steels, 3:2

austenitic, 4:18
SAE ferritic, 4:18-19
see Society of Automotive Engineers martensitic, 4:18-19
Safety codes, 2:7 Standard dimension ratio (SDR), 3:6
Sample connections, 11:5 Standards, 2:5-6; 7:1-2

dimensional, 7:1, 5
Sample piping, 11:5
Static mixers, 11:8-9
Saran, 9:6 pressure loss, 11:8
SD see System description Steel

carbon, 4:17-18; 8:3; 9:1-3
SDR stainless, 3:2; 4:18-19
see Standard dimension ratio austenitic, 4:18
ferritic, 4:18
Seismic martensitic, 4:18
codes, 2:6,8-9
loads, 2:8-9 Stop check valve, 10:9-10
zones, 2:8
Storage tank piping, 8:1
Selection criteria
piping materials, 3:1-2 Strain, 3:1, 18
valves, 10:1-3
Strength
Self-contained automatic valve, 10:12-13 tensile, 3:1; 7:1
yield, 3:1, 29-30; 8:1
Sensitive leak test, 3:31
Stress
Sizing allowable, 2:6; 3:5, 15-17; 4:14, 16
air and vacuum relief devices, 11:3 combined longitudinal, 3:17, 19; 4:16; 8:2, 6
drain, 8:7 cracking, 8:1; 9:1-2
piping, 3:7-14 design, 2:5; 9:1-2
D-9
EM 1110-1-4008
5 May 99
external loads, 3:15 for thermoplastic piping, 5:5-7

pressure, 3:3, 5; 8:2, 6 for thermoset pipe, 7:3-4
relieving, 4:7
thermal, 4:14-16; 5:3; 7:4; 8:2 Surge control
electrical, 12:4
Stress analysis, 3:1, 17-19 pressure, 2:9
for seismic excitation, 3:19
for thermal expansion, 3:18 Survey, Predesign, 2:2, 5; 12:2
for weight, 3:17
Swing check valve, 10:9-10, 21
Structural attachments, 2:9; 3:25, 27
System, description, 2:1
Structural integrity, 3:25; 7:3
Temperature, 9:1; 10:1
Supports, piping, 2:1, 8-9, 11; 3:17, 23-28, 29, 30; 7:3- brittle fracture, 3:29; 7:1
4; 8:6 design, 3:2
adjustment, 3:30 limits,
ambient systems, 3:17, 29 for fiberglass pipe, 7:1-2, 5
attachments piping, 3:29 for thermoplastic liners, 9:1
attachments to building, 2:9; 12:4 transition, 3:1, 29
coatings, protective, 3:30
cold spring, 3:30 Thermal analysis
cold systems, 3:27 allowable offset span in, 7:4
design of (general), 2:9-10; 3:23 free thermal, 7:4
dynamic loadings, 2:9 thermal modes, 7:4
hot systems, 3:27
installation of, 3:23 Thermal expansion, 2:7, 9; 4:14; 7:4-5; 8:2, 4, 6; 9:3
interstial, 8:6
load determination, 3:25-26 Thermoplastic piping, 5:1-11
loading considerations, 2:9-10; 4:14 available products, 5:1
locating supports, 2:9-10; 3:23, 25 dimensioning systems, 5:2
materials, special considerations, 4:10 jointing methods, 5:2-3
pump interconnection, 2:9-10, 15 pressure rating, 5:2
rod hangers, 2:9; 3:26, 29
rollers, 3:26-27, 29 Thermoplastics, 5:1-11
saddles, 3:27, 29 liners, 9:1-2
seismic loadings, 2:8-9 spacers, 9:2
selection, of, 3:23, 28, 29, 30
spacing of supports, 2:9; 3:23, 25-26; 4:9-10; 5:4; Thermoset pipe, 7:1-6
7:3-4
spring hangers, 3:26-27, 29; 5:4 Thermosetting resins, 7:1
temporary, 3:29-30
valves and fittings, 3:15; 10:9 Tilting disc check valve, 10:9-10
vibration dampers, 2:9
Tolerances, 3:15-16
Supports and support spacing
for double containment piping, 8:6 Toughness, 3:1
for elastomeric piping, 6:5
for metallic piping, 4:9-14 Turbulent flow, 3:8, 10
D-10
EM 1110-1-4008
5 May 99
Ultimate tensile strength, 3:1 Wafer valve, 10:7-8, 11-12
Uniform Building Code WHAMO, 3:6

seismic loads, 2:8
Wall relaxation, 8:2
UPS, 8:8
Wall thickness, 2:6-7; 3:5, 14-17; 7:4
Vacuum breaker, 11:1, 3, 4, 5 corrosion allowance, 3:15-16
location, 11:5
Water hammer, 2:8, 15; 3:5-8, 17; 7:1; 11:7
Valve
air relief, 11:1, 3, 4, 5 Weight, system, 2:7
angle, 10:11, 16
back-flow prevention, 10:1 Welders, qualification of, 3:29
ball, 10:8, 11
bleed-off of air, 11:1, 3-5 Welding
blow-off, 11:5 procedure specification, 3:29
butterfly, 2:15; 10:8, 12, 16-17, 21-22 tests, 3:29
check, 2:15; 10:9-10, 21
control, 10:13-20 Welds, examinations of, 3:29
diaphragm, 10:8, 21-22
drain, 11:5 Wheel load, 2:9-10; 7:4
gate, 10:11, 21
globe, 10:10-12, 16, 21-22 Wind load, 2:8
isolation, 10:1, 11, 13
location design, 2:15 Yield strength, 3:1, 29-30; 8:1
maintenance of, 10:11
pinch, 10:12
plug, 10:13
pressure rating, 10:1
pressure relief valves, 3:4-5; 11:5-6
recovery factor, 10:13, 15, 16-17, 20
regulating, 10:1
relief, 10:1
selection, 10:20
standards, 2:6
stem leakage, 10:7
supports, 3:15; 10:9
Valve location, 2:15
Vent, 2:11; 9:1,3

extension, 9:3
Vibration, 2:9; 5:5
Vinyl-ester fiberglass pipe, 7:4-5
Visual leak detection system, 8:8
D-11

Engineer Manual - Engineer and Design Liquid Process Piping - Review

Uploaded by

Copyright:

Available Formats

Engineer Manual - Engineer and Design Liquid Process Piping - Review

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engineer Manual - Engineer and Design Liquid Process Piping - Review

Uploaded by

Copyright:

Available Formats

CECW-ET 10 January 2003

Engineering and Design

Liquid Process Piping

Engineer and Design

LIQUID PROCESS PIPING

Distribution Restriction Statement

ENGINEERING AND DESIGN

Liquid Process Piping

Engineering and Design

3. Distribution Restriction. Approved for public release; distribution is unlimited.

4. References. References are provided in Appendix A.

FOR THE COMMANDER:

Engineering and Design

SUBJECT PARAGRAPH PAGE SUBJECT PARAGRAPH PAGE

TABLE OF CONTENTS - CONTINUED

SUBJECT PARAGRAPH PAGE SUBJECT PARAGRAPH PAGE

TABLE PAGE TABLE PAGE

LIST OF TABLES - CONTINUED

TABLE PAGE TABLE PAGE

FIGURE PAGE FIGURE PAGE

Chapter 1 1004/10 (Air Force) contain additional guidance

c 0.405 6 (0.236) 10 (0.394)

1-9. Manual Organization

Chapter 2 of this manual provides basic principles and

Appendix B contains a matrix that compares pipeline

2-1. Design Analyses 1. Function

Engineering calculations included in the design analyses 3. Description

2-2. Specifications b. Process Flow Diagram (PFD) Content

instrumentation or other minor equipment, isolation

2. All Valves and Identification

4. System Interconnections 7. Class Change

5. System Ratings and Operational Variables 8. Interconnections

maximum, average, minimum flow 9. Control Inputs/Outputs and Interlocks

6. Fluid Composition 2-4. Bases of Design

The bases of design are the physical and material

(Source: SAIC, 1998.)

Figure 2-2. Piping and Instrumentation Diagram (P&ID)

ANSI American National Standards Institute

e. Safety Provisions (1) For transient pressure conditions which exceed

WS = design snow load acting on the piping, N/m

Pipe flexibility is required to help control stress in liquid

Piping connections to pumps affect both pump operating

Miscellaneous routing considerations are: providing

Figure 2-3. Flexibility Arrangements

Figure 2-4. Remediation Process Piping Plan

Figure 2-5. Isometric View

Supports Piping is independently supported from the pump. A

Suction Connections The pump suction is continuously flooded, has 3

Fittings An eccentric reducer, flat side up, is provided when a

a. Strength Appendix B provides a matrix that correlates process

' 0.001123 m 3/kg % (&0.000013 m 3/kg)

The design pressure for the 150 mm (6 in) header should

Step 3. Determination of design pressure for the 100 mm

Step 4. The maximum allowable pressure in the 100 mm where:

and The velocity of the pressure wave is affected by the fluid

Step 8. Therefore, the maximum allowable pressure in where:

CECER has a computer program, WHAMO, designed to

' 4.71 MPa (682 psig)

a. Fluid Flow Sizing

where: and entrance losses. The coefficients can be determined