CPVC Manual
CPVC Manual
CPVC Manual
CPVC material is chlorinated polyvinyl chloride which is a specialty PVC compound characterized by unique thermal, physical and mechanical properties desirable for piping applications like improved impact resistance and good fire resistance capabilities). Principal uses for CPVC are domestic hot water and cold water piping, residential fire-sprinkling piping, and many industrial applications which can take advantage of its elevated-temperature capabilities and superior chemical resistance. Cosmoplast CPVC high pressure pipes and fittings satisfy the increasing demand for American and European standard CPVC pipes and fittings for plumbing applications, pertaining to hot and cold water distribution systems that demand high levels of toughness, chemical and thermal resistance.
FIELDS OF APPLICATIONS
Cosmoplast High Pressure CPVC pipes and fittings are widely used in
Hot and cold water distribution in residential, industrial and public buildings. Transportation of hot water in Heating Systems. Piping networks for sprinkler fire fighting systems Solar heating, central heating and radiant floor heating application Air Conditioning Drain Systems. Piping networks for swimming pools facilities. Piping networks for rainwater utilization. Irrigation networks. Circulation of hot and cold fluids in industrial applications. Transport of wide range of chemicals and corrosive fluids in industrial applications.
High Strength
Cosmoplast CPVC Pressure pipes and fittings are highly resilient, tough and durable products with high-tensile and high-impact strength. All these features guarantee higher pressure resistance capacity. CPVC pipes require less hangers and supports compared to other systems.
Corrosion Resistance
Cosmoplast High Pressure CPVC system is a high corrosion resistant, with superior ability to stand low pH levels water, coastal salt air exposure and corrosive soil. It also offers a major reduction in oxidation, which consequently guarantees the long durability of the system. CPVC Pressure pipes and fittings are highly resistant to industrial fumes, humidity, salt water, weather and underground conditions. Scratches or surface abrasions do not provide points which corrosive elements can attack.
CPVC Pressure pipes and fittings are resistant to galvanic and electrolytic attack. They can be used underground, underwater, and can be safely connected to metal parts.
Certain onsite temperatures are higher in the Gulf region, and Cosmoplast High Pressure CPVC system can easily withstand the ultraviolet exposure commonly experienced during the construction phase of the projects, provided the onsite inventories are appropriately stored. Although CPVC pipe can be installed in direct sunlight, it will be affected by ultra-violet light which tends to discolor the pipe and can cause a loss of impact strength. No other properties are impaired. If the pipe is to be installed in continuous direct sunlight, it is advisable to paint the exterior installations with two coats of white or light color water base latex paint for additional protection.
CPVC Pressure pipes and fittings have a lower thermal conductivity compared to metal pipes. This ensures that fluids maintain a more constant temperature and therefore they require less insulation than metal pipes. In most cases, pipe insulation is not required.
Laboratory testing and installation experience have demonstrated that the potential expansion problems in CPVC are much smaller than those which the coefficient of thermal expansion might suggest. The stresses developed within the CPVC pipes are generally much lower than those developed in equivalent metal pipe for equal temperature changes due to their elastic nature.
Low Condensation
Due to the CPVCs polymeric structure, costly condensation and damp concerns are eliminated, in addition to a considerable reduction in most of the long-term problems that would be experienced with metal installation.
Noise Reduction
Cosmoplast High Pressure CPVC system is a quite system, and therefore when used for water distribution in residential contexts, an additional advantage is derived. The low noise performance is due to the polymeric structure of the CPVC material, so the noise associated with water hammer is eliminated.
Cosmoplast CPVC pipes and fittings are retardant to bacterial growth which guarantees the quality and purity of water. They are suitable for aggressive low water pH levels of less than 6.5.
CPVC pressure pipe and fittings are lightweight (approximately one sixth the weight of steel) which results in reducing the transportation, handling, and installation costs. The installation is very easy and simple using CPVC solvent cement. Simple cutter, chamfering tool and CPVC solvent are the only requirements for leak proof jointing.
CPVC Pressure pipes and fittings have low coefficient of friction due to its smooth internal surfaces which results in low friction loss and high flow rate. Therefore they will not fail prematurely due to corrosion or scale build-up, especially in areas where water, soil, and/or atmospheric conditions are aggressive in nature like the Gulf Region. CPVC pipes guarantee full water carrying capacity because of lack of scale buildup, pitting and leaching which results in smooth and full bore flow and low water noise.
This special chemical structure of CPVC allows it to have a higher temperature resistance compared to PVC. CPVC can withstand temperature in excess of 93C (for short time loading up to 100 C ) while PVC can withstand temperature up to 60C. The two materials have almost the same chemical resistance.
CPVC enjoys a much higher strength than other common thermoplastic materials used in plumbing systems. Due to this feature, CPVC needs fewer hangers and supports than other common materials and eliminates the curvatures in pipe lines experienced in other systems. This feature also makes CPVC ideal for vertical installations (risers) and increases its pressure bearing capacity.
The thermal conductivity of CPVC material is lower than most of the common thermoplastics used in plumbing systems. This feature reduces the heat loss / gain of the fluids being transported in CPVC pipes. This leads to a higher energy saving and reduces the amount of thermal insulation needed for CPVC pipes.
Fire Resistance
CPVC material exhibits outstanding fire performance characteristics in terms of limited flame propagation and low smoke generation. When combined with its excellent mechanical strength, low thermal conductivity, and outstanding corrosion resistance, CPVC provides excellent value in terms of safety and performance in a wide range of applications. CPVC material has integral flame retarding property with very high Limiting Oxygen Index (LOI) of 60. This feature guarantees that CPVC pipes cannot be the ignition source of fire or support or sustain combustion. It does not increase fire load, has low smoke generation and low flame spread without flaming drips.
Ignition Resistance
CPVC has a flash ignition temperature of 482C while many other ordinary combustibles, such as wood, ignite at 260C or less. The following table shows the ignition temperature of some combustible materials:
Material CPVC PVC Polyethylene Paper Material CPVC PVC PVDF ABS Polypropylene Polyethylene
Burning Resistance
CPVC material will not sustain burning unless it is forced to burn, this is a result of its very high Limiting Oxygen Index (LOI) of 60 ( the percentage of oxygen needed in an atmosphere to support combustion). As Earth>s atmosphere is only 21% oxygen, CPVC will not burn unless continuously subjected to flame, it will stop burning when the ignition source is removed. Other combustible materials will support combustion due to their low LOI.
Working Pressure
The working pressure of CPVC pipes is directly related to the standard of production and schedule of pipe. The tables on page 14 and 15 show the dimensions and pressure ratings of CPVC pipes.
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JOINTING
CPVC pressure pipes and fittings are jointed using solvent welding process which involves using heavy duty solvent cement.
2 Remove burrs and filings from the outside and inside of the tube. 3 Clean the pipe and the fitting with dry cloth, in order to avoid any dust or sand that might affect the quality of the joint. Clean the spigot and socket area with a dry cloth (natural fibers) to remove all dirt and moisture from spigot and socket. 4 Apply cleaner solution to the outside surface of the pipe and to the inside surface of the fitting. Cleaner will prepare the surface for jointing for a better quality joint. 5 Using a suitably sized brush, apply a thin even coat of solvent cement to the internal surface of the fitting socket first then to the pipe spigot. Excess solvent cement must be avoided as pools of solvent cement will continue to attack the CPVC and weaken the pipe. Excess solvent cement will accumulate inside the system and may cause a reduction in the joint cross section. 6 While both surfaces are still wet with solvent cement, insert the pipe into the fitting in a single movement. Do not stop halfway, since the bond will start to set immediately and it will be almost impossible to insert further. For a better distribution of the solvent cement, twist the pipe a 1/4 turn during insertion into the socket. 7 Wipe any excess cement from the pipe and leave the joint to dry completely. 8 Hold the joint for around 30 seconds, during which avoid applying any load on the joint in order to avoid reducing the strength of the joint. 9 Leave the system for at least 12 hours before filling with water. 10 At temperatures of 16C and above, leave the system for 24 hours before pressure testing. At lower temperatures, 48 hours is necessary before pressure testing.
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Safety
Ensure good ventilation in the working areas. Forced ventilation should be used in confined spaces. Do not bring a naked flame close to the solvent cement operations. Spillage of solvent cement on the skin should be washed off immediately with soap and water. Should the solvent cement get in the eyes, wash them with clean water for at least 15 minutes and seek medical advice.
THREADED JOINTS
Cutting of threads on CPVC pipes is not an acceptable practice. Instead, moulded threaded adaptors should be used.
Note. Over tightening will over stress the fitting and could cause cracks and leakage.
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When making a transition connection to metal threads, use male threaded adapter whenever possible. This is necessary to avoid cracking the female uPVC fitting due to over tightening in presence of extra Teflon tape.
PIPE SUPPORTS
When CPVC pipes are installed above-ground, they must be supported properly to avoid vibrations and stresses.
Pipe supports and brackets should provide continuous support for at least 120 of the pipe circumference.
Sliding Joints
Sliding joints allow the pipe to move without restraint along its axis while still being supported. Pipe clamps with rubber lining should be used to prevent the support from scratching or damaging the pipe during expansion and contraction.
Fixed Joints
A fixed support rigidly connects the pipeline to a structure totally restricting movement in at least two planes of direction. Such a support can be used to absorb moments and thrusts.
Placement of Supports
The places of pipe clamps should be selected considering that thermal and other movements do not result significant bending moments at rigid connections or at bends or tees.
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Support Distances
Pipe clamps and hangers should be installed in proper distances as indicated in the following table:
Support Distances for Sch80 CPVC pipes Nominal Size(inch)
1 1.25 1.5 2 3 4 6 8
Temperature (C)
37 156 172 188 188 203 219 234 250 281 297 328 49 141 156 172 188 188 203 234 234 266 281 313
15 172 172 188 203 219 219 250 250 281 313 344
26 172 172 188 203 219 219 234 250 281 328 344
60 141 141 156 172 172 188 203 219 234 250 281
For Sch80 CPVC pipes. Distances in cm. The date in this table should be used as a general recommendation only and not as a guarantee of performance
TESTING AND COMMISSIONING
The pipeline may be tested as a whole or in sections, depending on the diameter and length of the pipe and the spacing between sections. Before performing pressure testing, all supports must be finished and the concrete properly cured (the minimum time is seven days). Special care should be taken while filling the system with water to ensure removing air from the system before pressurizing the system. uPVC pipelines are usually tested at 1.5 times the working pressure. After reaching the test pressure, the drop in pressure must be noted over time. Slight pressure drop normally occurs as the remaining air goes into solution, and due to some further expansion of the pipe. Re-pressurize the system to the testing pressure and again note the drop in pressure over the same time period.
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Constant pressure (or very small drop) indicates a satisfactory result, while bigger pressure drop may indicate a leak. It is recommended that the test pressure should be held for a minimum period of 15 minutes. The test pressure should never exceed 1.5 times the pipe pressure rating. After completing the pressure test, the pipeline should be thoroughly flushed and dosed with a sterilizing agent such as chlorine. Local authority requirements should be followed.
Handling
Take all reasonable care when handling CPVC, particularly in very cold conditions when the impact strength of the material is reduced. Do not throw or drop pipes, or drag them along hard surfaces. Do not scratch pipes against hard surfaces or drag them along the ground. In case of mechanical handling, use protective slings and padded supports. Metal chains and hooks should not make direct contact with the pipes. To avoid deformation over time, pipes should be stacked: either on a flat base or on a level ground or on 75mm x 75mm timber at 1m max. centers. For long-term storage (longer than 3 months) the maximum free height should not exceed 1.5m. The heaviest pipes should be on the bottom. Provide side support with 75mm wide battens at 1m centers. Vertical side supports should also be provided at intervals of 3m along rectangular pipe stacks. Maximum stack height is 1.7 meters regardless the pipe diameter. Store all materials in well-ventilated, shady conditions. Avoid direct exposure to sunlight for long periods. If stored in the open for long periods or exposed to strong sunlight, cover the stack with heavy sheets. Coverings such as black plastic must not be used as these can greatly increase the temperatures within the stack. Keep fittings in original packaging until required for use. Store fittings under cover. Do not remove from cartons or packaging until required.
Storage
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Ideally, stacks should contain one diameter pipe size only. Where this is not possible, stack largest diameter pipes at base of stack. Small pipes may be nested inside larger pipes. Do not place heavy items on top of the pipes. Protect the pipes from dirt, gravel or mud, as this could damage the ring seals inside the sockets. Pipes should be kept clean as much as possible, as this may save cleaning time while preparing pipes for welding.
Transportation
While in transit pipes should be well secured and supported. Chains or wire ropes may be used only if suitably padded to protect the pipe from damage. Pipes should be arranged safely on trucks avoiding crossing, bending and over stacking. Care should be taken that the pipes are firmly tied so that the sockets cannot rub together. Pipes may be unloaded from vehicles by rolling them gently down timbers, care being taken to ensure that the pipes do not fall onto one another or onto any hard or uneven surface. The pipes should also be fully supported over their total length.
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STANDARDS
Cosmoplast CPVC pipes and fittings are manufactured in accordance with the following standards:
Standard ASTM F 441 ASTM F 439 ASTMF437 topic Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe, Schedule 40 and 80. Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80. Standard Specification for Threaded Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80. Standard Specification for Chlorinated Polyvinyl Chloride (CPVC) Plastic Hot- and Cold-Water Distribution Systems. Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Polyvinyl Chloride (CPVC) Compounds. Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80. Plastics Piping Systems for Hot and Cold Water Installations - Chlorinated Poly Vinyl Chloride (PVC - C). Chlorinated Polyvinyl chloride (PVC-C) Pipes dimensions. Chlorinated Polyvinyl chloride (PVC-C) Pipes general quality and testing.
PIPE SPECIFICATIONS
ASTM F 441 : Sch80 Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipes
Nominal Size in Inch Outside Diameter Inch mm Schedule 80 Minimum Wall Thickness Inch mm Water Pressure Rating (BAR) at 83C at 23C
1 1.25 1.5 2 2 3 4 6 8
0.540 0.675 0.840 1.050 1.315 1.660 1.900 2.375 2.875 3.500 4.500 6.625 8.625
13.70 17.10 21.34 26.67 33.40 42.20 48.30 60.33 73.00 88.90 114.30 168.30 219.00
0.119 0.126 0.147 0.154 0.179 0.191 0.200 0.218 0.276 0.300 0.337 0.432 0.500
3.02 3.20 3.37 3.91 4.55 4.85 5.08 5.54 7.01 7.62 8.56 10.97 12.70
19.30 15.90 14.50 11.70 10.70 9.00 7.90 6.90 7.20 6.20 5.50 4.80 4.10
77.90 63.40 58.60 47.60 43.40 35.90 32.40 27.60 29.00 25.50 22.10 19.30 17.20
Note: Pressure Rating Applies for Water and for Unthreaded Pipes
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1 1.25 1.5 2 2 3 4 6 8
0.540 0.675 0.840 1.050 1.315 1.660 1.900 2.375 2.875 3.500 4.500 6.625 8.625
13.70 17.10 21.34 26.67 33.40 42.20 48.30 60.33 73.30 88.90 114.30 168.30 219.00
0.088 0.091 0.109 0.113 0.113 0.140 0.145 0.154 0.203 0.216 0.237 0.280 0.322
2.24 2.31 2.77 2.87 3.38 3.56 3.68 3.91 5.16 5.49 6.02 7.11 8.18
13.40 10.70 10.30 8.30 7.60 6.20 5.50 4.80 5.20 4.50 3.80 3.10 2.80
53.80 42.70 41.40 33.10 31.00 25.50 22.80 19.30 20.70 17.90 15.20 12.40 11.00
Note: Pressure Rating Applies for Water and for Unthreaded Pipes
16 20 25 32 40 50 63 75 90 110
1.2 1.5 1.9 2.4 3.0 3.7 4.7 5.6 6.7 8.2
1.5 1.9 2.3 3.0 3.7 4.6 5.8 6.9 8.2 10.0
1.8 2.3 2.8 3.6 4.5 5.6 7.0 8.4 10.0 12.3
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Art No. C-S- C-S- C-S-1 C-S-1 C-S-1 C-S-2 C-S-2 C-S-3 C-S-4
Item 1 1 1 2 2 3 4
90 ELBOW
Art No. C-E90- C-E90- C-E90-1 C-E90-1 C-E90-1 C-E90-2 C-E90-2 C-E90-3 C-E90-4
Item 1 1 1 2 2 3 4
45 ELBOW
Art No. C-E45- C-E45- C-E45-1 C-E45-1 C-E45-1 C-E45-2 C-E45-2 C-E45-3 C-E45-4
Item 1 1 1 2 2 3 4
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EQUAL TEE
Art No. C-T- C-T- C-T-1 C-T-1 C-T-1 C-T-2 C-T-2 C-T-3 C-T-4
Item 1 1 1 2 2 3 4
REDUCING TEE
Art No. C-T-. C-T-1. C-T-1. C-T-1. C-T-1.1 C-T-1.1 C-T-1.1 C-T-2.1 C-T-2.1 C-T-2.1 C-T-2.2 C-T-3.2 C-T-3.2 C-T-4.2 C-T-4.2
Item x 1x 1x 1x 1x1 1x1 1x1 2x1 2x1 2x1 2x2 3x2 3x2 4x2 4x2
REDUCING SOCKET
Art No. C-RS-. C-RS-1. C-RS-1. C-RS-1. C-RS-1.1 C-RS-1.1 C-RS-1.1 C-RS-2.1 C-RS-2.1 C-RS-2.1 C-RS-2.2 C-RS-3.2 C-RS-3.2 C-RS-4.2 C-RS-4.2
Item x 1x 1x 1x 1x1 1x1 1x1 2x1 2x1 2x1 2x2 3x2 3x2 4x2 4x2
PCS/CTN 480 320 280 318 196 200 120 112 112 60 45 48 36 21 14
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REDUCING BUSH
Art No. C-RB-. C-RB-1. C-RB-1.1 C-RB-1.1 C-RB-2.1 C-S-2.2 C-RB-3.2 C-RB-4.3
END CAP
Art No. C-EC- C-EC- C-EC-1 C-EC-1 C-EC-1 C-EC-2 C-EC-2 C-EC-3 C-EC-4
Item 1 1 1 2 2 3 4 Item 1 1 1 2
PCS/CTN 1200 570 500 317 240 146 75 52 28 PCS/CTN 275 180 120 96 48 36
UNION
Item 1
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Art No. C-FA- C-FA- C-FA-1 C-FA-1 C-FA-1 C-FA-2 C-FA-2 C-FA-3 C-FA-4
PCS/CTN 700 450 280 198 139 72 45 36 12 PCS/CTN 1000 600 350 150 200 130 60 48 18 PCS/CTN 300 180 110
Art No. C-MA- C-MA- C-MA-1 C-MA-1 C-MA-1 C-MA-2 C-MA-2 C-MA-3 C-MA-4
Item 1
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Item 1
Item 1 1 1 2
Item x x x x 1x1
Item x x x x
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Item x x x x
Item 1 1 1 2
Art No. C-DUV- C-DUV- C-DUV-1 C-DUV-1 C-DUV-1 C-DUV-2 C-DUV-2 C-DUV-3 C-DUV-4
Item 1 1 1 2 2 3 4 Item 1 1 1 2 3 4
Art No. C-SUV- C-SUV- C-SUV-1 C-SUV-1 C-SUV-1 C-SUV-2 C-SUV-3 C-SUV-4
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