Valvulas PVDF 1 PDF

SYGEF® PVDF
Pressure Piping
Engineering Handbook System
2
Table of Contents
Material Characteristics
General Information 5
Mechanical Properties 5
Chemical, Weathering and Abrasion Resistance 6
Thermal Properties 6
Flammability and Fire Rated Testing 6
Electrical Properties 7
Physiological Properties 7
Extractables 8
Discoloration Phenomena 8
Manufacturing
Complete System of Pipe, Fittings and Valves 9
Compliance with Microelectronic Standards 9
Compliance with Life Science Standards 10
Raw Materials 10
Manufacturing (Pipe) 10
Manufacturing (Fittings/Valves) 11
Manufacturing (Fabricated Products) 12
Traceability of Machined Components 12
Delivery, Storage and Handling 12
General Properties - SYGEF® PVDF 13
SYGEF® Plus HP PVDF Specification - IR/BCF 14
SYGEF® Standard PVDF Specification - IR/BCF 17
SYGEF® Standard PVDF Specification - Socket 20
Pressure/Temperature
Long-Term Stress 23
Working Temperature and Pressures for SYGEF® PVDF Pipe and Fittings 23
Dimensional Pipe Size

Pipe Size Comparison 24
Calculating Pipe Size

Friction Loss Characteristics 25
Hazen and Williams Formula 25
C Factors 25
Flow Rate vs Friction Loss - SYGEF® PVDF (PN16) 26
Flow Rate vs Friction Loss - SYGEF® PVDF (PN10) 30
Friction Loss Through Fittings 33
Gravity Drain Systems

Flow Rate for Gravity Drain Systems 34
Surge Pressure (Water Hammer)

Surge Pressure (Water Hammer) 35
Special Consideration 36
Expansion/Contraction
Allowing for Length Changes in PVDF Pipelines 38
Calculation and Positioning of Flexible Sections 38
Determining the Length Change 39
Determining the Length of the Flexible Section 40
Installation Hints 42
Pre-Stressing 42
3
Installation
The Incorporation of Valves 43
Vibration Dampeners 43
The Installation of Pipe Work under Plaster or Embedded in Concrete 43
Pipe Bracket Support Centers and Fixation of Plastic Pipelines 43
General Pipe Supports and Brackets 44
Shear Force of Restraint Fittings (Fixation Brackets) 44
Fusion Joining Technology

Reliable Fusion Joining 45
Socket Fusion Joining 45
IR Plus Infrared Butt Fusion Joining 45
BCF (Bead & Crevice Free) Fusion Joining 46
Socket Fusion
Socket Fusion Joining Method 47
Infrared (IR Plus) Fusion

Infrared (IR) Fusion Joining Method 51
Properties and Characteristics of IR Fusion Joints 52
Bead and Crevice Free (BCF Plus) Fusion

Bead and Crevice Free (BCF® Plus) Fusion Joining Method 53
Validated Welding Process

Fusion Training and Certification 55
Fusion Equipment 55
Weld Inspection 56
Mechanical Connections
Mechanical Joining of Piping Systems 57
Threaded Connections 57
Flanged Connections 57
Creating Flange Joints 58
Creating Union Joints 62
Documentation 64
Creating Threaded Joints 64
Pressure Testing
Introduction 66
Fractural Behavior of Thermoplastics 66
Overview of the different testing methods 66
Internal pressure test with water or a similar incompressible test fluid 67
Test Parameters 67
Pre-Test 67
Main Test 68
Observe if using compensators 68
Observe if using valves 68
Filling the pipeline 68
Max Test Pressure 69
Checks during testing 69
Internal pressure test with gas (compressible medium) 69
Modifications and repairs 69
Commissioning 70
Sterilization and Sanitization Methods

Autoclave Sterilization 71
In-Line Steam 71
Ozone Sanitization 71
Hot Water Sanitization 71
4
Material Characteristics
General Information
Polyvinylidene Fluoride (PVDF) is a semi-crystalline thermoplastic having outstanding mechanical, physical and
chemical properties. These result from the chemical structure of PVDF. Polyvinylidene Fluoride belongs to the class
of fluorinated polymers, whose best-known representative is polytetrafluoroethylene (PTFE). PTFE is characterized by
a superb heat resistance and the best chemical resistance of all polymers; a great disadvantage is that it is not melt
processable - e.g. into fittings. PVDF, on the other hand, combines various advantages of PTFE with good workability
into structural parts. The fluorine content in PVDF amounts to 59% by weight.
PVDF from GF is characterized by a very good mechanical behavior and high temperature resistance. Because of
the exceptionally wide pressure/temperature range in which PVDF can be used, it has opened, in connection with
the specific characteristics of this material, completely new areas of application in plastic piping fabrication. These
include applications in the semi-conductor, chemical and pharmaceutical industry, electroplating, paper and cellulose
processing, the automotive industry and water treatment. Pipes, fittings and valves of PVDF are uncolored and opaque
(milky, translucent).
By avoiding the addition of any additives, the outstanding characteristics of the material remain to the fullest extent,
especially concerning the chemical resistance and physiological harmlessness.
Advantages
• outstanding mechanical properties, even at high temperatures
• excellent chemical resistance
• no electrochemical corrosion
• long service life, even under intensely corrosive conditions
• outstanding resistance against Sunlight and Y-radiation
• very pure material without additives, stabilizers or plasticizers
• inhospitable to microbial growth
• physiologically harmless
• secure jointing by high-quality welding technology
• produced with smooth inner surfaces
• very low heat conductivity
• excellent flame retardant properties
Mechanical Properties
PVDF has a high tensile strength and stiffness. The impact strength is still good at temperatures around 32°F (0°C).
PVDF’s advantages are particularly prevalent at higher temperatures. This is due to the high fluorine content which causes
strong interactions between the PVDF chains. This, in turn, displaces the softening and the loss of properties to higher
temperatures. This also has an effect on the long-term creep strength.
PVDF has the highest long-term creep strength of all the polymers used for GF piping systems. The long-term behavior for
internal pressure resistance is provided by the hydrostatic strength curve based on the DVS 2205-1 Guidelines, Supplement
4 (see also the Pressure/Temperature section). The application limits for pipes and fittings, as shown in the pressure and
temperature diagram, can be determined from these curves.
5
Chemical, Weathering, and Abrasion Resistance
PVDF is resistant to most inorganic solvents and additionally to aliphatic and aromatic hydrocarbons, organic acids, alcohol
and halogenated solvents. PVDF is also not attacked by dry and moist halogens with the exception of fluorine. PVDF is not
resistant against strong basic amines, alkalis, and alkaline metals. Strong polar solvents, such as ketones and esters and
organic acids can cause PVDF to swell somewhat.
For detailed information, please refer to the detailed list of chemical resistance from GF or contact your GF subsidiary.
Outstanding resistance against UV light as well as gamma radiation permits, among other applications, the use of PVDF
piping outdoors. No loss of properties occurs. Abrasion resistance is considerable and approximately comparable to that of
polyamide.
Thermal Properties
PVDF shows its outstanding properties in a temperature range from -4ºF (-20°C) to 284ºF (140ºC). This allows using
the material in a wide range of applications. Especially at high temperatures, PVDF provides maximum security. Its high
crystalline melting point at around 343ºF (173°C) speaks for itself.
Please consult the pressure-temperature diagrams for your operational temperature. For temperatures below 32ºF (0°C),
the media must be prevented from freezing to avoid damaging the piping (as for other piping materials).
With a thermal coefficient of linear expansion of 0.78x10-4 in/inºF, PVDF lies clearly above that of metals. Because of this,
its thermal expansion must be taken into account during the planning of the piping system. As for all polymers, PVDF is a
good thermal insulator because its heat conductivity of 1.3 BTU-in/ft 2 /hr/ºF is very low. (For comparison, the value for steel
is 1733 BTU-in/ft2 /hr/ºF).
Flammability and Fire Testing

Combustion Behavior
PVDF displays an exceptionally good combustion behavior without the addition Comparative oxygen indices
of fire protection additives. Material decomposition begins at 716°F (380°C). Material % Oxygen
The oxygen index amounts to 44%. (Materials that burn with less than 21% of PMMA 17.3
oxygen in the air are considered to be flammable). PE 17.4
PP 17.4
PVDF thus also falls in the best flammability class V0 according to UL94, and
PIB 17.7
in the building materials class B1 (difficult to ignite) according to DIN 4102-1.
PS 18.1
SYGEF PVDF products show such excellent fire safety behavior that they are
®
PC 27.0
accepted and listed by Factory Mutual for use in clean rooms (FM 4910). PA 6.6 29.0
Installation within Designated Return Air Plenums ETFE 30.0
Current regulations and standards for testing materials for installations within SYGEF ®
43.7
designated return air plenums under IMC (International Mechanical Code), PVC 45
UMC (Uniform Mechanical Code/IAPMO, NFPA 90A,etc. are being reviewed PTFE 95
with regards to non-ferrous process water piping systems. These reviews may
lead to changes in required testing procedures and certifications for product conformance. For proposed installations of
SYGEF® PVDF Piping systems within designated return air plenums, please contact your local GF Area Sales Manager prior
to preparing project specifications.
6
Fire Testing
Since the combustion of PVDF produces hydrogen fluoride, which forms a corrosive acid in connection with
water, immediate cleaning of areas susceptible to corrosion with water containing detergent is necessary after a fire.
Additional combustion products are carbon monoxide and carbon dioxide. Concerning the choice of fire-fighting agents,
sand or powder-type extinguishing agents are recommended because the use of water may result in the development of
corrosive acids. Test method according to ASTM D635 The end of a test specimen is held horizontally, for 30 seconds, in the
flame of a Bunsen burner, the narrow side of the specimen being inclined at an angle of 45°.
PVDF stops burning immediately if the flame is removed. By way of comparison, unplasticised PVC also stops burning
immediately, while self-extinguishing polyester continues to burn for 2 seconds after the source of ignition has been
removed.
The HOOKER HLT 15 flame test This method of test is much more stringent than the ASTM D635 test. The test permits the
classification of non-flammable products into various categories.
A test specimen prepared according to ASTM D635 is clamped vertically and is then periodically exposed to the Bunsen
flame, using the following rhythm:
The test specimen must have stopped burning at Duration Operation

any rate before the flame is applied again. 5 seconds 1st Contact with Flame
10 seconds Flame Removed
SYGEF® will withstand four contact cycles with the
7 seconds 2st Contact with Flame
flame. After the fifth contact it melts, but without
burning. 14 seconds Flame Removed
ISO R 181 test according to SCHRAMM
20 seconds Flame Removed
A flat test specimen in horizontal position is
pressed for 3 min. against a rod heated to
1742°F (950°C). The loss in weight p in mg is 30 seconds Flame Removed
then determined, together with the longitudinal 25 seconds 5st Contact with Flame
shrinkage L in cm and assessed according to the 50 seconds Flame Removed
following equation: Lg = 100,000 pL in degrees
SCHRAMM
For SYGEF®, the result is 2.2 degrees SCHRAMM. By way of comparison, unplasticised PVC
shows 2.2 degrees SCHRAMM also, and self-extinguishing polyester 2.5 degrees SCHRAMM
Electrical Properties
PVDF is a good electrical insulator. Because of the possible electrostatic charges, caution is recommended when using
PVDF in applications where combustion or explosion dangers exist. The specific volume resistance is >1014 Ωcm; the
specific surface resistance is 1014 Ω.
Physiological Properties
PVDF is physiologically non-toxic as long as it is used below the maximum temperature of 302°F (150°C). During welding,
good ventilation is required or alternately the released gases must be extracted.
PVDF can be used in the USA in accordance with the relevant regulations of the Food and Drug Administration (FDA) for
food packaging and items that come into contact with food. The Federal Health Ministry of Germany generally recommends
that plastic items containing fluorine be thoroughly rinsed or boiled before their first use - a common procedure usual for
other materials too.
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Extractables
PVDF is a pure resin. Unlike other plastics, SYGEF® PVDF does not contain additives, stabilizers, antioxidants or extrusion/
injection molding aides. It is considered to be chemically inert and is not water soluble. SYGEF® Plus HP Grade PVDF pipes
and fittings are comprised of only PVDF while SYGEF® Plus HP Grade Valves also contain PTFE diaphragms. Testing shows
that PVDF is not detectable in water.
SYGEF® Plus HP Grade PVDF yields no polymeric extractables at any temperature. At elevated temperatures, fluoride is
a detectable ionic extractable in trace amounts yielding water quality well within USP specifications for production of DI,
USP and WFI. Testing with hot deionized water shows that trace elements are detectable at extremely low levels as surface
contaminants. They virtually disappear after the system is adequately flushed. Dynamic testing under flowing conditions
also indicated that the amount of extractables challenge the detection limits of modern analytical test equipment.
Additionally, SYGEF® Plus HP Grade PVDF piping system components comply with the recommendations of SEMI F57
Guidelines for extractable levels of metallic and ionic contaminants as well as TOC for polymer components. These levels
are far below those seen with traditional metal piping systems used widely in the pharmaceutical industry.
Discoloration Phenomena
PVDF exhibits a more intense degree of color change due to heat history and chemical effects when compared to other
thermoplastics. Because PVDF is absent of additives, changes in coloration are exhibited far more readily than otherwise
expected.
Coloration changes can vary from beige to dark brown. It is important to recognize that even a major discoloration (brown)
does not always relate to a degradation of the polymer. Such discoloration is common for PVDF materials operating in hot
ultrapure water systems at 158°F (70°C) to 176°F (80°C) and is the result of minor double bonding of carbon along the PVDF
linear molecule chain.
According to a 1993 report by a PVDF raw material supplier, the theoretical effects of such discoloration of PVDF are
outlined as follows:
• PVDF becomes completely black when only (1) in (1000) of PVDF monomer (-CH2-CF2-) transform to a (-CH=CF-)
molecule
• In a 3.2ft length of 2in (63mm) pipe there are about 2ft 2. of surface area
• When the discoloration affects .03937in of the surface (entire pipe appears black), this volume is 11in 3.
• PVDF has a density of ~ 0.06lb/in3, therefore, 11in3. Weights ~ 0.7lb.
• Since 59% of the (-CH2-CF2-) monomer is F2, the loss of 1 atom of F per 1000 results in 2.0x10 -4lbs F being removed
from the 3.2ft of pipe material; (0.7lb x 59%/2 x 1/1000) = 2.0x10 -4lbs
• There are 6.02 x1023 atoms per 0.04lb F; hence, 2.0x10-4lbs is equivalent to 2.98 x 1021 atoms
• If a 2in (63mm) pipe has a velocity of 5ft/sec., then the flow is approximately 61 gallons/min.
• Because brown discoloration occurs within 2 weeks time in a hot UPW system, the amount of H2O passing through
this 3.2ft of pipe is about 0.17x10 6ft3.
• Therefore, this 0.094g is diluted to levels challenging detection capabilities even when the PVDF appears black
2.0x10-4lbs/0.17x106ft3 = ~ 19ppt
• If a conservative factor of 1000 is used to demonstrate the difference between the first signs of discoloration (brown)
and the 1 per 1000 rule (black) the value is easily < 0.019ppt Fire Rated Construction
8
Manufacturing
Complete System of Pipe, Fittings and Valves
The production hall for SYGEF® Plus HP (PVDF) pipes, fittings and valves shall be maintained at Class 10,000 Cleanroom
(ISO Class 7) or better as defined by the current ISO Standard 14644-1. Specific class levels are assigned for each level of
production as described later in this section.
SYGEF® (PVDF) pipe shall be a Standard Dimensions Ratio (SDR) series which defines the outer pipe diameter, wall
thickness and tolerances. GF produces pipe and fittings rated for 232psi (16bar) from 3/8” (16mm) to 8” (225mm) and 150psi
(10 bar) from 3” (90mm) to 18” (450mm) when measured at 68°F (20°C).
Flanged connections have ANSI 150# bolt pattern. All mechanical connections for sample ports, instrumentation or venting
have either sanitary or approved ANSI threaded NPT connections.
All SYGEF® Plus HP (PVDF) valves have a minimum pressure rating of 150psi (10bar) at 68°F (23°C). High purity PVDF
valves in sizes through 2” (63mm) are Type 514/515 Diaphragm Valves as manufactured by GF. Additionally, Type 519 Zero-
Static Lateral Valves are available up to 4” (110mm) along the run. All diaphragm valves are weir style with PTFE diaphragm
seals backed with EPDM or FPM.
Compliance with Microelectronics Standards

Compliance with industry standards is very important to Georg Fischer. This is especially the case in the field of high purity
where SYGEF® Plus HP Grade (PVDF) piping system components are required to convey ultrapure water (UPW) and high
purity chemicals with qualities as characterized within SEMI documentation. Disregard for this requirement would impart
serious yield losses to the high tech end-users of piping systems.
For example, SEMI F63 defines the UPW quality used in today’s sub-100 nanometer semiconductor factories. SEMI F57
outlines the critical characteristics and performance criteria of polymer raw materials and components. SEMI F40 gives
the necessary steps for testing these raw materials and components.
To insure that manufacturing conditions and final product meet or exceed the requirements of SEMI F57 guidelines for
extractable levels of metallic, ionic and organic (TOC) contaminants standardized testing regimes have been adopted within
Georg Fischer’s high purity facility. This strict compliance to SEMI F57 demands routine sampling of production pipes,
fittings and valves, which are submitted to certified laboratories for testing using SEMI F40 protocol. Databases with Cpk
(process capability) indices are maintained and monitored for early warning indications of potential problems in either raw
material purity or production induced changes.
The leached levels seen in SYGEF® Plus HP (PVDF) continue to provide demanding customers with satisfactory results. At
the same time, they are far below those found coming from traditional metal piping systems, which are widely used in the
pharmaceutical industry.
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Compliance with Life Science Standards
SYGEF® Plus HP (PVDF) Piping Systems have been installed for use in Deionized (DI) Water, USP Water, and WFI systems
and are well suited to these applications. This material can be sanitized using hot water, steam, ozonation or chemicals and
does not require passivation for the life of the system. It can also be steam sterilized. Additionally, since SYGEF® Plus HP
(PVDF) piping components are produced and packaged in a high purity environment, no Clean In Place (CIP) procedures are
required at startup, provided that installation occurs in a controlled environment.
SYGEF® Plus HP (PVDF) meets the requirements of ASME BPE (Bioprocessing Equipment) Standard, Section PM and
Section SF.
Recent changes in the USP XXIII call for water to pass the Total Organic Carbon (TOC) test with limits of ≤ 500
ppb. Historically, the users of PVDF systems have focused on the much more rigorous TOC requirements of the
microelectronics industry. These systems typically pass using on-line monitoring equipment at limits of ≤ 5 ppb, 100 times
more stringent than the current USP XXIII requirement. Of significant importance, these results have been achieved with
virtually no unscheduled down time.
SYGEF® Plus HP (PVDF) has measurably smoother surfaces than those found in common grades of stainless steel used
in pharmaceutical systems. Piping system components are made from a pure fluoropolymer resin, containing no metals
such as iron, copper or nickel. This inert pipe cannot experience rouging or pitting corrosion. Additionally the BCF welding
process provides smooth weld surfaces, far superior to the results produced by welding on stainless steel. In stainless
steel systems, microscopic pitting from corrosion of the pipe surface, as well as welding beads create rough surfaces
which can harbor microorganisms. This smoother surface, combined with the smoother BCF weld result, presents fewer
opportunities on the piping system component surface for bacteria to adhere and proliferate. Thus, it requires less frequent
sanitization and less production down time.
Raw Materials
SYGEF® Plus HP (PVDF) pipe, fittings and valves shall be manufactured from natural, unpigmented, virgin polyvinylidene
fluoride (PVDF) homopolymer conforming to the standards of ASTM D3222. All raw material utilized for SYGEF® Plus HP
(PVDF) production shall be specially controlled regarding procurement, shipment, handling and storage prior to production
to minimize contact with extraneous contamination.
PVDF raw materials shall be handled in a clean room environment to prevent contamination. The raw material shall be
gravity fed into the processing equipment. Pneumatic conveyance of the raw material is prohibited.
PVDF raw material shall meet the testing requirements for impurities per SEMI F57.
Manufacturing (Pipe)
Environment
SYGEF® Plus HP (PVDF) pipe shall be extruded in a dedicated high purity PVDF production area which is located in a Class
1,000 Cleanroom (ISO Class 6) or better environment. All pipes shall be extruded on dedicated production equipment used
exclusively for the production of high purity PVDF. Pipe dimensions and tolerances shall be continually monitored with QC
sampling at designated time intervals compliant with Good Manufacturing Practices.
Stress Relieving:
Extrusion stresses shall be relieved by use of a continuous in-line annealing oven. Stress relief shall be measured and relate
to a maximum 0.4% dimensional change when tested according to ISO 10931-2
10
Pipe Identification
SYGEF® Plus HP (PVDF) pipe shall be identified on the pipe outer surface (on top) with the production lot, pipe diameter and
wall thickness. Pipe identification shall be accomplished by use of heat embossed lettering and without the use of any ink on
the pipe surface. After packaging, each pipe length shall have a label adhered to the outside of the outer polyethylene bag.
The label shall denote production lot, pipe diameter, wall thickness and surface quality.
Surface Finish
SYGEF® Plus HP (PVDF) pipe shall have samples taken which are measured for mean roughness of the interior pipe surface.
Using ISO 4288, SYGEF® Plus HP (PVDF) pipe, shall have profilometer mean roughness values compliant with SEMI F57 or
better.
Pipe interior shall also be visually inspected for defects on a lighted table prior to fitting with protective polyethylene end
caps and double bagged in heat sealed polyethylene liners immediately after production within the cleanroom.
Pipe Dimensional tolerances

Pipe shall be in accordance to the following values:
Size Tolerance Ovality Wall Tolerance

1/2” (20mm) +0.3, -0.0 0.3 1.9 +0.4, -0.0
3/4” (25mm) +0.3, -0.0 0.4 1.9 +0.4, -0.0
1” (32mm) +0.3, -0.0 0.5 2.4 +0.5, -0.0
1 1/4” (40mm) +0.3, -0.0 0.5 2.4 +0.5, -0.0
1 1/2” (50mm) +0.3, -0.0 0.6 3.0 +0.6, -0.0
2” (63mm) +0.4, -0.0 0.8 3.0 +0.6, -0.0
2 1/2” (75mm) +0.4, -0.0 0.9 3.6 +0.6, -0.0
3” (90mm) +0.4, -0.0 1.1 4.3 +0.7, -0.0
4” (110mm) +0.5, -0.0 1.3 5.3 +0.8, -0.0
6” (160mm) +1.0, -0.0 2.0 4.9 +0.8, -0.0
8” (200mm) +1.2, -0.0 2.5 6.3 +0.9, -0.0
8” (225mm) +1.4, -0.0 2.7 6.9 +0.9, -0.0
10” (250mm) +1.4, -0.0 3.1 7.7 +1.1, -0.0
12” (315mm) +1.6, -0.0 3.9 9.7 +1.3, -0.0
14” (355mm) +1.9, -0.0 4.4 10.8 +1.4, -0.0
16” (400mm) +2.1, -0.0 5.0 12.1 +1.6, -0.0
18” (450mm) +2.4, -0.0 5.6 13.6 +1.8, -0.0
Manufacturing (Fittings/Valves)
Environment
All high purity PVDF fittings and valves shall be manufactured on dedicated equipment in clean production cells that are
Class 100 (ISO Class 5) or better. Any machined valve components shall be performed with no coolant other than filtered
air.
Cleaning
Fittings and valves (diaphragm) shall be washed in a Class 100 Cleanroom (ISO Class 5), using DI water with nonionic,
phosphate free surfactant solution. After cleaning, the components shall be rinsed with hot (176°F/80°C) UPW water,
flushed with ambient UPW water, both meeting SEMI F63-00-0701 requirements, and heat dried with HEPA filtered air or
filtered nitrogen.
11
Identification
All high purity PVDF fittings and valves shall be molded with permanent identification to allow tractability to production lot
and raw material batch.
In addition, all high purity PVDF fitting and valve labels shall have an identification code or numbering scheme on the
packaging that permits traceability back to the lot and batch cleaning of fittings or valves.
Packaging
After cleaning, fittings and valves shall be immediately and individually heat sealed in PA6/PE double bags while in the
cleanroom. Valves shall be assembled in a Class 100 (ISO Class 5) environment. No external markings or labeling shall be
permitted except on the outer bag. The production label shall denote production lot, dimension and logistical information.
Manufacturing (Fabricated Products)

Production of PVDF fabricated items are to be done under a minimum Class 10,000 cleanroom as defined in the current
Federal Standard. Machine components made from semi-finished PVDF block and rod used in this fabrication of parts or
sub-assemblies shall be inspected, cleaned and packaged similar to fittings and valves. Final inspection is made prior to
packaging by 100% visual inspection of every weld. Pressure test for welded assemblies as required. Surface finish for any
machined component shall be: Ra = 0.62μ or better.
Tracebility of Machined Components

Welding of sub-components shall only be done by manufacturers certified technicians. All factory welds shall be
labeled using the manufacturers fusion machine printouts from actual welds. All finished parts and assemblies shall
be permanently marked with a traceable number which links incoming material, production dates, machines used and
welding personnel.
Delivery, Storage and Handling

Any material that becomes damaged and/or contaminated in transit handling or storage shall not be used. It must be
rejected by the quality control representative and returned to the manufacturer/distributor.
All material and equipment shall be handled and stored in an indoor location throughout the progress of the job in such a
manner as to prevent damage and/or contamination. Room shall be maintained dry and dust free. Room shall be kept at a
temperature between 60°F (15°C) and 85°F (30°C).
Piping, fittings, and valves shall be stored in their original factory sealed poly bags. Use nylon or polypropylene rope or soft
strand for slings and tie-downs used to let, load, or transport pipe bundles. Do not stack pipe higher than 2 feet.
All fabricated material shall be used within 48 hours of being removed from the storage site. All high-purity PVDF piping
system components shall be inspected and approved by fabricator and installer upon arrival into the fabrication clean room
and before spool fabrication begins.
Fabricated spool pieces shall be supported and padded to prevent damage during transport.
All pipe fitting ends of fabricated spool pieces shall be double bagged and sealed. Bags shall be secured with cap or
cleanroom tape a minimum 6 inches away from pipe end. Cleanroom tape directly over pipe or fitting end is not acceptable.
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12
General Properties - SYGEF® PVDF (Polyvinylidene Fluoride)
Material Data
The following table lists typical physical properties of PVDF (Polyvinylidene Flouride) thermoplastic materials. Variations
may exist depending on specific compounds and product.
Mechanical
Properties Unit SYGEF® ASTM Test
Plus HP/Standard
PVDF
Density lb/in3 0.0643 ASTM D792
Tensile Strength @ 73°F (Yield) PSI ≥ 7,250 ASTM D638
Tensile Strength @ 73°F (Break) PSI ≥ 6,500 ASTM D638
Modules of Elasticity Tensile @ 73°F PSI ≥ 246,560 ASTM D638
Compressive Strength @ 73°F PSI 12,500 ASTM D695
Flexural Modulus @ 73°F PSI 267,500 ASTM D790
Izod Impact @ 73°F Ft-Lbs/In of Notch ≥ 3.8 ASTM D256
Relative Hardness @ 73°F Durometer “D” 78 ASTM D2240
Thermodynamics
Melt Index gm/10min 1.10 ASTM D1238
Melting Point °F ≥ 336 ASTM D789
Coefficient of Thermal Linear
in/in/°F 0.67...1.00 (x 10-4) ASTM D696
Expansion per °F
Thermal Conductivity BTU-in/ft 2 /hr/ °F 75 ASTM D177
Specific Heat CAL/g/°C 0.32 DSC
Maximum Operating Temperature °F 284
Heat Distortion Temperature @ 264 PSI °F ≥ 220 ASTM D648
Other
Water Absorption % ≤ 0.04 ASTM D570
Limited Oxygen Index (LOI) % ≥ 43
Industry Standard Color Opaque RAL 9005
Food and Drug Association (FDA) YES CFR21.177.1520
United States Pharmacopeia (USP) YES USP 25 Class VI
SEMI YES F57
Factory Mutual YES FM4910
Note: This data is based on information compiled from multiple sources.
13
SYGEF® Plus HP PVDF Specification - IR/BCF
PART 2 - PRODUCTS – MATERIALS
2.01 PURE WATER PIPE AND FITTINGS

A. Polyvinylidene Fluoride pipe shall be manufactured from a virgin resin material, unpigmented and translucent.
Dimensions for all sizes shall be in accordance to ISO 10931. Pipe sizes 1/2” (20mm) through 4” (110mm)
shall be manufactured to have a pressure rating of 232 psi (16 bar) when measured at 68°F (20°C). Pipe sizes
3in (90mm) through 18” (450mm) shall be manufactured to have a pressure rating of 150 psi (10 bar) when
measured at 68°F (20°C). Pipe shall be manufactured and catalogued for BCF® Bead and Crevice Free) or
IR® (Infrared) methods. Pipe internal surface finish: for ≤ 8”(225mm) shall have an Ra ≤ 9.0µin (0.2µm) / for .
8”(225mm) shall have an Ra ≤ 12µin (0.3µm) / for 12”(315mm) shall have an Ra ≤ 16.0µin (0.4µm).
B. Polyvinylidene Fluoride fittings shall be manufactured from a virgin resin material, unpigmented and
translucent. Fittings 1/2” (20mm) through 4” (110mm) shall be manufactured to have a pressure rating
of 232 psi (16 bar) when measured at 68° F (20° C). Fitting sizes 3” (90mm) through 18” (450mm) shall be
manufactured to have a pressure rating of 150 psi (10 bar) when measured at 68°F (20°C). Fittings shall be
manufactured and catalogued for BCF® (Bead and Crevice Free) or IR® (Infrared) methods. Fitting internal
surface finish: for ≤ 8”(225mm) shall have an Ra ≤ 9.0µin (0.2µm) / for . 8”(225mm) shall have an Ra ≤ 12.0µin
(0.3µm) / for 12”(315mm) shall have an Ra ≤ 16.0µin (0.4µm).
C. Pipe and fittings shall have a temperature rating of -4°F (-20°C) to 284°F (140°C).
D. All components of the pipe and fitting system shall conform to FDA CFR 21 177.1520 (certificate of conformance
to be included with shop drawing submittal), USP 25 Class VI (certificate of conformance to be provided with
shop drawing submittal) and ASME-BPE. All pipe and fittings shall be marked with brand name, product
description, code number, material, and dimension and pressure rating information. Fittings shall be
embossed with a permanent identification during the production process to ensure full traceability.
E. Pipe and fittings shall be produced under ISO 14644-1 Class 7 (U.S. Fed. Standard 2.09 E Class 10’000)
conditions. Subsequent assembly, quality inspection and cleaning is to be carried out using 18MΩ pure water
under clean room ISO 14644-1 Class 5-6 (U.S. Fed. Standard 2.09E class 100-1000) conditions. Pipes will be
capped and each component (pipe and fittings) will be double bagged in a specified inner bag and an outer bag
under clean room ISO 14644-1 class 6 (U.S. Fed. Standard 2.09E Class 1000) conditions.
F. Shall be SYGEF® Plus PVDF Piping Systems as manufactured by GF Piping Systems LLC, Tustin CA.
2.02 VALVES
A. Diaphragm Valves: Diaphragm valves shall be constructed of polyvinylidene fluoride with EPDM or PTFE Seal
configurations, manufactured for installation in SYGEF® Plus Piping system, Type 514, 515, 517 and 519 (Zero
Static) as manufactured by GF Piping Systems LLC. Diaphragm valves shall be rated for 240 psi (16.5 bar) when
measured at 68°F (20°C). Pneumatic/Electrical valve actuators, if required, shall be supplied by GF Piping
Systems LLC to ensure proper system operation.
2.03 RECIRCULATING LABORATORY FAUCET

A. Recirculating Laboratory Faucet: Shall be constructed of polyvinylidene fluoride and designed to provide
a constant fluid flow to the point of use to eliminate dead legs. Faucet shall be Type 530 “Aqua Tap” as
manufactured by GF Piping Systems LLC, Tustin CA.
a. Faucet to be manufactured with needle type flow control for precise metering.
14
b. Faucet to be manufactured for deck or wall mounting options.
c. Recirculating laboratory faucet shall be installed in conjunction with an inline flow diverter (IFD)
manufactured of SYGEF® PVDF or PROGEF® Natural PP by GF Piping Systems LLC. The inline flow
diverter shall be designed to provide high flow from the distribution main through the faucet for
constant water movement. An orifice installed within the inline flow diverter is used to create a
differential pressure imbalance which forces water through the faucet with minimal pressure loss.
The inline flow diverter(s) shall be installed in the distribution main where shown on the drawings and
may serve up to three faucets. The diverters shall be manufactured and catalogued for BCF® (Bead and
Crevice Free), IR® (Infrared) or sanitary clamp joining methods.
d. Faucet shall have a pressure rating of 92 psi (6 bar).
e. Recirculating laboratory faucet(s) shall be connected to the inline flow diverter using smooth bore 5/8”
PFA or PE tubing for design flexibility and simplified piping installations. Tubing shall be connected to
faucet(s) and inline flow diverter connection points using easy flare style connection method. Installer
shall use GF Piping Systems LLC isolation ball valves installed inline (tubing) or optional emergency
shut-off clamps, to facilitate segregation of faucets from the pure water system if required for
maintenance or other purposes. Only catalogued AquaTap adaptors, accessories and tools shall be
used by the installer.
PART 3 - EXECUTION
3.1 HANDLING
A. Material shall be stored in original packaging and protected from environmental damage until installation.
Pipe shall be supported sufficiently to prevent sagging. Care shall be taken not to gouge or otherwise notch the
pipe in excess of 10% of the wall thickness.
3.2 INSTALLATION
A. System components shall be installed using the IR® (Infrared) ½” (20mm) through 12” (315mm) , BCF® (Bead
and Crevice Free) ½” (20mm) through 4” (110mm) joining methods according to current installation instructions
as delivered in print or documented online at www.gfpiping.com.
An on site installation seminar shall be conducted by GF personnel who are certified to conduct said seminar.
Seminar topics shall include all aspects of product installation (storage, set up, support spacing, fusion
process, machine care, testing procedure, etc.). At the conclusion of the seminar, all installers will be given
a written certification test and will be required to prepare and complete one fusion joint of the type being
implemented on the project. Upon successful completion of said test, the installer will be issued a certification
card verifying that they have met the requirements of the manufacturer with regards to knowledge of proper
product installation and testing methods.
B. Only the following GF Piping Systems LLC fusion units may be used to install the SYGEF® Standard piping
system:
For IR Fusion Installation – IR63Plus®, IR225 Plus®, Infrared Butt Fusion Machines
For BCF® Fusion Installations – BCF® Plus
Under this specification, the contractor shall be responsible for the purchase or rental of the proper machine
required to meet the intent of the specification and be used for installation of the product on site.
15
C. Installer shall ensure that all pipe and fittings used for Pure Water Piping are components of the same system.
No mixing of various manufacturers pipe and or fittings shall be allowed.
3.3 TESTING
A. The system shall be tested in accordance with the manufacturers’ recommendations. Please refer to Georg
Fischer’s technical handbook for “Pressure Testing” guidelines.
16
SYGEF® Standard PVDF Specification - IR/BCF

Dimensions for all sizes shall be in accordance to ISO 10931. Pipe sizes 3/8” (16mm) through 4” (110mm)
shall be manufactured to have a pressure rating of 232 psi (16 bar) when measured at 68°F (20°C). Pipe sizes
6in (160mm) through 12” (315mm) shall be manufactured to have a pressure rating of 150 psi (10 bar) when
measured at 68°F (20°C). Pipe internal surface finish shall be Ra ≤ 20.0µin (0.5µm).
translucent. Fittings 3/8” (16mm) through 4” (110mm) shall be manufactured to have a pressure rating of 232
psi (16 bar) when measured at 68°F (20°C). Fitting sizes 6” (160mm) and larger shall be manufactured to have a
pressure rating of 150 psi (10 bar) when measured at 68°F (20°C). Fittings shall be available in sizes from 3/8”
(16mm) up to 12” (315mm). Fittings shall be manufactured and catalogued for BCF® (Bead and Crevice Free),
IR® (Infrared) joining methods.
C. All components of the pipe and fitting system shall conform to the following applicable ASTM Standards,
D4101, D 638, D2837, D2122, FM 4910 and shall conform to FDA CFR 21 177.1520 (certificate of conformance
D. Shall be SYGEF® Piping System as manufactured by GF Piping Systems LLC, Tustin CA.
2.02 VALVES
A. Ball Valves: Ball valves shall be full port, true union end constructed of polyvinylidene fluoride with EPDM
or FPM seals available, manufactured for installation in SYGEF® Standard Piping system, Type 546 and as
manufactured by GF Piping Systems LLC. Ball valves shall be rated for 232 psi (16 bar) when measured at 68°F
(20°C). Pneumatic/Electric valve actuators, if required, shall be supplied by GF Piping Systems LLC to ensure
proper system operation.
B. Diaphragm Valves: Diaphragm valves shall be constructed of polyvinylidene fluoride with EPDM or PTFE Seal
configurations, manufactured for installation in SYGEF® Standard Piping system, Type 514, 515, 517 and 519
(Zero Static) as manufactured by GF Piping Systems LLC. Diaphragm valves shall be rated for 150 psi (10 bar)
when measured at 68°F (20°C). Pneumatic/Electrical valve actuators, if required, shall be supplied by GF
Piping Systems LLC to ensure proper system operation.
C. Three Way Ball Valves: Ball valves shall be L-Port/T-Port type constructed of polyvinylidene fluoride with
EPDM or FPM seats available, manufactured for installation in SYGEF® Standard Piping system, Type 343
as manufactured by GF Piping Systems LLC. Three way ball valves shall be rated for 150 psi (10 bar) when
17
D. Butterfly Valves: Butterfly valves shall be constructed of polyvinylidene fluoride with EPDM or FPM seats
available, manufactured for installation in SYGEF® Standard Piping system, Type 567 (lug style) or Type 568
(wafer style) as manufactured by GF Piping Systems LLC. Pneumatic/Electrical valve actuators, if required
shall be supplied by GF Piping Systems LLC to ensure proper system operation.

PART 3 - EXECUTION
3.1 HANDLING
3.2 INSTALLATION
A. System components shall be installed using the IR® (Infrared), BCF® (Bead and Crevice Free) joining methods
according to current installation instructions as delivered in print or documented online at www.gfpiping.com.
18
system:
For Socket Fusion Installation – SG 110, SG 160 Socket Fusion Machines or MSE Handtool
For IR Fusion Installation – IR63 Plus®, IR225 Plus®, IR-315Plus®, Infrared Butt Fusion Machines
For BCF® Fusion Installations – BCF® Plus
3.3 TESTING
19
SYGEF® Standard PVDF Specification - Socket

Pipe sizes 3/8” (16mm) through 2” (63mm) shall be manufactured to have a pressure rating of 232 psi (16
bar) when measured at 68°F (20°C). Pipe internal surface finish shall be Ra ≤ 20.0µin (0.5µm). Pipe shall be
manufactured in sizes from 3/8” (16mm) through 2” (63mm).
translucent. Fittings 3/8” (16mm) through 2” (63mm) shall be manufactured to have a pressure rating of
232 psi (16 bar) when measured at 68°F (20°C). Fittings shall be available in sizes from 3/8” (16mm) up to 2”
(63mm).
C. All components of the pipe and fitting system shall conform to the following applicable ASTM Standards,
D3222, D 638, D2837, D2122, FM 4910 and shall conform to FDA CFR 21 177.1520 (certificate of conformance
D. Shall be SYGEF® Piping System as manufactured by GF Piping Systems LLC, Tustin CA.
2.02 VALVES
A. Ball Valves: Ball valves shall be full port, true union end constructed of polyvinylidene fluoride with EPDM
or FPM seals available, manufactured for installation in SYGEF® Standard Piping system, Type 546 and as
manufactured by GF Piping Systems LLC. Ball valves shall be rated for 232 psi (16 bar) when measured at 68°F
(20°C). Pneumatic/Electric valve actuators, if required, shall be supplied by GF Piping Systems LLC to ensure
proper system operation.
B. Diaphragm Valves: Diaphragm valves shall be constructed of polyvinylidene fluoride with EPDM or PTFE Seal
configurations, manufactured for installation in SYGEF® Standard Piping system, Type 514, 515, 517 and 519
(Zero Static) as manufactured by GF Piping Systems LLC. Diaphragm valves shall be rated for 150 psi (10 bar)
when measured at 68°F (20°C). Pneumatic/Electrical valve actuators, if required, shall be supplied by GF
Piping Systems LLC to ensure proper system operation.
C. Three Way Ball Valves: Ball valves shall be L-Port/T-Port type constructed of polyvinylidene fluoride with
EPDM or FPM seats available, manufactured for installation in SYGEF® Standard Piping system, Type 543
as manufactured by GF Piping Systems LLC. Three way ball valves shall be rated for 150 psi (10 bar) when
D. Butterfly Valves: Butterfly valves shall be constructed of polyvinylidene fluoride with EPDM or FPM seats
available, manufactured for installation in SYGEF® Standard Piping system, Type 567 (lug style) or Type 568
(wafer style) as manufactured by GF Piping Systems LLC. Pneumatic/Electrical valve actuators, if required
shall be supplied by GF Piping Systems LLC to ensure proper system operation.
20
PART 3 - EXECUTION
3.1 HANDLING
21
3.2 INSTALLATION
A. System components shall be installed using the socket fusion joining methods according to current installation
instructions as delivered in print or documented online at www.gfpiping.com.
system:
For Socket Fusion Installation – SG 110, SG 160 Socket Fusion Machines or MSE Handtool
3.3 TESTING
22
Pressure/Temperature
Long-Term Stress
To determine the long-term strength of thermoplastic pipe, lengths of pipe are capped at both ends (Figure 1) and
subjected to various internal pressures, to produce circumferential stresses that will predict failure in from 10hrs to 50yrs.
The test is run according to ASTM D1598, “Standard Test for Time to Failure of Plastic Pipe Under Long-Term Hydrostatic
Pressure.”
The resulting failure points are used in a statistical analysis (outlined in ASTM D2837) to determine the characteristic
regression curve that represents the stress/time-to-failure relationship of the particular thermoplastic pipe compound.
The curve is represented by the equation
log T = a+b log S
Where a and b are constants describing the slope and intercept of the curve, and T and S are time-to-failure and stress,
respectively.
Length = 7 x min.
dia. 12” min.
Figure 1 for any size
O.D. = “Do”
wall = “t”
End Closure - Fused
The regression curve may be plotted on log-log paper as shown in Figure 2 and extrapolated from 5yrs to 25yrs. The
stress at 25yrs is known as the hydrostatic design basis (HDB) for that particular thermoplastic compound. From this HDB
the hydrostatic design stress (HDS) is determined by applying the service factor multiplier.
Figure 2 Figure 3
Based on 25yrs
25yrs
5800 240
50 °F
4351 68 °F
86 °F 220
104 °F
3626 122 °F 200
140 °F PVDF PN16
Permissible Pressure (PSI)
2901 180
158 °F
176 °F 160
2176 194 °F
Hoop Stress (lbs/in2)
203 °F 140
212 °F
120
230 °F
1450 PVDF PN10
1305 248 °F 100
1160
266 °F 80
1015
870 284 °F 60
725 40
20
580
508
-10 10 30 50 70 90 110 130 150 170 190 210 230 250 270 290
435
Temperature (°F)
363
290
10hrs
5yrs
100hrs
1hr
10yrs
25yrs
50yrs
0.1hr
1000hrs
1yr
Time to Failure
Regression Curve Working Temperature and Pressures for

Stress/Time to failure for SYGEF® PVDF SYGEF® PVDF
Based on 25-year service life. Service Factor C=2.0
23
Dimensional Pipe Size
Pipe Size Comparison
Table 1
Outside Dimensions Wall Thickness Inside Dimensions

Nominal Outside SYGEF® PVDF SYGEF® PVDF SYGEF® PVDF SYGEF® PVDF SYGEF® PVDF SYGEF® PVDF
Diameter PN16 PN10 PN16 PN10 PN16 PN10
3/8” - (16mm) 16.0mm — 1.9mm — 12.2mm —
1/2” - (20mm) 20.0mm — 1.9mm — 16.2mm —
3/4”- (25mm) 25.0mm — 1.9mm — 21.2mm —
1” - (32mm) 32.0mm — 2.4mm — 27.2mm —
1 1/4” - (40mm) 40.0mm — 2.4mm — 35.2mm —
1 1/2” - (50mm) 50.0mm — 3.0mm — 44.0mm —
2” - (63mm) 63.0mm — 3.0mm — 57.0mm —
2 1/2” - (75mm) 75.0mm — 3.6mm — 67.8mm —
3” - (90mm) 90.0mm 90.0mm 4.3mm 2.8mm 81.4mm 84.4mm
4” - (110mm) 110.0mm 110.0mm 5.3mm 3.4mm 99.4mm 103.2mm
6” - (160mm) 160.0mm 160.0mm 7.7mm 4.9mm 144.6mm 150.2mm
8” - (200mm) 200.0mm 200.0mm 9.6mm 6.2mm 180.8mm 187.6mm
9” - (225mm) 225.0mm 225.0mm 10.8mm 6.9mm 203.4mm 211.2mm
10” - (250mm) — 250.0mm — 7.7mm — 234.6mm
12” - (315mm) — 315.0mm — 9.7mm — 295.6mm
14” - (355mm) — 355.0mm — 10.8mm — 333.4mm
16” - (400mm) — 400.0mm — 12.1mm — 375.8mm
18” - (450mm) — 450.0mm — 13.6mm — 422.8mm
24
Calculating Pipe Size
Friction Loss Characteristics
Sizing for any piping system consists of two basic components: fluid flow design and pressure integrity design. Fluid flow
design determines the minimum acceptable diameter of pipe and pressure integrity design determines the minimum wall
thickness required. For normal liquid service applications an acceptable velocity in pipes is 7 ±3 (ft/sec), with a maximum
velocity of 7 (ft/sec) at discharge points.
Pressure drops throughout the piping network are designed to provide an optimum balance between the installed cost of
the piping system and the operating cost of the pumps.
Pressure loss is caused by friction between the pipe wall and the fluid, minor losses due to obstructions, change in
direction, etc. Fluid pressure head loss is added to elevation change to determine pump requirements.
Hazen and Williams Formula

The head losses resulting from various water flow rates in plastic piping may be calculated by means of the Hazen and
Williams formula. (located in Figure 4):
C Factors
Tests made both with new pipe and pipe that had been in service revealed that (C) factor values for plastic pipe ranged
between 160 and 165. Thus the factor of 150 recommended for water in the equation (located in Figure 4) is on the
conservative side. On the other hand, the (C) factor for metallic pipe varies from 65 to 125, depending upon the time in
service and the interior roughening. The obvious benefit is that with PVDF piping systems, it is often possible to use a
smaller diameter pipe and still obtain the same or even lower friction losses.
4Q(0.1337)
Independent variable for these tests are gallons per minute and V =
nominal pipe size (OD). Dependent variables are the
( )
Di 2
60 smooth.
velocity friction head and pressure drop per 100ft. of pipe, with the interior
12
Hazen and Williams Formula:
( )
V 1.852
ΔH = (L + Le) · D
1.318 · C · ( 4 )0.63i
Figure 4 Step 1: Solve for

ΔPV:= ΔH/2.31
V - Fluid Velocity (ft/sec) 4Q(0.1337)

V=
( )
∆P - Head Loss (lb/in2 /100 ft of pipe 4Q(0.1337) Di 2
V= 60
∆H - Head Loss (ft of water /100 ft of pipe) 12
( )
Di 2
L - Length of Pipe Run (ft) 60
4Q(0.1337)
V = 12
Step 2: Solve for ∆H: D 2
Le - Equivalent Length of Pipe for minor losses (ft)
Di - Pipe Inside Diameter (in)
60
ΔH = (L + Le) · 12 (( )
i
V
D
1.318V· C · ( 4 )0.63 i
1.852
)
( )
1.852
Q - Fluid Flow (gal/min) ΔH = (L + Le) · D
C - Constant for Plastic Pipes (conservative - 150) 1.318 · C · ( 4 )0.63 1.852
i
ΔP = ΔH/2.31
( )
V
ΔH = (L + Le) · D
=1.318
ΔP∆P:
Step 3: Solve for · C · ( 4 )0.63
ΔH/2.31
i
ΔP = ΔH/2.31
25
Flow Rate vs. Friction Loss - SYGEF® PVDF (PN16)
Table 2
Flow V ∆H ∆P V ∆H ∆P V ∆H ∆P V ∆H ∆P Flow
Rate Rate
(GPM) 16mm 20mm 25mm 32mm (GPM)
0.5 0.89 0.97 0.42 0.5
0.75 1.33 2.05 0.89 0.75
1 1.77 3.49 1.51 1.00 0.88 0.38 1
2 3.54 12.58 5.45 2.01 3.17 1.37 1.17 0.86 0.37 2
3 5.31 26.66 11.54 3.01 6.71 2.90 1.76 1.81 0.78 1.07 0.54 0.23 3
4 7.08 45.42 19.66 4.02 11.43 4.95 2.35 3.09 1.34 1.43 0.92 0.40 4
5 8.85 68.66 29.72 5.02 17.28 7.48 2.93 4.67 2.02 1.78 1.39 0.60 5
6 10.63 96.24 41.66 6.03 24.22 10.48 3.52 6.54 2.83 2.14 1.95 0.84 6
7 12.40 128.04 55.43 7.03 32.22 13.95 4.11 8.70 3.77 2.49 2.59 1.12 7
8 14.17 163.96 70.98 8.03 41.26 17.86 4.69 11.15 4.83 2.85 3.32 1.44 8
9 9.04 51.32 22.22 5.28 13.86 6.00 3.21 4.12 1.79 9
10 10.04 62.38 27.00 5.86 16.85 7.29 3.56 5.01 2.17 10
11 11.05 74.42 32.22 6.45 20.10 8.70 3.92 5.98 2.59 11
12 12.05 87.43 37.85 7.04 23.62 10.22 4.28 7.03 3.04 12
13 7.62 27.39 11.86 4.63 8.15 3.53 13
14 8.21 31.42 13.60 4.99 9.35 4.05 14
15 8.80 35.71 15.46 5.34 10.62 4.60 15
17.5 10.26 47.50 20.56 6.23 14.13 6.12 17.5
20 11.73 60.83 26.33 7.13 18.09 7.83 20
25 14.66 91.96 39.81 8.91 27.35 11.84 25
30 10.69 38.34 16.60 30
35 12.47 51.01 22.08 35
40 14.25 65.32 28.28 40
Note: Caution should be taken when velocities fall within the shaded levels.
26
Table 2 - continued
Rate Rate
1 0.21 0.02 0.01 1
2.5 0.53 0.11 0.05 2.5
5 1.06 0.40 0.17 0.68 0.13 0.06 5
10 2.13 1.43 0.62 1.36 0.48 0.21 0.81 0.14 0.06 10
15 3.19 3.03 1.31 2.04 1.02 0.44 1.22 0.29 0.13 0.86 0.12 0.05 15
20 4.25 5.16 2.23 2.72 1.74 0.75 1.62 0.49 0.21 1.15 0.21 0.09 20
25 5.32 7.80 3.38 3.40 2.63 1.14 2.03 0.75 0.32 1.43 0.32 0.14 25
30 6.38 10.94 4.73 4.08 3.69 1.60 2.43 1.05 0.45 1.72 0.45 0.20 30
35 7.45 14.55 6.30 4.77 4.91 2.13 2.84 1.39 0.60 2.01 0.60 0.26 35
40 8.51 18.63 8.07 5.45 6.29 2.72 3.25 1.79 0.77 2.29 0.77 0.33 40
45 9.57 23.17 10.03 6.13 7.82 3.39 3.65 2.22 0.96 2.58 0.95 0.41 45
50 10.64 28.16 12.19 6.81 9.51 4.12 4.06 2.70 1.17 2.87 1.16 0.50 50
55 11.70 33.60 14.55 7.49 11.35 4.91 4.46 3.22 1.39 3.15 1.38 0.60 55
60 12.76 39.48 17.09 8.17 13.33 5.77 4.87 3.78 1.64 3.44 1.63 0.70 60
65 8.85 15.46 6.69 5.27 4.39 1.90 3.73 1.89 0.82 65
70 9.53 17.73 7.68 5.68 5.03 2.18 4.01 2.16 0.94 70
75 10.21 20.15 8.72 6.08 5.72 2.48 4.30 2.46 1.06 75
80 10.89 22.71 9.83 6.49 6.45 2.79 4.59 2.77 1.20 80
95 12.93 31.22 13.52 7.71 8.86 3.84 5.45 3.81 1.65 95
100 8.11 9.74 4.22 5.73 4.19 1.81 100
125 10.14 14.73 6.38 7.17 6.33 2.74 125
150 12.17 20.65 8.94 8.60 8.88 3.84 150
175 14.20 27.47 11.89 10.03 11.81 5.11 175
200 11.47 15.12 6.55 200
225 12.90 18.81 8.14 225
27
Table 2 - continued
Rate Rate
20 0.80 0.09 0.04 20
25 0.99 0.13 0.06 25
30 1.19 0.19 0.08 0.80 0.07 0.03 30
35 1.39 0.25 0.11 0.93 0.09 0.04 35
40 1.59 0.32 0.14 1.07 0.12 0.05 40
45 1.79 0.39 0.17 1.20 0.15 0.06 45
50 1.99 0.48 0.21 1.33 0.18 0.08 0.63 0.03 0.01 50
75 2.98 1.01 0.44 2.00 0.38 0.17 0.95 0.06 0.03 0.60 0.02 0.01 75
100 3.98 1.72 0.75 2.67 0.65 0.28 1.26 0.11 0.05 0.81 0.04 0.02 100
125 4.97 2.60 1.13 3.33 0.98 0.43 1.58 0.16 0.07 1.01 0.05 0.02 125
150 5.97 3.65 1.58 4.00 1.38 0.60 1.89 0.22 0.10 1.21 0.08 0.03 150
175 6.96 4.85 2.10 4.67 1.84 0.79 2.21 0.30 0.13 1.41 0.10 0.04 175
200 7.96 6.21 2.69 5.34 2.35 1.02 2.52 0.38 0.16 1.61 0.13 0.06 200
225 8.95 7.73 3.35 6.00 2.92 1.27 2.84 0.47 0.20 1.81 0.16 0.07 225
250 9.95 9.39 4.07 6.67 3.55 1.54 3.15 0.57 0.25 2.02 0.19 0.08 250
275 10.94 11.21 4.85 7.34 4.24 1.84 3.47 0.68 0.30 2.22 0.23 0.10 275
300 11.93 13.16 5.70 8.00 4.98 2.16 3.78 0.80 0.35 2.42 0.27 0.12 300
325 12.93 15.27 6.61 8.67 5.78 2.50 4.10 0.93 0.40 2.62 0.31 0.14 325
350 9.34 6.63 2.87 4.41 1.07 0.46 2.82 0.36 0.16 350
400 10.67 8.48 3.67 5.04 1.37 0.59 3.23 0.46 0.20 400
450 12.00 10.55 4.57 5.67 1.70 0.74 3.63 0.57 0.25 450
500 13.34 12.83 5.55 6.30 2.07 0.90 4.03 0.70 0.30 500
600 7.56 2.90 1.26 4.84 0.98 0.42 600
700 8.82 3.86 1.67 5.64 1.30 0.56 700
800 10.08 4.94 2.14 6.45 1.67 0.72 800
900 11.35 6.15 2.66 7.26 2.07 0.90 900
1000 12.61 7.48 3.24 8.06 2.52 1.09 1000
1200 9.68 3.53 1.53 1200
1400 11.29 4.70 2.03 1400
1600 12.90 6.02 2.61 1600
28
Table 2 - continued
Flow V ∆H ∆P Flow
Rate Rate
(GPM) 225mm (GPM)
100 0.64 0.02 0.01 100
150 0.96 0.04 0.02 150
200 1.27 0.07 0.03 200
250 1.59 0.11 0.05 250
300 1.91 0.15 0.07 300
350 2.23 0.20 0.09 350
400 2.55 0.26 0.11 400
500 3.19 0.39 0.17 500
600 3.82 0.55 0.24 600
700 4.46 0.73 0.32 700
800 5.10 0.94 0.41 800
900 5.73 1.17 0.51 900
1000 6.37 1.42 0.62 1000
1150 7.33 1.84 0.80 1150
1300 8.28 2.31 1.00 1300
1450 9.24 2.83 1.22 1450
1600 10.19 3.39 1.47 1600
1750 11.15 4.01 1.73 1750
1900 12.11 4.67 2.02 1900
29
Table 3
Rate Rate
20 0.74 0.07 0.03 20
25 0.93 0.11 0.05 25
30 1.11 0.16 0.07 0.74 0.06 0.03 30
40 1.48 0.26 0.11 0.99 0.10 0.04 40
50 1.85 0.40 0.17 1.24 0.15 0.07 0.58 0.02 0.01 0.37 0.01 0.00 50
75 2.78 0.85 0.37 1.86 0.32 0.14 0.88 0.05 0.02 0.56 0.02 0.01 75
100 3.70 1.44 0.62 2.47 0.54 0.23 1.17 0.09 0.04 0.75 0.03 0.01 100
125 4.63 2.18 0.94 3.09 0.82 0.35 1.46 0.13 0.06 0.94 0.04 0.02 125
150 5.55 3.06 1.32 3.71 1.15 0.50 1.75 0.19 0.08 1.12 0.06 0.03 150
175 6.48 4.07 1.76 4.33 1.53 0.66 2.04 0.25 0.11 1.31 0.08 0.04 175
200 7.40 5.21 2.26 4.95 1.96 0.85 2.34 0.32 0.14 1.50 0.11 0.05 200
225 8.33 6.48 2.80 5.57 2.44 1.05 2.63 0.39 0.17 1.69 0.13 0.06 225
250 9.25 7.88 3.41 6.19 2.96 1.28 2.92 0.48 0.21 1.87 0.16 0.07 250
275 10.18 9.40 4.07 6.81 3.53 1.53 3.21 0.57 0.25 2.06 0.19 0.08 275
300 11.10 11.04 4.78 7.42 4.15 1.80 3.51 0.67 0.29 2.25 0.23 0.10 300
325 12.03 12.80 5.54 8.04 4.81 2.08 3.80 0.78 0.34 2.43 0.26 0.11 325
400 9.90 7.07 3.06 4.67 1.14 0.49 3.00 0.39 0.17 400
450 11.14 8.79 3.81 5.26 1.42 0.61 3.37 0.48 0.21 450
500 12.37 10.69 4.63 5.84 1.72 0.75 3.74 0.58 0.25 500
600 7.01 2.41 1.04 4.49 0.82 0.35 600
700 8.18 3.21 1.39 5.24 1.09 0.47 700
800 9.35 4.11 1.78 5.99 1.39 0.60 800
1000 11.68 6.21 2.69 7.49 2.11 0.91 1000
1200 14.02 8.71 3.77 8.99 2.95 1.28 1200
1400 10.49 3.93 1.70 1400
1600 11.98 5.03 2.18 1600
1800 13.48 6.26 2.71 1800
30
Table 3 - continued
Rate Rate
100 0.59 0.02 0.01 100
150 0.89 0.04 0.02 0.72 0.02 0.01 150
200 1.18 0.06 0.03 0.96 0.04 0.02 200
250 1.48 0.09 0.04 1.20 0.05 0.02 0.75 0.02 0.01 250
300 1.77 0.13 0.06 1.44 0.08 0.03 0.90 0.02 0.01 0.71 0.01 0.01 300
350 2.07 0.17 0.07 1.68 0.10 0.04 1.06 0.03 0.01 0.83 0.02 0.01 350
400 2.36 0.22 0.09 1.92 0.13 0.06 1.21 0.04 0.02 0.95 0.02 0.01 400
500 2.95 0.33 0.14 2.39 0.20 0.09 1.51 0.06 0.03 1.19 0.04 0.02 500
750 4.43 0.69 0.30 3.59 0.42 0.18 2.26 0.14 0.06 1.78 0.08 0.03 750
1000 5.91 1.18 0.51 4.79 0.71 0.31 3.02 0.23 0.10 2.37 0.13 0.06 1000
1250 7.39 1.79 0.77 5.99 1.07 0.46 3.77 0.35 0.15 2.96 0.19 0.08 1250
1300 7.68 1.92 0.83 6.23 1.15 0.50 3.92 0.37 0.16 3.08 0.21 0.09 1300
1350 7.98 2.06 0.89 6.47 1.24 0.54 4.07 0.40 0.17 3.20 0.22 0.10 1350
1400 8.27 2.21 0.96 6.70 1.32 0.57 4.22 0.43 0.19 3.32 0.24 0.10 1400
1500 8.86 2.51 1.09 7.18 1.50 0.65 4.52 0.49 0.21 3.56 0.27 0.12 1500
1750 10.34 3.34 1.44 8.38 2.00 0.87 5.28 0.65 0.28 4.15 0.36 0.16 1750
2000 11.82 4.27 1.85 9.58 2.56 1.11 6.03 0.83 0.36 4.74 0.46 0.20 2000
2250 13.30 5.31 2.30 10.78 3.19 1.38 6.79 1.04 0.45 5.34 0.58 0.25 2250
2500 11.97 3.87 1.68 7.54 1.26 0.54 5.93 0.70 0.30 2500
2750 13.17 4.62 2.00 8.30 1.50 0.65 6.52 0.84 0.36 2750
3000 9.05 1.76 0.76 7.11 0.98 0.43 3000
3500 10.56 2.35 1.02 8.30 1.31 0.57 3500
4000 12.07 3.00 1.30 9.49 1.67 0.72 4000
4500 13.57 3.74 1.62 10.67 2.08 0.90 4500
5000 11.86 2.53 1.09 5000
5500 13.04 3.02 1.31 5500
31
Table 3 - continued
Flow V ∆H ∆P V ∆H ∆P Flow
Rate Rate
(GPM) 400mm 450mm (GPM)
400 0.75 0.01 0.01 400
500 0.93 0.02 0.01 0.74 0.01 0.00 500
750 1.40 0.04 0.02 1.11 0.02 0.01 750
1000 1.87 0.07 0.03 1.47 0.04 0.02 1000
1250 2.33 0.11 0.05 1.84 0.06 0.03 1250
1300 2.43 0.12 0.05 1.92 0.07 0.03 1300
1350 2.52 0.12 0.05 1.99 0.07 0.03 1350
1400 2.61 0.13 0.06 2.06 0.08 0.03 1400
1500 2.80 0.15 0.07 2.21 0.09 0.04 1500
1750 3.27 0.20 0.09 2.58 0.11 0.05 1750
2000 3.73 0.26 0.11 2.95 0.15 0.06 2000
2250 4.20 0.32 0.14 3.32 0.18 0.08 2250
2500 4.67 0.39 0.17 3.69 0.22 0.10 2500
2750 5.13 0.47 0.20 4.05 0.26 0.11 2750
3000 5.60 0.55 0.24 4.42 0.31 0.13 3000
3500 6.53 0.73 0.32 5.16 0.41 0.18 3500
4000 7.47 0.93 0.40 5.90 0.53 0.23 4000
4500 8.40 1.16 0.50 6.64 0.65 0.28 4500
5000 9.33 1.41 0.61 7.37 0.80 0.34 5000
5500 10.27 1.69 0.73 8.11 0.95 0.41 5500
6000 11.20 1.98 0.86 8.85 1.12 0.48 6000
6500 12.13 2.30 0.99 9.58 1.29 0.56 6500
7000 10.32 1.48 0.64 7000
7500 11.06 1.69 0.73 7500
8000 11.80 1.90 0.82 8000
32
Friction Loss Through Fittings and Valves
Table 4
Elastomer Butterfly Valve

For Industry Standard
Male/Female Adapter
Ball Valve, Full Bore

45 Elbow (Molded)
90 Elbow (Molded)
(Single Reduction)
Flow thru branch
Reducer Bushing
Diaphragm Valve
Flow thru run
Type 5-Series
Standard Tee
Standard Tee
(Full Open)
(Full Open)
Fitting or
Valve
Type
SYGEF® PVDF
Nominal
Equivalent Length of Pipe (ft.)
Pipe Size
16mm 0.9 0.5 0.6 1.8 — 0.5 0.1 — 1.7
20mm 1.5 0.8 1.0 4.0 1.0 1.0 0.2 8.1 2.5
25mm 2.0 1.0 1.4 5.1 1.1 1.3 0.3 9.6 3.3
32mm 2.7 1.3 1.7 6.0 1.2 1.6 0.3 14.0 4.2
40mm 3.5 1.7 2.3 6.9 1.4 2.2 0.4 11.0 5.0
50mm 4.2 2.1 2.7 8.1 1.7 2.6 0.5 12.0 6.7
63mm 5.5 2.7 4.3 12.0 2.6 3.5 0.8 13.0 10.0
75mm 7.0 3.5 5.1 14.3 3.6 — — — 13.3
90mm 8.0 4.0 6.3 16.3 4.4 — — — 20.0
110mm 11.0 5.5 8.3 22.1 5.2 — — — 26.7
160mm 16.0 8.0 13.0 32.0 7.0 — — — 33.3
200mm 20.0 10.0 16.5 40.0 10.0 — — — 40.0
225mm 22.5 11.2 18.6 45.0 11.2 — — — 46.7
250mm 25.0 12.5 30.5 50.0 12.5 — — — 60.7
315mm 31.5 15.7 38.4 63.0 15.7 — — — 78.9
355mm 29.8 17.9 36.1 71.6 17.6 — — — —
400mm 33.8 20.3 40.8 80.7 19.8 — — — —
450mm 38.1 22.9 46.0 91.0 22.4 — — — —
33
Gravity Drain Systems
Flow Rate for Gravity Drain Systems
Drainage flow is caused by gravity due to slope of all drainage piping. Drainage piping is deliberately designed to run only
partially full; a full pipe, particularly a stack, could blow out or suck out all the trap seals in the system. For a given type
of pipe (friction,) the variables in drainage flow are slope and depth of liquid. When these two factors are known, the flow
velocity V and flow rate Q can be calculated. The approximate flow rates and velocities can be calculated as follows:
FORMULA
Q - Flow Rate (gpm) Example Problem: 1.486

System Information
Q =A· · R2/3 · S1/2 Q =
A - Section Area Pipe (ft ) 2
n
Material: 6” (160mm)
n - Manning Friction Factor 0.009
SYGEF® PVDF (PN10) FORMULA
R - Hydraulic Radius of pipe 0D(ft)/4 Outer Diameter: 6.3in (160.0mm)
Q =
1.486 S1/2
S - Hydraulic Gradient - Slope (in/ft) Inside Diameter: 5.9in (150.2mm) V = · R2/3 ·
n 12
Q =
FORMULA
1.486 1.486 1.486

Q =A· · R2/3 · S1/2 Q = .0953 · · (0.1232)2/3 · (0.0208)1/2 V = · (0.1232)2/3 ·
Q - Flow Rate (gpm) n 0.009 0.009 Q =
A FORMULA
- Section Area Pipe 0.1906 full = 0.0953 ½full (ft2)
FORMULA
Q = 15.74 · 0.248 · 0.144 V = 165.1 · 0.248 · 0.012
n - Manning1.486
Friction Factor 0.009 1.486 S1/2 1.486 1.486 0.144
Q =A· ·R ·S V =
2/3 1/2
· R Q· = .0953 ·
2/3 · (0.1232)2/3 · (0.0208)1/2 V = · (0.1232) ·
2/3
R - Hydraulic nRadius of pipe 0.1232n (ft) 12 0.009 0.009 12
Q = 0.562 (ft3/sec) V = 0.491 (ft/sec)
S - Hydraulic Gradient - Slope 1/8 (in/ft) = 0.0104
FORMULA
Slope Q = 15.74 · 0.248 · 0.144
1/4 (in/ft) = 0.0208 V = 165.1 · 0.248 · 0.012
1.486 S 1/2
Q = 252.2 (gpm)
V = n
· R2/3 · Slope 1/2 (in/ft) = 0.0416
12
Table 5 Q = 0.562 (ft3/sec) V = 0.491 (ft/sec)
Approximate Discharge Rates and Velocities in Sloping Drains Flowing Half-Full
SYGEF® PVDF
Q (PN16)
= 252.2 (gpm) SYGEF® PVDF (PN10)
1/8 (in/ft) Slope 1/4 (in/ft) Slope 1/2 (in/ft) Slope 1/8 (in/ft) Slope 1/4 (in/ft) Slope 1/2 (in/ft) Slope
Flowrate
Flowrate
Flowrate
Flowrate
Flowrate
Flowrate
Nominal
Velocity
Velocity
Velocity
Velocity
Velocity
Velocity
(gpm)
(gpm)
(gpm)
(gpm)
(gpm)
(gpm)
Pipe
(fps)
(fps)
(fps)
(fps)
(fps)
(fps)
Diameter
16mm 0.2 0.07 0.3 0.09 0.4 0.13
20mm 0.5 0.08 0.7 0.11 0.9 0.16
25mm 1.0 0.09 1.4 0.13 1.9 0.19
32mm 1.9 0.11 2.6 0.16 3.7 0.22
40mm 3.7 0.13 5.3 0.19 7.5 0.26
50mm 6.8 0.15 9.6 0.22 13.5 0.31
63mm 13.5 0.18 19.0 0.26 26.9 0.36
75mm 21.4 0.20 30.3 0.29 42.8 0.41
90mm 34.8 0.23 49.3 0.33 69.7 0.46 38.4 0.24 54.3 0.33 76.7 0.47
110mm 59.3 0.26 83.9 0.37 118.7 0.53 65.6 0.27 92.8 0.38 131.2 0.54
160mm 161.2 0.34 228.0 0.48 322.5 0.68 178.4 0.35 252.3 0.49 356.9 0.69
200mm 292.6 0.39 413.7 0.56 585.1 0.79 322.8 0.40 456.6 0.57 645.7 0.81
225mm 401.6 0.43 567.9 0.60 803.1 0.85 442.8 0.44 626.2 0.62 885.6 0.87
250mm 586.0 0.47 828.7 0.66 1172.0 0.94
315mm 1085.3 0.55 1534.9 0.77 2170.7 1.09
355mm 1496.0 0.59 2115.7 0.84 2992.0 1.18
400mm 2058.6 0.64 2911.3 0.91 4117.2 1.28
450mm 2818.7 0.69 3986.2 0.98 5637.4 1.39
34
Surge pressure, or water hammer, is a term used to describe dynamic surges caused by pressure changes in a piping
system. They occur whenever there is a deviation from the steady state, i.e.; when the velocity of the fluid is increased or
decreased, and may be transient or oscillating. Waves of positive or negative pressure may be generated by any of the
following:
• Opening or closing of a valve
• Pump startup or shutdown
• Change in pump or turbine speed
• Wave action in a feed tank
• Entrapped air
The pressure waves travel along at speeds limited by the speed of sound in the medium, causing the pipe to expand and
contract. The energy carried by the wave is dissipated and the waves are progressively damped (see Figure 5).
The pressure excess to water hammer must be considered in addition to the hydrostatic load, and this total pressure must
be sustainable by the piping system. In the case of oscillatory surge pressures, extreme caution is needed as surging at
the harmonic frequency of the system could lead to catastrophic damage.
Wavelength
Figure 5
The maximum positive or

negative addition of pressure
Pressure
Change due to surging is a function
of fluid velocity, fluid density,
bulk fluid density and pipe
dimensions of the piping
Dampened Pressure Wave system. It can be calculated
using the following steps.
Step 1
STEP 1:
Determine the velocity of the pressure wave in pipes.
√ √
V w - Velocity of Pressure Wave (ft./sec) K 3.19 x 105
K - Bulk Density of Water 3.19 x 105 (lb/in2)
Vw = Vw = 1
Vw = 4870
ni · δ 144 · 1.937
ni - Conversion Factor 1/144 (ft2 /in2)
δ - Fluid Density of Water 1.937 (slugs/ft3)
STEP 2:
2L 2 · 500
tc = tc = tc = 0.2 (sec)
Vw 4870
STEP 3:
1.937 · 4 · 4870
Pi = δ · V · Vw ni Pi = Pi = 2
144
35
STEP 4:
√ √
K 3.19 x 105
Vw =
STEP 1:
Vw = 1
Vw = 4870 (ft/sec)
n ·δ · 1.937
√√ √√
STEP 1: 144
K i 3.19 x 105
Vw =2
Step Vw = 1
Vw = 4870 (ft/sec)
STEP 2: n K 3.19 x 10 5
· δ · 1.937
Vw =time for
Critical Vw = 1441
i valve closure. Vw = 4870 (ft/sec)
ni · δ 144 ·t1.937
STEP 1:
STEP 2: 2L 2 · 500c - Time for Valve Closure (sec)
√ √
tc = tc = tc = 0.2
V - Velocity (sec) Wave (ft/sec)
of Pressure
Vw 4870 w K 3.19 x 105
STEP 2:
Vw = Vw = Vw = 48
2L 2 · 500 L - Upstream Pipe Length (ft) ni · δ
1
· 1.937
tc = tc = tc = 0.2 (sec) 144
V2L 24870
· 500
tc = w
tc = tc = 0.2 (sec)
Step 3 3: V
STEP 4870 STEP 2:
w
Maximum pressure increase; assume valve Pi - Maximum Total Pressure (lb/in2)
closure
STEP 3: time is less than the critical closure
1.937time
·4
· 4870
δ - Fluid Density (slugs/ft 2L 2 · 500
tc = 2) )
3
Pi =velocity
and fluid δ · V goes
· Vw ntoi 0. Pi = Pi = 262 (lb/in tc = tc = 0.2 (sec)
STEP 3: 144 V - Fluid Velocity (ft/sec) Vw 4870
1.937 · 4 · 4870 Vw - Velocity of Pressure Wave
Pi = δ · V · Vw ni Pi = Pi = 262 (lb/in2)
1.937144· 4 · 4870 in - Conversion Factor 1/144 (ft2 /in2)
Pi = δ · V · Vw ni Pi = Pi = 262 (lb/in 2
)
STEP 4:
144 STEP 3:
Special Consideration
STEP P
1.937 · 4 · 4870
Calculate
4:
max
= Maximum
the Pi + Ps Instantaneous
Pmax = 262 + 50
System Pmax = 312 (lb/in
Cautionary Note )Pi = δ · V · Vw ni
2
Pi = Pi
Pressure. 144
STEP 4:
Caution is recommended if Pmax is greater than the maximum
Pmax = Pi + Ps Pmax = 262 + 50 Pmax = 312 (lb/in2)
system design pressure multiplied by a safety factor of 2x.
Pmax = Pi + Ps Pmax = 262 + 50 Pmax = 312 (lb/in2)
e.g. - Pipe is rated at 150 psi. If Pmax exceeds 300psi (150psi x 2
STEP 5: STEP 4:
Pmax - Maximum System Operating Pressure (lb/in2) safety factor), then precaution must be implemented in case of
Pi maximum pressure wave (i.e. water hammer) to prevent possible
2- ·Maximum
δ · L · VPressure Increase (lb/in ) 2
STEP 5: · ni 2 · 1.9372 · 500pipe
1
· 4 ·failure. P = Pi + P2s Pmax = 262 + 50 Pmax = 312
Pg P=s - Standard System OperatingPPressure
g
= (lb/in )
144
Pg = max
26.9 (lb/in )
STEP 5: tv 2
2 · δ · L · V · ni 2 · 1.937 · 500 · 4 · 144
1
Pg = Step 4 Pg = Pg = 26.9 (lb/in2)

2 · δ ·t L · V · ni 2 · 1.937 2· 500 · 4 · 144
1
Pg = Determine v the Maximum Pmax =PPggPressure

System +P
= s
Pmax
Increase = 26.9
with + 50Valve
Gradual = 76.9
g
=(lb/in )
26.9 2(lb/in
PClosure 2
)
tv 2 STEP 5:
Pg - Gradual Pressure Increase with Valve Closure (lb/in )2
PmaxLength
L - Upstream Pipe = Pg(ft.)
+ Ps Pmax = 26.9 + 50 = 76.9 (lb/in
2 · δ) · L · V · ni
2
1
2 · 1.937 · 500 · 4 ·
V - Fluid VelocityP(ft./sec)
=P + Ps Pg =(lb/in2)
Pmax = 26.9 + 50 = 76.9 Pg = 144
max g
ni - Conversion Factor 1/144 (ft2 /in2)
tv 2
tc - Time of Valve Closure (sec)
Pmax = Pg + Ps Pmax = 26.9 + 50 =
Example Problem
A water pipeline from a storage tank is connected to a master valve, which is hydraulically actuated with an electrical
remote control. The piping system flow rate is 300 (gal/min) with a velocity of 4 (ft./sec); thus requiring a 6” (160mm)
nominal pipeline. The operating pressure of the system will be 50 (lb/in2), the valve will be 500 (ft.) from the storage
tank and the valve closing time is 2.0 (sec). Determine the critical time of closure for the valve, and the internal system
pressure should the valve be instantaneously or suddenly closed vs. gradually closing the valve (10 times slower).
Pipe Details
System Information Other Information
Material: 6” (160mm) SYGEF® (PVDF) PN10 Bulk Water Density (K) 3.19 x 105 (lb/in2)
Flow Rate: 300 (gal/min) Fluid Density (δ) 1.937 (slugs/ft3)
Pipeline Length: 500 (ft) Valve Closing Time 2.0 (sec)
Operating Pressure: 50 (lb/in )2
Water Velocity 3.5 (ft/sec)
36
Step 1 - Velocity of Pressure Wave STEP 1:
√ √
Determine the Velocity of the Pressure Wave
K 3.19 x 105
V w - Velocity of Pressure Wave (ft/sec) Vw = Vw = 1
Vw = 4870 (ft/
K - Bulk Density of Water 3.19 x 10 (lb/in ) 5 2
STEP 1: ni · δ 144 · 1.937
√ √
STEP 1:
ni - Conversion Factor 1/144 (ft 2 /in2) K 3.19 x 105
V = Vw = Vw = 4870 (ft
√ √
STEP 2:
δ - Fluid Density 1.937 (slugs/ft ) 3
STEPw1: 1
K 3.19 x 105 ni · δ · 1.937
Vw = STEP 1: Vw = STEP 1: Vw = 4870 (ft/sec)
144
√ √
ni · δ
1
144 · 1.937
2L K 2 · 5003.19 x 10t 5 = 0.2 (sec)
VtSTEP =2: tc V = =
√ √ √
cw 5= Vw = 4870 (ft/s
√
c
Step 2 -1:Critical Valve Closure KTime 3.19 x 10 K Vnw · δ w
48701x 10
3.19 ·
5
1.937
STEP
STEP 2:
Vw = Vw = 1 Vw =
Viw = 4870 Vw = (ft/sec) 144 Vw = 4870 (ft/sec)
Determine the Critical Closure Timen · δ · 1.937 1
√ √
STEP 1:
i 144 n · δ2L 2 · 500 · 1.937
K 3.19 x 10 5 STEP 1: i
tc 2:= (ft/sec) tc =
144
tc = 0.2 (sec)
√√ √√
Vw = Closure Time (sec)Vw = V =STEP
4870 K V 3.19 4870 x 10 5
t - Critical 2L 1 · 500
2 w
=ni · δSTEP t = 144 · 1.937 tc VSTEP =2:STEP Vw = 3.19 Vw = 4870 (ft/sec)
c
STEPt1: =w0.2 (sec)

2: 3: w
V - Velocity K x 105
of
c Pressure
VwWave 4870c(ft/sec) 4870
1
w
Vw = ni · δ2L Vw = 2 · · 1.937
500 V = 4870 (ft/sec)
t = t = 144
t = w
0.2 (sec)
√ √
L - Upstream Pipe Length 500 (ft) 1
Kt = 2L 3.19 x210 · 500 c n · δ c · 1.937
1.937 · 4c · 4870
STEP 2:
t =
5
P t = 2L
i
= 0.2 ·VVw(sec)
· V n 2 · 500
144
P 4870 =
Vw = Vw = tc V2:= wSTEP
=i c 4870
3: δ (ft/sec)twc =i tc = 0.2 (sec) Pi = 262 (
ni · δ
c
V 1c 4870 STEP
V 4870
i
144
w 144 · 1.937 STEP 2: w
STEP 2L3: 2 · 500
tc = tc = tc = 0.2 (sec) 1.937 · 4 · 4870
2L 2 · 500
Step 3STEP 2: Vw
- Maximum Pressure Increase 4870 tc = STEP P2L 3:= δ · V ·t V =n P = tc = 0.2 (sec) Pi = 262
c w i2 · 500 i
STEP 3: 1.937 · 4 ·
t 4870=
i
V t = 4870 t = 144
0.2 (sec)
Determine the Pi Maximum
= δ · V Pressure
· Vw ni Increase; Pi Assume:
= Valve Closure
cSTEP 3:Time
STEP
w
Pi = 262
V4:w< Critical Closure
c (lb/inTime )t and Fluid Velocity
4870
c
2 c goes to 0.
2L 2 · 500 144 1.937 · 4 · 4870
tc = Pressure Increase
P - Maximum tc (lb/in
= ) tc = 0.2 (sec) Pi = δ · V · Vw ni Pi = Pi = 262 (
2
i
STEP 3:
Vw P 4870 1.937 ·P4 · 4870 = P + P P 1.937= 2622· 4 + · 144
504870 P Pi = 262(lb/in
= 312
δ - Fluid Density 1.937 (slugs/ft ) 3
= δ · V · Vw ni Pi = STEP Pi 3:=STEP δmax · 4:V · Vwi ni sPi =P262 =max(lb/in ) max (lb/in
V - Fluid Velocity 4 (ft/sec)
i
STEP 3:
144 i
144
V - Velocity of Pressure Wave 4870 (ft/sec)1.937 · 4 · 4870
w
Pi = STEP
δ · 4:V · Vw ni Pi = Pi = 262 (lb/in2) 1.937 · 4 ·+4870
n - Conversion
STEP 3: Factor 1/144 (ft /in )2 2
144 Pi =STEP δP·max V·V = Pni + Ps P =Pmax = 262 50 Pmax
Pi ==262 312(lb/in
(lb/in
1.937 ·144 4 · 4870
i
4: w i i
Pmax = PSTEP i
+P 4: s Pmax = 262 + 50 PSTEP = δSTEP
i Pmax
4:
· V=5:·312 Vw n(lb/ini
2P =
) i 144
Pi = 262 (lb/in2
1.937 · 4 · 4870 P
Pi = δ ·Maximum
Consideration: V · Vw ni Instantaneous Pi = System Pressure max Pi == P 262i
+ P(lb/in
s
2 P
) max = 262 + 50 Pmax = 312 (lb/in2
STEP 4: Pmax = Pi + Ps System P 2
144= 262P+ 50= P +PP = i312 · δ · L · V · n P (lb/in =
2
262 )than+the2 50 · 1.937 P · 500= ·
3124 ·
1
(lb/in 2
)P
Determining the Maximum Instantaneous Pressure:
max PgSTEP
Caution=max is
4: STEP 5:
recommended
i maxs if P
max
is
max greaterPg = Maximum System
max
144
g
Operating Pressure multiplied by a 2x Service Factor. t v
2
STEP 4:
Pmax STEP= P5:i + Ps Pmax = 262 + 50 Pmax = 312 (lb/in2)
Pmax 2= ·Pδi +· LPs· V · ni Pmax = 262 + 50
P - Maximum Instantaneous Operating Pressure (lb/in ) 2 1
max
2 · 1.937 Pmax· 500 = 312 · 4 (lb/in
· 144 2)
STEP 4:
P - Valve Pressure (instantaneous) (lb/in ) 2 P = STEP
Pg max = Pi + 1P 5:
PPmax == 262 P
Pg +g+P50 = PPmax ==26.9
312 +(lb/in50 =2)76.9Pg
i
2 · δ · L · V · ni 2 · 1.937 · 500 · 4 · t s max s max2
PP =
- Standard
s
SystemSTEP 5:
Operating PressureP (lb/in=) 2
STEP 5: 144v
Pg = 26.9 (lb/in2)
g
Pmax
In this case, t
= Pvi + P
6” (160mm) SYGEF Pmax
PVDF
®
g
pipe=is262
rated + at 50 2 2 · δ
Pmax = 312 (lb/in i) · L · V · n 2
2 · 1.937 · 500 · 4 · 144
1
s
2 · δ ·design L · Vis· outside
ni Pg = 1 Pg = Pg
22··1.937
δ · L ·· V500 tv· ni· 4 · 144Pmax =PPg2
1
STEP
150psi. 5:
Therefore,
Pg =
the system safety
Pg = STEP 5: =+·26.9
P1.937 (lb/in·P500 22 ·=
) 4 26.9
· 144 + 50 = 76.9
P = s max
Pg = 2
limits (300psi max). tPv = P + P
g
P = 26.9 t +250 = 76.9 (lb/ing2) g 2
2 · δ · L · V · ni max g s
2 · 1.937 max
· 500
STEP 5:
· 4 · 144
1 v
Pg = Pg = 2 · δ · L · V · nP = 26.9 Pmax(lb/in = Pg2+)·P1.937
2
P500 = 26.91
+ 50 = 76.9 (
t 2 i g s · max · 4 · 144
STEP 5: P
Pmax = Pgg + Ps = 2 · δ · L · V
Pt max = 26.9 · n + 50= =P76.9 P = 2(lb/in
1
Pg = 26
· 1.937 P)max ·2500 · 4 · +14450 = 76.9
v 2
Pg =
i Pmax Pgg +=Ps
g = 26.9 Pg =(lb/i
26.
v
2 · δ · L · V · ni tv 1 2
Pg = Pmax = Pg +PPs = 2 · P1.937 max
= ·26.9
500 ·+450 · 144 = 76.9 (lb/in Pg = 26.9
2
) (lb/in2)
g
tv 2 P max
= P g
+ Ps Pmax = 26.9 + 50 = 76.9 (lb/in
Pmax = Pg + Ps Pmax = 26.9 + 50 = 76.9 (lb/in
Pmax = Pg + Ps Pmax = 26.9 + 50 = 76.9 (lb/in2)
37
Expansion/Contraction
Allowing for Length Changes in PVDF Pipelines
Variations in temperature cause greater length changes in thermoplastic materials than in metals. In the case of above
ground, wall or duct mounted pipe work, particularly where subjected to varying working temperatures, it is necessary to
make suitable provision for length changes in order to prevent additional stresses.
Calculation and Positioning of Flexible Sections

It is possible to take advantage of the very low modulus
of elasticity of PVDF by including special sections of pipe
423
420
which compensate thermal length changes. The length of 400
the flexible section mainly depends upon the pipe diameter
and the extent of the length change to be compensated.
In order to simplify planning and installation, the third
330
influencing factor— the pipe wall temperature —is not
300
taken into account, particularly as installation usually
takes place in the temperature range between 37°F (3°C)
and 77°F (25°C).
Modulus of Elasticity
Where the pipe work changes direction or branches off, E x 10 3 (PSI)
213
200
there is always a natural flexible section.
L ¼a L
There are two primary methods of controlling or
150
compensating for thermal expansion of plastic piping Fixed Guide Fixed
Fixed Guide
systems: taking advantage of offsets and changes of
100
direction
½ a in the piping and expansion loops. a ½a ½a
25
87
Guide Type 1 - Offsets/Changes in Direction Guide

Fixed Guide Fixed Guide
Most piping systems have occasional changes in directions
0
¼a which will allow the thermally included length changes to ¼a
PE100
POLYPRO
PVDF
ABS
PVC
CPVC
be taken up in offsets of the pipe beyond the bends. Where 6”m
this method is employed, the pipe must be able to float

except at anchor points.
Fixed Guide Fixed Guide Fixed
Guide Fixed Guide Guide Fixed Guide
Changes in Direction Offsets
38
6”min. 6”min.
Type 2 -Expansion Loops

For expansion loops the flexible section is broken into two
offsets close together. By utilizing the flexible members
between the legs and 4 elbows the “a” length is slightly Fixed
shorter than the “a” in the standalone offset.
Guide Guide
Expansion Loop

Determining the Length Change (ΔL) (Example 1)
In order to determine the length of flexible section (a) required, the extent of the length change must be ascertained first
of all, by means of the following formula where
∆L = L · ∆T · δ (inch) = (inch) · (ºF) · (inch/inchºF)
L
ΔL = Length change in inches
Installation Temperature
L = Length in inches of the pipe or pipe section where the
length change is to be determined Expansion
+∆l
ΔT = Difference between installation temperature and
Contraction
maximum or minimum working temperature in °F -∆l
δ = Coefficient of linear expansion - 0.000078 in/in°F
Important: L = 315in
L
If the operating temperature is higher than the installation temperature, then the pipe becomes longer. If, on the other
Installation Temperature
hand, the operating temperature is lower than the installation temperature,
Fixed then the
Point pipe contracts its length. The
installation temperature must therefore be incorporated into the calculation, as wellExpansion
as the maximum and minimum +∆l
operating temperatures. Contraction
-∆l
Installation
Problem L = 315in
L = 315in
+∆l2
The procedure is explained using a coolant pipe as an example:
Length of the pipe from the fixed point to the branch where the Fixed Point Fixed Point
length change is to be taken up: L = 315in
Temperature Requirements Installation
Installed Temp Operating Temp Defrost/Cleaning
Expansion L = 315in
Tv = 73°F T1= 40°F T2= 95°F +∆l2
Difference in Contraction Temperature L=

Fixed Point 315in
-∆l1
ΔT1 = Tv - T1 = 73°F - 40°F = 33°F
Fixed Point
Difference in Expansion Temperature Expansion
ΔT2 = T2 - Tv = 95°F - 73°F = 22°F L = 315in
-∆l1
Contraction during service with coolant Contraction Fixed Point
– ΔL1 = L · ΔT1 · δ = 315in · 33 · (0.000078) = 0.81in
Expansion during defrosting and cleaning

Contraction
+ΔL 2 = L · ΔT2 · δ = 315in · 22 · (0.000078) = 0.54in
39
Length Change (ΔL) in Inches
Table 6
Length of Pipe Section (ft)
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
5 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.4 0.4 0.4 0.4 0.4 0.5
10 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.6 0.7 0.7 0.7 0.8 0.8 0.9 0.9
15 0.1 0.1 0.2 0.3 0.4 0.4 0.5 0.6 0.6 0.7 0.8 0.8 0.9 1.0 1.1 1.1 1.2 1.3 1.3 1.4
20 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
25 0.1 0.2 0.4 0.5 0.6 0.7 0.8 0.9 1.1 1.2 1.3 1.4 1.5 1.6 1.8 1.9 2.0 2.1 2.2 2.3
Temperature Change in (°F)
30 0.1 0.3 0.4 0.6 0.7 0.8 1.0 1.1 1.3 1.4 1.5 1.7 1.8 2.0 2.1 2.2 2.4 2.5 2.7 2.8
35 0.2 0.3 0.5 0.7 0.8 1.0 1.1 1.3 1.5 1.6 1.8 2.0 2.1 2.3 2.5 2.6 2.8 2.9 3.1 3.3
40 0.2 0.4 0.6 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.7
45 0.2 0.4 0.6 0.8 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.2 3.4 3.6 3.8 4.0 4.2
50 0.2 0.5 0.7 0.9 1.2 1.4 1.6 1.9 2.1 2.3 2.6 2.8 3.0 3.3 3.5 3.7 4.0 4.2 4.4 4.7
55 0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.1 2.3 2.6 2.8 3.1 3.3 3.6 3.9 4.1 4.4 4.6 4.9 5.1
60 0.3 0.6 0.8 1.1 1.4 1.7 2.0 2.2 2.5 2.8 3.1 3.4 3.7 3.9 4.2 4.5 4.8 5.1 5.3 5.6
65 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.0 3.3 3.7 4.0 4.3 4.6 4.9 5.2 5.5 5.8 6.1
70 0.3 0.7 1.0 1.3 1.6 2.0 2.3 2.6 2.9 3.3 3.6 3.9 4.3 4.6 4.9 5.2 5.6 5.9 6.2 6.6
80 0.4 0.7 1.1 1.5 1.9 2.2 2.6 3.0 3.4 3.7 4.1 4.5 4.9 5.2 5.6 6.0 6.4 6.7 7.1 7.5
90 0.4 0.8 1.3 1.7 2.1 2.5 2.9 3.4 3.8 4.2 4.6 5.1 5.5 5.9 6.3 6.7 7.2 7.6 8.0 8.4
100 0.5 0.9 1.4 1.9 2.3 2.8 3.3 3.7 4.2 4.7 5.1 5.6 6.1 6.6 7.0 7.5 8.0 8.4 8.9 9.4
Determining the Length of the Flexible Section (a) (Example 2)

The values required to determine the length of the flexible (a) section are: Formula for
The maximum length change ΔL in comparison with the zero position during Flexible Sections (a)
installation, (which can be either an expansion or a contraction), and the pipe
diameter (d).
a = k ∆L · d
If values ΔL and (d) are known, Table 7 shows the length of flexible section (a) a = Length of Flexible Section
required. k = Constant (k = 21.7 PVDF)
∆L = Change in Length
d = Outside Diameter of Pipe
L ½a
15 ¼a L
½a
15
Fixed Fixed Guide Fixed G

Fixed Guide Fixed
½a
25 ½a
½a a ½a
25
Guide Guide Guide Fixed
Fixed Guide Guide Guide

¼a
6”min. 6”min.
6”min. 6”min.
Change of Direction Expansion Loop Offset
Fixed Guide Fixed G

Fixed
Fixed Guide Fixed

Guide Fixed
Guide Guide
40
Table 7: Flexible Sections (a) in Inches where ΔT ≤ 20°F
Values shown are minimum values.
PVDF Nominal Pipe Diameter
400mm
200mm
450mm
250mm
355mm
225mm
160mm
315mm
110mm
40mm
63mm
20mm
50mm
90mm
75mm
25mm
32mm
0.1 6 7 8 9 10 11 12 13 14 17 19 20 22 24 26 27 29
0.2 9 10 11 12 14 15 17 18 20 24 27 29 30 34 36 39 41
0.3 11 12 13 15 17 19 20 22 25 30 33 35 37 42 44 47 50
0.4 12 14 15 17 19 22 24 26 29 34 39 41 43 48 51 54 58
0.5 14 15 17 19 22 24 26 29 32 39 43 46 48 54 57 61 65
0.6 15 17 19 21 24 26 29 32 35 42 47 50 53 59 63 67 71
0.7 16 18 20 23 25 29 31 34 38 46 51 54 57 64 68 72 76
Length Change - ΔL (in)
0.8 17 19 22 24 27 31 33 37 40 49 54 58 61 68 73 77 82
0.9 18 20 23 26 29 32 35 39 43 52 58 61 65 72 77 82 87
1.0 19 22 24 27 30 34 37 41 45 54 61 65 68 76 81 86 91
2.0 27 30 34 39 43 48 53 58 64 77 86 91 96 108 115 122 129
3.0 33 37 42 47 53 59 65 71 78 94 105 112 118 132 141 149 158
4.0 39 43 49 54 61 68 75 82 90 109 122 129 136 153 162 172 183
5.0 43 48 54 61 68 76 83 91 101 122 136 144 152 171 181 193 204
6.0 47 53 60 67 75 84 91 100 111 133 149 158 167 187 199 211 224
7.0 51 57 64 72 81 90 99 108 119 144 161 171 180 202 215 228 242
8.0 54 61 69 77 86 97 106 116 128 154 172 183 193 216 229 244 258
9.0 58 65 73 82 91 103 112 123 135 163 183 194 204 229 243 258 274
10.0 61 68 77 86 96 108 118 129 143 172 193 204 215 242 257 272 289
41
Installation Hints
The length changes in pipe sections should be clearly controlled by the arrangement of fixed brackets. It is possible to
distribute the length changes in pipe sections using proper positioning of fixed brackets (see adjoining examples).
If it is not possible to include a flexible section at a change of direction or branch, or if extensive length changes must
be taken up in straight sections of pipe work, expansion loops may also be installed. In this case, the length change is
distributed over two flexible sections.
Note
ΔL ΔL
To eliminate bilateral expansion thrust blocks are
recommended at intersections.
F
Example:
For a 2” (63mm) PVDF expansion loop where Dt=20°F, the
length change of 0.82in would require a flexible section
length of a = 10in (DL = 0.82/2). A single flexible section on
the other hand, would need to be 20in. (DL = 0.82) in length.
ΔL ΔL/2 ΔL/2
Pre-Stressing F F
In particularly difficult cases, where the length changes are large and acting in one direction only, it is also possible to
pre-stress the flexible section during installation, in order to reduce the length of (a). This procedure is illustrated in the
following example:
Installation conditions
¼a Not Recommended L Recommended
L = 315in.
d = 63mm. (nominal) L
Installation temperature: 73°F L/2 L/2
½a a
Max. working temperature: 95°F
Material: SYGEF® PVDF Guide
Guide Fixed F
1 . Length change ¼a
F F
+ΔL = L • ΔT •  = 315 • 22 • (0.000078) = 0.54in. ΔL/2 ΔL/2
2. Flexible section required to take up length change of ΔL = 0.54in

according to Table 7:
a = approx. 36in. L = 394in ΔL
3. If, on the other hand, the flexible section is pre-stressed to ΔL/2, the required length of flexible section is reduced to
approx. 48in. The length change, starting from the zero position, then amounts
F to
±ΔL/2 = 0.54in/2 = 0.27in. a = 3.84in
a = approx. 25in. (per Table 7)

Guide Fixed Guide
In special cases, particularly at high working temperatures, pre-stressing of a flexible section improves the appearance
of the pipeline in service, as the flexible section is less strongly deflected.
L = 394in - ΔL/2 ΔL/2
a = 1.92in
42
Installation
The Incorporation of Valves
Valves should be mounted as directly as possible; they should be formed as fixed points. The actuating force is thus
transmitted directly, and not through the pipeline. Any changes in length which arise can be prevented with the appropriate
fixed points, before and after the valve.
For safe mounting of plastic valves, GF valves are equipped with metal threaded inserts for direct mounted installation.
Vibration Dampeners
There are two principal ways to control stress caused by vibration. You can usually observe the stability of the system
during initial operation and add restraints or supports as required to reduce effects of equipment vibration. Where
necessary restraint fittings may be used to effectively hold pipe from lifting or moving laterally.
In special cases where the source of vibration is excessive (such as that resulting from pumps running unbalanced),
an elastomeric expansion joint or other vibration absorber may be considered. This may be the case at pumps where
restricting the source of vibration is not recommended.
The Installation of Pipe Work under Plaster or Embedded in Concrete

Padded Pipe Work
Where pipe work installed under plaster or embedded in concrete changes direction or branches off, the flexible
section under consideration must be padded along the length (a), which is based on the calculated length change. The
accompanying tees or elbows must, of course, also be included in the padding. Only flexible materials, such as glass wool,
mineral wool, foam plastic or similar may be used for padding.
Pipe Bracket Support Centers and Fixation of Plastic Pipelines

General Pipe Supports and Brackets
PVDF pipelines need to be supported at specific intervals, depending upon the material, the average pipe wall temperature,
the specific gravity of the medium, and the diameter and wall thickness of the pipe. The determination of the pipe support
centers has been based on the permissible amount of deflection of the pipe between two brackets. The pipe bracket
centers given in Table 8 are calculated on the basis of a permissible deflection of max. 0.01 in (0.25 cm) between two
brackets.
Pipe Bracket Spacing in the Case of Fluids with Specific Gravity ≤ 1.0 (62.4 Lb/Ft3)
Where fluids with a specific gravity exceeding 1.0 (62.4 lb/ft3) are to be conveyed, the pipe bracket centers given in Table 8
must be divided by the specific gravity of the fluid, resulting in shorter distances between the supports.
Installation of Closely Spaced Pipe Brackets

A continuous support may be more advantageous and economical than pipe brackets for small diameter horizontal pipe
work, especially in a higher temperature range. Installation in a “V”-or “U”-shaped support made of metal or heat-resistant
plastic material has proven satisfactory.
Pipe Bracket Requirements

When mounted, the inside diameter of the bracket must be greater than the outside diameter of the pipe, in order to allow
length changes of the pipe at the specified points. The inside edges of the pipe bracket must be formed in such a way that
no damage to the pipe surface is possible. GF pipe brackets meet these requirements. They are made of plastic and may
be used under rugged working conditions and also in areas where the pipe work is subjected to the external influence of
aggressive atmospheres or media. GF pipe brackets are suitable for PVC, CPVC, PE, PP and PVDF pipes.
Arrangement of Fixed Brackets

If the pipe bracket is positioned directly beside a fitting, the length change of the pipeline is limited to one direction only
43
(one-sided fixed point).
If it is, as in most cases, necessary to control the length change of the pipeline in both directions, the pipe bracket must be
positioned between two fittings. The pipe bracket must be robust and firmly mounted in order to take up the force arising
from the length change in the pipeline. Hanger type brackets are not suitable as fixed points.
General Pipe Supports and Brackets for Liquids with a Specific Gravity ≤ 1.0 (62.4 lb/ft3)
Table 8
Pipe Size Size Pipe Bracket Intervals L (ft.) for SYGEF® PVDF
(mm) (inch) ≤65°F 104°F 140°F 176°F 212°F 248°F 284°F
20mm 1/2 2.8 2.5 2.3 2.0 1.6 1.5 1.3
25mm 3/4 3.1 2.8 2.5 2.2 2.0 1.6 1.5
32mm 1 3.6 3.3 3.0 2.6 2.3 2.0 1.6
40mm 1 1/4 3.9 3.6 3.3 3.0 2.5 2.1 1.8
50mm 1 1/2 4.6 4.3 3.8 3.3 3.0 2.5 2.0
63mm 2 4.6 4.3 3.9 3.6 3.1 2.6 2.1
75mm 2 1/2 4.9 4.6 4.3 3.9 3.4 2.8 2.3
90mm 3 5.2 4.9 4.6 4.3 3.6 3.1 2.8
110mm 4 5.9 5.6 5.1 4.8 4.1 3.6 3.1
160mm 6 7.1 6.7 6.1 5.6 5.1 4.4 3.8
200mm 8 7.9 7.4 6.9 6.2 5.6 4.9 4.3
225mm 9 8.4 7.9 7.2 6.9 5.9 5.2 4.6
250mm 10 8.7 8.2 7.5 7.2 6.2 5.6 4.9
315mm 12 9.8 9.4 8.5 8.2 7.1 6.2 5.4
355mm 14 10.7 9.6 8.7 7.8 7.0 6.3 5.7
400mm 16 11.6 10.4 9.4 8.5 7.6 6.8 6.2
450mm 18 12.8 11.5 10.4 9.3 8.4 7.6 6.8
Note, general rule of thumb: Pipe spacing can be adjusted by dividing the support spacing by the specific gravity.
Example: 63mm pipe carrying media with a specific gravity of 1.6 – 4.6ft divided by 1.6 = approx. 2.8ft centers.
Shear Force of Restraint Fittings (Fixation Brackets)

Pipe Size Size Shear Force in lbs
(mm) (inch) @ 68°F (20°C) @ 104°F (40°C) @ 140°F (60°C)
20mm 1/2 1798 1506 1214
25mm 3/4 2158 1798 1461
32mm 1 2697 2248 1798
40mm 1 1/4 3147 2698 2023
50mm 1 1/2 3821 3147 2473
63mm 2 4496 3821 2922
75mm 2 1/2 8317 6969 5620
90mm 3 9442 7868 6294
110mm 4 11015 9217 7418
44
Fusion Joining Technology
Reliable Fusion Joining

Assembly and joining of this system is performed by heat fusion. Fusion joints are made by heating and melting the pipe
and fitting together. This type of joint gives a homogeneous transition between the two components without the lowering of
chemical resistance.
Three different fusion methods for Georg Fischer’s SYGEF® PVDF Piping Systems are available and commonly used in
today‘s demanding applications. These include socket fusion, Infrared (IR) butt fusion and BCF® (Bead & Crevice Free)
fusion.
Socket Fusion Joining

Socket Fusion Joining can be used to join socket fusion fittings available in sizes 3/8”(16mm) to 2”(63mm). The socket
fusion method of joining uses a heated non-stick “female” bushing to melt the outside of the pipe end and a heated non-
stick “male” bushing to heat the inside of the corresponding size of fitting. After several seconds, when the outside of the
pipe and the inside of the fitting are melted, the bushings are removed and the pipe is pushed into the fitting. Due to the
large area of pipe to fitting contact (3-5 times the cross sectional area of the pipe), the resulting joint is actually several
times stronger than the pipe itself. The pipe and fittings for this system are also manufactured to have an interference
fit; because of this interference it is not possible to slide a fitting over the pipe without the use of heat to melt the surface
to be joined. This feature prevents the possibility of inadvertently leaving a joint unfused, and more importantly causes
displacement of some material during fusion thereby guaranteeing a high strength, reliable, reproducible joint.
Advantages
• Fast fusion times
• Low Installation Cost
• Easiest fusion method
• Corrosion resistant
IR Plus® Infrared Butt Fusion Joining

IR Plus® Infrared Butt Fusion Joining is an ideal method to join IR fusion fittings in the size range of up to 18” (450mm) to
achieve the maximum joint consistency.
Using the process-controlled fusion machinery, high-strength butt fusion joints can be made with many advantages over
the conventional, pressure type butt fusion methods. A non-contact IR heating plate is used, along with a predetermined
overlap to join the pipe (or fitting) ends together eliminating the potential for operator error. Reliable, reproducible, high
strength joints with smaller internal and external beads can be achieved.
Advantages
• Non-contact heating
• Smaller internal and external beads repeatability
• Low stress joint
• Ease of operation due to fully automated fusion machinery
• Automatic fusion joining record (if desired) using optional printer or PC download
45
BCF® (Bead & Crevice Free) Fusion Joining
The Georg Fischer BCF® (Bead and Crevice Free) joining system produces bead and crevice free joints for SYGEF® PVDF
(polyvinylidene fluoride) piping. It is used where there is extreme concern about the presence of small beads or crevices
in the piping system. Such applications can be found in the Semiconductor, Pharmaceutical, and Food and Beverage
Industries.
The BCF® joining machine automatically clamps and aligns the pipe and fitting, and produces the seamless joint by a
proprietary heatfusion method. The machine’s electronic logic circuits provide temperature monitoring and heat sensing
to automatically produce the proper weld for the particular pipe size. The BCF® system is offered in 1/2” (20mm) through
4” (110mm) pipe diameters; with 90° elbows, T’s, unions, diaphragm valves, zero static diaphragm valves, reducers (both
concentric and eccentric), and flange adapters.
Advantages
• Completely smooth inner surface
• Low stress joint
• Ease of operation due to fully automated fusion machinery
• Automatic fusion joining record (if desired) using optional printer or PC download
46
Socket Fusion
Socket Fusion Joining Method
In this form of fusion jointing, which requires heating tools, the pipe end is inserted into the socket of the fitting; no
additional material is used. The pipe end and fitting socket are heated to fusion temperature using a heating bush and a
heating spigot, respectively, and are then pushed together.
Details of the requirements for machines and equipment used for fusion jointing thermoplastics are contained in DVS 2208
Part 1.
The pipe end, fitting socket and heating tools correspond in such a way that the necessary jointing pressure is attained
during jointing, resulting in a homogeneous joint.
The Principle of Fusion Joining
A. Fitting
B. Heating Spigot
C. Heating Element
D. Heating Bush
E. Pipe
General requirements
The basic rule is that only similar materials can be fusion jointed. For best results, only components which have a density
between 0.061 lb/in3 and 0.065 lb/in3 and a melt flow index in the range from 2.2x10 -3 lb/10min to 5.5x10-2 lb/10min should
be fusion jointed. This requirement is met by PVDF socket fusion fittings from GF.
In socket fusion, attention must be paid to the minimum wall thicknesses of the pipes. The following table in this
introduction contains details.
Tools required
Apart from the tools normally used in plastic piping construction, such as pipe cutters or a saw with a cutting guide, the
socket fusion jointing method requires certain special tools.
Important: The tools described here may be used for GF socket fusion fittings made of PVDF, PP and PE.
Pipe peeling and chamfering tool
This is used to calibrate the pipe end. This reduces the force exerted
to push the pipe into the heating bush, while preventing damage to the
surface coating of the heating bush. At the same time the pipe end is
chamfered and the insertion depth marked.
Note: Further information on the fusion jointing equipment hire service

and training courses are available from GF.
47
Heating element for manual fusion jointing
The element is heated electrically. The heating bush and spigot are
removable. A separate pair is required for each pipe size.
Important: The surfaces of the heating tool which come into contact with
the pipe or the fitting must have a non-stick coating.
Fusion jointing machine
A fusion jointing machine is recommended for fittings with a diameter of

d = 1 1/2” (50mm) or more. It is also better to use a machine for smaller
joints if there is a large number to be made.
A. Pipe The machine should be set up and operated according to its

B. Heating Element manufacturer’s instructions. The procedure detailed below (including the
C. Fitting preparation) is for fusion jointing with the help of a manual jointing tool.
Set the temperature of the heating tool to 500°F (260°C). Check

the temperature. The fusion temperature must be between 482°F
(250°C) and 518°F (270°C). To test the thermostat, check the fusion
temperature from time to time on the outside of the heating bush, using
a fast acting thermoprobe or tempil sticks [487°F (253°C) or 525°F
(274°C)]. This is particularly important when working in strong wind.
Use a clean cloth or dry paper to clean the heating bush and the heating
spigot. The tools must be cleaned after making each fusion joint.
Cut the pipe square using a cutter for plastic pipes and deburr the inside
edges with a knife.
Make sure that the tools and pipes are clean and grease-free even
beyond the fusion zone; if necessary, clean with a cleaning fluid.
48
For pipes ranging in size from d = 1/2” (20mm) to d = 2” (63mm) peel
the pipe end until the blades are flush with the pipe end.
Should ovality of the pipe prevent the peeling tool from being properly applied, the pipe must first be rounded (e.g. in a vice
or with a screw clamp).
Use a scraper to complete the peeling of any area where ovality impairs the effectiveness of the peeling tool.
If the peeling tool can be pushed onto the pipe without removing any material, then the dimensional accuracy of the pipe’s
outside diameter and of the peeling tool should be checked.
Contact GF for resharpening or replacing the blades. Should this work be carried out independently, use a mandrel gauge
to adjust the blades to the following diameters.
Outside Pipe Diameter Peeled Diameter Peeled Length

in (mm) (mm) (mm)
3/8” (16mm) 15.85 to 15.95 13
1/2” (20mm) 19.85 to 19.95 14
3/4” (25mm) 24.85 to 24.95 16
1” (32mm) 31.85 to 31.95 18
1 1/4” (40mm) 39.75 to 39.95 20
1 1/2” (50mm) 49.75 to 49.95 23
2” (63mm) 62.65 to 62.95 27
The peeling length l corresponds to the length of the peeling blades.
For pipes of diameter d = 16 mm, chamfer about 2 mm of the pipe end

at an angle of 15°. Prepare about 15 mm of the pipe end with a scraper.
Mark off the jointing length of 13 mm on the pipe.
Thoroughly clean the fitting socket with absorbent paper and cleaning
fluid (e. g. Tangit cleaner). Use fresh paper each time.
49
Fusion Joining Procedure
Heating
Quickly push first the fitting onto the heating spigot to the correct depth
and then the pipe into the heating bush axially, without twisting, and hold
firmly. The heating times in the table below are measured from this point
on.
Fusion joints should not be used for pipes whose walls are thinner than
those listed in the table.
Heating times and minimum wall thicknesses for socket fusion joints
Minimum Pipe Change (Max.

Pipe Outside Wall Thickness Heating Time Time) Cooling Fixed Cooling Total
Diameter (mm) (mm) (sec) (sec) (sec) (min)
3/8” (16mm) 1.5 4 4 6 2
1/2” (20mm) 1.9 6 4 6 2
3/4” (25mm) 1.9 8 4 6 2
1” (32mm) 2.4 10 4 12 4
1 1/4” (40mm) 2.4 12 4 12 4
1 1/2” (50mm) 3.0 18 4 12 4
2” (63mm) 3.0 20 6 18 6
The temperature and heating time must be strictly observed
Jointing (by hand)

Pull the fitting and pipe from the heating tools with a snap off action as
soon as the heating period has elapsed.
Paying attention to the alignment marks, immediately push them

together axially without twisting. Hold them together for the same
duration as the heating period.
Pressure testing
All fusion joints must be allowed to cool completely before pressure testing, i.e. as a rule wait about an hour after the last
joint has been completed.
50
Infrared (IR Plus®) Fusion
Infrared (IR) Fusion Joining Method
In infrared (IR) fusion joining the fusion areas of the components
being joined (pipes, fittings, valves) are heated to fusion temperature
without contact to the heating element and joined by means of
mechanical pressure without using additional materials.
1 Pipe
2 Heating element
3 Fitting
The resulting fusion joints are homogeneous and display the following characteristics:
• Non-contact heating of the joining components eliminates the risk of contamination and inhomogeneities;
• Smaller joining beads due to adjustment of joining pressure path prior to the fusion process itself, i.e.
elimination of the equalization process
• Adjustment of the joining pressure path also ensures excellent reproducibility of the fusion joints
• Low-stress fusion joints due to very uniform heating by means of IR radiator
General Requirements
The basic rule is that only similar materials can be fusion joined.
For the best results only components which have a melt flow index
in the range from 0.6x10-3lb/10min to 3.7x10 -3lb/10min should be
fusion joined. The components to be joined must have the same
wall thicknesses in the fusion area. Maximum permissible wall
displacement: 10%.
Only same wall thicknesses in the fusion area

A incorrect
B correct
IR fusion joining must only be performed by personnel trained in the use of this method. Training is provided world-wide
by qualified GF IR Plus® welding instructors.
Tools Required
Infrared fusion joining requires a special joining machine in addition to the tools normally used for plastic pipe work
construction (pipe cutters, etc.).
GF Supplies Three Types of IR Plus® Fusion Joining Machines

IR 63 Plus® for fusion 1/2” to 2” IR 110 Plus® for fusion 1/2” to 4” IR 225/315 Plus® for fusion 2” to 8”
51
General Conditions
Protect the area of the fusion joint from adverse weather conditions, such as rain, snow or wind. The permitted
temperature range for IR Plus® fusion joining between 41°F (5°C) and 104°F (40°C). Outside this range, suitable action
must be taken to ensure that these conditions are maintained. It must also be ensured that the components being joined
are in this temperature range.
Preparing the Fusion Joint and Operating the IR Fusion Joining Machine
In principle, IR fusion joining machines do not require any special preparation, but it should be ensured that the
components being joined are clean. Operation of the IR machines is defined exactly in the operating instructions, but we
strongly recommend attending a 1-day training course to become a qualified IR welder.
Properties and Characteristics of IR Fusion Joints

Non-Contact Heating
The components being joined are heated uniformly and without contact to the ideal fusion temperature by infrared
radiation.
A defined gap between the heating element and the end faces minimizes the risk of contamination of the joining surface.
Contamination of the heating element by plastic particles is thus also eliminated.
Reduced Bead Formation

The fusion bead produced during joining is considerably reduced without any loss of quality. Bead forming equalization is
eliminated by non-contact softening of the end faces. The minimal, defined bead is only formed during the joining process.
The fusion area thus has improved flow dynamics, low clearance volume, and greater throughput area.
Reproducible Joining Processes

The joining path controls the joining pressure and thus the fusion process. The high reproducibility of the joints is assured
by the clearly defined and controlled process sequence.
Clear, Simple Operator Guidance

Clear, unambiguous operator guidance via the liquid crystal display leads the user interactively through the fusion process
in logical operating steps.
Welding Report/Traceability
The welding parameters for the relevant welding operations can be read out directly via various interfaces on the machine.
It is possible to print these out on paper (commercially available printers), on labels or to employ electronic data output
(PCMCIA card).
This automatically provides an accurate record with all essential fusion parameters for each individual fusion joint, as
required.
52
Bead and Crevice Free (BCF® Plus) Fusion
Bead and Crevice Free (BCF® Plus) Fusion Joining Method
The fusion jointing process consists in transmitting precisely defined thermal energy to the pipe and fitting ends being
joined by means of half-shell heating elements.
At the same time an elastic, pressurized bladder supports the inside surface of the fusion zone in order to prevent the
formation of an internal fusion bead.
Holding the melted thermoplastic under controlled pressure ensures ideal, homogeneous fusion of the plastic
components.
Fully automatic process control of the fusion jointing process with a fusion jointing machine developed in-house by GF
permits very simple handling and reproducible fusion quality.
1. Pipe Clamping Element

2. Fitting
3. Heating element with fitting - clamping device
4. Pressurized Bladder
5. Pipe
6. Compressor for Bladder
7. Cooling Air Blower
8. Control Panel
9. Compressed Air Supply
1. Pressurized Bladder
2. Welding Zone
3. Heating Element
4. Clamping Position
5. Pipe/Fitting
General Requirements
SYGEF® fittings and SYGEF® pipes are suitable for work-
ing pressures up to 232 psi (16 bar) at 68°F (20°C) (water).
SYGEF® diaphragm valves are designed for a maximum
working pressure of 150 psi (10 bar) at 68°F (20°C) (water).
Refer to the chapter on pressure/temperature diagrams for
details of permissible working pressures.
Tools required
BCF® jointing requires the Georg Fischer BCF® jointing
machine in addition to the tools normally used for plastic
pipework construction (pipe cutters, etc.).
53
Preparing the fusion joint and operating the BCF® Plus fusion jointing machine
In principle, BCF® Plus fusion jointing machines do not require any special preparation, other than to ensure that all
components being joined are clean.
Operation of the BCF® Plus machines is defined exactly in the operating instructions, but we strongly recommend attending
a 1-day training course to become a qualified BCF® welder.
Properties and characteristics of BCF® Plus fusion joints

Welding free from beads and crevices
The result of the jointing process is a surface similar to the actual pipeline components, free from beads or crevices. There
are therefore no dead spaces, the surface roughness lies in the range Ra 9.8µin (0.25µm).
Reproducible jointing processes

The high reproducibility of the joints is assured by the clearly defined and controlled process sequence.
Clear, simple operator guidance

Clear, unambiguous operator guidance via the liquid crystal display leads the user interactively through the fusion process
in logical operating steps.
Welding report/traceability
The welding parameters for the relevant welding operations can be read out directly via various interfaces on the machine.
It is possible to print these out on paper (commercially available printers), on labels or to employ electronic data output
(PCMCIA card).
This automatically provides an accurate record with all essential fusion parameters for each individual fusion joint.t
54
Validated Welding Process
Fusion Training and Certification
SYGEF® Plus HP (PVDF) piping installation shall only be performed by factory trained and certified installers in accordance
with the manufacturer’s written procedures. Each installer shall complete the manufacturers Certification Course
including written test examinations and submittal of fusion test welds to the manufacturer for weld evaluation. All PVDF
pipe, valves and fittings shall be properly prepared in accordance with high purity standards and the manufacturer’s
written instructions. Each certified welder shall display at all times a permanent certification card showing name,
type of fusion machine, certification number and date of certification. Installation practices, including support spacing
and expansion considerations, shall be in compliance with the manufacturer’s certification course and written
recommendations.
Fusion Equipment
All SYGEF® Plus HP (PVDF) Infrared Fusion Components shall be joined using the IR-63 Plus®,IR-110 Plus® or the IR-225
Plus® Infrared Fusion Machine. The infrared fusion machines shall utilize overlap distance measurement as a precise
means of developing joining pressure. The joining equipment shall control the fusion process through an integrated
software program which automatically compensates for ambient temperature variations and limits operator dependency.
The fusion process shall produce repeatable weld profiles that can be visually inspected according to a specified Weld
Inspection Program (see 2.8 Weld Inspection part A).
For ease of installation, all fusion

equipment shall permit the use of
Typical Fusion Times
remote or in-place fusion welding of all
components up to 2” (63mm) diameter. Size Size Typical Fusion
(mm) (inch) Time (sec)
Printouts or electronic storage using a 1/2” (20mm) 1/2 108
PCMCIA card for weld history and fusion
3/4” (25mm) 3/4 108
parameters shall be made (and retained)
1” (32mm) 1 152
for every weld. Printouts are accessible
1 1/4” (40mm) 1 1/4 152
through a standard parallel port interface
1 1/2” (50mm) 1 1/2 203
or PCMCIA card on the IR Plus Fusion
machine. 2” (63mm) 2 149
2 1/2”(75mm) 2 1/2 187
Joining Times Using the IR Plus Fusion 3” (90mm) 3 214
Equipment: The fusion times to complete
4” (110mm) 4 254
an IR Plus weld shall be based on ambient
6” (160mm) 6 263
temperature conditions which reduces
8” (200mm) 8 294
the overall welding process by up to 50%
8” (225mm) 9 330
compared to standard IR butt fusion.
Typical fusion times shall be as follows: 10”(250mm) 10 754
12” (315mm) 12 890
14”(355mm) 14 Consult Factory
16”(400mm) 16 Consult Factory
18” (450mm) 18 Consult Factory
55
Weld Inspection
Georg Fischer shall provide a written Weld Inspection Program to the Quality Inspector or System Owner that specifies
minimum guidelines for IR weld acceptance. Inspection of infrared butt fusion welds shall reveal uniform double fusion
beads of minimal size and proper alignment of component parts having a maximum displacement relating to 10% of the
pipe wall thickness. All properly made IR fusion welds should be uniform in color with a smooth and consistent appearance
indicating proper fusion temperature, heating time and joining pressure. At a minimum the following requirements shall be
met:
• Two complete weld beads for the full 360° circumference
• No contamination within the fusion zone
• A maximum of 10% component misalignment
• The “k” value (“k” defined as the height as measured at the center of weld bead compared to pipe wall ) shall be $ 0.
For further criteria refer to manufacturer’s Weld Inspection Program (WIP).‑
56
Mechanical Connections
Mechanical Joining of Piping Systems
Flange Connections Flange adapters for butt fusion
Coated Metal Flanges Backing Rings
Unions Plastics-oriented connections between same plastics

Transitions to other plastics
Seal: O-ring
Threaded Fittings Plastic fittings with reinforcement ring and tapered Female NPT
threads.
Threaded Connections
The Following Different Types of Threads Are Used
Designation of the thread According to Typical use Description
standard
G (Buttress Threads) ISO 228 Unions Parallel internal or external pipe
thread, where pressure-tight joints
are not made on the threads
NPT = National (American ASTM F1498 Transition and Taper internal or external pipe
Standard) Pipe Taper threaded fittings thread for plastic pipes and fittings,
where pressure-tight joints are
made on the threads
Flanged Connections
Creating Flange Joints
When making a flange connection, the following points have to be taken into consideration:
There is a general difference between the connection of plastic pipes and so-called adapter joints, which represent the
transition from a plastic pipe to a metal pipe or a metal valve. Seals and flanges should be selected accordingly.
Flanges with sufficient thermal and mechanical stability should be used. GF flange types fulfil these requirements.
A robust and effective seal can only be achieved if sufficient compressive forces are transmitted to the flange stub end
via the backup ring. These compressive forces must be of sufficient magnitude to overcome fluctuating hydrostatic and
temperature generated forces encountered during the lifetime of the joint. In assembling the stub ends, gasket and backup
rings it is extremely important to ensure cleanliness and true alignment of all mating surfaces. The correct bolt tightening
procedure must also be followed and allowance made for the stress relaxation characteristics of the plastic stub ends.
Alignment
1. Full parallel contact of the sealing faces is essential.
2. The backup ring must contact the stub end evenly around the circumference.
3. Misalignment can lead to excessive and damaging stresses in either the stub
57
Creating Flange Joints
When to Use a Flange?
Flanges may be used when:
• The piping system may need to be dismantled
• The installation is temporary or mobile
• Transitioning between dissimilar materials that can not be bonded together
Vinyl Flanges
Visually inspect flanges for cracks, deformities or other obstructions on the sealing surfaces.
Gasket
A rubber gasket must be used between the flange faces in order to ensure a good seal. GF recommends a 0.125” thick,
full-face gasket with Shore A scale hardness of 70±5, and the bolt torque values (Table 9) are based on this specification.
For other hardness requirements, contact GF Technical Services. Select the gasket material based on the chemical
resistance requirements of your system. A full-face gasket should cover the entire flange-to-flange interface without
extending into the flow path.
Size O.D. I.D. Size O.D. I.D.

(in) (in) (in) (in) (in) (in)
1/2” (20mm) 3.50 0.59 6” (160mm) 10.98 5.94
3/4” (25mm) 3.86 0.79 8” (200mm) 13.50 8.15

OD 1” (32mm) 4.25 1.02 8” (225mm) 13.50 8.15
ID 1 1/4” (40mm) 4.61 1.34 10” (250mm) 16.00 9.84
1 1/2” (50mm) 5.00 1.69 12” (315mm) 19.00 11.81
2” (63mm) 5.98 2.20 14” (355mm) 21.00 12.87
2 1/2”(75mm) 7.01 2.60 16” (400mm) 23.50 15.39
3”(90mm) 7.48 3.07 18” (450mm) 27.00 16.77
4” (110mm) 9.02 3.94
Fasteners
It is critical to avoid excessive compression stress on a plastic flange. Therefore, only low-friction fastener materials
should be used. Low-friction materials allow torque to be applied easily and gradually, ensuring that the flange is not
subjected to sudden, uneven stress during installation, which can lead to cracking.
Either the bolt or the nut, and preferably both, should be zinc-plated to ensure minimal friction. If using stainless steel bolt
and nut, lubricant must be used to prevent high friction and seizing. In summary, the following fastener combinations are
acceptable:
• zinc-on-zinc, with or without lube
• zinc-on-stainless-steel, with or without lube
• stainless-on-stainless, with lube only
Cadmium-plated fasteners, while becoming more difficult to obtain due to environmental concerns, are also acceptable
with or without lubrication. Galvanized and carbon-steel fasteners are not recommended. Use a copper-graphite anti
seize lubricant to ensure smooth engagement and the ability to disassemble and reassemble the system easily. Bolts must
be long enough that two complete threads are exposed when the nut is tightened by hand. Using a longer bolt does not
compromise the integrity of the flange connection, although it wastes material and may make tightening more difficult due
to interference with nearby system components.
58
Fastener Specifications - SYGEF® PVDF
Flange No. of Length1 Bolt Size Washer Size Suggested bolt length for flange-
1
Size (in) Bolts (in) (in) and Type (in) and

to-flange connection with 0.125”
Type2
thick gasket. Adjust bolt length
1/2” (20mm) 4 3.25 1/2” SAE GRD 5 1/2” SAE
as required for other types of
3/4” (25mm) 4 3.50 1/2” SAE GRD 5 1/2” SAE
connections.
1” (32mm) 4 3.50 1/2” SAE GRD 5 1/2” SAE
1 1/4” (40mm) 4 3.75 1/2” SAE GRD 5 1/2” SAE Minimum spec. Use of a stronger or
2
1 1/2”(50mm) 4 4.00 1/2” SAE GRD 5 1/2” SAE thicker washer is always acceptable
2” (63mm) 4 4.50 1/2” SAE GRD 5 1/2” SAE as long as published torque limits
2 1/2” (75mm) 4 5.00 5/8” SAE GRD 5 5/8” SAE are observed.
3” (90mm) 4 5.00 5/8” SAE GRD 5 5/8” SAE
Also known as Type A Plain Washers,
3
4” (110mm) 8 5.00 5/8” SAE GRD 5 5/8” SAE
Narrow Series.
6” (160mm) 8 6.50 3/4” SAE GRD 5 3/4” SAE
8” (200mm) 8 7.00 3/4” SAE GRD 5 3/4” SAE ASTM F436 required for larger sizes
4
8” (225mm) 8 7.00 3/4” SAE GRD 5 3/4” SAE to prevent warping at high torque.
10” (250mm) 12 7.50 7/8” SAE GRD 5 7/8” SAE
12” (315mm) 12 8.00 7/8” SAE GRD 5 7/8” SAE
14” (355mm) 12 8.00 1” SAE GRD 5 1” SAE
16” (400mm) 16 9.00 1” SAE GRD 5 1” SAE
18” (450mm) 16 10.00 1 1/8” SAE GRD 5 1 1/8” SAE
A washer must be used under each bolt head and nut. The purpose
of the washer is to distribute pressure over a wider area, reducing the
compression stress under the bolt head and nut. Failure to use washers
voids the GF warranty.
Torque Wrench
Compared to metals, plastics are relatively flexible and deform slightly under stress. Therefore, not only must bolt torque
be controlled in order to avoid cracking the flange, but continuing to tighten the bolts beyond the recommended torque
levels may actually make the seal worse, not better.
Because bolt torque is critical to the proper function of a plastic flange, a current, calibrated torque wrench accurate to
within ±1 ft.lb. must be used when installing plastic flanges.
Experienced installers may be tempted to forgo the use of a torque wrench, relying instead on “feel.” GF does not endorse
this practice. Job-site studies have shown that experienced installers are only slightly better than new trainees at
estimating bolt torque by feel. A torque wrench is always recommended.
59
Checking System Alignment
Before assembling the flange, be sure that the two parts of the system being joined are properly aligned. GF has developed
a “pinch test” that allows the installer to assess system alignment quickly and easily with minimal tools. First check the
gap between the flange faces by pinching the two mating components toward each other with one hand as shown below. If
the faces can be made to touch, then the gap between them is acceptable.
Next check the angle between the flange faces. If the faces are completely flush when pinched together, as shown above,
then the alignment is perfect, and you may continue installation. Otherwise, pinch the faces together so that one side is
touching, then measure the gap between the faces on the opposite side. The gap should be no more than 1/8”.
To assess high-low misalignment, pull the flange faces flush together. If the faces are concentric within 1/8”, then the
high-low misalignment is acceptable
If the gap between the mating components can not be closed by pinching them with one hand, or if the angle or high-low
misalignment between them is too large, then using the bolts to force the components together will result in excessive
stress and possible failure during or after installation. In this case, inspect the system to find the greatest source of
misalignment and refit the system with proper alignment before bolting.
60
Tightening the Bolts
Tightening one bolt to the maximum recommended torque while other bolts are only hand-tight, or tightening bolts in the
wrong order, produces uneven stresses that may result in poor sealing. To ensure even distribution of stresses in the fully-
installed flange, tighten the bolts in a star pattern as described in ANSI B16.5.
The torque required on each bolt in order to achieve the best seal with minimal mechanical stress has been carefully
studied in laboratory and field installations, and is given in Table 9.
To ensure even distribution of stresses and a uniform seal, tighten the bolts to the first torque value in the sequence, using
a star pattern, then repeat the star pattern while tightening to the next torque value, and so on up to the maximum torque
value.
All plastics deform slightly under stress. A final tightening after 24 hours is recommended, when practical, to ensure that
any bolts that have loosened due to relaxation of the polymer are fully engaged.
If a flange leaks when pressure-tested, retighten the bolts to the full recommended torque and retest. Do not exceed the
recommended torque before consulting an engineer or GF representative.
Table 9
Multiple Pass Bolt Torque
Torque Sequence Torque Sequence

Size Size Max. (ft-lb, lubed*) (ft-lb, unlubed**)
(in) (mm) Torque 1st 2nd 3rd 4th 1st 2nd 3rd 4th
1/2” 20mm 22 5 — — — 5 10 22 —
3/4” 25mm 22 5 — — — 5 10 22 —
1” 32mm 22 5 — — — 5 10 22 —
1 1/4” 40mm 22 5 — — — 5 10 22 —
1 1/2” 50mm 22 5 — — — 5 10 22 —
2” 63mm 22 5 — — — 5 10 22 —
2 1/2” 75mm 30 5 12 30 — 15 20 30 —
3” 90mm 30 5 12 30 — 15 20 30 —
4” 110mm 30 10 15 30 — 15 25 30 —
6” 160mm 44 12 24 44 — 20 32 44 —
8” 200/225mm 58 15 35 58 — 30 40 50 58
10” 250mm 58 25 50 58 — 20 40 50 58
12” 315mm 75 30 60 75 — 20 50 65 75
14” 355mm 140 46 92 126 140 35 70 105 140
16” 400mm 140 46 92 126 140 35 70 105 140
18” 450mm 140 46 92 126 140 35 70 105 140
* Assumes the use of SS, zinc- or cadmium-plated bolt and/or nut along with copper-graphite anti seize lubricant brushed directly onto
the bolt threads.
** Assumes the use of zinc- or cadmium-plated bolt, nut, or both. Never use unlubricated, uncoated bolts and nuts with plastic flanges,
as high friction and seizing lead to unpredictable torque and a high incidence of cracking and poor sealing.
61
Note that the torques listed in Table 9 are for flange-to-flange connections in which the full faces of the flanges are in contact. For other
types of connections, such as between a flange and a butterfly valve, where the full face of the flange is not in contact with the mating
component, less torque will be required. Do not apply the maximum listed torque to the bolts in such connections, which may cause
deformation or cracking, since the flange is not fully supported by the mating component. Instead, start with approximately two-thirds of
the listed maximum torque and increase as necessary to make the system leak-free after pressure testing.
Documentation
Keep Instructions Available
Provide a copy of these instructions to every installer on the job site prior to beginning installation. Installers who have
worked primarily with metal flanges often make critical mistakes when installing plastic flanges. Even experienced plastic
installers will benefit from a quick review of good installation practices before starting a new job.
Installation Tags
Best practices include tagging each flange with
• Installer’s initials
• Installation date
• Final torque value (e.g., “29.2-31.5”)
• Confirmation of 24-hour torque check (“y” or “n”)
Installed By
Date
Final Torque (ft-lb)
24-hour Check
Installed By
This information can be recorded on pre-printed stickers, as shown below, and placed on each flange immediately after
Date
installation.
Experience has shown that installation tags speed up the process of resolving system leaks and product failures, improve
communication between the contractor and distributor or manufacturer, highlight training opportunities, and promote
worker diligence.
Creating Union Joints

Introduction
Because unions and ball valves have similar, threaded nut connectors, these instructions have been written with both
of these components in mind. GF unions and ball valves are designed to provide many years of service when installed
properly.
As with any piping system component, unions and valves have particular considerations that must be kept in mind
during installation in order to ensure best performance. Even experienced installers will benefit from reviewing these
instructions before each installation.
Valve Support
Valves must be well-supported. An unsupported or insufficiently-supported valve body will twist when opened and closed,
subjecting the union connection to torque stress that may cause cracking or distortion and subsequent leakage.
62
System Alignment
The major contributor to union nut failures is misalignment. Uneven compression of the o-ring will cause leaks to occur.
Union nuts can be damaged by the stress of holding a misaligned system together.
Sealing Mechanism
GF union connections use an o-ring as the sealing mechanism which is highly effective under relatively low tightening
force.
Dirt and Debris

An often overlooked issue is the presence of dirt and debris on the o-ring or sealing surface. This will prevent proper
o-ring sealing; if it is present on the nut or body threads, it will clog the threads and prevent proper tightening.
Installation
Understand and carefully follow these installation steps in order to ensure a seal that is sufficient to guard against leaks
while avoiding excessive forces that can damage the union nut.
End Connectors
Always remove the union nut and end connectors from the ball valve for installation. Make sure that you slide the union nut
onto the pipe, with the threads facing the proper direction, BEFORE installing the end connector.
O-Ring Placement
Once the cement has cured, ensure that the o-ring is securely seated in its groove. The o-ring should rest securely in place
without adhesive or other aids.
Never use any foreign substance or object to hold the o-ring in place.
Union Connection
There should be no gap between the mating components, so that the threaded nut serves only to compress the o-ring, thus
creating the seal. However, a small gap (less than 1/8”) between the mating components is acceptable.
Never use the union nuts to draw together any gaps between the mating faces of the components or to correct
any system misalignment.
Hand-Tightening (all sizes) (see Table 10)

The next step is to hand-tighten the union nut. With the o-ring in place, engage the nut with its mating threads and turn
clockwise with one hand. Continue turning with moderate force until the nut no longer turns.
Be careful to use reasonable force when tightening the nut. Your grip should be firm but not aggressive. The nut should
turn easily until it bottoms out and brings the mating faces into direct contact.
It is recommended that you place an indexing mark with a permanent marker on the union nut and body to identify the hand
tight position.
Optional: Further Tightening (2”) (see Table 10)

Based on experience, or system requirements, the installer may choose to turn the nut an additional 1/8 turn
(approximately 45°) in order to ensure a better seal before hydrostatically pressure testing the system. To do this, use a
strap wrench to turn the nut 1/8 turn past the index mark applied after assembly.
Do not exceed 1/8 turn past the index mark.
Do not use any metallic tools. (Tool marks on the union nut will void manufacturer’s warranty.)
At this point, the system should be hydrostatically pressure tested before turning the union nut any farther.
63
Table 10
Tightening Guide for Union and Ball Valve Nuts
Nominal Size Initial Additional Additional
(inch) Pre-Test Post-Test
½ Hand-Tight None 1/8 Turn (max)
¾ Hand-Tight None 1/8 Turn (max)
1 Hand-Tight None 1/8 Turn (max)
1½ Hand-Tight None 1/8 Turn (max)
2 Hand-Tight 1/8 Turn (max) 1/8 Turn (max)
Post-Test Tightening (Sizes 3/8” to 1½” only) (see Table 10)

It is highly unlikely that any union nut connection; when tightened as instructed above, will leak under normal operating
conditions.
In the unlikely event that a leak occurs, the union nut at the leaking joint may be tightened an additional 1/8 turn, as
described above. The system should then be re-tested. If the joint still leaks after post-test tightening, do not continue to
tighten the nut at the leaking joint. Disassemble the leaking joint, re-check system alignment, and check for obstructions
in the sealing area. If the cause of a leak can not be determined, or if you suspect that the union or valve is defective,
contact your GF representative at (800) 854-4090 for further instructions.
Installed By
Quality Check After Assembly
To check if the union connections are installed in a stress-free manner, GF recommends thatDate
a random check of alignment
be done by removing the nut on selected union connection one at a time. A properly installed system will not have any
movement of the piping as the nut is loosened. If any springing action is noticed, steps should be taken to remove the
Final Torque (ft-lb)
stress prior to re-installing the union nut.
24-hour Check
Documentation
Keep Instructions Available
Provide a copy of these instructions to every installer on the job site prior to beginning installation.
Installation Tags
Best practices include tagging each union with: Installed By
• Installer’s initials
• Installation date
Date
This information can be recorded on pre-printed stickers,
as shown below, and placed on each union nut immediately
after installation.
Experience has shown that installation tags speed up the process of resolving system leaks and product failures, improve
communication between the contractor and distributor or manufacturer, highlight training opportunities, and promote
worker diligence. See the GF vinyl technical manual for information on guides, support spacing, and allowance for thermal
expansion.
Creating Threaded Joints

Introduction
NPT threaded connections are not recommended for high pressure systems or those greater than two inches. They also
should be avoided in systems where leaks would be dangerous or costly.
When properly installed, threaded connections offer the benefit of an easy and inexpensive transition to metal systems.
They can also be used for joining plastic where the installation is expected to be modified or moved later.
64
Design Considerations
Due to the difference in stiffness between plastic and metal, a metal male-to-plastic female joint must be installed with
care and should be avoided if possible. Only molded or machined adapters may be threaded. Threading reduces the rated
pressure of the pipe by one-half.
Preparation
Thread Sealant
A thread sealant (or “pipe dope”) approved for use with plastic or PTFE (“Teflon”) tape must be used to seal threads.
Use a thin, even coat of sealant.
PTFE tape must be installed in a clockwise direction, starting at the bottom of the thread and overlapping each pass. GF
recommends no more than 3 wraps.
Making the Connection

Start the threaded connection carefully by hand to avoid cross threading or damaging threads. Turn until hand tight. Mark
the location with a marker. With a strap wrench on the plastic part, turn an additional half turn. If leakage occurs during
pressure testing, consult the chart for next steps.
Threaded Connection Guide

Connection Type Next Step
Plastic to Plastic Tighten up to 1/2 turn
Plastic Male to Metal Female Tighten up to 1/2 turn
Metal Male to Plastic Female Consult Factory
Alignment
Threaded connections are susceptible to fracture or leaking due to misalignment. Pipe should be installed without
bending.
65
Pressure Testing
Introduction
A lot of international and national standards and guidelines are available for leak and pressure tests. Therefore often it is
not easy to find the applicable test procedure or for example the test pressure.
The purpose of a pressure test is to:

• Ensure the resistance to pressure of the pipeline and
• Show the leak tightness against the test media.
Usually the pressure test is done as a water pressure test and only in exceptional cases (with consideration to special
safety precautions) as a gas pressure test with air or nitrogen.
The following comparison should point out the difference between water and air as a test medium:
• Water is an incompressible medium, which means, setting for example a 3.2ft (1m) PVDF pipe 6” (160mm) under
a pressure of 45 psi (3 bar) results in an energy of ca. 1 Joule.
• In contrast air is a compressible medium; the same pipe has with 45 psi (3 bar) pressure an energy of already 5000
Joule.
• If there were a failure during the pressure test, the waterfilled pipe would fly 1” high, the airfilled pipe 360ft! And this
with a test pressure of only 45psi (3 bar).
Fractural Behavior of Thermoplastics

In case of failures thermoplastic materials show different behaviors. PE and PB (to a lesser degree ABS) have a ductile
behavior, that means brittle fracture cannot occur.
Nevertheless, the following safety precautions must be taken into consideration during the internal pressure test. As
mentioned before the pressure test is the first loading placed on the pipeline and uncover any existing processing faults
(e.g. insufficient welding).
Remark: Gas leak tightness cannot be demonstrated by =a water pressure test, also not with increased test pressure!
Overview of the different testing methods

Testing Method Internal Pressure Test Leak Test
Medium Water Gas/Air* Compressed Air* Gas/Air Gas/Air
Behavior Incompressible Compressible Compressible Compressible Compressible
Test Pressure 1.5 x Operating Operating 7 psi (0.5 bar) 22 psi (1.5 bar)
(up to system max.) (up to system max.,
but not to exceed
150psi)
Safety Hazard Minor High High Minor Moderate
Material All Plastics ABS PB, PE All Plastics ABS
Informative High: High: High: Minor Moderate
Value Proof of resistance Proof of resistance Proof of resistance
to pressure to pressure to pressure
including tightness including tightness including tightness
against test against test against test
medium medium medium
* Please consider the applicable safety precautions
66
Internal pressure test with water or a similar incompressible test fluid
General
The internal pressure test is done when installation work has been completed and necessitates an operational pipeline
or operational test sections. The test pressure load should furnish experimental proof of operational safety. The test
pressure is not based on the working pressure, but rather on the internal pressure load capacity, derived from the pipe
wall thickness.
Test pressures are therefore determined in relation to SDR and the pipe wall temperature. The 100-h value from the long-
term behavior diagram is used for the test clamping.
Test Parameters
The following table indicates recommended methods of testing the internal pressure.
Object Pre-Test Main Test

Test pressure P #P # 0.85 x P
(depends on the pipe
wall temperature or the
permissible test pressure of
the built-in components, see
clause Determining the test
pressure)
Test duration L # 325ft : 3 h L # 325ft : 3 h
(depends on the length of
the pipeline, respectively the 325ft , L # 1640ft : 6 h 325ft , L # 1640ft : 6 h
sections)
Checks during the At least 3 checks, distributed At least 2 checks, distributed
testing (test pressure and over the test duration with over the test duration without
temperature progression restoring the test pressure restoring the test pressure
should be recorded)
Pre-test Material Pressure Drop
The pre-test serves to prepare the piping system PVC 7.2 psi/h (0.5 bar/h)
for the actual test (main test). In the course of pre- CPVC 7.2 psi/h (0.5 bar/h)
testing, a tension-expansion equilibrium in relation ABS 8.7 psi/h (0.6 bar/h)
to an increase in volume will develop in the piping PP 11.6 psi/h (0.8 bar/h)
system. A material-related drop in pressure will PE 17.4 psi/h (1.2 bar/h)
occur which will require repeated pumping to restore PB 20.3 psi/h (1.4 bar/h)
the test pressure and also frequently a re-tightening PVDF 11.6 psi/h (0.8 bar/h)
of the flange connection screws.
The guidelines for an expansion-related pressure

decrease in pipes are:
67
Main test
In the context of the main test, a much smaller drop in pressure can be expected at constant pipe wall temperatures so
that it is not necessary to pump again. The checks can focus primarily on leak detection at the flange joints and any position
changes of the pipe.
Observe if using compensators

If the pipeline to be tested contains compensators, this has an influence on the expected axial forces of the pipeline.
Because the test pressure is higher than the working pressure, the axial forces on the fixed points become higher. This has
to be taken into account when designing the fixed points.
Observe if using valves

When using a valve at the end of a pipeline (end or final valve), the valve and the pipe end should be closed by a dummy
flange or cap. This prevents inadvertent opening of the valve or any pollution of the inside of the valve.
Filling the pipeline

Before starting with the internal pressure test, the following points must be checked:
• Was installation done according to the available plans?

• All pressure relief devices and flap traps mounted in the flow direction?
• All end valves shut?
• Valves in front of other devices are shut to protect against pressure.
• Visual inspection of all joints, pumps, measurement devices and tanks.
• Has the waiting period after the last fusion / cementing been observed?
Now the pipeline can be filled from the geodetic lowest point. Special attention should be given to the air vent. If possible,
vents should be provided at all the high points of the pipeline and these should be open when filling the system. Flushing
velocity should be at least 3ft/sec.
Reference values for the filling volume are given in the table below.
Adequate time should be allowed between filling and testing the pipeline, so that the air contained in the piping system can
escape via the vents: ca. 6 - 12 h, depending on the nominal diameter.
Pipe Size (d) Diameter Pipe Size V (gpm)

Test Pressure (%) up to 110mm 160 to 450 # 3” (90mm) 2.3
10 < 3 min 3 - 7 min 4” (110mm) 4.8
20 < 6 min 6 - 20 min 6” (160mm) 11.0
30 < 9 min 9 - 30 min 8” (200/225mm) 24.0
40 < 12 min 12 - 40 min 10” (250mm) 32.0
50 < 15 min 15 - 50 min 12” (315mm) 48.0
60 < 17 min 17 - 63 min 14” (400mm) and Above > 95.0
70 < 21 min 21 - 77 min
80 < 24 min 24 - 93 min
90 < 28 min 28 - 105 min
100 < 30 min
68
Max Test Pressure
50°F 68°F 86°F 104°F 122°F
(10°C) (20°C) (30°C) (40°C) (50°C)
SYGEF® PVDF (PN16) 300 psi 300 psi 275.5 246.5 217.0
SYGEF PVDF (PN10)
®
191 psi 191 psi 174.0 159.9 140.0
Checks during testing

The following measurement values must be recorded consistently during testing:
• Internal pressure at the absolute low point of the pipeline

• Medium and ambient temperature
• Water volume input
• Water volume output
• Pressure drop rates
Internal pressure test with gas (compressible medium). Maximum test pressure should
never exceed 7 psi (0.5 bar) max.
If it is not possible to do an internal pressure test with water (e.g. pipeline must be kept dry), a leak test can be carried out
with slight overpressure. For safety reasons the test pressure must then be limited to maximum 7 psi (0.5 bar).
For the leak test all the joints should be sprayed with a foam-forming medium and subsequently checked. A soap solution,
which can be removed simply with water after the test, is best.
Attention: Commercial leak detection sprays can cause stress cracks in plastics. Using these sprays remove any residues
after testing.
Since the efficiency of this leak test is very restricted due to the low load, it should be used preferably for systems with
working pressures under 7psi (0.5 bar).
Modifications and repairs

The following safety measures are to be observed when modifying or repairing piping systems:
• wear protective clothing

• drain the respective pipeline section completely
• rinse the pipe section
• protect against dripping
• clean and dry the joints
An important factor for the competent repair of piping systems is to have the work carried out by trained professionals.
Modifications and repair work may not weaken the piping system mechanically.
To ensure the operational safety of the piping system following a modificati or a repair, an interanl pressure test should be
done.
69
Commissioning
When putting a pipeline into operation for the first time, besides the internal pressure test, temperature effects are also
generally examined. Thermal stress, i.e. expansion, was not simulated during testing.
We recommend an initial inspection at the earliest 3 days, at the latest 7 days, after commissioning and recording the
results.
The inspection checks should include:
• critical points in the system (visual inspection)

• flange joints, unions, valves (leak-proof)
• safety and leak detection equipment (condition, function)
Continuous inspection of the piping system should be done by operating personnel during their usual rounds according to
the operating instructions.
70
Sterilization and Sanitization Methods
Autoclave Sterilization
PVDF piping components exhibit no changes upon repeated exposure to typical temperatures experienced in autoclave
cycles; however, autoclaving is not recommended for PVDF valves due to dissimilar materials for construction of
diaphragm and valve bonnets.
In-Line Steam
PVDF piping, fittings and valves exhibit thermal stability up to 284°F (140°C). Therefore, in-line steam sterilization, typically
executed at temperatures of up to 273°F (134°C), can be performed without adverse affects, provided that the pipe is
properly supported. PVDF offers better insulation than metal and has a significantly lower surface temperature.
Ozone Sanitization
PVDF can be sanitized using continuous ozone concentration levels of up to 0.2 ppm without adverse effects. Ozone is
commonly removed using UV light at a wavelength of 1.0x10-5in (254nm). The light sources can be safely installed in PVDF
piping systems provided a 90° deflection is introduced by either a fully lined diaphragm valve or a 90° stainless steel elbow.
Ozone does not require the purchase of additional cleaning agents; does not require rinsing of the system afterwards; and
does not add unwanted substances in the water.
Hot Water Sanitization

PVDF is rated up to maximum operating temperatures of 284°F (140°C), it can be hot water sanitized which requires no
additives or removal processes. This method of sanitization is typically used to maintain USP and WFI systems for the
pharmaceutical industry. PVDF systems that are operated for long periods of time at temperatures above 140°F (60°C) will
need to be properly supported at all horizontal and vertical lengths of the piping system.
71
GF Piping Systems > worldwide at home
Our sales companies and representatives
ensure local customer support in over 100 countries. www.gfpiping.com
The technical data is not binding. They neither

constitute expressly warranted characteristics nor
guaranteed properties nor a guaranteed durability.
They are subject to modification. Our General Terms
of Sale apply.
Australia Denmark / Iceland Korea Poland Sweden / Finland

George Fischer Pty Ltd Georg Fischer A/S Georg Fischer Piping Systems Georg Fischer Sp. z o.o. Georg Fischer AB
Riverwood NSW 2210 Australia 2630 Taastrup Guro-3 dong, Guro-gu, Seoul, Korea 02-226 Warszawa 12523 Älvsjö-Stockholm
Phone +61(0)2 9502 8000 Phone +45 (0)70 22 19 75 Phone +82(0)2 2081 1450 Phone +48(0)22 313 10 50 Phone +46(0)8 506 775 00
[email protected] [email protected] Fax +82(0)2 2081 1453 [email protected] [email protected]
www.georgefischer.com.au www.georgfischer.dk [email protected] www.georgfischer.pl www.georgfischer.se
Austria France Malaysia Romania Switzerland

Georg Fischer Georg Fischer SAS Georg Fischer (M) Sdn. Bhd. Georg Fischer Georg Fischer
Rohrleitungssysteme GmbH 95932 Roissy Charles de Gaulle Cedex 40460 Shah Alam, Selangor Piping Systems Ltd Rohrleitungssysteme (Schweiz) AG
3130 Herzogenburg Phone +33(0)1 41 84 68 84 Phone +60 (0)3 5122 5585 020257 Bucharest - Sector 2 8201 Schaffhausen
Phone +43(0)2782 856 43-0 [email protected] [email protected] Phone +40(0)21 230 53 80 Phone +41(0)52 631 30 26
[email protected] www.georgefischer.fr [email protected] [email protected]
www.georgfischer.at Mexico www.export.georgfischer.com www.piping.georgfischer.ch
Germany Georg Fischer S.A. de C.V.
Belgium / Luxembourg Georg Fischer GmbH Apodaca, Nuevo Leon Russia Taiwan
Georg Fischer NV/SA 73095 Albershausen CP66636 Mexico Georg Fischer Piping Systems Georg Fischer Piping Systems
1070 Bruxelles/Brüssel Phone +49(0)7161 302-0 Phone +52 (81)1340 8586 Moscow 125047 San Chung City, Taipei Hsien
Phone +32(0)2 556 40 20 [email protected] Fax +52 (81)1522 8906 Tel. +7 495 258 60 80 Phone +886 2 8512 2822
[email protected] www.georgfischer.de [email protected] Fax +886 2 8512 2823
www.georgfischer.be Middle East www.georgfischer.ru
India George Fischer Piping Systems United Kingdom / Ireland
Brazil Georg Fischer Piping Systems Ltd Dubai, United Arab Emirates Singapore George Fischer Sales Limited
George Fischer Ltda 400 076 Mumbai Phone +971 4 289 49 60 George Fischer Pte Ltd Coventry, CV2 2ST
04795-100 São Paulo Phone +91 224007 2001 [email protected] 528 872 Singapore Phone +44(0)2476 535 535
Phone +55(0)11 5687 1311 [email protected] www.export.georgfischer.com Phone +65(0)67 47 06 11 [email protected]
[email protected] www.georgfischer.in [email protected] www.georgefischer.co.uk
Netherlands www.georgefischer.com.sg
Canada Italy Georg Fischer N.V. USA / Latin America / Caribbean
Georg Fischer Piping Systems Ltd Georg Fischer S.p.A. 8161 PA Epe Spain / Portugal Georg Fischer LLC
Brampton, ON L6T 4E3 20063 Cernusco S/N (MI) Phone +31(0)578 678 222 Georg Fischer S.A. Tustin, CA 92780-7258
Phone +(905) 792-8005 Phone +3902 921 861 [email protected] 28046 Madrid Phone +1(714) 731 88 00
[email protected] [email protected] www.georgfischer.nl Phone +34(0)91 781 98 90 Toll Free 800 854 40 90
www.gfpiping.ca www.georgfischer.it [email protected] [email protected]
Norway www.georgfischer.es www.gfpiping.com
China Japan Georg Fischer AS
Georg Fischer Georg Fischer Ltd 1351 Rud
Piping Systems Ltd Shanghai 556-0011 Osaka, Phone +47(0)67 18 29 00
Pudong, Shanghai 201319 Phone +81(0)6 6635 2691 [email protected]
Phone +86(0)21 58 13 33 33 [email protected] www.georgfischer.no
[email protected] www.georgfischer.jp
www.cn.piping.georgfischer.com
#1274 (5/2012)
© Georg Fischer LLC
Printed in USA

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SYGEF® PVDF

General Properties - SYGEF® PVDF 13

SYGEF® Plus HP PVDF Specification - IR/BCF 14

SYGEF® Standard PVDF Specification - IR/BCF 17

SYGEF® Standard PVDF Specification - Socket 20

Dimensional Pipe Size

Calculating Pipe Size

Gravity Drain Systems

Surge Pressure (Water Hammer)

Fusion Joining Technology

Infrared (IR Plus) Fusion

Bead and Crevice Free (BCF Plus) Fusion

Validated Welding Process

Sterilization and Sanitization Methods

Flammability and Fire Testing

Installation within Designated Return Air Plenums ETFE 30.0

The test specimen must have stopped burning at Duration Operation

Compliance with Microelectronics Standards

Pipe Dimensional tolerances

Size Tolerance Ovality Wall Tolerance

Manufacturing (Fabricated Products)

Tracebility of Machined Components

Delivery, Storage and Handling

2.01 PURE WATER PIPE AND FITTINGS

2.03 RECIRCULATING LABORATORY FAUCET

d. Faucet shall have a pressure rating of 92 psi (6 bar).

For BCF® Fusion Installations – BCF® Plus

2.01 PURE WATER PIPE AND FITTINGS

2.03 RECIRCULATING LABORATORY FAUCET

b. Faucet to be manufactured for deck or wall mounting options.

d. Faucet shall have a pressure rating of 92 psi (6 bar).

For BCF® Fusion Installations – BCF® Plus

2.01 PURE WATER PIPE AND FITTINGS

b. Faucet to be manufactured for deck or wall mounting options.

d. Faucet shall have a pressure rating of 92 psi (6 bar).

Regression Curve Working Temperature and Pressures for

Outside Dimensions Wall Thickness Inside Dimensions

3/8” - (16mm) 16.0mm — 1.9mm — 12.2mm —

1/2” - (20mm) 20.0mm — 1.9mm — 16.2mm —

3/4”- (25mm) 25.0mm — 1.9mm — 21.2mm —

1” - (32mm) 32.0mm — 2.4mm — 27.2mm —

1 1/4” - (40mm) 40.0mm — 2.4mm — 35.2mm —

1 1/2” - (50mm) 50.0mm — 3.0mm — 44.0mm —

2” - (63mm) 63.0mm — 3.0mm — 57.0mm —

2 1/2” - (75mm) 75.0mm — 3.6mm — 67.8mm —

3” - (90mm) 90.0mm 90.0mm 4.3mm 2.8mm 81.4mm 84.4mm

4” - (110mm) 110.0mm 110.0mm 5.3mm 3.4mm 99.4mm 103.2mm

6” - (160mm) 160.0mm 160.0mm 7.7mm 4.9mm 144.6mm 150.2mm

8” - (200mm) 200.0mm 200.0mm 9.6mm 6.2mm 180.8mm 187.6mm

9” - (225mm) 225.0mm 225.0mm 10.8mm 6.9mm 203.4mm 211.2mm

10” - (250mm) — 250.0mm — 7.7mm — 234.6mm

12” - (315mm) — 315.0mm — 9.7mm — 295.6mm

14” - (355mm) — 355.0mm — 10.8mm — 333.4mm

16” - (400mm) — 400.0mm — 12.1mm — 375.8mm

18” - (450mm) — 450.0mm — 13.6mm — 422.8mm

Hazen and Williams Formula

Figure 4 Step 1: Solve for

V - Fluid Velocity (ft/sec) 4Q(0.1337)

25 0.99 0.13 0.06 25