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Advanced PE: Fusion Welded Thermoplastic Piping “Anti-Leak”
Fluid Flow Specification Guide for Chemical Liquid Applications
General: To provide the Owner an Advanced PE Thermoplastic Chemical Piping System
designed to minimize the incidence of leaks and/or failures while in operation. The primary goal
is to keep the liquid in the pipe. If implemented, this specification guide will help insure a SAFE
WORKPLACE for both plant personnel and the environment.
Scope: This specification guide is limited in scope; it only covers the wetted fluid flow
thermoplastic piping components that convey chemical liquids throughout process piping systems
in above or below ground applications. Components include: Pipe, Fittings, Valves, Sensors and
all other components that may come in contact with chemical liquids.
This specification guide covers Piping Material and Compatibility, Piping Components, Storage
and Handling of Components, Thermal Fusion Welding of Components, Mechanical Joints,
Piping System Design, Installation and Testing, Personnel Training and Certification, Fusion
Equipment, Commissioning and Maintenance of both Single-Wall and Double-Wall Thermoplastic
Piping Systems.
This specification guide does not cover Tanks, Pumps or Automation and Control systems but
does cover their connections to the piping system.
Applicable Industries: This specification guide applies to any industry or industrial applications
that involve chemical or water liquid processes. Chemical FEED for Water/Wastewater and
General industries and Chemical WASTE, BLENDING, and MANUFACTURING for Chemical
Process Industries are all Applicable Industries.
“Anti-Leak” Technology: “Anti-Leak” Technology has been developed to specifically limit leaks
and/or failures in chemical liquid piping systems. To achieve this goal, only BEST PRACTICES
have been incorporated into these guidelines while chronically troublesome practices have been
excluded. Primarily, these BEST PRACTICES are concerned with the piping material itself,
joining systems used and system design and installation.
Advanced PE: PE is short for “Polyethylene”. Advanced PE is the latest advancement in High
Density PE resin technology. The main technical advantage this new resin system has is its high
“Environmental Stress Crack Resistance”. Advanced PE is approximately 27 times more stress
crack resistant than the previous generation of PE resin. This makes the new resin system much
more suitable for a broad range of chemical applications. Advanced PE resin is called “PE100RC”
– “RC” meaning “Resistance to Cracks” and has a cell classification of PE445584C.
Joining Systems: Of the entire pipe to fitting joining systems available in thermoplastic piping,
Thermal Fusion has the highest joint integrity. The thermal fusion weld is completely nonmechanical. Thermal Fusion joining methods; “Socket”, “Butt” and “Electro” Fusion are the
primary joining systems used in this specification guide.
Mechanical joints are not as good as non-mechanical joints but cannot be avoided. All valves
have mechanical joints and some components like tanks and pumps have flange connections.
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For this reason, 0-ring connections and gasket/flange connections are included in this
specification guide.
Other joining systems like “Solvent Cementing” and “Threading” are not permitted and are
specifically excluded from this specification guide.
Statement of Fact: NO PIPING SYSTEM IS PERFECT – ALL CHEMICAL PIPING SYSTEMS
FAIL EVENTUALLY. The challenge is to find the right system for a given application that offers a
minimal risk of failure at a reasonable cost of ownership while offering a high return on
investment.
Specification:
Section 001
GENERAL
1.1
SUMMARY
A.
Furnish a complete chemical fluid handling piping system to include: single and/or
double-wall pipe, fittings, specialty fittings, fabrications, valves, accessories and/or chemical feed
skids.
1.2
References
A.
The following standards apply to products used within this section:
ASTM D 1598, ASTM D 1559, ASTM D 2122, ASTM D 2837, ASTM D 2657, ASTM F
2620, ASTM D 3035, ASTM D 3350
B.
The system design shall meet the requirements of ASME/ANSI B31.3 for design criteria
where temperature and pressure fall within the limits of the code.
Section 002
Material of Components
2.1
Definitions
A.
PE 100-RC: High-density polyethylene with a cell classification of: PE445584C.
2.2
System Material Description
A.
All pipe, fittings and fabricated piping components shall be produced of virgin Black PE
100-RC uniform resins conforming to material requirements according to “PAS 1075”.
B.
All other system components such as Valves, Instrumentation, Strainers etc. shall be
made of other materials compatible with the application. Such components shall connect to the
piping system via PE 100-RC “End Connectors” where available or flange connections if no PE
100-RC “End Connectors” are available.
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2.3
Quality Assurance
A.
Obtain system components from a single source having responsibility and accountability
to answer and resolve problems regarding proper installation and design, compatibility,
performance, and acceptance.
Section 003
Chemical Compatibility
3.1
Chemical Compatibility Procedure
A.
The Owner/System Designer will provide the Piping System Manufacturer the following
information regarding the Application:
1)
2)
3)
4)
5)
Chemical Media and Concentration(s)______________
Temperature______________
Pressure______________
Type of Installation___________________
Other_______________
B.
The manufacturer will check the application based on the provided information and issue
a statement of compatibility for the material here in specified. The statement will contain the
application information, an affirmation of compatibility or non-compatibility and the expected
useful life of the system based on the System Criteria if available. The manufacturer will also
provide references for similar applications if available. If the material specified here in is not
compatible with the application, the manufacturer may submit an alternative material that is
compatible along with its specification.
Section 004
Piping and Fittings
4.1
Pipe
A.
All single and double-wall piping shall be extruded and seamless and furnished in straight
lengths. Coiled single-wall pipe may also be used. All piping shall be produced based on an SDR
system and calculated utilizing a hydrostatic design basis according to ASTM D 2837.
Table of SDR Ratings:
SDR
7.4
11
17
33
Pressure Rating @ 68° F
230 psi
150 psi
90 psi
45 psi
B.
Single-wall pipe sizes ½” (20mm) and ¾” (mm) shall be SDR 7.4 and sizes 1” (32mm)
through 12” (315mm) shall be SDR 11.
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C.
Fabricated double-wall pipe shall be SDR 7.4 or 11 for the primary pipe and SDR 11 or
33 for the secondary pipe. Pipe lengths shall be fabricated and furnished from the factory with all
necessary floating “Support Clips” required and properly spaced for the application and “End
Discs” pre-installed ready for field welding.
D.
Co-extruded double-wall pipe shall be SDR 11 for the primary pipe and SDR 17 for the
secondary pipe with continuous interconnecting ribs between the two pipes.
4.2
Fittings
A.
All single-wall “Socket Fusion” style fittings shall be injection-molded with a wall thickness
of SDR 7.4 – which is greater than or equal to the wall thickness of the pipe. Single-wall “Socket
Fusion” fittings with an SDR rating of 7.4 may be fused to either SDR 11 or SDR 7.4 pipe.
B.
All single-wall “Butt Fusion” style fittings shall be either injection-molded with a wall
thickness of SDR 11 or fabricated from the pipe itself. Available molded single-wall fittings shall
be used over fabricated fittings at all times. If a fabricated single-wall fitting must be used, the
installer shall check its pressure rating to insure it exceeds the system design pressure.
C.
Single-wall “Electro Fusion” Couplings may also be used for ease of installation like final
welds up in the rack etc. but are not to be used as primary connections throughout the system.
D.
All double-wall fabricated fittings shall be made of injection-molded fittings and designed,
manufactured and furnished from the factory ready for simultaneous “Butt Fusion” welding to the
pipe. Other fitting components may be machined. The primary and secondary fittings are to be
the same SDR thickness as their respective pipes.
E.
Fittings for co-extruded double-wall pipe shall be either injection-molded or fabricated
from the pipe itself base on availability. Where molded fittings are available, they shall be used
over fabricated fittings. Simultaneous “Butt Fusion” is the only acceptable joining method. If
fabricated fittings are to be used, the installer shall check their pressure ratings to insure they
exceed the system design pressure.
F.
The manufacturer shall supply all fittings whether molded or fabricated from the factory.
The installer shall not fabricate fittings in the field.
4.3 Deliveries, Storage and Handling of Components
A.
Manufacturer shall deliver all piping components to arrive on-site wrapped or protected to
avoid damage in shipping.
B.
Deliver all fittings and other components to arrive on-site in boxes.
C.
Pipe, fitting and other components should be stored on elevated platforms in a dry
location protected from the environment.
D.
Lift, support and transport all components with due care to avoid damage.
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Section 005
Fusion Welding of Components
5.1
Acceptable Welding Methods
A.
The only acceptable welding methods are:
1. “Socket Fusion”
2. “Butt Fusion”
3. “Electro Fusion”
No other welding method shall be allowed for pipe and fitting welds. “Hot Air” welding with
welding rod made of PE 100-RC material shall be used only for welding “End Discs” for fabricated
double-wall pipe.
5.2
Available and Preferred Welding Methods per Pipe Size
A.
In sizes ½” (20mm) and ¾” (25mm), only “Socket Fusion” fittings are available and
“Socket Fusion” is also the preferred welding method for these sizes including 1” (32mm) size.
B.
In sizes 1” (32mm) through 4” (110mm), both “Socket Fusion” and “Butt Fusion” fittings
are available. For sizes 1 ½” (50mm) through 4” (110mm), “Butt Fusion” is the preferred welding
method though both can be used. In sizes 6” (160mm) through 12” (315mm), only “Butt Fusion” is
available.
C.
In sizes 1 ½” (50mm) through 12” (315mm), for pipe-to-pipe connections, “Butt Fusion” is
the preferred welding method. This eliminates the need for a Coupling and one extra weld.
“Electro Fusion” couplings may also be used for pipe-to-pipe connections.
C.
All double-wall systems are joined by simultaneous “Butt Fusion”.
Section 006
Mechanical Joints
6.1
General
A.
Mechanical Joints are necessary in every piping system. All valves and other accessories
will have O-ring seals. Flange connections to tanks and pumps and for pipe sections may also be
needed but should be kept to a minimum.
B.
If threaded components must be used, male and/or female threaded adapters will be
furnished by the manufacturer, otherwise, no threaded connections are allowed. Most, if not all of
the valves and other components furnished are to have PE 100-RC end connectors for fusion
directly onto pipes or fittings.
6.2
O-rings, Diaphragms, Flanges and Gaskets
A.
All O-rings, Diaphragms or wetted elastomeric parts in valves and other components
shall be compatible with the chemical media.
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B.
All flange components shall consist of a PE 100-RC “Stub End” and a loose
Polypropylene/Steel “Backing Ring”.
C.
All flange gaskets shall be PTFE/EPDM or EPDM depending on the chemical application.
The gaskets shall be “LOW TORQUE” “AV” style as manufactured by Asahi/America.
Section 007
“Anti-Leak” Technology
7.1
“Anti-Leak” Technology on Skid Mounted Equipment
A.
If the owner is having skid-mounted equipment provided, the equipment manufacturer
shall provide PE 100-RC pipe and fittings with “Anti-Leak” technology on the skid. All components
such as, Valves, Gauge Guards, Calibration Columns, Regulating and Relief Valves, Strainers,
Sensors, Pulsation Dampeners, and Pump Connections shall interface with the piping and fittings
via PE 100-RC “End Connectors” with O-ring seals or Flange connections if needed. This
technology has been developed and is commercially available.
7.2
“Anti-Leak” Technology for Valves and Components
A.
If the owner is not having skid mounted equipment provided, all valves and other
components such as: Gauge Guards, Calibration Columns, Regulating and Relief Valves,
Strainers, Sensors, Pulsation Dampeners, and Pump Connections shall interface with the piping
and fittings via PE 100-RC “End Connectors” with O-ring seals or Flange connections if needed.
This technology has been developed and is commercially available from.
Section 008
Piping System Design
8.1
General
A.
The owner/designer shall be responsible for the design of the system. The manufacturer
shall work with and furnish the owner/designer all technical information necessary to facilitate the
design process. See Addendum 1 “Design and Installation Guide”
8.2
Special Design Considerations
A.
Hazardous Chemicals should be handled in a safe manner. If pipe runs are located in
areas where personnel might be present or underground, double-wall piping should be
considered.
B.
The design shall incorporate all the necessary components for proper hanging, anchoring
and supporting of the piping system. “Restraint Fittings” shall be used to provide fixed points for
sectioning out the expansion and contraction of the piping and to protect fittings from excessive
movement. No metal hardware such as hangars, clamps, banding or pipe clips should come in
contact with the piping.
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Section 009
Installation and Testing
9.1
General
A.
The piping system shall be installed and tested according to the manufacturers
recommendations and in accordance with all design documents and specifications. See
Addendum 1 “Design and Installation Guide”
B.
Factory Field Technician services may be used to assist the installers in the welding of
components.
Section 010
Personnel Training and Certification
10.1
General
A.
To help insure a proper installation, personnel shall receive on-site factory representative
training and certification just prior to beginning the work. The factory representative shall inspect
the welds at the beginning of the work.
B.
Training classes shall be conducted with the actual welding equipment to be used on the
job and shall cover proper safety and operating procedures of the tools. A separate certification
card is required for each tool.
C.
Each installer is required to demonstrate a proper understanding of welding and safety
procedures for each tool and submit sample welds for inspection by the manufacturer.
Section 011
Fusion Equipment
11.1
General
A.
Only Factory approved welding equipment shall be used. Equipment may be rented or
purchased.
B.
If welding equipment is purchased by the installer, the equipment shall be turned over to
the owner in good working condition after the project is completed.
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Section 012
Commissioning and Maintenance
12.1
General
A.
Before completion of the work, a factory representative shall be present for final
inspection of the welds and commissioning of the systems such as leak detection etc.
B.
The factory representative shall also discuss maintenance procedures and provide weld
training for plant personnel.
End of Specification Guide
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Addendum 1: Advanced PE: “Anti-Leak” Design and Installation Guide
General: This Advanced PE design and Installation “GUIDE” reflects what we consider to be
“BEST PRACTICE” based on experience over 5 years of handling Sodium Hypochlorite in both
above and below ground applications. This “GUIDE” is in reference to Sodium Hypochlorite
service but should also be considered for other chemical applications.
Sodium Hypochlorite Service is one of the most challenging applications for any piping system to
handle. There is no “PERFECT” piping system for Sodium Hypochlorite. Every Sodium
Hypochlorite system has its unique set of characteristics and care should be taken in the specific
design in order to handle those unique characteristics.
Asahi/America will assist the designer throughout the design process to insure the “BEST
PRACTICE” is incorporated into the Specification and Design. In the installation, Asahi/America
will provide Training and Certification for the installers and Inspection and Commissioning upon
completion of the project.
SECTION 001
Application Evaluation
1.1
Evaluating the Application
A.
The owner/designer will provide Asahi/America the application conditions of service.
Media: ________________________
Concentration: ________________________
Pressure: _________________________
Temperature: ________________________
Application Conditions:
 Above or Below Ground
 Indoors or Outdoors and Temperatures
 Process line or Fill line
 Type of Support System e.g. Hangers or Continuous
B.
Asahi/America engineering will assess the application to determine Chemical Suitability
and will issue a report.
C.
If the Advanced PE piping system is chosen for the application, Asahi America will run a
“Static Calculation” for the system to determine “Buckling Pressure” and “Operating Pressure”.
These calculations will show if a “Restrained System” falls within the “Maximum Allowable Stress”
of the material and if the “Maximum Allowable Operating Pressure” exceed the system operating
pressure.
Material
SDR
Advanced PE
Advanced PE
7.4
11
Maximum permitted
buckling pressure [bar]
Buckling pressure of the
application [bar]
Maximum permitted
operating pressure [bar]
Maximum inside
pressure of the
application [bar]
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Advanced PE
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SECTION 002
Joining Methods (Sodium Hypochlorite)
2.1
Table of Acceptable Joining Methods:
Joining
Method
Socket
Fusion
Butt
Fusion
ElectroFusion
Static
O-Ring
Flange
Thread
Solvent
Cement
**
½”
¾”
1”
1 ½” – 4”
6” – 12”
YES
YES
YES
NO*
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
N/A
YES
NO
NO
YES
NO
NO
YES
NO
NO
YES
NO
NO
YES
NO
NO
NOTES:
* Socket Fusion may be used under certain conditions.
** Couplings should be avoided in long runs of straight piping.
SECTION 003
Restraining and Supporting the System
3.1
General
A.
In above ground applications, proper supports, restraints, guides etc. are essential to
ensure the integrity of the piping system during its useful life. Limiting the amount of movement of
the pipe and fittings is the preferred method of design. This involves the use of “Restraint” fittings
and Guides/Supports between restraints. In close fitting applications, the amount of movement of
the piping is generally low enough to not require very many restraints. In longer runs of pipe,
restraints and guides/supports between restraints without loops is the preferred method of
design. This is possible as long as the system stress is below the “Maximum Allowable Stress” of
the material.
B.
In below ground applications, the piping is considered to be continuously supported and
restrained.
C.
Direct metal contact with the piping should be avoided.
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3.2
Restraints
A.
“Restraint” Fittings are designed to provide fixed points in the piping system without
clamping down with too much force on the wall of the pipe. A circumferential plastic pipe clip is
attached to the restraint fitting. As the piping expands and contracts, the sides of the clip will
contact the posts on the restraint fitting thus stopping the movement of the pipe at that point.
B.
In longer runs of straight piping, the fittings on either end of the runs should be restrained
on both sides to lock the fitting down. Horizontal runs of straight piping between the restraints
should be either continuously supported or should have circumferential pipe clips designed to
allow movement in the beam direction only. The stress from expansion and contraction will then
be absorbed in the wall of the pipe.
3.3
Pipe Clips
A.
Plastic pipe clips designed for the piping system should be used as supports/hangers.
The clips are circumferential around the pipe thus guiding the pipe but do not clamp down with
too much force. This allows the pipe to move primarily in the beam direction with little bending
between clips.
B.
Where other supports like metal hangars are used, there should be a non-metallic
material touching the piping and the amount of movement at that spot should be minimal.
3.4
Continuous Support
A.
In the smaller sizes like ½”, ¾” and 1”, the support spacing is close enough that
continuous support should be considered. This is mainly a consideration where there are longer
runs of straight piping above ground. The continuous support method should also guide the
piping so as to avoid excessive bending/snaking of the pipe between restraints.
3.5
Support Spacing Table:
SDR 11* Support Spacing (distance in inches)
Dimension
inch (mm)
1/2" (20mm)
3/4" (25mm)
1" (32mm)
1-1/2" (50mm)
2" (63mm)
3" (90mm)
4" (110mm)
6" (160mm)
8" (200mm)
10" (250mm)
12" (315mm)
Temperature °F
68
23
26
30
41
47
59
65
81
91
102
114
86
22
24
30
39
45
57
63
77
87
98
110
104
20
22
26
35
41
53
59
73
83
94
106
122
18
22
26
33
39
49
57
69
79
91
100
140
16
20
22
30
35
45
51
63
75
83
93
* For SDR 7, use a factor of 1.07 for min. distance
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SECTION 004
Outdoor Applications – Above Ground
4.1
General
A.
Advanced PE piping is Black color and can be installed outdoors in direct sunlight. The
Carbon Black pigment provides the piping with a built-in UV protection.
B.
Most outdoor above ground Sodium Hypochlorite applications are either tank “FILL” lines
or “TRANSFER” lines.
C.
In Sodium Hypochlorite service, the Advanced PE system performs best in ambient or
below ambient temperature applications. Where the temperature exceeds ambient, the material
will have a more limited expected useful life. Care should be taken to keep the temperature of the
bleach as close to or below ambient temperature as much as possible.
Tank Fill Lines and Transfer Lines – Sodium Hypochlorite
4.2
A.
Sodium Hypochlorite tank fill lines and transfer lines are perhaps the most challenging
application for the Advanced PE piping System. There are several reasons for this.




B.
They are usually outdoors in direct sunlight
They can have stagnant Sodium Hypochlorite sitting in them for long periods of time
The sun can raise the temperature of the Sodium Hypochlorite if it is allowed to sit in the
piping
If the lines are evacuated after filling the tanks, there will still be puddles of liquid in the
piping and the heated conditions can cause the Sodium Hypochlorite to degrade and offgas Chlorine Gas
For these reasons, the following items should be considered:



Applying AGRU Coat white coating to help reduce the temperature effects of the Sun or
provide shade for the piping if possible
Using Double-Wall piping as an added measure of protection for the primary pipe
Flushing the lines with water after filling to avoid stagnant or puddled Sodium
Hypochlorite
SECTION 005
Outdoor Applications – Under Ground
5.1
Tank Fill Lines and Transfer Lines – Sodium Hypochlorite
A.
Advanced PE piping under ground for Sodium Hypochlorite service while not exposed to
direct sunlight, could still have some of the conditions described in 4.2.A. above. Consequently,
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the use of Double-Wall piping and flushing the piping with water should still be considered for
those reasons as well as the added concern of protecting the environment.
End of Addendum 1
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