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ASTRAL CHEM PRO is proven CPVC piping system meeting all challenging application requirement of industrial piping system. It gives trouble free service to the industry for years together.

ASTRAL CHEM PRO

ASTRAL CHEM PRO industrial piping system can be used up to 93°C temperature & intermittent up to 110°C & pressure based on the pipe sizes. ASTRAL CHEM PRO CPVC industrial piping system is suitable for many industrial requirements like Metal Treating Pump & Raiser, Food & beverages, Industrial waste water, Chemical processing etc. ASTRAL POLY TECHNIK LIMITED is the only Indian company manufacturing industrial grade Chlorinated Polyvinyl Chloride (CPVC) Pipes of schedule 40 & 80 and fittings of schedule 80 confirming to ASTM Standards ranging from ½”(15mm) to 12” (300mm). All ASTRAL CHEM PRO CPVC industrial pipes are produced from compound confirming to ASTM D1784.

 

 Many chemicals encountered in the process industry aggressively corrode most metal equipment resulting in process leaks, flow restrictions and ultimately premature failure. In addition to metals there are other thermoplastics used in industry which get affected by these aggressive chemicals at elevated temperatures and pressures and lead to premature failure. Long Service life, minimum downtime and environmental compliance are critical to the success and growth of firms in the process industry. A challenging effort is required for the industry to achieve the successes where corrosion can decrease piping life, interrupt production and create potential environmental hazards. As a result, these industries often require process-piping systems those are made of materials that can withstand tough industrial environments. Ideally, this means a cost effective material that will resist corrosion and eventually providing mechanical strength, safety and long lasting performance.

 

  WHY ASTRAL CHEM PRO?

• ASTRAL is pioneer in CPVC piping industry having more than 17 years of expertise in CPVC piping system.

• One of the most advanced CPVC industrial piping systems available globally.

• The compound meets or exceeds the requirement of cell class 24448 against the standard cell class 23447.

• Complete product ranges from ½” (15mm) to 12” (300mm) with a wide range of all fittings.

• Provides special non-metallic valves like Ball valve, Butterfly valve, Diaphragm valve and Non return valve, manual & actuated.

• Astral imparts complete knowledge of CPVC piping system including training, installation & after sales service support.

• Dedicated sales force on industrial systems.

 

GENERAL SPECIFICATIONS: ASTRAL CHEM PRO CPVC Industrial Systems are produced from specialty plastic compounds known as post-chlorinated polyvinyl chloride (CPVC). The compounds meet cell class 24448 as defined by ASTM D1784 and have a design stress of 2000 psi and a maximum service temperature of 93ºC. The compound is listed by the National Sanitation Foundation for use with portable water in accordance with NSF Standard 14. The colour is light grey.

Pipe: Pipe meets or exceeds the requirements of ASTM F441 in Schedule 40 and 80 dimensions. Available in size range 15mm (½”) to 300 mm (12”).

 Fittings: Fittings meet or exceed the requirements of ASTM F437 (Schedule 80 threaded) or ASTM F439 (Schedule 80 socket). Available in size range ½” to 12”. 

Primer/Solvent Cement: All socket type joints are made up employing primer and solvent cements that meet or exceed the requirements of ASTM F656 and ASTM F493. Both primer and solvent cement confirm with the requirements of NSF Standard 14. Only CPVC solvent cement and primer are to be used when making CPVC solvent cement joints.  Marking and Uniformity: Pipe and fittings made from ASTRAL CHEM PRO CPVC compounds are clearly marked with the manufacturer’s name or trademark, material designation and applicable ASTM Standard.

 

Applicable Standards: 

ASTM D1784: Standard Specification for Rigid Polyvinyl Chloride (PVC) and Chlorinated Polyvinyl Chloride (CPVC) Compounds.

ASTM F441: Standard Specification for Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe, Schedules 40 and 80.

ASTM F437: Standard Specification for Threaded Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80.

ASTM F439: Standard Specification for Stocket-Type Chlorinated Polyvinyl Chloride Plastic Pipe Fittings, Schedule 80.

ASTM F402: Standard Practice for Safe Handing of Solvent Cement and Primer Used for Joining Thermoplastic Pipe and Fittings.

ASTM F493: Standard Specification for solvent Cements for Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe and Fittings.

ASTM F656: Standard Specification for Primers Used in Solvent Cement Joints of Polyvinyl Chloride (PVC) Plastic Pipe and Fittings.

 

BASIC USE: ASTRAL CHEM PRO CPVC pipes and fittings are intended for use in both pressure and drain applications in general chemical manufacturing plants, pulp and paper plants, waste water treatment plants, metal treating/electroplating plants, water purification plants, and food processing plants where excellent resistance to corrosion from a wide range of chemicals, acids, and bases at temperatures up to 93°C is required.

 

 SYSTEM DESIGN: The system is designed in accordance with standard industry practice for thermoplastic industrial piping systems and takes into consideration such factors as pressure and flow requirements, friction loss, operating temperatures, support spacing, anchoring, bracing and thrust blocking, temperature correction factors, joining methods, chemical environment, collapse and loading, and thermal expansion and contraction.

 

 CAUTIONS/LIMITATIONS: Air or compressed gas should never be used for pressure testing rigid thermoplastic piping systems. Temperature correction factors to be applied when operating temperatures exceed 23° C. Only Schedule 80 pipe may be threaded up to and including 4” size, and threads to be in accordance with ANSI B1.20.1 Taper pipe Thread. Only water soluble oil or water to be used when threading Chem Pro pipe. Digressing type solvents should never be used to clean threads. Only Teflon tape should be used when making plastic connections. Flanged systems should not exceed 150 psi working pressure. Threaded joints should have 50% of the pressure rating of Schedule 80 pipe.

 

 ASTRAL CHEM PRO CPVC is not recommended for use with most polar organic solvents such as chlorinated or aromatic hydrocarbons, esters, or ketones. Prior testing is recommended when required service includes surfactant, oil, or grease. Consult ASTRAL for specific chemical resistance information.

Pipes

Fittings

THERMAL EXPANSION AND THERMAL STRESSES 

 

Outside Diameters and Wall Thicknesses For CPVC 4120, SDR 11 Plastic Pipe As Per ASTM D-2846

Nominal Size

(in.)   (mm)  

Outside Diameter, in. (mm)

Wall Thickness, in. (mm) 

Pressure Ratting. PSI (Kg.Cm²)

Average

Tolerance

Minimum

Tolerance

 

180°F           (82°C)

½*         (15)

 

± 0.003 (0.08)

 

+0.020 (0.51)

400

(28.1)

100

(7.0)

¾           (20)

 

± 0.003 (0.08)

 

+0.020 (0.51)

400

(28.1)

100

(7.0)

1            (25)

 

± 0.003 (0.08)

 

+0.020 (0.51)

400

(28.1)

100

(7.0)

1¼         (32)

 

± 0.003 (0.08)

 

+0.020 (0.51)

400

(28.1)

100

(7.0)

1½         (40)

 

± 0.004 (0.10)

 

+0.020 (0.51)

400

(28.1)

100

(7.0)

2           (50)

 

± 0.004 (0.10)

 

+0.023 (0.58)

400

(28.1)

100

(7.0)

 

 

* For ½" wall thickness minimum is not a function of SDR.

THERMAL EXPANSION AND CONTRACTION:

Like all piping material, Astral CPVC PRO expands when heated and contracts when cools down. CPVC piping (regardless of pipe diameter) will expand about 1 inch per 50 feet of length when subjected to 50° F temperature increase, therefore, allowances must be made for this resulting movement. However, laboratory testing and installation experience have demonstrated that the practical issues are much smaller than the coefficient of thermal expansion would suggest. The stresses developed in CPVC pipe are generally much smaller than those developed in metal pipe for equal temperature changes because of the difference in elastic modulus. Required loops are smaller than those recommended by the Copper Development Association for copper systems.

Expansion is mainly a concern in hot water lines, generally, thermal expansion can be accommodated with changes in direction. However, a long straight run may require an offset or loop. Only one expansion loop, properly sized is required in any single straight run, regardless of its total length. If more convenient, two or more, smaller expansion loops, properly sized, can be utilized in a single run of pipe to accommodate the thermal movement. Be sure to hang pipe with smooth straps that will not restrict movement. For convenience, loop (or offset) length have been calculated for different pipe sizes and different run length with a temperature increase (?T) of about 80°F. The results, shown in table A and B, are presented simply as a handy guide for quick and easy determinations of acceptable loop length for other temperatures and run length can be calculated utilizing the following equations :

Where: 

L = Loop length (in.) E = Modulus of elasticity at maximum temperature (psi) S = Working Stress at maximum temperature (psi) D = Outside diameter of pipe (in.) ΔL = Change in length due to change in temperature (in.)

Thermal Expansion Formula Where: ΔL = Change in length due to change in temperature (in.) Lp = Length of pipe (in.) C   = Coefficient of thermal expansion (in. / in. /°F)       = 3.4 x 10-5 in. / in./°F for CPVC ΔT = Change in temperature (°F)

Temperature

    °F                (°C)  

Modulus, E (psi)

Stress, S(psi)

 

     73               (27)

423,000

2000

 

     90               (32)

403,000

1800

 

   110               (43)

371,000

1500

 

   120               (49)

355,000

1300

 

   140               (60)

323,000

1000

 

   160               (71)

291,000

750

 

   180               (82)

269,000

500

 

 

TABLE A

Astral CPVC PRO IPS PIPES (ASTM D 2846) Calculated Loop (Offset) Length with ΔT of approx. 80°F in inches   

Nominal  Pipe Size

mm           in.

Length of Run in Feet 

40

60

80

100

Loop Length(L) in inches 

15              ½

22

27

31

34

20              ¾

26

32

36

41

25               1

29

36

41

46

32               ¼

32

40

46

51

40             1½

35

43

50

56

50                2

40

49

57

64

 

TABLE B Astral CPVC PRO IPS PIPES (ASTM F 441) Calculated Loop (Offset) Length with ΔT of approx. 80°F in inches

      Nominal Pipe Size

               mm           in.

Length of Run in feet 

40

60

80

100

 

     65          2½

47

57

66

74

    75            3

52

63

73

82

  100            4

58

72

83

92

  150            6

71

87

100

112

 200            8

81

99

114

128

250           10

90

111

128

143

300           12

98

121

139

156

 

HORIZONTAL AND VERTICAL SUPPORT :

Horizontal & Vertical runs of Astral CPVC PRO Pipe should be supported by pipe clamps or by hangers located on the horizontal connection close to the riser. Hangers should not have rough or sharp edges, which come in contact with the pipe.

 

TRANSITION FITTINGS & JOINTS:

Special transition fittings or joints are used whenever CPVC piping is connected to a metal valve, fittings, or other appurtenance such as a filter, or to parts made of another plastic. These special transition fittings can have many forms. One common form is the true union with a metal end and a CPVC end held together with a plastic or metal gland nut and having an elastomeric seal between them. Other forms are the flanged joint, the grooved joint, insert molded metal in CPVC fittings, patented push-on type fittings and finally the CPVC female threaded adapter with an elastomeric seal at the bottom of the thread. The later fittings are designed so that they have no thread interference and rely entirely on the elastomeric seal for water tightness. They require only minimal torque to attain an adequate seal.

Standard compression fittings which utilize brass of plastic ferrules can be used to assemble CPVC. However, Teflon® tape should be applied over the brass ferrule to compensate for the dissimilar thermal expansion rates of the brass and CPVC that could possibly otherwise result in a leak. Care should be taken not to over-torque the compression connection.

Metal fittings with CPVC socket inserts are also available. The tubing is cemented directly into the socket in the same way as all-CPVC fittings.

The standard practice is to thread a male thread adapter into the female threaded part, such as a valve of stop, and then solvent cement to the CPVC pipe. However, when using the male thread adapter, there are two limitations that the installer must consider when deciding where and how to use it. First, the male thread adapter may develop a drip leak if the joint is subjected to very broad temperature range. And second, some thread sealants intended to minimize leak problems may chemically attack the CPVC and cause stress cracking of the adapter (see Thread Sealants section). The preferred method of transitioning between metal and CPVC plumbing component is to use an insert molded metal-in-CPVC fitting or true union with a metal and a CPVC end.

CPVC pipes and fittings can be installed underground. Since these piping systems are flexible systems, proper attention should be given to burial conditions. The stiffness of the piping system is affected by sidewall support, soil compaction, and the condition of the trench. Trench bottoms should be smooth and regular in either undisturbed soil or a layer of compacted backfill. Pipe must lie evenly on this surface throughout the entire length of its barrel. Excavation, bedding and backfill should be in accordance with the provision of the local Plumbing Code having jurisdiction.

 

TRENCHING :

The following trenching and burial procedures should be used to protect the piping system.

The trench should be excavated to ensure the sides will be stable under all working conditions. The trench should be wide enough to provide adequate room for the following: - Joining the pipe in the trench. - Snaking the pipe from side or side to compensate for expansion and contraction. - Filling and compacting the side fills.  The space between the pipe and trench wall must be wider than the compaction equipment used in the compaction of the backfill. Minimum width shall not be less than the greater of either the pipe outside diameter plus 16 inches or the pipe outside diameter times 1.25 plus 12 inches. Trench width may be different if approved by the design engineer.

The trench bottom should be smooth, free of rocks and debris, continuous, and provide uniform support. If ledge rock, hardpan or large boulders are encountered, the trench bottom should be padded with bedding of compacted granular material to a thickness of at least 4 inches. Foundation bedding should be installed as required by the engineer.

Trench depth is determined by the pipe’s service requirements. Plastic pipe should always be installed at least below the frost level. The minimum cover for lines subject to heavy overhead traffic is 24 inches.

A smooth trench bottom is necessary to support the pipe over its entire length on firm stable material. Blocking should not be used to change pipe grade or to intermittently support pipe over low sections in the trench.

 

 

BEDDING AND BACKFILLING:

Even though sub-soil conditions vary widely from place to place, the pipe backfill should be stable and provide protection to the pipe.

The pipe should be surrounded with a granular material which is easily worked around the sides of the pipe. Backfilling should be performed in layer of 6 inch with each layer being sufficiently compacted to 85% to 95% compaction.

A mechanical tamper is recommended for compacting sand and gravel backfill which contain a significant proportion of fine grained material, such as silt and clay. If a tamper is not available, compacting should be done by hand.

The trench should be completely filled. The backfill should be placed and spread in fairly uniform layers to prevent any unfilled spaces or voids. Large rocks, stones, frozen clods, or other large debris should be removed. Heavy tampers or rolling equipment should only be used to consolidate only the final backfill.

 HANDLING :

The pipe should be handled with reasonable care. Because thermoplastic pipe is much lighter in weight than metal pipe, there is sometimes a tendency to throw it around. This should be avoided.

The pipe should never be dragged or pushed from a truck bed. Pallets for pipe should be removed with a fork lift. Loose pipe can be rolled down timbers as long as the pieces do not fall on each other or on any hard or uneven surface.

In all cases, severe contact with any sharp objects (rocks, angle irons, forks on forklifts, etc.) should be avoided.

 STORING:

If possible, pipe should be stored inside. When this is not possible, the pipe should be stored on level ground which is dry and free from sharp objects. If different schedules of pipes are stacked together, the pipes with the thickest walls should be at the bottom.

The pipes should be protected from the sun and be in an area with proper ventilation. This will lessen the effects of ultraviolet rays and help prevent heat built-up.

If the pipes are stored in racks, it should be continuously supported along its length. If this is not possible, the spacing of the supports should not exceed three feet (3’).

When storage temperatures are below 0°C (32°F), extra care should be taken when handing the pipe. This will help prevent any problems which could be caused by the slightly lower impact strength of PVC pipes at temperature below freezing.

 

Hot and Cold water compatible:

 

Astral CPVC PRO Piping System is compatible with both hot and cold water. It withstand very high temperature compared to any other thermoplastic plumbing systems. Many solar and electric water heaters have CPVC piping system for heat efficiency and lower installation cost.

 

 Corrosion resistance:

Astral CPVC PRO Piping System gives excellent resistance even under the harshest of water conditions so there are none of the purity worries from corrosion of metal pipe or soldered joints. Astral CPVC PRO Piping System keeps pure water as pure.

 

 Lower bacterial growth:

Bacteria build up with CPVC is far lower than with alternative piping materials - Copper, Steel and other thermoplastics.

 

 Tough, rigid material:

Astral CPVC PRO Piping System has a much higher strength than other thermoplastics used in plumbing. This means that CPVC needs less hangers and supports and there is no unsightly looping of the pipe. Astral CPVC PRO Piping System has a higher pressure bearing capability. This leads to the same flow rate with a smaller pipe size.

 

 No Scale, pit or leach formation:

Even after years of use in the most aggressive conditions, Astral CPVC PRO Piping System won’t corrode, standing up to low pH water, coastal salt air exposures and corrosive soils. Astral CPVC PRO Piping System stays as solid and reliable as the day it was installed. It maintains full water carrying capacity because its scale resistance means no build up to cause water pressure loss.

 

 Unaffected by chlorine in the water:

Some materials may be adversely affected by chlorine contained in the water supply, which can cause breakdown of the polymer chains and potential leaks. In this respect, Astral CPVC PRO Piping System is unaffected by the chlorine present in potable water supply.

 

 Chemical resistance:

CPVC has excellent chemical resistance to strong mineral acids and bases.

 

 Low thermal expansion:

Astral CPVC PRO Piping System has a lower coefficient of thermal expansion than alternative plastics, reducing the amount that the pipe expands when hot water is running, again reducing unsightly ‘looping’ of the pipe.

 

Easy, cold welding process:

CPVC uses a simple, solvent cement jointing method. Tools required are very simple and inexpensive (chamfering tool and pipe cutter only) and do not require the need for an electrical source.

 

 Superior insulation:

Astral CPVC PRO Piping System is more energy efficient than metal pipe. As an insulator it does not lose heat the way metal pipes do. Heat loss and thermal expansion are reduced.

 

 Fire safety:

CPVC has a limiting Oxygen Index (LOI) of 60. Thus in air, Astral CPVC PRO Piping System does not support combustion. No flaming drips, does not increase the fire load, low flame spread, low smoke generation.

 

 Cost seffective:

CPVC Plumbing System is very cost effective than any other plumbing systems. It saves cost on fittings, loops, anchors, offsets, insulation, labour and expensive tools. More over CPVC plumbing systems last longer more than 50 years.