VOLUME VIII: ENPURETM HIGH PURITY POLYPROPYLENE

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VOLUME VIII:ENPUREHIGH PURITYPOLYPROPYLENESYSTEM MANUALTMIndustrial TechnicalManual SeriesF O U R T HE D I T I O NIPEX ENPURE HIGH PURITYPOLYPROPYLENE SYSTEMTM

IPEX Enpure High PurityPolypropylene SystemTMIndustrial Technical Manual SeriesVol. VIII, 4th Edition 2017 by IPEX. All rights reserved. No part of this book maybe used or reproduced in any manner whatsoever without priorwritten permission.The information contained here within is based on currentinformation and product design at the time of publication and issubject to change without notification. IPEX does not guarantee orwarranty the accuracy, suitability for particular applications, orresults to be obtained therefrom.

ABOUT IPEXAt IPEX, we have been manufacturing non-metallic pipe and fittings since 1951. We formulate our own compoundsand maintain strict quality control during production. Our products are made available for customers thanks to anetwork of regional stocking locations throughout North America. We offer a wide variety of systems includingcomplete lines of piping, fittings, valves and custom-fabricated items.More importantly, we are committed to meeting our customers’ needs. As a leader in the plastic piping industry, IPEXcontinually develops new products, modernizes manufacturing facilities and acquires innovative process technology. Inaddition, our staff take pride in their work, making available to customers their extensive thermoplastic knowledge andfield experience. IPEX personnel are committed to improving the safety, reliability and performance of thermoplasticmaterials. We are involved in several standards committees and are members of and/or comply with the organizationslisted on this page.For specific details about any IPEX product, contact our customer service department.

SAFETY ALERTSEngineered thermoplastics are safe inert materials that do not pose any significant safety or environmental hazards duringhandling or installation. However, improper installation or use can result in personal injury and/or property damage. It isimportant to be aware of and recognize safety alert messages as they appear in this manual.The types of safety alert messages are described below.This safety alert symbol indicates important safety messages in thismanual. When you see this symbol be alert to the possibility of personalinjury and carefully read and fully understand the message that follows.WARNING“WARNING” identifies hazards or unsafe practices thatcan result in severe personal injury or death ifinstructions, including recommended precautions, arenot followed.CAUTION“CAUTION” identifies hazards or unsafe practices thatcan result in minor personal injury or product orproperty damage if instructions, includingrecommended precautions, are not followed.Note: The use of the word “NOTE” signifies special instructions which are important but are not related to hazards.For the materials described in this manual, the following warming applies.CAUTIONWARNING NEVER use compressed air or gas in PVC/CPVC/PP/PVDFpipe and fittings.AIR/GAS NEVER test PVC/CPVC/PP/PVDF pipe and fittings withcompressed air or gas, or air-over-water boosters. ONLY use PVC/CPVC/PP/PVDF pipe for water andapproved chemicals.Use of compressed air or gas in PVC/CPVC/PP/PVDFpipe and fittings can result in explosive failures andcause severe injury or death.Enpure High Purity Polypropylene Systemi

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CONTENTSEnpureTM High Purity Polypropylene System ManualAbout IPEXSafety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iSection One:General InformationOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2High Purity Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Material Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Section Two:Process Piping DesignIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Section Three:InstallationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Joining Methods – Socket Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Joining Methods – Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Joining Methods – Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Section Four:ValvesVKD Series Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41VM Series Diaphragm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43SR Series Ball Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Recirculating Faucet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Section Five:DimensionsPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Section Six:SpecificationsEnpure PP High Purity Industrial Piping Systems . . . . . . . . . . . . . . . . . . . . .59Enpure High Purity Polypropylene SystemIII

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SECTION ONE: GENERAL INFORMATIONOVERVIEWGENERALINFORMATIONThis manual provides the most up-to-date and comprehensiveinformation about the Enpure high purity piping systemsproduced by IPEX. Written with the needs of the engineer andcontractor in mind, all aspects of High Purity Polypropylene(PP) systems are covered. This includes material properties,specifications, system selection and installation.Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.1

GENERALINFORMATIONBENEFITSVirgin MaterialAbrasion ResistanceEnpure is manufactured from special high purity virginpolypropylene materials. No regrind material is used in themanufacturing process, thereby avoiding contamination bycolorants or other materials and potential loss of physicalproperties due to the incorporation of heat stressed materials.To avoid contamination after manufacturing, the pipe iscapped and boxed immediately after production.The inherent abrasion resistance of natural PP allowssubstantial increases in life expectancy compared to othermaterials. In many applications, natural polypropyleneout-performs other materials such as metals.Extended LifeOnce properly selected for the application and correctlyinstalled, Enpure products provide years of maintenance freeservice. Enpure was first introduced in 1984 and has beenoperated successfully in demanding high purity and industrialapplications for over 23 years.Lower CostsIPEX Enpure natural PP has lower material and installationcosts than other comparable materials such as stainless steelor PVDF.Chemical ResistanceEnpure natural PP offers a complete high purity systemincluding pipe, fittings and valves with outstanding resistanceto most organic and inorganic chemicals in common use. It ispotentially vulnerable to strong oxidizing acids, certainorganic solvents and chlorinated hydrocarbons. For specificapplications see the IPEX Chemical Resistance Guide.Biological ResistanceEnpure natural PP piping is resistant to fungi and bacterialgrowth. The smoothness of the interior walls inhibits bacterialgrowth by eliminating sites where bacteria can adhere.Corrosion ResistanceOur thermoplastic materials are immune to damage fromnaturally corrosive soil conditions as well as electrochemicalor galvanic corrosion. These non-corroding properties extendservice life and lower maintenance costs even inbelow-grade applications.Improved FlowIPEX piping is smooth and has a substantially lowerroughness factor than metal and other materials, and sincethermoplastics do not rust, pit, scale or corrode, the interiorwalls remain smooth in virtually any service. This highcarrying capacity results in higher flow rates throughout theservice life of the application.Service TemperatureIPEX Enpure line of pipe, fittings and valves are designed tomeet the highest purity standards. It is because of this thatthere are no additives in the virgin polypropylene material.Additives such as antioxidants and UV stabilizers helpthermoplastic materials with oxidation resistance. SinceEnpure does not contain these additives, it is pressure ratedat 73ºF (23ºC) and will experience lower pressure capabilitiesand a shortened service life if operated at elevatedtemperatures.Note: Estimated service life of PP in elevated temperatureoperation can be found in ISO 8584-1.Standards and ApprovalsIPEX manufactures the widest range of thermoplastic pipingsystems available. All products are produced to the strictestinternal quality control specifications and meet or exceedapplicable regulatory standards.Enpure natural polypropylene materials are priorsanctioned by the US Food and Drug Administration.(FDA Code of Federal Regulations CFR Title 21 –177.1520 (2002). This includes Enpure Schedule 40 andSchedule 80 plain end polypropylene pipe materials, aswell as all fittings and valves.Enpure natural polypropylene materials meet or exceed NSFrequirements for potable water.IPEX will assist customers in obtaining additional productapprovals that may be required in a particular jurisdiction.2Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.

HIGH PURITY SYSTEMSIncreasingly, manufacturing industries and research facilitiesrequire high purity water systems for their operations. Waterpurification technologies such as distillation, de-ionization,reverse osmosis and filtration produce of purified water,eliminating a variety of impurities such as bacteria,particulates and both organic and inorganic contaminants.To meet the increased demand for pure water, in manyapplications a centralized source of high purity water isestablished on site. The water is produced, stored anddistributed on an as needed basis. Often there is aconsiderable distance from the source of water production tothe point of use. In these situations to maintain highstandards of water quality, it is very important to select thecorrect layout design and distribution piping material.however it contains additives which are susceptible toleaching. The joining method used with PVC will alsocontribute to contamination of high purity water. Solventcement will typically get on the inside of the pipe duringinstallation and then be extracted by the high purity waterover time. This same phenomenon occurs to the additives inthe pipe material.The Enpure natural polypropylene line contains very lowquantities of leachable elements which are usually removedduring pre-rinses of the system at startup. Unlike metalpiping, which will continue to be affected by aggressive highpurity water after startup, Enpure will not be adverselyaffected and will provide optimum high purity water qualityfor the duration of its service life.Joining MethodsJoining methods should also be considered when reviewingsources of potential contamination. Refer to pg 18 formore details.Piping MaterialEnpure SystemTraditional materials for handling high purity water have beenmetal piping, principally stainless steel, tin-lined copper andaluminum. These materials can exhibit problems with tracemetal contamination (e.g. aluminum, iron, nickel andchromium), degrading water quality and adversely affectingend use applications. Similar contamination problems can befound with glass piping, where elements such as sodium,boron, silica, lead and arsenic can be leached out of thepiping. These types of contamination can be avoided byusing the proper thermoplastics.IPEX's Enpure piping system is one of the few products thatcan meet the rigorous demands of high purity applications.Enpure is manufactured from special high purity, natural,polypropylene material that has been successfully used inhospitals, laboratories, universities, chemical andpharmaceutical plants for over two decades (23 years).Its applications can range from distilled water (resistivity ofless than 1 meg ohm) through to de-ionized water with aresistivity of 18 meg ohm.Over the past twenty years, advances in thermoplastictechnology have enabled the effective use of plastics forhigh-purity water distribution systems, even in aggressiveultra high purity installations. In these instances, the waterwill attempt to leach out any dissolvable elements or ionspresent in the system, from any of the piping components orother materials present in the system. This aggressive actionintroduces contaminants that can degrade water quality andcan result in deterioration of the piping system itself. PVCmay be used for high purity water distribution systemsEnpure meets electronics industry E-2 water standards andAAMI dialysis water standards.To ensure the highest purity possible, the IPEX Enpuresystem was tested for trace leachables. Testing wasconducted by an independent analytical laboratory and asummary of the procedures and findings are provided intabular and graphical form on the following pages. Also, forcomparative analysis, translucent blue PVC, currentlypromoted for the same application, was tested underidentical conditions.Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.3GENERALINFORMATIONHigh purity systems have stringent requirements, whether theapplication is for ultra pure water or for transportingchemically pure reagents or foodstuffs. The following willfocus on high purity water systems, although the sameemphasis on purity applies to other applications.

GENERALINFORMATIONStatic Leach AnalysisThis test represents a process shutdown scenario where the piping system would be offline for a given amount of time.Higher concentration levels of trace elements would leach out of the piping system due to the stagnant process water.This test utilized 18.2 MegOhm-cm UPW and Enpure Schedule 80 – 1" diameter by 16" long pipe samples(approximately 47 square inches of wet surface contact area).The test was performed at 73ºF. The test results shown in Tables 1 & 2 detail the trace leachables recorded.Type E-2 Water requirements (Table 1) along with AAMI water requirements (Table 2) are shown as an indicator ofsuitability for the semiconductor and dialysis industries.This test was then repeated at elevated temperatures 180ºF for Enpure and 140ºF for Blue PVC (max for PVC). Whentemperature is elevated, the leachable concentrations generally increase. At higher temperatures, the Enpure productout performed the Blue PVC for trace leachables.Table 1: Static Leach Test results comparing Enpure toTranslucent Blue PVC and Type E-2 water requirements.Detection Type E-2LimitWater Req.(x10-8)(x10-8)ElementTable 2: Static Leach Test results comparing Enpure, TranslucentBlue PVC and AAMI DialysisEnpurex 10-8@ 73ºFBlue PVCx10-8@ itrate0.050.10.09*Phosphate0.050.1**Blue PVCx10-8@ TinZinc0.0060.1**Zinc4Enpurex 10-8@ 73ºF200Aluminum* below detection limit- not required by test method- bold indicated noncompliance with the 0.0920.002-*0.0180.006100**NOTE:1. TOC total organic carbon2. Electronics and semiconductor Type E-2 Water perASTM D5127-993. Association for the Advancement of MedicalInstrumentation (AAMI) guidelines for dialysis water.* below detection limitEnpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.

Dynamic Leach AnalysisThe test assembly rig was hooked up to the UPW supply onthe upstream side and on the downstream side of the test rigand the water was allowed to "run to drain". The test rig UPWwas setup to "run to drain" as a result of the independent testlaboratory concerns that the blue PVC would contaminatetheir piping system rig.The particle frequency of 4 sizes, ranging from 0.05 micronup to 0.20 micron( N/mL), were recorded and are presentedin Figures 1 & 2.In both the static and dynamic leach analysis it was foundthat Enpure PP exceeds the performance of Blue TranslucentPVC and meets electronics industry E-2 and AAMI dialysiswater standards. Enpure also reduces cost on system startup and shutdowns of ultra pure water (UPW) since there areless dissolved materials to be leached out of the pipe andjoints, As seen in Table 1 and Table 2. Figure 1 and Figure2 show that it takes much less time for the particle count toapproach Zero (0) with Enpure pipe compared to TranslucentPVC. At a cost of approximately 10/ L for UPW thisbecomes a valuable asset.The test utilized 18.2 MegOhm-cm UPW flowing at 1 USgallon per minute (US GPM) & Enpure Schedule 80 –1" diameter by 48" long pipe samples (approximately 141square inches of wet surface contact area). The test durationwas 4 hours and all UPW, after passing through the testsamples was analyzed and then "run to drain".Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.5GENERALINFORMATIONThis test represents the purging of contaminants in a processline during a start-up phase. Since Ultra Pure Water (UPW)is expensive, the expectation is for these contaminants to fallwithin acceptable levels as soon as possible. The longer timerequired for the contaminants to drop in concentration resultsin added expense and is representative of what will occurevery time the system is started up after a shutdown.

GENERALINFORMATIONFigure 1: 0.05 micron particle count during successive 20 minute intervals over a four hour time periodEnpure High Purity PolypropyleneBlue Translucent PVC0.05µ Particle Readings800Particle count ed Time (min)Figure 2: 0.20 micron particle count during successive 20 minute intervals over a four hour time periodEnpure High Purity PolypropyleneBlue Translucent PVC0.20µ Particle Readings100905804Particle count 0100120140160180200220240Elapsed Time (min)6Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.

MATERIAL DESCRIPTIONPP (Polypropylene)GENERALINFORMATIONEnpure is manufactured from a selection of pure virgin polypropylene with no added plasticizers, pigments or re-grind.The material is a lightweight polypropylene conforming to ASTM D4101 that is chemically resistant to organic solventsas well as acids and alkalis. It is vulnerable to strong oxidizing acids, chlorinated hydrocarbons and aromatics and is notrecommended for these systems. Polypropylene has proven to be an excellent material for high purity water systems andindustrial drainage systems where mixtures of acids, bases and solvents are involved. Enpure pipe, fittings and valves arejoined by socket fusion. Flanging and mechanical joints are also available.Table 3 – Physical PropertiesMATERIALSPROPERTIESNatural PPStandardsSpecific Gravity0.905ASTM D792Tensile Strength at Yield (psi)3,900ASTM D638180,000 - 190,000ASTM D6387,000ASTM D790no breakASTM D2565,500 - 8,000ASTM D695Modulus of Elasticity Tensile (psi) at 73 F (23ºC)Flexural Strength (psi)Izod Impact, (ft.lbs./in.) at 73 F (23ºC), notchedCompressive Strength (psi)Poisson's RatioCoefficient of Linear Expansion (in./in./ F x 10-5)Linear Expansion Factor, (in./100 ft./10 F)Maximum Operating Temperature, ( F)0.38 - 0.406.1ASTM D6960.732180Heat Distortion Temperature, ( F) at 264 psi125 - 140ASTM D648Thermal Conductivity, (BTU/in./hr./sq.ft./ F)1.2ASTM C1770.02ASTM D570Water Absorption, (%) 24 hrs. at 73 F (23ºC)Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.7

GENERALINFORMATIONAPPLICATIONSEnpure's superior chemical and physical properties, plus ease of installation, make it an ideal piping system for conveyingacids, alkalis, solvents and deionized water, distilled water, brine, caustic soda and other liquids where high purity andchemical resistance capability is required. It has particular applications in industries such as: Chemical Manufacturing Food Processing Pharmaceutical Manufacturing Hospitals Laboratories Universities Research Facilities Photographic chemical processing Biotechnology Effluent treatment plants Water treatment plants8Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.

SECTION TWO: PROCESS PIPING DESIGNINTRODUCTIONThermoplastics are engineered materials that are suitable for a wide variety of piping assignments in process applications.To effectively implement the use of plastics in high purity applications, it is considered necessary to have both a workingknowledge of piping design and an appreciation of the unique properties of thermoplastics.This section will review the design process and consider the most important factors in designing plastic piping systems.PROCESSPIPING DESIGNEnpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.9

PROCESSPIPING DESIGNDESIGN PROCESSEstablish System RequirementsDetermining PressureBefore the proper materials can be chosen, the system designrequirements must be determined. This establishes the scopeof the project and determines design and materialspecifications. Factors to be considered, but not limited to,include:The carrying capacity of any pipe is a function of its hoopstrength and the geometry of the pipe as defined by its wallthickness and diameter at a given temperature. Maximumoperating pressures for Enpure PP pipe and fittings are givenin Table 4.1.Liquid composition Chemical characteristics Variations in fluid chemistry2.Process flow Required flow rate Required pressure Changes in velocity Potential pressure drops Potential pressure surges Minimum and maximum operating temperatures3.4.5.Table 4 – Pressure Ratings for Enpure Schedule 40& Schedule 80 PP pipe (psi)System Location / Environment Above / below ground or overhead Climate (extreme heat or cold) Expected fluctuations in ambient temperatureInstallation Space restrictions Difficult access New or retrofit Joining of dissimilar materialsBudget Considerations Material cost Installation cost Maintenance cost Lifetime costDetermine Appropriate SizingIn addition to accounting for specific system parameters,pipe size must also be determined. To select appropriate size,it is essential that there is an understanding of the mostimportant physical factors affecting thermoplastic pipe,which are:a. pressure limitationsb. frictional lossc. temperature limitationsd. the pressure/temperature relationshipSize(in.)Sch 40 PP73ºF (23ºC)Sch 80 PP73ºF 01502120150380115480115B. Friction Loss through PipingAs fluid flows through a piping system, it will experiencefriction resistance between the fluid and the pipe wallresulting in a pressure loss. This is a result of fluid: densityviscosityvelocitytemperaturetype of flowsmoothness of the pipe wall.Friction loss can be determined by referring to publishedtables, such as those in Tables 5 and 6 or it can becalculated. The most widely used equation to calculatefriction loss under pressure is the Hazen-Williams equation.Hazen-Williams1.852f 0.2083 x (100/C) 1.852 xQDiA. Pressure LimitationsPressure RatingsPP process pipe is primarily designed to withstand internalpressure under continuous or steady state loading. Short termhigher pressure bursts or surges can be accommodated tovarying degrees, but it is the long term strength of thematerial that determines its performance.104.8655where:f friction loss (ft. of H2O/100 ft.)Q flow rate (gpm)Di pipe inside diameter (in.)C flow coefficient (constant at 150 for PP)Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including air-over-water-boosters.

18.474.433.161.26Enpure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including 21.791.661.531.411.28Friction Head(ft)1"Friction Loss(psi)1.03Friction ction Head(ft)1.16Friction iction 24.423.312.652.211.551.10Friction .190.81Friction ion 255.144.133.232.421.731.140.670.440.320.16Friction Loss(psi)PROCESSPIPING Friction .034.223.472.792.181.641.170.770.450.212"Friction .831.501.210.940.710.510.330.200.09Table 5 – Carrying Capacity and Friction Loss for Schedule 40 Thermoplastic Pipe11

npure High Purity Polypropylene SystemCAUTION: Do not use or test the products in this manual with compressed air or other gases including 75Friction Head(ft)9.47Friction Loss(psi)1.73Velo

Enpure System IPEX's Enpure piping system is one of the few products that can meet the rigorous demands of high purity applications. Enpure is manufactured from special high purity, natural, polypropylene material that has been successfully used in hospitals, laboratories, universities, ch

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