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In Memoriam:

Steve Clark

President & CEO, Aquatherm


November 1, 1957 May 24, 2013

THERMAL EXPANSION
IN PIPING SYSTEMS
New Solutions to an age old
Engineering Challenge
Steve Clark, P.E., C.E.M.
President & CEO
Aquatherm

THERMAL EXPANSION

a = Thermal Expansion Coefficient


Steel -- 1/100 oF/100 FT
Copper 1.5/100 oF/100 FT
Plastics - 10/100 oF/100 FT
L = Straight length of pipe
dT = Max operating Temp Installed Temp

THERMAL EXPANSION FORCE


F = AE a (T2T1)
Notice that the initial length and change in length
do not matter in calculating the stresses and
forces.
A = Cross section of pipe in
E = Young Modulus
Steel 27.5 x 106 lbf /in2
Polypropylene .29 x 106 lbf /in2
a = Coefficient of Linear Expansion

THERMAL EXPANSION STRESS


Steel 19,148 lb/in2 Irresistible
force
Polypropylene 2,518 lb/in2
Manageable force

A LITTLE INTERNAL RESTRAINT


Fiber strips in bedded middle layer
running parallel with the axial force
Resist Thermal Expansion
Reduce expansion from 10
inches per 100 per 100 F
to 2.3 inches per 100 per
100 F
Also increase the R-value
of the pipe wall from 1 to
1.4 per inch

WHY ENGINEERED PP-R SYSTEMS?


The Right Features
Faser-composite Layer
Innovative fiber
core layer reduces
thermal linear
expansion by 75%
(comparable to copper expansion)

Faser-composite PPR vs. Regular PPR

THERMAL EXPANSION STRESS


Steel 19,148 lb/in2 Irresistible force
Polypropylene 2,518 lb/in2 Manageable
force
Polypropylene with fiber 630 lb/in2 Minor
force

A LITTLE EXTERNAL RESTRAINT

For buried pipe, the frictional force


Eq. 1: F = ApC c + LpWtan( )
Where: Ap = , ft2 ; area of pipe surface bearing against the soil
C = Cohesion of the soil, lb/ft2
c = proportionality constant based on shear tests of surface to soil
interface
Lp = Length of pipe, ft.
ODp = Outside diameter of pipe, ft.
W = 2We + Wp + Ww , lb/ft.; normal force per unit length
We = Vertical load on top and bottom surfaces (prism load), lb/ft
Wp = Weight of pipe, lb/ft
Ww = weight of water in pipe, lb/ft

RESTRAINED BY THE SOIL


Using this worst-case soil (silty sand)
loading for a section of Aquatherm SDR 7.4
PP-R piping results in a frictional force of
5,634 lbf at a burial depth of 1 ft. This is well
above the axial force imposed by the
thermal expansion (4,800 lbf ) and will
readily restrain the pipe from movement.
Note that at a burial depth of 3 ft., this
frictional force increases to 16,350 lbf over
this same section of piping.

ELIMINATING THERMAL
EXPANSION LOOPS
Saves Installation costs - Pipe, fittings, labor,
space
Energy SavingsIncrease Pressure Drop
Maintenance Cost Savings
Fusion connections make thrust blocking
unnessary

5 to 40 % more
pressure drop
More heat loss

ADDITIONAL DISTRIBUTION SAVING


OPPORTUNITIES
Reduce heating supply temperature, but
keep high delta T
Reduces thermal expansion and stresses
Reduces heat loss
Energy Source options
Higher efficiencies
More flexibility in Energy Sources
Heat pumps, solar, waste heat,

ADDITIONAL DISTRIBUTION SAVING


OPPORTUNITIES
Use Natural Insulation
Dry Sand
R- value is .3 to .7 per inch
10 inches sand replaces 1 to 1.5 inches of
insulation

CHILLED WATER DISTRIBUTION SAVING


OPPORTUNITIES
Raise Chilled Water Return temperature, high delta T
Reduces thermal expansion and stresses
Reduces heat gains
Energy Source options
Higher efficiencies
More flexibility in Energy Sources
Heat pumps, geothermal, thermal storage,

Use Natural Insulation

Dry Sand
R- value is .3 to .7 per inch
10 inches sand replaces 1 to 1.5 inches of insulation
Drainage, do not trap moisture against pipe

TRENCH DESIGN

CLEAN ENERGY OPTIONS

Co-generation
Tri-generation
Solar thermal
Geothermal
Ground or ground water
source heating and cooling
Waste energy recovery
Fuel switching
Bio-fuels
High efficiency chillers
Direct cooling from tower
cooling
Thermal storage
Time of day rates

HVAC SYSTEMS EUROPEAN TRENDS


Hydronics
Moving thermal energy with air takes 10 times more energy
than with water.

Radiant heat Low temp heat source


Lower room temperature
Low auxiliary energy

Radiant cooling Warmer cooling source 55 F


Warmer room temp
Low auxiliary energy
In Germany over 60% of new construction uses radiant cooling

OVERCOMING ROADBLOCKS FACING


THERMAL DISTRIBUTION
Campus disruption
First cost
Maintenance cost

AVOIDING CAMPUS DISRUPTION


The future is boring

Directional (horizontal) boring and pulling the pipe


Fusing pipe together before pulling
Avoids trenching and ripping up surface
Go under parking lots or tennis courts, trees, etc..

REDUCING FIRST COST


Horizontal pipe pulling
Eliminate insulation
Insulation systems can cost more then the
pipe
IECC and ASHRAE have added an exception
for Buried Chilled Water Pipe Insulation

Eliminate thrust blocking


Eliminate expansion loops

REDUCING MAINTENANCE COSTS


Eliminate Leaks
From Joints
Fusion connections
No leak path
Strongest part of System

From Pipe
Right material
Compatible with water
Compatible with all common chemicals

THERMAL FUSION JOINTS


Two pieces heat and become one

Socket fusion
Butt welding
Electro-fusion
Outlet fusion

THE RIGHT CONNECTION:


HEAT FUSION (WELDED)
Perfectly bonded connection
(stronger than the pipe)
Labor saving
No glues, gaskets, solders or crimps

Most socket connections in


under 2 min
No dangerous chemicals or open
flames
No FM burn permits required

BUTT WELDING
LARGE PIPE

Face pipe ends flat


Heat pipe ends
Hold together under
pressure

MINIMIZES LIABILITY
No leaks
No weak links at fittings
No gaskets
No bad crimps
No working its way loose
Abrasion resistant
Chemical resistant
10 year warranty

Covers parts, labor, and water damage

METAL AND WATER DONT MIX

WHY PP-R SYSTEMS?


Polypropylene-Random
produced using a by product of refining process

Sustainable
50 60 year service life rating for most systems

Recyclable
LEED friendly
Non-toxic
Energy saving
Low Pressure Drop / Low Heat Loss

Eliminates: Corrosion,
Abrasion, Leaching,
Toxins, Leaks

INSULATION OPTIONS
Insulating Chilled Water Lines unnecessary
Not required under ASHREA 90.1 or IECC 2012
Does not pay back

Insulating Hot Water lines may be done


using sand
Saves first cost
About R=.5 per inch

UNIVERSITY OF SOUTHERN
MISSISSIPPI
$10 million Science Building
USMGP Physical Plant
7 years old energy efficient
district energy plan had
sufficient capacity
Located approximately 2,000 feet
away

USM CHILLED WATER


DISTRIBUTION OBSTACLES
Campus Icon: The Friendship Oak.
500 years old
On The Beach - salt-laden environment

USM CHILLED WATER


DISTRIBUTION FEEDBACK
Trench through open field
Directional Boring under
Tennis Courts, Campus
thoroughfare, building and
The Friendship Oak.

SUMMARY

District Energy Systems


are the best answer to our
energy dilemma.
Medium-temperature fluid
thermal distribution
systems offer the most
advantages for District
Energy.
Technologies like
eliminating expansion
loops, horizontal boring,
heat fusion, and
engineered polypropylene
pipe make it better than
ever!

In Memoriam:
Steve Clark

President & CEO, Aquatherm


November 1, 1957 May 24, 2013

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