Pipe Design
Pipe Design
Chapter 22
(PIPE DESIGN)
THIS CHAPTER discusses pipe systems, materials, design, installation, supports, stress calculations,
pipe expansion and flexibility, bends and loops, and application of pipe systems commonly used for
heating, air conditioning, refrigeration, and service water.
• When selecting and applying components; applicable local codes, state or provincial codes, and
voluntary industry standards (Some of which have been adopted by code jurisdictions) must be
followed.
The following organizations in the United States issue codes and standards for piping systems and components:
Chapter IV of ASME Standard B31.9 lists applicable U.S. codes and standards for HVAC piping. In
addition, it gives requirements for safe design and construction of piping systems for building heating and
air conditioning.
DESIGN CONSIDERATIONS:
Pipes are conduits in which fluids [compressible (e.g., air, steam) and non-compressible (e.g., water)] flow
in a system, in response to a pressure differential.
NOTE: The Darcy-Weisbach equation, with the Moody chart or Colebrook equation, can be used as
an alternative to pressure drop charts or tables.
• Each HVAC system and, under some conditions, portions of a system require a study of the
conditions of operation to determine suitable materials.
• For example, because the static pressure of water in a high-rise building is higher in the lower
levels than in the upper levels, a heavier pipe or different materials may be required for
different vertical zones.
• Table 1 lists some typical systems and materials used for heating and air-conditioning metallic
piping. The list is not all inclusive, because piping systems are constantly being
developed. The pressure and temperature rating of each component selected must be
considered; the lowest rating establishes the operating limits of the system.
• Boiler piping: ASME Standard B31.1 and the ASME Boiler and Pressure Vessel Code (Section I) specify piping
inside code-required stop valves on boilers that operate above 15 psig with steam, or above 160 psig or
250°F with water. These codes require fabricators and contractors to be certified for such work. The field
or shop work must also be inspected while it is in progress, by inspectors commissioned by the National
Board of Boiler and Pressure Vessel Inspectors.
• Refrigeration piping: ASHRAE Standard 15 and ASME Standard B31.5.
• Plumbing systems: Local codes.
• Sprinkler systems: NFPA Standard 13.
• Fuel gas: NFPA Standard 54/ANSI Standard Z223.1.
DESIGN EQUATIONS:
Darcy-Weisbach Equation:
Pressure drop caused by fluid friction in fully flow, fluids is described by the Darcy-Weisbach equation:
Hazen-Williams Equation:
The loss coefficient for valves appears in another form as Cv, a dimensional coefficient expressing the flow through
a valve at a specified pressure drop.
See the section on Control Valve Sizing in Chapter 47 of the 2020 ASHRAE Handbook—HVAC Systems and
Equipment for more information on valve coefficients.
Stress Calculations:
Although stress calculations are seldom required, the factors involved should be understood. The main areas of
concern are (1) internal pressure stress, (2) longitudinal stress caused by pressure and weight, and (3) stress from
expansion and contraction. Stress calculation for metallic pipe & nonmetallic pipe (plastic).
• Both equations incorporate an allowance factor A to compensate for manufacturing tolerances, material
removed in threading or grooving, and corrosion.
• For the seamless, butt-welded, and electric resistance welded (ERW) pipe most commonly used in HVAC
work, the standards apply a manufacturing tolerance of 12.5%.
• Working pressure for steel pipe (see Table 16) has been calculated using a manufacturing tolerance of
12.5%, standard allowance for depth of thread (where applicable), and a corrosion allowance of 0.065 in.
for pipes 2 1/2 in. and larger and 0.025 in. for pipes 2 in. and smaller.
• Where corrosion is known to be greater or smaller, pressure rating can be recalculated using Equation (10).
• Higher pressure ratings than shown in Table 16 can be obtained:
by using ERW or seamless pipe in instead of continuous-weld (CW) pipe 4 in. and less, and seamless pipe
in instead of ERW pipe 5 in. and greater (because of higher joint efficiency factors) or by using heavier
wall pipes.
2- Longitudinal Stress Caused by Pressure and Weight:
• Longitudinal stresses caused by pressure, weight, and other sustained forces are additive, and the sum of
all such stresses must not exceed the basic allowable stress S at the highest temperature at which the
system will operate.
• Longitudinal stress caused by pressure. equals approximately one-half the hoop stress caused by internal
pressure; thus, at least one-half the basic allowable stress is available for weight and other sustained forces.
• Table 15 lists allowable stress ranges for commonly used piping materials.
Loads on most pipe-supporting elements are moderate and can be selected safely in accordance with manufacturers’
catalog data and the information presented in this section; however, some loads and forces can be very high,
especially in multistory buildings and for large-diameter pipe, particularly where expansion joints are used at a
high operating pressure. Consequently, a qualified engineer should design or review all anchors and pipe-supporting
elements, especially for the following:
• Steam systems operating above 15 psig.
• Hydronic systems operating above 160 psig or 250°F.
• Risers over 10 stories or 100 ft.
• Systems with expansion joints, especially for pipe diameters 3 in. and greater
• Pipe sizes over 12 in. diameter.
• Anchor loads greater than 10,000 lb (10 kips).
• Moments on pipe or structure more than 1000 ft·lb.
Therefore, in addition to design requirements for pressure, weight, and other loads, piping systems must
accommodate thermal and other movements to prevent the following:
• Failure of pipe and supports from overstress and fatigue.
• Leakage of joints.
• Detrimental forces and stresses in connected equipment.
• Designing to a stress range SA of 15,000 psi and assuming E = 27.9 * 10^6 psi, Equation (15) reduces to
Equation (16), which provides reasonably low-end reactions without requiring too much extra pipe.
• In addition, Equation (16) may be used with A53 continuous (butt-) welded, seamless, and ERW pipe, and
B88 drawn copper tubing.
• The guided cantilever method of designing L bends assumes no restraints; therefore, care must be taken in
supporting the pipe.
• For horizontal L bends, it is usually necessary to place a support near point B (see Figure 4), and any
supports between points A and C must provide minimal resistance to piping movement; this is done by
using slide plates or hanger rods of ample length, with hanger components selected to allow for swing no
greater than 4°.
• For L bends containing both vertical and horizontal legs, any supports on the horizontal leg must be spring
hangers designed to support the full weight of pipe at normal operating temperature with a maximum load
variation of 25%.
• The force developed in an L bend that must be sustained by anchors or connected equipment is determined
by the following equation 17:
Z Bends:
• Z bends, as shown in Figure 5, are very effective for accommodating pipe movements. A simple and
conservative method of sizing Z bends is to design the offset leg to be 65% of the values used for an L bend
in Equation (18):
Steel Pipe:
• Seamless pipe (Type S), made by piercing or extruding.
• Continuous-weld (Type F CW) furnace butt-welding (BW, i.e., welding pipe in a single plane) process forces
and joins the edges together at high temperature and Type F steel pipe is not allowed for ASME Standard
B31.5 refrigerant piping.
• Electric current welds the seam in electric-resistance-welded (Type E ERW) pipe.
• ASTM standards such as A53 and A106 specify steel pipe A and B grades. The A grade has a lower tensile
strength and is not widely used.
• The ASME pressure piping codes require that a longitudinal joint efficiency factor E (Table 15) be applied to
each type of seam when calculating the allowable stress.
• ASME Standard B36.10M specifies the dimensional standard for wrought steel pipe.
• Steel pipe is manufactured with wall thicknesses identified by schedule or weight class. Although schedule
numbers and weight class designations are related, they are not constant for all pipe sizes.
• Standard weight (STD) and Schedule 40 pipe have the same wall thickness through NPS 10. For 12 in. and
larger standard weight pipe, the wall thickness remains constant at 0.375 in., whereas Schedule 40 wall
thickness increases with each size. A similar equality exists between Extra Strong (XS) and Schedule 80
pipe through 8 in.; above 8 in., XS pipe has a 0.500 in. wall, whereas Schedule 80 increases in wall thickness.
Table 16 lists properties of representative steel pipe.
• Joints in steel pipe are made by welding or by using threaded, flanged, or grooved fittings or socket welding.
• Unreinforced welded-in branch connections weaken the main pipeline, and added reinforcement or sleeves
is necessary, unless the excess wall thickness of both mains and branches is sufficient to sustain the pressure.
• The ASME Standard B31 series gives formulas and guidelines for determining whether reinforcement is
required.
• Such calculations are seldom needed in HVAC applications because (1) the fitting is designed in accordance
with a standard listed in the applicable ASME B31 table and used within the pressure and temperature
limits of that standard, and (2) fittings such as tees, and reinforced outlet fittings provide integral
reinforcement.
• Because of their inherent resistance to corrosion and ease of installation, copper and copper alloys are
often used in heating, air conditioning, refrigeration, and water supply installations.
• The two main standards for copper tube are:
1- ASTM Standard B88, which includes Types K, L, M, and DWV for drain-waste-vent service.
2- ASTM Standard B280, which specifies air-conditioning and refrigeration (ACR) tube for refrigeration service.
• Types K, L, M, and DWV designate descending wall thicknesses for copper tube.
• All types have the same outside diameter (OD) for corresponding sizes.
• Table 17 lists properties of ASTM B88 copper tube.
• In the plumbing industry, tubes of nominal size approximate the inside diameter.
• The heating and refrigeration trades specify copper tube by the outside diameter.
• ACR (air-conditioning and refrigeration) tubing has a different set of wall thicknesses.
• Types K, L, and M tube may be hard drawn or annealed (soft) temper.
• Copper tubing is joined with soldered or brazed, wrought or cast copper capillary socket-end fittings. See
Table 20 for lists pressure/ temperature ratings of soldered and brazed joints.
• Small copper tubes are also joined by flare or compression fittings.
• Hard-drawn tubing has a higher allowable stress than annealed tubing, but if hard tubing is joined by
soldering or brazing, the annealed allowable stress should be used.
• Brass pipe and copper pipe are also made in steel pipe thickness for threading. High cost has eliminated
these materials from the market, except for special applications.
• The heating and air-conditioning industry generally uses Types L and M tubing, which have higher internal
working pressure ratings than the solder joints used at fittings.
• Type M should be used with care when exposed to potential external damage.
• Type K may be used with brazed joints for higher pressure-temperature requirements or for direct burial.
• Copper and brass should not be used in ammonia refrigerating systems, or in acidic drains from condensing
boilers.
Ductile Iron:
• Ductile iron has now replaced cast iron for pressure pipe. Ductile iron is stronger, less brittle, and like cast
iron in corrosion resistance. It is commonly used for buried pressure water mains or in other locations
where internal or external corrosion is a problem.
• Joints are made with flanged fittings, mechanical joint (MJ) fittings, or elastomer gaskets for bell and spigot
ends.
• Bell and spigot and MJ joints are not self-restrained, though restrained MJ systems are available.
• Ductile-iron pipe is made in seven thickness classes for different service conditions.
• AWWA Standard C150/A21.50 covers the proper selection of pipe classes.
PIPE (Metallic):
• Selecting a plastic for a specific purpose requires attention to the temperatures, pressures, chemicals, and
stresses the piping will be subjected to in the specific application.
• All are suitable for cold water.
• Plastic pipe should not be used for compressed gases or compressed air if the pipe’s material is subject
to brittle failure.
• For other liquids and chemicals, refer to charts provided by plastic pipe manufacturers and distributors.
• Table 18 gives properties of the various plastics discussed in this section; the last column gives the relative
cost of small pipe in each category.
• Table 2 lists some applications pertinent to HVAC.
• Plastic piping materials fall into two main categories: thermoplastics and thermosets.
• Thermoplastics melt and are formed by extruding or molding. They are usually used without reinforcing
filaments.
• Thermosets are cured and cannot be reformed. They are normally used with glass fiber reinforcing
filaments.
7- PVDF:
• Polyvinylidene fluoride is widely used for ultrapure water systems and in the pharmaceutical
industry and has a wide temperature range.
• This material is over 20 times more expensive than PVC.
• It is joined by heat fusion, and fittings are made for this purpose.
• For smaller sizes, mechanical joints can be used.
• See ASTM Standard D2122 for information on PVDF.
Thermosetting piping:
• Used in HVAC is called (1) reinforced thermosetting resin (RTR) and (2) fiberglass-reinforced plastic (FRP).
• RTR and FRP are interchangeable and refer to pipe and fittings commonly made of (1) fiberglass-reinforced
epoxy resin, (2) fiberglass reinforced vinyl ester, and (3) fiberglass-reinforced polyester.
• Pipe and fittings made from epoxy resin are generally stronger and operate at a higher temperature than
those made from polyester or vinyl ester resins, so they are more likely to be used in HVAC.
PEX:
• Cross-linked polyethylene is made from high-density polyethylene (HDPE) and contains cross-linked bonds
in the polymer structure. This changes the thermoplastic to a thermoset.
• It can be used up to 300°F.
• PEX is used in building services pipework systems, hydronic radiant heating and cooling systems, and
domestic water piping.
• PEX comes in two types: barrier and non-barrier. The barrier, a thin sheet of aluminum between layers of
PEX material or a layer of polymer film, prevents oxygen dissolved in water from diffusing through the pipe
and corroding metal components. Non barrier PEX is acceptable for plumbing systems.
• PEX can be ordered as A, B, or C (these designations refer to the manufacturing process and not the pipe’s
structural or chemical properties).
• All PEX tubing (A, B, C) comply with the same standards: refer to ASTM Standards F876, F877, and F2023;
CSA Standard B137.5; and NSF/ANSI Standards 14 and 61 for further information.