TECHNICAL DATA TDCD

THERMACOR Calculation and Design 15.103

EXPANSION CALCULATIONS AND LOOP SIZING 12.05.06

EXPANSION CALCULATIONS AND LOOP SIZING

In a bonded system, the carrier pipe, foam insulation, and
EXPANSION COMPENSATION
outer protective jacket are joined together forming one co-
hesive unit that expands and contracts together. Thermal
expansion of the carrier pipe during operation is therefore
Elbow
transfered to the polyurethane foam and outer jacket.
These movements are naturally restricted to a certain ex-
tent by the friction between the soil and jacket. In extreme
cases, the force of friction can become so great that free Z-Bend
expansion cannot occur and the unit becomes “fixed” into
place. In such a case, the opposing force from thermal
expansion can place impermissibly high stresses in the Loop
carrier pipe. Therefore, free expansion must be allowed to
occur, but expansion must ultimately be compensated for
through system design. The most common method is the
inclusion of expansion elbows, loops, or z-bends.
NATURAL FIXED POINT
Thermal expansion will occur between all fixed points in
the piping system. If the system has the same covering
height, natural fixed points will occur in the center of a line
section between two expansion elbows. Unequal covering
will cause the fixed point to be displaced due to varying
frictional forces and if there is any doubt, the fixed point
L L2
should be set with an anchor. In all cases, this fixed point L1 = L2
should be considered when calculating expansion.

GUIDELINES FOR LOOP SIZING

1. The expansion loop is usually located on the side of EXPANSION LOOP
the hottest line.
2. The expansion loop as a rule should be located in the
center of the distance between two anchors. H
3. The height of the expansion loop is normally twice the W
width. The exception to this rule occurs when more
than one line runs parallel in a common trench. The
dimensions of the loops for the additional line must be L

increased to allow nesting of the loops.

CALCULATIONS EXAMPLE
1. The formula for calculating thermal expansion: Find the loop size for a 6” diameter steel pipe carrying
ΔL = C x L x (Tf - Tg) x 12in./ft. 200°F heating water with 200 ft. between anchors and
Coefficient of thermal expansion (C): an average annual ground temperature of 50°F.
Steel (C) = 6.5 x 10-6 in./in.°F Given:
Copper (C) = 9.2 x 10-6 in./in.°F Steel (C) = 6.5 x 10-6 in./in.°F
Distance between fixed points (L) in feet. Distance (L) = 200 ft.
Temperature of fluid (Tf) Temp. Diff. (ΔT) = (200°F - 50°F) = 150°F
Temperature of ground (Tg) Pipe Diam. (D) = 6”
2. After calculating the expansion, find the expansion Calculations:
loop size from the charts for the applicable pipe or ΔL = C x L x (Tf - Tg) x 12in./ft.
tube. Loop sizes are taken to the nearest half foot on ΔL = 6.5 x 10-6 x 200 x (200 - 50) x 12
the height and width. ΔL = 2.34 in. (expansion)
From the expansion loop chart for steel:
Requires 5’x10’ expansion loop.
 TECHNICAL DATA TDCD
THERMACOR Calculation and Design 15.104
EXPANSION LOOP SIZES 12.05.06

EXPANSION LOOP SIZES FOR STEEL PIPE EXPANSION LOOP SIZES FOR COPPER TUBING
Expansion loops are sized for A53 Grade B ERW steel pipe allowable stresses. Expansion loop dimensions are for ASTM B-88 seamless cop-
per tubing based on an allowable stress of 6,000 psi. as stated
in the copper development association handbook for copper
tubing. Pressure shall not exceed 150 psig.

PIPE LOOP SIZE PIPE LOOP SIZE PIPE LOOP SIZE

SIZE ΔL (FT) SIZE ΔL (FT) SIZE ΔL (FT)
(IN) (IN) (IN) (IN) (IN) (IN)
H W H W H W
3/4 0.00 - 1.50 4 2 10 0.00 - 0.42 4 2 3/4 0.00 - 2.09 4 2
1.50 - 6.00 6 3 0.42 - 0.91 6 3 2.09 - 4.69 6 3
1 0.00 - 1.00 4 2 0.91 - 1.44 8 4 4.69 - 8.35 8 4
1.00 - 4.14 6 3 1.44 - 2.00 10 5 1 0.00 - 1.62 4 2
2.00 - 2.57 12 6 1.62 - 3.65 6 3
1-1/4 0.00 - 0.93 4 2 2.57 - 3.16 14 7
0.93 - 3.33 6 3 3.65 - 6.49 8 4
3.16 - 3.80 16 8 6.49 - 10.14 10 5
3.33 - 5.56 8 4 3.80 - 4.14 18 9
1-1/2 0.00 - 0.88 4 2 1-1/4 0.00 - 1.32 4 2
12 0.00 - 0.39 4 2 1.32 - 2.98 6 3
0.88 - 2.75 6 3 & 0.39 - 0.87 6 3
2.75 - 4.75 8 4 2.98 - 5.31 8 4
14 0.87 - 1.34 8 4 5.31 - 8.30 10 5
2 0.00 - 0.85 4 2 1.34 - 1.88 10 5
0.85 - 2.38 6 3 1.88 - 2.43 12 6 1-1/2 0.00 - 1.12 4 2
2.38 - 4.00 8 4 2.43 - 3.00 14 7 1.12 - 2.53 6 3
3.00 - 3.57 16 8 2.53 - 7.02 8 4
2-1/2 0.00 - 0.78 4 2 7.02 - 10.11 10 5
3.57 - 4.14 18 9
0.78 - 2.14 6 3
2.14 - 3.71 8 4 16 0.00 - 0.41 4 2 2 0.00 - 0.89 4 2
3.71 - 5.31 10 5 0.41 - 0.85 6 3 0.89 - 1.93 6 3
0.85 - 1.32 8 4 1.93 - 3.44 8 4
3 0.00 - 0.72 4 2 3.44 - 5.37 10 5
1.32 - 1.83 10 5
0.72 - 1.78 6 3 5.37 - 7.73 12 6
1.83 - 2.34 12 6
1.78 - 3.00 8 4
2.34 - 2.86 14 7 2-1/2 0.00 - 0.69 4 2
3.00 - 4.35 10 5
2.86 - 3.43 16 8 0.69 - 1.56 6 3
3-1/2 0.00 - 0.68 4 2 3.43 - 4.00 18 9 1.56 - 2.78 8 4
0.68 - 1.35 6 3 2.78 - 4.35 10 5
1.35 - 2.70 8 4 4.35 - 6.26 12 6
2.70 - 3.84 10 5 6.26 - 8.52 14 7
3.84 - 5.00 12 6
3 0.00 - 0.58 4 2
4 0.00 - 0.63 4 2 0.58 - 1.31 6 3
0.63 - 1.45 6 3 1.31 - 2.33 8 4
1.45 -2.41 8 4 2.33 - 3.65 10 5
2.41 - 3.45 10 5 3.65 - 5.26 12 6
3.45 - 4.52 12 6 5.26 - 7.16 14 7
5 0.00 - 0.42 4 2 7.16 - 9.34 16 8
0.42 - 1.27 6 3 4 0.00 - 0.99 4 2
1.27 - 2.12 8 4 0.99 - 1.77 6 3
2.12 - 3.00 10 5 1.77 - 2.76 8 4
3.00 - 3.96 12 6 2.76 - 3.98 10 5
3.96 - 4.13 14 7 3.98 - 5.42 12 6
6 0.00 - 0.46 4 2 5.42 - 7.08 14 7
0.46 - 1.16 6 3 7.08 - 8.96 16 8
1.16 - 1.87 8 4 5 0.00 - 0.80 6 3
1.87 - 2.35 10 5 0.80 - 1.42 8 4
2.35 - 3.51 12 6 1.42 - 2.22 10 5
3.51 - 4.26 14 7 2.22 - 3.20 12 6
8 0.00 - 0.54 4 2 3.20 - 4.36 14 7
0.54 - 1.00 6 3 4.36 - 5.70 16 8
1.00 - 1.64 8 4 5.70 - 7.21 18 9
1.64 - 2.30 10 5 6 0.00 - 1.19 8 4
2.30 - 2.95 12 6 1.19 - 1.86 10 5
2.95 - 3.64 14 7 1.86 - 2.68 12 6
3.64 - 4.35 16 8 2.68 - 3.65 14 7
3.65 - 4.77 16 8
4.77 - 6.03 18 9
6.03 - 7.45 20 10