All too often, utilities are unaware of the potentially significant energy savings over the life cycle of the pipe material. Many do not make the proper flow rate comparisons and instead focus solely on the price per foot on the bid form. They ultimately pay more in the long run. Ductile iron pipes have a smooth internal surface, which minimizes frictional losses during water flow, similar to the smoothness of other internal pipe surfaces, such as PVC and HDPE. The reduced friction means less energy is required to pump water through the system. As a result, water utilities can achieve notable energy savings, translating into lower electricity bills over time.
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The design of Ductile iron pipe allows for optimal flow characteristics. Their consistent and smooth interior prevents turbulence, ensuring a steady and efficient water flow. This inherent efficiency in water transport can lead to decreased energy consumption compared to systems with less optimized pipes. Regarding the INSIDE DIAMETER of water pipelines, bigger is better when a utility looks at the monthly electric bills for pumping water throughout the system. Why is this the case?
To get water to customers at adequate pressure, head losses must be overcome using pumps to apply energy. Head loss is the reduction in the fluid's total head (pressure) as it moves through a pipeline. This energy costs the water utility in the form of an electric bill. The less power that must be applied, the lower the utility's electric bill and the utility's customers' water and sewer rates.
These annual cost savings can be easily calculated using the head loss value and inserting that value into a pumping cost equation such as that used in the University of Michigan Study “A Framework to Evaluate the Life Cycle Costs and Environmental Impacts of Water Pipelines” (ASCE Conference Proceedings, Pipelines ). They can even be further extended by evaluating pumping cost savings over many years using a present-worth approach. This long-term cost-effectiveness of DI pipe can make water utilities feel financially prudent and responsible.
These calculations can be conveniently performed using the Energy Savings Calculator on the McWane Pocket Engineer mobile and desktop app. The calculator evaluates the inside diameters of different pipeline materials against that of Ductile Iron, allowing the user to be confident in their decision-making process.
I mentioned earlier that the roughness of the pipe's interior surface is a factor in calculating head loss. This is commonly known as the pipe's “C” factor. It should be noted that although some other pipe materials have higher “C” factors due to the presence of smoother inside surfaces, this component doesn’t affect pipeline flows nearly as much as increased inside diameter. Research has also found that the “C” factor of Ductile iron pipe remains consistent throughout many years of service.
Now, let’s look at an example of a utility installing a mile-long 8” pipeline in a subdivision. The materials being evaluated and considered are Ductile iron pipe and PVC.
In determining the energy costs to the utility of each respective material, the project model, as noted in the information below, has been established (Please note that these rates apply to the time of the publication):
By going through the steps of first determining the respective head loss that must be overcome in each pipeline, then converting that into pumping costs the utility will incur based on the assumptions listed, one finds that using Ductile iron pipe will result in a cost savings to the utility of over $80,000 during the 100-year estimated service life of the ductile iron pipe. The reason for this cost savings to the utility is that the 8” DI pipe (Class 350) has a 9.76% larger inside diameter than the 8” PVC pipe (DR-14).
Ductile iron pipe is made from up to 95% recycled scrap iron and steel. DI pipe can also be recycled, making it an environmentally friendly choice. Choosing sustainable materials aligns with modern practices of reducing carbon footprints. As utilities and municipalities strive to adopt eco-friendly solutions, using DI pipe can be a step toward sustainability and responsible resource management.
McWane Ductile facilities are among the manufacturing leaders in their regions, using recycled materials for their water pipe and electric utility pole products. Additionally, they have implemented environmental practices that, in many instances, exceed national standards. Supporting these efforts is a robust environmental management system that helps assure compliance with applicable environmental regulations, standards, permit conditions, and voluntary commitments.
PVC pipe is made from chlorine (derived from salt) and carbon (predominantly derived from oil and gas via ethylene). PVC is also derived from vinyl chloride, which is a toxin. It is made rigid by adding a stabilizer, and at one time, the PVC industry used lead as a stabilizer. Today, PVC manufacturers use other chemicals that may pose health risks, but some foreign manufacturers continue to use lead. In addition, the recycled content of PVC is nearly zero, and PVC can only be downcycled.
HDPE pipe is made from ethylene derived from oil and natural gas. To form an HDPE pipe, ethylene in pellet form is melted into a molding machine and then extruded into its finished pipe form. Little, if any, true recycling is involved with HDPE products manufactured for the water and sewer industry.
After reading this Iron Strong blog, you can see why Ductile iron pipe is a favored solution for water distribution systems. It offers various benefits over alternate materials. Energy savings are important to utilities and their end-consumers and should always be . As water utilities and municipalities explore ways to reduce energy consumption, cut operational costs, and embrace sustainable practices, adopting DI pipe emerges as a wise, practical, and forward-thinking decision.
The reduced pumping costs, optimal flow characteristics, minimal maintenance requirements, and environmental sustainability make DI pipe an attractive choice for those looking to make their water systems more durable and energy-efficient. In the long run, choosing DI can translate into tangible savings on your electric bill, reducing electrical demand on the nation’s energy grid and contributing to a more resilient and sustainable water infrastructure. Most of the utility’s capital investment is underground. When planning for investment in the critical components of your system, ALL factors should be considered.
If you have any questions regarding your water or wastewater infrastructure project, your local McWane Ductile representative is equipped with the expertise to assist you. Many of our team members have managed small and large water utility systems, served in engineering consulting firms, and bring decades of experience solving field issues involving pipeline construction and operation. From design to submittal to installation, we strive to educate and assist water professionals throughout the water and wastewater industry.
Though there is a list of advantages and disadvantages to the Ductile Iron Pipe, it is still a well-suited choice for many projects. Their main advantages are strength and durability, corrosion resistance, flexibility and impact resistance, high flow capacity, and environmental friendliness.
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In addition to these advantages, ductile iron pipes also have disadvantages. Expensive cost, high weight, complex installation, and challenging maintenance are examples of the disadvantages you may encounter. Moreover, you can choose the material of the pipes used in your projects differently based on some key features. These materials include ductile iron, cast iron, steel, prestressed reinforced concrete, and PVC plastic. Here, you can learn more about them to make the most appropriate choice.
Ductile iron pipes offer many advantages. Although there are many advantages and disadvantages to ductile iron pipes, the advantages outweigh the disadvantages. Referring to ASCE, these benefits make DI pipes a popular choice for many applications.
The durability of ductile iron pipes might be their most known advantage. Ductile iron combines iron, silicon, carbon, and a small amount of magnesium. This combination gives it a unique molecular structure, which leads to improved strength. The ability to endure high pressure makes them suitable and proper for so many applications. This strength is not only due to the chemical and physical properties of iron, but it is also a result of the centrifugal casting method in manufacturing. This is especially beneficial in gas and water distribution systems. Using appropriate pipe installation methods and relying on ductile iron pipe strength and durability makes this material a long-lasting solution for your projects.
Corrosion resistance in water pipelines is crucial. Among all the advantages and disadvantages of ductile iron pipes, corrosion resistance is highlighted in the pipe material comparison. They are highly resistant to corrosion, which makes them a perfect choice for achieving a long lifespan for ductile iron pipes.
The cost of ductile iron pipe maintenance and repair is also significantly reduced. This feature helps the pipes remain functional throughout their service life.
The mechanical properties of ductile iron prove to us that this material is less brittle than other types of iron. Thus, ductile iron pipes are more flexible and show more resistance to impact. This way, the potential for cracking or fracture is reduced, which makes these pipes durable. Ductile iron pipes can also withstand sudden pressure due to their impact resistance. Furthermore, this feature is especially beneficial for applications in areas subject to earthquakes or seismic activities. This way, sudden movements of the earth would never lead to the rupture of the whole structure.
Ductile iron pipes provide a high flow capacity due to their smooth interior surface. This ensures efficient fluid transportation. The high flow capacity that ductile iron pipes provide is beneficial, especially in large-scale industrial projects and applications. This feature contributes to the popularity of ductile iron pipes in many industries since it offers cost savings, enhanced efficiency, and system reliability.
Among all the advantages and disadvantages of ductile iron pipes that could be possibly mentioned, being eco-friendly is the most crucial one in today’s life. As various industries have destroyed the environment tremendously, being environmentally friendly is a significant factor to consider, which ductile iron pipes guarantee. This is because they are made from recycled materials. These pipes have lower friction, which leads to saving energy, so it reduces pumping costs and makes them eco-friendly. This energy efficiency causes lower greenhouse gas emissions, leaving a smaller environmental footprint.
As you can see, ductile iron pipes have advantages and disadvantages. Though the advantages are numerous, according to Xylem, there are still a few disadvantages. Considering these factors might help when deciding the best option for specific applications.
A primary disadvantage of ductile iron pipes is their high initial cost, especially compared to other materials. These higher expenses extend to many steps, such as the purchase price, transportation, installation, and maintenance of ductile iron pipes. This certainly is a highlighted factor when it comes to projects set with low budgets or even large-scale projects that need a huge amount of these materials.
Ductile iron pipes are considerably heavier than other alternatives. Comparing ductile iron to PVC or HDPE perfectly proves this point. This higher weight causes higher transportation and installation costs. Also, labor requirements are increased due to the heavy weight of these pipes. In addition to all the above factors, the heavy weight can be a safety hazard for workers handling these heavy materials. That is why safety protocols are a must on job sites.
Since ductile iron pipes have heavier weights and specific material properties, more specialized equipment and expertise are required for installation when working with ductile iron pipes. This also raises the project’s overall expenses. For instance, the need for heavy lifting machinery raises the costs of the project significantly. As the project gets larger, the management of the logistics of transporting and installing these heavy pipes gets more critical.
This is where the advantages and disadvantages of ductile iron pipes cross. Although they have good corrosion resistance, they are not fully immune to corrosion. Harsh environmental conditions can weaken the protection barrier to ensure these pipes’ corrosion resistance. Exposure to certain chemicals or elements running in the pipes increases the potential for corrosion over time. This compromises the structural integrity of the pipes, which could result in leaks and failures.
In addition to the challenging installation due to the weight and material properties, maintaining and repairing these pipes can also be quite a challenge over time. The processes of maintenance and repair have their own complexities and additional costs. Maintaining and repairing ductile iron pipes requires specialized tools and expertise. The result is increased expenses and downtime, especially compared to other materials used for manufacturing pipes.
Several different materials can be used to make pipes. Each has its own specifications, advantages, and disadvantages. Each has some highlighted features. These features can be used to make decisions regarding specific requirements your project might have. Some of the primary features are listed below.
Here, some of the material’s most decision-making features are compared in a table so that you can make the right choice based on your needs.
Specification Ductile Iron Cast Iron Steel Pipe Prestressed Reinforced Concrete PVC Plastic Strength and Durability High High High High Low Corrosion Resistance Good Moderate Moderate Good High Flexibility and Impact Resistance High Low Moderate Moderate Low Weight Heavy Heavy Moderate Heavy Lightweight Installation Complexity Moderate Moderate Low to Moderate High Low Maintenance Requirements Low High Moderate Low Low Environmental Friendliness High Moderate Moderate High Moderate Cost-Effectiveness Moderate Low Moderate Low High Temperature Resistance High Moderate High Moderate Low Load-Bearing Capacity High High High High Low Pipe Diameter Availability Wide range Wide range Wide range Wide range Wide range Flow Efficiency High Moderate Moderate High HighAs with all materials, ductile iron pipes have several advantages and disadvantages. The most important thing to consider when choosing the right material for you is to compare all the features. In a specific condition and for each project, some of these advantages and disadvantages outweigh others. The key to making wise choices is to choose a material with advantages and disadvantages that match our needs. You can contact us for more information and help.
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