Design and installation considerations for successful PE water pipelines Timplas Industries and Borouge Pte. Kota Kinabalu, Malaysia 1 December 2011 Slide 1 © 2011 Borouge Pte Ltd Contents A brief introduction to Timplas and Borouge The design of pressure pipelines How to ensure you specify the best quality PE100 The life span of PE100 pipes at higher temperatures What is polyethylene, PE80 and PE100 Jointing of polyethylene pressure pipelines Whole life cost savings using PE100 pipes Conclusion 2 Borouge reference line 2006 © 2006 Borouge Pte Ltd A brief introduction to Timplas and Borouge A successful international partnership 3 Borouge reference line 2006 © 2006 Borouge Pte Ltd Borouge…. A successful joint venture combining resources, feedstock and technology leadership Borouge – A JV between ADNOC and Borealis, combining the best of Europe and the Middle East JV formed in 1998, production start up in 2001 in Ruwais, Abu Dhabi. Current capacity of over 2,000 KT/year of PE and Polypropylene (PP) . Will increase to over 4,000 KT/year in 2014 once Borouge 3 commissioned. 4 Borouge reference line 2006 © 2006 Borouge Pte Ltd UAE Austria Borouge – a leading force in the international plastics market Borouge Production Head Office Borouge Sales and Marketing Head Office Borouge production Borouge sales offices 5 Borouge reference line 2006 © 2006 Borouge Pte Ltd Borouge representative office Innovation Centre Borealis customer service centre Borealis Head Office Borealis production Providing Solutions in Polyolefins Infrastructure Automotive 6 Borouge reference line 2006 © 2006 Borouge Pte Ltd Advanced Packaging What is polyethylene, PE80 and PE100 7 Borouge reference line 2006 © 2006 Borouge Pte Ltd Polyethylene molecular shapes and densities HDPE (PE100) MDPE (PE80) LLDPE LDPE 8 Borouge reference line 2006 © 2006 Borouge Pte Ltd PE Material Density (kg/m3) HDPE 940 - 965 MDPE 930 - 940 LLDPE 910 - 930 LDPE 900 - 910 Molecular density and material properties - common misconceptions Polyethylene High Density Polyethylene - HDPE Medium Density Polyethylene - MDPE Linear Low Density Polyethylene - LLDPE Low Density Polyethylene – LDPE Increasing density, tensile strength, elastic modulus, crystalinity, abrasion and chemical resistance Not all MDPE is PE80 and not all HDPE is PE100 – Most of it isn’t! PE having a MRS (Minimum Required Strength) of 10 MPa (N/mm2) can be a PE100 - PE number = 10 X MRS in MPa Also a PE having an MRS of 8MPa can be a PE80 9 Must meet the requirements of ISO4427 or MS1058 (water) / ISO4437 (gas) Borouge reference line 2006 © 2006 Borouge Pte Ltd Evaluating a material’s MRS using the ISO9080 standard method MRS is the continuous hoop stress that the PE must sustain after a 50 year design life at a continuous temperature of 20oC. High quality PE pipes can now meet this after 100 years Test is carried out at high temperatures to accelerate the aging. 1 year at 80oC = 100 years at 20oC 10 Borouge reference line 2006 © 2006 Borouge Pte Ltd The development of polyethylene since 1955 HD High Density >PE100 •„ LS-H PE100 •HD HD/ BM PE80 MD/BM PE80 Borouge reference line 2006 © 2006 Borouge Pte Ltd LD Low Density UM Unimodal HD Borstar® era LD •LD 1950’s 11 ••„LS― LS HD/UM PE63 PE32 MD Med. Density 1960’s 1970’s 1980’s 1990’s 2000’s 2010+ BM Bimodal LS Low Sag H HSCR Design of polyethylene pipelines 12 Borouge reference line 2006 © 2006 Borouge Pte Ltd Principal standards related to design of polyethylene pressure pipelines MS 1058 : 2005 parts 1 and 2 (SIRIM) PE Pipe for Water Supply ISO 4427 : 2007 parts 1, 2, 3 and 5 Plastics piping systems — Polyethylene pipes and fittings for water supply ISO 4437: 2007 Buried polyethylene pipes for supply of gaseous fuels EN 1295 : 1997 Structural design of buried pipelines under various conditions of loading BS 9295 : 2010 Guide to the structural design of buried pipelines ISO 9080: 2003 13 Plastics piping and ducting systems - Determination of the longterm hydrostatic strength of thermoplastics materials in pipe form by extrapolation Borouge reference line 2006 © 2006 Borouge Pte Ltd SDR - Standard Dimension Ratio and pressure pipe design SDR 17 σh = p x dm 2xs P x do - s 10 2 x s σh = hoop stress (N/mm2) P = internal pressure (bar) dm = mean pipe diameter (mm) do = outside pipe diameter (mm) SDR 11 s = wall thickness (mm) Combining the equation for hoop stress and the SDR expression we get: σh = P x (SDR -1) 20 14 Borouge reference line 2006 © 2006 Borouge Pte Ltd PN = 20 x MRS MRS = min. required strength (MPa) (SDR -1) x SF PN = pipe nominal pressure (bar) SF = safety factor Safety factors, pressure ratings and resistance to surge pressures As MRS refers to the maximum continuous hoop stress, which is due to operation pressures, rather than peak pressures, hence the safety factor is 1.25 for water and 2.0 for gas pipeline systems PN = 20 x MRS (SDR -1) x SF SDR11 (PE100) SDR17 (PE100) Water PN 16 bar Water PN 10 bar Gas Gas PN 10 bar PN 6.25 bar PE pipes are designed for service life, not catastrophic or ultimate conditions PE is a plastic material and the short term (1 minute) burst resistance of the material is 3.5 – 4.5 the rated pressure – ASTM D1599 : 1999 PE pipelines are therefore normally designed as having a ‗surge rating‘ of 1.5 or 2.0 twice the rated pressure. ie. 20 bar in the case of a PN10 pipeline 15 Borouge reference line 2006 © 2006 Borouge Pte Ltd With low sag PE100 pipes should not be limited to small diameters and low pressures SDR 16 Max. Operating Pressure [bar] 26 6.3 22 7.5 21 8 17 10 13.6 12.5 11 16 9 20 7.4 25 Borouge reference line 2006 © 2006 Borouge Pte Ltd Pipe wall thickness [mm] 450 17.2 20.5 21.5 26.7 33.1 40.9 50.3 61.5 500 19.1 22.8 23.9 29.7 36.8 45.4 55.8 68.3 560 21.4 25.5 26.7 33.2 41.2 50.8 62.5 76.5 630 24.1 28.7 30.0 37.4 46.3 57.2 70.3 86.0 710 27.2 32.3 33.9 42.1 52.2 64.4 79.3 96.9 800 30.6 36.4 38.1 47.4 58.8 72.6 89.3 900 34.4 41.0 42.9 53.3 66.1 81.7 1000 38.2 45.5 47.7 59.3 73.5 90.7 1200 45.9 54.6 57.2 71.6 88.2 109.1 1400 53.5 63.7 66.7 83.0 102.9 1600 61.2 72.7 76.2 94.8 117.6 1800 68.8 81.8 85.7 105.8 2000 76.4 90.9 95.2 117.6 Structural design of buried pipes, ring stiffness and nominal stiffness A pipes ability to resist external loads is referred to as its Ring Stiffness Pipe ring stiffness (S) = E I/D3 I = pipe wall moment of inertia (I = e3/12 for solid walled pipes) e = wall thickness E = short term modulus of elasticity (Young‘s Modulus) D = mean pipe diameter ‗E‘ for PE 100 = ~1100 MPa Nominal stiffness (SN) is the pipe ring 17 stiffness in MPa (KN/m2)divided by 1000 Borouge reference line 2006 © 2006 Borouge Pte Ltd Pressure pipes have very high ring stiffness Gravity pipe manufacturers and the standards refer to nominal pipe stiffness classes. Typically SN4 and SN8 with SN16 being the highest class. Pressure pipes have a relatively high wall thickness (e) and therefore have a very high ring stiffness gravity pipes highest class SN16 SDR 17 (PN10) PE100 SN22 SDR 11 (PN16) PE100 SN92 Hence Engineers do not in practice consider the structural design of buried pipelines due to external loads unless there are exceptional circumstances When distribution network pipes (not > OD 315 mm) are laid beneath roads with less than 0.6 m cover it‘s best to check structural calculations. 18 Borouge reference line 2006 © 2006 Borouge Pte Ltd Design of the pipe bed and surround for regular PE100 pipelines The bed and surround should ideally comply with UK water industry standard WIS 4-08-2. Otherwise: gravel or broken stone graded 5 – 10 mm coarse sand or a sand and gravel mix with gravel less than 20mm good quality granular material free sharp stones or large lumps ie. 20 mm or not > pipe wall thickness) 19 Borouge reference line 2006 © 2006 Borouge Pte Ltd Minimum compaction of 85% standard Proctor density required Key points concerning the continuous nature of PE pipelines PE pipes should be welded or mechanically joined together to form a continuous pipeline By doing so designers can avoid the need for thrust blocks and the construction of large valves chambers or anchors designed to take thrust The ends of the PE pipeline must be anchored in some way in order to prevent ‗pull out‘ Because of their high level of toughness, flexibility and continuity, PE100 pipelines are the best option for areas having poor ground conditions For the same reasons, PE is also the preferred material to use in trenchless technology applications Using coiled pipes greatly reduces the number of joints so reducing costs 20 and jointing time Borouge reference line 2006 © 2006 Borouge Pte Ltd Specify coiled pipe for 160 mm OD and higher, depending on local producers European pipe producers regularly coil pipes of up to 225 mm OD and have coiled pipes of up to 315 mm OD Many producers can provide 50 to 100 m long coiled pipes of up to 160 mm OD Max. coil length for small diameters is 500m 21 Borouge reference line 2006 © 2006 Borouge Pte Ltd Jointing of polyethylene pressure pipelines 22 Borouge reference line 2006 © 2006 Borouge Pte Ltd Jointing of PE100 pipes and fittings - Butt Fusion Jointing Electrofusion Jointing Mechanical Jointing Preferred option, joint is To be used when pipes To be used in very stronger that the pipe No fittings required Continuous fully 23 homogeneous pipe Borouge reference line 2006 © 2006 Borouge Pte Ltd cannot be butt welded Electro-fusion fittings required demanding conditions End load resistant fittings Also used for connecting to other materials Use the international standards to help specify good pipe jointing ISO 14236 – 2000 Plastic pipes and fittings – Mechanical joint compression fittings for use with PE pressure pipes in water supply systems (up to 110 mm OD) ISO21307 – 2011 Butt fusion jointing procedures for PE pipes and fittings used in the construction of gas and water distribution systems (up to 70mm wall thickness) ISO12176 : Part 1 – 2010 Equipment for fusion jointing of PE systems - Butt fusion ISO12176 : Part 2 – 2008 Equipment for fusion jointing of PE systems - Electrofusion ISO8085 : Part 3 – 2004 24 PE fittings for use with PE pipes for the supply of gaseous fuels - specification for electrofusion fittings (up to 630 mm OD) - can be applied to water fittings Borouge reference line 2006 © 2006 Borouge Pte Ltd Animation showing the butt fusion process 25 Borouge reference line 2006 © 2006 Borouge Pte Ltd How to ensure that you specify the best quality PE100 26 Borouge reference line 2006 © 2006 Borouge Pte Ltd •d o n ‘ t crack under pressure The PE100+ Association and its role for PE pipe quality assurance Slide 27 © 2011 Borouge Pte Ltd PE100+ Association Founded on 24th February, 1999 by Borealis, Elenac and Solvay Consisting of 8 member companies currently - Borealis, Borouge, Ineos, LyondellBasell, Prime Polymer, SABIC, SCG Plastics (Thailand) and Total Petrochemicals Supported by Advisory Committee and working closely with other plastic pipe, standards and utility bodies 28 Borouge reference line 2006 © 2006 Borouge Pte Ltd What does the ‘+’ in PE100+ represent? and the benefit to water and gas utilities Certified PE100 material consistency of 3 critical properties due to regular testing cycle Promotion of quality beyond the raw material to the entire chain of pipes & fittings, installation and maintenance Peace of mind for utilities due to use ready made compounds without the influence of carbon black master batch compatibility/consistency, due to poor homogenisation during extrusion and incomplete testing/certification Applicants and members each have to send 5 no. 110 mm OD SDR 11 pipes to 3 independent testing laboratories every 7 months. After passing 2 test cycles applicants can become members If utilities and other end users specify that their pipes and fittings must 29 be manufactured from a PE100+ certified material they can be confident that they are getting the best. Borouge reference line 2006 © 2006 Borouge Pte Ltd PE100+ Membership Technical Requirements 30 Borouge reference line 2006 © 2006 Borouge Pte Ltd Whole life cost savings using PE100 pipes 31 Borouge reference line 2006 © 2006 Borouge Pte Ltd Background to asset management and whole life costing – why do we look at it? Asset management is the systematic approach to sustainably managing assets, their performance and costs over the whole life cycle Studies undertaken by European utilities and in Shanghai show that construction costs are typically be less than 25% of whole life cost 32 Borouge reference line 2006 © 2006 Borouge Pte Ltd Design and Construction Commissioning Replacement and Disposal Failure Rates and Repair Costs O & M Costs inc. Pumping and Leakage Whole life cost in RMB per km Typical breakdown of whole life costs for a DN100 pipeline in Shanghai’s suburban areas 33 Borouge reference line 2006 © 2006 Borouge Pte Ltd Xu Zhaikai, Chen Zhihui, Zheng Xiaoming Shanghai Municipal Waterworks Fengxian Co., Ltd. Comparison of whole life costs for different pipelines in Shanghai’s rural areas PE whole life costs are for SDR 17 (PN10) pipelines Total WLC cost in Shanghai rural with current unit price ¥1 8 , 0 0 0 , 0 0 0 ¥1 6 , 0 0 0 , 0 0 0 ¥1 4 , 0 0 0 , 0 0 0 Shanghai uses only 6 m pipes. Installation costs could be further reduced by using longer pipes and coiled pipes ¥1 2 , 0 0 0 , 0 0 0 ¥1 0 , 0 0 0 , 0 0 0 PE DI Steel ¥8 , 0 0 0 , 0 0 0 ¥6 , 0 0 0 , 0 0 0 ¥4 , 0 0 0 , 0 0 0 ¥2 , 0 0 0 , 0 0 0 ¥0 DN100 34 Borouge reference line 2006 © 2006 Borouge Pte Ltd DN150 DN300 DN400 DN800 The life span of PE100 pipes at higher temperatures 35 Borouge reference line 2006 © 2006 Borouge Pte Ltd Different factors affecting the lifetime of plastic pipes Material Factors Initial MRS & aging rate Slow crack growth Additives – carbon black Pipe manufacture Lifetime Environmental Factors Average temperatures Quality of backfill Abrasion (slurries) Chemical attack 36 Borouge reference line 2006 © 2006 Borouge Pte Ltd Loading Factors Operational pressures Surge pressures Soil loads Notches and scratches Material Lifetime Assessment – 100 years lifetime with modern high quality PE100 σLPL = lower confidence limit hydrostatic strength 50 years = 10.633 MPa 100 years = 10.50 MPa High quality PE100 materials still exceed the MRS after 100 years at 20oC The average annual temperature in coastal Sabah is 27.5oC (BBC & World Met. Centre) 37 Borouge reference line 2006 © 2006 Borouge Pte Ltd 50 years = 105.64 hours 100 years = 105.94 hours Pressure reduction factors due to higher ambient temperatures - ISO 4427 Annex A of ISO 4427 includes a temperature reduction table conservatively based on an old PE100 grade (Type A) As modern PE100 grades have a much better performance it allows designers to take account of these The pressure reduction for the type A material at 27.5oC is 10% The pressure reduction for a modern material such as Borouge or Borealis HE3490-LS is less than 1%. 38 Borouge reference line 2006 © 2006 Borouge Pte Ltd Conclusion - Pipelines are like a chain, only as strong as their weakest link PE100 pipeline projects must be economically designed by engineers who are familiar with the material and whom have been trained in its proper use The pipes must be manufactured from a high quality raw material PE100+ and MS1058 : 2005 Part 1 certified They should be manufactured in a high quality facility and in full accordance with national and international standards They must be joined together by properly trained and certified welding technicians using equipped that is tested and certified in accordance with the international standards The pipelines must be correctly installed in accordance with the standards and engineering specification by an experienced contractor employing trained staff The supervision of the works should be undertaken by a suitably trained and 39 experienced site team Borouge reference line 2006 © 2006 Borouge Pte Ltd Thank you for your attention 40 Borouge reference line 2006 © 2006 Borouge Pte Ltd Andrew Wedgner [email protected] KH Lou [email protected] PE100 pipe case studies 41 Borouge reference line 2006 © 2006 Borouge Pte Ltd Case 1: Water supply to Quomoy Island, China Subsea pipeline from Xiamen water treatment plant around bay and to island of Quemoy. Project by Xiamen water company and Pipe producer – Chinaust Plastics Design of two 12.6 km 800mm OD, SDR17 PE pipes Special railway built to transfer 300m welded PE pipe strings BorSafe HE3490-LS PE100 material specified due to demanding installation conditions and need for a high security of supply 42 Borouge reference line 2006 © 2006 Borouge Pte Ltd Case 3: Yas island gas distribution network, Abu Dhabi, UAE This was the largest single gas distribution network so far laid in Abu Dhabi It comprised just over 20 km of SDR 11 PE100 pipelines of up to 400 mm OD The network supplied facilities including the the Formula 1 race track, the Ferrari World theme park and the 7 star Yas Island Hotel The pipes were produced in the UAE by Union Pipe 43 Borouge reference line 2006 © 2006 Borouge Pte Ltd Industries and Hepworth‘s using BorSafe HE3490-LS Case 3: Overcoming challenging conditions to supply the Tianjin eco-city in China This 4.5 km 800 mm OD SDR 17 pipeline was laid in very challenging conditions including a horizontal directionally drilled section under the Ji Canal Due to the conditions the end user 44 decide to us a High Strength Crack Resistant (HSCR) PE100 material Borouge reference line 2006 © 2006 Borouge Pte Ltd Tianjin TEDA water company: ―the provision of pipe produced from high stress crack resistant BorSafe HE3490-LS-H for the canal crossing addressed all our concerns regarding installation and possible abrasion damage.‖ Case 4: Borouge 2 seawater cooling pipelines produced from our own PE100 For Borouge 1 large GRP pipes were used which failed twice causing emergency shutdowns of the plant. Borouge decided to use their own material for the 2nd plant: • 4 x 2.5km 1600mm dia. 3 bar inlet pressure pipelines • 6 x 2.5km 1600mm dia. gravity outfall pipelines All 25 km of 1600mm pipes, which were all produced in Abu Dhabi by Union Pipes Industry using Borouge‘s HE3490-LS material 45 Borouge reference line 2006 © 2006 Borouge Pte Ltd
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