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PE100 and PE100+ Materials and Pipes
d o n ‘ t c r a c k u n d e r p r e s s u r e
Citypipe, Moscow June 2010
O. Anisimova, PE100+ Association
d o n ‘ t c r a c k u n d e r p r e s s u r e 206 2010PE100+Association
PE pipes - Impressive track record
1950’s - first PE pressure pipe installed
1970’s - 2nd generation PE for water and gas
- crosslinked PE (PEX) for hot water
1990’s - bimodal PE100 introduced (RCP, creep
resistance)
- higher pressures and larger pipes
- PO pipe markets growing
2000 - high momentum and market needs …
raising the technological barrier.
d o n ‘ t c r a c k u n d e r p r e s s u r e 306 2010PE100+Association
Key success factor for PE pipes
• Flexibility - Long lengths in coils, Curving trenches
• Light weighting
• Ease to install - Modern installation techniques (relining, HDD,…)
• Cost effective butt welding, safe and practical electro fusion
• Leak tight pipeline (Earthquakes, ground move)
• No corrosion
• Innovation through new generations
• High level of standards
• Safe for gas transportation
• Environmentally friendly
• …
d o n ‘ t c r a c k u n d e r p r e s s u r e 406/2010
PE100: combining 3 key properties
Long term resistance to internal pressure
Minimisation of damagein case of accidental failure
Long term resistanceTo mechanical failure
DESIGN
INSTALLATION SAFETY
d o n ‘ t c r a c k u n d e r p r e s s u r e 506/2010
PE100: combining 3 key properties
MRS (MPa)
RCP: S4 Pressure (bar)ESCR: Notch (MPa)
PE80
PE100
Increased strength
High safety External stress resistance
d o n ‘ t c r a c k u n d e r p r e s s u r e 606/2010
What is a PE100 Material ?
11 1010 100100 10001000 10000100001000010000
00
10000001000000
str
ess
(MP
a)
LTHS
20 °C
MRSMRS
50 yrs
Ductile failure
Failure time
80 °C
100 yrs
A pipe material correctly tested according to ISO9080 for up to 9000h at 80°C without knee gives a statistically valid extrapolation at 20°C of 9000h*100 = 900.000h = 100 yearsBrittle Failure
1010
d o n ‘ t c r a c k u n d e r p r e s s u r e 706/2010
Environmental Stress Cracking Resistance / ESCR
• What is Environmental Stress Cracking / ESC (= Slow Crack Growth / SCG?)
– long term ageing process leading to brittle failure
– accelerated by scratches and stones
• How is the resistance to ESC measured?– Appearance of ‘knee’ in regression curves
(realistic but expensive + time consuming)
– Notch test:Standard laboratory test on notched pipes - ESC accelerated by stress concentration in notch
– Test with accelerating agents
d o n ‘ t c r a c k u n d e r p r e s s u r e 806/2010
A
APipe end caps
Position of minimumwall thickness
Section A-A
4 equi-spaced notches around circumference.Remaining wall thickness: 78 - 82 % of wall thickness Test Requirements
PE-class
PE80
PE100
Test temp.
80
80
Hoopstress
4.0
4.6
Testperiod
h
500
500
MPaCO
ESCR: How is it measured?ESCR: How is it measured?Notched Pipe TestNotched Pipe Test
d o n ‘ t c r a c k u n d e r p r e s s u r e 906/2010
Rapid Crack Propagation / RCP
What is RCP?
Under adverse conditions of high pressure and/or low temperature an impact on a pressurised pipe may lead to a fast running crack possibly hundreds of meters long
d o n ‘ t c r a c k u n d e r p r e s s u r e 1006/2010
WHY PE100 ? PREPARED FOR THE UNEXPECTED !
• RAPID CRACK PROPAGATION
d o n ‘ t c r a c k u n d e r p r e s s u r e 1106/2010
Rapid Crack Propagation / RCPS4 Test results (0 °C) - ISO 13477
44 > 24> 24
MDPE
Crack arrest
Crack propagationPE100
Cra
ck L
en
gth
Equivalent gas network pressure ( bar )
Use of MDPE limited to 4 barNo RCP risk with PE100 for pressures of up to 24 bar
d o n ‘ t c r a c k u n d e r p r e s s u r e 1206/2010
THE ORIGIN OF PE100 PROPERTIES
• POLYETHYLENE IS A SEMICRYSTALLINEPOLYMER, CONTAINING A CRISTALLINEPHASE AND AN AMORPHOUS PHASE.
• PE100 CORRESPONDS TO THE SELECTIVE REINFORCING OF THE AMORPHOUS PHASE BY BRANCHING AND MOLECULAR WEIGHT CONTROL
d o n ‘ t c r a c k u n d e r p r e s s u r e 1306/2010
PE100 Bimodal Process
HDPE homo-polymer
Bimodal HDPE
Cat.
H2
EthyleneCo-monomer
H2
Ethylene
Reactor 1 Reactor 2
d o n ‘ t c r a c k u n d e r p r e s s u r e 1406/2010
Advantages of the Bimodal Process
Low Mw PE linear structures HMW PE with shot chain branching
Reactor 1 Reactor 2
d o n ‘ t c r a c k u n d e r p r e s s u r e 1506/2010
Long term stress – Tie Molecules
(2) Under low-level stress, tie molecules begin to stretch and relax, then they begin to untangle.
(3) Ultimately, the few remaining tie molecules can no more support the load, and as a result the material fails in a brittle manner
The tie molecules and their entanglements are responsible for passing the stress into the crystals.
Fibrils are kept together by the amorphous region, wheremolecules are entangled with formation of physical bonds
A PE Spherulite
(2)
(3)
d o n ‘ t c r a c k u n d e r p r e s s u r e 1606/2010
IMPROVING Environmental Stress Cracking Resistance
The best way to increase the stress cracking resistance
is to work on tie molecules
Very complex process, requiring advanced skills and mastery in material design
through careful control of the polymerization process
Only a consistent quality control across production chain, from raw materials to
pipes, can give assurance of pipe durability and its long term performance
d o n ‘ t c r a c k u n d e r p r e s s u r e 1706/2010
Ahead of Standardisation
• On technical level, the PE100+ Association has the objective to be at the forefront
• On ISO level, norms exist for water and gas pipes in PE – on CEN as well
• The Association always seek :– to set requirements for reliable PE 100 materials– to install neutral quality control scheme
d o n ‘ t c r a c k u n d e r p r e s s u r e 1806/2010
Water networks…
Sewers and water networks in cities all over the world are ageing and in some places are malfunctioning
Water distribution network performances
Necessity of replacement or rehabilitation of old pipe networks in the ground of cities…
One simple reason to make the good choice
• « NOT RICH ENOUGH TO PAY TWICE IN A LIFETIME »
Country Italy Germany UK France
Leaks (%) 38-45 8-15 15-16 20-22
AGICI source 2008
d o n ‘ t c r a c k u n d e r p r e s s u r e 1906/2010
Organoleptic and Health Requirements
• We certify the use of approved additives
• We check the quality of raw materials
• We adopt dedicated specifications for production of drinking water material
• We control the organoleptic properties of our finished material
• An organoleptic material converted into an organoleptic pipe
WHO GUARANTEES QUALITY OF A DRINKING WATER PIPE ?
Pipes cannot give any negative change to the quality of Drinking Water
d o n ‘ t c r a c k u n d e r p r e s s u r e 2006/2010
PE100 . Max safety at lower cost
Pipe
Material
SDR Max
pressure
Relative
weight of
pipe
Relative
cost of pipe
(estim.)
PE80 11 10 bar 100 % 100 %
PE100 17 10 bar 66 % 75 %
d o n ‘ t c r a c k u n d e r p r e s s u r e 2106/2010
Spain case study: PE100 bring value
Gas Natural PE gas network
0
10000
20000
30000
1989 1992 1995 1998 2001
km
Source : Gas Natural
0
20
40
60
80
100
Steel PE100
Relative cost for a 8 bar pipelineGas Distribution network
Size 20-40 63 - 315 > 315
Material PE80 PE100 Steel
SDR 11 17.6 -
Pressure 4 bar 4 bar (MOP 6)
-
TOTAL SAVING with respect to Steel 1.5 M€/y
PE100 use for 8 bar pipelines save 30% cost with respect to Steel
d o n ‘ t c r a c k u n d e r p r e s s u r e 2206/2010
TOTAL COSTS COMPARISONSteel 16 bar vs. PE100 10 bar Würzburg / Germany - Thüga
0102030405060708090
100
Steel PE100
Ind
ex (
%)
Laying cost
Material cost
d o n ‘ t c r a c k u n d e r p r e s s u r e 2306/2010
PE SAFE OPTION AGAINST EARTHQUAKES
EARTHQUAKES RESISTANCE OF PE GAS NETWORK
Year Country - City Magnitude (Richter)
Length of PE network
Damages to PE network
1993 Japan – Kushiro
7.8 155 km 0
1994 USA – Northridge CA
6.8 58000 km (41 % of total)
27 (5% of total)
1995 Japan - Kobe 7.2 >20000 km 0 (total 26.500)
1999 Colombia - Armenia
5.9 115 km 0
d o n ‘ t c r a c k u n d e r p r e s s u r e 2406/2010
Gas with PE100 . Max safety at lower cost
Pipe Material SDR Max
pressure
Relative
weight of
pipe
Relative cost
of pipe
(estim.)
PE80 11 4 bar 100 % 100 %
PE100 17 6 bar 66 % 87 %
d o n ‘ t c r a c k u n d e r p r e s s u r e 2506/2010
Advantages by fully compounded materials
• Material and standards specifically designed in collaboration with gas and water industry
• Directly compounded in the production plant, before testing
• “Ready made” compounds are tested by the raw material supplier over a long period of time to demonstrate compliance with the MRS value
• Tough quality control in plant, lab and independent institutes
• Large use and availability, meeting the most severe quality specifications.
• Traceability of raw materials in case of claims
• Ready made compounds have proven to deliver high quality and consistency levels.
d o n ‘ t c r a c k u n d e r p r e s s u r e 2606/2010
Three major geographical markets for HDPE pipe world wide
C&E-EU+Rus
W. Europe
N. America
NE Asia
N. America S. AmericaAfrica SE AsiaNE Asia Middle EastInd. Sub. Cont. W. EuropeC&E-EU+Rus
C&E-EU+Rus
W. Europe
N. America
NE Asia
N. America S. America Africa
SE Asia NE Asia Middle East
Ind. Sub. Cont. W. Europe C&E-EU+Rus
Europe
1317 kT
Europe
1646 kT
4010 kT 4992 kT
The global HDPE Pipe market will grow close to 25% in 5 years
2008 2013
d o n ‘ t c r a c k u n d e r p r e s s u r e 2706/2010
0
200
400
600
800
1000
1200
1400
1600
1800
2007 2008 2009 2010 2011 2012 2013
vo
lum
e [
kt]
W.EU C&E-EU+Rus Total Europe+
32
9 k
t
European growth is mainly concentrated in C&E-EU+CIS countries
European HDPE Pipe market grows
with >300 Kt up to 201375 % of the growth will be in C&E-EU+RUS
d o n ‘ t c r a c k u n d e r p r e s s u r e 2806/2010
European HDPE pressure pipe market outlook
0
200
400
600
800
1 000
1 200
1 400
1 600
1 800
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Mar
ket
[kt]
0
10
20
30
40
50
60
70
80
Sh
are
[%]
Total EU Pipe market PE100 PE80 total PE100 share PE80 mono-mod PE80 bi-mod
PE-100 will gain market share of >70 % from 2013 Overall growth period 2008-2013: 5-6% p.a. PE 100 grows 10-12 %PE80 mono mod will vanish
PE100 share will grow >70%, however PE80 bi-mod will stay
d o n ‘ t c r a c k u n d e r p r e s s u r e 2906/2010
PE100: a successful value propositionClear advantages offered by PE100 trough life-cycle of pipes :
1. Present Value: Cost advantages over other conventional materials (Steel, PE80, Ductile Iron, …)
2. Lifetime: 100 yrs extrapolation in creep resistance
3. Quality cost: Pre-compounded materials simplified quality control – Highest Quality consistency
4. Maintenance: No maintenance except third party damage
5. Failures: Minimal failure rate
6. Provisions: No replacement needed before at least 50 years
7. Operations: Excellent hydraulic performance, pressure increase possible, easy extension, trenchless options with cost benefits associated
d o n ‘ t c r a c k u n d e r p r e s s u r e 3006/2010
Added value of PE100 PIPES to industry • Continuous Development
PE100 pipes - worldwide recognized tool to improve access to drinking water, sanitation, energy; Improving millions people life around the world
• Delivering SafetyPE100 pipes proven safe and reliability for gas transport and water supply, and now more prefered choice of major European gas companies
• Addind Value PE100 provide enhanced value to plastics pipes, allowing effective replacement of traditional materials.Complete industry built around – PE does what other materials can’t do
Creating trust through high quality standards and correct industrial practices along supply chain while promoting high material quality
d o n ‘ t c r a c k u n d e r p r e s s u r e 3106/2010
Thank you for your attention
d o n ‘ t c r a c k u n d e r p r e s s u r e
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