PE100 Pipes Bimodal Innovation of Pressure Pipe Bimodal Innovation of Pressure Pipe

Applications

Presented By: Khaled Al-BaniTechnical Marketing – HDPEPolymers SBU

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Content

PE100 Pipes

• Advantages & Process

• Tests & Properties

• Applications

• Approval Steps & associations

• Q & A• Q & A

2

Transportation means

SABIC pipe materials

3

Solutions

Utility

pipes out of

SABIC pipe materials

pipes out of

bimodal

Polyethylene

(Source: egeplast GmbH/Germany)

(Source: egeplast GmbH/Germany)

(Source: swb Germany)

(Source: swb Germany)

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PE100 Pipes

Advantages & Process

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Advantages of PE

� Safe

� Long life (100 years design time)

� Non corrosive

� Light weight

� Easy installation (e.g. trenchless)

SABIC pipe materials

� Easy installation (e.g. trenchless)

� Leakage free

� Environmental friendly

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Advantages of PE

� Flexibility (Earthquakes, Coils )

�Cost effective butt welding

� Safe electro fusion

� good tensile Strength for welding

� Well controlled systems

SABIC pipe materials

� Well controlled systems

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Bimodal HDPE Process

Bimodal HDPE is mix of:

1. LOW Molecular fraction which gives:

• Good Processability• High stiffness• High crystallinty

2. HIGH Molecular fraction which gives

• High resistance to Slow Crack Growth

• High creep behavior

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Generation Period Development

1st ~1970’ s LD (PE32, PE40)

HD (PE50, PE63)

2nd ~1980’ sMD (PE80) ~1990’ s

HD (Unimodal PE80)

PE Pipe Developments

2nd ~1980’ sHD (Unimodal PE80)

3rd ~presentMD (Bimodal PE 80)

HD(Bimodal PE80, PE100, PE100+)

~Future PE125

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Classification

MRS*

@ 50 years, 20 C

(MPa)

Corresponding Design

Pressure

bar

(based on SDR 11)

PE 80 8.0 12.5

PE Pipe Classifications

PE 100 10.0 16.0

*MRS: Minimum Required Strength

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PE100 Pipes

Tests & Properties

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Requirements for the resin

Density MFR OIT Carbon Black

SABIC pipe materials

Density MFR OIT Carbon Black Content

Dispersion Volatile/Water content

Organoleptic properties

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PE100PE80

10 MPa

8 MPa

IPT (MRS)

Triangle of market requirements of pipe grades

PE80

RCP (S4)500 hr

SCG (Notch test)

PC ≥ (MOP)/2.4–0.722

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Hydrostatic strength

• Needed for lifetime assessment• Needed for evaluation of design stress

• Entails pipe dimensions

lplσ

20°C

σlpl ≥ 8 MPa => PE 80

σlpl ≥ 10 MPa => PE 100

SABIC ppipe materials

time

σ

80°C

60°C

σlpl

50 years

The intersect of 50 years with the 20 °C lpl-line renders the stress

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Hydrostatic strength

20

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Ho

op

str

es

s in

MP

a

20 °C

40 °C

Regression line of PE 100 Vestolen A 6060 R black

SABIC pipe materials

0,1 1 10 100 1000 10000 100000 1000000

Time in h

3

10

9

8

77

6

5

4

3

Ho

op

str

es

s in

MP

a

40 °C

60 °C

80 °C

50 years

100 years

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Resistance to Slow Crack growth

• Pipe are pulled from trucks andover the ground causing scratchesand scores

• Test simulates the insertion of scores

• 4 longitudinal notches equidistandly

SABIC pipe materials

• 4 longitudinal notches equidistandly • around the circumference• remaining ligament 80 % of nominalpipe wall

• Requirement 500 h minimum failure time at 80 °C

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Resistance to Rapid Crack Propagation

SABIC pipe materials

Full Scale test

Requirement:PE 80: 20 bars at 0 °CPE 100: 24 bars at 0 °C

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Resistance to Rapid Crack Propagation

SABIC pipe materials

S4 test

Requirement:PE 80: 8 bars at 0 °CPE 100: 10 bars at 0 °C

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PE100 Pipes

Applications

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SABIC® Vestolen

MRS MRF5 Density Typical Applications

SABIC® HDPE MRS MRF5 Density Typical Applications

P 6006 black PE 100 0,22 959 Water, Gas, Sewage, Sheets

P 5510 black PE 80 HD 0,5 955 Water, Gas, Sewage, Sheets

Portfolio HDPE grades

SABIC pipe material grades

Vestolen

A 6060 R black PE 100 0,3 958 Water, Gas, Sewage, Sheets

A 6060 R blue PE 100 0,35 949 Water

A 5061 R black PE 80 HD 0,5 956 Water, Gas, Sewage, Sheets

A 4062 R black PE 80 MD 0,8 953 Water, Gas, Sewage

A 4062 R yellow PE 80 MD 0,8 944 Gas

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Standard: EN 1555/ISO4437

Pipe marking: - Full coloured - Black with stripes

Gas Gas Pipes

Stripe compound

PE100 – Orange Yellow

PE80 –Yellow

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Standard: EN 12201/ISO4427

Pipe marking: - Full coloured - Black with stripes

Potable Water Potable Water Pipes

Stripe compound

PE100 – Dark Blue

PE80 – Blue

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Standard: EN 13244

Pipe marking: Black with stripes

SewageSewage Pipes

Stripe compound

PE100 – Brown

PE80– Brown

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Categories of HDPE Pipes - Application

Application Standard Classification Color & Strip Photo

GasGasEN1555/

ISO4437

PE80Fully Yellow Color

Black with Yellow strip

PE100Full Color Yellow Orange

Black with Yellow orange strip

Fully Blue Color

WaterWaterEN 12201/

ISO4427

PE80Fully Blue Color

Black with Blue strip

PE100Fully Dark Blue Color

Black with Dark Blue strip

Sewage Sewage EN 13244

PE80Fully Brown Color

Black with Brown strip

PE100Fully Brown Color

Black with Brown strip

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Standard: EN 13476

Pipe marking: Pipe is composed of two layers. Outer layer is structured, inner layer is even

Corrugated pipes

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Standard: DIBt approval (Germany)

Pipe marking: black without stripes

Wound pipes/Spiral pipes

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Standard: End user specificationPipe marking: End user specificcation

Cable Duct pipes

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Jacketing pipes

Standard: EN 253

Requirements: Density > 935 kg/m³CB 2 % - 3%OIT (210°C) > 20 minIPT (80°C/4.6 MPa) > 165 h

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Mining pipes

Standard: End user specificationPipe marking: End user specificcation

� It could be used in Surface and Underground� PE good abrasion and corrosion resistance

Material Weight Loss (mg) Material Weight Loss (mg) Abrasion Test

PE100 20

PE80 22

PP 163

UPVC 332

Mild Steel 1081

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PE100 Pipes

Approval Steps &

associations

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Basic Approval

Fundamental test to prove „fit for purpose“

Fundamental test to prove „compliance

Principle Procedure for PE 100 - Material Approvals

Country Approval

Customer Approval

prove „compliance with national requirements“

Fundamental test to prove “harmless processing of the material“

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Approval Scheme for PE100

Initial Type Test

Country Approval

Customer Approval

Customer/ compoundCompoundCompoundResponisble

Kind

AENOR

DVGW

IIP

NF

SIS

AENOR

DVGW

IIP

NF

SIS

ISO 4437

ISO 4427

EN 1555

EN 12201

1.5 Year 3-6 Months 3 - 6 Months

Standards

Time Frame

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PE100 Consumption in Middle East, KTA

� High Growth Market AAG = 15%

� In KSA, AAG about 20%� Very Attractive Market� Supported by availability of

raw materials.

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Pipe Network Current situation in GCC:

• High leakage rates and maintenance cost for traditional pipes can be virtually eliminated with high quality plastics pipe systems. In GCC, leak rate vary from 15% to 50% of water pipe network resulting of billions $ loss.

• Building infrastructutre creates a tremendous market potential for plastics pipes but:

� Lack of local safe guards and knowledge makes it difficult to distinguish � Lack of local safe guards and knowledge makes it difficult to distinguish between poor and high quality plastics pipe systems

� Poor quality pipe systems have created problems for end users and is a threat to the reputation of plastics pipes in the future

� The lack of standards and certification schemes makes introduction of better pipes difficult

In 2006, about 1500 pipe leakage in Riyadh City only causing lose of more than One Billion SR. Source: Ministry of W&E

GCC Piping System- Overview

• Water Applications

• Shortage of water specially in GCC

• High Leakage level in current piping systems

• Big projects to revamp the old piping systems.

• New Industrial cities

• Traditional Piping system is not the optimum solution

• Gas Applications• Gas Applications

• GCC has big gas recoveries

• Gas piping system is growing

• need to resolve current problems (lifetime, cost, corrosion)

• Sewage Application

� Sewage system is new

PE100 Opportunities in ME- Summary

• Big infrastructure Projects in ME

• PE100 has good records in Europe & America

• High potential to replace the tradition pipe network (cost & product features)

• Availability of Raw Materials from ME

• Innovations in Product improvement, welding & installation.

Product Perceptions

Negative perceptions of plastic pipe

compared to traditional (Iron, copper, etc..)n

Use of Non certified base materials.

PE100 Pipes Challenges in GCC

Business Integration

Lack of business integrations

Consistency of Quality

materials.

Not following quality standards

Business Integration

Base` Resin

Suppliers

Plastic Pipe Producers

Fitting/ Joints

Producers

Installers/ Contractors

Well integrated System

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