PVC-O PIPES a revolution in water and sewerage solutions Pipe Revolution... · Company Established...
Transcript of PVC-O PIPES a revolution in water and sewerage solutions Pipe Revolution... · Company Established...
CONFIDENTIALCONFIDENTIAL
PVC-O PIPES a revolution in water and sewerage solutions
Contents
1. Company
2. Technology
3. Product Overview
4. Value Proposition
5. Summary
CompanyEstablished in 2013 as the pioneer in manufacturing PVC-O pipes (Class 500) in Malaysia and South East Asia.
Malaysia 65%
Malaysia 25%
Spain 10%
Product Brand:
CompanyOur manufacturing plant in Malaysia features state-of-the-art technology using MOLECOR’S own air-based molecular orientation system, capable of producing 11,000 MT/annum
• Transfer of technology and market intelligence to Molecor SEA Sdn Bhd:
• Headquarters in Wisma Fitters, KL• Cutting edge plant in Gebeng, Kuantan• Under ECER (East Coast Economic Region) • Supported by MIDA (Malaysia Investment
Development Authority)
• Manufacturing plant in Gebeng, Kuantan
• 11,000MT full annual production capacity• Production started in Q1 2015• Product Range: PN16 & PN25; DN90 –
DN630• managed by 40 technical personnel in
operation and engineering.
CompanyKey Milestone: Customized incentive under East Coast Economic Region (ECER)
CompanyKey Milestone: Signing of MOU with AVK (manufacturer of fittings & valves)
CompanyKey Milestone: SIRIM certification – ISO 16422 and SPAN approvals for HYPRO PVC-O Class 500 for use in Water Supply and Sewerage
Water Supply SewerageSIRIM
CompanyKey Milestone: Production of PVC-O pipes in Gebeng, Kuantan
CompanyGaining wide market acceptance: Exhibitions and Presentations
CompanyBy 2006, total PVC-O pipes installed capacity worldwide over 38,000 tonnes/year.
10.000 T/y
3.000 T/y
9.000 T/y
7.000 T/y3.000 T/y
2.000 T/y
3.000 T/y
1.000 T/y
Countries currently producing PVC-O pipes
CompanyBy 2015, MOLECOR products are accepted globally in 5 continents, with 72% of market share in PVC-O pipes are produced using MOLECOR technology. There are > 6400km of successful pipe installation.
23.000 T/y
3.000 T/y
12.000 T/y
9.000 T/y
3.000 T/y
12.500 T/y3.000 T/y
12.000 T/y
12.000 T/y6.000 T/y
26.000 T/y
6.000 T/y
3.000 T/y
11.000 T/y
6.000 T/y
3.000 T/y
Countries currently producing PVC-O pipes
Countries manufacturing with MOLECOR technology … and growing
Company
Country Standard
International (ISO) – Malaysia etc. ISO 16422:2014
Spain UNE-ISO 16422:2008
United Kingdom BS-ISO 16422:2006
France AFNOR T 54-948:2010
Australia/New Zealand AZ/NZS 4441:2008
United States (USA) ASTM 1483-05
Canada CSA 137.3.1-09
Columbia NTC 5425:2012
Brazil ABNT NBR 15750:2009
Peru NTP-ISO 16422:2012
South Africa SANS 16422:2007
Saudi Arabia SASO-ISO 16422:2009
The quality of MOLECOR PVC-O is manifested through acceptance and compliance of respective product certifications of each country.
CompanyThe water quality conveyed using HYPRO PVC-O pipes are demonstrated through EU conformity of sanitariumcertifications.
Guarantee of water quality through:• Material used in the manufacturing are safe
in contact with water• No trace of heavy metal• No harmful growth of aquatic
microorganisms
CompanyMOLECOR has strong track record for infrastructure projects for pipes applications globally.
Project (Local) Application Year Location Length OD (mm) &
Pressure (bar)
Palm Oil Effluent Effluent transport 2015Kuala Kertil,
Kedah5.0 km 160mm PN16
Water transport in Papua New
GuineaPotable water supply 2015
Papua New
Guinea8.0 km 110 to 160 mm PN16
Halalhub Potable water supply 2015 Kelantan 3.0 km 200 mm PN16
Water transport to MRSM Kuala
BerangPotable water supply 2015
Kuala Berang,
Terengganu1.5 km 110 to 160 mm PN16
Project (International) Application Year Location Length OD (mm) &
Pressure (bar)
Potable water network renewal from
Uga-Las BrenasPotable water supply 2012 Yaiza, Spain 14.0 km 315mm PN25
Water supply to cruise dock Potable water supply 2012Arrecife,
Spain2.0 km
140 to 200 mm
PN12.5/PN16
Water supply to area Le Dreux Potable water supply 2012 Dreux, France 4.00 km 200 to 250 mm PN16
Main distribution to Asa de la Bietre Potable water supply 2011 Dijon, France 30.0 km 140 to 250 mm PN16
Distribution scheme in Sta Lucia Potable water supply 2011 La Martinica 2.0 km 250 mm PN16
New Irrigation system in MontillaIrrigation water
supply2010
Cordoba,
Spain23.0 km
110 to 400 mm
PN12.5/PN16/20
New Irrigation system in Asa La
Beitre
Irrigation water
supply2011 Dijon, France 55.0 km 110 to 400 mm PN16
TechnologyThe molecular orientation process modifies the PVC structure by giving the polymer molecules a specific orientation.
Polimeric Chains
Molecular Bonds
Orientation
Process
Direction of Orientation
• Inherently layered structure is achieved without modifying chemical composition.
• Excellent mechanical properties.
TechnologyThe orientation process transforms the PVC structure from amorphous to laminate / multi-layered structure.
AMORPHOUS
STRUCTURE
(PVC-U)
LAYERED
STRUCTURE
(PVC-O)
• This significantly improves the impact resistance of the pipe.
• Prevention of crack propagation.
TechnologyMOLECOR’S air-based orientation technology enables theproduction of PVC-O pipes at consistent quality, higherproduction rate and competitive price.
• Patented air-based molecular orientation process to class 500 (highest degree)
• In-line production of integrated socket system• Largest range of diameter from 90mm to 800mm• Highest quality assurance (Raw Material,
Mixing,Proforma Pipes & Finished Goods)
PVC compound
Technology
The result of molecular orientation process enhances the mechanical properties of PVC.
PVC-U PVC-O
Characteristics Performance Ratio
Impact Resistance
1 5
Crack Propagation
1 5
Fatigue Resistance
1 3
Elasticity / E-modules
1 1.5
Strength 1 2
Product OverviewThe usage of MOLECOR PVC-O offers outstanding value propositions in terms of technical and cost benefitsP
VC
-O A
DV
AN
TA
GE
S
SUPERIOR MECHANICAL PROPERTIES
STRONGER, FLEXIBLE
EXCELLENT HYDRAULIC
PERFORMANCE
LARGER BORE, SMOOTHER PIPES
LONG TERM PERFROMANCE
50 YEARS, NO SCALLING AND
CORROSION
SUSTAINABILITY GREEN PRODUCT
EASY, FAST INSTALLATION
COST AND TIME EFFECTIVENESS
Value Proposition: Superior MechanicalProperties.Molecular orientation enhances the mechanical properties of PVC, giving the material its strength to hydrostatic resistance and flexibility.
• Better than other polymer pipes and close to characteristics of metal-based pipes.
Metal material characteristicTensile Resistance
Value Proposition: Superior MechanicalProperties.
PVC-O is exceptionally resistant to material fatigue and has a good chemical resistance, capable to sustain greater hydrostatic pressure and corrosion degradation.
Extreme impact resistance
Scratches/cracks do not progress in the pipe
High resistance to external point loads
Integrated socket system + rubber seal ensures total leak tightness – decreasing non revenue water in operation.
Value Proposition: Superior MechanicalProperties.
Uniaxial tensile test minimum stress 48 MPa in accordance with ISO 16422 and ISO 6259-2
• PVC-O: Layered structure can be seen on broken test pieces
• Other material: Clean break
Value Proposition: Superior MechanicalProperties.
Minimum ring stiffness in accordance with ISO 16422 and ISO 9969
• HYPRO PVC-O achieves 35% higher ring stiffness than required in the standard.
• PVC-O structure does not break or crack even up to 100% deflection.
Value Proposition: Superior MechanicalProperties.
Technical characteristic compared to the other alternate materials.
HYPRO PVC-O 500
uPVC HDPE-100 HDPE-80
Product Standard
Unit ISO 16422 EN1452 EN12201 EN12201
Minumumrequired strength
(MRS)MPa 50.0 25.0 10.0 8.0
Overall Service Coefficient (c)
[] 1.4 2.0 1.25 1.25
Design Stress (σ) MPa 36.0 12.5 8.0 6.3
Traction Axial Resistance
MPa >48 >48 19 19
Traction TangentialResistance
MPa >90 >48 19 19
Elasticitymodulus (E)
MPa >4,000 >3,000 1,100 1,100
Value Proposition: Superior MechanicalProperties.
Non-Mechanical characteristics of PVC-O
Characteristic Unit Value
Density Kg/dm³ 1.35 – 1.46
Vicat Temperature °C > 80
Thermal ConductivityKcal/mh°C
0.14 - 0.18
Absolute roughness (ε) mm 0.007
Absolute roughness
(Hazen Williams)[ ] 150
Manning Roughness
Coefficient[ ] 0.009
Value Proposition: Excellent HydraulicPerformance.The technical benefits are highly significant in terms of hydraulic capacity and long term performance.
more free section
Larger bore of PVC-O pipes means maximum hydraulic capacity
• 41% more than Ductile Iron• 32% more than HDPE• 15% more than PVC
Value Proposition: Excellent HydraulicPerformance.
The technical benefits are highly significant in terms of hydraulic capacity and long term performance.
less roughness
PVC-O x 750PVC-U x 750
Smoother bore of PVC-O pipes means
maximum flow of water
lowest energy consumption.
Hazen-Williams Coefficient
PVC-O, C = 150Other Material, C = 100 ~ 120
fluid speed
load loss
pumping energy
Value Proposition: Excellent HydraulicPerformance.
The technical benefits are highly significant in terms of hydraulic capacity and long term performance.
• Flexible pipes (polymer pipes) generate much lower surge pressures than rigid materials (concrete or iron).
• Risk of breaks is significantly reduced due to excellent mechanical properties of PVC-O
Value Proposition: Long Term Performance.
PVC-O is exceptionally resistant to fatigue and has a good chemical resistance in results of capable to withstanding the pressure work for years.
design life of 50 years
• The stress (50 years) that PVC-O class 500 can bear is 50MPa
• 500% vs HDPE 100 (10Mpa)
• 200% vs PVC-U (25Mpa)
• 10% vs PVC-O of lower class (45Mpa)
Value Proposition: Long Term Performance.Densities of bacterial biomass fixed on plastic-based materials were the lowest. No scaling and corrosion in the pipe. Also, almost inert to chemicals at any concentration.
• Cement lined pipes contains 2.6 times more bacterial biomass.
• Plastic based material is not suitable for bacterial growth.
Reference:Impacts of pipe materials on densities of fixed bacterial biomass in a drinking water distribution systemAuthors: P Niquette, P Servais, R Savoir - Water research, 2000 - Elsevier
Value Proposition: Enhanced sustainability
MOLECOR PVC-O employs the least energy consumption in the production process and pumping operation.
Reduce greenhouse gas emissions and low
embodied energy• By approximately 20% compared to HDPE pipes
• By about 46-48% for comparable ductile iron and concrete
pipes over the product life cycle
Source: Dr. José María Baldasano Recio et al, 2005, Universitat Politecnica de Catalunya
Value Proposition: Enhanced sustainability
• High quality of raw material used in the production
• 100% virgin ethylene based resin used – no heavy metal traces.
• Organic heat stabilizer and ethylene based resin used in the production.
• 100% recyclable – pulvenized & reprocessed for low end product reuse.
Consumes less rawmaterials
PVC-O with highermechanical properties
MOLECOR PVC-O employs the least energy consumption in the production process and pumping operation. MOLECOR PVC-O only use the finest quality of raw materials.
Value proposition: Quick, Cost Efficient installation
Due to its light weight, PVC-O pipes are easy to install and they can be lifted without mechanical assistance. This translate into lower installation cost.
Socket system: easy and efficient jointing even for bigger dimensions.
Value proposition: Quick, Low-Priced installation
Due to its light weight, PVC-O pipes are easy to install and they can be lifted without mechanical assistance. This translate into lower project cost including equipment rental, fuel and labour.
HYPRO PVC-O allows installation of up to 315mm diameter
without cranes or other lifting machines
FITTINGSCompatibility with all type of fittings and market solutions.
Ductile Iron specific fittings for PVC-O
Ductile Iron fittings with flanged system
Steel fittings exclusively designed for a particular
project
Cnventional PVC fittings, plug-type
Universal fittings for fixings with other
materials
FITTINGSWide range of accessories: EN 12842.
The usage of PVC-O offers outstanding value propositions across the value chains in terms of technical and cost benefits.
PVC-O
ADVANTAGES
INSTALLERWATER
COMPANYEND USER
hydraulics
long term performance
cost effectiveness
cost effectiveness
easiness
environmental friendliness
water quality warranty
Summary
Summary
The most TECHNOLOGICALLY ADVANCED WATER
& SEWERAGE SOLUTION available
TO-DATE
With unbeatable properties product and technicalsolutions at competetive cost and assured operability.
PV
C-O
AD
VA
NTA
GE
S
SUPERIOR MECHANICAL PROPERTIES
STRONGER, FLEXIBLE
EXCELLENT HYDRAULIC
PERFORMANCE
LARGER BORE, SMOOTHER PIPES
LONG TERM PERFROMANCE
50 YEARS, NO SCALLING AND
CORROSION
SUSTAINABILITY GREEN PRODUCT
EASY, FAST INSTALLATION
COST AND TIME EFFECTIVENESS
CONFIDENTIALCONFIDENTIAL
www.molecor.com
[email protected]@molecorsea.com
Thank YouMolecor (SEA) Sdn BhdWISMA FITTERS No. 1 Jalan Tembaga SD 5/2
Bandar Sri Damansara
52200 Kuala Lumpur
MALASIA
Telephone: +603 6276 7155
Facsimile: +603 6275 1378