1. don‘t crack under pressure
PE100 and PE100+
Materials and Pipes
Citypipe, Moscow
June 2010
O. Anisimova, PE100+ Association
2. 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.
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3. 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
• …
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4. PE100: combining 3 key properties
DESIGN
Long term resistance
to internal pressure
Long term resistance Minimisation of damage
To mechanical failure in case of accidental failure
INSTALLATION SAFETY
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6. What is a PE100 Material ?
Ductile failure
20 °C
A pipe material
stress (MPa)
LTHS correctly tested
10 MRS according to ISO9080
for up to 9000h at 80°C
without knee gives a
statistically valid
80 °C extrapolation at 20°C of
9000h*100 = 900.000h =
Brittle Failure
100 years
50 yrs 100 yrs
Failure time
1 10 100 1000 10000 1000000
10000
0
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7. 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
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8. ESCR: How is it measured?
Notched Pipe Test
4 equi-spaced notches around circumference.
Remaining wall thickness: 78 - 82 % of wall thickness
A Test Requirements
Test
PE-class Test temp. Hoopstress period
O
C MPa h
Pipe end caps A
PE80 80 4.0 500
Position of minimum
wall thickness
PE100 80 4.6 500
Section A-A
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9. 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
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10. WHY PE100 ?
PREPARED FOR THE UNEXPECTED !
• RAPID CRACK
PROPAGATION
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11. Rapid Crack Propagation / RCP
Crack Length S4 Test results (0 °C) - ISO 13477
Crack propagation
MDPE PE100
Crack arrest
4 > 24
Equivalent gas network pressure ( bar )
Use of MDPE limited to 4 bar
No RCP risk with PE100 for pressures of up to 24 bar
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12. THE ORIGIN OF PE100 PROPERTIES
• POLYETHYLENE IS A SEMICRYSTALLINE
POLYMER, CONTAINING A CRISTALLINE
PHASE AND AN AMORPHOUS PHASE.
• PE100 CORRESPONDS TO THE
SELECTIVE REINFORCING OF THE
AMORPHOUS PHASE BY BRANCHING
AND MOLECULAR WEIGHT CONTROL
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14. Advantages of the Bimodal Process
Reactor 1 Reactor 2
Low Mw PE linear structures HMW PE with shot chain
branching
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15. Long term stress – Tie Molecules
A PE
Spherulite
Fibrils are kept together by the amorphous region, where
molecules are entangled with formation of physical bonds
(3
)
The tie molecules and their
entanglements are responsible for (2
passing the stress into the crystals. )
(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
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16. 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
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17. 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
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18. Water networks…
Sewers and water networks in cities all over the world are ageing
and in some places are malfunctioning
Water distribution network performances
Country Italy Germany UK France
Leaks (%) 38-45 8-15 15-16 20-22
AGICI source 2008
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 »
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19. Organoleptic and Health Requirements
Pipes cannot give any negative change to the quality of Drinking Water
WHO GUARANTEES QUALITY OF A DRINKING WATER PIPE ?
• 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
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20. PE100 . Max safety at lower cost
Pipe SDR Max Relative Relative
Material pressure weight of cost of pipe
pipe (estim.)
PE80 11 10 bar 100 % 100 %
PE100 17 10 bar 66 % 75 %
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21. Spain case study: PE100 bring value
Gas Distribution network
Relative cost for a 8 bar pipeline
Size 20-40 63 - 315 > 315
100
Material PE80 PE100 Steel
80
SDR 11 17.6 - 60
Pressure 4 bar 4 bar - 40
(MOP 6)
20
TOTAL SAVING with respect to Steel 1.5 M€/y
0
Steel PE100
Gas Natural PE gas network
30000
PE100 use for 8 bar
pipelines save 30% cost
20000
with respect to Steel
km
10000
Source : Gas Natural
0
1989 1992 1995 1998 2001
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22. TOTAL COSTS COMPARISON
Steel 16 bar vs. PE100 10 bar
Würzburg / Germany - Thüga
100
90
80
70
Index (%)
60
Laying cost
50
40 Material cost
30
20
10
0
Steel PE100
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23. PE SAFE OPTION AGAINST EARTHQUAKES
EARTHQUAKES RESISTANCE OF PE GAS NETWORK
Year Country - City Magnitude Length of PE Damages to PE
(Richter) network network
1993 Japan – 7.8 155 km 0
Kushiro
1994 USA – 6.8 58000 km (41 27 (5% of total)
Northridge CA % of total)
1995 Japan - Kobe 7.2 >20000 km 0 (total 26.500)
1999 Colombia - 5.9 115 km 0
Armenia
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24. Gas with PE100 . Max safety at lower cost
Pipe Material SDR Max Relative Relative cost
pressure weight of of pipe
pipe (estim.)
PE80 11 4 bar 100 % 100 %
PE100 17 6 bar 66 % 87 %
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25. 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.
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26. Three major geographical markets
for HDPE pipe world wide
4010 kT 4992 kT
NE Asia
W. Europe NE Asia W. Europe
Europe Europe
1317 kT 1646 kT
C&E-EU+Rus C&E-EU+Rus
N. America
N. America
2008 2013
N. America S. America N. America S. America Africa
Africa SE Asia
NE Asia Middle East SE Asia NE Asia Middle East
Ind. Sub. Cont. W. Europe
C&E-EU+Rus Ind. Sub. Cont. W. Europe C&E-EU+Rus
The global HDPE Pipe market will grow close to 25% in 5 years
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27. European HDPE Pipe market grows
with >300 Kt up to 2013
75 % of the growth will be in C&E-EU+RUS
1800
+ 329 kt
1600
1400
volume [kt]
1200
1000
800
600
400
200
0
2007 2008 2009 2010 2011 2012 2013
W.EU C&E-EU+Rus Total Europe
European growth is mainly concentrated in C&E-EU+CIS countries
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28. European HDPE pressure
pipe market outlook
1 800 80
PE-100 will gain market share of >70 % from 2013
1 600 Overall growth period 2008-2013: 5-6% p.a. 70
PE 100 grows 10-12 %
1 400 PE80 mono mod will vanish 60
1 200
50
Market [kt]
Share [%]
1 000
40
800
30
600
20
400
200 10
0 0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Total EU Pipe market PE100 PE80 total PE100 share PE80 mono-mod PE80 bi-mod
PE100 share will grow >70%, however PE80 bi-mod will stay
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29. PE100: a successful value proposition
Clear 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
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30. 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 Safety
PE100 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
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31. don‘t crack under pressure
Thank you for your attention
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