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

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WHY PE100 ? PREPARED FOR THE UNEXPECTED !

• RAPID CRACK PROPAGATION

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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

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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