Malaysia District Water Eng Meeting Rev A

8/12/2019 Malaysia District Water Eng Meeting Rev A

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Borouge reference line 2006

© 2006 Borouge Pte Ltd

Contents

A brief introduction to Timplas and Borouge

What is polyethylene, PE80 and PE100

The design of pressure pipelines

Jointing of polyethylene pressure pipelines

How to ensure you specify the best quality PE100

Whole life cost savings using PE100 pipes

The life span of PE100 pipes at higher temperatures

Conclusion



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A brief introduction to Timplas andBorouge

A successful international partnership



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Borouge…. A successful joint venture combining

resources, feedstock and technology leadership

AustriaUAE

Borouge – A JV between

ADNOC and Borealis,

combining the best of

Europe and the Middle East

JV formed in 1998,

production start up in 2001

in Ruwais, Abu Dhabi.

Current capacity of over

2,000 KT/year of PE and

Polypropylene (PP) .

Will increase to over 4,000

KT/year in 2014 once

Borouge 3 commissioned.

http://www.borouge.com/



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Borealis customer service centre

Borealis Head Office

Borealis production

Innovation Centre

Borouge Production Head Office

Borouge Sales and Marketing Head Office

Borouge production

Borouge sales offices

Borouge representative office

Borouge – a leading force in the

international plastics market



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Providing Solutions in Polyolefins

Infrastructure

Automotive Advanced Packaging



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What is polyethylene, PE80 and PE100



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Polyethylene molecular shapes and densities

PE

Material

Density

(kg/m3)

HDPE 940 - 965

MDPE 930 - 940

LLDPE 910 - 930

LDPE 900 - 910

HDPE

(PE100)

MDPE

(PE80)

LLDPE

LDPE



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Molecular density and material properties

- common misconceptions

Polyethylene

High Density Polyethylene - HDPE

Medium Density Polyethylene - MDPE

Linear Low Density Polyethylene - LLDPE

Low Density Polyethylene – LDPE

Increasing density,

tensile strength,

elastic modulus,

crystalinity,

abrasion andchemical resistance

Not all MDPE is PE80 and not all HDPE is PE100 – Most of it isn’t!

PE having a MRS (Minimum Required Strength) of 10 MPa (N/mm2) can be

a PE100 - PE number = 10 X MRS in MPa

Also a PE having an MRS of 8MPa can be a PE80

Must meet the requirements of ISO4427 or MS1058 (water) / ISO4437 (gas)





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The development of polyethylene since 1955

1950’s 1960’s 1970’s 1980’s 1990’s 2000’s 2010+

•LD

•HD•„ •LS―

•„ >PE100

PE100

PE80

PE80

PE63

PE32 •LDLD

HD

HD/UM

MD/BM

•HDLS

LS-H

Borstar ® era

HD/BM

HD High Density

MD Med. Density

LD

Low Density

UM Unimodal

BM Bimodal

LS Low Sag

H HSCR



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Design of polyethylene pipelines



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Principal standards related to design of

polyethylene pressure pipelines

MS 1058 : 2005 parts 1 and 2 (SIRIM)PE Pipe for Water Supply

ISO 4427 : 2007 parts 1, 2, 3 and 5

Plastics piping systems — Polyethylene pipes and fittings for water supply

ISO 4437: 2007

Buried polyethylene pipes for supply of gaseous fuels

EN 1295 : 1997

Structural design of buried pipelines under various conditions of loading

BS 9295 : 2010

Guide to the structural design of buried pipelines

ISO 9080: 2003

Plastics piping and ducting systems - Determination of the longterm

hydrostatic strength of thermoplastics materials in pipe form by extrapolation



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SDR - Standard Dimension Ratio and

pressure pipe design

σh = p x dm P x do - s2 x s 10 2 x s

σh = hoop stress (N/mm2)

P = internal pressure (bar)

dm = mean pipe diameter (mm)do = outside pipe diameter (mm)

s = wall thickness (mm)

Combining the equation for hoop stress and the SDR expression we get:

σh = P x (SDR -1) PN = 20 x MRS MRS = min. required strength (MPa)

20 (SDR -1) x SF PN = pipe nominal pressure (bar)

SF = safety factor

SDR 17

SDR 11



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Safety factors, pressure ratings and

resistance to surge pressures

As MRS refers to the maximum continuous hoop stress, which is due tooperation pressures, rather than peak pressures, hence the safety factor is

1.25 for water and 2.0 for gas pipeline systems

PN = 20 x MRS

(SDR -1) x SF

SDR11 (PE100)

Water PN 16 bar

Gas PN 10 bar

SDR17 (PE100)

Water PN 10 bar

Gas PN 6.25 bar

PE pipes are designed for service life, not catastrophic or ultimate conditions

PE is a plastic material and the short term (1 minute) burst resistance of the

material is 3.5 – 4.5 the rated pressure – ASTM D1599 : 1999

PE pipelines are therefore normally designed as having a ‗surge rating‘ of 1.5

or 2.0 twice the rated pressure. ie. 20 bar in the case of a PN10 pipeline

With l



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With low sag

PE100 pipes

should not be

limited to smalldiameters and

low pressuresSDR Max. Pipe wall thickness

Operating [mm]Pressure

[bar] 450 500 560 630 710 800 900 1000 1200 1400 1600 1800 200

26 6.3 17.2 19.1 21.4 24.1 27.2 30.6 34.4 38.2 45.9 53.5 61.2 68.8 76.4

22 7.5 20.5 22.8 25.5 28.7 32.3 36.4 41.0 45.5 54.6 63.7 72.7 81.8 90.9

21 8 21.5 23.9 26.7 30.0 33.9 38.1 42.9 47.7 57.2 66.7 76.2 85.7 95.2

17 10 26.7 29.7 33.2 37.4 42.1 47.4 53.3 59.3 71.6 83.0 94.8 105.8 117.13.6 12.5 33.1 36.8 41.2 46.3 52.2 58.8 66.1 73.5 88.2 102.9 117.6

11 16 40.9 45.4 50.8 57.2 64.4 72.6 81.7 90.7 109.1

9 20 50.3 55.8 62.5 70.3 79.3 89.3

7.4 25 61.5 68.3 76.5 86.0 96.9



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Structural design of buried pipes, ring

stiffness and nominal stiffness

A pipes ability to resist external loads isreferred to as its Ring Stiffness

Pipe ring stiffness (S) = E I/D3

I = pipe wall moment of inertia

(I = e3/12 for solid walled pipes)

e = wall thickness

E = short term modulus of elasticity

(Young‘s Modulus)

D = mean pipe diameter

‗E‘ for PE 100 = ~1100 MPa

Nominal stiffness (SN) is the pipe ring

stiffness in MPa (KN/m2)divided by 1000



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Pressure pipes have very high ring

stiffness

Gravity pipe manufacturers and the standards refer to nominal pipe stiffnessclasses. Typically SN4 and SN8 with SN16 being the highest class.

Pressure pipes have a relatively high wall thickness (e) and therefore have

a very high ring stiffness

gravity pipes highest class SN16

SDR 17 (PN10) PE100 SN22

SDR 11 (PN16) PE100 SN92

Hence Engineers do not in practice consider the structural design of buried

pipelines due to external loads unless there are exceptional circumstances

When distribution network pipes (not > OD 315 mm) are laid beneath roads

with less than 0.6 m cover it‘s best to check structural calculations.



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Design of the pipe bed and surround for

regular PE100 pipelines

The bed and surroundshould ideally comply withUK water industry standardWIS 4-08-2. Otherwise:

gravel or broken stonegraded 5 – 10 mm

coarse sand or a sandand gravel mix withgravel less than 20mm

good quality granular

material free sharpstones or large lumps ie.20 mm or not > pipe wallthickness)

Minimum compaction of 85%standard Proctor density required



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Key points concerning the continuous

nature of PE pipelines

PE pipes should be welded or mechanically joined together to form acontinuous pipeline

By doing so designers can avoid the need for thrust blocks and the

construction of large valves chambers or anchors designed to take thrust

The ends of the PE pipeline must be anchored in some way in order to

prevent ‗pull out‘

Because of their high level of toughness, flexibility and continuity, PE100

pipelines are the best option for areas having poor ground conditions

For the same reasons, PE is also the preferred material to use in

trenchless technology applications

Using coiled pipes greatly reduces the number of joints so reducing costs

and jointing time



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Specify coiled pipe for 160 mm OD and

higher, depending on local producers

European pipeproducers regularly

coil pipes of up to

225 mm OD and

have coiled pipes of

up to 315 mm OD

Many producers can

provide 50 to 100 m

long coiled pipes of

up to 160 mm OD

Max. coil length forsmall diameters is

500m



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Jointing of polyethylene pressurepipelines



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Jointing of PE100 pipes and fittings -

Butt Fusion Jointing

Preferred option, joint is

stronger that the pipe

No fittings required

Continuous fully

homogeneous pipe

Electrofusion Jointing

To be used when pipes

cannot be butt welded

Electro-fusion fittings

required

Mechanical Jointing

To be used in very

demanding conditions

End load resistant fittings

Also used for connecting

to other materials



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Use the international standards to help

specify good pipe jointing

ISO 14236 – 2000

Plastic pipes and fittings – Mechanical joint compression fittings for use with

PE pressure pipes in water supply systems (up to 110 mm OD)

ISO21307 – 2011

Butt fusion jointing procedures for PE pipes and fittings used in the

construction of gas and water distribution systems (up to 70mm wall thickness)

ISO12176 : Part 1 – 2010

Equipment for fusion jointing of PE systems - Butt fusion

ISO12176 : Part 2 – 2008

Equipment for fusion jointing of PE systems - Electrofusion

ISO8085 : Part 3 – 2004

PE fittings for use with PE pipes for the supply of gaseous fuels - specification

for electrofusion fittings (up to 630 mm OD) - can be applied to water fittings



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Animation showing the butt fusion process



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How to ensure that you specify thebest quality PE100



Slide 27


The PE100+ Association and its role

for PE pipe quality assurance

•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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PE100+ Association

Founded on 24th February, 1999 by Borealis, Elenac and Solvay

Consisting of 8 member companies currently - Borealis, Borouge, Ineos,

LyondellBasell, Prime Polymer, SABIC, SCG Plastics (Thailand) and

Total Petrochemicals

Supported by Advisory Committee and working closely with other plastic

pipe, standards and utility bodies

http://www.lyondellbasell.com/LyondellBasell_Home

http://www.borouge.com/



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What does the ‘+’ in PE100+ represent?

and the benefit to water and gas utilitiesCertified PE100 material consistency of 3 critical properties due to regular

testing cycle

Promotion of quality beyond the raw material to the entire chain of pipes &

fittings, installation and maintenance

Peace of mind for utilities due to use ready made compounds without the

influence of carbon black master batch compatibility/consistency, due topoor homogenisation during extrusion and incomplete testing/certification

Applicants and members each have to send 5 no. 110 mm OD SDR 11

pipes to 3 independent testing laboratories every 7 months. After passing 2

test cycles applicants can become members

If utilities and other end users specify that their pipes and fittings must

be manufactured from a PE100+ certified material they can be

confident that they are getting the best.



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PE100+ Membership Technical Requirements



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Whole life cost savings usingPE100 pipes

B k d t t t d



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Background to asset management and

whole life costing – why do we look at it?

Asset management isthe systematic

approach to sustainably

managing assets, their

performance and costs

over the whole life

cycle

Studies undertaken by

European utilities and

in Shanghai show that

construction costs aretypically be less than

25% of whole life cost

Commissioning

Failure Rates andRepair Costs

O & M Costsinc. Pumpingand Leakage

Replacementand Disposal

Design andConstruction

T i l b kd f h l lif t f



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Typical breakdown of whole life costs for a

DN100 pipeline in Shanghai’s suburban areas

Xu Zhaikai , Chen Zhihu i , Zheng Xiaom ing

Shanghai Mun icipal Waterworks Feng xian Co., Ltd.

W h o l e l i f e c o s t i n R M B p e r k m

Comparison of whole life costs for different



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T o t a l W L C c o s t i n S h a n g h a i r u r a l w i t h c u r r e n t u n i t p r i c e

0

2 0 0 0 0 0 0

4 0 0 0 0 0 0

6 0 0 0 0 0 0

8 0 0 0 0 0 0

1 0 0 0 0 0 0 0

1 2 0 0 0 0 0 0

1 4 0 0 0 0 0 0

1 6 0 0 0 0 0 0

1 8 0 0 0 0 0 0

D N 1 0 0 D N 1 5 0 D N 3 0 0 D N 4 0 0 D N 8 0 0

P E

D I

S t e e l

Comparison of whole life costs for different

pipelines in Shanghai’s rural areas

PE whole lifecosts are for

SDR 17 (PN10)

pipelines

Shanghai uses

only 6 m pipes.Installation

costs could be

further reduced

by using longer

pipes and

coiled pipes



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The life span of PE100 pipes at

higher temperatures

Different factors affecting the lifetime of



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Different factors affecting the lifetime of

plastic pipes

LifetimeEnvironmental Factors

Average temperatures Quality of backfill

Abrasion (slurries)Chemical attack

Material Factors Initial MRS & aging rate

Slow crack growth Additives – carbon black

Pipe manufacture

Loading Factors

Operational pressuresSurge pressures

Soil loadsNotches and scratches

Material Lifetime Assessment 100 years



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σLPL = lower confidencelimit hydrostatic strength

50 years = 10.633 MPa

100 years = 10.50 MPa

High quality PE100materials still exceed the

MRS after 100 years at

20oC

The average annual

temperature in coastalSabah is 27.5oC

(BBC & World Met. Centre)50 years = 105.64 hours 100 years = 105.94 hours

Material Lifetime Assessment – 100 years

lifetime with modern high quality PE100

Pressure reduction factors due to higher



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Pressure reduction factors due to higher

ambient temperatures - ISO 4427

Annex A of ISO 4427 includes atemperature reduction table

conservatively based on an old

PE100 grade (Type A)

As modern PE100 grades have a

much better performance it allowsdesigners to take account of these

The pressure reduction for the

type A material at 27.5oC is 10%

The pressure reduction for a

modern material such as Borouge

or Borealis HE3490-LS is less

than 1%.

Conclusion Pipelines are like a chain



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Conclusion - Pipelines are like a chain,

only as strong as their weakest link

PE100 pipeline projects must be economically designed by engineers who are

familiar with the material and whom have been trained in its proper use

The pipes must be manufactured from a high quality raw material

PE100+ and MS1058 : 2005 Part 1 certified

They should be manufactured in a high quality facility and in full accordance

with national and international standards

They must be joined together by properly trained and certified welding

technicians using equipped that is tested and certified in accordance with the

international standards

The pipelines must be correctly installed in accordance with the standards and

engineering specification by an experienced contractor employing trained staff

The supervision of the works should be undertaken by a suitably trained and

experienced site team



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Thank you for you r at tent ion

Andrew Wedgner [email protected]

KH Lou [email protected]

mailto:[email protected]






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PE100 pipe case studies

Case 1: Water supply to Quomoy Island



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Case 1: Water supply to Quomoy Island,

China

Subsea pipeline from Xiamen water

treatment plant around bay and to

island of Quemoy.

Project by Xiamen water company and

Pipe producer – Chinaust Plastics

Design of two 12.6 km 800mm OD,SDR17 PE pipes

Special railway built to transfer 300m

welded PE pipe strings

BorSafe HE3490-LS PE100 material

specified due to demandinginstallation conditions and need for a

high security of supply

Case 3: Yas island gas distribution network



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Case 3: Yas island gas distribution network,

Abu Dhabi, UAE

This was the largest singlegas distribution network so

far laid in Abu Dhabi

It comprised just over 20 km

of SDR 11 PE100 pipelines

of up to 400 mm OD

The network supplied facilities including the the

Formula 1 race track, the Ferrari World theme park

and the 7 star Yas Island Hotel

The pipes were produced in the UAE by Union Pipe

Industries and Hepworth‘s using BorSafe HE3490-LS

Case 3: Overcoming challenging conditions to



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supply the Tianjin eco-city in China

Tianjin TEDA water company:

―the provision of pipe produced

from high stress crack resistant

BorSafe HE3490-LS-H for thecanal crossing addressed all our

concerns regarding installation

and possible abrasion damage.‖

This 4.5 km 800 mm OD SDR 17 pipeline

was laid in very challenging conditions

including a horizontal directionally drilled

section under the Ji Canal

Due to the conditions the end user

decide to us a High Strength Crack

Resistant (HSCR) PE100 material

Case 4: Borouge 2 seawater cooling pipelines



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Case 4: Borouge 2 seawater cooling pipelines

produced from our own PE100

For Borouge 1 large GRP pipes were

used which failed twice causingemergency shutdowns of the plant.

Borouge decided to use their own

material for the 2nd plant:

• 4 x 2.5km 1600mm dia. 3 bar inletpressure pipelines

• 6 x 2.5km 1600mm dia. gravity outfall

pipelines

All 25 km of 1600mm pipes, which were

all produced in Abu Dhabi by Union

Pipes Industry using Borouge‘s

HE3490-LS material

Documents

Malaysia District Water Eng Meeting Rev A