PE pipe systems for water distribution and transportation networks

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Heather Edwards
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1 PE pipe systems for water distribution and transportation networks MEMBER OF

PE pipe systems for water distribution and transportation networks Water is precious we need to preserve it!

In the poorest communities, millions of people still spend many hours every day collecting water from standpipes, water traders or from polluted water sources.

failure of pipes made from other low quality materials.

In the congested streets of London PE pipes have been used to renovate and replace almost 2,000km of old water pipes with the minimum of disturbance to the daily life of the city.

2 PE pipe systems for water distribution and transportation networks Water is precious we need to preserve it! In many countries in the Middle East, Africa and Asia water is becoming a scarce commodity, a situation that will only get worse due to rising populations and increasing urbanisation. In the poorest communities, millions of people still spend many hours every day collecting water from standpipes, water traders or from polluted water sources. In areas where water distribution networks exist, leakage levels from old worn out infrastructure are often high and water quality is poor due to the internal corrosion of the metallic pipes and failure of pipes made from other low quality materials. Polyethylene (PE) pipes do not corrode and provide the ideal solution for renovation of old systems and installing new ones, even in challenging environments. In the congested streets of London PE pipes have been used to renovate and replace almost 2,000km of old water pipes with the minimum of disturbance to the daily life of the city. Collecting water for the family in the slums of Naivasha, Kenya Benefits of choosing PE pipes for water distribution The 850mm HSCR PE100 pipe strings ready to be installed by Horizontal Directional Drilling (HDD) in New Zealand In addition to being corrosion free, PE pipes are generally welded together, which gives leak free joints that are extremely resistant to the circumferential and axial forces generated by earth movements. This strength also allows engineers to avoid the use of pipeline structures such as thrust blocks and enables the pipes to be installed using a variety of trenchless techniques such as the lining of old water mains and installation under rivers or roads using Horizontal Directional Drilling (HDD). These new technologies enable the new pipes to be installed at a fraction of the cost of conventional open trench installation and with the minimum disturbance to the environment. Over 40 years successful experience of using PE water pipes for distribution networks in Europe has shown that PE pipes to have the lowest leakage rate and whole life cost of any pipeline material. High Stress Crack Resistant PE100 materials Butt welding a strategic water HSCR PE100 pipeline in the mountains of Afghanistan PE100 pipes have been successfully used for water distribution for over 20 years but with the increasing use of trenchless installation and sandless pipe bedding, Borealis and Borouge decided to provide additional security against failure due to Slow Crack Growth (SCG) that can be initiated by severe external scoring and point loads that pipes may experience when installed using these techniques. They therefore developed a range of High Stress Crack Resistant (HSCR) PE100 materials which inhibit the growth of any cracks developed due to higher stresses and notches in the pipe surface. One example of an HSCR PE100 pipe in use is the 2km of 850mm diameter water main produced from BorSafe HE3490-LS-H installed under an area of native forest near Auckland in New Zealand.

Ensuring the quality of the installed PE distribution systems Poor dispersion of carbon black Carbon black agglomeration Poor dispersion and agglomeration using natural PE plus master-batch Specify

materials included in the PE100+ Association Quality List together with a modern single screw extruder and ancillaries.

If a natural PE material is used with a master-batch on a single screw extruder poor dispersion or agglomeration of the additives can occur which will lead to substandard pipe performance.

BorSafe ready-made compounds are easy to extrude and Borouge has a local network of technical service engineers to help you get the best from the material.

3 Ensuring the quality of the installed PE distribution systems Poor dispersion of carbon black Carbon black agglomeration Poor dispersion and agglomeration using natural PE plus master-batch Specify pre-compounded materials for pipe production High quality materials are essential for the production of good quality pipes therefore pipe manufacturers should only use fully certified pre-compounded materials included in the PE100+ Association Quality List together with a modern single screw extruder and ancillaries. This will ensure that all the additives are well dispersed and the products meet the international standards. If a natural PE material is used with a master-batch on a single screw extruder poor dispersion or agglomeration of the additives can occur which will lead to substandard pipe performance. A number of examples have been recorded which have led to premature failures and costly replacements. BorSafe ready-made compounds are easy to extrude and Borouge has a local network of technical service engineers to help you get the best from the material. Specify PE100+ Association Quality Listed materials Borouge can supply a full range of materials from the PE100+ Association Quality List. These are regularly tested by certified independent laboratories to confirm their compliance in the three key properties: 1) Creep Rupture Strength, 2) Stress Crack Resistance and 3) Resistance to Rapid Crack Propagation This ensures that these materials are consistently manufactured to a high quality standard and pipeline engineers can be confident that they will provide a long maintenance free life in service. PE100+ Association Quality List (January 2013) For complete list and more information, visit Extending quality to installation It is equally important that the quality of the welding and installation of the system matches the quality of the products. Therefore the pipe welders should be trained and certified by a recognised independent training institution. There are a number of institutions who offer PE installation welding in each region and for more details please contact the Gulf Plastic Pipe Academy (GPPA) at or your local Borouge Pipe Technical Service representative. Training pipeline welders at the SKZ Training Centre in Dubai

Borouge PE materials for water distribution Standard Pressure Pipe Materials All PE100 and PE80 materials are bimodal and specifically designed for pressure pipe and fitting production to EN

Product Material Type Colour Application BorSafe HE3490-LS PE100 compound Black Extrusion of pressure pipes BorSafe HE3490-IM PE100 compound Black Injection moulding of fittings BorSafe ME3440 PE80

4 Borouge PE materials for water distribution Standard Pressure Pipe Materials All PE100 and PE80 materials are bimodal and specifically designed for pressure pipe and fitting production to EN 12201/ISO 4427 specifications. Compounds that are designated LS are low sag materials ideal for producing large diameter thick walled pipes. Product Material Type Colour Application BorSafe HE3490-LS PE100 compound Black Extrusion of pressure pipes BorSafe HE3490-IM PE100 compound Black Injection moulding of fittings BorSafe ME3440 PE80 compound Black Extrusion of pressure pipes High Stress Crack Resistant Materials High Stress Crack Resistant (HSCR) PE100 compounds are designed to meet all the requirements of EN 12201/ISO 4427 plus the additional security of resistance to crack growth specified in PAS Product Material Type Colour Application BorSafe HE3490-LS-H HSCR PE100 Black Extrusion or co-extrusion of pipes compound for demanding conditions BorSafe HE3494-LS-H HSCR PE100 Dark Blue Extrusion or co-extrusion of water pipes compound for demanding condition Useful websites and references Borouge Borealis PE100+ Association The Gulf Plastic Pipes Academy International Society for Trenchless Technologies Plastics Pipes for Water Supply and Sewage Disposal Lars-Eric Janson, 2003 Development of a New High Performance PE pressure pipe system, Kania, G., Bresser, R. & Salles, C. from design phase to reality No Dig. Rome 2007 Special high quality PE100 pipe materials ensure long service life McGoldrick, J et al. and solve practical end-user problems Wiesbadener Kunststoffrohrtage, 2007 The Use of High Stress Crack Resistant PE Pipes Walton, D. & Murali, M. for Demanding Installation Conditions SAPPMA Conference, 2008 A tough initiation for PE100 in Kuwait s Oil Industry Hayes, P. R. Plastic Pipes XV, Washington 2010 The Development of multilayer pipe constructions Goetzloff, C. Plastics Pipes XIV, Budapest 2008

5 About Borouge Borouge is a leading provider of innovative, value creating plastics solutions. A joint venture between the Abu Dhabi National Oil Company (ADNOC), one of the world s major oil and gas companies, and Austria based Borealis, a leading provider of chemical and innovative plastics solutions, Borouge is a groundbreaking joint venture at the forefront of the next generation of plastics innovation. With its base in the United Arab Emirates and Marketing & Sales head office in Singapore, Borouge employs more than 3,000 people representing over 40 nationalities and serves customers in 50 countries across the Middle East, Asia and Africa. Building on the unique Borstar and Borlink technologies and over 50 years of experience in polyolefins, Borouge provides innovative, sustainable and value creating plastics solutions for infrastructure (pipe systems, and power and communication cables), automotive and advanced packaging applications that address global challenges such as climate change, food protection, access to fresh water, energy conservation, healthcare and waste management. In 2010 Borouge tripled the annual production capacity of its plant in Abu Dhabi to 2 million tonnes, and with further expansion to 4.5 million tonnes in 2014, Borouge and Borealis will have a combined annual production capacity of approximately 8 million tonnes of polyethylene and polypropylene. Borouge is expanding its commercial and logistics network in the Middle East and Asia and investing in its Innovation Centre in Abu Dhabi and R&D Application Centre in Shanghai. Focused on our company mission, Value Creation through Innovation, we ensure that our customers throughout the value chain, around the world, can rely on differentiated products and reliability of supply. Borouge is committed to the principles of sustainability and is a signatory of the chemical industry s Responsible Care Global Charter. Together with Borealis, Borouge is proactively addressing the world s water and sanitation challenges through the Water for the World initiative. Visit and see how we are Shaping the Future with Plastics. Borouge PF BR 314 R EN Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borouge extends no warranties and makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors. Our products are intended for sale to industrial and commercial customers. It is the customer s responsibility to inspect and test our products in order to satisfy himself as to the suitability of the products for the customer s particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred. No statement herein shall be construed as an endorsement of any product or process. No one is authorised to make representations or give warranties or assume any other liabilities on behalf of Borouge except if in writing and signed by a duly authorised Borouge employee. Insofar as products supplied by Borouge are used in conjunction with third party materials, it is the responsibility of the customer to obtain all necessary information relating to the third party materials and ensure that Borouge products when used together with these materials are suitable for the customer s particular purpose. No liability can be accepted in respect of the use of Borouge products in conjunction with other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third party materials. For more information contact: info@borouge.com or visit BorECO, BorSafe and Shaping the Future with Plastics are trademarks of Borealis group. Borstar is a registered trademark of Borealis group. Borouge Pte Ltd 1 George Street #18-01 Singapore Tel: Fax: info@borouge.com

Benefits of using BorSafe HE3490-IM to produce Injection Moulded Fittings

Benefits of using BorSafe HE3490-IM to produce Injection Moulded Fittings MEMBER OF BorSafe HE3490-IM solves problems and reduces costs for fitting manufacturers BorSafe HE3490-IM is the first tailor made