Wide applications of plastics

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Godfrey Baldwin
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1 Order of Engineers and Architects Beirut Lebanon Wide applications of plastics By: Mr. Barry Lemon Technical support manager Georg Fischer piping system

2 Industrial Piping Systems Thermoplastic Pressure Piping Systems for Industrial Applications

distribution Water extraction and treatment Waste water

3 From source to point of use Wherever you are positioned within the water cycle Water usage and consumption Water distribution Water extraction and treatment Waste water treatment & reuse Industrial Plastic Piping System Lebanon

4 Our solutions From water extraction and treatment Sea water extraction and desalination treatment PE Piping Chlorine Analyzer System Actuated Ball Valve and many more! Industrial Plastic Piping System Lebanon

5 Our solutions to water treatment and recycling Waste water treatment facility 3-Way Ball Valve Pneumatic Diaphragm Valve 2270 Ultrasonic Level Sensor & 2260 Ultrasonic Level Transmitter and many more! Industrial Plastic Piping System Lebanon

6 What advantages do we bring with plastics? Little or No corrosion with Plastics. Plastics generally much lighter in weight. Smoother bores mean better flow rates. No Problems with Lime scale in water pipes. Low maintenance costs No painting

7 Tubing Blockage due to scaling Imagine the loss of performance in this pipe before it was fully blocked. Often you can chemically remove scaling but your process must be stopped first. Chemicals to do this also cost money

8 Build up of Sediments in a Metal Pipe Smooth internal surfaces of thermoplastic pipelines discourage the building of thick sediment layers. Using certain materials it is possible to deform the pipe to break away this sediment

9 Tubing blockage due to corrosion debris When a pipe corrodes the material must go somewhere. Buy a d110 pipe to use as a d63! If any of this material breaks off what damage will it do to your valves, pumps and flow monitoring equipment?

10 Pitting Corrosion Pitting increases flow losses and makes a pipeline increasingly difficult to clean. Oxides may taint the fluid

11 Market Segments and Target Groups Automotive Battery Manufacturing Biotechnology Bromine Ceramics Chemicals Electronics Food & Beverages Hospitals Metal Surface Treatment Metal Recovering Metal Refining Optical Industry Paints Pulp & Paper Pharmaceuticals Photo & Film Sugar Swimming Pools Textiles 11

12 Applications Effluent Treatment Potable Water Purified Water Water for Injection (WFI) Ultra-pure Water Chemicals at various Concentrations 12

13 Selection Criteria 1. Piping Material 2. Chemical Resistance 3. Pressure/Temperature Limitations 4. Product Range - Pipe, Fittings, Valves, Monitoring Equipment, Size Range 5. Safety and Environmental Aspects 6. Expected Life Span 7. Installed Cost, Maintenance 13

14 Materials for Solvent Cementing PVC-U Unplasticised Polyvinyl Chloride PVC-C Chlorinated Polyvinyl Chloride ABS Acrylonitrile Butadiene Styrene 14

15 Materials for Fusion Jointing HDPE High Density Polyethylene PP-H Polypropylene Homopolymer PP-n Polypropylene natural PVDF Polyvinylidene Fluoride 15

16 Chemical Resistance 17

17 Ultra Violet (UV) Resistance of Thermoplastic Piping Excellent Good Not Resistant 18

18 Pressure/Temperature Curves 19

19 Pressure/Temperature Curves 20

20 Pressure/Temperature Curves 21

(Polyvinylchloride, unplasticized) PVC-C

21 Overview GF Piping Materials Solvent Cemented Systems: PVC-U (Polyvinylchloride, unplasticized) PVC-C (Polyvinylchloride, chlorinated) ABS (Acrylnitrile-Butadien- Styrene) Fusion Welded Systems: PE (Polyethylene) PP (Polypropylene) PB (Polybutylene) PVDF (Polyvinylidendifluoride) Industrial Plastic Piping System Lebanon

22 Weldable Systems Polyolefine PE (Polyethylene) PP (Polypropylene) PB (Polybutylene) Fluoroplastics PVDF (Polyvinylidenfluoride) Industrial Plastic Piping System Lebanon

23 Polybutylene (PB) - Instalflex Industrial Plastic Piping System Lebanon

24 Cost Comparison for a Complete Piping Installation PTFE Lined Steel Rubber Lined Steel Stainless Steel PVDF Polypropylene ABS PVC-U Epoxy Clad PVC-U Epoxy Clad PP % Material Assembly Bracket and Fixing 25

25 Jointing Technology 26

26 Jointing Methods Solvent Cementing Fusion Jointing Socket Butt IR-Plus (Infra Red) BCF-Plus (Bead & Crevice Free) Electrofusion PVC-U, PVC-C, ABS PP-H, PE, PVDF PP-H, PP-n, PE, PVDF PP-H, PP-n, PVDF, PVDF-HP PP-n, PVDF, PVDF-HP PE 27

27 Factors Influencing the Quality of Jointing in Thermoplastic Piping Systems Manufacturer, 5% Raw Material Injection moulding Assembly Cleanliness Product design Packaging Influenced by: Production control Batch control Quality control Installer, 95 % Work site conditions Personnel qualification Personnel training Pipe and fitting tolerances Joint preparation Equipment maintenance Power source Joint contamination Ambient temperature Jointing procedure Influenced by: Site control? 28

28 Fusion Jointing Basic facts Fusion Parameters Temperature Melting of material Molecular chains are made moveable Pressure Molecular chains pressed together Time Depending on: Wall thickness Melt Flow Index Thermal conductivity Structure of the material 29

29 == +GF+ DEKA == PP-N == SDR 11 == = SYGEF Plus= =+GF+ =PVDF= =SDR21 =PN16 =RH5101 =Made in Germany= = = = SYGEF Plus= =+GF+ =PVDF= =SDR21 =PN16 =RH5101 =Made in Germany= = = Fusion Jointing Materials, Dimensions Socket Fusion = SYGEF Plus= =+GF+ =PVDF= =SDR21 =PN16 +GF+ DEKA == PP-N == SDR 11 == == = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN16 Butt Fusion == +GF+ DEKA == PP-N == SDR 11 == = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN16 =RH5101 =Made in Germany= = = Infra Red (IR) Fusion = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN16 =RH5101 =Made in Germany= = = Bead and Crevice Free (BCF) Fusion = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN PE PP-H PP-n SYGEF Plus SYGEF Plus PVDF-S PVDF 30

30 Installation requirements

31 Installation requirements Expansion and contraction Calculated using the coefficient of linear expansion (δ) given in millimetres per metres/degrees Centigrade Material mm/m/ C PVC-U 0.08 PVC-C 0.07 ABS 0.10 PP 0.15 PE PVDF 0.12 to 0.18 PB

32 Installation requirements Example calculations Material PVC-U PE 100 Pipe Length 8 metres 12 metres Installation Temp. 25 C 25 C Working Temp. 40 C 5 C Temperature difference + 15 C - 20 C L = L * T * δ PVC-U 8 x 15 x 0.08 = 9.6mm expansion PE x 20 x 0.20 = 48.0mm contraction 33

33 Installation requirements Fix points, Directional changes 34

34 Installation requirements Principle of a flexible section 35

35 Installation requirements Calculating the length of flexible section a Data required:- Maximum change of L from the 0 position at time of installation Pipe OD (d) To calculate the length a use the following formula:- (a,d and L in mm) 36

36 Installation requirements Diagram to determine the length of flexible section a 37

37 Installation requirements Supporting plastic piping The distance between supports depends on: Type of plastic material Pipe size Working Temperature Specific Gravity of medium transported Horizontal or vertical piping 38

38 Installation requirements Inspection prior to testing Specific components Jointing technique Equipment and tools used Visual inspection of joints Provisions made for expansion and contraction Fix points Pipe bracketing and supports 39

39 Installation requirements Pressure testing Medium: Liquid normally water PN 10: PN x 1.5 = 15 bar > PN 10: Design pressure + 5 bar i.e. PN bar = 21 bar Solvent cement joints Test pressure 1 bar per hour waiting time after completion of the last joint Fusion joints Full test pressure after complete cooling of the last joint Leaky joints have to be cut out and must be replaced 40

40 Control Loop Controller Transmitter Positioner (Control valve) Pilot valve (ON-OFF actuated valve) Sensor Valve Pipe Installation fitting Industrial Plastic Piping System Lebanon

41 +GF+ Diaphragm Valve Position indicator pin Lockable handwheel Housing nut Diaphragm holder Compression piece Indication diaphragm material Diaphragm Valve body Industrial Plastic Piping System Lebanon

Flow Rates over 100% improved DN Kv today [l/min @ P = 1bar] Kv competitor [l/min @ P = 1bar] Kv new valve [l/min @ P = 1bar] Improvement - current valve Improvement - competitor 15 72 56 (94) 125

42 Flow Rates over 100% improved DN Kv today P = 1bar] Kv competitor P = 1bar] Kv new valve P = 1bar] Improvement - current valve Improvement - competitor (94) % +128 % (+33%) % +98 % % +175 % % +152 % % +202 % % +125 % conventional design +GF+ design Industrial Plastic Piping System Lebanon

43 44 Any Questions?

Thermoplastic Piping and Ozone Applications Joe Poniatowski AALSO 09 Seattle

Thermoplastic Piping and Ozone Applications Joe Poniatowski AALSO 09 Seattle YES Asahi America sells pipe too!! Thermoplastic Piping Systems Industrial/Environmental Proline C.G. PVDF E-CTFE Halar Air