Order of Engineers and Architects Beirut Lebanon Wide applications of plastics By: Mr. Barry Lemon Technical support manager Georg Fischer piping system 1 17.12.2014
Industrial Piping Systems Thermoplastic Pressure Piping Systems for Industrial Applications
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 - 17.12.2014 Lebanon
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 - 17.12.2014 Lebanon
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 - 17.12.2014 Lebanon
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. 6 17.12.2014
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. 7 17.12.2014
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. 8 17.12.2014
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? 9 17.12.2014
Pitting Corrosion Pitting increases flow losses and makes a pipeline increasingly difficult to clean. Oxides may taint the fluid. 10 17.12.2014
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
Applications Effluent Treatment Potable Water Purified Water Water for Injection (WFI) Ultra-pure Water Chemicals at various Concentrations 12
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
Materials for Solvent Cementing PVC-U Unplasticised Polyvinyl Chloride PVC-C Chlorinated Polyvinyl Chloride ABS Acrylonitrile Butadiene Styrene 14
Materials for Fusion Jointing HDPE High Density Polyethylene PP-H Polypropylene Homopolymer PP-n Polypropylene natural PVDF Polyvinylidene Fluoride 15
Chemical Resistance 17
Ultra Violet (UV) Resistance of Thermoplastic Piping Excellent Good Not Resistant 18
Pressure/Temperature Curves 19
Pressure/Temperature Curves 20
Pressure/Temperature Curves 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 - 17.12.2014 Lebanon
Weldable Systems Polyolefine PE (Polyethylene) PP (Polypropylene) PB (Polybutylene) Fluoroplastics PVDF (Polyvinylidenfluoride) Industrial Plastic Piping System - 17.12.2014 Lebanon
Polybutylene (PB) - Instalflex Industrial Plastic Piping System - 17.12.2014 Lebanon
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 0 20 40 60 80 100 120 140 160 180 200 % Material Assembly Bracket and Fixing 25
Jointing Technology 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
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
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
== +GF+ DEKA == PP-N == SDR 11 == = SYGEF Plus= =+GF+ =PVDF= =SDR21 =PN16 =RH5101 =Made in Germany= =211717 1= = SYGEF Plus= =+GF+ =PVDF= =SDR21 =PN16 =RH5101 =Made in Germany= =211717 1= Fusion Jointing Materials, Dimensions 16 20 25 32 40 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 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= =211717 1= Infra Red (IR) Fusion = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN16 =RH5101 =Made in Germany= =211717 1= Bead and Crevice Free (BCF) Fusion = SYGEF Plus= =+GF+ =PVDF-S= =SDR21 =PN16 16 20 25 32 40 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 PE PP-H PP-n SYGEF Plus SYGEF Plus PVDF-S PVDF 30
Installation requirements 31 17.12.2014
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 100 0.20 PVDF 0.12 to 0.18 PB 0.13 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 100 12 x 20 x 0.20 = 48.0mm contraction 33
Installation requirements Fix points, Directional changes 34
Installation requirements Principle of a flexible section 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
Installation requirements Diagram to determine the length of flexible section a 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
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
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 16 + 5 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
Control Loop Controller Transmitter Positioner (Control valve) Pilot valve (ON-OFF actuated valve) Sensor Valve Pipe Installation fitting Industrial Plastic Piping System - 17.12.2014 Lebanon
+GF+ Diaphragm Valve Position indicator pin Lockable handwheel Housing nut Diaphragm holder Compression piece Indication diaphragm material Diaphragm Valve body Industrial Plastic Piping System - 17.12.2014 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 +74 % +128 % (+33%) 20 120 137 271 +126 % +98 % 25 230 175 481 +109 % +175 % 32 341 301 759 +123 % +152 % 40 460 418 1263 +175 % +202 % 50 685 768 1728 +152 % +125 % conventional design +GF+ design Industrial Plastic Piping System - 17.12.2014 Lebanon
44 Any Questions?