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Plastics pipes

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    Session: 3 Best materials for a safe and reliable gas grid

    Plastics pipes A look into the future

    S H Beech - SHB Consulting

    1

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    Summary

    Useof

    plastics

    for

    gas

    distribution

    Essentia requirements

    Fusionwelding

    Multilayerpipes

    Conclusion

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    Why

    use

    plastics?

    ,

    Flexible,resistanttogroundmovement

    Endloadresistantleakfreefusionjoints

    Suppliedin

    lightweight

    coils

    (< 200

    mm

    diameter)reducingjointingfrequency

    Ideall suitedtoNoDi technolo

    Maintenancefree,trackrecordofreliabilityand

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    Plastics

    for

    gas

    distribution Usedsince1960sfor

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    Supplied

    in

    coils

    No-dig technology

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    Essential

    requirements

    RCPand

    slow

    crack

    growth

    resistance

    De ormation e ecto environment

    Jointing/fusionwelding

    characteristics

    StandardsandCodesofPracticepromoting

    hi h ualit

    Costeffective

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    Plastics

    pipes

    industry

    Continualmaterial

    developments

    Manu acturers eve opnewmu ti ayeran

    compositeproducts

    Increasingdiameterrangeforelectrofusionfittings

    ISO/TC138

    and

    CEN

    TC

    155

    are

    very

    active

    in

    develo mentofstandards

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    Harmonisation of Polyethylene Pipe

    Recent advances in materials and extrusion technology are leading toincreased use of large diameter thicker walled pipe. This project was set up

    ec ve

    y t e 1 + ssoc at on to ac eve t e o ow ng o ect ve.

    To develop both short term and long term tests to assess the integrity ofbuttfusion welds in thick walled pipe, to allow the harmonisation and

    optimisation of buttfusion procedures, and to allow machinery, operators andin-field welds to be assessed.

    An exam le of collaboration between the end user manufacturer test laboratories

    d o n t c r a c k u n d e r p r e s s u r e

    and material suppliers)

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    Welded pipe rings

    Cutting test

    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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    Gas

    distribution

    systems

    Source

    feeds

    >

    100

    bar Highpressuregrid,~60to85bar

    Localtransmissionmediumpressure

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    Plasticsforgasdistribution

    CurrentlyplasticsmainlyusedinLPsystem

    Futurepotential

    use

    of

    plastics

    systems?

    Indoors stemsre uireresistancetopermeation,assessrisktofire/damage

    Medium hi h

    ressuresre uires

    stren th

    beyondplasticscurrentlyused

    Multila erandcom ositeconstructionsprovide

    the

    answer

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    Multilayerpipe

    ISO18225

    ML

    pipe

    for

    outdoor

    applications

    Barrierlayerpipeforcontaminatedgroundorto

    eliminatepermeation

    PEpipewithaluminiumcentrelayerforindoor

    applications behaveslikecopperpipe

    Readilyused

    in

    Germany

    and

    the

    Netherlands

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    Multilayerpipe

    Typical

    5

    layer

    pipe PE Aluminium PE

    Adhesivelayersfor

    Fittingsshouldseal

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    Medium/HPPlasticspipes

    Canplasticsmakethenextsteptohigher

    Monolayerpipe

    material

    strength

    limitations

    RTPRe n orce T ermop ast csP pes

    TypicallyPE

    base

    pipe,

    tape

    reinforcement,

    extru e outer ayer

    Aramid(KevlarorTwaron),glass,steelmeshor

    cor AllplasticsbyusingorientedPEtape

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    RTPpipeconstructions

    PE Kevlar tape PE(Courtesy of Soluforce-Pipelife)

    or ente tape (Courtesy of Egeplast GmbH)

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    RTPproperties

    retained Corrosionresistance

    Suppliedincoils limitedto200mmdia.forroadtransport

    joining

    Squeezeoffpossible

    p pescan

    ac eve

    ara ng

    o

    >150bar,50years65C

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    Propertycomparison

    Flexibility Strength

    Steel pipes

    Light

    weight

    Ductility

    Resistance to corrosion Weldability

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    RTPApplications

    Aboveground

    service

    in

    desert

    steel

    failsinafewyears!

    Oilgathering70bar,waterinjection90bar

    forgasdistributionparticularlyin

    Germany

    Pressuresupto42bar

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    RTPDesignforgas

    Takeintoaccountpotentialgaspermeationintoreinforcementlayer

    Noriskofouterlayerblowoffat>42bar/65C

    Alightercheaperconstructioncanbeusedforthispressurerange

    Permeationcanbereducedor

    eliminated RTPnotvulnerabletoRCP wrapped

    tapepreventsaxialcrackgrowth

    Resistantto1100Cjetfirefor6

    minutes Highresistancetodamage

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    Damagetolerance

    Fieldtestswithbackhoehittin ,horizontaldrillin

    Worst

    case

    situation Superficialdamageofoutercover,notaffectingpipe

    Oneextremecasecreateshole(backhoehitspipeverticallyon

    topof

    pipe)

    Similartestsonsteeldamagecoatingwhichmayaffectlongtermperformance

    Failureprobability

    for

    both

    systems

    within

    acceptable

    limits

    (Ref. RTP systems for gas distribution, Wolters et al., 23rd World Gas Conference, 2006)

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    ElectrofusionJointing

    Innersleeve

    EF

    welded

    to

    prevent

    exposure

    of

    fibre

    layer

    to

    gas

    FibrereinforcedexternalsleevewithEFcoil

    Fullendloadresistance

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    Jointing

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    Jointing

    Swa edorcom ressionfittin s

    hydraulically

    pressed

    on

    pipe

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    Jointtests

    Pressuretestsfailinpipe

    Nofailure axialtensiletests

    bar noleakage

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    RTPGastrials

    Date Company Field/Location Application Press/Temp Size Length

    Nov 03 Fahum Gas

    Egypt

    El Fayoum Gas distribution 36 bar/20 C 4 in 380 m

    Apr 04 VNG Berlin Plant Brine gas waste

    line

    5 in 60 m

    Aug 04 Badenwerk

    Gas GmbH

    Buchig-

    Oberacker

    Gas distribution 25 bar/15 C 5 in 4500 m

    Oct 04 Ruhrgas Hannover Gas distribution 25 bar/15 C 4 in 600 m

    Mar 05 SGC Syna SJC-SBC Sour Gas 90 bar/60 C 4 in 6 m

    Aug 05 Shell Brunei Seria ULLG 50 bar/25 C 5 in 18 km

    Aug 05 Shell Syria

    (AFPC)

    Tanak Field Production gas 98 bar/55 C 5 in 11 m

    Oct 05 E.ON Hirschbach Gas 22-42 bar/15 C 4 in 440 m

    ermany

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    StandardsforRTP

    highpressure

    gas

    applications

    (up

    to

    40

    bar)

    APIRP15S,RecommendedPracticefortheQualificationofSpoo a eRein orce P asticLinePipe,pu is e yt eAmericanPetroleumInstitute(API)2006.

    DVGWTechnische

    Regel

    VP

    642

    (2004),

    Faserverstaerkte

    PE

    Rohre(RTP)undzugehoerigeVerbinderfuerGasleitungenmitBetriebsdrueckenueber16bar

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    Costs

    Ref. Aramid reinforced plastic pipes, high strength pipes for gas transportation, D. von Amein,W.Wessing, E.ON Ruhrgas AG

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    Conclusions

    1960sfor

    low

    pressure

    gas

    distribution

    solving

    corrosion

    issuesofmetals(PrimarilyinPE)

    Reliabilityanddurabilityhasbeenproven

    Multilayer

    and

    RTP

    pipe

    systems

    are

    now

    available

    to

    extend

    distribution

    UltimatelyRTPsystemsmaybeconsideredforhighpressure

    pipelines

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    Thanksforyourattention!

    Theauthorwishestothankthefollowing

    forsupportandprovidinginformation:

    PE100+Association

    SoluforcePipelife

    FriatecAG

    EgeplastGmbH

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