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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