Plastic Pipes in the Industry: The right choice! - KRV · Plastic products enable significant savings of energy and greenhouse gas emission (production and use are the most important

Plastic Pipes in the Industry:The right choice!

Legal details / Editor:

Kunststoffrohrverband e.V.Kennedyallee 1-553175 BonnGermany

Phone: +49-(0)2 28 / 9 14 77-0Fax: +49-(0)2 28 / 9 14 77-19

e-mail: [email protected]: http://www.krv.de oder http://www.wipo.krv.de

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Contents

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Introduction Page 4

General requirements for piping systems in the chemical process Page 5 industry (CPI)

The chemical resistance of plastic pipes Page 6

Standardization / Quality assurance / Approval Page 7

Sustainability Page 8

Materials Page 10

Jointing techniques Page 15

Special Requirements of Plastics Page 18

Versatile piping concept Page 19

Examples of applications Page 20

Quo vadis industrial piping? Page 24

The Kunststoffrohrverband e.V. Page 25

Members of industrial pipes group Page 26

During the last 60 years plastics have changed our lives more than we could ever have imagined. A modern car con-structed without any plastics is unthinkable, packaging films prevent our food from spoiling and gas as well as water are conveyed through plastic pipes.

Introduction

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Einleitung Seit nunmehr 60 Jahren bestimmen Kunst-stoffe unseren Alltag. Ein modernes Auto ist ohne Kunststoff undenkbar, Verpa-ckungsfolien schützen unsere Nahrungs-mittel, Kunststoffrohre transportieren Gas und Wasser. Hochleistungsfolien versie-geln Deponien und feinste Kunststofffasern sind die Basis für moderne Sport- und Funktionskleidung. Bild: BMW Amaturentafel Bild: High Voltage Kabel Wesentliche Bedeutung haben die Kunststoffe für die chemische Industrie. Vor ca. 60Jahren wurden die ersten Kunststoffrohre in Frankfurt bei der Fa. Höchst verlegt. Heute spielen Kunst-stoffrohre bei praktisch jedem industriellen Prozess eine maßgebliche Rolle. Grund dafür ist die enorme Vielseitigkeit von Kunststoff-lösungen. Je nach Anwendung werden maßgeschnei-derte Kunststoffrohre eingesetzt. Hohe Chemikalienbe-ständigkeit, ausgereifte Verbindungstechniken und ein umfassender Normungsrahmen garantieren effiziente, ökonomische und vor allem sichere Lösungen. Bilder: Polymerisationsanlage

High voltage cable with functional multilayer sheathing out of plastics installed on the industrialsite “Höchst”. In 2012 PVC-pipes already celebrate their 80 years anniversary.

High proportion of plastics in the automotive industry

Plastic pipes have a high importance in the chemical process industry. About 60 years ago the first plastic pipes were installed on the industrial site “Höchst” in Frankfurt. Today plastic pipes play an important role in virtually every industrial process.

The reason for this is the vast variety of solutions plastic pipes offer because plastic pipes can be adapted for each application. High chemical resistance, advanced jointing techniques and a comprehensive standardisation framework ensure efficient, economical and in particular safe solutions.

Polymerisation plant

High performance geomembranes secure durable sealing of landfills and plastic fibres represent the basis for modern sportswear respectively functional clothing.

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Wet separator out of GRP

“More than 40 years of experience with various plastic pipes and their jointing technology when handling concentrated acids and alkalis in chemical apparatus engineering at Heraeus in Hanau givesus confidence for the future.” (H. Lipp; Technical Maintenance; W.C. Heraeus GmbH, Hanau)

General requirements for piping systems in the chemical process industry (CPI)

The use of plastic piping systems for conveyance of chemicals or well-defined process water-qualities have specific demands on the complete system. Apart from remarkable breadth and depth of the product range it is primarily the chemical resistance of the polymeric material that decides the applicability of a given system. As a

result of this no other segment in plastic piping is offering such a wide range of different polymeric materials. The table summarizes the primary customer requirements.

•Highsafetystandard/emergencyrunningproperties•Chemicalresistance/lowleachout•Legalconformance•Longservicelife/fieldreferences•Systemsolutions•Easymaintenance,repairandinstallation•Economiccost/performanceratio

Regarding the total market of plastic piping systems, industrial piping only represents a small part. However, due to the often very individual and high technical requirements it is more than justified to label this segment as top-end of the market.

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Fertilizer

Basic chemicals (e.g. Chlorine

Alkali – electrolysis)

Pulp & Paper

Disinfection/ Cleaning

Exhaust-gas purification/- treatment

Coating / PicklingPetrochemistry (on / off-shore)

Scrubber / Heat-Exchanger/

Ventilation

Semiconductor-industry

Life-Science,(Food/Pharma), Filtration-devices

Water-Treatment (e.g.VE,UPW,

industrial wastewater)

Requirements for industrial pipe systems

Application areas for plastic pipe systems

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The chemical resistance of plastic pipes

“Today corrosion of polymers can be controlled and managed when using plastic piping systems in contact with aggressive chemicals.” (Dr. P. Bergsjö, Research Leader, “Polymeric Materials Dept.“ Swerea KIMAB, Stockholm Schweden)

The success of plastic piping systems in chemical engineering is due to both the huge variety of materials and the exceptional high level of their chemical resistance. In this respect it needs to be considered that the chemical

resistance of a given plastic piping system is influenced by a variety of factors. The following graph shows the main factors:

Relying on more than 50 years of practical experience and a well developed understanding in researching the basic corrosion mechanism, in most cases it is possible to specify the material compatibility of the particular material reliably. According to current knowledge, plastic piping systems allow for conveying any chemicals at operating temperatures even over 100°C.

When selecting the materials and systems close collabora- tion between the user and the manufacturer is essential. The tables of “chemical resistance” should therefore rather be looked at as a tool for basic orientation.

Chemical resistance

of industrial piping

Mainly set by the chemical structure of the polymer

Extensive possibilities to alter the material by the formulation,processingandinstallation

Reallife:Mixturesofchemicalsimpurities, fluctuating operational conditions

Additionaldynamicstress(installation,vibration, changeofT-Fluctuating,welding,etc.)

Dynamical and discontinuous service

„Ein ausgereiftes und auf internationaler Ebene koordiniertes und stetig aktualisiertes NormenundStandardisierungssystem für Halbzeuge und Rohstoffe ist das Rückgrat jeglicher Qualitätssicherungvon Rohrleitungssystemen auf Kunststoffbasis. Damit leistet das hohe Niveau der Normen auf diesem Gebiet einen sehr großen Beitrag zum erwiesenermaßen sicheren Betrieb der aus diesen Produkten gefertigten Anlagen gerade im Segment des industriellen Anlagenbaus.“ (Hans Telgen, Präsident des Europäischen Kunststoffrohrverbandes (TEPPFA))

Standardization / Quality assurance / Approval

Both formulation as well as processing effect the proper-ties of the components of a given polymer-based piping system substantially. Quality assurance of these products is guaranteed by a well organized body of standards that are continuously updated. German basic standards or European application standards frequently are used as the foundation of many international standards. In particular special approvals that are based on additional guidelines and

supervised by independent testing institutes are well recognized. A noticeable example for this market is the approval issued by the German Institute for Building Technology (DIBT, Berlin). Although this is a national German approval, it has a very high international reputation in terms of guarantee of a high level of quality assurance and documented third-party-supervision.

On a global level the national and European standards are completed by other international Standards (e.g. ISO, ASTM, BS, JS).

Standardization of welding, solvent cement jointing and jointing of plastic pipes in general has been - also globally - regulated successfully for many years by the German welder Association (DVS). The harmonization of the standards with corresponding ones of other countries is a continuous process.

Company standards and special approvals that have been developed over decades complement these standards.

Due to a lack of harmonized European standards a CE- Marking of the plastic piping system components is not possible yet.

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“A standardization system for semi-finished products and raw materials that is operated on an international level and continuously updated is the backbone for any quality assurance for plastic piping systems. Due to this, such a high level of standardization contributes significantly to the proven safe operation of the respective plants especially in the segment of chemical process industry.” (Hans Telgen, President of the European plastic pipe and fitting Association (TEPPFA))

DVS / AWSEuropean

application standards

National basic standards

Internal standards CESpecial approvals (e.g.shipbuilding,

ATEX,FM)

DIBT-Approval Technical rulesStandards / Approvals

DIN CERTCO Guide lines

Sustainability

In Europe, the demand of energy for production, use, recovery and disposal of plastics is about 4.300 million GJ/a The total emissions of greenhouse gas account for about 200 million t/a

It can be concluded that the replacement of plastic products by other materials wherever possible would take about 57 % (1.500-3.300 GJ/a) more energy than it takes today for the whole life cycle of all plastic products

Energy consumption of plastic products in the course of their life cycle (examined case studies which cover 63 % of the total market) and their potential substitutes split into the stages of their life cycle: production, use and waste management. The positive values represent the

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consumption of energy, while negative values illustrate energy saving with low loss of organic materials, avoided primary production (by recycling) and saved generation of electricity and heat (by thermal recovery).

(Source: Die Auswirkungen von Kunststoffen auf Energieverbrauch und Treibhausgasemissionen in Europa“, DENKSTATT GmbH, June 2010)

Plastic products need less energy than alternative products

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Demand in energy for use

Use(lowloss of organic materials)

plastic products alternatives

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Changes in product mass, energy consumption and greenhouse gas emissions, if plastic products were theoretically replaced by alternative materials.

Plastic products enable significant savings of energy and greenhouse gas emission (production and use are the most important areas for savings).

The study above examined the impact of different materials on the total demand of energy of products over entire life cycle (cradle to grave).

The results show that plastic products allow solutions which are resource efficient.

The replacement of plastic products by other materials increases in most cases the energy consumption as well as the emission of greenhouse gases.

From the perspective of their entire life cycle plastic products belong to the most energy efficient materials. Plastic products often enable a reduction of material consumption.

(Source: „Die Auswirkungen von Kunststoffen auf Energieverbrauch und Treibhausgasemissionen in Europa“, DENKSTATT GmbH, June 2010)

Plastic products enabled energy savings of about 2.400 mio GJ/a:

146 million t/a 6.690 Million GJ/a 330 Million t/a

39 Millionen

t/a

4.270 million GJ/a

220 million

t/a

+57 % +61 %

Total mass for equal

functional units

Energy Consumption over entire life cycle

Greenhouse gas emissions over entire life cycle

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Materials

Piping systems made of plastics are tried and tested in industrial applications. They are recognized as an excellent transport system for safety-relevant applications under very

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“Due to its unique chemical resistance combined with ideal thermo-mechanical properties and an attractive cost-benefit ratio, PVC will remain a very important material for industrial piping with interesting growth potential.” (Filipe Constant; CED of SolVin, Brüssel)

Acrylonitrile butadiene styrene (ABS)

ABS is an amorphous thermoplastic which is jointed using adhesive technology. Due to its mechanical properties, its good chemical resistance and its excellent impact strength, even at low temperatures, the material is suitable for a range of applications, especially in refrigeration and air conditioning.

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Relevante Werkstoffe "Aufgrund seiner einzigartigen chemischen Beständigkeit, idealen thermo-mechanischen Ei-genschaften und einem attraktiven Kosten-Nutzen-Verhältnis wird der Werkstoff PVC auch in Zukunft ein sehr bedeutendes Material mit interessantem Wachstumspotential im industriellen Rohrleitungsbau bleiben."

(Filipe CONSTANT; CEO of SolVin, Brüssel) Rohrsysteme aus Kunststoff haben sich in der Industrie bewährt. Sie sind das ideale Transport-system für sicherheitsrelevante Anwendungen unter sehr aggressiven Bedingungen. Die Vielfalt an unterschiedlichen Kunststoffen verfolgt stets das Ziel, für jede Herausforderung die wirt-schaftlichste Lösung zu bieten. Acrylnitril-Butadien-Styrol (ABS) ABS ist ein amorpher Thermoplast, der mittels Klebetechnik verbunden wird. Auf Grund seiner mechanischen Eigenschaften, seiner guten chemischen Widerstandsfähigkeit und seiner hohen Schlagzähigkeit auch im unteren Temperaturanwendungsbereich, eignet sich der Werkstoff für eine Vielzahl von Anwendungen speziell in der Kälte- und Klimatechnik.

Eigenschaften ABS - hohe Steifigkeit mit niedrigem thermischen Längenaus-

dehnung - gute chemische Beständigkeit gegenüber wässrigen Salz-

lösungen, vielen Säuren und Basen - Temperatureinsatz: -40°C bis +70°C - gute Witterungsbeständigkeit auch bei Einwirkung der

kurzwelligen UV-Anteile des Sonnenlichts

Glasfaserverstärkter Kunststoff (GFK) GFK ist ein hochfester Verbundwerkstoff bestehend aus Reaktionsharz, Glasfaser und reinen, nicht quellfähigen Füllstoffen, der besonders bei mechanisch, thermisch oder chemisch hoch beanspruchten Rohrleitungssystemen zum Einsatz kommt. Das Herstellverfahren erlaubt die Kombination der verschiedensten Rohstoffe (Glasfaser, Reaktionsharz, Zuschlagsstoffe) zum fertigen Endprodukt So können GFK-Rohre individuell den spezifischen Anforderungen der An-wendung entsprechend hergestellt werden. Die sehr hohe Steifigkeit und Festigkeit insbesondere bei hohen Temperaturen und unter che-mischem Angriff zeichnen GFK aus. In Verbindung mit dem geringen Gewicht hat der Werkstoff besonders bei großen Nennweiten entscheidende Vorteile. Im Verbund mit thermoplastischen Auskleidungen (z.B. PP oder PVDF) kann die chemische Resistenz zusätzlich erhöht werden.

Eigenschaften GFK - Nennweiten von DN 25 bis DN 4000 - sehr hohe Steifigkeit und Festigkeit - sehr geringe thermische Ausdehnung - sehr gute hydraulisch Ablaufleistung - hohe Druckfestigkeit von PN 1 bis PN 32 - Temperatureinsatz: - 60°C bis +120°C - Widerstand gegen Brandeinwirkung - problemlose Übergänge zu anderen Werkstoffen durch

Sonderbauteile und Spools"

aggressive conditions. The variety of plastics available allows for providing the most efficient solution for any challenge.

- High rigidity with low thermal expansion- Good chemical resistance to aqueous salt solutions, many acids and alkalis- Temperature range: -40°C to +70°C

ABS properties

Glass-fibrereinforcedplastic(GRP)

GRP is a high-strength compound material consisting of reaction resin, glass fibre and pure, non-absorbent fillers which is used primarily in piping systems exposed to substantial mechanical, thermal or chemical stresses. The production process enables a wide range of different raw materials (glass fibre, reaction resin, additives) to be combined into a final product. Thus GRP pipes can be produced individually to match the specific requirements of the application.

GRP is characterized by its excellent rigidity and strength, especially at high temperatures and where aggressive chemicals are used. Because of its low weight, the material has decisive advantages, especially for large dimensions. Chemical resistance can be increased even further in conjunction with thermoplastic lining (e.g. PP or PVDF).

- Excellent strength and rigidity- Very low thermal expansion- Extremely good pressure rating- Temperature range: -60°C to +120°C

GRP properties

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Polyethylene (PE)

PE has excellent processability and very good UV resistance. The good chemical resistance, combined with its robustness and rigidity, makes it suitable for a versatile range of applications.

- Very good pressure rating- Excellent corrosion resistance- Excellent combination of stability and flexibility- Outstanding UV and weather-resistance in black composition- Temperature range: -40°C to +95°C

PE properties

Polypropylene (PP)

PP possesses increased rigidity, especially at higher temperatures, making it ideal for above ground pipework installations. Characteristics include high chemical resistance and good long-term properties to a range of media, even at high temperatures.

- High strength and rigidity- High resistance to stress cracking to acids, alkaline solutions and solvents- Excellent welding properties- Temperature range: 0°C to +95°C

PP properties

Polyvinyl chloride (PVC)

A distinction is made between PVC-U and PVC-C. Both materials have excellent fire characteristics.

Unplasticized PVC-U (U = Unplasticized) is one of the oldest plastics. Its cost-effectiveness and simple thermo- mechanical workability make it a good universal material.

PVC-C is produced by post-chlorination of PVC. This gives it greater temperature resistance compared to PVC-U and in some cases improved chemical resistance.

- Good rigidity with low thermal expansion- Good chemical resistance to acids, alkaline solutions, alcohol, oil and petrol- Temperature range: 0°C to +60°C

PVC-U properties

- Good resistance to mineral acids, salt solutions, various organics, wet chlorine gas and oxidants- Increased heat resistance up to 100°C- Temperature range: 0°C to +95°C

PVC-C properties

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Polyvinylidene fluoride (PVDF)

PVDF is a highly crystalline thermoplastic high-performance plastic. It also displays a high level of rigidity even at high temperatures. The material is outstandingly resistant to a range of organic and inorganic media. PVDF exhibits excellent resistance to solvents and cleaning solutions (particularly good for high-purity substances and fluids).

- Excellent chemical resistance- Physiologically safe (according to BfR and FDA)- Flame resistant- Exceptionally good ageing resistance also under exposure to UV and weather- Temperature range: -30°C to +140°C

PVDF properties

This list only describes some examples of some of the materials available and their properties. Information on other materials and their properties can be obtained from the companies listed on page 26 ff.

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Plastics for any application

Plastics are split into 3 major polymer groups. According to the degree of crosslinking they are distinguished into ther-moplastics, thermosets and elastomers. Thermoplastics and

thermosets are used in various applications of piping sys-tems whereas elastomers are used as seals.

Thermoplastics

The base polymers Polyethylene, Polypropylene and Polyvinylchloride are characterized by longevity, high resistance to corrosion and low weight. Due to these features they are well established in the construction of chemical apparatus. Thermoplastics can be tailored for any use by optimization of their morphology and chemical composition which finally makes them the ideal partner for a multitude of applications. Most important issues always are safety and durability. The ability of the afore mentioned plastics to be jointed by either adhesive bonding or welding provides a high level of safety to the chemical apparatus and piping construction.

The excellent processability of the base polymers is reflected in smooth and glossy surfaces of pipes and fittings, which eventually minimizes the hydraulic resistance. The steadi-ly increasing requirements for plastic piping systems in the field of chemical apparatus construction are the driving

force for continuous development of the base polymers. Due to their high durability at elevated temperatures and their outstanding resistance against chemicals they offer a high benefit and optimal cost performance ratio for the end user.

Polyethylene, Polypropylene and PVC can be optimized for special applications in their chemical composition or downstream treatment (e.g. crosslinking), Polypropylene provides the opportunity to improve properties by nucleation. The thereby generated polymer structure results in a higher rigidity with good impact strength. This benefits the chemical resistance and thus provides a higher safety level for the end user.

Microscopic pictures of PP-H crystal patterns by linearly polarized light (left picture: non nucleated, right picture: nucleated)

A result of nucleation is the low surface roughness and therefore a smooth inner pipe surface – beneficial for hydraulic resistance

Thermosets

Thermosets - which are also called duroplasts - are plastics that cannot be reformed after the initial manu- facturing process. Thermosets are thermally stable polymers hat are three-dimensionally crosslinked via covalent bonds. The three-dimensional crosslinking is the basis for the high temperature resistance, strength and rigidity of thermoset resin systems. For GRP pipe systems the dominant thermo-plasts are Unsaturated Polyester resins and Epoxy resins.

Also other polymers for example Polyurethanes are relevant. Thermosets are made by direct crosslinking of the polymer chains with each other or with the aid of further monomers. The crosslinking process is initialized by either heat irradiation or the aid of chemical additives e.g. Peroxides.

The formed molecular structure is thermally stable and the polymers cannot be molten after curing.

By crosslinking of polymers new characteristics can be created (e.g. high point load and temperature resistance)

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Special plastic formulations

Adapted to your requirements

In contrast to traditional materials, plastics offer a high level of innovation and customization options.

Applications in the chemical process industry often require individual adjustments. Here "customizing" means developing solutions to specific problems.

In areas at risk of explosion, plastics with good intrinsic electric insulation can be adjusted using antistatic or electrically conductive by using special additives.

Adding soot reduces electrical surface resistance.

The results are as follows:

Flame resistance properties are often required in ventilation systems. High oxygen index, materials width and special formulations of PPs and PP-ELs have self-extinguishing properties, PVC and PVDF have this characteristic as standard.

In GRP pipes this is achieved by adding Alusil.

Pipes often need to follow a predefined, multibranched route, passing, avoiding or going underneath obstacles. The media flow can be joined or separated in shaft assemblies and pass through predefined transfer points. Where the combination of standardised pipes and fittings reaches its limits in terms of the fulfilment of individual design specifications, the variability of plastic in terms of forming and design allows the production of special tailored solutions.

In accordance with the planning specifications, individual components or designs such as shaft assemblies or pipe bridges can then be pre-manufactured in the factory.

Special designs- Double-containment pipe system with matching fittings

- Pipes with special formulations, e.g. dimensions and colours or material modifications

- Individually designed special fittings as system components

- Complex designs, e.g. shaft assemblies or distribution systems

Special solutions:

Fire test on a plastic pipe to IMO 753 Standard

Collection unit made of electrically conductive polyethylene

BreakdownofmaterialsbasedonspecificresistanceinaccordancewithBGR132orDINIEC60093

conductive antistatic insulating

Specificresistance[Ohmxcm]10-6 10-3 100 103 106 109 10111012 1015 1018

cooper germanium electrically conductive materials

antistatic materials

standard plastics

− quick replacement, adaptability− design as loose flange and/or fixed flange− applicable for assembling of prefabricated parts− short stub end, gaskets and screws are necessary− removable longitudinally, axial load connection

Flange joints:

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“It is the diversity and long-term experience in polymer welding – gained over decades - in the field of industrial applications that enables a safe jointing of plastic piping. Due to the guidelines of DVS this is guaranteed to be top quality.” (Dr. B. Baudrit; Group-Leader “Polymer jointing”, Southern German Polymer Center, Würzburg)

Jointing techniques

The versatile possibilities for jointing plastic piping systems depend on the choice of material. In designing a plastic pipe system it is therefore important to obtain information about possible jointing techniques and their applicability as early as possible in the planning phase. The choice of the most

appropriate jointing procedure is usually influenced by (the factors) economics, the construction of the components, external and internal influences on the system as well as local conditions. By the following overview some information to the established jointing techniques are given.

− easy welding procedure− simple preparation of the weld− easy handling of the welding equipment− constant quality of the weld− welding bead inside and outside the pipe− axial load connection− covers all pipe dimensions

Butt fusion:

− easy welding procedure− simple preparation of the weld− easy handling of the welding equipment− constant quality of the weld− welding bead inside the pipe− axial load connection− applicable for dimensions up to 160 mm

Socket fusion:

− quick, automatable− smaller weld bead− no direct contact of the heater to the material− axial load connection

IR-butt fusion:

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− easy welding procedure− simple preparation of the weld− easy handling− constant quality of the weld− no welding bead inside the pipe− welding in difficult locations possible− axial load connection− usable for a wide range of dimensions

Electro-fusion:

Laminate connection:

− quick replacement− connection to different materials− thickness and width of the laminate is variable (application of the laminate in layers)

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• Heizelement-Muffenschweißung

− Einfache Handhabung während der Schweißung − Einfache Schweißnahtvorbereitung − Unkomplizierte Bedienung der Schweißgeräte − Gleichbleibende Schweißnahtqualität − Schweißwulst im Inneren der Verbindung − Längskraftschlüssige Verbindung − Schnell, kostengünstig, stabil − Für Dimensionen bis 160 mm geeignet

• Heizwendel-Schweißung − Einfache Handhabung während der Schweißung − Einfache Schweißnahtvorbereitung − Unkomplizierte Bedienung der Schweißgeräte − Gleichbleibende Schweißnahtqualität − Kein Absatz oder Schweißwulst im Inneren − Schweißen an schwerzugänglichen Stellen möglich − Längskraftschlüssige Verbindung − Schnell, kostengünstig, stabil

• Warmgas-Draht-Verschweißung: − Manuell, hoher Erfahrungsfaktor benötigt − Universell / geeignet für beliebige Bauteilgeometrien − Extruder- Schweißung ist ein teilmechanisiertes

Warmgasschweißverfahren − Standardverfahren im Verbundrohrleitungsbau,

Apparatebau (Schächte und Behälter), Rohrleitungsbau (Mantelrohre)

− Längskraftschlüssige Verbindung

• Flanschverbindung: − Schneller Austausch, Anpassbarkeit − Ausführung als Los- oder Festflanschvariante − Gut für Vorfertigungsmontagen − Vorschweißbund, Dichtungen und Schrauben erfor-

derlich − Keine längskraftschlüssige Verbindung (lösbar)

• Verschraubungen und Klemmverbindung: − Schnellverbindungsmöglichkeit − Einfache Montage, Demontage und Wiedermontage − Verarbeitung ohne spezielle Werkzeuge und

Hilfsmittel möglich − Keine längskraftschlüssige Verbindung (lösbar)

• Laminatverbindung:

− Schneller Austausch, Anpassbarkeit − Verbindung mit anderen Werkstoffen − Qualifiziertes Personal − Lagenweiser Aufbau in Stärke und Fläche

− simple and quick assembling on site− preassembled coupling on one side of the pipe− for pipes without sockets possible− axial and non-axial load connections

Mechanical couplers:

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− no bead, high welding factor− limitation on pipe dimensions− up to now restricted for polyolefines and PVDF

BCF fusion jointing:

− manual processing procedure, experience necessary− universal, usuable for any kind of component geometry− extruder welding is partly mechanised hot gas welding procedure− standard procedure in composite pipeline construction, apparatus construction (tanks and vessels), pipeline construction (e.g. casing pipes)− axial load connection

Hot gas welding:

− quick connection possible− simple assembly, dis- and reassembly possible− assembling possible without the need for special tools− pressure bearing connection

Union and compression fittings:

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− easy and simple, no machining necessary− limited with respect to the pipe dimensions− manual processing procedure− use of the correct type of cement required− pressure bearing connection

Solvent Cementing:

Compared to metallic piping systems plastic pipes have a higher sensitivity to time and temperature. In principle, several types of internal and/or external loads can affect a

pipe system. This especially applies to buried pipe systems. Potential types of stresses are outlined below.

Basic requirements for a professionally designed pipe system are good technical knowledge coupled with many years of experience in application and process technology.

Plastic piping systems provide the possibility to use environmentally-friendly, easy to maintain, economic and

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durable pipe systems. In project planning and installation of thermoplastic pipe systems specific material properties (e.g. higher linear compensation) always have to be considered. Calculations are needed to design reliably pipe systems. As illustrated below, the classification of plastic pipe systems is generally determined by the installation.

Special Requirements of Plastics

Installation pre-requisites

Internal and external loads on pipe systems

Internal pressure

Internal overpressure

Internal under-pressure

ExternalInternal (e.g.flowmedium)

Soil load

Chemical influences

Pipe bending Temperature loads

Tensile and compressive

loads

External load

(buried pipe systems)

Traffic load

Groundwater

above ground systems

withlengthcompensation

in buildings

outdoors

withoutlengthlinearcompensation

in buildings

outdoors

withoutanyconsiderablelength compensation

subject to soil loads

subjecttotrafficloads

ingroundwater

withlimitedpossibilitiesfor length change

compensation

in foundations

in ceilings

inwalls

buried systems concrete encased systems

Versatile piping concept

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“Composite pipes with thermoplastic inner liners are indispensable in modern chlorine-alkali eletrolysis, in order to meet the high demands on chemical resistance and economics.” (Dr. S. Pelkonen, Senior Vice President Elektrolysis Division Uhde GmbH)

Except plastic pipe systems there is no category (of pipe systems) that shows a wider range of different piping possibilities in the industrial market.

Concept Jointing technology Typical Diameters (OD/mm) Characteristics

Double containment piping

Solvent cement jointing; butt fusion welding

20-225 (inner pipe) Increased safety due to pipe-in-pipe-concept, leakage control by a vacuum system, visual control (transparent outer PVC pipe) or vacuum measuring

Dual laminates Welding (butt-fusion, rod welding) flanging

25-4000 Increased safety due to pipe-in-pipe-concept. Significant increase in the range of applicability for thermoplastic liners as they are only used as “chemical barrier”. All mechanical load is handled by the GRP-layer

Ventilation pipes Socket jointing in combination with sol-vent cementing and rod / or butt welding

< 800 Frequently the only economic alternative to convey corrosive fumes

Tubes Push-fit-sockets, flaring, screwing,/plug connection, screw joint, customized solutions

< 2 in Coiled tubing; frequently fully fluorinated polymers, are used in the semicon-industry as inner pipes in double-pipe systems

Customized piping Multiple and very individual

Usually < 250 Pipes as semi-finished products; mostly no system-concept required

Thermoplastic (pressure) piping

Welding, solvent cement jointing, flanging

16-4000 Standard in the CPI

Straight GRP pipe Socket jointing, adhesive jointing, laminate jointing, flanging

16-2000 High safety due to pipe-in-pipe possible; variety and adaptation due to combination of resins according to service conditions (T, medium)

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„Plastic pipe systems have improved the sustainability of chlorine plants at many chemical factories at AKZO Nobel.“ (B. Rijpkema; AkzoNobel Engineering & Operational Solutions; Arnheim, Niederlande)

Examples of application

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Leitungssysteme für Prozesskühlwasser Bei einem Wasserge-misch mit Schwefelsäure-gehalt (36%) bei 40°C kommen Rohrsysteme aus PE, PP und PVC zum Einsatz.

Langlebige Komplettlösung für Beizan-lagen Kunststoffrohrsysteme sind für zahlreiche che-mische Anforderungen die richtige Lösung: Salpetersäure und Flusssäure bei 70°C: PP-H Destilliertes Wasser bei 80°C: PP-H Wässrige Schwefelsäure bei 90°C: PVDF Schwefelsäure (95 %): PVC-C, PVC-U Natriumsulfat bei 85°C: PVC-C

Hohe chemische Widerstandsfähigkeit Bei dem Rückgewinnungsprozess von Säurebeize (Salpetersäure 20% und Flusssäure 5%) zur Ober-flächenbehandlung von Metallen gewährleisten Rohrsysteme aus PP-H einen störungsfreien Be-trieb.

Case Studies / Referenzen Kunststoff-Rohrsysteme haben bei AKZO Nobel die Nachhaltigkeit der Chlorfabriken und vieler weiterer chemischer Anlagen verbessert.

(B. Rijpkema; AkzoNobel Engineering & Operational Solutions; Arnheim, Niederlande)

Chemische Prozessindustrie Chemical Process Industry

Piping for process coolantFor water blended with 36 % Sulphur acid and a temperature of 40°C, PE, PP or PVC offer cost effective high performance solutions.

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Chemische Prozessindustrie

Highchemicalresistance

During the reclaiming of pickling acid (Nitric acid 20% and Hydrofluoric acid 5 %) used for surface-treatment of metals, pipe systems made of PP-H ensure an undisturbed operation.

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Chemische Prozessindustrie

Long-term complete solutions for pickling plants

Plastic piping systems are the right solution for a lot of chemical requirements:

Nitric acide and Hydrofluoric acid at 70°C: PP-Hdistilled water at 80°C: PP-HSulphur acid at 90°C : PVDFSulphur acid (95°%) : PVC-C, PVC-USodium Sulphate at 85°C: PVC-C

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Water treatment

Corrosion resistant plastic pipes are the ideal transportation system for water. They reliably fulfill the hygienic requirements and ensure long-lasting durability and high operational safety. Plastic piping systems are used for conditioning of industrial and municipal sewage water,

UltrapurewaterfacilityMaterials PVDF and PP-H; medium: ultrapure water (up to 18 MOhm); IR-welding, polishing grade in a semiconductor factory; usage of diaphragm valves/balanced disc stop valves.

swimming pool devices and desalting plants. Standardized system elements and customized parts afford an adjustment to constructional circumstances.

Recentmaterialsforwatertreatmentfacilities

Ventilation and air conditioning

Ventilation and air conditioning systems made of plastic are low in weight and simple to install. In particular, they excel in chemical resistance and temperature resistance.

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Saferemovalofchemicallycontaminatedwasteair

Refrigeration systems

Pre-insulated PN 10 ABS pipe with jacket pipe in PE (Cool-Fit system); medium: glycol and water mixture; Temps = -8°C to -4°C; working pressure = 3 bar; use in the food industry.

Energy and heat transport

Energyefficientsystemsolutions

Geothermal heat exchangers under warehouses, roads and car parks are capable of cooling process water by between 20°C and 50°C using the outside temperature. Depending on the process and cooling water temperature, the usage period can be up to 4000 hours at full capacity per year. Energy efficiency can be increased by simple pump control and use of environmental controls. Performance figures > 100 achieved. This solution keeps roads, car parks and storage areas free of snow and ice.

Combined with cooling production water, a highly efficient, resource-friendly cooling system consisting of a plastic heat exchanger system results.

Self-extinguishing properties are a prerequisite for use in buildings. PPs and PP-ELs, PVC and PVDF are particularly suitable as materials.

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Powerplantengineering

HighdurabilityinenergypowerplantsPlastic pipes have a proven track record in power plant engineering. They guarantee both long usage times and high operational safety and reduce operating costs. Poly- propylene is used in gas desulphurisation plants. Its outstanding resistance to chemical and abrasive materials

makes other safety systems superfluous. GRP and PE are used in cooling water systems. Especially their low weight for large nominal widths and mechanical long-term stability are clear benefits compared to traditional materials.

Food industry

Based on current legislation, plastic pipes which are in contact with food are known as food accessory products and require approval due to statutory cross-EU regulati-ons. Additional conditions for the inspection determine the status of "Physiological Harmlessness".

Hence the approval of the system components result from specific, complex inspections of finished parts within clearly defined media categories. The use of plastic pipes sets demanding requirements in terms of the material, connection methods and system components. Some of the well-known plastics have already established themselves in this market as a cost-effective, sustainable alternative to stainless steel.

Use of food-approved PVC pipe systems in the vinegar and preserves industry (here: 25 % glacial acetic acid at T = 15°C)

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Although the segment of industrial piping is still regarded as a comparatively small market, polymer piping systems are steadily gaining importance. This is due to high level of innovation in the field of semi-finished products and the compounding of polymers. One example for this is the trend to increase the pressure-performance of polymer pipes. To achieve this there are various concepts in which multilayer-approach, application of oriented layers retaining the same polymer and the use of innovative copolymers or fillers are

What does the future hold?

“Especially the segment of industrial piping is predestinated for polymers to show their high level of adaptability and versatility to their best advantage. The optimized use of these materials in such a demanding environment requires a steady development of their formulations following the actual state of research. Keeping this maintained, polymers will comply with all requirements placed in terms of performance of the material or components – not only initially but over the entire duration of use.”

(Prof. Dr.Matthias Rehahn; Head of German Polymer Institute, Darmstadt)

important trends. Topics such as “functional coating” and “nanotechnology” will contribute to the development of very interesting new products in this industry. Regarding pipe jointing the butt fusion welding of PVC-U and C-PVC is currently establishing as an alternative for traditional adhesive technology and laminate jointing. The significantly increased commitment to consolidate and further develop the knowledge of polymer corrosion has already been mentioned elsewhere.

Kunststoffrohrverbande.V.,anAssociationoftheGermanPlasticPipeIndustry, Is the Key Contact for ExpertsKunststoffrohrverband e.V. (KRV) is the trade association of the German plastic pipe industry and is headquartered in Bonn, Germany. It is the lobby and sounding board of the industry and deals with technical/ scientific, economic, and ecological issues. Among the members of the association are globally renowned raw material manufacturers and virtually all important producers of plastic pipes and fittings in Germany.

KRV represents the coordination and information centre for its member companies and, at the same time, is a competent point of contact for professionals. The association cooperates intensively with institutions from the fields of regulation, application, science, material testing, and further partners in the value chain of plastic pipes. With its member companies, the association sets the benchmark in the standardisation and committee work, in terms of quality, security, comfort, and quality of life. As institution across manufacturers and across products, KRV is a valuable contact partner for politics.

The plastic pipe industry, its materials, pipes, assembly and laying techniques are subject to constant improvement. The raw materials, pipe and manhole systems made of plastics have established themselves in all market segments such as the gas and drinking water supply, sewage networks, in the multifaceted offerings of the building equipment and services engineering, in the field of communication, environmental protection, refurbishment, agriculture, and in many industrial areas of application. Today, a world without plastic pipes is no longer imaginable.

With its four application-based sections Utilities, Sewer, Building Equipment, and Industrial Pipes, two central committees with cross-functional tasks, and a state-of-the-art infrastructure in the fields of technology and IT, the Association of the Plastic Pipe Industry is well positioned for future market and product trends. Thus, it is able to respond in a quick and adaptive way to the advanced Europe- anisation and globalisation and to changing and new tasks.

A half-day training session named “Kunststoffrohre in der Industrie: Die richtige Wahl!” (“Plastic pipes in the industry: the right choice!”), set up by the Industry Pipes section and KRV provides at changing locations during the autumn of every year, the attendees with interesting speeches from the in-dustry pipe field. For more information, please visit the website of KRV: http://www.krv.de.

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Members of industrial pipes group

AkathermFIPGmbH Web:http://www.akatherm-fip.de

AmitechGermanyGmbH Web:http://www.amitech-germany.de

BänningerKunststoff-ProdukteGmbH Web:http://www.baenninger.de

BorealisPolymereGmbH Web:http://www.borealisgroup.com

GeorgFischerGmbHWeb:http://www.georgfischer.de

GeorgFischerDEKAGmbH Web:http://www.piping.georgfischer.com

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GERODURMPMKunststoff-verarbeitungGmbH& Co.KG Web:http://www.gerodur.de/

LyondellBasellWeb:http://www.lyondellbasell.com

Sabic EuropeWeb:http://www.sabic.com

SIMONA AGWeb:http://www.simona.de

SolVinGmbH&Co.KGWeb:http://www.solvinpvc.com

WestfälischeKunststoffTechnikGmbHWeb:http://www.wkt-online.de/

Kunststoffrohrverband e.V.Kennedyallee 1-553175 BonnGermany

Phone: +49-(0)2 28 / 9 14 77-0Fax: +49-(0)2 28 / 9 14 77-19

e-mail: [email protected]: http://www.krv.de oder http://www.wipo.krv.de

Documents

Plastic Pipes in the Industry: The right choice! - KRV · Plastic products enable significant savings of energy and greenhouse gas emission (production and use are the most important