Polyolefin materials in industrial pipe applications

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Design of polyolefin pipesForburiedwaterandgasdistributionsystemsitisnormaltodesignPEandPPpipelinesforoperationat20°CbutpolyolefinpipelinesareabletooperateathighertemperaturesandguidelinesaregivenintherelevantstandardssuchasISO4427andDIN8077(seeTable1).HoweverthesestandardstendtobeconservativeastheyhavetocoverawiderangeofmaterialsandrigoroustestinghasshownthatmodernmaterialsperformsignificantlybetteranditisrecommendedthatdesignerscontactBorougetoobtainthelatestinformation.

Polyolefin materials in industrial pipe applications

• Seawaterintakeandoutfallpipes• Waterinjectionlines• Treatedsewagepumpingmain• Oilflowlines• Rawwaterpumpingmain

• Collectingandtransportingcoalseamgas• Dredgingpipeline• Pre-insulateddistrictcoolingandheatingpipes• Slurrytransportationinmines• Factorycompressedairlines

Polyolefin(PO)pipelinesarewellknowntoutilitycompaniesthroughouttheworldwheretheyareusedforwaterandgasdistribution,andforsewageandwastewaterdisposal.Therearenowalsoagrowingnumberofsuccessfulexamplesofpolypropylene(PP)andpolyethylene(PE)pipesbeingusedinindustrialandminingapplications.InmostcasesthePEandPPpipelinesarereplacingmetallicsystemsowingtotheirsuperiorresistancetocorrosion,abrasionandchemicalattack.Thisbrochureprovidesinformationonthepropertiesofthesematerialsandshowssomeofthesuccessstoriesfromaroundtheworld.

Some typical applications for PO pipes in the industrial sector are listed below:

Abrasion resistance of polyolefin pipesPolyolefinmaterialshaveanexceptionalabrasion resistancecompared tootherpipematerials.Comparedtosteel,thewearrateofPEis4-6timeslower,whichiswhyPEhasreplacedmetalpipesforminetailingslurrylines.

Acomparisonwithothernon-metallicmaterialssuchasasbestoscement,GRPandclaypipesusingtheDarmstadtmethod(EN295)isshowninGraph1ontheright.ClearlyPEandPPpipesoutperformallthealternativepipematerials.

Corrosion and chemical resistance of polyolefin pipes Corrosion which is the Achilles heel of metallic pipes - it is estimated that upto3%of theGDPofWesternEuropean countries is lost annually in corrosiondamage. In most situations corrosion is not an issue for polyolefin pipes andevenseawaterposesnoproblems.Thismakesthemidealforsubmarineoutfallpipelinesandseawaterintakepipelines.

PEandPParebothhighlyresistanttochemicalsandotheraggressivemedia(refertoISO/TR10358).Indeedacidicoralkalinebasedindustrialsolutions,hydrocarbonbasedfuels,detergentsandothercleaningsolutionsarestored,transportedandsoldinpipes,vesselsorpackagingmadeofpolyolefinmaterials.PPpipelinesareparticularlyresistanttoacidsandcanoperateuptotemperaturesof80-90°C.

Max. operating pressure for Max. operating pressure for SDR 11 pipe – 50 years/10 years* SDR 11 pipe – 50 years/10 years*

Temp PE100 PP-H PP-R Temp PE100 PP-H PP-R°C ISO4427 DIN8077 DIN8077 °C IS04427 DIN8077 DIN8077

20 16bar 12.4bar 15.4bar 60 NA 7.4bar 7.7bar

30 13.9bar 10.5bar 13.0bar 70 NA 4.8bar 5.1bar

40 11.8bar 10.0bar 11.0bar 80 NA 4.7bar* 4.8bar*

50 10.4bar* 8.3bar 9.2bar 95 NA 2.6bar* 2.6bar*

Note: - Design lifetime 50 years except where marked with an asterisk where it is a 10 year lifetime - For critical pipelines laid above ground we recommend the use of an additional 0.8 design factor

Table 1: Typical operating limits for polyolefin materials

Average abrasion (am in mm)

2,0

1,5

1,0

0,5

0,25

00 50 100 150 200 250 300 350 400 450 n in 1000

Cement pipe

MC-DUR linedcement pipe GRP pipe

Clay pipe

PVC-pipe

PP or HDPE pipe

Number of load cycles (n in 1000)

Graph 1: Abrasion resistance of different pipe materials as measured in the Darmstadt test

Some examples of polyolefin industrial pipes from around the world

Kaolin slurry transportation in Cape Town, South AfricaPE100pipelinetransportingkaolinslurryat16barpressureinstalledin1996.Duringthefirstfiveyearsofoperationthepipelinewallwasmonitoredregularlybutshowednosignificantlossofwallthickness.

Process water at 80°C in Donauchemie, AustriaBetaPP-Hpipestransportingprocesswaterat80°CinachemicalplantinAustria.Installedinthe1980sthe1600mmdiameterpipelinewasthelargestPPpipelineofitsday.Inplacesthepipeisinstalledtoadepthof5mandisstilloperating.

Acids and abrasive slurries in Hindustan Zinc, IndiaBetaPP-Hpipesusedtotransportabrasiveslurriesandacidsattemperaturesof50-90°CintheirplantinIndia.Aswellasresistingtheabrasionitisimportantthatthepipesaretoughenough to withstand the removal of pipeline blockages. Trials using alternative materialsshowedthataswellasmeetingtheserequirementsBetaPP-Hwasalso18%lowerinfullyinstalledcostcomparedtoaGRPsystemand40%lowerthanaCPVCsystem.

Large diameter sea outfall for a new refinery in Abu Dhabi, UAEThelargediameterseaoutfallforthecoolingwaterofanewrefineryinAbuDhabihasbeenconstructed using the latest spiral winding technology and high stiffness BorECO BA212Epolypropylene from Borouge. The external pipe profile was filled with grout to reducebuoyancyandthenthe3metrediameterpipeswerebuttweldedtogethertoform300metrelongstringsreadyforinstallation.ThissamespiralwindingtechnologyofPEandPPmaterialscanbeusedtoproducetanksandsilosforstoringindustrialchemicalsandprocessmaterials.

Lining a water injection pipeline in KuwaitInternalcorrosionofsteelpipeisamajorproblemformanyoilandgascompanies,andanalternativetoregularreplacementofthesepipelinesistouse“close-fit”internalliningwithPE,whichwillextendthelifeofthepipeline.TheKuwaitOilCompanychoosestotestthisoptionandforhighersecurityspecifiedhighstresscrackresistantBorSafeHE3490-LS-Htoprotectsomeoftheirwaterinjectionlines.ThePEpipelengthswereweldedandpressuretested and then inserted into the steel pipe using “Swagelining™” technology. The linedsectionofpipewasthenputbackintoservicesothattheperformancecouldbemonitoredandcomparedtounlinedsections.

Acids and abrasive slurries, Hindustan Zinc, India

Lining a water injection pipeline, Kuwait

Large diameter sea outfall for a new refinery, Abu Dhabi, UAE

Sea water cooling pipes in Abu Dhabi, UAE

Hamersley Mine, Australia

Process water across the desert in Paraburdo, AustraliaPE100pipetransportingindustrialwatertoHamersleyironoremine58kmacrossthedesert.The500mmdiameterpipelinewasinstalledin1995andisstillrunningsmoothly.

Crude oil transportation pipes in Sim Sim, OmanPE100pipetransportingwater-crudeoilmixtureat50°Cand10barpressureacrossthedesert.Installedin1997toreplacesteelpipeswhichwerefailingafteronlytwoyears,thesepipesarestilloperatingandrecenttestsconfirmthattheyarecapableofcontinuingformanyyears.

Sea water cooling pipes in Abu Dhabi, UAEPE100 pipes transporting sea water for cooling the new Borouge petrochemical plant atRuwais.Thenetworkcomprisesof1600mmdiameter6barpressureinletpipelinesand6of1600mmdiametergravityoutletpipelines.TheinitialBorougeplantusedlargediameterGRPpipesbutsincethesesufferedfromanumberoffailurestheyhavebeenreplacedbyPE100pipesinthenewplant.

Firewater main renovation in Stenungsund, SwedenPE100wasusedforrenovatingthe40yearoldsteelfiremainsattheBorealispolyethyleneplant inStenungsund,Sweden.Partof thepipelinewasreplacedbyopencutandpartby“pipebursting”theoldpipeline.

Some useful web sites and references

Borouge www.borouge.com

Borealis www.borealisgroup.com/pipe

PE100+Association www.pe100plus.net

TheGulfPlasticPipesAcademy www.yourppa.org

PlasticsPipesforWaterSupplyandSewageDisposal Lars-EricJanson,2003

ThePotentialofPolyolefinsinIndustrialApplications Ettinger,V.,DubaiPlastPro,2002

EngineeringPropertiesofPolyethylene TR-35,PlasticsPipeInstitute,1997

Materials for Industrial applications

PE GradesBorSafe HE3490-LS ThisisaPE100pressurepipecompoundprovidinganexcellentbalanceofproductionandenduseproperties.

BorSafe HE3490-LS-HThisPE100pressurepipecompoundhasexceptionalresistance

tostresscrackingmakingthepipelessvulnerabletofailureduetoinstallationdamageorpointloads.

BorSafe HE3490-IMThisisaPE100compoundwithimprovedflowproperties,whichmakesitidealfortheproductionofinjectionmouldedfittings.

PP GradesBeta(b) – PP BE60-7032 Auniquebnucleatedgradewithafinehighlycrystallinestructurewhichexhibitshigherimpactstrengththroughoutthecompleteoperationaltemperaturerange0°Cto95°Cmakingittheidealmaterialforindustrialpipesandfabricatedcomponentswhicharetransportinghazardousfluids.

RA130EThisisahighmolecularweight,lowmeltflowratepolypropylenerandom(PP-R)material,whichisidealforhightemperatureindustrialpipeandfittingapplications.

Alfa(a) – BE50 and BE50-7032 Ahighstiffnessanucleatedpolypropylenehomopolymerthatisideallysuitedfortheproductionofnonpressurepipesandsheets.

BorECO BA212EThisisahighmodulusblockcopolymerpolypropylene(PP-BHM)materialspecificallydesignedforthecosteffectiveproductionofsolidandstructuralwallnon-pressurepipesandfittings.

BorECO BA415EThisisanintermediatestiffnessPP-Bmaterialwithexcellentprocessingperformancewhichisidealfortwinwallpipeandfittingproduction.

Commercial Reference Material Type Colour Application

Beta(b)–PPBE60-7032 PP-H Grey Pressurepipesandfittings

RA130E PP-R Natural Pressurepipesandfittings

Alfa(a)BE50-7032 PP-H Grey Nonpressurepipes,fittingsandsheets

BorECOBA212E PP-BHM Natural Nonpressurepipes,fittingsandsheets

BorECOBA415E PP-B Natural Nonpressurepipes,fittingsandsheets

Commercial Reference Material Type Colour Application

BorSafeHE3490-LS PE100 Black Pipeinsizes63–2500mm

BorSafeHE3490-LS-H PE100HSCR Black Pipesforthetoughestconditions

BorSafeHE3490-IM PE100Highflow Black Injectionmouldedfittingsandsheets

Read these case stories where polyolefin materials have provided a durable solution• Corrosion resistant• High resistance to acids and other chemicals• Wide operating temperature range up to 95°C • Fusion welded leak-proof jointing

About Borouge

Borouge is a leading provider of innovative, value creating plastics solutions. A joint venture between

the Abu Dhabi National Oil Company (ADNOC), one of the world’s major oil and gas companies, and

Austria based Borealis, a leading provider of chemical and innovative plastics solutions; Borouge is a

groundbreakinginternationalpartnershipattheforefrontofthenextgenerationofplasticsinnovation.

With its base in the United Arab Emirates and Marketing & Sales head office in Singapore, Borouge

employsapproximately1,700people representingmore than40nationalitiesandservingcustomers in

morethan50countriesacrosstheMiddleEast,Asia-Pacific,Indiansub-continentandAfrica.

BuildingonBorealis’uniqueBorstar®technologyandexperience inpolyolefinsformorethan50years,

Borougeprovidesinnovative,valuecreatingplasticssolutionsforinfrastructure(pipesystems,andpower

andcommunicationcables),automotivesandadvancedpackaging.

In 2010 Borouge tripled its annual production capacity in Abu Dhabi to 2 million tonnes and together

with Borealis has an annual manufacturing capacity of over 5.4 million tonnes of polyethylene and

polypropylene.ThecurrentBorouge3expansionprojectwillbecompletedattheendof2013resulting

inanadditionalcapacityof2.5milliontonnesperyear(t/y)beingfullyoperationalbymid-2014.Borougeis

alsoinvestinginplantsandlogisticshubsinAsiaandanInnovationCentreinAbuDhabi.Focusedonour

companymission,Value Creation through Innovation,weensurethatourcustomersthroughoutthevalue

chain,aroundtheworld,canalwaysrelyonsuperiorproductsandsecurityofsupply.

Borouge is committed to the principles of Responsible Care® and together with Borealis proactively

contributestowardsaddressingtheworld’swaterandsanitationchallengesthroughtheirWaterfor the

World™initiative.

Visitwww.borouge.comandseehowweareShapingtheFuturewithPlastics.

Disclaimer Theinformationcontainedhereinistoourknowledgeaccurateandreliableasofthedateof publication. Borouge extends no warranties and makes no representations as to the accuracyorcompletenessof the informationcontainedherein, andassumesno responsibility regarding theconsequencesof itsuseor foranyprintingerrors.Ourproductsare intended forsale to industrialand commercial customers. It is the customer’s responsibility to inspect and test our products inordertosatisfyhimselfastothesuitabilityoftheproductsforthecustomer’sparticularpurpose.Thecustomerisalsoresponsiblefortheappropriate,safeandlegaluse,processingandhandlingofourproducts.Nothinghereinshallconstituteanywarranty(expressorimplied,ofmerchantability,fitnessforaparticularpurpose,compliancewithperformanceindicators,conformitytosamplesormodels,non-infringementorotherwise),norisprotectionfromanylaworpatenttobeinferred.Nostatement

hereinshallbeconstruedasanendorsementofanyproductorprocess.Nooneisauthorisedtomakerepresentationsorgivewarrantiesorassumeanyother liabilitiesonbehalfofBorougeexcept if inwritingandsignedbyadulyauthorisedBorougeemployee.InsofarasproductssuppliedbyBorougeareusedinconjunctionwiththirdpartymaterials,itistheresponsibilityofthecustomertoobtainallnecessary informationrelatingtothethirdpartymaterialsandensurethatBorougeproductswhenused together with these materials are suitable for the customer’s particular purpose. No liabilitycanbeacceptedinrespectoftheuseofBorougeproductsinconjunctionwithothermaterials.Theinformationcontainedhereinrelatesexclusivelytoourproductswhennotusedinconjunctionwithanythirdpartymaterials.

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