Development of a new high performance PE pressure pipe system, from design phase to reality
Nov 29, 2007
Since the introduction of the first systems more than 40 years ago, PE raw material producers and pipe producers have continuously joined their efforts to propose better and better pressure pipe solutions to the end-users and installers. The development of modern installation techniques, in particular trenchless technologies, has created a need for improved systems, with enhanced insensitivity to installation conditions.
1st Generation HDPE | 2nd Generation HDPE | 3rd Generation HDPE | 3rd Generation HDPE | |
---|---|---|---|---|
Pipe since installed | 1965 | 1975 | 1990 | 1990 |
Classification | PE63 | PE80 | PE80 | PE100 |
Design stress | 5.0 MPa | 6.3 MPa | 6.3 MPa | 8.0 MPa |
Stage II knee point 80°C | 100-300 H | 1000-3000 | >10 000 | >10 000 |
Notch test, 4,6 Mpa/80°C | 10 | 100-200 | >1000 | >1000 |
Rapid crack propagation/Pc110SDR11 | <3 bar | <3 bar | >10 bar | >10 bar |
Lot of modern techniques (pipe bursting, directional drilling, relining, etc…) have been developed combining faster and cheaper installation (up to 60% less than traditional type of installation), with also minimize disturbance to the neighbourhood, the latest benefit being specially important in urban areas. They offer new possibilities for relining or replacing of old pipelines. PE, due to its properties, is the reference material for these installation methods.
But these techniques can happen to be more aggressive and demanding to pipe materials, which can be in contact with hard or sharp objects.
There is also a clear trend, over different European countries, for classic installation in trenches, to move from the traditional sandbed laying to sandless bedding and to use or as-dug material as backfill material to fill-up the trench after installation of the pipe system. Depending of the type of soil in the specific area of installation, this is also creating a new challenge for pipe materials.
We have seen before that SCG is a key parameter when in comes to lifetime of the pipes; we are now able to demonstrate that this new material has taken yet another step of at least one decade in the resistance to slow crack growth in the notched pipe test. However we can show not only that but also an unprecedented resistance to SCG in all of the tests to which the material has been subjected until now.
Test | Standard | Test conditions | Result | Requirement |
---|---|---|---|---|
NPT (a) | ISO 13479 | 80°C / 9,2 bar | > 18000 h | 165 h1 500h2 |
FNCT (b) | ISO DIS 16770-3 | 80°C / 4 MPa / Arkopa | ca. 6000 h | >3500 h3 |
ACT (c ) | 90°C / NM-5 | ca. 4000 h | 330 h4 | |
PENT (d) | ASTM F-1473 | 80°C / 4,4/ MPa5 | >10000 h | >50 h |
b) FNCT = Full Notch Creep Test
c) ACT= Accelerated Creep Test
d) PENT = Pennsylvania University Notch Test
1 = EN 1555 and EN 12201 requirement
2 = PE100+ association requirement
3 = DVGW requirement for sandless bedding
4 = Provisional DVGW requirement for sandless bedding
Figure 6: Summary of test results for BorsafeTMHE3490-LS-H
The new developed RAUPROTECT pipe system was used in the dimension d63 SDR11 for more than 2.4 km and 2,252m d110-pipes under hardest construction side conditions in 2006 in Germany. In hard rock conditions, the pipe has been installed by horizontal drilling and by using a plow-in technology to build a new gas distribution system for the E.ON company.
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REHAU AG + Co
91058 Erlangen
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+49 9131 92-5496