Beruflich Dokumente
Kultur Dokumente
Abstract
Since the introduction of the first PE pipe 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.
Rehau and Borealis, have gathered their respective long expertise and knowledge in PE
pipes and raw materials to develop a new pipe system with outstanding crack resistance to
meet new market expectations and needs.
This paper will describe the different steps the two companies have passed together, from
analysis of the market needs to the first actual projects of the newly created
RAUPROTECTII solution.
Keywords:
Slow Crack Growth, sandless bedding installation, trenchless technologies ,
RAUPROTECT II RAUSISTO, BorsafeHE3490-LS-H
1. INTRODUCTION
Among many applications, Polyethylene (PE) pipes are used worldwide for water supply
and gas distribution, contributing significantly to improve the reliability and the quality of
the networks.
Since the first pipe productions almost 50 years ago, PE has developed an impressive
successful track record, and is today the preferred choice for these applications.
Ease of installation, low maintenance and corrosion free are some of the well-known
reasons for this success story.
Another key reason is the constant efforts of both raw materials producers and pipe
producers for improved quality and reliability.
After the development of HDPE pipe materials like PE63 and then PE80, the first PE100
materials arrived on the market at the end of the 1980s. These materials were a real
milestone in the development of HDPE pipe materials because they facilitated the use of
higher service pressures or pipes having thinner wall at the same service pressures and at
the same time they also offered the end-user other advantages such as high resistance to
Slow Crack Growth and high resistance to Rapid Crack Propagation.
1st 2nd 3rd 3rd
Generation Generation Generation Generation
HDPE HDPE HDPE HDPE
Pipe installed 1965 1975 1990 1990
since
Classification PE63 PE80 PE80 PE100
Design stress 5.0 MPa 6.3 MPa 6.3 MPa 8.0 MPa
Stage II knee 100-300 H 1000-3000 >10 000 >10 000
point 80C
Notch test, 4,6 10 100-200 >1000 >1000
Mpa/80C
Rapid crack <3 bar <3 bar >10 bar >10 bar
propagation/Pc
110SDR11
Figure 1: evolution of pipe properties
Pipes made from these modern materials are considered as perfectly adapted to classic
installation conditions: open trench with sand-bedding of the pipe, and refill of the trench
with carefully chosen reinstatement materials.
However, the last 10 years have seen new challenges for pipes, with the development of
new installation techniques.
The bimodal process consists of two polymerization reactors in series. Figure 1, shows a
simplified view of the basic principles of the bimodal process. The Borstar low pressure
slurry loop and gas phase reactor process is illustrated. The catalyst is fed into the first
reactor, where polymer is formed as powder particles through polymerization of the
ethylene monomer and suitable amounts of comonomer, continuing in a series mode into
the second reactor.
Figure 6: Bimodal Borealis Borstar polymerisation process
4.2 BorsafeHE3490-LS-H
With the help of the Borstar process and according to the description in the previous
section, it has been possible to create a material which enables the pipe producer to make
any dimension from 20mm to up to more than 2000mm and wall thicknesses of >100mm.
Not only does this material provide the possibility to make any pipe dimension, it also
possesses an excellent resistance to impact failures e.g. Rapid Crack Propagation, and
excellent resistance to internal pressure manifested by the PE100 designation according
to ISO 9080 standard extrapolation method.
Figure8: REHAU RAUPROTECT II RAUSISTO pipes for gas, water and sewage
The challenge given to Rehaus development engineers to design this completely new
system solution was based on:
- the demonstrated technical fact that higher stress concentration is located at the
opposite inner surface of the pipe while external point loads and internal pressure
are combined during the whole lifetime of the pipe system.
- The requirement for this new pipe to keep the traditional key benefits of PE pipes,
e.g. flexibility, ease of installation and weldability .
Figure 9: Traceability-Barcode according ISO 12176-4 (Code 128, type C) and ISO 13950
5.4 Field test: Gas pipe installation in Holzthaleben / Germany
One of the first important projects using the new developed RAUPROTECT pipe system
was in Holzthaleben in Germany.
The gas distribution company E.ON has chosen this system for a new gas distribution
system, installed in very demanding conditions: the pipes had to be installed in very tough
rocky soil , using horizontal drilling and ploughing-in installation techniques.
2,4 km of pipes diameter 63 SDR11 and 2,3 km of diameter 110 SDR 11 have been
successfully installed for that project.
6.CONCLUSION
PE pressure pipes systems are designed for a longlife time, and are showing today the
best leakage statistics compared with
They have proven, since several decades to offer a safe solution for gas and drinking
water distribution, contributing to protect these precious fluids. They are in particular
showing the best leakage statistics among all pipe materials.
One of the key reasons for this success is the innovation potential shown by both PE raw
material producers and pipe producers; recently, a new market need for tougher materials
for installation in demanding conditions has pushed for the development of a new
generation of pipes.
The new RAUPROTECT II RAUSISTO system, based on the combination of
BorSafeHE3490-LS-H, a new PE100 material with outstanding resistance to slow crack
growth and modern state-of-the-art pipe-design will continue to secure the safe transport
and distribution of potable water and gas for generations to come!