Plastic Pipes in the Industry: The right choice! Legal details / Editor:
Kunststoffrohrverband e.V. Kennedyallee 1-5 53175 Bonn Germany
Phone: +49-(0)2 28 / 9 14 77-0 Fax: +49-(0)2 28 / 9 14 77-19
e-mail: [email protected] Web: http://www.krv.de oder http://www.wipo.krv.de
2 Contents
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
3 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 Introduction sind die Basis für moderne Sport- und During the last 60 years plastics have changed our lives High performance geomembranes secure durable sealing of Funktionskleidung. more than we could ever have imagined. A modern car con- landfills and plastic fibres represent the basis for modern structed without any plastics is unthinkable, packaging films sportswear respectively functional clothing. prevent our food from spoiling and gas as well as water are conveyed through plastic pipes.
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. HöchstHigh voltage verlegt. cable Heutewith functional spielen multilayer Kunst- sheathing out High proportion of plastics in the automotive industry stoffrohre bei praktisch jedem industriellen Prozess eine maßgeblicheof plastics installed Rolle. on the industrialsite “Höchst”. In 2012 PVC-pipes already celebrate their 80 years anniversary.
Grund dafür ist die enorme Vielseitigkeit von Kunststoff- Plastic pipes have a high importance in the chemical lösungen. Je nach Anwendung werden maßgeschnei- process industry. About 60 years ago the first plastic pipes derte Kunststoffrohre eingesetzt. Hohe Chemikalienbe- were installed on the industrial site “Höchst” in Frankfurt. ständigkeit, ausgereifte Verbindungstechniken und ein Today plastic pipes play an important role in virtually every umfassender Normungsrahmen garantieren effiziente, industrial process. ökonomische und vor allem sichere Lösungen. 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.
Wet separator out of GRP
Bilder: Polymerisationsanlage
Polymerisation plant 4 4 General requirements for piping systems in the chemical process industry (CPI)
“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 gives us confidence for the future.” (H. Lipp; Technical Maintenance; W.C. Heraeus GmbH, Hanau)
The use of plastic piping systems for conveyance of result of this no other segment in plastic piping is offering chemicals or well-defined process water-qualities have such a wide range of different polymeric materials. The table specific demands on the complete system. Apart from summarizes the primary customer requirements. 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
Regarding the total market of plastic piping systems, Requirements for industrial pipe systems industrial piping only represents a small part. However, due to the often very individual and high technical requirements • High safety standard / emergency running properties it is more than justified to label this segment as top-end of • Chemical resistance / low leachout the market. • Legal conformance • Long service life / field references • System solutions • Easy maintenance, repair and installation • Economic cost / performance ratio
Basic chemicals Fertilizer (e.g. Chlorine Pulp & Paper Alkali – electrolysis)
Water-Treatment (e.g. VE, UPW, Disinfection/ industrial Cleaning waste water)
Life-Science, Exhaust-gas (Food / Pharma), purification / Filtration-devices - treatment
Scrubber / Semiconductor- Petrochemistry Heat-Exchanger / Coating / Pickling industry (on / off-shore) Ventilation
Application areas for plastic pipe systems
5 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 resistance of a given plastic piping system is influenced by engineering is due to both the huge variety of materials a variety of factors. The following graph shows the main and the exceptional high level of their chemical resistance. factors: In this respect it needs to be considered that the chemical
Mainly set by the chemical structure of the polymer
Extensive possibilities to alter the material by the Chemical formulation, processing and installation
resistance Real life: Mixtures of chemicals impurities, of industrial fluctuating operational conditions Additional dynamic stress (installation, vibration, piping change of T-Fluctuating, welding, etc.) Dynamical and discontinuous service
Relying on more than 50 years of practical experience and When selecting the materials and systems close collabora- a well developed understanding in researching the basic tion between the user and the manufacturer is essential. corrosion mechanism, in most cases it is possible to specify The tables of “chemical resistance” should therefore rather the material compatibility of the particular material reliably. be looked at as a tool for basic orientation. According to current knowledge, plastic piping systems allow for conveying any chemicals at operating temper- atures even over 100°C.
6 Standardization / Quality assurance / Approval
„Ein“A standardization ausgereiftes und system auf internationaler for semi-finished Ebene products koordiniertes and raw und materials stetig aktualisiertes that is operated Normenund on an Standardisierungssysteminternational level and continuously für Halbzeuge updated und Rohstoffe is the backbone ist das for Rückgrat any quality jeglicher assurance Qualitätssicherung for plastic vonpiping Rohrleitungssystemen systems. Due to this, aufsuch Kunststoffbasis. a high level of standardizationDamit leistet das contributes hohe Niveau significantly der Normen to auf the diesem Gebietproven einensafe operation sehr großen of theBeitrag respective zum erwiesenermaßen plants especially sicherenin the segment Betrieb of der chemical aus diesen process Produkten industry.” gefertigten Anlagen gerade im Segment des (Hans industriellen Telgen, President Anlagenbaus.“ of the European plastic pipe and fitting Association (TEPPFA)) (Hans Telgen, Präsident des Europäischen Kunststoffrohrverbandes (TEPPFA))
Both formulation as well as processing effect the proper- supervised by independent testing institutes are well ties of the components of a given polymer-based piping recognized. A noticeable example for this market is the system substantially. Quality assurance of these products is approval issued by the German Institute for Building guaranteed by a well organized body of standards that are Technology (DIBT, Berlin). Although this is a national continuously updated. German basic standards or European German approval, it has a very high international reputation application standards frequently are used as the foundation in terms of guarantee of a high level of quality assurance and of many international standards. In particular special documented third-party-supervision. approvals that are based on additional guidelines and
European National basic DVS / AWS application standards standards
DIBT-Approval Standards / Approvals Technical rules
DIN CERTCO Guide lines Special approvals Internal standards CE (e.g. ship building, ATEX, FM)
On a global level the national and European standards are Company standards and special approvals that have been completed by other international Standards (e.g. ISO, ASTM, developed over decades complement these standards. BS, JS). Due to a lack of harmonized European standards a CE- Standardization of welding, solvent cement jointing and Marking of the plastic piping system components is not jointing of plastic pipes in general has been - also globally possible yet. - 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.
7 Sustainability Plastic products need less energy than alternative products In Europe, the demand of energy for production, use, It can be concluded that the replacement of plastic recovery and disposal of plastics is about 4.300 products by other materials wherever possible would million GJ/a take about 57 % (1.500-3.300 GJ/a) more energy than it takes today for the whole life cycle of all plastic The total emissions of greenhouse gas account for about products 200 million t/a
6.000 Demand of energy for production
5.000 Waste (net saving)
4.000 Demand in energy for use
3.000 Use (low loss of organic materials) 2.000 [mio GJ/a] 1.000
0
Total energy consumption (+) and saving (-) Total -1.000 plastic products alternatives
-2.000
Energy consumption of plastic products in the course of consumption of energy, while negative values illustrate their life cycle (examined case studies which cover 63 % of energy saving with low loss of organic materials, avoided the total market) and their potential substitutes split into primary production (by recycling) and saved generation of the stages of their life cycle: production, use and waste electricity and heat (by thermal recovery). management. The positive values represent the
(Source: Die Auswirkungen von Kunststoffen auf Energieverbrauch und Treibhausgasemissionen in Europa“, DENKSTATT GmbH, June 2010)
8 Plastic products enabled energy savings of about 2.400 mio GJ/a:
Total mass Energy Consumption Greenhouse gas emissions for equal over entire life cycle over entire life cycle functional units
146 million t/a 6.690 Million GJ/a 330 Million t/a +370 % +57 % +61 % 4.270 220 million million GJ/a t/a
39 Millionen t/a Replaceable
46,4 million t including not replaceable plastics plastic
products alternative materials alternative materials (incl. not substitutable plastic materials) alternative materials (incl. not substitutable plastic materials) plastic products plastic products
Changes in product mass, energy consumption and greenhouse gas emissions, if plastic products were theoretically replaced by alternative materials.
(Source: „Die Auswirkungen von Kunststoffen auf Energieverbrauch und Treibhausgasemissionen in Europa“, DENKSTATT GmbH, June 2010)
Plastic products enable significant savings of energy The replacement of plastic products by other materials and greenhouse gas emission (production and use are increases in most cases the energy consumption as well the most important areas for savings). as the emission of greenhouse gases.
The study above examined the impact of different From the perspective of their entire life cycle plastic materials on the total demand of energy of products products belong to the most energy efficient materials. over entire life cycle (cradle to grave). Plastic products often enable a reduction of material The results show that plastic products allow solutions consumption. which are resource efficient.
9 Relevante Werkstoffe
Materials "Aufgrund seiner einzigartigen chemischen Beständigkeit, idealen thermo-mechanischen Ei- genschaften und einem attraktiven Kosten-Nutzen-Verhältnis wird der Werkstoff PVC auch in Zukunft“Due to ein its sehrunique bedeutendes chemical resistance Material combined mit interessa with ntemideal thermo-mechanicalWachstumspotential properties im industriellen and an Rohrleitungsbauattractive cost-benefit bleiben." ratio, PVC will remain a very important material for industrial piping with interesting growth potential.” (Filipe CONSTANT; (Filipe Constant; CEO CED of SolVin,SolVin, Brüssel) 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 anPiping unterschiedlichen systems made of Kunststoffen plastics are tried verfolgt and tested stets in da saggressive Ziel, für conditions.jede Herausforderung The variety of plastics die wirt-available allows schaftlichsteindustrial applications. Lösung They zu arebieten. recognized as an excellent for providing the most efficient solution for any challenge. transport system for safety-relevant applications under very Acrylnitril-Butadien-Styrol (ABS)
ABSAcrylonitrile ist ein amorpher butadiene Thermoplast, styrene (ABS) der mittels Klebetechnik verbunden wird. Auf Grund seiner mechanischenABS is an amorphous Eigenschaften, thermoplastic seiner which is guten jointed chemischen using adhesive Widerstandsfähigkeit technology. Due to its mechanical und seiner properties, hohen its good Schlagzähigkeitchemical resistance auch and itsim excellentunteren impact Temperaturanwendung strength, even at lowsbereich, temperatures, eignet the sich material der isWerkstoff suitable for für a range of eineapplications, Vielzahl especially von Anwendungen in refrigeration and speziell air conditioning. in der Kälte- und Klimatechnik.
ABS propertiesEigenschaften ABS
- High rigidity with low thermal expansion - hohe Steifigkeit mit niedrigem thermischen Längenaus- - Good chemical resistance to aqueous salt solutions, many acids and alkalis - Temperaturedehnung range: -40°C to +70°C - 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
GlasfaserverstärkterGlass-fibre reinforced Kunststoffplastic (GRP) (GFK)
GFKGRP is ist a high-strengthein hochfester compound Verbundwerkstoff material consisting bestehend of reaction a resin,us Reaktionsharz, glass fibre and pure, Glasfaser non-absorbent und reinen, fillers which is nichtused primarily quellfähigen in piping Füllstoffen, systems exposed der besondersto substantial bei mechanical, mechanisch, thermal thermisch or chemical oder stresses. chemisch The production hoch process beanspruchtenenables a wide range Rohrleitungssystemen of different raw materials zum (glass Einsatz fibre, reaction komm resin,t. Das additives) Herstellverfahren to be combined erlaubt into a diefinal product. KombinationThus GRP pipes cander be verschiedensten produced individually Rohstoffe to match the(Glasfase specific r,requirements Reaktionsharz, of the application.Zuschlagsstoffe) zum fertigen Endprodukt So können GFK-Rohre individuell den spezifischen Anforderungen der An- wendungGRP is characterized entsprechend by its hergestellt excellent rigidity werden. 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 Dieresistance sehr canhohe be Steifigkeitincreased even und further Festigkeit in conjunction insbesonde with thermoplasticre bei hohen lining Temperaturen (e.g. PP or PVDF). 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 oderGRP PVDF) properties kann die chemische Resistenz zusätzlich erhöht werden.
- ExcellentEigenschaften strength and rigidity GFK - Very low thermal expansion - Extremely- Nennweiten good pressure vonrating DN 25 bis DN 4000 - Temperature- sehr range: hohe -60°C Steifigkeit to +120°C 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 10 Sonderbauteile und Spools"
10 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.
PE properties - 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
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.
PP properties - 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
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.
PVC-U properties - 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-C 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
11 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).
PVDF properties - 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
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.
12 Plastics for any application
Plastics are split into 3 major polymer groups. According to thermosets are used in various applications of piping sys- the degree of crosslinking they are distinguished into ther- tems whereas elastomers are used as seals. moplastics, thermosets and elastomers. Thermoplastics and
Thermoplastics The base polymers Polyethylene, Polypropylene and force for continuous development of the base polymers. Due Polyvinylchloride are characterized by longevity, high to their high durability at elevated temperatures and their resistance to corrosion and low weight. Due to these outstanding resistance against chemicals they offer a high features they are well established in the construction of benefit and optimal cost performance ratio for the end chemical apparatus. Thermoplastics can be tailored for user. any use by optimization of their morphology and chemical composition which finally makes them the ideal partner for Polyethylene, Polypropylene and PVC can be optimized a multitude of applications. Most important issues always for special applications in their chemical composition or are safety and durability. The ability of the afore mentioned downstream treatment (e.g. crosslinking), Polypropylene plastics to be jointed by either adhesive bonding or welding provides the opportunity to improve properties by provides a high level of safety to the chemical apparatus and nucleation. The thereby generated polymer structure results piping construction. in a higher rigidity with good impact strength. This benefits the chemical resistance and thus provides a higher safety The excellent processability of the base polymers is reflected level for the end user. 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
Microscopic pictures of PP-H crystal patterns by linearly A result of nucleation is the By crosslinking of polymers polarized light (left picture: non nucleated, right picture: low surface roughness and new characteristics can nucleated) therefore a smooth inner be created (e.g. high point pipe surface – beneficial for load and temperature hydraulic resistance resistance)
Thermosets Thermosets - which are also called duroplasts - are Also other polymers for example Polyurethanes are relevant. plastics that cannot be reformed after the initial manu- Thermosets are made by direct crosslinking of the polymer facturing process. Thermosets are thermally stable polymers chains with each other or with the aid of further monomers. hat are three-dimensionally crosslinked via covalent bonds. The crosslinking process is initialized by either heat The three-dimensional crosslinking is the basis for the high irradiation or the aid of chemical additives e.g. Peroxides. temperature resistance, strength and rigidity of thermoset resin systems. For GRP pipe systems the dominant thermo- The formed molecular structure is thermally stable and the plasts are Unsaturated Polyester resins and Epoxy resins. polymers cannot be molten after curing.
13 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.
Fire test on a plastic pipe to IMO 753 Standard The results are as follows:
Breakdown of materials based on specific resistance in accordance with BGR 132 or DIN IEC 60093
conductive antistatic insulating Specific resistance [Ohm x cm] 10-6 10-3 100 103 106 109 1011 1012 1015 1018
cooper germanium electrically antistatic standard conductive materials plastics materials
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 Collection unit made of electrically conductive polyethylene standard.
In GRP pipes this is achieved by adding Alusil.
Special designs Special solutions: Pipes often need to follow a predefined, multibranched route, - Double-containment pipe system with matching fittings passing, avoiding or going underneath obstacles. The media flow can be joined or separated in shaft assemblies and pass - Pipes with special formulations, e.g. dimensions and through predefined transfer points. Where the combination colours or material modifications of standardised pipes and fittings reaches its limits in terms of the fulfilment of individual design specifications, the - Individually designed special fittings as system variability of plastic in terms of forming and design allows components the production of special tailored solutions. - Complex designs, e.g. shaft assemblies or distribution In accordance with the planning specifications, indivi- systems dual components or designs such as shaft assemblies or pipe bridges can then be pre-manufactured in the factory.
14 Jointing techniques
“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)
The versatile possibilities for jointing plastic piping systems appropriate jointing procedure is usually influenced by (the depend on the choice of material. In designing a plastic pipe factors) economics, the construction of the components, system it is therefore important to obtain information about external and internal influences on the system as well as possible jointing techniques and their applicability as early local conditions. By the following overview some infor- as possible in the planning phase. The choice of the most mation to the established jointing techniques are given.
Flange joints: − 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
Socket 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
Butt fusion: − 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
15
• 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 benötigtElectro-fusion: − Universell / geeignet für beliebige Bauteilgeometr− easy welding procedureien − Extruder- Schweißung ist ein teilmechanisiertes− simple preparation of the weld − easy handling Warmgasschweißverfahren − constant quality of the weld − Standardverfahren im Verbundrohrleitungsbau,− no welding bead inside the pipe − welding in difficult locations possible Apparatebau (Schächte und Behälter),− axial load connection Rohrleitungsbau (Mantelrohre) − usable for a wide range of dimensions − Längskraftschlüssige Verbindung
• Flanschverbindung: IR-butt fusion: − quick, automatable − smaller weld bead − Schneller Austausch, Anpassbarkeit− no direct contact of the heater to the material − Ausführung als Los- oder Festflanschvariante− axial load connection − Gut für Vorfertigungsmontagen − Vorschweißbund, Dichtungen und Schrauben erfor- derlich − Keine längskraftschlüssige Verbindung (lösbar) Mechanical couplers: • Verschraubungen und Klemmverbindung:− simple and quick assembling on site − preassembled coupling on one side of the pipe − for pipes without sockets possible − Schnellverbindungsmöglichkeit − axial and non-axial load connections − Einfache Montage, Demontage und Wiedermontage − Verarbeitung ohne spezielle Werkzeuge und Hilfsmittel möglich − Keine längskraftschlüssige Verbindung (lösbar)
• Laminatverbindung: Laminate connection: − quick replacement − − connection to different materials Schneller Austausch, Anpassbarkeit− thickness and width of the laminate is variable − Verbindung mit anderen Werkstoffen (application of the laminate in layers) − Qualifiziertes Personal − Lagenweiser Aufbau in Stärke und Fläche
16 17
• 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 • Heizelement-Muffenschweißung • Heizwendel-Schweißung− Einfache Handhabung während der Schweißung − Einfache Schweißnahtvorbereitung − Einfache Handhabung− Unkomplizierte während derBedienung Schweißung der Schweißgeräte − Einfache Schweißnahtvorbereitung− Gleichbleibende Schweißnahtqualität − − Schweißwulst im Inneren der Verbindung Unkomplizierte Bedienung− Längskraftschlüssige der Schweißgeräte Verbindung − Gleichbleibende Schweißnahtqualität− Schnell, kostengünstig, stabil − Kein Absatz oder− Schweißwulst Für Dimensionen im bis Inneren 160 mm geeignet − Schweißen an• schwerzugänglichenHeizwendel-Schweißung Stellen möglich − Längskraftschlüssige Verbindung − Schnell, kostengünstig,− Einfache stabil Handhabung während der Schweißung − Einfache Schweißnahtvorbereitung − Unkomplizierte Bedienung der Schweißgeräte • Warmgas-Draht-Verschweißung:− Gleichbleibende Schweißnahtqualität − Kein Absatz oder Schweißwulst im Inneren − Manuell, hoher Erfahrungsfaktor− Schweißen an schwerzugänglichen benötigt Stellen möglich − Universell / geeignet− Längskraftschlüssige für beliebige Bauteilgeometr Verbindung ien − − Schnell, kostengünstig, stabil Extruder- Schweißung ist ein teilmechanisiertes Warmgasschweißverfahren• Warmgas-Draht-Verschweißung: − Standardverfahren im Verbundrohrleitungsbau, − Apparatebau (Schächte Manuell, und hoher Behälter), Erfahrungsfaktor benötigt − Universell / geeignet für beliebige Bauteilgeometrien Rohrleitungsbau −(Mantelrohre) Extruder- Schweißung ist ein teilmechanisiertes − LängskraftschlüssigeWarmgasschweißverfahrenSolvent Verbindung Cementing: − Standardverfahren im Verbundrohrleitungsbau, − easy and simple, no machining necessary • Apparatebau (Schächte und Behälter), Flanschverbindung: Rohrleitungsbau− limited with respect (Mantelrohre) to the pipe dimensions − Längskraftschlüssige− manual processing procedure Verbindung − Schneller Austausch, − Anpassbarkeituse of the correct type of cement required − Ausführung als• Los-Flanschverbindung: −oder pressure Festflanschvariante bearing connection
− Gut für Vorfertigungsmontagen− Schneller Austausch, Anpassbarkeit − Vorschweißbund,− Dichtungen Ausführung alsund Los- Schrauben oder Festflanschvariante erfor- derlich − Gut für Vorfertigungsmontagen − − Vorschweißbund, Dichtungen und Schrauben erfor- Keine längskraftschlüssigederlich Verbindung (lösbar) − Keine längskraftschlüssige Verbindung (lösbar) • Verschraubungen und UnionKlemmverbindung: and compression fittings: • Verschraubungen− quick connection und possible Klemmverbindung:
− − simple assembly, dis- and reassembly possible Schnellverbindungsmöglichkeit− Schnellverbindungsmöglichkeit − assembling possible without the need for special tools − Einfache Montage,− Demontage Einfache Montage, und Demontage Wiedermontage und Wiedermontage − pressure bearing connection − Verarbeitung ohne− spezielle Verarbeitung Werkzeuge ohne spezielle und Werkzeuge und Hilfsmittel möglich Hilfsmittel möglich − Keine längskraftschlüssige Verbindung (lösbar) − Keine längskraftschlüssige Verbindung (lösbar) • Laminatverbindung: • Laminatverbindung: − Schneller Austausch, Anpassbarkeit − Verbindung mit anderen Werkstoffen − Schneller Austausch,− QualifiziertesHot Anpassbarkeit gas welding: Personal − Verbindung mit anderen− Lagenweiser Werkstoffen Aufbau in Stärke und Fläche − manual processing procedure, experience necessary − Qualifiziertes Personal− universal, usuable for any kind of component geometry − Lagenweiser Aufbau− in extruder Stärke welding und Flächeis partly mechanised hot gas welding procedure − standard procedure in composite pipeline construction, apparatus construction (tanks and vessels), pipeline 17 construction (e.g. casing pipes) − axial load connection
17
BCF fusion jointing: − no bead, high welding factor − limitation on pipe dimensions − up to now restricted for polyolefines and PVDF
17 Special Requirements of Plastics Installation pre-requisites Compared to metallic piping systems plastic pipes have a pipe system. This especially applies to buried pipe systems. higher sensitivity to time and temperature. In principle, Potential types of stresses are outlined below. several types of internal and/or external loads can affect a
Internal and external loads on pipe systems
Tensile and External load Internal Chemical Temperature Pipe bending compressive pressure influences loads (buried pipe loads systems)
Internal Soil load Internal Internal under- overpressure External (e.g. flow pressure medium) Traffic load
Groundwater
Basic requirements for a professionally designed pipe system durable pipe systems. In project planning and installation of are good technical knowledge coupled with many years of thermoplastic pipe systems specific material properties (e.g. experience in application and process technology. higher linear compensation) always have to be considered. Calculations are needed to design reliably pipe systems. As Plastic piping systems provide the possibility to use illustrated below, the classification of plastic pipe systems is environmentally-friendly, easy to maintain, economic and generally determined by the installation.
above ground concrete encased buried systems systems systems
without length linear without any considerable with limited possibilities with length compensation compensation for length change length compensation compensation
in buildings in buildings subject to soil loads in foundations
outdoors outdoors subject to traffic loads in ceilings
in ground water in walls
18 Versatile piping concept
“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.
Typical Diameters Concept Jointing technology Characteristics (OD/mm) Double Solvent cement 20-225 (inner pipe) Increased safety due to pipe-in-pipe- containment piping jointing; concept, leakage control by a vacuum butt fusion welding system, visual control (transparent outer PVC pipe) or vacuum measuring
Dual laminates Welding 25-4000 Increased safety due to pipe-in-pipe- (butt-fusion, concept. Significant increase in the rod welding) range of applicability for thermoplastic flanging liners as they are only used as “chemical barrier”. All mechanical load is handled by the GRP-layer Ventilation pipes Socket jointing in < 800 Frequently the only economic combination with sol- alternative to convey corrosive fumes vent cementing and rod / or butt welding Tubes Push-fit-sockets, < 2 in Coiled tubing; frequently fully flaring, screwing,/plug fluorinated polymers, are used in the connection, screw joint, semicon-industry as inner pipes in customized solutions double-pipe systems Customized piping Multiple and very Usually < 250 Pipes as semi-finished products; mostly individual no system-concept required Thermoplastic Welding, solvent 16-4000 Standard in the CPI (pressure) piping cement jointing, flanging Straight GRP pipe Socket jointing, 16-2000 High safety due to pipe-in-pipe adhesive jointing, possible; variety and adaptation due laminate jointing, to combination of resins according to flanging service conditions (T, medium)
19 Case Studies / Referenzen
Case Studies / Kunststoff-RohrsystemeReferenzen haben bei AKZO Nobel die Nachhaltigkeit der Chlorfabriken und vieler weiterer chemischer Anlagen verbessert. (B. Rijpkema; AkzoNobel Engineering & Operational Solutions; Arnheim, Niederlande) Kunststoff-Rohrsysteme haben bei AKZO Nobel die Nachhaltigkeit der Chlorfabriken und vieler Case Studies / Referenzen weiterer chemischerChemische Anlagen Prozessindustrie verbessert. (B. Rijpkema; AkzoNobel Engineering & Operational Solutions; Examples of application Kunststoff-Rohrsysteme haben bei AKZO Nobel die Nachhaltigkeit der ChlorfabrikenArnheim, undNiederlande) vieler Leitungssysteme für weiterer chemischer Anlagen verbessert. Prozesskühlwasser „Plastic pipe systems have improved the(B. sustainability Rijpkema; AkzoNobel of chlorine Engineering plants at many & Operational chemical factoriesSolutions;
at AKZO Nobel.“ (B. Rijpkema; AkzoNobel Engineering & Operational Solutions;Arnheim, Arnheim, Niederlande) Niederlande) Bei einem Wasserge-
Chemische Prozessindustrie misch mit Schwefelsäure- gehalt (36%) bei 40°C Chemische Prozessindustrie kommen Rohrsysteme Chemical Process Industry aus PE, PP und PVC zum Einsatz.Leitungssysteme für Piping for process coolant ProzesskühlwasserLeitungssysteme für ForProzesskühlwasser water blended with 36 % Sulphur acid and a temperature Hohe chemische Widerstandsfähigkeit BeiofBei 40°C,einem einem PE, PP Wasserge-Wasserge- or PVC offer cost effective high performance misch mit Schwefelsäure- mischsolutions. mit Schwefelsäure- Bei dem Rückgewinnungsprozess von Säurebeize gehalt (36%) bei 40°C (Salpetersäure 20% und Flusssäure 5%) zur Ober- gehaltkommen (36%) Rohrsysteme bei 40°C flächenbehandlung von Metallen gewährleisten kommenaus PE, PP Rohrsysteme und PVC zum Rohrsysteme aus PP-H einen störungsfreien Be- Einsatz. trieb. aus PE, PP und PVC zum Einsatz.
Long-termHohe chemische complete solutionsWiderstandsfähigkeit High chemical resistance for pickling plants Bei dem Rückgewinnungsprozess von SäurebeizeLanglebige Komplettlösung für Beizan- Hohe chemische(Salpetersäure Widerstandsfähigkeit 20% und Flusssäure 5%) zur Ober-lagen flächenbehandlung von Metallen gewährleisten Rohrsysteme aus PP-H einen störungsfreien Be- Kunststoffrohrsysteme sind für zahlreiche che- Bei dem Rückgewinnungsprozesstrieb. von Säurebeize mische Anforderungen die richtige Lösung: (Salpetersäure 20% und Flusssäure 5%) zur Ober- Salpetersäure und Flusssäure bei 70°C: PP-H Destilliertes Wasser bei 80°C: PP-H flächenbehandlung von Metallen gewährleisten Wässrige Schwefelsäure bei 90°C: PVDF Rohrsysteme aus PP-H einen störungsfreien Be- Schwefelsäure (95 %): PVC-C, PVC-U trieb. Natriumsulfat bei 85°C: PVC-C
Langlebige Komplettlösung für Beizan- lagen
Kunststoffrohrsysteme sind für zahlreiche che- Plastic piping systems are the right solution for a lot of During mischethe reclaiming Anforderungen of pickling acid die (Nitric richtige acid Lösung:20% and chemical requirements: HydrofluoricSalpetersäure acid 5 %) used und for Flusssäure surface-treatment bei 70°C: of metals, PP-H pipe systemsDestilliertes made of PP-HWasser ensure bei an 80°C:undisturbed21 PP-H operation. Nitric acide and Hydrofluoric acid at 70°C: PP-H LanglebigeWässrige SchwefelsäureKomplettlösung bei 90°C: PVDF für Beizan- distilled water at 80°C: PP-H Schwefelsäure (95 %): PVC-C, PVC-U Sulphur acid at 90°C : PVDF lagenNatriumsulfat bei 85°C: PVC-C Sulphur acid (95°%) : PVC-C, PVC-U Sodium Sulphate at 85°C: PVC-C Kunststoffrohrsysteme sind für zahlreiche che- mische Anforderungen die richtige Lösung: Salpetersäure und Flusssäure bei 70°C: PP-H 20 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 21
21 Water treatment
Recent materials for water treatment facilities
Corrosion resistant plastic pipes are the ideal transportation swimming pool devices and desalting plants. Standardized system for water. They reliably fulfill the hygienic system elements and customized parts afford an adjustment requirements and ensure long-lasting durability and high to constructional circumstances. operational safety. Plastic piping systems are used for conditioning of industrial and municipal sewage water,
Ultrapure water facility Materials 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.
21 Ventilation and air conditioning
Safe removal of chemically contaminated waste air
Ventilation and air conditioning systems made of plastic Self-extinguishing properties are a prerequisite for use in are low in weight and simple to install. In particular, they buildings. PPs and PP-ELs, PVC and PVDF are particularly excel in chemical resistance and temperature resistance. suitable as materials.
Energy and heat transport Refrigeration systems Energy efficient system solutions
Pre-insulated PN 10 ABS pipe with jacket pipe in PE (Cool-Fit Geothermal heat exchangers under warehouses, roads and system); medium: glycol and water mixture; Temps = -8°C to car parks are capable of cooling process water by between -4°C; working pressure = 3 bar; use in the food industry. 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.
22 Power plant engineering
High durability in energy power plants Plastic pipes have a proven track record in power plant makes other safety systems superfluous. GRP and PE are engineering. They guarantee both long usage times and used in cooling water systems. Especially their low weight high operational safety and reduce operating costs. Poly- for large nominal widths and mechanical long-term stability propylene is used in gas desulphurisation plants. Its are clear benefits compared to traditional materials. outstanding resistance to chemical and abrasive 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)
23 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)
Although the segment of industrial piping is still regarded important trends. Topics such as “functional coating” and as a comparatively small market, polymer piping systems “nanotechnology” will contribute to the development of are steadily gaining importance. This is due to high level of very interesting new products in this industry. Regarding innovation in the field of semi-finished products and the pipe jointing the butt fusion welding of PVC-U and C-PVC compounding of polymers. One example for this is the trend is currently establishing as an alternative for traditional to increase the pressure-performance of polymer pipes. To adhesive technology and laminate jointing. The significantly achieve this there are various concepts in which multilayer- increased commitment to consolidate and further develop approach, application of oriented layers retaining the same the knowledge of polymer corrosion has already been polymer and the use of innovative copolymers or fillers are mentioned elsewhere.
24 Kunststoffrohrverband e.V., an Association of the German Plastic Pipe Industry, Is the Key Contact for Experts
Kunststoffrohrverband 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.
25 Members of industrial pipes group
Akatherm FIP GmbH Web: http://www.akatherm-fip.de
Amitech Germany GmbH Web: http://www.amitech-germany.de
Bänninger Kunststoff-Produkte GmbH Web: http://www.baenninger.de
Borealis Polymere GmbH Web: http://www.borealisgroup.com
Georg Fischer GmbH Web: http://www.georgfischer.de
Georg Fischer DEKA GmbH Web: http://www.piping.georgfischer.com
26 GERODUR MPM Kunststoff- verarbeitung GmbH & Co.KG Web: http://www.gerodur.de/
LyondellBasell Web: http://www.lyondellbasell.com
Sabic Europe Web: http://www.sabic.com
SIMONA AG Web: http://www.simona.de
SolVin GmbH &Co.KG Web: http://www.solvinpvc.com
Westfälische Kunststoff Technik GmbH Web: http://www.wkt-online.de/
27 Kunststoffrohrverband e.V. Kennedyallee 1-5 53175 Bonn Germany
Phone: +49-(0)2 28 / 9 14 77-0 Fax: +49-(0)2 28 / 9 14 77-19 e-mail: [email protected] Web: http://www.krv.de oder http://www.wipo.krv.de