innovative developments in pvc pressure pipe systems and unconventional applications first brazilian...
TRANSCRIPT
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INNOVATIVE DEVELOPMENTS IN PVC PRESSURE PIPE SYSTEMS AND UNCONVENTIONAL APPLICATIONS
First Brazilian
PVC Congress. Sao Paulo, June 2005.
Mike Osry
DPI Plastics (Pty) Ltd. South Africa
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Objectives• Advantages of PVC which have made it the preferred material for pressure pipes for mains water supply and irrigation in most Countries of the world.
• Innovative developments in PVC pipe technology and unconventional applications which demonstrates the materials:
- Versatility
- Cost effectiveness
- Long-term durability
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What is PVC?
• Polyvinyl Chloride – Unplasticised PVC
or PVC-U.
• Polymerisation of Vinyl Chloride
manufactured from oil and salt.
• Only 43% of PVC made from non-renewable
Petroleum feed-stock and 57% from
salt.
• Supplied in powder form to Pipe
Manufacturers.
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What is PVC?/Cont.• Mixed in high-speed mixers with stabilisers and other additives.
Dryblend suitable for extrusion into PVC pipes.
• PVC is very versatile and formulations can be made to give special properties:
- High strength PVC-U pressure pipes.
- Impact modified PVC pressure pipes (PVC-M) with greater toughness.
- Sewer and drainage pipes with filler for greater stiffness and cost benefits.
- Products with high resistance to sunlight (e.g. rainwater gutters).
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Extrusion of PVC Pressure Pipes
• Twin Screw Extruders designed to provide the right combination of shear and heat.
• Gellation, the melting of the PVC polymer particles through heat (185oC) and shear – the key to the development of PVC’s excellent properties.
Outside diameter and wall thickness is accurately controlled to close tolerances.
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Extrusion of PVC Pressure Pipes/Cont.
• Socketed in-line to standard 6m lengths.
• Sealing rings inserted.
• Pipe now ready to use.
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PVC-U: Historical Overview
• World’s leading plastic pipe resin – over two-thirds ofglobal demand (by weight).
• Proven durability over approximately 60 years : WHY?
• Continuous Improvements:
- PVC Polymer
- Raw Material Formulations
- Extrusion equipment
- Properties and quality of PVC-U pipes.
- Quality testing and quality management systems (ISO 9001-2000)
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Development of Tough PVC Pipes
Motivation:
Harsh environments such as mining and civil construction sites
Trend to larger diameters and pressure classes
Handling and installation
Predictability of long-term performance
Safety in underground mining
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Example of a harsh environment!
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Impact Modified PVC Pipes in Mining• Extreme conditions of temperature, transport, handling and installation.
• Gold mines now down to 5 000m underground.
• Major requirement is safety.
- Rock face temperature underground : 50oC.
- Ambient temperature >40oC, humidity 90%.
- To cool environment – pipes with chilled water at 5oC.
- Pipes made to SANS 1283.
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20 metre high energy impact test
Impact Modified PVC in Mining/Cont.
Impact Test Samples of PVC Mine Pipe Showing Toughness Properties
(20kg mass from 20m height)
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Mine pipe Jointing - Minelok
• Pipes are suspended along haulage ways (not burried).
• Therefore pipes require a positive locking joint to resist end thrust.
• ‘Victaulic’ steel flanged joint especially developed for PVC mine pipes.
• Steel Minelok ends pressed onto PVC pipes – interference fit.
• PVC pipes fully compatible with steel pipes used in mines.
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Minelok Steel End Coupling
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PVC Mine Pipe Coupling System
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Installation with Bent Pipes! (2500m)
Mineflo Pipes Conveying Chilled Water (5oC)
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Note suspension of pipes underground
Mineflo Pipes for Chilled Water
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Chilled Water PVC Pipe Installation in Mine Haulage Way
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Backflo Pipes in Mining
• High pressure return of slurries and slimes back underground.
• Work on existing mine dumps to extract gold and return underground.
• Prevents the Johannesburg ‘Mine Dump Skyline’!
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Airflo PVC Pipes
• 7 bar compressed air in mines (rock drilling, pipe installation, etc.)
• Pipes must be ‘fail-safe’ under all conditions – stored energy effects.
• High toughness and ductility – high speed detonation tests.
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Drainflo PVC Pipes
• Used for draining water back out of mines.
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Hi-Impact Pipes – Johannesburg City Council
• These tough pipes used extensively by Johannesburg City.
• Ease of handling and installation vs. steel pipes.
• End-thrust resistant joints reduce need for thrust blocks in installations.
• Made to SANS 1283.
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Material and Energy Efficient Pressure Pipes
Motivation:
• Limited capital resources.
• Critical need for potable water in developing countries.
• Reduce poverty and disease.
• Improve quality of life.
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Ultraflo PVC-M Pressure Pipes
• Successful history and proven durability with modified PVC pressure pipes in mining environment.
• Toughness as important a property as strength.
• PVC-M pressure pipes made to SANS 966-Part 2.
• Also made in UK, Australia and New Zealand to local standards.
• Pipes in 6m lengths with integral socket and rubber seal.
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Ultraflo PVC-M Pressure Pipes/Cont.
• Ease of manufacture, especially in large diameters – up to 630mm or greater.
• Larger pipe bore and increased hydraulic capacity.
• Working pressures of 6, 10, 16, 20 and 25 bar.
• Ease of transport, handling and installation.
• Over 40 000 km installed in Southern Africa over 10 years (one manufacturer).
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Biaxially Oriented PVC (PVC-O)
• In-line process with high output rates per meter.
• High strength and toughness.
• Cost effective – higher pressures up to 20 and 25 bar.
• Material efficient product with excellent handling and installation.
• Increased hydraulic capacity.
• Resistance to pressure surges and fatigue caused by pressure cycling.
• Made to SANS 1808-85: 2004.
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A construction site illustration of the toughness properties of PVC-O Pipes
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Worldwide Use of PVC Pressure Pipes
• PVC Pressure pipes used for almost 60 years.
• Advances in:
- PVC polymer raw material
- Pipe extrusion technology
- Quality management systems and testing procedures
- Pipe Quality
- Pipeline design
- Ease of installation
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• All ensure long lifetime and low operation costs.
• Current Life Cycle Assessment now assumes a Lifetime of 100 years.
• In the USA, the use of PVC is more than three times that of HDPE and double that of ductile iron.
• PVC is the world’s leading plastic-pipe material (over 66% of global usage).
Worldwide Use of PVC Pressure Pipes/cont.
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THANK YOU FOR YOUR ATTENTION
THE FUTURE IS IN OUR DREAMS