suitability of pe pipe systems for conveying disinfected
TRANSCRIPT
Suitability of PE Pipe Systems for
Conveying Disinfected Drinking
Water Under Pressure
OzPipe Conference, Sydney, Australia
07 November 2019
Dr Jeroen Wassenaar
– About Qenos
Introduction
Mechanism of disinfectant induced degradation
Materials with enhanced disinfectant resistance
Conclusion
33
Qenos is a strategic pillar of the Australian manufacturing industry...
AUSTRALIAN MADE
Australasia’s sole manufacturer
and leading supplier of
polyethylene (PE) and
distributor of specialty polymers
PEOPLE
700 employees
350 contractors
REVENUE
Annual revenue of
A$700 – 900 million
OWNERSHIP
Qenos is owned by
China National
BlueStar Group
44
…adding value to Australian gas…
New South
Wales
Northern
Territory
Victoria
Tasmania
South
Australia
Western Australia
Queensland
Botany
Gippsland
Basin
Altona
Cooper
Basin
Qenos Botany
Ethane feedstock supplied by Santos via dedicated 1,375km pipeline from Moomba to Qenos Botany
Qenos Altona
Ethane feedstock supplied from Bass Strait via Longford and Long Island Point processing plants
The ingenious transformation by Qenos and its
customers turn ethane gas into high value products
55
…to supply the Australian polyethylene market.
33%Pipe
25%Film
11%Roto
Moulding
12%Blow Moulding
11%Dairy
7%Injection
About Qenos
– Introduction
Mechanism of disinfectant induced degradation
Materials with enhanced disinfectant resistance
Conclusion
77
HDPE Pipe is protected against disinfectants and has a track record of
long lifetimes under typical drinking water conditions
• Louis Pasteur: “We drink 90% of our illnesses”
• Continuous chlorination started in UK and USA the early 20th century
• HDPE pipe networks have been used to transport chlorinated water for nearly 60 years
– Long lifetime at T ≤ 20°C and residual chlorine ≤ 0.6 mg/L
– Premature brittle failures have been observed in warm regions globally
• Research identifies the following
key risk factors:
Source: PIPA POP018
88
Guidance from PIPA and PPI quantifies resistance to disinfectants and
defines operating window for conventional PE100 pipe
6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9
0.5 1.9 1.9 2.1 2.8 3.6 5.6 9.3 9.3 9.3 9.3 9.3
0.7 1.4 1.6 1.9 2.2 2.7 3.5 4.6 6.4 9.1 9.3 9.3
1.0 1.1 1.2 1.4 1.6 1.9 2.4 3.1 4.3 5.6 8.2 9.3
1.5 0.9 1.0 1.1 1.3 1.5 1.9 2.4 3.1 4.1 5.9 8.4
2.0 0.7 0.9 1.0 1.1 1.3 1.7 2.1 2.8 3.6 5.3 7.6
2.5 0.7 0.7 0.8 1.0 1.2 1.5 1.9 2.5 3.2 4.5 6.7
3.0 0.7 0.7 0.8 1.0 1.2 1.4 1.8 2.3 3.0 4.1 5.9
4.0 0.6 0.6 0.7 0.8 1.0 1.2 1.6 2.0 2.5 3.5 5.1
Residual
Cl mg/L
Average Water pH
Suitability of conventional PE100 at 21°C for PN16-rated DN25 pipe, operated at ≤600kPa
NOTE: For Chlorine and Hypochlorite disinfectants
6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9
0.5 0.6 0.6 0.7 0.9 1.2 1.8 3.0 3.0 3.0 3.0 3.0
0.7 0.4 0.5 0.6 0.7 0.9 1.1 1.5 2.1 2.9 3.0 3.0
1.0 0.4 0.4 0.4 0.5 0.6 0.8 1.0 1.4 1.8 2.6 3.0
1.5 0.3 0.3 0.4 0.4 0.5 0.6 0.8 1.0 1.3 1.9 2.7
2.0 0.2 0.3 0.3 0.4 0.4 0.5 0.7 0.9 1.2 1.7 2.4
2.5 0.2 0.2 0.3 0.3 0.4 0.5 0.6 0.8 1.0 1.5 2.1
3.0 0.2 0.2 0.3 0.3 0.4 0.4 0.6 0.7 1.0 1.3 1.9
4.0 0.2 0.2 0.2 0.3 0.3 0.4 0.5 0.7 0.8 1.1 1.6
Suitability of conventional PE100 at 30°C for PN16-rated DN25 pipe, operated at ≤600kPa
Residual
Cl mg/L
Average Water pH
NOTE: For Chlorine and Hypochlorite disinfectants
+9°C
PDI* Resistance to
Disinfectants
0-1 <50y
1-2 50-100y
>2 >100y
Source: PIPA POP018, PPI TN44/TN49, ASTM F2263
* Pipe disinfectant index
99Source: PIPA POP018
About Qenos
Introduction
– Mechanism of disinfectant induced degradation
Materials with enhanced disinfectant resistance
Conclusion
1111
Hypochlorite (HOCl) effect on polymer
embrittlement
HOCl dissociates in water to short lived radicals
able to affect surface only
The dissociation fraction of stable Cl2 gas
increases fast at elevated temperature even at
neutral pH (3 orders magnitude over 10°C)
Resin/pipe is protected until active AO is depleted
Auto-oxidative degradation takes place
εb - material property indication via tensile test elongation at break
OOT - additive presence via oxidation onset temperature
CI - polymer degradation indication via carbonyl index (presence of C=O group)
Source: M Bredacs et al. 19th Plastics Pipe Conference Sep 2018, Las Vegas
Field experience and research provide more understanding of the
aging mechanism of PE in presence of water with disinfectants
1212
Remedies
Higher wall thickness
High stress-crack resistance
(HSCR)
Advanced resin stabilisation
(RD)
Source: Chung et al. (Jana Labs) Environmental Factors in Performance Forecasting of Plastic Piping Materials. ANTEC. 2003, p5
Oxidation of inner wall
Formation of micro-cracks
Crack Initiation
Crack propagation via
SCG mechanism
Crack Propagation
Disinfectant (oxidation) induced degradation can be mitigated through
advanced material selection and higher wall thickness
Rate of initiation determined by:
• Material (stabilisation)
• Temperature
• Oxidation (type & concentration of disinfectant)
• Stress (operating pressure & wall thickness)
Rate of propagation determined by:
• Material (resistance to slow crack growth)
• Temperature
• Stress (operating pressure & wall thickness)
1313
Increasing wall thickness reduces stress as one of the drivers for
“brittle” failure
• Suez found in their aging bench* that increasing the
thickness by 50% doubles the longevity of PE pipe
when operated at the same pressure
• Recognised by selected asset owners in design
standards where minimum PN20 is specified
*Conditions: 40°C, pH 7.2, 4 mg/L HClO
Source: Rabaud et al. (Suez), AWWA Distribution System Symposium, Sept 2010, Washington D.C.
About Qenos
Introduction
Mechanism of disinfectant induced degradation
– Materials with enhanced disinfectant resistance
Conclusion
1515
Various test methods have been developed recently to measure HDPE
resistance to disinfectants
• Accelerated qualitative (<1000h)
– NOL-ring test, ClO2 (LNE, France)
– Autoclave, ClO2 (IRETI, Italy)
– Accelerated aging (PCCL, Austria)
– …
• Full-scale quantitative hydrostatic pipe
testing in presence of chlorine disinfectants
(>1y)
– ASTM F2263 (Jana, USA)
– Accelerated aging bench (Suez, France)
NOL-ring test setup
Source: E.J.W. van der Stock et al. 19th Plastics Pipe Conference Sep 2018, Las Vegas
1616
ASTM F2263 testing simulates high operating temperature and
disinfectant concentrations
Source: Jana Laboratories
1717
ASTM F2263 testing principle is similar to hydrostatic strength
evaluation but at constant chlorine concentration
Source: Jana Laboratories
1818
Categorisation Minimum calculated time, h
Category 1 (CC1) 8,100
Category 2 (CC2) 3,700
Category 3 (CC3) 1,350
ASTM F2263 testing allows to calculate Chlorine Classification that is
used to quantify resistance to disinfectants
• <DN20 pipes used for ASTM F2263 testing
• Full regression testing
– Min. 3 temperatures (e.g. 90, 100, 110°C)
– Min. 2 stress levels (e.g. 0.93 & 1.49 MPa)
– Chlorine (NaClO): 4.3 ppm
– pH 6.8 / ORP > 825 mV / flow rate 54 dm3/h
• PPI TN-43:2012 provides Chlorine Classification (CC)
to be used for calculating Pipe Disinfectant Index
(PDI)
<DN20, 2.48 MPa, 90°C
Pictures courtesy by ELEMENT
Source: ASTM F2263, PPI TN44/TN49
1919
The use of a PE100 with CC2 classification allows to significantly
extend the operating window for disinfected potable water piping
6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9
0.5 0.6 0.6 0.7 0.9 1.2 1.8 3.0 3.0 3.0 3.0 3.0
0.7 0.4 0.5 0.6 0.7 0.9 1.1 1.5 2.1 2.9 3.0 3.0
1.0 0.4 0.4 0.4 0.5 0.6 0.8 1.0 1.4 1.8 2.6 3.0
1.5 0.3 0.3 0.4 0.4 0.5 0.6 0.8 1.0 1.3 1.9 2.7
2.0 0.2 0.3 0.3 0.4 0.4 0.5 0.7 0.9 1.2 1.7 2.4
2.5 0.2 0.2 0.3 0.3 0.4 0.5 0.6 0.8 1.0 1.5 2.1
3.0 0.2 0.2 0.3 0.3 0.4 0.4 0.6 0.7 1.0 1.3 1.9
4.0 0.2 0.2 0.2 0.3 0.3 0.4 0.5 0.7 0.8 1.1 1.6
Suitability of conventional PE100 at 30°C for PN16-rated DN25 pipe, operated at ≤600kPa
Residual
Cl mg/L
Average Water pH
NOTE: For Chlorine and Hypochlorite disinfectants
PDI* Resistance to
Disinfectants
0-1 <50y
1-2 50-100y
>2 >100y
* Pipe disinfectant index
Use of PE100 with
CC2 & PN20-rating
6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9
0.5 3.7 3.8 4.2 5.5 7.1 11.2 18.3 18.3 18.3 18.3 18.3
0.7 2.7 3.1 3.7 4.4 5.3 6.9 9.1 12.6 17.9 18.3 18.3
1.0 2.2 2.4 2.7 3.1 3.8 4.8 6.2 8.4 11.2 16.3 18.3
1.5 1.8 2.0 2.2 2.6 2.9 3.7 4.8 6.2 8.0 11.7 16.6
2.0 1.5 1.8 2.0 2.2 2.6 3.3 4.2 5.5 7.1 10.4 15.0
2.5 1.5 1.5 1.6 2.0 2.4 2.9 3.7 4.9 6.4 9.0 13.2
3.0 1.5 1.5 1.6 2.0 2.4 2.7 3.5 4.6 5.9 8.0 11.7
4.0 1.3 1.3 1.5 1.6 2.0 2.4 3.1 4.0 4.9 6.9 10.1
Suitability of PE100 with CC2 rating at 30°C for PN20-rated DN25 pipe, operated at ≤600kPa
Residual
Cl mg/L
Average Water pH
NOTE: For Chlorine and Hypochlorite disinfectantsSource: PIPA POP018, PPI TN44/TN49, ASTM F2263
2020
PE100 RCD (Resistant to Crack & Disinfectants) has been developed to
provide highest protection against brittle failure
• Hostalen CRP 100 RCD black developed by
LyondellBasell and available through Qenos in
Australia & New Zealand
• ASTM F2263 testing indicates preliminary CC2
classification
– Suitable for potable water at higher
temperatures and disinfectant concentrations
• Classified as PE100 HSCR, meeting PIPA
POP016 requirements
– Suitable for trenchless pipe installation
Source: LyondellBasell
500
5,000
5,000
0 2,000 4,000 6,000
PE100 StandardRequirement
PE100 HSCRPOP016 Requirement
Hostalen CRP100RCD Black
Time to failure (hrs)
Stress Crack Resistance PerformanceNotched Pipe Test (ISO 13479)
>
Source: Element report P-19/70-v1
Source: KIWA report LC 14782
Hostalen is a trademark owned and or/used by the LyondellBasell family of companies.
Trademarks and copyright of LyondellBasell are acknowledged.
2121
CRP 100 RCD pipe samples have been tested to failure in ASTM F2263,
allowing for design life extrapolation
Source: Element report P-19/70-v1
Pipe samples at 90°C are still on test but is not
expected to change outcome significantly
Hostalen is a trademark owned and or/used by the LyondellBasell family of companies.
Trademarks and copyright of LyondellBasell are acknowledged.
2222
Extrapolation per ASTM F2263 indicates ability of CRP 100 RCD to meet
POP013 rerating even at 4.3ppm hypochlorite
Maximum Allowable Operating Pressure in m head adapted from PIPA POP013
Temp (°C) Min Life (yr)
Extrapolated time to
failure @ 4.3 ppm
Chlorine (yr)*
Design
Factor
PN 4 PN 6.3 PN 8 PN 10 PN 12.5 PN 16 PN 20 PN 25
SDR41 SDR26 SDR21 SDR17 SDR13.6 SDR11 SDR9 SDR7.4
20 100 >100 1.0 40 64 80 100 127 160 200 250
25 100 >100 1.1 36 58 73 91 115 145 182 227
30 100 >100 1.1 36 58 73 91 115 145 182 227
35 50 >100 1.2 33 53 67 83 106 133 167 208
40 50 >100 1.2 33 53 67 83 106 133 167 208
45 35 100 1.3 31 49 62 77 99 123 154 192
50 22 53 1.4 29 46 57 71 91 114 143 179
55 15 27 1.4 29 46 57 71 91 114 143 179
60 7 14 1.5 27 43 53 67 85 107 133 167
80 1 2 2.0 20 32 40 50 63 80 100 125
* Extrapolated time to failure for Hostalen CRP 100 RCD Black according to preliminary ASTM F2263 extrapolation using 3-parameter LTHS model at 4.3 ppm
hypochlorite, pH 6.8, flow of 54 dm3/h
Source: Element report P-19/70-v1, PIPA POP013
Hostalen is a trademark owned and or/used by the LyondellBasell family of companies.
Trademarks and copyright of LyondellBasell are acknowledged.
About Qenos
Introduction
Mechanism of disinfectant induced degradation
Materials with enhanced disinfectant resistance
– Conclusion
2424
Conclusions
• HDPE piping materials and systems have been designed to transport disinfected water
and >50y track record supports use for water ≤ 20°C and residual chlorine ≤ 0.6 mg/L,
covering the vast majority of installations globally
• The combination of high temperature and high chlorine concentrations may result in
accelerated aging of the material, potentially leading to premature brittle failure
• Hostalen CRP 100 RCD Black is able to extend the operating window for HDPE piping to
include higher temperatures and residual chlorine concentrations
– Preliminary classified CC2 per ASTM F2263 and PPI TN-43:2012
– Able to meet PIPA POP013 rerating at 4.3 ppm Cl / pH 6.8 / 54 dm3/h
Hostalen is a trademark owned and or/used by the LyondellBasell family of companies.
Trademarks and copyright of LyondellBasell are acknowledged.