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AGRULINE

PE piping system for gas- and water supply – PE 80 / PE 100. AGRULINE. AGRULINE. PROPERTIES OF PE 80 / PE 100. Properties Welding technology Advantages of the AGRULINE-SYSTEM Supply program References Installation Approvals. AGRULINE. Properties Welding technology Advantages

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AGRULINE

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  1. PE piping system for gas- and water supply – PE 80 / PE 100 AGRULINE

  2. AGRULINE PROPERTIES OF PE 80 / PE 100

  3. Properties Welding technology Advantages of the AGRULINE-SYSTEM Supply program References Installation Approvals AGRULINE • Properties • Weldingtechnology • Advantages • Supply program • References • Installation • Approvals

  4. PROPERTIES OF PE 80 / PE 100 General properties of PE: • flexibility (earthquake-proof, ...) • low specific weight of 0,95g/cm3 • favourable transportation (e. g. coiled bundles) • very good chemical resistance • good weathering resistance • good weldability

  5. Material Asbestoscement PVC Steel Cast iron PE-HD length 221.947 m 99.956 m 3.810 m 1.030 m 115.182 m failur ratio in % 71,7% 27,3% 0,7% 0,3% 0,0% failure ratio 1,43 1,21 0,82 1,29 0,0 per Km (ø= 1) Material Steel Cast iron PE-HD length 21.338 m 12.204 m 1.458 m failure 25.821 630 0 failure/Km 1.210 52 0 PROPERTIES OF PE 80 / PE 100 Earthquake Statistics: Earthquake in Colombia (1999) Earthquake in Kobe (1995)

  6. very good abrasion resistance no deposits and no overgrowth possible resistant to roots resistant to rodents resistant to all kinds of microbic corrosion low permeability suitable for potable water PROPERTIES OF PE 80 / PE 100 General properties of PE :

  7. PROPERTIES OF PE 80 / PE 100 General properties of PE :

  8. 40,0 30,0 20,0 10°C 20°C 10,0 9,0 30°C 8,0 2 40°C MRS 8 [N/mm ] 7,0 50°C 6,0 60°C v s 70°C 5,0 80°C 4,0 3,0 reference stress 2,0 50 1 10 25 100 time to fail [years] 1,0 2 3 4 5 6 10 1,0 10 10 10 10 10 time to fail [h] PROPERTIES OF PE 80 / PE 100 Creep Curve of PE 80: MRS 8: “minimum required strength”for an operating time of 50 years and a temperature of 20°C = 8 N/mm2 Design life of Agru- Products: 50 years

  9. 40,0 30,0 20,0 10°C 20°C 30°C 10,0 40°C 9,0 50°C 8,0 MRS 10 2 60°C 7,0 [N/mm ] 70°C 6,0 80°C v s 5,0 4,0 3,0 reference stress 2,0 50 1 10 25 100 time tofail [years] 1,0 6 2 3 4 5 10 1,0 10 10 10 10 10 time to fail [h] PROPERTIES OF PE 80 / PE 100 Creep Curve of PE 100: MRS 10:“minimum required strength”for an operating time of 50 years and a temperature of 20°C = 10 N/mm2 Design life of Agru- Products: 50 years

  10. s da SDR= s da Example: da = 110 mm s = 10 mm SDR = ? 110 da = 11 SDR = = s 10 PROPERTIES OF PE 80 / PE 100 Standard Dimension Ratio: SDR ... standard dimension ratio da ... outside diameter [mm] S ... wall thickness [mm]

  11. 20 . MRS Pad.= (SDR - 1) . Cmin Example: PE 100 ==> MRS = 10 N/mm2 SDR 11 C = 1,25 pad. = ? 20 . MRS pad.= = (SDR - 1) . Cmin 20 . 10 = = 16bar (11 - 1) . 1,25 PROPERTIES OF PE 80 / PE 100 Working pressure pad. ... admissible working pressure [bar] MRS ... minimum required strength [N/mm2] SDR ... standard dimension ratio Cmin ... minimum safety factor (= 1,25 acc. ISO 12162)

  12. safety factor safety factor safety factor C = 1.25 C = 1.6 C = 2.0 SDR PE 80 PE 100 PE 80 PE 100 PE 80 PE 100 7,4 20 25 15,3 19,2 12,3 15,3 11 12,5 16 10 12,5 8 10 17 8 10 6,2 7,8 5 6,2 17,6 7,5 9,6 6 7,5 4,8 6 PROPERTIES OF PE 80 / PE 100 Working pressures: Admissibleworkingpressures in bar for PE-pipesandfittings in dependency on thesafetyfactor.

  13. PROPERTIES OF PE 80 / PE 100 Working pressure depends of medium

  14. SDR PE 80 PE 100 11 5 bar 10 bar 17 2,5 bar 6 bar pressure test (C=2) RCP PE 80 8 bar 5 bar PE 100 10 bar >20 bar PROPERTIES OF PE 80 / PE 100 Admissible working pressures for gas application: acc. DVGW G 472 / ÖVGW PG 392/2 • Pressure limit for example SDR 11

  15. TREND PE 100 PROPERTIES OF PE 80 / PE 100 The new trend at PE-piping systems: PE80

  16. PROPERTIES OF PE 80 / PE 100 Advantages of PE 100:in comparison to older PE-generations (PE 63/PE 80) • higher strength (MRS=10N/mm2) • higher working pressure at the same SDR-ratio • lower wall thickness (higher rate of flow and lower weight) at the same working pressure • bigger pipe dimensions produceable • higher resistance against SCG (slow crack growth) • higher resistance against RCP (rapid crack propagation)

  17. cast iron: corrosion, heavier, no flexibility, rough surface (higher pressure losses),... Substituted Materials: PROPERTIES OF PE 80 / PE 100

  18. Substituted Materials : PROPERTIES OF PE 80 / PE 100 • concrete: corrosion, heavier, no flexibility, rough surface (higher pressure losses),...

  19. Substituted Materials : PROPERTIES OF PE 80 / PE 100 • PVC: high brittleness, no weldability, no flexibility...

  20. AGRULINE WELDING TECHNOLOGY

  21. heating element butt fusion • heating element socket fusion • electro fusion • electro fusion saddle Welding Methods for PE: WELDING TECHNOLOGY

  22. Weldability of PE 100: WELDING TECHNOLOGY The weldabilityhasbeenprovenby well-known testinginstitutes (TÜV-Rheinland, HESSEL Ingenieurtechnik, BECETEL/University Gent in Belgium): • weldingof PE 100 with PE 100 or PE 80 ispossiblewithout • restrictionsacc. relevant weldinginstructions (e.g.: DVS • regulations) • thisis valid forelectrofusionandbuttwelding

  23. electrofusion electro fusion sockets + elongated fittings electro fusion fittings Electro fusion saddles butt welding flange connection adaptors WELDING TECHNOLOGY Joining Methods for the AGRULINE-System:

  24. indicator connection pin pipe end welding wire middle stop WELDING TECHNOLOGY Electro Fusion: Principle: The welding wire is heated up due to the energy input of the welding machine. Pipe and electro fusion fitting are welded together.

  25. indicator welding wire WELDING TECHNOLOGY Electro Fusion Saddle: Principle: The welding wire is heated up due to the energy input of the welding machine. Pipe and electro fusion saddle are welded together.

  26. Welding equipment: welding machine + generator clamping device pipe cutter peeling tool and scraper knife PE-cleaner fluffless, absorbent paper WELDING TECHNOLOGY Electro Fusion:

  27. heating element pipe end WELDING TECHNOLOGY Butt Welding Principle: • preparation of the welding • alignment and pre-heating • joining and cooling

  28. bolts backing ring pipe gasket stub flange WELDING TECHNOLOGY Flange Connection: Principle: The stub flanges which are welded on the pipe ends are connected by means of backing rings and bolts. The tightness is provided by the gasket.

  29. WELDING TECHNOLOGY Adaptors: Application area: • adaptor PE/steel • connection to valves and apparatus

  30. AGRULINE ADVANTAGES OF AGRULINE SYSTEM

  31. ADVANTAGES OF AGRULINE SYSTEM • high quality injection moulded fitting • complete range of electrofusion and butt welding fittings, special fittings and welding equipment • available systems in PE 80 and PE 100 • use of high quality and pure raw materials • extensive product control and complete documentation of all performed tests • work certificates are available • production acc. international relevant standards • short delivery times because of high storage capacity are guaranted

  32. ADVANTAGES OF AGRULINE SYSTEM Requirements on E-fittings • weldability with different PE materials • PE 80 / PE 100 / PE-Xa • construction acc. to international standards • maximum protection against damage and environmental influences • biggest application scope • gas and water supply • sewage and industrial application

  33. ADVANTAGES OF AGRULINE SYSTEM Requirements on E-fittings • weldable under extreme conditions • Worst Case ( -10°C and +50°C) • optimized connector plug terminal • weldable with all universal fusion equipment • reproduceable quality of the welding seam • short welding times

  34. material PE 100 reinforced connector plugs injection moulded welding indicator optimized welding times embedded resistance wire (modular construction) optimized shrinking behaviour optimized production design MOP 16bar/20°C high resistance against track force injection moulded in dimensions E-couplers Ø20 - 400 E-fittings Ø20 - 225 full automatic production ADVANTAGES OF AGRULINE SYSTEM AGRULINE – E-Fitting

  35. ADVANTAGES OF AGRULINE SYSTEM production technique 1 - injection moulded sleeve 2 - coiled resistance wire around the sleeve;and welded connector plug

  36. 4,0 mm ADVANTAGES OF AGRULINE SYSTEM Resistance wire connection • optimum wire fixation by point welding • better resistance emission

  37. ADVANTAGES OF AGRULINE SYSTEM production technique 3 - injection moulded fitting 4 - modular system the resistance wire is completely embedded in the fitting body smooth surface in the welding zone

  38. cleaned inside surface dirty inside surface ADVANTAGES OF AGRULINE SYSTEM system advantage of embedded resistance wire • smooth inside surface in the welding zone • easy cleaning of the welding zone • no residues of dirt • no residues of cleaning liquids

  39. ADVANTAGES OF AGRULINE SYSTEM system advantage of embedded resistance wire • covered resistance wire around the whole socket length • no medium contact possible • no corrosion during the application • no contamination of the medium possible

  40. welding zone cooling zone cooling zone moulded insertion taper ADVANTAGES OF AGRULINE SYSTEM system advantage of embedded resistance wire • protected resistance wire • damage impossible • elongated cooling zone for a better pipe guidance and optimum pressure set up in the welding zone take notice of the high ovality and internal pipe stresses at pipe coils

  41. defined wire distance to the socket inside gap ADVANTAGES OF AGRULINE SYSTEM system advantage of embedded resistance wire constant temperature of approx. 220°C in the whole welding zone • good heat emission • no thermic damage in the welding zone • constant controlled heat emission and the heat is drawn off sufficiently during the welding process

  42. homogeneous adhesion in the whole welding zone peel test according DVS 2207 – part 5 ADVANTAGES OF AGRULINE SYSTEM system advantage of embedded resistance wire • no thermic damaged material in the welding zone • high welding seam force

  43. insert length ADVANTAGES OF AGRULINE SYSTEM system advantage insert length • Construction according to EN 1555: • large insert length • generous pipe guidance

  44. 15° - angle marking ADVANTAGES OF AGRULINE SYSTEM system advantage angle marking > Ø90mm: • Tee, elbow 90° and elbow 45°

  45. ADVANTAGES OF AGRULINE SYSTEM proofed quality (welding on the limit) • Worst-Case Test A (overheating) according to ISO 11413: • thin walled pipe (SDR 17) • welding at 42V (simulation of wire resistance- and welding box tolerances) • welding with minimum gap • Worst-Case Test B (adhesion) according to ISO 11413 : • thick walled pipe (SDR 7,4) • welding at 38V (simulation of wire resistance- and welding box tolerances) • welding with maximum gap • test A and B welded at -10°C und +50°C • all weldings are made with a maximum pipe ovality of 1,5%

  46. electrofusion fitting perfect welding adhesion fault scraped pipe unscraped pipe ADVANTAGES OF AGRULINE SYSTEM Preparing of the welding seam • influence of surface pollution or oxide film onto the welding quality • scraping of the pipe surface is general necessary ( DVS 2207-part 7 - 1995)

  47. manual peel test - DVS 2207-5 tensile load test ISO 13951 decohesion test ISO 13955 ADVANTAGES OF AGRULINE SYSTEM welding seam quality standard requirements are completely fulfilled

  48. long term tensile test DVS 2203-4-BB1 internal pressure test ADVANTAGES OF AGRULINE SYSTEM welding seam quality standard requirements are completely fulfilled

  49. ADVANTAGES OF AGRULINE SYSTEM Long time tensile test (across the Weldingzone) • Test construction: • Specimen out of a welded electro fusion joint Ø160 mm with PE 100 pipe SDR 11 • accomplishment by Ing. Dr. J. Hessel • execution acc. DVS 2203-4 paper 1 • with 2% liquid Arkopal N-100 • Tensile tension: 3N/mm² • Temperature: 80 °C

  50. loading E-Fitting Welding wire area Pipe Welding zone loading ADVANTAGES OF AGRULINE SYSTEM Long time tensile test (across the Weldingzone)

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