1

Tank Storage Istanbul 2010

11

Charles SmithFuelling System Designer

A viable alternative to SteelHD-PE Fuel Pipe Systems

now a part of

2

Now the global piping leader

2

Worldwide Fuel System Solution Provider 29 Years retail fuel station piping.

• 30,000+ sites. 159 countries.

• Shell, ExxonMobil, Chevron, BP, MOC’s.

• EN14125 IP2 & UL971 Approvals• EN14125, IP2 & UL971 Approvals

Storage tanks / pressure vessels.

• To 250 m3 capacity.

• AST/ UST’s in carbon or stainless steel.

• Petro-chemical, pharmaceutical, water, food and power generation.

Fuel compatible non-metallic pipe line.

• 400 mm ~16″ max. Ø

• 10 ~ 20 bar rating – design dependant

• +60˚C operating limit

• PE 100 with PA Liner.

• API 15LE equivalence

Introducing HD-PE and its Performance

Pipeline engineering

specification factors include: p

• Codes/ Regulations

• Chemical compatibility

• Pressure rating

• Temperature rating

• Environmental factors

• Heat trace requirementsHeat trace requirements

• Sizing

• UV stability

• Cost of Ownership – Capital, Installation, Operational = Whole Life

3

Limitations of Unlined Polyethylene

• Liquid hydrocarbons permeate PE

• Permeation doubles every 10°C above 20°C. xy

• Hydrocarbon exposure affects:– Pressure rating

– Linear Expansion

– Safety

– Environment

xPermeation

Mass gain12%Pressure

De-rating

Pressure rating: BarLined PE 7.3Unlined PE 100 4.6Unlined PE 80 3.7SDR 13.6 PE operating at 50˚C

Permeation3-7 g/m2/day

GasolineElongation

4%

g50%

Multi-Layer HD-PE

• HD-PE pipe system with nylon fuel barrier layer – dating from 1986.

• Wide compatibility with fuels and chemicalsp y

• Reduced friction loss of liner

• Diameters from 1″ to 16″

• Range of wall thickness &pressure rating

• Fusion welded

• PE 100 vs. PE80– 25% higher pressure rating g p g

– Increased bore/flow

– Improved stress crack resistance

4

The Barrier Liner• Internal, visible PA liner

– Co-extruded and bonded directly during the extrusion process.

N d l i t– Never delaminates

• Material combination benefits include:– Highest fuel compatibility

– Highest pressure ratings

– Lowest permeation

– Lowest friction losses

– Lowest paraffin waxing

Compatibility – Fuels and BeyondFuels & Additives• Regular Unleaded Gasoline

• Premium Unleaded Gasoline

Bio-Fuels

• Ethanol 0-100%

• ASTM Fuel C 100%

• EN14125 Test Fuel 1 and 2

• No. 2 Fuel Oil

• ETBE, MTBE

• Toluene

• Diesel

• Heavy oils

• Bio-Diesel 0-100%

• Methanol 0-100%

Aviation & Marine

• JET A-1

• F34 (JP-8)

• AVGAS 100LL

• Kerosene

• Hydraulic fluid

• AdBlue (Diesel exhaust fluid)

• Ballast water

• Slop

Manufacture is within the permeation and stability limits of UL971 and EN14125 requirements for hydrocarbon compatibility.

5

Electrofusion or Butt FusionJoining pipe-to-pipe in-situ

Electro-fusion• Simple and effectiveSimple and effective

• Ideal for smaller diameters

• Useful for elbows, tees, terminations

• Suits confined space assembly

Butt fusion• Saves cost of fusion couplers

• Easy automatic preparation.

S ti l t f i• Same pressure rating as electro-fusion

• Many machines will accept elbows & tees

• Much easier than steel!

Both methods are reliable and 100% leak-free.

Pressure Drop example 250-400 mm

6

Fittings – Full Range

HD-PE and Steel Compared - CorrosionTypical situations enhancing corrosion in metal piping

• Aggressive soils and environments.

• Salt water.

• Discontinuity or scratches in protective coatings• Discontinuity or scratches in protective coatings creates anodic and cathodic regions.

• Stray currents.

• MIC (Microbiologically Influenced Corrosion), promoted by bacteria in water and Diesel.

• Bore scale.

Pressure Loss Example (bar)

315 mm pipe, 5000 m - Gasoline, 11400 l/min flow315 mm pipe, 5000 m Gasoline, 11400 l/min flow

Rheomax 8.9

Steel New 13.5

Steel Mild Corrosion 20.2

Steel several years service 24.7

7

HD-PE and Steel Compared - MechanicalHD-PE Limitations

• Max 140 F operating temperature

HD-PE Advantages

• 1/3rd Installation weight

• Pressure rating 145 - 290 PSI

• Max. Diameter 16″

• Not Fire Rated

• Low installation cost

• Flexibility-less fittings

• Absorbs water hammer

• No thrust blocks

• Lowest Friction losses

• Reduced Pumping costs

• Constant Pressure drop

• No Cathodic protectionp

• No Corrosion

• No Maintenance costs

• Extended Replacement cycle

= Low cost of ownership

FRP non-metallic alternative to HD-PEPlastic Thermoset• Higher pressure rating

• Higher operating temperature

• Large diameters

• Similar fuel compatibility

However:• Relies on adhesives for jointing

• Cold climate installation issues

• Potential handling impact damagePotential handling impact damage

• Inflexible

8

HD-PE - Areas of Application• Automotive Fuels

• Oils & Chemicals

• Contaminated water

• Salt water

• Demineralised water

• Above ground

• Under ground

• Under water

• Jetties

• Can be heat traced

• Can be pigged

HD-PE Above Ground InstallationDesign Factors

consider in design: -

• Temperature variation – seasonal & diurnalp

• Pipe layout, supports and constraints

• Potential mechanical or impact loading

• Chemical exposure

• UV radiation

• Fire protection

9

Marine Onshore Terminal - Iceland (2007)Fuel: Diesel & Petrol

Pressure: 9 bar

Flow per line: 900 m3/ hour

Case Studies

Ease of handling

9 Storage Tanks

Diameter : 315 mm SDR 13.6

Length: 2 x 750 m in parallel

Elevation: 74 m

Location: Whale Bay

Customer: Olíudreifing

Choice based on: Ease of handling

Butt fusion welding

• Need to replace corroded steel

• 8 year experience with 6″ UPP

• Benefit of 50 year life expectancy

Multi-Phase Extraction- AustraliaContaminant Vapour & Fluid Phase

Hydrocarbon Jet Fuels

Case Studies

6 pipe diameters

Leak Tight joints

In-situ site remediation

Bulk Terminal leak

Groundwater impact

Total project meterage 31 km

Ø Pipe mm 32 63 110 160 225 250

Length metres 1,352 1,220 10,000 10,000 5,000 4,100

Lines Extraction and Injection

Leak Tight joints

Reduced labour and fittings

Groundwater impact

Benefits• No permeation

• Fast Electro-fusion welding

• Fewer joints, use of coils

10

Medium: Crude Oil & Natural Gas

Pressure: 30 - 75 psi

Flow Rate: 80 barrels per hour

Oilfield Flow Lines 2009Case Studies

Diameter: 90 mm SDR 9

Length: 4,200 ft

Location: New Mexico

Customer: Apache

Benefits• Fast long coil installation1000 ft 3” coils

Line from pump jack

• Reduced maintenance costs

• Reduced paraffin wax build up

• Above ground installation

• Pressure safety rating

Above ground flow line

Other InstallationsMarinas • UK

• Caribbean

• Gulf

Aviation • France

• Australia

• New Zealand • Gulf

• USA

• New Zealand

• Belgium

Rail• Hungary

• UK

• France

Mining• Ghana

• Australia

Coastal Fuelling • Spain

• Australia

• Qatar

Military• Australia

• USA

11

Cost / Benefit Analysis of HD-PE

HD-PE Pipeline – the attractive alternative to steel

Capital Cost Lower than coated steelLo er Transport costsLower Transport costs

Installation Cost Lower costLess timeFewer fittings – with coilsNo thrust blocks on larger diameters

Operational Cost Reduced energy requirementReduced maintenance costZero inspection cost (for corrosion)

R l t C t E t d d l t lReplacement Cost Extended replacement cycleDesign life of 50 years

Reliability No leaksNo corrosionNo worries

NO CORROSION = NO INSPECTION = NO MAINTENANCE

Thank you for listening

Questions?

12

now a part of

23

Now the global piping leader

Tank Storage Istanbul 2010

2424

Charles SmithFuelling System Designer

A viable alternative to SteelHD-PE Fuel Pipe Systems

13

Material PropertiesMaterial Property Units

Liner Polyamide PA 6/12Material Density – PE100 (4710) 960 Kg/m³ Tensile Strength 18 MPa Elongation to Break > 600% Flexural Modulus 900 MPa Brittleness Temperature < -70ºC

Linear Thermal Expansion 1.6 x 10¯4

mm/mm/ºC Thermal Conductivity 0.2 W/m/ºC Pressure Rating (SDR 13.6) Standard 10 Bar Burst Pressure - Typical 40 Bar Vacuum Rating - 0.9 Bar

The coefficient of thermal expansion is 1.0 x 10-4 in/in/°F. A general rule is one-inch change in length per 100 feet of unrestrained pipe per 10°F change in temperature or 0.16m per 100m per 10°C

Vacuum Rating 0.9 Bar

Operating Temperature Range -40ºF to +140ºF -40ºC to +60ºC

Rated life at +23 ºC At least 50 years

Technical Data

Wall Thickness mm ID mm

OD SDR OD SDR

9 11 13 6 9 11 13 6mm 9 11 13.6 mm 9 11 13.6

63 7 5.8 4.63 63 49 51 54

90 10 8.2 6.62 90 70 73 76

110 12.2 10 8.09 110 85 90 94

160 17.8 14.6 11.7 160 124 131 136

200 22.2 18.2 14.7 200 155 164 171

225 25.0 20.5 16.5 225 175 184 192

250 27.8 22.7 18.4 250 194 204 213

315 35.0 28.6 23.2 315 245 258 268

355 39.4 32.3 26.1 355 276 290 303

400 44.4 36.4 29.4 400 311 327 341

14

Technical Data

Weight in KG / metre

OD SDR

9 11 13 6mm 9 11 13.6

63 1.2 1 0.8

90 2.4 2.0 1.6

110 3.6 3.0 2.5

160 7.6 6.4 5.7

200 11.9 10 8.2

225 15.1 12.6 10.4

250 18.6 15.6 12.8

315 29.6 24.7 20.4

355 37.6 31.4 25.9

400 47.7 39.9 32.9

Technical Data

Pressure (bar) v. Temperature Temperature v. Life in Years

SDR SDR

°C 9 11 13.6 °C 9 11 13.6

20 16.8 13.5 10.7 20 50

25 15.7 12.6 10.0 25 50

30 14.7 11.8 9.4 30 50

35 13.8 11.0 8.8 35 50

40 12.9 10.3 8.2 40 50

45 12 1 9 7 7 7 45 5045 12.1 9.7 7.7 45 50

50 11.4 9.1 7.3 50 37.1

55 10.9 8.7 6.9 55 19.9

60 10.4 8.3 6.6 60 10.8

15

Technical DataAbove Ground Installation

Distance between Supports (Metres)

OD SDR

mm 9 11 13.6

63 1.1 1.1 1.090 1.4 1.4 1.3110 1.6 1.6 1.5160 2.1 2.0 1.9200 2.4 2.3 2.2225 2.6 2.5 2.4250 2 8 2 7 2 6250 2.8 2.7 2.6315 3.3 3.1 3.0355 3.6 3.4 3.2

400 3.9 3.7 3.5