INNOVATIVE DEVELOPMENTS IN PVC PRESSURE PIPE SYSTEMS AND UNCONVENTIONAL APPLICATIONS

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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 PVCs 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

• Worlds leading plastic pipe resin over
  two-thirds of
• global 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

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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 gt40oC, humidity 90.
• - To cool environment pipes with chilled water
  at 5oC.
• - Pipes made to SANS 1283.

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Impact Modified PVC in Mining/Cont.
20 metre high energy impact test
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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Mineflo Pipes Conveying Chilled Water (5oC)
Installation with Bent Pipes! (2500m)
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Mineflo Pipes for Chilled Water
Note suspension of pipes underground
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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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Worldwide Use of PVC Pressure Pipes/cont.

• 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 worlds leading plastic-pipe material
  (over 66 of global usage).

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THANK YOU FOR YOUR ATTENTION
THE FUTURE IS IN OUR DREAMS